Buku Pedoman Reparasi Beat

DAFTAR ISI CARA MEMAKAI BUKU INI KETERANGAN UMUM

Buku Pedoman Reparasi ini menguraikan prosedur servis untuk skuter HONDA BEAT.

RANGKA / BODY PANELS / SISTEM PEMBUANGA PEMBUANGAN N GAS

Ikuti petunjuk pada Jadwal Perawatan (Bab 3) untuk mempertahankan skuter pada kondisi operasional puncak. Adalah sangat penting untuk menjalankan perawatan berkala 1 dan 2 pada waktunya. Servis ini mengadakan penyesuaian terhadap keausan awal yang terjadi dalam masa pemakaian mula. Bab 1 dan 3 berlaku untuk skuter secara keseluruhan. Bab 2 menggambarkan prosedur untuk pelepasan/pemasangan komponen yang mungkin diperlukan untuk men jalankan servis yang diuraikan pada bab-bab bab-bab berikutnya. Bab 4 sampai dengan 17 menguraikan bagian-bagian skuter yang dikelompokkan menurut lokasi. Carilah bab yang Anda inginkan pada halaman ini, kemudian bacalah daftar isi pada halaman pertama dari bab itu. Kebanyakan bab dimulai dengan gambar susunan atau gambar sistem, keterangan servis dan cara mencari penyebab kesukaran untuk bab itu. Halaman-halaman berikutnya memberikan prosedur servis secara mendetil. Jika Anda tidak mengetahui sumber penyebab kesukaran, bacalah bab 19, TROUBLESHOOTING TROUBLESHOOTING..

Semua keterangan, gambar, petunjuk dan spesiﬁkasi di dalam publikasi ini berdasarkan data-data produk terakhir yang tersedia pada waktu persiapan untuk pencetakan. PT Astra Astra Honda Motor berhak membuat perubahan pada setiap waktu tanpa pemberitahuan dan tanpa ikatan apapun. Dilarang mengutip atau mencetak ulang bagian dari penerbitan ini tanpa ijin tertulis penerbit. Buku Pedoman ini ditulis untuk orang yang telah memiliki pengetahuan dasar perawatan skuter Honda.

K A R E G G N E P N A T A L A R E P & N I S E M

A K G N A R

N A K I R T S I L E K

1 2

PERAWATAN

3

SISTEM PELUMASAN

4

SISTEM BAHAN BAKAR

5

PENURUNAN / PEMASANGAN MESIN

6

CYLINDER HEAD/VAL HEAD/VALVES/CYLINDER/PISTON VES/CYLINDER/PISTON

7

KICKSTARTER / DRIVE PULLEY / DRIVEN PULLEY / CLUTCH

8

FINAL REDUCTION

9

CRANKCASE / CRANKSHAFT

10

RODA DEPAN / SUSPENSI / KEMUDI

11

RODA BELAKANG / SUSPENSI

12

SISTEM REM

13

BATERAI / SISTEM PENGISIAN / ALTERNATOR ALTERNATOR

14

SISTEM PENGAPIAN

15

SISTEM STARTER LISTRIK

16

LAMPU / METER / SAKLAR-SAKLAR

17

DIAGRAM LISTRIK

18

TROUBLE SHOOTING

19

CATATAN PENTING UNTUK KEAMANAN Di dalam buku ini tidak dimuat pembahasan secara mendetail mengenai prosedur kerja bengkel standar,, prinsip - prinsip keamanan serta pekerjaan servis standar. standar standar. Adalah penting untuk mengetahui bahwa buku ini hanya memuat beberapa peringatan terhadap cara-cara servis tertentu yang dapat menimbulkan KECELAKAAN BADANIAH kepada mekanik atau dapat merusak kendaraan atau menyebabkannya tidak aman untuk dikendarai. Harap dimengerti dimengerti bahwa peringatan-peringatan peringatan-peringatan ini tidak tidak dapat dapat meliputi meliputi semua cara-cara pelaksanaan servis, baik yang dianjurkan dianjurkan oleh Honda maupun maupun yang tidak, ataupun akibat-akibat akibat-akibat yang mungkin berbahaya yang timbul dari setiap cara pelaksanaan servis, juga bahwa Honda tidak dapat menyelidiki semua cara - cara tersebut. Setiap orang yang menggunakan prosedur kerja ataupun tool, balk yang dianjurkan oleh Honda maupun tidak, harus meyakinkan dirinya sendiri dengan pasti bahwa keamanan pribadi maupun keamanan kendaraan tidak terancam oleh cara pelaksanaan servis ataupun tool yang dipilih.

1. KETERANGAN UMUM 1

SPESIFIKASI RODA BELAKANG/ PERATURAN SERVIS ................................... ..................... .............. 1-2 SERVICE RULES ??????????? ?????????????????????? ??????????? 1 1-2 -2

SUSPENSI ....................................... .................................................. ........... 1-7 REAR WHEEL/SUSPENSION SPECIFICATIONS ????????????????????? ????????????????????? 1-7

IDENTIFIKASI MODEL .................................. .................... .............. 1-2 MODEL IDENTIFICATION ????????????? ?????????? ??? 1-2

SPESIFIKASI SISTEM REM ....................... ....................... 1-7

BRAKE SYSTEM SPECIFICATIONS ????? 1-7 SPESIFIKASI UMUM ..................................... ..................................... 1-4 GENERAL SPECIFICATIONS??????????? 1-4

SPESIFIKASI B ATERAI/SISTEM

SPESIFIKAS SPESIF IKASII SISTEM PELUMASAN ..... PELUMASAN ......... ...... .. 1-5 LUBRICATION SYSTEM

BATTERY/CHARGING SYSTEM/ PENGISIA PENGISIAN/AL N/ALTERNA TERNATOR TOR ..... .......... .......... .......... ........ ... 1-8 ALTERNATOR SPECIFICATIONS ?????? 1-8

SPECIFICATIONS ????????????????????? ????????????????????? 1-5

SPESIFIKASI SISTEM PENGAPIAN.......... 1-8

SPESIFIKAS SPESIFIKASII SISTEM BAHAN BAKAR .... ....... ... 1-5

FUEL SYSTEM SPECIFICATIONS??????? SPECIFICATIONS??????? 1-5 SPESIFIKASI CYLINDER HEAD/VALVES.... 1-5

CYLINDER HEAD/VALVES SPECIFICATIONS ????????????????????? 1-5 ????????????????????? SPESIFIKASI CYLINDER/PISTON................ 1-6 CYLINDER/PISTON SPECIFICATIONS ?? 1-6 SPESIFIKASI KICKSTARTER/DRIVE

IGNITION SYSTEM SPECIFICATIONS ?? 1-8 SPESIFIKASI SISTEM STARTER

ELECTRIC STARTER SYSTEM LISTRIK..................................... LISTRIK..................... .................................. .................. 1-8 SPECIFICATION ?????????????????????? ?????????????????????? 1-8 SPESIFIKASI LAMPU/METER/

LIGHTS/METERS/SWITCHES SAKLAR....................................... SAKLAR...................... ................................ ............... 1-8 SPECIFICATION ?????????????????????? ?????????????????????? 1-8

PULLEY/DRIV PULLEY/DRIVEN EN PULLEY/CL PULLEY/CLUTCH UTCH ..... .......... ....... .. 1-6

NILAI NILAI TORSI STANDARD STANDARD ..... .......... .......... .......... .......... ....... 1-9

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH ??? 1-6 SPESIFIKASI FINAL SPECIFICATIONS FINAL REDUCTION........... REDUCTION................ ..... 1-6

STANDARD TORQUE VALUES ????????? 1-9 NILAI TORSI TORSI MESIN & RANGKA............... 1-9

ENGINE & FRAME TORQUE VALUES ?? 1-9 FINAL REDUCTION SPECIFICATIONS?? 1-6 SPESIFIKASI CRANKCASE/

TITIK-TITIK PELUMASAN &

CRANKSHAFT............................................... CRANKSHAFT............................ ................... 1-6

LUBRICATION & SEAL POINTS ??????? 1-12 PERAPATAN ...................................... ................... ......................... ...... 1-12

CRANKCASE/CRANKSHAFT SPECIFICATIONS ?????????????? ??????? 1-6 SPESIFIKASI RODA ????????????????????? DEPAN/

CABLE & HARNESS ROUTING ???????? 1-141-14 PERLETAKA PERLETAKAN N KABEL & HARNESS....... HAR NESS.......

SUSPENSI/ KEMUDI ..................................... ..................................... 1-7

FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS ????????????????????? ????????????????????? 1-7

EMISSION CONTROL SYSTEMS??????? 1-241-24 SISTEM-SIS SISTEM-SISTEM TEM PENGATURAN PENGAT URAN EMISI..

1-1

KETERANGAN UMUM

SERVICE RULES PERATURAN SERVIS GENERALINFORMATION

1. 1. 2. 3. 2. 4. 3. 5. 4. 6. 5. 7. 8. 6. 7. 8.

Use genuine Honda or Honda-recommended Honda-recommended parts and lubricants lubricants or their equivalents. equivalents. Parts that don’t meet meet Honda’s design specifications specifications Pakailah parts Pakailah dan pelumas Parts yang tidak memenuhi may cause parts dan damage to the scooter.asli Honda atau yang direkomendasikan oleh Honda atau sejenisnya. Parts yang spesifikasi rancangan Honda mengakibatkan kerusakan pada skuter. Use the special special tools designed fordapat this product to avoid damage and incorrect assembly. assembly. Use only metric tools tools when servicing the scooter. untuk Metricproduk bolts, nuts and screws screw s are not interchangeable intercha ngeable with English fasteners. Pakailah special tools yang tools yang telah dirancang ini untuk menghindari kerusakan dan kesalahan pada pemasangan. Install new new gaskets, O-rings, cotter cotte r pins, and and lock plates plates when reassembling. Hanya pergunakan metric tools tools ketika menservis skuter. Baut, mur dan sekrup metric tidak dapat dipertukarkan dengan When tightening bolts or nuts, begin with the the larger diameter or inner bolt first. first. Then tighten to the specified specified torque diagonally in incremental incremental pengencang sistem Inggris. steps unless a gasket particular sequence is specified. Pasanglah , O-ring , cotter pin, pin, dan lock plates baru plates baru ketika perakitan kembali. Clean parts in cleaning solvent upon disassembly. disas sembly. Lubricate Lubrica te any sliding slidi surfaces before reassembly. Ketika mengencangkan mengenc angkan baut atau mur, mulailah mulaila h dengan bautngdengan denga n diameter yang lebih besar atau atau baut di sebelah sebelah dalam After reassembly, reasse mbly, check all parts for proper installation inst allation and a nd operation. dulu. Kemudian kencangkan dengan torsi pengencangan yang telah ditentukan secara bersilang dalam langkah-langkah Route all electrical wiresbila as shown from page 1-14, Cable and Harness Routing. peningkatan kecuali telah ditentukan urutan tertentu. Bersihkan parts Bersihkan parts yang yang telah dilepaskan dalam larutan pembersih. Lumasi semua permukaan luncur sebelum perakitan kembali. Setelah perakitan perakitan kembali, kembali, periksalah periksalah semua bagian terhadap pemasangan dan dan pengoperasian yang benar. Alurkan semua semua kawat listrik seperti seperti diperlihatkan diperlihatkan mulai halaman halaman 1-14, Perletakan Kabel dan Harness.

MODEL IDENTIFICATION

IDENTIFIKASI MODEL

1-2

KETERANGAN UMUM The frame serial numberdicetak is stamped on the seat stay stay as(penahan shown. Nomor seri rangka pada seat sadel) seperti diperlihatkan.

NOMOR SERI RANGKA

The engine number is stamped thebawah lower left of the crankcase. Nomor seriserial mesin dicetak pada sisionkiri dariside crankcase (bak crankcase (bak mesin).

NOMOR SERI MESIN

The carburetor identification number is pada stamped leftbadan side ofkarburator. the carburetor Nomor identifikasi karburator dicetak sision kirithe dari body.

NOMOR IDENTIFIKASI KARBURATOR

1-3

KETERANGAN UMUM

GENERAL SPECIFICATIONS SPESIFIKASI UMUM DIMENSI DIMENSIONS

RANGKA FRAME

MESIN ENGINE

KARBURATOR PERALATAN CARBURETOR PENGGERAK DRIVE TRAIN

KELISTRIKAN ELECTRICAL

1-4

BAGIAN SPESIFIKASI ITEM SPECIFICATIONS Panjang menyeluruh 1.859 mm Overall length 1,850 mm (72.8 in) Lebar menyeluruh 676 mm Overall width 676 mm (26.6 in) Tinggi menyeluruh 1.053 mm Overall height Jarak sumbu roda 1.240 mm 1,040 mm (40.9 in) W h e e l b a s e 1,240 mm (48.8 in) Tinggi tempat duduk 737 mm S e a t h e i g h t 7 37 mm (29.0 in) Tinggi pijakan kaki 260 mm Footpeterendah g height ke tanah 260 mm (10.2 in) Jarak 135 mm G r o u n d c l e a r a n c e 1 35 mm (5.3 in) Berat motor siap pakai 89,2 kg Curb rangka weight 89.2 (tulang kg (196.bawah) 7 lbs) Jenis Jenis under bone Frame typdepan e Under bone type Suspensi Garpu teleskopik Jarak 80,5 mm Front pergerakan suspension poros depan Telescopic fork Suspensi belakang Unit swing (unit Front axle travel 80berayun) .5 mm (3.17 in) Jarak 75,0 mm Rear spergerakan uspension poros belakang Unit swing Ukuran depan 80/90-14M/C 40 Rear axlban e trav el 75.0 mm (2.95 in) Ukuran ban belakang 90/90-14M/C 46P Front tire size 80/90 - 14M/C40P Merek (Depan/Belakang) SRI FT235 90/90 - 14M/C46P Rear tirban e size (Depan/Belakang) Rem Tire bdepan rand SRI (Front/Rem Rear) cakram hidraulik FT235 Rem belakang Mekanis, mendahului-mengikuti mendahului-mengikuti Front brake Hydraulic disc brake Sudut caster 26° 30′ Rear brake Mechanical leading trailing Panjang trail 79,0 mm Caster angle 26°30’ Kapasitas tangki bahan bakar 3,3 liter Trail length 79.0 mm (3.11 in) Diameter dan langkah 50,0 x 55,0 mm 3 Fuel tank capacity 3.3 liter (0.87 US gal, 0.73 lmp gal) Volume langkah 108,0 cm Bore and strokekompressi 50.0 x 55.0 mm (1.97 x 2.17 in) Perbandingan 9,2 : 1 D i s p l a c e m e n t 1 08.0 cm3 (6.59 cu-in) Peralatan penggerak klep 2 klep, SOHC digerakkan rantai tunggal C o m p r e s s i o n r a t i o 9 . 5 : 1 Klep masuk membuka ] pada peng10° BTDC (sebelum TMA) Valve train 2 valveTMB) , single chain driven SOHC menutup ] angkatan 35° ABDC (setelah Intakbuang e valve membukao]p1enmm s at 1 mm (0.04 i25 n) °l BBDC ift 1 0 BTDC ° Klep (sebelum TMB) at 1 mm (0.04 i0n°) liATDC ft 35° ABDC menutup c]loses (setelah TMA) Sistem ° Exhauspelumasan t valve opens at 1 mm (0.04 iDi n) bawah lift 2 5 BBDC tekanan paksaan dgn bak oli basah Jenis pompa oli closes at 1 mm (0.04 iTrochoid n) lift 0° ATDC Sistem pendinginan Lubrication system Forceddengan pressurepaksaan and wet sump Pendinginan udara Saringan Oil pump udara type Trochoid Saringan kertas Berat mesin 24,9 kg Coolinkosong g system Forced air cooled Jenis CV (constant V velocity) Air filkarburator tration iscous paper element Diameter throttle 22 mm atau ekuivalennya Engine dry weight 24.9 kg (54.9 lbs) Sistem Kopeling kering, Carburekopeling tor type CVjenis (conssentrifugal tant velocityotomatis ) 2,68 : 1 0,85 : 1 Throttle bore 22 mm (0.9 in) or equivalent Perbandingan Clutch system drive belt (sabuk penggerak) Dry, automatic centrifugal clutch Reduksi akhir 10,625 (51/18 Drive belt ratio 2x.645/12) 8 : 1 - 0.85 : 1 Sistem pengapian DC – CDI Final reduction 10.625 (51/18 x 45/12) Sistem Kickstarter dan motor Ignitionstarter system DC -CDI starter listrik Sistem pengisian Alternator dengan output fase tunggal Starting system Kickstarter with electric starter motor Regulator/rectifier Fase tunggal/dibuka oleh SCR, pembetulan setengah Charging system Single phase output alternator gelombang Regulator/rectifier SCR shorted/single phase, half wave rectification Sistem penerangan Alternator Lighting system Alternator

KETERANGAN UMUM

LUBRICATION SYSTEM SPECIFICATIONS SPESIFIKASI SISTEM PELUMASAN

Satuan: mm BAGIAN STANDARD BATAS SERVIS Unit: mm (in) Kapasitas oli Pada penggantian oli 0,7 liter SERVICE ITEM STANDARD mesin Pada pembongkaran mesin 0,8 liter LIMIT Oli mesin dianjurkan Supreme atau Engine oil yang capacity After drainingFederal Oil0.7 liter (0.7Flick US qt, 0.6oli lmp qt) – mesin 4 tak sejenis dengan klasifikasi After disassembly 0.8 liter (0.8 US qt, 0.7 lmp qt) – API serviceHonda SG, "4-stroke motorcycle oil" or equivalent Recommended engine oil Viskositas: motor SAE 10W-30 JASO MB oil Rotor pompa Jarak renggang pada ujung 0,15 API service classification: SG or0,20 higher oli rotor (except oils labeled as energy conserving on – Jarak renggang antara rotor 0,15 – 0,21the circular API service label) 0,35 dan rumah JASO T 903 standard: MB Jarak renggang ke samping 0,05 – 0,10Viscosity: SAE 10W-30 0,12 rotor pompa Oil pump rotor Tip clearance 0.15 (0.006) 0.20 (0.008) Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014) Side clearance 0.05 – 0.10 (0.002 – 0.004) 0.12 (0.005)

SPESIFIKASI SISTEM BAHAN BAKAR FUEL SYSTEMBAGIAN SPECIFICATIONS Nomor identifikasi karburator Main jet ITEM Slow jet Carburetor identification number Tahanan Main jet listrik SE thermal valve Float level (tinggi permukaan pelampung) Slow jet Pembukaan awal pilot screw SE thermal valve resistance Putaran stasioner Float level Vakuum yang ditentukan Pilot screw initial opening untuk PAIR control valve Jarak main bebas Engine idle speed putaran gas tangan PAIR control valve specified vacuum Throttle grip free play

SPESIFIKASI AVK2CH # 100 SPECIFICATIONS # 35 AVK2CH Ω (20°C) 3,2 – 5,6 #100 13,0 #35 mm Lihat halaman 3.2 – 5.6 Ω (25°5-20 C/77°F) –1 1.700 ±13.0 100mm menit (0.51 (rpm) in) 60 kPa (450 mmHg) See page 5-20 2± – 100 6 mm 1,700 min-1 (rpm) 60 kPa (450 mmHg) 2 – 6 mm (0.1 – 0.2 in)

SPESIFIKASI CYLINDER HEAD/VALVES BAGIAN STANDARD CYLINDER HEAD/VALVES SPECIFICATIONS IN/EX (masuk/ buang) IN/EX IN/EX IN/EX IN/EX IN IN/EX EX IN IN EX EX IN IN EX EX IN IN/EX EX IN/EX IN IN EX EX IN/EX IN/EX

1314 kPa (13,4 kgf/cm2, 191 psi) pada 520 min -1(rpm) 0,05 STANDARD 10,000 – 10,015 2 10,04 1314 kPa (13.4 kgf/cm , 191 psi) at 520 min -1 (rpm) – 9,972 – 9,987 9,91 10.000 – 10.015 (0.3937 – 0.3943) 0,013 – 0,043 0,08 9.972 – 9.987 (0.3926 – 0.3932) 32,4006 – 32,6406 32,37 0.013 – 0.043 (0.0005 – 0.0017) 32,0064 – 32,2464 31,97 32.4006 – 32.6406 (1.27561 – 1.28506) 0,14 ± 0,02 32.0064 – 32.2464 (1.26009 – 1.26954) 0,14 ± 0,02 0.14 ± 0.02 (0.006 ± 0.001) 4,975 – 4,990 4,90 0.14 ± 0.02 (0.006 ± 0.001) 4,955 – 4,970 4,90 4.975 – 4.990 (0.1959 – 0.1965) 5,000 – 5,012 5,03 4.955 – 4.970 (0.1951 – 0.1957) 5.000 – 5.012 (0.1969 – 0.1973) 0,010 – 0,037 0,08 0.010 – 0.037 (0.0004 – 0.0015) 0,030 – 0,057 0,10 0.030 – 0.057 (0.0012 – 0.0022) 9,1 – 9,3 9.1 – 9.3 (0.36 – 0.37)

IN/EX IN/EX IN/EX IN/EX

1,0 1.0 (0.04) 29,78 29.78 (1.172)

Kompressi cylinder Perubahan bentuk melengkung ITEMpada cylinder head Rocker arm D.D. rocker arm Cylinder compression Cylinder head warpage D.L. rocker arm shaft Rocker arm Rocker arm I.D. Jarak renggang arm ke shaft Rocker arm shaft O.D. Camshaft Tinggi cam lobe (bubungan) Arm to shaft clearance Camshaft lobe height Valve, ValveCam clearance (jarak renggang

valve guide Valve, valve guide

klep) Valve clearance D.L. valve stem Valve stem O.D. D.D. valve guide Valve guide I.D. Jarak renggang stem-ke-guide Stem-to-guide clearance

Proyeksi valve guide di atas Valve guide projection above cylinder head cylinder head Lebar valve seat Valve seat width Panjang bebas valve spring Valve spring free length

Satuan: mm BAGIAN Unit: mm (in) SERVICE LIMIT

1,5 29,11

– 0.05 (0.002) 10.04 (0.395) 9.91 (0.390) 0.08 (0.003) - 32.37 (1.274) 31.97 (1.259) – – 4.90 (0.193) 4.90 (0.193) 5.03 (0.198) 0.08 (0.003) 0.10 (0.004) – 1.5 (0.06) 29.11 (1.146)

1-5

KETERANGAN UMUM

CYLINDER/PISTON SPECIFICATIONS SPESIFIKASI CYLINDER/PISTON BAGIAN Cylinder

D.D. ITEM Kelonjongan Cylinder I.D. Ketirusan Out-of-round Perubahan bentuk melengkung Taper Piston, piston D.L. piston Warpage rings, piston pin Piston, piston Piston O.D. Titik pengukuran D.L. piston rings, piston pin Piston O.D. measurement point Piston pin bore I.D.pin D.D. lubang piston Piston pinpin O.D. D.L. piston Piston-to-piston pin clearance Jarak renggang antara Piston ring-to-ring Top piston-ke-piston pin groove clearance Second Jarak renggang Ring paling atas piston ring-ke-alurnya Piston ring end gap Top kedua Ring Celah pada ujung Ring paling atas Second piston ring Ring kedua Oil (side rail) Ring oli (side Cylinder-to-piston clearance rail) Connecting rod small end I.D. Jarak renggang antara cylinder-ke-piston Connecting rod-to-piston pin clearance D.D. kepala kecil connecting rod Jarak renggang antara connecting rod-ke-piston pin

STANDARD 50,000 – 50,015 50,10 STANDARD 0,05 50.005 – 50.015 - (1.9687 – 1.9691) 0,05 – 0,05 – 49,970 – 49,990 49,90 – 49.970 49.990 (1.9673 – 1.9681) 6,0 mm– dari bagian 6.0 (0.24) from bottom of skirt bawah piston 13.002 13,002––13.008 13,008(0.5119 – 0.5121) 13,04 12.994 12,994––13.000 13,000(0.5116 – 0.5118) 12,96 0.002 0,002––0.014 0,014(0.0001 – 0.0006) 0,02 0.015 – 0.050 (0.0006 – 0.0020) 0.015 0,015––0.050 0,050(0.0006 – 0.0020) 0,08 0.10 – 0.25 (0.004 – 0.0020) 0,08 0,015 – 0,050 0,10––0.25 0,25(0.004 – 0.0020) 0,45 0.10 0,10––0.70 0,25(0.008 – 0.028) 0,45 0.20 0,20 –– 0,70 0.015 0.045 (0.0006 – 0.0018) 13.010 – 13.028 (0.5122 – 0.5129) 0,015––0.034 0,045(0.0004 – 0.0013) 0,09 0.010 13,010 – 13,028 13,05 0,010 – 0,034 0,05

Satuan: mm BATAS SERVISUnit: mm (in) SERVICE LIMIT 50.10 (1.972) 0.05 (0.002) 0.05 (0.002) 0.05 (0.002) - 49.95 (1.967) – 13.04 (0.513) 12.96 (0.510) 0.02 (0.001) 0.08 (0.003) 0.08 (0.003) 0.45 (0.018) 0.45 (0.018) – - 0.09 (0.004) 13.05 (0.514) 0.05 (0.002)

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH SPECIFICATIONS SPESIFIKASI KICKSTARTER/DRIVE PULLEY/ ITEM STANDARD DRIVEN PULLEY/CLUTCH Drive belt width Lebar drive belt Movable drive face Movable drive face Clutch Clutch Driven pulley Driven pulley

BAGIAN Bushing I.D. D.D.O.D. bushing Boss D.L. boss Weight roller O.D. D.L. weight roller Lining thickness Ketebalan lapisan kanvas Clutch outer I.D. D.D. clutch outer Face spring free length Panjang bebas Driven face O.D. face spring D.L. driven face Movable driven face I.D. D.D. movable driven face

STANDARD 18.5 (0.73) 18,5 22.035 – 22.085 (0.8675 17,5 – 0.8695) 22,035 22.010– –22,085 22.025 (0.8665 22,11 – 0.8671) 22,010 21,98 15.92 –– 22,025 16.08 (0.627 – 0.633) 15,92 – 16,08 – 15,3 2,0 112.0 – 112.2 (4.41 – 4.42) 112,0 – 112,2 112,5 124.2 (4.89) 124,2 33.965 – 33.985 (1.3372 121,4 – 1.3380) 33,965 34.000– –33,985 34.025 (1.3386 33,94 – 1.3396) 34,000 – 34,025 34,06

Unit: mm (in) SERVICE Satuan: LIMIT mm BATAS SERVIS 17.5 (0.69) 22.11 (0.871) 21.98 (0.865) 15.3 (0.60) 2.0 (0.08) 112.5 (4.43) 121.4 (4.78) 33.94 (1.336) 34.06 (1.341)

FINAL REDUCTION SPECIFICATIONS SPESIFIKASI FINAL REDUCTION ITEM BAGIAN Final reduction oil capacity After draining Kapasitas oli final Pada penggantian periodik After disassembly reduction Setelah pembongkaran Recommended final reduction oil Oli final reduction yang dianjurkan

Unit: mm (in) SPECIFICATIONS SPESIFIKASI 0.10 liter (0.11 US qt, 0.09 lmp qt) 0,10 liter 0.12 liter (0.13 US qt, 0.11 lmp qt) 0,12 liter Honda "4-stroke motorcycle oil" or equivalent motor oil Federal Oil Supreme Flick atau oli mesin 4 tak sejenis dengan API service classification: SG or higher (except oils labeled as energy klasifikasi API service SG, Viskositas: SAE 10W-30 JASO MB conserving on the circular API service label) JASO T 903 standard: MB Viscosity: SAE 10W-30

SPESIFIKASI CRANKCASE/CRANKSHAFT BAGIAN STANDARD CRANKCASE/CRANKSHAFT SPECIFICATIONS Crankshaft

Crankshaft

1-6

Jarak renggang ke samping connecting rod Jarak renggang ITEMradial connecting rod Keolengan Connecting rod side clearance Connecting rod radial clearance Runout

0,10 - 0,35 0 – 0,012

0,55

0,05 STANDARD 0,10 0.10 – 0.35 (0.004 – 0.014) 0 – 0.012 (0 – 0.0005) –

Satuan: mm BATAS SERVIS Unit: mm (in) SERVICE LIMIT 0.55 (0.022) 0.05 (0.022) 0.10 (0.004)

KETERANGAN UMUM

FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS Satuan: mm SPESIFIKASI RODA DEPAN/SUSPENSI/KEMUDI BAGIAN Kedalaman minimum alur telapak ban ITEM Tekanan udara Pengendara saja ban (dingin) Pengendara dan Minimum tire tread depth pembonceng Cold tire pressure Driver only Keolengan axle (poros roda) Driver and passenger Keolengan Radial Axle runout pelek roda Aksial Wheel rim runout Radial Fork (garpu) Panjang bebas pegas Axial Keolengan Fork Spring tabung free length Minyak garpu yang Pipe runout dianjurkan Recommended fluid Tinggi permukaan Fluid level minyak Fluid capacity Kapasitas minyak

STANDARD BATAS SERVIS Unit: mm (in) Sampai ke indikator SERVICE STANDARD 2 200 kPa (2,00 kgf/cm , 29 psi) LIMIT 2 200 kPa (2,00 kgf/cm , 29 psi) – To the indicator 200 kPa (2.00 kgf/cm2, 29 psi) – - kPa (2.00 kgf/cm2, 290,20 200 psi) – – 2,0 0.2 (0.01) – 2,0 2.0 (0.08) 311,3 – 305,1 2.0 (0.08) - (12.26) 0,20 311.3 305.1 (12.01) Minyak sokbreker – 0.2 (0.01) Fork fluid – 50 50 (2.0) – 3 75 ± 1 cm 3 – 75 ± 1 cm (2.5 ± 0.03 US oz, 2.6 ± 0.04 Imp oz)

REAR WHEEL/SUSPENSION SPECIFICATIONS SPESIFIKASI RODA BELAKANG/SUSPENSI BAGIAN ITEM Kedalaman minimum alur telapak ban Tekanan Pengendara saja Minimumudara tire tread depth ban Pengendara dan Colddingin tire pressure Driver only pembonceng Driver and passenger Keolengan pelek Radial Wheel rim runout Radial roda AksialAxial

Satuan: mmmm (in) Unit: STANDARD BATAS SERVIS SERVICE STANDARD Sampai ke indikator LIMIT 2 225 kPa (2,25 kg/cm , 33 psi) – To the indicator 2 225 kPa (2,25 kg/cm , 33 psi)kgf/cm2, 33 psi) 225 kPa (2.25 – 2 225 kPa (2.25 kgf/cm , 33 psi) – – 2,0 2.0 (0.08) – 2,0 2.0 (0.08)

BRAKE SYSTEM SPECIFICATIONS SPESIFIKASI SISTEM REM BAGIAN ITEM Jarak main bebas rear brake lever (handel rem blk.) Rear brake lever free play D.D. rear brake drum ( tromol rem belakang) Rear brake drum I.D. Minyak rem yang dianjurkan Specified brake fluid Brake disc Ketebalan Brake disc Thickness (cakram rem) Perubahan bentuk melengkung Warpage Master cylinder D.D. Cylinder Master cylinder Cylinder I.D. D.L. Piston Piston O.D. Caliper D.D. Cylinder Caliper Cylinder I.D. D.L. Piston Piston O.D.

Satuan:Unit: mm mm (in) STANDARDSTANDARD BATAS SERVIS SERVICE LIMIT 10 - 20 10 – 20 (0.4 – 0.8) – 130,0 131,0 130.0 (5.12) 131.0 (5.16) DOT 3 atau 4 DOT 3 or 4 – 3,3 – 3,7 3,0 3.3 – 3.7 (0.13 – 0.15) 3.0 (0.12) 0,10 – 0.10 (0.004) 11,000 – 11,043 11,055 11.000 – 11.043 (0.4331 – 0.4348) 11.055 (0.4352) 10,957 – 10,984 10,945 10.957 – 10.984 (0.4314 – 0.4324) 10.945 (0.4309) 32,030 – 32,080 32,090 32.030 – 32.080 (1.2610 – 1.2630) 32.090 (1.2634) 31,948 – 31,998 31,94 31.948 – 31.998 (1.2578 – 1.2598) 31.94 (1.257)

1-7

KETERANGAN UMUM

BATTERY/CHARGING SYSTEM/ALTERNATOR SPECIFICATIONS SPESIFIKASI BATERAI/SISTEM PENGISIAN/ALTERNATOR Baterai Battery

Alternator Alternator

BAGIAN ITEM Kapasitas Capacity Kebocoran arus listrik Current leakage Voltase Bermuatan penuh Voltage Fully charged Perlu diisi listrik kembali Needs charging Arus pengisian Normal Charging current Normal Cepat Quick Kapasitas Capacity

SPESIFIKASI SPECIFICATIONS 12 V – 3,5 Ah 12 V – 3.5 Ah maksimum 0,5 mA 0.5 mA max. Di atas 12,8 V Above 12.8 V Di bawah 12,3 V Below 12.3 V 0,4 A / 5-10 jam 0.4 A/5 – 10 h 3,0 A / 0,5 jam 3.0 A/0.5 h -1 0,140 kW / 5.000 menit (rpm) 0.140 kW/5,000 min-1 (rpm)

SPESIFIKASI SISTEM PENGAPIAN IGNITION SYSTEM SPECIFICATIONS BAGIAN

SPESIFIKASI CPR 8EA - 9 (NGK), U24EPR9 (DENSO) SPECIFICATIONS CPR CPR 9EA 8EA – 9 (NGK) – 9 (NGK)

Busi

Standard ITEM Untuk pengendaraan lama pada Spark plug Standard kecepatan tinggi For extended high speed riding Jarak renggang busi Spark plug gap Voltase puncak ignition coil Ignition coil peak voltage Voltase puncak ignition pulse generator Ignition pulse generator peak voltage Ignition timing (pengaturan waktu pengapian) Ignition timing

CPR 9EA – 9 (NGK) 0,80 – 0,90 mm 0.80 – 0.90 mm (0.031 – 0.035 in) minimum 100 V 100 V minimum minimum 0,7 V 0.7 V minimum 14° sebelum TMA pada putaran stasioner 14° BTDC at idle speed

ELECTRIC STARTER SYSTEM SPECIFICATION SPESIFIKASI STARTER LISTRIK BAGIAN Panjang sikat starter motor ITEM Starter motor brush length

STANDARD 7,0

3,5 STANDARD 7.0 (0.28)

Satuan: mm BATAS SERVIS Unit: mm (in) SERVICE LIMIT 3.5 (0.14)

SPESIFIKASI LAMPU2 / METER2 / SAKELAR2 BAGIAN SPESIFIKASI LIGHTS/METERS/SWITCHES SPECIFICATION Bola lampu Bulbs

Sekring Fuse

1-8

Lampu besar Lampu senja ITEM Lampu belakang/rem Headlight Lampu seinlight depan Position Lampu sein belakang Tail/brake light Lampu penerangan instrumen Front turn signal light Indikator lampu jauh Rear turn signal light Indikator lampu sein Instrument light Sekring Highutama beam indicator Sekring Turn tambahan signal indicator Main fuse Sub fuse

12 V – 32/32 W 12 V – 3,4 W SPECIFICATIONS 12 V12 –V 5/18 W W – 32/32 12 V –12 10VW– 3.4 x 2W 12 V –1210VW x2 W – 5/18 12 V – 1,7 W 2 x2 12 V – 10x W 12 V WW x 2 12–V1,7 – 10 12 V – 3,4 WW x 2 12 V – 1.7 15 12 AX 1 V – 1.7 W 10 12 AX V 1– 3.4 W 15 A x 1 10 A x 1

KETERANGAN UMUM

STANDARD VALUES NILAI TORSITORQUE STANDARD JENIS PENGIKAT TYPE FASTENER Baut dan mur hex 5 mm 5 mm hex bolt and nut Baut dan mur hex 6 mm 6 mm hex bolt nut SH) (termasuk bautand flens (Include SH flange Baut dan mur hex bolt) 8 mm 8 mmdan hex mur bolt and Baut hex nut 10 mm 10 mm hexmur bolthex and12 nutmm Baut dan 12 mm hex bolt and nut

TORSI JENIS TORQUE PENGIKATFASTENER TYPE N.m (kgf.m; lbf.ft) N·m (kgf·m, lbf·ft) 5,2 (0,5; 3,8) Sekrup 5 mm 5.2 (0.5, 3.8) 5 mm screw 10 (1,0; 7) Sekrup 6 mm 10 (1.0, Baut 7) mm screw flens 66mm 6 mm bolt 22 (2,2; 16) (termasuk NSHF)flange dan mur (Include NSHF) 22 (2.2, 16) 34 (3,5; 25) Baut flens 8 mm dan mur and nut 34 (3.5, 25) 8 mm mm flange bolt and nut 54 (5,5; 40) Baut flens 10 dan mur 10 mm flange bolt and nut 54 (5.5, 40)

TORSI TORQUE N.m (kgf.m; lbf.ft) N·m (kgf·m, lbf·ft) 4,2 (0,4; 3,1) 4.2 (0.4, 3.1) 9,0 (0,9; 6,6) 12 (1,2; 9) 9.0 (0.9, 6.6) 12 (1.2, 9) 27 (2,8; 20) 39 (4,0; 29) 27 (2.8, 20) 39 (4.0, 29)

TORSI PENGENCANGAN MESIN & RANGKA ENGINE & FRAME VALUES • Spesifikasi torsi yang terdaftar diTORQUE bawah adalah untuk pengikat tertentu. Pengikat lain harus dikencangkan dengan torsi pengencangan standard yang terdaftar di atas. •• Torque specifications listed below are for specified fasteners. •RANGKA/BODY Others should bePANELS/SISTEM tightened to standardPEMBUANGAN torque values listed above. GAS JUMDIAMETER TORSI FRAME/BODY PANELS/EXHAUST SYSTEM BAGIAN CATATAN LAH ULIR (mm) N.m (kgf.m; lbf.ft) THREAD TORQUE ITEM Q'TY REMARKS Cooling fan cover screw 2 5 0,8 (0,1; 0,6) DIA. (mm) N·m (kgf·m, lbf·ft) Cooling fan cover bolt 2 6 9 (0,9; 6,6) Cooling fan cover screw 2 5 0.8 (0.1, 0.6) Muffler mouting bolt 2 10 59 (6,0; 44) Cooling fan cover bolt 2 6 9 (0.9, 6.6) Muffler mounting bolt 2 10 59 (6.0, 44) PERAWATAN JUMDIAMETER TORSI MAINTENANCE BAGIAN CATATAN LAH ULIR (mm) N.m (kgf.m; lbf.ft) THREAD Spark plug (busi) ITEM 1 Q'TY 10 16 (1,6;TORQUE 12) REMARKS DIA. (mm) lbf·ft) Valve adjusting screw lock nut 2 5 10N·m (1,0;(kgf·m, 7) Oleskan oli pd. ulir Spark plug (1.6, 12) Engine oil drain bolt 1 1 12 10 24 (2,4;1618) Valve adjusting screw lock nut 2 5 10 (1.0, 7) Apply oil to the threads Engine oil strainer screen cap 1 30 20 (2,0; 15) Engine oil drain bolt 1 12 24 (2.4, 18) Final reduction oil check bolt 1 8 13 (1,3; 10) Engine oil strainer cap (2.0, 15) Final reduction oilscreen drain bolt 1 1 8 30 13 (1,3;2010) Final reduction oil check boltscrew 8 (1.3, 10) Air cleaner housing cover 4 1 5 1,1 (0,1;130,8) Final reduction oil drain bolt 1 8 13 (1.3, 10) SISTEM PELUMASAN Air cleaner housing cover screw 4 5 1.1 (0.1, 0.8) JUMDIAMETER TORSI LUBRICATION SYSTEM BAGIAN CATATAN LAH ULIR (mm) N.m (kgf.m; lbf.ft) Oil pump plate screw Oil pump mountingITEM bolt Oil pump plate screw Oil pump mounting bolt SISTEM BAHAN BAKAR FUEL SYSTEM

BAGIAN Inlet pipe band screw ITEM SE thermal valve body screw Inletthermal pipe band screw SE valve setting plate screw SE thermal valve body screw Vacuum chamber cover screw SE thermal Slow jet valve setting plate screw Main jet chamber cover screw Vacuum Needle Slow jetjet holder Float screw Main chamber jet Float chamber Needle jet holderdrain screw PAIR check valve cover screw Float chamber screw Fuel auto valve lock nut Float chamber drain screw PAIR check valve cover screw Fuel auto valve lock nut PELEPASAN/PEMASANGAN MESIN

ENGINE REMOVAL/INSTALLATION BAGIAN

Engine hanger link nut (sisi mesin) ITEM Engine hanger link nut (Engine side)

1 2 Q'TY 1 2

4THREAD 6 DIA. (mm) 4 6

3 (0,3; TORQUE 2,2) 10N·m (1,0;(kgf·m, 7) lbf·ft) 3 (0.3, 2.2) 10 (1.0, 7)

JUMDIAMETER TORSI LAH ULIR (mm) N.m (kgf.m; lbf.ft) 2 Q'TY 5THREAD 2 (0,2; TORQUE 1,5) DIA. (mm) N·m (kgf·m, lbf·ft) 2 5 3,4 (0,4; 2,5) 2 5 2 (0.2, 1.5) 1 4 2,1 (0,2; 1,5) 5 3.41,5) (0.4, 2.5) 2 2 4 2,1 (0,2; 4 2.11,1) (0.2, 1.5) 1 1 1,5 (0,2; 1 2 2,1 (0,2; 4 2.11,5) (0.2, 1.5) 1 1 2,5 (0,3; – 1.51,8) (0.2, 1.1) 3 1 4 2,1 (0,2; – 2.11,5) (0.2, 1.5) 1 1 1,5 (0,2; 1,1) – 2.5 (0.3, 1.8) 2 3 4 2,1 (0,2; 4 2.11,5) (0.2, 1.5) 1 1 16 – 22,5 (2,3; 1.5 17) (0.2, 1.1) 2 4 2.1 (0.2, 1.5) 1 16 22.5 (2.3, 17) JUMDIAMETER TORSI LAH ULIR (mm) N.m (kgf.m; lbf.ft) THREAD 1 10 49 (5,0;TORQUE 36) Q'TY DIA. (mm) N·m (kgf·m, lbf·ft) 1 10 49 (5.0, 36)

REMARKS

CATATAN REMARKS

CATATAN REMARKS

1-9

KETERANGAN UMUM CYLINDER CYLINDER HEAD/VALVES/CYLINDER/PISTON HEAD/VALVES/CYLINDER/PISTON JUMDIAMETER TORSI THREAD TORQUE ITEM Q'TY ULIR (mm) REMARKS BAGIAN CATATAN LAH N.m (kgf.m; lbf.ft) lbf·ft) DIA. (mm) N·m (kgf·m, Intake shroudmounting mountingscrew screw 3 3 5 0,8 (0,1; Intake shroud 5 0.80,6) (0.1, 0.6) Exhaust shroudmounting mounting bolt 1 1 6 7 (0,7; 75,1) Exhaust shroud bolt 6 (0.7, 5.1) Cylinder headnut nut 4 4 7 18 (1,8;1813) pd. uliroil to the threads Cylinder head 7 (1.8, 13) Oleskan oliApply Oleskan oli pd. ulir Cylinder head bolt 2 6 12 (1,2; 9) Cylinder head bolt 2 6 12 (1.2, 9) Apply oil to the threads Oleskan oli pd. ulir Cam sprocket bolt 2 5 8 (0,8; 5,9) Cam sprocket bolt 2 5 8 (0.8, 5.9) Apply oil to the threads Cam chain tensioner lifter screw 1 6 4 (0,4; 3,0) Cam chain tensioner lifter screw 1 6 4 (0.4, 3.0) Cylinder head cover special bolt 2 6 12 (1,2; 9) Cylinder head cover special bolt 2 6 Cam chain tensioner slider pivot pin bolt 1 6 10 (1,0;127)(1.2, 9) Cam chain tensioner slider pivot pin bolt 1 6 10 (1.0, 7) KICKSTARTER/DRIVE PULLEY/DRIVENPULLEY/CLUTCH PULLEY/CLUTCH KICKSTARTER/DRIVE PULLEY/DRIVEN JUMDIAMETER TORSI THREAD TORQUE ITEM Q'TY ULIR (mm) REMARKS BAGIAN CATATAN LAH N.m (kgf.m; lbf.ft) lbf·ft) DIA. (mm) N·m (kgf·m, Left cover plate screw 5 5 4 3 (0,3; 32,2) Left crankcase crankcase cover plate screw 4 (0.3, 2.2) Drive pulley face nut 1 14 108 (11,0; pd. uliroil to the threads Drive pulley face nut 1 14 108 80) (11.0, 80)Oleskan oliApply Clutch/driven pulley nut 1 28 54 (5,5; 40) Clutch/driven pulley nut 1 28 54 (5.5, 40) Clutch outer nut 1 12 49 (5,0; 36) Clutch outer nut 1 12 49 (5.0, 36) FRONT WHEEL/SUSPENSION/STEERING RODA DEPAN/SUSPENSI/KEMUDI ITEM BAGIAN

Front axlenut nut Front axle Front brakedisc discsocket socket bolt Front brake bolt Handlebar post nut Rear brakepost lever Handlebar nutpivot bolt Rear brake lever pivotbolt nut Rear brake lever pivot Bottom bridge Rear brake leverpinch pivot bolt nut Fork socket bolt Bottom bridge pinch bolt Steering stem Fork socket bolttop thread Steering stem lock nut Steering stem top thread Steering stem lock nut RODA BELAKANG/SUSPENSI REAR WHEEL/SUSPENSION BAGIAN ITEM

Rear axle nut Engine hanger Rear axle nut link nut (sisi rangka) Engine hanger link nut (Frame side) SISTEM REM BRAKE SYSTEM BAGIAN Rear brake arm bolt ITEM Brake caliper bleed valve Rear brake armcylinder bolt Brake master reservoir cap screw Brake caliper Brake pad pinbleed valve Brake master cylinder reservoir Front brake lever pivot bolt cap screw Brake brake pad pinlever pivot nut Front Front brake bolt Front brakelever light pivot switch screw Front brake lever pivot Brake hose oil bolt nut Front brake light switch screw Brake caliper mounting bolt Brake caliper Brake hose oil pin bolt Brake caliper mounting bolt

Brake caliper pin

1-10

THREAD TORQUE JUMDIAMETER TORSI Q'TY REMARKS CATATAN LAH ULIRDIA. (mm)(mm)N.m (kgf.m; lbf.ft) lbf·ft) N·m (kgf·m, 1 1 12 12 59 (6,0;5944) (6.0, 44) U-nut U-nut 4 4 8 42 (4,3;4231) 8 (4.3, 31) ALOC bolt: ALOC bolt: 1 10 59 (6,0; 44) ganti dgn. replace yg. baru with new ones 1 1 5 10 1 (0,1;59 0,7) (6.0, 44) 1 1 5 4,5 (0,5; 5 1 3,3) (0.1, 0.7) 4 1 10 5 64 (6,5; 4.547) (0.5, 3.3) 2 4 8 10 20 (2,0;6415) (6.5, 47) Oleskan cairan pengunci 1 2 26 8 Lihat hal.20 11-22 (2.0, 15) Apply locking agent 1 26 Lihat hal. 11-22 1 26 See page 11-22 1 26 See page 11-22

JUMDIAMETER TORSI CATATAN LAH ULIR THREAD (mm) N.m (kgf.m; lbf.ft) TORQUE Q'TY REMARKS DIA. (mm) 118 N·m (kgf·m, 1 16 (12,0; 87) lbf·ft) U-nut, Oleskan oli pd. ulir 1 1 10 16 69 (7,0; 11851) (12.0, 87) U-nut, Apply oil to the threads 1 10 69 (7.0, 51) JUMDIAMETER TORSI CATATAN LAH ULIR (mm) N.m (kgf.m; lbf.ft) THREAD TORQUE 1Q'TY 6 10 (1,0; 7) ALOC bolt: ganti dengan yang baru REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) 1 8 6 (0,6; 4,4) 6 (1.0, 7) ALOC bolt: replace with a 2 1 4 2 (0,2; 10 1,5) new one 1 8 6 (0.6, 4.4) 1 10 18 (1,8; 13) 4 (0.2, 1.5) 1 2 6 1 (0,1; 20,7) (1.8, 13) 1 1 6 10 6 (0,6;18 4,4) 1 6 1 (0.1, 1 4 1 (0,1; 0,7) 0.7) 1 6 (0.6, 4.4) 2 10 34 (3,5;6 25) 4 (0.1, 0.7) ALOC bolt: ganti dengan yang baru 2 1 8 30 (3,1;1 22) 1 2 8 10 18 (1,8;3413) (3.5, 25) 2 8 30 (3.1, 22) ALOC bolt: replace with new ones 1 8 18 (1.8, 13)

KETERANGAN UMUM BATTERY/CHARGING SYSTEM/ALTERNATOR BATTERY/SISTEM PENGISIAN/ALTERNATOR JUMDIAMETER TORSI THREAD TORQUE ITEM Q'TY ULIR (mm) BAGIAN LAH N.m (kgf.m; lbf.ft) lbf·ft) DIA. (mm) N·m (kgf·m, Cooling fan mounting mountingbolt bolt 3 3 6 10 (1,0;107)(1.0, 7) Cooling fan 6 Flywheel nut 1 10 39 (4,0;3929) Flywheel nut 1 10 (4.0, 29) Ignition pulse generator 2 5 6 (0,6; lgnition pulse generator 2 5 64,4) (0.6, 4.4)

REMARKS CATATAN

IGNITION SYSTEM SISTEM PENGAPIAN ITEM BAGIAN Key shutter shutter socket Key socketbolt bolt ELECTRIC STARTER SYSTEM SISTEM STARTER LISTRIK ITEM BAGIAN Starter motor case screw Starter motor case screw OTHERS

LAIN-LAIN

ITEM

BAGIAN Carburetor throttle cable holder mounting screw Carburetor throttle cable holder Brake shoescrew anchor pin nut mounting Brake nut (when shoe using anchor the stakepin nut) (sewaktu memakai stake (when using the normal nut)nut) (sewaktu memakai normalbolt nut) Muffler protector mounting Muffler protector mounting bolt Sidestand pivot nut Sidestand pivotbolt nut Sidestand pivot Sidestand pivot bolt

THREAD TORQUE JUMTORSI Q'TY DIAMETER DIA. (mm) N·m LAH ULIR (mm) N.m (kgf.m;(kgf·m, lbf.ft) lbf·ft) 6 1 1 6 10 (1,0;107)(1.0, 7)

REMARKS CATATAN

THREAD TORQUE Q'TY DIAMETER JUMTORSI DIA. (mm) N·m (kgf·m, lbf·ft) LAH ULIR (mm) N.m (kgf.m; lbf.ft) 3 4 2 (0.2, 1.5) 3 4 2 (0,2; 1,5)

REMARKS CATATAN

THREAD TORQUE Q'TY DIA. (mm) N·m (kgf·m, lbf·ft) JUMDIAMETER TORSI 5 3.4 lbf.ft) (0.4, 2.5) LAH 2 ULIR (mm) N.m (kgf.m; 2 5 3,4 (0,4; 2,5) 1 8 1 8 20 (2.0, 15) 20 (2,0;1815) (1.8, 13) 18 (1,8;10 13) 2 6 (1.0, 7) 2 1 6 10 10 (1,0; 7) 29 (3.0, 21) 1 1 10 10 29 (3,0; 1021) (1.0, 0.7) 1 10 10 (1,0; 0,7)

REMARKS

CATATAN

1-11

KETERANGAN UMUM

LUBRICATION & SEAL POINTS TITIK-TITIK PELUMASAN & PERAPATAN ENGINE MESIN

MATERIAL BAHAN Liquid sealant (recommended: Liquid sealant (dianjurkan: Three Bond 1207B or Three Three Bond 1207B atau Three Bond 1215 or equivalent) Bond 1215 atau sejenisnya) Liquid sealant (recommended: Liquid sealant (dianjurkan: Three Bond 5211C or SHIThree Bond 5211C atau NETSU-SILICONE KE45T or SHINETSU-SILICONE KE45T Three Bond 1215 or equivaatau Three Bond 1215 atau lent) sejenisnya) Adhesive (recommended: Adhesive (dianjurkan: CEMEDINE 575 or Three CEMEDINE atau Three Bond 1194 or575 equivalent) Bond 1194 atau sejenisnya) Locking agent (recommended: Locking agent (dianjurkan: Three Bond 2415 or 1322N or Three Bond 2415 1322N LOCKTITE 200 or atau equivalent) atau LOCKTITE 200 atau Molybdenum oil solution (a sejenisnya) mixture of 1/2 engine oil and 1/ Molybdenum solution 2 molybdenumoil disulfide (campuran dari ½ oli mesin grease) dan ½ molybdenum Molybdenum disulfidedisulfide paste grease) Molybdenum disulfide paste

Multi-purpose grease Grease Multi-purpose grease (Shell ALVANIA R3 or Grease (gemuk) IDEMITSU AUTOREX B or (Shell ALVANIA R3 atau equivalent) IDEMITSU AUTOREX B atau Engine oil sejenisnya) (Without molybdenum additives) Oli mesin (Tanpa molybdenum additives)

Degrease

Bersihkan dari gemuk

1-12

LOCATION LOKASI Right crankcase mating surface Permukaan penyatuan right crankcase

REMARKS CATATAN See page 10-9 Lihat hal. 10-9

Cylinder head mating surface (semicircular area) Permukaan penyatuan cylinder head (daerah setengah lingkaran)

See page 7-8 Lihat hal. 7-8

Cylinder head cover and seal rubber mating surface (hatched See page 7-7 Cylinder head cover dan permukaan penyatuan Lihat hal. 7-7 area) seal rubber (daerah penutupan) Driveshaft bearing set plate bolt threads Ulir driveshaft bearing set plate bolt Air supply pipe mounting bolt threads Ulir air supply pipe mounting bolt

See page 9-16 Lihat hal. 9-16 See page 5-25 Lihat hal. 5-25

Camshaft cam lobes

Camshaft cam lobes (bubungan camshaft) Kickstarter spindle sliding surface Kickstarter driven gear shaft Permukaan luncur kickstarter spindle Kickstarter driven gear friction spring sliding area Kickstarter driven gear shaft Kickstarter spindle dust seal lip Daerah luncur kickstarter driven gear friction spring Driven face inner surface Bibir kickstarter spindle dust seal Movable driven face cam groove Permukaan dalam driven face Starter pinion gear shaft (both end) Alur movable driven face cam Driven face ball bearing and needle bearing Starter pinion gear shaft (kedua ujungnya) Oil pump drive gear teeth Driven face ball bearing dan needle bearing Oil pump rotor whole surface Oil pump shaft and pump cover sliding area Gigi-gigi oil pump drive gear Oil pumppermukaan driven gear teeth Seluruh oil pump rotor Rocker arm shaft sliding Daerah luncur oil pumpsurface shaft dan pump cover Rocker arm Gigi-gigi oilroller pumpsliding drivenarea gear Camshaft decompressor rotating Permukaan luncur rocker arm surface shaft Camshaft bearing Daerah luncur rocker arm roller Cam sprocketberputar teeth Permukaan camshaft decompressor Camshaft bearing Cam chain whole surface Gigi-gigi cam sprocket Timing sprocket teeth Seluruh permukaan camsurfaces chain Piston and cylinder sliding Gigi-gigi timing sprocket Piston pin hole sliding area Permukaan luncur piston dan cylinder Piston ring whole surface and ring grooves Daerah luncur lubang piston pin Piston pin outer surface Seluruh permukaan piston ring dan alur ring Connecting rod small end inner surface Permukaan luar piston pin Crankshaft bearings Permukaan dalam connecting rod small end Connecting rod big end bearing (kepala kecil connecting rod) Valve stem (valve guide sliding area) Crankshaft bearings Valve stem seal surface Connecting rodinner big end bearing (bantalan kepala Bearing area of drive, counter and final shaft besar connecting rod) Drive, and final gear teeth Valve counter stem (daerah luncur valve guide) Cam set plunger whole surface Permukaan dalam valve stem seal Ball/needle bearing sliding area Daerah bearing dari drive, counter dan final shaft Each O-ring whole surface Gigi-gigi drive, counter dan final gear Seluruh permukaan cam set plunger Oil seal lips and outer surfaces Daerah luncur ball/needle Right crankshaft tapered areabearing Seluruh permukaan masing-masing Drive/driven pulley face and drive belt O-ring Bibir dan permukaan luar seal inner surface Left crankcase cover bearingoil bushing Daerah meruncing dari right crankshaft Muka drive/driven pulley dan drive belt Permukaan dalam left crankcase cover bearing bushing

0.1 – 0.3 g 0.2 – 0.3 g 0,1 –0,3 g 0,2 – 0,3 g 7.0 – 8.0 g 2.0 – 2.5 g 7,0 – 8,00.1 g – 0.3 g 2,0 – 2,5 g 0,1 – 0,3 g

0.5 – 1.0 cc

0,5 – 1,0 cc

Fill up 2 cc minimum Fill up 3 cc minimum

Isi dengan minimum 2 cc Isi dengan minimum 3 cc

KETERANGAN UMUM RANGKA FRAME BAHAN MATERIAL Multi-purpose grease dengan Multi-purpose grease with tekanan sangat tinggi extreme pressure (recom(dianjurkan: EXCELIGHT EP2 mended: EXCELIGHT EP2 buatan KYODO YUSHI, manufactured by KYODO Japan, atau Shell ALVANIA YUSHI, japan. or Shell ALVAEP2 atau sejenisnya) NIA EP2 or equivalent) Grease (Shell BEARING Grease GREASE HD atau sejenisnya) (Shell BEARING GREASE Multi-purpose grease HD or equivalent) Multi-purpose grease

Silicone grease Silicone grease

Brake fluid (minyak rem) Brake 3 fluid (DOT atau DOT 4) (DOT 3 or DOT 4) Fork fluid (minyak sokbreker) Fork fluid Adhesive (Honda bond A atau Adhesive sejenisnya) (Honda bond A or equivalent) Locking agent (recommended: Locking agent (dianjurkan: Three Bond 2415 or 1322 N or LOCKTITE or atau equivalent) Three Bond 200 2415 1322 N atau LOCKTITE 200 atau sejenisnya)

LOKASI LOCATION Steering bearing race Steering bearing race Bibir steering stem dust seal Steering stem dust seal lip

CATATAN REMARKS Isi dengan minimum 3 g Fill up 3 g minimum

Bagian dalam speedometer gear box Speedometer gear box inside Bibir front wheel dust seal Permukaan luncur front wheel axle Front wheel dust seal lip Seluruh permukaan front wheel distance collar Front wheel axle sliding surface Daerah luncur front wheel bearing Front wheel distance collar whole surface Bibir speedometer gear box seal Front wheel sliding Rear brake bearing cam dan shaftarea Oleskan masing-masing Speedometer gear box seal lip 0,2 – 0,3 g Rear brake and shaft eachg0.2 - 0.3 g Rear brakecam anchor pin shaft Oleskan Apply 0,2 – 0,3 Rear brake anchordust pin shaft Apply 0.2 - 0.3 g Bibir rear brake seal Rear brake dust seal lip Permukaan luncur rear brake lever pivot bolt Rear brake leverthrottle pivot bolt sliding surface drum Daerah luncur cable-ke-throttle Oleskan 0,1 – 0,2 g Throttle cable-to-throttle drum sliding area Apply 0.1 - 0.2 g Daerah kontak seat catch (penahan tempat duduk) Daerah centerstand Seat catch contact areapivot Daerah sidestand pivot Centerstand pivot area Sidestand pivot area Bagian dalam cable cap boot Rear brake cablerear cap brake boot inside Daerah kontak front brakepiston lever-ke-master piston Oleskan Apply 0,1 g 0.1 g Front brake lever-to-master contacting area Daerah luncur front brake lever pivot Front brake lever pivot sliding area Daerah luncur caliper Oleskan Apply minimum g Brake caliper pinbrake sliding area pin 0.4 g0,4 minimum Seluruh permukaan brake caliper dust seal Brake caliper dust seal whole surface Speedometer cable Speedometer cable Bagian dalam throttle cable boot Oleskan 0,1 g Throttle cable boot inside Apply 0.1 g Bagian dalam throttle cable Oleskan minimum 0,2 g Throttle cable inside Apply 0.2 g minimum Bagian dalam dan daerah luncur master cylinder Master cylinder inside and sliding area Seluruh permukaan brake caliper piston seal Brake caliper piston seal whole surface Seluruh permukaan brake caliper piston Brake caliper piston whole surface Master cylinder piston cup Master cylinder piston cupoil seal Bibir fork dust seal dan Fork dustpermukaan seal and oil seal Seluruh forklips spring seat O-ring Fork spring seathandlebar O-ring whole surface Bagian dalam grip rubber Handlebar grip rubber inside Daerah penyatuan PAIR control valve r ubber PAIR control valve rubber-to-air cleaner housing mating area -ke-air cleaner housing Daerah penyatuan airhose-to-housing cleaner connecting Air cleaner connecting matinghose-kearea housing Centerstand shaft bolt threads See page 10-11 Ulir centerstand shaft bolt Lihat hal. 10-11

1-13

KETERANGAN UMUM

CABLE & HARNESS ROUTING PERLETAKAN KABEL & HARNESS STARTER SWITCH WIRE

DIMMER SWITCH WIRE LIGHTING SWITCH WIRE

TURN SIGNAL SWITCH WIRE RIGHT HANDLEBAR SWITCH WIRE FRONT BRAKE HOSE

FRONT BRAKE LIGHT SWITCH WIRE

LEFT HANDLEBAR SWITCH WIRE

HORN SWITCH WIRE

REAR BRAKE CABLE

REAR BRAKE LIGHT SWITCH WIRE THROTTLE

REAR BRAKE CABLE

HANDLEBAR SWITCH/ SPEEDOMETER WIRE

FRONT BRAKE HOSE HANDLEBAR SWITCH/ SPEEDOMETE R WIRE

HANDLEBAR SWITCH/ SPEEDOMETER WIRE

SPEEDOMETER CABLE FRONT BRAKE HOSE THROTTLE CABLE

SPEEDOMETER CABLE

REAR BRAKE CABLE

THROTTLE CABLE

IGNITION SWITCH WIRE

HORN WIRE FRONT BRAKE HOSE HANDLEBAR SWITCH/ SPEEDOMETER WIRE Letakkan penutup kawat terminal klakson dengan lubang pembuangan menghadap ke bawah :

1-14

SPEEDOMETER

KETERANGAN UMUM HORN WIRE SPEEDOMETER CABLE

MAIN WIRE HARNESS

THROTTLE CABLE

REAR BRAKE CABLE

FRONT BRAKE HOSE

MAIN WIRE HARNESS

SPEEDOMETER CABLE

FRONT BRAKE HOSE

1-15

KETERANGAN UMUM

MAIN WIRE HARNESS Jepit daerah dengan pita putih:

REAR BRAKE CABLE

SIDESTAND SWITCH WIRE

THROTTLE CABLE

BATTERY NEGATIVE (–) CABLE

FUSE BOX WIRE

1-16

BATTERY POSITIVE (+) CABLE

STARTER RELAY WIRE

KETERANGAN UMUM

STARTER ENRICHMENT (SE) THERMAL VALVE WIRE

PULSE SECONDARY AIR INJECTION (PAIR) CONTROL VALVE VACUUM HOSE

CRANKCASE BREATHER HOSE CARBURETOR AIR VENT HOSE FUEL VALVE VACUUM HOSE

THROTTLE CABLE ALTERNATOR/IGNITION PULSE GENERATOR WIRE

STARTER MOTOR/ GROUND CABLE

CARBURETOR DRAIN HOSE

SIDESTAND SWITCH WIRE AIR SUPPLY PIPE

STARTER ENRICHMENT (SE) THERMAL VALVE WIRE

CRANKCASE BREATHER HOSE

ALTERNATOR/ IGNITION PULSE GENERATOR WIRE


1-17

KETERANGAN UMUM

°

5 7

SISI ATAS

CARBURETOR VACUUM PISTON HOSE

AIR CLEANER CONNECTING HOSE BAND CRANKCASE BREATHER HOSE

SISI ATAS

CARBURETOR VACUUM PISTON HOSE CLIP FUEL HOSE

FUEL VALVE VACUUM HOSE CARBURETOR AIR VENT HOSE

THROTTLE CABLE

SISI ATAS

INLET PIPE BAND


1-18

KETERANGAN UMUM FUEL LEVEL SENSOR WIRE

REGULATOR/ RECTIFIER WIRE

SPARK PLUG WIRE

GROUND CABLE (KECIL)

BOLT

GROUND CABLE (BESAR) Sambungan air supply hose dengan sisinya yang bertanda mengahadap keluar. TANDA

AIR SUPPLY PIPE


AIR SUPPLY HOSE

STARTING ENRICHMENT (SE) THERMAL VALVE WIRE

AIR SUPPLY HOSE

Terpasang

SISI ATAS

AIR SUPPLY HOSE

HOSE BAND

ALTERNATOR/ IGNITION PULSE GENERATOR WIRE

SPARK PLUG WIRE


1-19

KETERANGAN UMUM

CARBURETOR VACUUM PISTON HOSE

THROTTLE CABLE FUEL HOSE FUEL VALVE VACUUM HOSE

FUEL HOSE


FUEL VALVE VACUUM HOSE FUEL VALVE VACUUM HOSE THROTTLE CABLE



CARBURETOR AIR VENT HOSE

1-20

KETERANGAN UMUM GROUND CABLE

STARTER MOTOR CABLE

GROUND CABLE ALTERNATOR/IGNITION PULSE GENERATOR WIRE

IGNITION PULSE GENERATOR WIRE

1-21

KETERANGAN UMUM

CRANKCASE BREATHER DRAIN HOSE

FINAL REDUCTION CASE BREATHER HOSE Sewaktu memasang pedal kikstarter pada posisi standard:

SEJAJAR

REAR BRAKE CABLE

CARBURETOR DRAIN Waktu memasang standard samping pada posisi standard:

1-22

Waktu memasang standard utama pada posisi standard:

KETERANGAN UMUM

POSITION LIGHT WIRE

LEFT FRONT TURN SIGNAL LIGHT WIRE

RIGHT FRONT TURN SIGNAL LIGHT WIRE HEAD LIGHT WIRE

RIGHT REAR TURN SIGNAL LIGHT WIRE TAIL/BRAKE LIGHT WIRE

TAIL/BRAKE LIGHT/REAR TURN SIGNAL LIGHT WIRE

LEFT REAR TURN SIGNAL LIGHT WIRE Tepatkan daerah yang berpita putih dengan tab

TAIL/BRAKE LIGHT/REAR TURN SIGNAL LIGHT WIRE

1-23

KETERANGAN UMUM

EMISSION CONTROL SYSTEMSEMISSI SISTEM-SISTEM PENGATURAN SOURCEEMISSI OF EMISSIONS SUMBER The combustion process produces carbon monoxide and hydrocarbons. Controlling hydrocarbon emission is very important because, under Proses pembakaran karbon monoksida dan subjected hidrokarbon. Pengaturan hidrokarbon adalah sangat certain conditions, theymenghasilkan react to form photochemical smog when to sunlight. Carbonemissi monoxide does not react in the samepenting way, but oleh it is karena, pada kondisi tertentu, mereka bereaksi membentuk photochemical smog ketika terkena cahaya matahari. Karbon toxic. monoksida tidak bereaksi dengan cara yang sama, tetapi ia beracun. Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide, oxides of nitrogen and hydrocarbons. Honda Motor Co., Ltd. menggunakan penyetelan karburator yang miskin maupun sistem lain, untuk mengurangi karbon monoksida, oksida dari nitrogen dan hidrokarbon.

CRANKCASE EMISSION CONTROL SYSTEM

The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned to the combustion chamber through the air cleaner and carburetor.

SISTEM PENGATURAN EMISSI CRANKCASE

Mesin dilengkapi dengan sistem crankcase (bak mesin) tertutup untuk mencegah pengeluaran emissi bak mesin ke dalam atmosfir. Blow-by gas (gas hasil pembakaran yang masuk ke dalam bak mesin melalui piston ring ) dikembalikan ke dalam ruang pembakaran melalui air cleaner (saringan udara) dan karburator.

CARBURETOR

AIR CLEANER

UDARA BLOW-BY GAS

1-24

KETERANGAN UMUM EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDARY AIR INJECTION SYSTEM) SISTEM PENGATURAN EMISSI GAS PEMBUANGAN The exhaust emission control system consists of a secondary air supply system which introduces filtered air into the exhaust gas in the exhaust (PULSE SECONDARY AIR INJECTION SYSTEM)

port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system. This charge of fresh air promotes burning the unburned exhaust and changes aterdiri considerable amountsecondary of hydrocarbons and carbon monoxide into relatively harmless carbon Sistem of pengaturan emissi gasgas pembuangan dari sebuah air supply system [sistem penyaluran udara kedua] dioxide and water vapor. yang memasukkan udara yang telah disaring ke dalam gas pembuangan pada lubang pembuangan. Udara segar ditarik ke dalam

lubang pembuangan setiap kali ada tekanan negatif pada sistem gas pembuangan. Suntikan inireverse meningkatkan This model has the pulse secondary airpulsa injection (PAIR) control valve and PAIR check valve. PAIR checkudara valve segar prevents air flow pembakaran gas pembuangan yangvalve belum terbakar dan mengubah besar dan karbon monoksida keengine dalam through the system. The PAIR control reacts to high intake manifoldsejumlah vacuum and willhidrokarbon cut off the supply of the fresh air during karbon dioksida danpreventing uap air yang relatifintidak berbahaya. deceleration, thereby afterburn the exhaust system. No adjustment to the pulse secondary air injection system should be made, although periodic inspection of the components is recommended. Model ini mempunyai pulse secondary air injection (PAIR) control valve dan PAIR check valve. PAIR check valve [klep penahan PAIR] mencegah terjadinya arus udara terbalik melalui sistem. PAIR control valve [klep pengatur PAIR] bereaksi terhadap vakuum intake manifold [manipol pemasukan] yang tinggi dan akan menutup penyaluran udara segar selama deselerasi mesin, dengan demikian mencegah terjadinya afterburn [pembakaran susulan] dalam sistem gas pembuangan.

Tidak perlu melakukan penyetelan terhadap pulse secondary air injection system, walaupun disarankan untuk melakukan pemeriksaan berkala dari komponen-komponennya. PAIR CONTROL VALVE

CHECK VALVE

PAIR AIR CLEANER

UDARA SEGAR UDARA VAKUM

EXHAUST PORT

NOISE EMISSION CONTROL SYSTEM [SISTEM PENGATURAN EMISSI KEBISINGAN] DILARANG MENGUTAK-ATIK SISTEM PENGATURAN EMISSI KEBISINGAN: Undang-undang melarang tindakan-tindakan berikut atau penyebab daripada: (1) Pelepasan atau dibuat tidak bekerjanya oleh seseorang, selain untuk tujuan perawatan, NOISE EMISSION CONTROL SYSTEM perbaikan atau penggantian, dari setiap peralatan atau elemen rancangan yang telah dipasang pada sebuah kendaraan untuk TAMPERING WITHkebisingan THE NOISE CONTROL SYSTEM ISpenyerahannya PROHIBITED: Local lawpelanggan may prohibit the following acts or the thereof: tujuan pengaturan sebelum penjualan atau kepada akhir atau sementara ia causing dipergunakan: (1) The or rendering inoperative by setelah any person, other than for elemen purposesrancangan of maintenance, repair or telah replacement, of anyatau device or element atau (2)removal pemakaian sebuah kendaraan peralatan atau sedemikian dilepaskan dibuat tidak of design incorporated into any vehicle for the purpose of noise control prior to its sale or delivery to the ultimate customer or while it is in use; dapat bekerja oleh seseorang. (2) ANTARA the use of the vehicle afterYANG such device or element of design has PENGUTAK-ATIKAN been removed or rendered inoperative by any person. DI TINDAKAN2 DIANGGAP MERUPAKAN ADALAH TINDAKAN-TINDAKAN SEPERTI DI BAWAH INI: AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: 1. Melepaskan atau melubangi knalpot, komponen pengaturan aliran, pipa pendahulu atau setiap komponen lain yang 1. Removal of or puncturing of the muffler, baffles, header pipes or any other component which conducts exhaust gases. menyalurkan gas pembuangan. 2. Removal of or puncturing of any setiap part of bagian the intake system. 2. Melepaskan atau melubangi dari sistem pemasukan udara. 3. Lack of proper maintenance. 3. Tidak menjalankan perawatan yang layak. 4. Replacing anybagian movingbergerak parts of the vehicle, or partsatau of thebagian exhaustdari or intake with partsatau otherpemasukan, than those specified the lain manufacturer. 4. Mengganti dari kendaraan, sistemsystem, pembuangan denganbypart daripada yang telah ditentukan oleh pembuatnya.

1-25

CATATAN

2. RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS

2

BODY PANEL LOCATIONS????????????? LOKASI BODY PANEL.......................... 2-22-2

SEAT ????????????????????????????????? TEMPAT DUDUK ........................................2-8 2-8

PETA PELEPASAN BODY CHART PANEL....... 2-2 BODY PANEL REMOVAL ?????? 2-2

GRAB RAIL................................................. 2-8 GRAB RAIL ??????????????????????????? 2-8

KETERANGAN SERVIS ........................2-3 SERVICE INFORMATION ?????????????? 2-3

BODY COVER............................................. 2-9 BODY COVER????????????????????????? 2-9

TROUBLESHOOTING 2-32-3 TROUBLESHOOTING........................... ?????????????????

UNDER COVER ........................................ 2-10 UNDER COVER ?????????????????????? 2-10

FRONT UPPER 2-42-4 FRONT UPPERCOVER COVER ........................ ????????????????

FLOOR PANEL/FRONT 2-11 FLOOR PANEL/FRONTINNER INNER COVER.. COVER 2-11

FRONT HANDLEBAR 2-52-5 FRONT HANDLEBARCOVER COVER .............. ??????????

REAR FENDER......................................... 2-11 REAR FENDER??????????????????????? 2-11

REAR HANDLEBAR 2-52-5 REAR HANDLEBARCOVER COVER ................ ???????????

LEFT CRANKCASE .........2-12 2-12 LEFT CRANKCASECOVER COVER DUCT DUCT ?????

FRONT LOWER COVER FRONT LOWER COVER.......................2-6 ??????????????? 2-6

COOLING FAN COVER ............................ 2-12 COOLING FAN COVER ??????????????? 2-12

FRONT INNER UPPER 2-6 FRONT INNER UPPERCOVER COVER ............ ????????? 2-6

TRIM CLIPS .............................................. 2-13 TRIM CLIPS ????????????????????????? 2-13

FRONT FENDER.................................... 2-7 FRONT FENDER ?????????????????????? 2-7

BATTERY COVER .................................... 2-13 BATTERY COVER ???????????????????? 2-13

LUGGAGE BOX..................................... 2-7 LUGGAGE BOX ??????????????????????? 2-7

EXHAUST PIPE/MUFFLER ...................... 2-14 EXHAUST PIPE/MUFFLER ???????????? 2-14

CENTER BODY COVER ........................2-8

CENTER BODY COVER ???????????????? 2-8

2-1

RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS

LOKASI BODYLOCATIONS PANEL BODY PANEL FRAME/BODYPANELS/EXHAUSTSYSTEM

(8) (1) (10)

(9)

(2) (11) (3)

(6)

(14) (5)

(17) (13)

(15) (12) (7)

(16)

(4) (1) Front handlebar cover (hal. 2-5) (1) Front handlebar cover (page 2-5) (2) Rear handlebar cover (hal. 2-5) (2) Rear handlebar cover (page 2-5) (3) Front upper cover (hal. 2-4) (3) Front Front upper (4) lower cover cover(page (hal. 2-4) 2-6) (4) Front Front lower (5) fendercover (hal.(page 2-7) 2-6) (5) Front Front fender (page 2-7) (6) inner upper cover (hal. 2-6) (6) Front inner upper cover (page (7) Center body cover (hal. 2-8)2-6) (7) Seat Center(hal. body cover (page 2-8) (8) 2-8) (8) Seat (page 2-8)

(9) Luggage box (hal. 2-7) (9) Luggage box (page 2-7) (10) Grab rail (hal. 2-8) (10) Grab rail (page 2-8) (11) Body cover (hal. 2-9) (11) Body cover (page 2-9) (12) Under cover (hal. 2-10) (12) Under (page 2-10) (13) Floorcover panel/Front inner cover (hal. 2-11) (13) Floor inner cover (page 2-11) (14) Rearpanel/Front fender (hal. 2-11) (14) Rear fender (page 2-11) (15) Left crankcase cover duct (hal. 2-12) (15) Left crankcase cover duct (16) Cooling fan cover (hal.(page 2-12)2-12) (16) Cooling cover (page 2-12) (17) Batteryfan cover (hal. 2-13) (17) Battery cover (page 2-13)

BODY PANEL REMOVAL CHART PETA PELEPASAN BODY PANEL • This chart shows removal order of frame covers by means of arrow. •

Peta ini memperlihatkan urutan pelepasan dari penutup rangka dengan perantaraan anak panah. (5) Front fender

(3) Front upper cover

(1) Front handlebar cover

(9) Luggage box

(4) Front lower cover

(2) Rear handlebar cover

(15) Left crankcase cover duct

(6) Front inner upper cover

(16) Cooling fan cover

(12) Under cover

(17) Battery cover

2-2

(7) Center body cover

(8) Seat

(13) Floor panel/Front inner cover

(10) Grab rail

(11) Body cover

(14) Rear fender


SERVICE INFORMATION KETERANGAN SERVIS UMUM GENERAL • This coverspelepasan removal anddan installation of the body exhaust system. Babsection ini meliputi pemasangan bodypanels panelsand dan sistem pembuangan gas. • Always the exhaust pipe gasket after removing the exhaust pipe from the engine. Selalureplace ganti exhaust pipe gasket setelah melepaskan exhaust pipe (pipa pembuangan gas) dari mesin. • When installing the exhaust system, loosely install all of the exhaust pipe fasteners. Always pipe tighten the exhaust joint Selalu first, then tighten the Ketika memasang sistem pembuangan gas, pasanglah semua pengikat exhaust dengan longgar. kencangkan mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly. exhaust joint (penyambung pipa pembuangan gas) dulu, kemudian kencangkan mounting fasteners (pengikat pemasangan). • Always inspect the exhaust system for leaks dulu, after installation. Jika mounting fasteners dikencangkan exhaust pipe mungkin tidak akan duduk dengan benar.

• • •

•

Setelah pemasangan, selalu periksa sistem pembuangan gas terhadap kebocoran.

TORQUE VALUES NILAI TORSI Cooling Cooling fan fancover coverscrew screw Cooling fan cover bolt Cooling fan cover bolt Muffler mounting mounting bolt bolt

0.8 (0,1 N·m kgf.m; (0.1 kgf·m, 0.6 lbf·ft) 0,8 N.m 0,6 lbf.ft) 9 N·m (0.9 kgf·m, 6.6 lbf·ft) 9 N.m (0,9 kgf.m; 6,6 lbf.ft) 5.9 (0,6 N·m kgf.m; (0.6 kgf·m, 4.4 lbf·ft) 5,9 N.m 4,4 lbf.ft)

TROUBLESHOOTING TROUBLESHOOTING Excessive exhaust noise Suara knalpot berisik • Broken exhaust system gas rusak Sistem pembuangan • Exhaust gas leak Ada kebocoran gas pembuangan Poor performance Unjuk kerja lemah • Deformed exhaust system Sistemgas pembuangan gas berubah bentuk • Exhaust leak • Clogged muffler gas pembuangan Ada kebocoran Muffler tersumbat • •

• • •

2-3


FRONT FRONT UPPER COVER COVER REMOVAL/INSTALLATION PELEPASAN/PEMASANGAN Remove thesebagai following: Lepaskan berikut:

Be careful to Hati-hati agarnot tidak damage the tabs, merusak tabs, stoppers danslots. slots. stoppers and

– Two boltsbulb and socket license plate - Headlight (hal. holder 17-6) from the front side – Two screws from the lower front side - Position light bulb socket (hal. 17-6) – Six screws from the rear side - Front turn signal light bulb sockets (hal. 17-8) - Enam screws Remove the front upper cover by releasing the following: - Front turn signal units kanan/kiri – Tabs on the lower front - Headlight adjusting boltside of the front upper cover from the slots on the front lower cover - Headlight retainers – Stoppers unit around the rear side of the front upper cover - Headlight from the front inner upper cover and front inner cover Perakitan adalah dalam urutan terbalik dari Disconnect the headlight/front turn signal light 6P connector. pembongkaran. Remove the two cushion rubbers. Setel arah sinar headlight (hal. 3-18) Installation is in the reverse order of removal. pemasangan front upper cover.

LICENSE PLATE HOLDER FRONT UPPER COVER 6P CONNECTOR

BOLTS

setelah

TABS STOPPERS CUSHION RUBBERS

SCREW

DISASSEMBLY/ASSEMBLY PEMBONGKARAN/PERAKITAN Remove thesebagai following: Lepaskan berikut: – Headlight bulblicense socket (page - Dua bolts dan plate 17-6) holder dari sisi depan ? Position light bulb socket (page 17-6) - Dua screws dari sisi depan bawah – Front turn signal light bulb sockets - Enam screws dari sisi belakang (page 17-8) – Six screws Lepaskan upper – Right/leftfront front turn signalcover units dengan melepaskan sebagai berikut: – Headlight adjusting bolt – Headlight retainers – Headlight - Tabs (lidahunit pemasangan) pada sisi depan bawah dari front upper cover dari slots (lubang2 pemasangan) Assembly is in the reverse order of disassembly. pada front lower cover the headlight aim (page 3-18) bagian after installing the front -Adjust Stoppers (penahan) di sekitar belakang dari upper frontcover. upper cover dari front inner upper cover dan front inner cover.

FRONT TURN SIGNAL UNITS FRONT UPPER COVER

SCREWS

Lepaskan headlight/front turn signal light 6P connector (connector 6P lampu besar/lampu sein). Lepaskan kedua cushion rubbers. Pemasangan pelepasan.

adalah

dalam

urutan

terbalik

dari

BOLT RETAINERS HEADLIGHT UNIT

2-4


FRONT HANDLEBAR HANDLEBAR COVER COVER FRONT PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Longgarkan rear view mirror lock nuts (mur pengunci Loosen the rearview mirror lock nuts. kaca spion). Remove the rearview mirrors by turning them counterclockwise. Lepaskan rear view mirrors (kaca spion) dengan memutar mereka berlawanan arah jarum jam. Remove the following: – Two screws fromberikut: the front side Lepaskan sebagai – Two screws from the rear side - Dua screws dari sisi depan Hati-hati agarnot tidak the front handlebar cover by releasing the following: Be careful to -Remove Dua screws dari sisi belakang

REAR VIEW MIRRORS FRONT HANDLEBAR COVER STOPPER BOSSES

merusak tabs, damagebosses, the bosses, – Four bosses the upper side of the front handlebar cover Lepaskan frontonhandlebar cover dengan melepaskan stoppers dan slots. tabs, stoppers and

from the hole on the rear handlebar cover slots. sebagai berikut: –

Two slots on the upper side of the front handlebar cover from tabs on the rearsisi handlebar cover - Empatthebosses pada atas dari front handlebar – cover Two dari stoppers on the front handlebar cover from the slots lubang pada rear handlebar cover. on the combination meter - Dua slots pada sisi atas dari front handlebar cover – dari Hole on pada the front from the front brake tabs rearhandlebar handlebarcover cover. master cylinder - Dua stoppers pada front handlebar cover dari slots

HOLES SLOT

pada combination meter. Installation is in the reverse order of removal. - Lubang pada front handlebar cover dari front brake master cylinder TAB Pemasangan pelepasan.

adalah

dalam

urutan

terbalik

dari

SCREW

REAR REAR HANDLEBAR HANDLEBAR COVER COVER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan sebagai berikut: Remove the following: - – Front Frontupper uppercover cover (hal. (page2-4) 2-4) - – Front (hal. 2-5) Fronthandlebar handlebar cover cover (page 2-5) Lepaskan/keluarkan berikut ini: Disconnect/release theconnectors/kawat-kawat following connectors/wires: -? Speedometer dari the combination meter. Speedometer cable cable from combination meter Hornconnectors connectors - – Horn Front/rear brake light switch connectors - – Brake light switch connectors depan/belakang Handlebar switch/speedometer wire 4P and 4P 6P connectors - – Handlebar switch/speedometer wire dan 6P – connectors Handlebar switch/speedometer wire boss from the handlebar - Handlebar switch/speedometer wire boss dari – handlebar Handlebar switch/speedometer wire from the wire guide -Remove Handlebar switch/speedometer wire dari wire guide the following:

FRONT BRAKE LIGHT SWITCH CONNECTORS

REAR HANDLEBAR COVER REAR BRAKE LIGHT SWITCH CONNECTORS

SPEEDOMETER CABLE

WIRE BOSS

Lepaskan sebagai berikut: – Three screws from the front side – Rear handlebar cover - Tiga screws dari sisi depan Rear handlebar is in thecover reverse order of removal. Route wire -Installation Alurkan wirethe harness dengan benar (hal. Pemasangan adalah dalam urutan terbalik harness properly 1-14). (page 1-14).

dari

pelepasan.

WIRE GUIDE SCREWS

HORN CONNECTORS

4P/6P CONNECTORS

2-5


FRONT FRONT LOWER LOWERCOVER COVER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan berikut: Remove thesebagai following: - Front – Frontupper uppercover cover (hal. (page2-4) 2-4) – Two screws - Empat screwsfrom dariboth sisi sides depan – Two screws fromhook the lower side - Bolt dan luggage dari front sisi belakang

Be careful not to Hati-hati agar tidak damage the hooks. merusak hooks.

Remove thewire frontboss lowerdari cover by releasing the hooks on its Lepaskan lubang dari front inner upper lower side from the under cover. cover. Tarik front inner cover sedikit ke belakang untuk Installation is in the reverse order of removal. membuat ruangan bagi pelepasan front inner upper cover. Lepaskan bagian atas dari front inner upper cover dari rear handlebar cover, kemudian tarik ke atas dan keluarkan.

Pemasangan pelepasan.

adalah

dalam

urutan

terbalik

dari

SCREWS

FRONT LOWER COVER HOOKS

FRONT FRONT INNER INNER UPPER UPPER COVER COVER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan berikut: Remove thesebagai following: FRONT INNER UPPER COVER

- Front – Frontupper uppercover cover (hal. (page2-4) 2-4) - Dua screws sisiside – Four screwsdari fromkedua the front - Dua dari sisi depan – Boltscrews and luggage hook from bawah the rear side Lepaskan cover melepaskan hooks Release thefront wire lower boss from the dengan hole of the front inner upper cover.sisinya yang bawah dari under cover. pada Slightly pull the front inner cover backward to make space Hati-hati Be careful agarnot tidak to for front inner upper cover removal. Pemasangan adalah dalam urutan terbalik dari merusak front inner Release the upper side of the front inner upper cover from the damage the front pelepasan. covercover dan front inner and finner ront rear handlebar cover, then pull it upward and remove it. upper cover. cover. inner upper

HOLE BOLT WIRE BOSS

Installation is in the reverse order of removal.

LUGGAGE HOOK SCREWS

2-6


FRONT FENDER FENDER (SPAKBOR DEPAN) FRONT REMOVAL/INSTALLATION PELEPASAN/PEMASANGAN Remove thesebagai following: Lepaskan berikut: – Four bolts - Empat bolts – Front fender - Front fender Installation is in the reversedalam order of removal. Pemasangan adalah urutan terbalik pelepasan.

FRONT FENDER dari

BOLTS

LUGGAGE BOX (KOTAK BAGASI) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan berikut: Remove thesebagai following:

WIRE HARNESS COVER

- Baterai 14-12) – Battery(hal. (page 14-12) - – ICM (hal. 15-11) ICM (page 15-11) - Screw sisi atas side – Screwdari from thedepan front upper - Dua sisi – Two screwsdari fromkedua both sides screws – Two boltsdan andcollars collars dari fromsisi the belakang upper rear atas side - Dua bolts – Two boltsdari from thedepan inner front side - Dua bolts sisi dalam – Wire harness cover cover - Wire harness

BOLTS

COLLARS

Remove the luggage box upward while pulling the wire harlurkan wire harness Lepaskan luggage box ke atas sementara menarik wire its hole. harness keluar dari lubangnya. dengan benar (hal. ness out of

1-14) Route the wire Installation is in the reverse order of removal. harness properly Pemasangan adalah dalam urutan terbalik (page 1-14) pelepasan.

dari SCREWS

LUGGAGE BOX WIRE HARNESS

2-7


CENTER CENTER BODY BODY COVER COVER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan kunci duduk Unlock the seat withtempat the ignition key. dengan anak kunci kontak. Open the seat. Buka tempat duduk. Remove the following: Lepaskan sebagai berikut: ? Screw from front upper side Two screws from frontatas. lower side - – Screw dari sisi depan – Two screws from both sides - Dua screws dari sisi depan bawah -Push Duathe screws kedua sisithe center body cover upward upperdari front side of

HOOK

SCREWS

and release fromsisi thedepan floor panel. Dorong ke itatas atas dari center body cover lepaskan dari body panelcover lantai. Hati-hati agarnot tidak Remove the center while releasing its hooks from Be careful to dan merusak hooks dan damage the hooks the slots on the body cover by sliding it forward. slots. and slots. Lepaskan center body cover sementara melepaskan Installation isdari in the reverse removal.cover dengan hooks-nya slots order pada of body menggesernya ke depan.


adalah

dalam

urutan

terbalik

dari SLOT

CENTER BODY COVER

TEMPAT DUDUK SEAT PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan (hal. 2-8). Remove thecenter centerbody body cover cover (page 2-8)

LUGGAGE BOX LID

Lepaskan luggage boxit.lid (tutup kotak Unhook the kaitan luggage dari box lid and remove bagasi) Slide thedan pin lepaskan. out and remove the seat. Geser pin keluar dan lepaskan tempat duduk. Installation is in the reverse order of removal. Pemasangan adalah dalam urutan terbalik dari pelepasan.

TEMPAT DUDUK PIN

GRAB GRAB RAIL RAIL (PEGANGAN TANGAN) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan kunci duduk Unlock the seat withtempat the ignition key. dengan anak kunci Open the seat. kontak. Buka tempat duduk. Remove the following: Lepaskan sebagai berikut: ? Four bolts Grab rail - – Empat bolts -Installation Grab rail is in the reverse order of removal.


2-8

adalah

dalam

urutan

GRAB RAIL

BOLTS terbalik

dari


BODY COVER COVER BODY PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan sebagai berikut: Remove the following: - – Center Centerbody bodycover cover (hal. (page2-8) 2-8) Grabrail rail(hal. (page 2-8) - – Grab 2-8) Two screwsdari from thebawah lower side - – Dua screws sisi – Special bolt from the lower left side - Special bolt dari sisi kiri bawah – Two bolts from the upper side - Dua bolts dari sisi atas Hati-hati agarnot tidak Be careful to merusak dan damage hooks the hooks tabs. and tabs.

Remove the body by releasing the following tabs/ Lepaskan dengan melepaskan body cover cover bosses/hooks: tabs/bosses/hooks berikut ini: - – Rear shock absorber cover tab dengan Rear shock absorber cover tab by slightly bending it agak membengkokkannya – Grab rail mounting bosses by slightly pulling the body - Grab mounting bosses dengan sedikit menarik coverrail upward body cover ke atas – Hooks on the front side of the body cover by pulling it - Hooks pada sisi depan dari body cover dengan backward menariknya ke belakang Disconnect the tail/brake light/rear turn signal light 6P connector. Lepaskan tail/brake light/rear turn signal light 6P

Alurkan wire the harness Installation is in the reverse order of removal. Route wire connector. dengan benar (hal. harness properly Pemasangan adalah dalam urutan terbalik (page 1-14). 1-14). pelepasan.

dari

BOLTS SCREWS

BODY COVER

HOOKS/TABS

REAR SHOCK ABSORBER COVER TAB

SPECIAL BOLT GRAB RAIL MOUNTING BOSSES

TAIL/BRAKE LIGHT/REAR TURN SIGNAL LIGHT 6P CONNECTOR

2-9

RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS PEMBONGKARAN/PERAKITAN DISASSEMBLY/ASSEMBLY Lepaskan sebagai berikut: Remove the following: - –Empat screws Four screws - – Tail/brake turnsignal signal Tail/brakelight/rear light/rear turn lightlight unit unit (unit lampu belakang/lampu rem/lampu sein belakang) – Right/left body covers - –Body Twocovers screwskanan/kiri - –Dua screws Rear shock absorber cover - Rear shock absorber cover Assembly is in the reverse order of disassembly. Perakitan adalah dalam urutan terbalik dari pembongkaran.

TAIL/BRAKE LIGHT/REAR TURN SIGNAL LIGHT UNIT

SCREWS

SCREWS

BODY COVER

REAR SHOCK ABSORBER COVER

UNDER UNDER COVER COVER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan sebagai berikut: Remove the following: - –Dua screws sisi Two screwsdari from thedepan front side - –Empat screws dari kedua sisi Four screws from both sides - –Dua screws dari sisi belakang Two screws from rear side

HOOKS SCREWS

Lepaskan coverbydengan Remove theunder under cover releasing melepaskan the following: sebagai berikut: – Hooks on the front side from the slots on front lower - Hooks pada sisi depan dari slots pada front lower cover cover – Tabs on both sides from the floor step - Tabs pada kedua sisi dari floor step Installation is in the reverse order of removal. Pemasangan adalah dalam urutan terbalik dari pelepasan.

TABS UNDER COVER

2-10

SCREWS


FLOOR PANEL/FRONT PANEL/FRONT INNER INNERCOVER COVER FLOOR REMOVAL/INSTALLATION PELEPASAN/PEMASANGAN Lepaskan sebagai berikut: Remove the following: FLOOR PANEL/FRONT INNER COVER

- –Front lower Front lowercover cover(hal. (page2-6) 2-6) - –Front inner Front innerupper uppercover cover (hal. (page2-6) 2-6) - –Body cover 2-9) Body cover(hal. (page 2-9) Undercover cover(hal. (page 2-10) - –Under 2-10) Remove the floor panel/frontinner inner cover bydengan pulling Lepaskan floor panel/front cover assembly assembly it upward while the screwmelepaskan tabs from the screw frame. tabs menariknya ke releasing atas sementara dari rangka.is in the reverse order of removal. Installation


adalah

dalam

urutan

terbalik

dari

SCREW TABS

REAR FENDER FENDER (SPAKBOR BELAKANG) REAR PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan sebagai berikut: Remove the following:

BOSSES

- –Body cover 2-9) Body cover(hal. (page 2-9) - –Fuel tank 5-26) Fuel tank(hal. (page 5-26)

HOOKS BOLTS

Lepaskan ketiga Remove the three bolts. bolts. Remove therear rear fender fender while releasingmelepaskan the bosses andbosses hooks Lepaskan sementara by pulling straight back and remove it. ke belakang dan dan hooksitdengan menariknya lurus melepaskannya. Installation is in the reverse order of removal.


adalah

dalam

urutan

terbalik

dari

REAR FENDER

2-11


LEFT CRANKCASE CRANKCASE COVER COVER DUCT DUCT LEFT REMOVAL/INSTALLATION PELEPASAN/PEMASANGAN Lepaskan sebagai berikut: Remove the following: - – Dua bolts Two bolts - – Left crankcase Left crankcasecover cover duct duct Packing - – Packing is in the reverse order of removal. Installation Pastikan bahwa Make sure the Pemasangan packing berada packing is indalam good kondisi baik ganti pelepasan. condition anddan replace bila perlu. it if necessary.

adalah

dalam

urutan

LEFT CRANKCASE COVER DUCT

terbalik

dari

PACKING BOLTS

COOLING COOLINGFAN FANCOVER COVER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan kedua screws dan kedua bolts. Remove the two screws and two bolts. Lepaskan starting enrichment (SE) thermal valve wire Release the starting enrichment (SE)guide thermal valve wire and dan starter motor wire dari wire dari cooling fan starter motor wire from the wire guide of the cooling fan cover. cover. Lepaskan cooling Remove the coolingfan fancover. cover. adalah urutan terbalik lurkan wire Pemasangan Installation is in the reversedalam order of removal. Route the wire pelepasan. harness dengan baik harness properly (hal. 1-14) TORQUE: (page 1-14).

SE THERMAL VALVE/STARTER MOTOR WIRE

dari SCREW

Cooling fan cover screw: TORSI: Cooling fan (0.1 cover screw: 0.8 N·m kgf·m, 0.6 lbf·ft) 0,8fan N.m (0,1bolt: kgf.m; 0,6 lbf.ft) Cooling cover Cooling fan cover bolt: 9 N·m (0.9 kgf·m, 6.6 lbf·ft) 9 N.m (0,9 kgf.m; 6,6 lbf.ft)

JOINT NUTS

COOLING FAN COVER BOLTS

2-12


TRIM CLIPS

REMOVAL PELEPASAN Push the centerpin pindari of the trim clip. Tekan center trim clip. Remove thetrim trimclip. clip. Lepaskan

CENTER PIN

TRIM CLIP

PEMASANGAN INSTALLATION Naikkan centerpinpin denganthe menekan retaining Raise the center by pushing retaining tabs back. tabs kembali. Install the trim clip.

RETAINING TABS CENTER PIN

Push the trim center pin until the pin is flush with the outer casing. Pasang clip.

Tekan center pin sampai pin rata dengan outer casing.

TRIM CLIP

TRIM CLIP

CENTER PIN

BATTERY COVER BATTERY COVER

REMOVAL/INSTALLATION PELEPASAN/PEMASANGAN

Unlock the ignition key. Open penguncian the seat. Buka dengan anak kunci kontak. Naikkan tempat duduk. Remove the trim clip (see page 2-13). Remove thetrim battery Lepaskan clip cover. (lihat hal. 2-13). Lepaskan battery cover. Installation is in the reverse order of removal.


adalah

dalam

urutan

terbalik

BATTERY COVER

dari

TRIM CLIP

2-13


EXHAUST PIPE/MUFFLER PIPE/MUFFLER (KNALPOT) PELEPASAN REMOVAL Remove the following: Lepaskan sebagai berikut: Two joint nuts - – Dua joint nuts – Two muffler mountingbolts bolts - Dua muffler mounting – Exhaust pipe/muffler - Exhaust pipe/muffler – Gasket - Gasket

GASKET

JOINT NUTS

PEMASANGAN INSTALLATION Ganti exhaust gasket dengan Replace the exhaust gasket with yang a new baru. one. Tempatkan exhaust pipeonto flange pada stud Set the exhaust pipe flange the stud bolts and bolts install dan the pasang joint jangan kencangkan joint nuts, but nuts, do nottetapi tighten them yet. Install the mereka muffler dulu. mounting bolts, but do not tighten them yet. Pasang muffler mounting bolts, tetapi jangan Tighten the joint nuts first, kencangkan mereka dulu.then tighten the muffler mounting bolts to the specified torque. Kencangkan nuts dulu, kemudian kencangkan TORQUE:59 joint N·m (6.0 kgf·m, 44 lbf·ft) muffler mounting bolts dengan torsi yang ditentukan. After installation, make sure the exhaust system does not leak. TORSI: 59 N.m (6,0 kgf.m; 44 lbf.ft) Setelah pemasangan, pastikan pembuangan gas tidak bocor.

bahwa

sistem

BOLTS EXHAUST PIPE/MUFFLER

2-14

3. PERAWATAN

3

KETERANGAN SERVIS ...........................3-2 SERVICE INFORMATION?????????????? 3-2

OLI FINAL DRIVE .....................................3-13 3-13 FINAL DRIVE OIL????????????????????

JADWAL PERAWATAN ...........................3-4 MAINTENANCE SCHEDULE ??????????? 3-4

MINYAK 3-14 BRAKEREM............................................ FLUID ??????????????????????? 3-14

SALURAN BAHAN BAKAR .....................3-5 FUEL LINE ??????????????????????????? 3-5

KEAUSAN BRAKE SHOES/PADS........... 3-15 BRAKE SHOES/PADS WEAR ?????????? 3-15

CARA KERJA OPERATION THROTTLE .......................3-5 THROTTLE ?????????????? 3-5

SISTEM ............................................ 3-15 BRAKEREM SYSTEM ????????????????????? 3-15

AIRAIR CLEANER ..........................................3-6 CLEANER ???????????????????????? 3-6

BRAKE LIGHT SWITCH........................... 3-17 BRAKE LIGHT SWITCH ?????????????? 3-17

CRANKCASE BREATHER.......................3-6 CRANKCASE BREATHER?????????????? 3-6

CARA KERJA LOCK??????????? ..................3-17 3-17 BRAKE LOCKBRAKE OPERATION

SPARK PLUG (BUSI) ...............................3-7 SPARK PLUG ????????????????????????? 3-7

PENYETELAN ARAH LAMPU BESAR ....3-18 3-18 HEADLIGHT AIM ????????????????????

JARAK RENGGANG KLEP......................3-8 VALVE CLEARANCE ?????????????????? 3-8

KEAUSAN CLUTCH SHOES....................3-18 3-18 CLUTCH SHOES WEAR???????????????

OLIENGINE MESIN OIL ................................................3-9 ?????????????????????????? 3-9

SIDESTAND.............................................. 3-18 SIDESTAND?????????????????????????? 3-18

ENGINE OIL STRAINER ENGINE OIL STRAINERSCREEN.........3-11 SCREEN?????? 3-11

SUSPENSI ................................................3-19 3-19 SUSPENSION?????????????????????????

PUTARAN MESIN.............3-11 ENGINE STASIONER IDLE SPEED ????????????????? 3-11

MUR, BAUT, PENGIKAT .......................... 3-20 NUTS, BOLTS, FASTENERS ??????????? 3-20

SECONDARY AIR SUPPLY SYSTEM....3-12 SECONDARY AIR SUPPLY SYSTEM ??? 3-12

RODA/BAN ............................................... 3-20 WHEELS/TIRES ?????????????????????? 3-20

DRIVE BELT ...........................................3-13 DRIVE BELT????????????????????????? 3-13

STEERING HEAD BEARINGS ................. 3-21 STEERING HEAD BEARINGS?????????? 3-21

3-1

PERAWATAN

SERVICE INFORMATION KETERANGAN SERVIS M AINTENANCE

UMUM GENERAL is extremely flammable and is dapat explosive under certain conditions. Work Bekerjalah in a well ventilated area. Smoking or allowing flames or Bensin sangat mudah terbakar dan meledak pada kondisi tertentu. di tempat dengan ventilasi baik. Merokok • ? Gasoline sparks in the work area or where the gasoline is stored can cause a fire or explosion. atau membiarkan api atau percikan bunga api di tempat kerja atau tempat di mana bensin disimpan dapat menyebabkan ? Ifkebakaran the engine must running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. The exhaust atau be ledakan. contains poisonous carbon gas that may cause loss of consciousness may tempat lead to death. the engineventilasi in an open areaJangan or with Jika mesin harus hidupmonoxide untuk melakukan sesuatu pekerjaan, pastikanand bahwa kerja Run mempunyai baik. • an exhaust evacuation system in enclosed area. sekali-kali menjalankan mesin di dalam ruangan tertutup. Gas pembuangan mengandung gas karbon monoksida beracun ? Place the scooter on a level ground before starting any work. yang dapat menghilangkan kesadaran dan dapat menuju ke kematian. Jalankan mesin di tempat terbuka atau di tempat tertutup yang mempunyai sistem pemindahan gas pembuangan. Letakkan skuter di atas tanah mendatar sebelum memulai sesuatu pekerjaan. •

SPECIFICATIONS SPESIFIKASI

ITEM Throttle grip freeplay BAGIAN Spark plug Standard Jarak main bebas throttle grip For extended high speed riding Busi Standard Spark plug gap Untuk pengendaraan lama Valve clearance IN kecepatan tinggi EX Jarak renggangengine busi oil Recommended Jarak renggang klep IN (Masuk) EX (Buang) Oli mesin yang dianjurkan

SPECIFICATIONS 2 – 6 mm (0.1 – 0.2 in) SPESIFIKASI CPR8EA-9 (NGK) 2 – 6 mm(NGK) CPR9EA-9 CPR8EA-9 0.80 – 0.90 mm(NGK), (0.031 U24EPR9 – 0.035 in) (DENSO) pada 0.14 CPR9EA-9 (NGK) ± 0.02 mm (0.006 ± 0.001 in) 0.14 ± 0.02 mm (0.006 ± 0.001 in) 0,80 "4-stroke – 0,90 mm Honda motorcycle oil" or an equivalent motor oil API service ± 0,02SG 0,14 mm classification: or higher (except oils labeled as energy conserving on the0,14 circular APImm service label) ± 0,02 JASO T 903Oil standard: MB Flick atau oli mesin 4 tak sejenis Federal Supreme Viscosity: 10W-30 dengan SAE klasifikasi API service SG, Engine oil capacity After draining 0.7Viskositas: liter (0.7 US qt, 0.6 Imp qt) SAE 10W-30 JASO MB Afterpenggantian disassembly periodik 0.80,7 liter (0.8 US qt, 0.7 Imp qt) Kapasitas oli mesin Pada liter Engine idle speed 1,700 ± 100 min-1 (rpm) Pada pembongkaran mesin 0,8 liter Drive belt width mesin Service 17.5 mm-1 (rpm) (0.69 in) Putaran stasioner 1.700limit: menit ± 100 Recommended Honda "4-stroke motorcycle Lebar drive beltfinal reduction oil Batas servis: 17,5 mm oil" or an equivalent motor oil API service classification: or higher (except oils labeled as energy conserving Oli final reduction yang dianjurkan Federal OilSGSupreme Flick atau oli mesin 4 tak sejenison thedengan circularklasifikasi API service label) API service SG, JASO T 903 standard: MB JASO MB Viskositas: SAE 10W-30 Viscosity: SAE 10W-30 Kapasitas oli final Pada penggantian periodik 0,10 liter Final reduction oil Afterpembongkaran draining 0.10 liter (0.11 US qt, 0.09 Imp qt) reduction Pada 0,12 liter capacity Afterbelakang disassembly 0.12 Jarak main bebas handel rem 10 liter – 20(0.13 mm US qt, 0.11 Imp qt) Rear brake lever free play 10 – 20 mm (0.4 2,0 – 0.8 in) Ketebalan clutch lining (kanvas kopeling) Batas servis: mm 2 in) Clutch lining thickness Service limit: 2.0 mm (0.08 Tekanan udara ban Pengendara Depan 200 kPa (2,00 kgf/cm , 29 psi) 2 2psi) Cold tire pressure Driver only Front 200 kPa (2.00 kgf/cm , 29 dingin saja Belakang 225 kPa (2,25 kgf/cm , 33 psi) 2 225 kPa (2.25 kgf/cm , 332,psi) Pengendara dan Depan Rear 200 kPa (2,00 kgf/cm 29 psi) 2 Driver and passengerBelakang Front 200 kPa (2.00 kgf/cm , 292,psi) pembonceng 225 kPa (2,25 kgf/cm 33 psi) 2 Rear 225 kPa (2.25 kgf/cm , 33 psi) Ukuran ban Depan 80/90 – 14M/C40P Tire size Front 80/90 – 14M/C40P Belakang 90/90 – 14M/C46P 90/90 – 14M/C46P Merek ban SRI Depan Rear FT235 Tire brand SRI Front FT235 Belakang FT235 Rear FT235 Kedalaman minimum alur telapak ban Depan Sampai ke indikator Minimum tire tread depth Front ToSampai the indicator Belakang ke indikator Rear To the indicator

3-2

PERAWATAN TORQUE VALUES NILAI TORSI Spark plug Spark plug(busi) AirAir cleaner housing cleaner housingcover cover screw screw Valve adjusting screw Valve adjusting screwlock lock nut nut Engine oiloil drain Engine drainbolt bolt Engine oil strainer cap Engine oil strainerscreen screen cap Final reduction oil check bolt Final reduction oil check bolt Final reduction oil drain bolt Final reduction oil drain bolt

16 N.m (1,6 kgf.m; 12 lbf.ft) 16 N·m (1.6 kgf·m, 12 lbf·ft) 1,1 N.m (0,1 kgf.m; 0,8 lbf.ft) 1.1 N·m (0.1 kgf·m, 0.8 lbf·ft) 10 N.m (1,0 kgf.m; 7 10 N·m (1.0 kgf·m, 7 lbf·ft)lbf.ft) ApplySemprotkan engine oil to oli themesin threadspada and ulir dan duduk seatingpermukaan surface. 24 N.m (2,4 kgf.m; 18 lbf.ft) 24 N·m (2.4 kgf·m, 18 lbf·ft) 20 N.m (2,0 kgf.m; 15 lbf.ft) 20 N·m (2.0 kgf·m, 15 lbf·ft) 13 N.m (1,3 kgf.m; 10 13 N·m (1.3 kgf·m, 10 lbf·ft) lbf.ft) 13 N.m (1,3 kgf.m; 10 lbf.ft) 13 N·m (1.3 kgf·m, 10 lbf·ft)

TOOLS TOOLS Valve adjusting wrench 07908-KE90000

3-3

PERAWATAN

MAINTENANCE SCHEDULE JADWAL PERAWATAN Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period. Jalankan Pemeriksaan Sebelum Jalan di dalam Buku Pedoman Pemilik pada masing-masing periode perawatan yang I:dijadwalkan. Inspect and Clean, Adjust,dan Lubricate or Replace if Lumasi necessary. C: Clean. R: Replace. A:Bersihkan. Adjust. L: Lubricate. P: Periksa Bersihkan, Setel, atau Ganti bila perlu. B: G: Ganti. L: Lumasi. PB: Perawatan Berkala. Bagian-bagian berikut memerlukan pengetahuan mekanis tertentu. Beberapa bagian yang ditandai * daninfor**) The following items require some mechanical knowledge. Certain items (particularly those marked * and(terutama **) may require more technical mation tools. Consult anbanyak authorized Honda dealer. dapat and memerlukan lebih informasi teknis dan perkakas khusus. Hubungi AHASS Anda. FREQUENCY WHICHEVER JADWAL PERAWATAN BERKALA, MANA YANG TERCAPAI TERLEBIH DAHULU COMES FIRST ODOMETER READING (NOTE 1) FREKUENSI → PEMBACAAN ODOMETER (km) - Catatan 1 X1,000 km 1 4 8 12 PB 1 PB 2 X1,000 PB mi 3 ↓ 0.6 2.5 5 7.5 BAGIAN YANG DISERVIS 500 2.000 Months 4.000 8.000 12.000 ITEMS 6 12 18 * SALURAN BAHAN BAKAR P P P P P * FUEL LINE I I I CARA KERJAOPERATION GAS TANGAN P P P P PI ** THROTTLE I I AIR CLEANER Catatan 2 NOTE2 SETIAPEVERY 16.000 km: G km (10,000 mi) R ** AIR CLEANER 16,000 CRANKCASE BREATHER Catatan 4 NOTE4 B B B B BC CRANKCASE BREATHER C C BUSI P P P G P SPARK PLUG I R I * JARAK RENGGANG KLEP P P P P P * VALVE CLEARANCE I I I I OLI MESINOIL G G SETIAP 4.000 ENGINE R R km: GR R ENGINE OIL SCREEN B ** ENGINE OILSTRAINER STRAINER SCREEN C * PUTARAN STASIONER MESIN P P P P P * ENGINE IDLE SPEED I I I I * SECONDARY AIR SUPPLY SYSTEM P P * SECONDARY AIR SUPPLY SYSTEM I * DRIVE BELT SETIAP 8.000 km: P * DRIVE BELT EVERY 8,000 km (5,000 mi) I, SETIAP 24.000 km: G EVERY 24,000 km (15,000 mi) R * OLI FINAL DRIVE Catatan 3 * FINAL DRIVE OIL NOTE3 MINYAK REM Catatan 3 P P P P P BRAKE FLUID NOTE3 I I I KEAUSAN BRAKE SHOES/PADS P P P P P BRAKE SHOES /PADS WEAR I I I SISTEM REM P P P P P BRAKE SYSTEM I I I I * SAKELAR LAMPU REM P P P P P * BRAKE LIGHT SWITCH I I I * CARA KERJA BRAKE LOCK P P P P P * BRAKE LOCK OPERATION I I I I * ARAH SINAR LAMPU BESAR P P P P P * HEADLIGHT AIM I I I ** KEAUSAN CLUTCH SHOES P ** CLUTCH SHOES WEAR I STANDARD SAMPING P P P P P SIDESTAND I I I * SUSPENSI P P P P P * SUSPENSION I I I * MUR, BAUT, PENGENCANG P P P P P * NUTS, BOLTS, FASTENERS I I ** RODA/BAN Catatan 3 P P P P P ** WHEELS/TIRES I I I ** BANTALAN KEPALA KEMUDI P P -I ** STEERING HEAD BEARINGS I I

*

LIHAT REFER TO HALAMAN PAGE 3-5 3-5 3-5 3-5 3-6 3-6 3-6 3-6 3-7 3-7 3-8 3-8 3-9 3-9 3-11 3-11 3-11 3-11 3-12 3-12 3-13 3-13 3-13 3-13 3-14 3-14 3-15 3-15 3-15 3-15 3-17 3-17 3-17 3-17 3-18 3-18 3-18 3-18 3-18 3-18 3-19 3-19 3-20 3-20 3-20 3-20 3-21 3-21

HARUS DISERVIS OLEH AHASS, KECUALI BILA PEMILIK MEMPUNYAI TOOLS YANG TEPAT DAN DATA * SERVIS SHOULD SERVICEDDAN BY AN AUTHORIZED Honda MEKANIS DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE YANGBE DIPERLUKAN, MEMPUNYAI KETRAMPILAN UNTUK MENGERJAKANNYA. DATA AND IS MECHANICALLY QUALIFIED. ** DEMI KEAMANAN, KAMI MENGANJURKAN AGAR PEKERJAAN-PEKERJAAN INI HANYA DILAKUKAN OLEH ** AHASS. IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED Honda DEALER. CATATAN: NOTES: 1. Pada pembacaan odometer lebih tinggi, ulangilah pada interval frekuensi yang ditentukan di atas. 1.2. AtServis higher odometer readings, repeat at the interval here. lebih sering jika dikendarai di frequency daerah yang luarestablished biasa basah atau berdebu. 2. Service more frequently when riding in unusually wet or dusty areas. 3. Ganti setiap 2 tahun. Penggantian memerlukan ketrampilan mekanis. 3. Replace every 2 years. Replacement requires mechanical skill. 4. Servis lebih sering jika dikendarai dalam hujan atau dengan gas penuh. 4. Service more frequently when riding in rain or at full throttle.

3-4

PERAWATAN

FUEL LINEBAHAN BAKAR SALURAN Lepaskan body cover 2-9) Remove the body cover(hal. (page 2-9) Periksa hosefor (slang bahan bakar) terhadap Check thefuel fuel hose deterioration, damage or leakage. pemburukan kondisi, kerusakan atau kebocoran. Replace the fuel hose if necessary. Ganti bila hose perlu. hose Also,fuel check the fuel fittings for leakage. Juga, hose fittings Installperiksa the bodyfuel cover (page 2-9). (peralatan pemasangan fuel hose) terhadap kebocoran. Pasang body cover (hal. 2-9)

FUEL HOSE

CARA KERJA THROTTLE (GAS TANGAN) THROTTLE OPERATION CATATAN: Pemakaian kembali cable (kabel gas)throttle yang • ? Reusing a damaged or throttle abnormally bent or kinked rusak, tertekuk atau bengkok secara tidak normal cable can prevent proper throttle slide operation and may dapat kerja lead to amengganggu loss of throttle cara control whilethrottle riding. slide yang benar dan dapat mengakibatkan hilangnya Check for any deterioration or damage to the throttle cable. pengontrolan atas throttle sewaktu pengendaraan. Check the throttle grip for smooth operation. Check that the throttle opens and automatically closes in all steering posiPeriksa terhadap pemburukan kondisi atau kerusakan tions. pada throttle cable. Periksa throttle grip (putaran gas If the throttle gripkelancaran does not return properly, lubricate the tangan) terhadap cara kerja. Periksa bahwa throttlemembuka cable. throttle dan secara otomatis menutup kembali For cable lubrication, disconnect the throttle cable at their pada semua posisi kemudi. pivot points and apply commercially available cable lubricant or light weight oil. tidak kembali dengan benar, lumasi Jika throttle grip throttle cable. If the throttle grip still does not return properly, replace the Untuk melumasi cable, lepaskan throttle cable pada titikthrottle cable. titik perputarannya dan oleskan dengan pelumas kabel With dapat the engine idling, the handlebar the way to the yang dibeli di turn pasaran atau olialldengan berat right and left to ensure that the idle speed does not change. If ringan. idle speed increases, check the throttle grip free play and throttle cable routing. Jika throttle grip tetap tidak dapat kembali dengan benar, gantilah throttle cable. Sementara mesin berputar stasioner, putar handlebar (stang stir) sama sekali ke kanan dan kiri untuk memastikan bahwa putaran stasioner tidak berubah. Jika putaran stasioner naik, periksa jarak main bebas throttle grip dan alur perletakan throttle cable.

Ukur jarak bebas throttle pada throttle grip Measure themain throttle grip free play atgrip the throttle grip flange. flange. FREEPLAY: 2 – 6 mm (0.1 – 0.2 in) JARAK MAIN BEBAS: 2 – 6 mm

2 – 6 mm (0.1 – 0.2 in)

3-5

PERAWATAN Throttle grip free playthrottle can be adjusted by turning the adjuster. Jarak main bebas grip dapat disetel dengan memutar adjuster (penyetel). Remove the body cover (page 2-9).

ADJUSTER

Loosen thebody lock nut and(hal. turn 2-9). the adjusting nut as required. Lepaskan cover Tighten the lock Longgarkan locknut. nut (mur pengunci) dan putar adjusting nut (mur penyetel) Recheck the throttlesebanyak operation. diperlukan. Install the body cover Kencangkan lock nut.(page 2-9).

Periksa kembali cara kerja throttle. Pasang body cover (hal. 2-9). LOCK NUT

AIR AIR CLEANER CLEANER CATATAN: viscous paper element (elemen cannot bekertas cleaned because the • ? The Viscous paper element kental) tidak element a dust adhesive. dapat contains dibersihkan oleh karena element ? If the scooter is used indebu. unusually wet or dusty areas, mengandung perekat more frequent inspections are required. • Jika skuter dipakai di daerah yang luar biasa basah atau berdebu, diperlukan pemeriksaan yang lebih Remove the screws and air cleaner housing cover from the sering. right side. Remove and discard the air cleaner element in accordance Lepaskan screws dan air cleaner cover dari sisi with the maintenance schedule (pagehousing 3-4). kanan. Replace the element any time if it is excessively dirty or damLepaskan dan buanglah air cleaner element sesuai aged. dengan jadwal perawatan (hal. 3-4). Install element the removed parts waktu in the reverse ordermenjadi of removal. Ganti setiap ia telah sangat kotor atau rusak. TORQUE: Pasang parts housing yang telah dilepaskan dalam urutan Air cleaner cover screw: terbalik1.1 dari pelepasan. N·m (0.1 kgf·m, 0.8 lbf·ft) TORSI: Air cleaner housing cover screw: 1,1 N.m (0,1 kgf.m; 0,8 lbf.ft)

COVER

ELEMENT

SCREWS

CRANKCASE BREATHER CRANKCASE BREATHER

? Service more frequently when ridden in rain, at full throtCATATAN: tle, or after the scooter is washed or overturned. Service if • Servis lebih sering jika dikendarai dalam hujan, the deposit level can be seen in the transparent section of atau pada gas penuh, atau setelah skuter dicuci the drain hose. atau telah terbalik. Lakukan servis bila tinggi Release the crankcase breather hose dalam from the hose permukaan endapan dapatdrain terlihat bagian clamp. tembus pandang dari drain hose (slang pembuangan). Remove the crankcase breather drain hose plug from the hose

HOSE CLAMP

end and drain deposits into a suitable container. Lepaskan crankcase breather drain hose (slang Install the crankcase breather hosedari plughose and set the pembuangan pernapasan bakdrain mesin) clamp crankcase breather hose to the hose clamp. (klem slang). Remove the body cover (page 2-9). Lepaskan crankcase breather drain hose plug (penyumbat slang pembuangan pernapasan bak mesin) dari ujung hose dan keluarkan endapan ke dalam penampung yang sesuai.

Pasang crankcase breather drain hose plug dan tempatkan crankcase breather hose pada hose clamp. Check the crankcase breather hose for deterioration, damage or leakage. Replace the crankcase breather hose if n ecessary. Also check the crankcase breather hose fittings for leakage. Install the body cover (page 2-9).

3-6

DRAIN HOSE

HOSE PLUG

PERAWATAN Lepaskan body cover (hal. 2-9). SPARK PLUG Periksa crankcase breather hose terhadap pemburukan kondisi, kerusakan atau kebocoran. ? Clean around the spark plug base with compressed air ore removing the plug, and make sure that no debris is Ganti crankcase breather hose bila perlu. Juga periksa crankcase breather hose fittings terhadap ? kebocoran. Pasang body cover (hal. 2-9). ? ?

SPARK PLUG (BUSI) ? allowed to enter the combustion chamber.

BREATHER HOSE

CATATAN: Remove the center body cover (page 2-8). Bersihkan disekitar dasar busi dengan udara dari • Disconnect the spark plug cap and clean around the spark kompressor sebelum melepaskan busi, dan plug base. pastikan bahwa kotoran tidak memasuki ruang Remove the spark plug. pembakaran. Lepaskan center body cover (hal. 2-8). Lepaskan spark plug cap (topi busi) dan bersihkan daerah di sekitar dasar busi. Lepaskan spark plug.

SPARK PLUG CAP Inspect or replace as described in the maintenance Periksa atau ganti seperti diuraikan di dalamschedule jadwal (page 3-4). (hal. 3-4). perawatan Periksa sebagai berikutnya dan ganti bila perlu. Check the following and replace if necessary.

SPARK PLUG CENTER ELECTRODE

Insulatorfor terhadap • ? Insulator damage kerusakan • ? Electrodes Electrodes (kutub-kutub busi) terhadap keausan for wear • ? Burning Kondisicondition, terbakar, coloration; perubahan warna; -? – ?

Coklat sampai muda kondisii Dark totua light browncoklat indicates goodmenunjukkan condition. baik. Excessive lightness indicates malfunctioning ignition system lean mixture. Warnaormuda yang berlebihan menunjukkan sistem Wet or blackyang sootytidak deposit indicates over-rich mixture. pengapian bekerja dengan baik atau campuran bahan bakar yang miskin. If the electrode is contaminated with carbon deposits, clean - theEndapan yang basah atau hitam arang menunjukkan electrode using a spark plug cleaner. campuran bahan bakar yang terlalu Always kaya.use the specified spark plug on this scooter.

INSULATOR

SIDE ELECTRODE

SPECIFIED SPARK PLUG: Jika elektroda terkontaminasi dengan endapan karbon, Standard: bersihkan electrode dengan menggunakan spark plug cleaner.

Selalu pakai spark plug yang ditentukan pada skuter ini. CPR8EA-9 (NGK) For extended high speed riding: CPR9EA-9 (NGK) BUSI YANG DITENTUKAN: Standard: CPR8EA-9 (NGK), U24EPR9 (DENSO) Untuk pengendaraan lama pada kecepatan tinggi: CPR9EA-9 (NGK)

3-7

PERAWATAN Ukur jarak antara center dan electrodes Measure therenggang spark plugbusi gap between the center and side elecside electrodes (elektrode dan samping) dengan trodes with a feeler gauge of tengah a wire type. If necessary, adjust the gap by kawat. bending the side electrode feeler gauge (alat voeler) jenis carefully. Bila perlu, setel jarak renggang busi dengan menekuk electrode samping dengan hati-hati. SPARK PLUG GAP: 0.80 – 0.90 mm (0.031 – 0.035 in) JARAK RENGGANG BUSI: 0,80 – 0,90 mm

0.80 – 0.90 mm (0.031 – 0.035 in)

Install and handplug tighten the dengan spark plug to the pada cylinder head, spark (busi) tangan cylinder Domengencangkan not overtighten Pasang angan then tighten the spark plug to the specified torque.torsi yang theberlebihan. spark plug. head, kemudian kencangkan busi dengan busi secara

ditentukan. TORQUE:16 N·m (1.6 kgf·m, 12 lbf·ft) TORSI: Connect 16 the N.m spark(1,6 plugkgf.m; cap. 12 lbf.ft) Pasang spark plug cap (topi(page busi). Install the center body cover 2-8). Pasang center body cover (hal. 2-8).

SPARK PLUG CAP

JARAK VALVE RENGGANG CLEARANCEKLEP PEMERIKSAAN INSPECTION CATATAN: Periksaand dan setel klep the sementara • ? Inspect adjust thejarak valve renggang clearance while engine is mesin dalam keadaan dingin (di bawah 35° C). cold (below 35°C/95°F). Remove the following: Lepaskan sebagai berikut: ? Cylinder head cover (page 7-7) - Cylinder head cover (hal. 7-7) ? Cooling fan cover (page 2-12) - Cooling fan cover (hal. 2-12) Rotate the crankshaft clockwise by rotating the cooling fan Putar crankshaft (poros engkol) searah jarum jam slowly and align the "T mark" on the flywheel with the index dengan memutar cooling fan dengan pelan dan notch on the right crankcase. mentepatkan "tanda T" pada flywheel dengan index Make (takik sure the piston ispada at TDC (Top Dead Center) the notch penunjuk) right crankcase (bak on mesin compression stroke. kanan). This position can be confirmed by checking that there is slack in the rocker arm. piston berada pada TDC (Top Dead Pastikan bahwa If there is no is because piston is moving through Center) [TMAslack, (TitikitMati Atas)] the pada langkah kompressi. the exhaust stroke to TDC. Posisi ini dapat dipastikan dengan memeriksa bahwa Rotate the crankshaftpada one full turnarm. by rotating the cooling fan ada kerenggangan rocker slowly and match up the "T" mark Jika tidak ada kerenggangan, again. berarti bahwa piston sedang bergerak melalui langkah pembuangan ke TDC. Putar crankshaft satu putaran penuh dengan memutar cooling fan dengan pelan dan mentepatkan "tanda T" sekali lagi.

3-8

PENUNJUK

TANDA "T"

SPARK PLUG

PERAWATAN Check the clearance inserting a feeler gauge Periksa jarakvalve renggang klep by dengan memasukkan feeler between(lidah the valve adjustingantara screw and valveadjusting stem. gauge pengukur) valve screw (sekrup penyetelan klep) dan valve stem (tangkai klep). VALVE CLEARANCE: ± 0.02 mm (0.006 IN: 0.14 JARAK RENGGANG KLEP:± 0.001 in) ± EX: 0.14 0.02 mm (0.006 ± 0.001 in) IN: 0,14 0,02 mm EX: 0,14 0,02 mm

Jika jarak tidak sesuai, longgarkan valve If the valverenggang clearance klep is incorrect, loosen the valve adjusting adjusting lock nut the danvalve setel jarak renggang screw lockscrew nut and adjust clearance by turningklep the dengan adjusting sampai tahanan adjustingmemutar screw until there is a screw slight drag on theada feeler gauge. Apply pada enginefeeler oil to the valve adjusting screw lock nut threads sedikit gauge. and seating surface. Semprotkan oli mesin pada ulir valve adjusting screw Holdnut thedan adjusting screw and tighten the lock nut. lock permukaan duduk. Tahan adjusting screw dan kencangkan lock nut. TOOL: Valve adjusting wrench 07908-KE90000 TOOL:

FEELER GAUGE

ADJUSTING SCREW

LOCK NUT

Valve adjusting wrench 07908-KE90000 TORQUE:10 N·m (1.0 kgf·m, 7 lbf·ft) TORSI: kgf.m; 7 lbf.ft) Recheck 10 theN.m valve(1,0 clearance. Install the following: Periksa kembali jarak renggang klep. Pasang sebagai ? Cylinder headberikut: cover (page 7-7) ? Cooling fan cover - Cylinder head cover(page (hal.2-12) 7-7)

VALVE ADJUSTING WRENCH

- Cooling fan cover (hal. 2-12)

OLI MESIN ENGINE OIL PEMERIKSAAN TINGGI PERMUKAAN OLI OIL LEVEL CHECK Letakkan atas standard on utamanya di atas Support theskuter scooterdiwith its centerstand a level surface. tanah mendatar. Start the engine letbiarkan it idle forberputar 3 - 5 minutes. Hidupkan mesinand dan stasioner selama Stop the engine and wait for 2 3 minutes. 3-5 menit. Matikan selama 2-3 menit. Removemesin the oildan fillertunggu cap/dipstick and wipe off the oil from the dipstick with a clean cloth. Lepaskan oil filler cap/dipstick (tutup pengisian Insert the oil filler cap/dipstick without it in, oli/tangkai pengukur) dan sekalah oli screwing dari dipstick remove kain it andbersih. check the oil level. dengan The level should be between the "UPPER" and "LOWER" Masukkan oil filler cap/dipstick tanpa menyekrupkannya level lines of the oil filler cap/dipstick. ke dalam, lepaskan dan periksa tinggi permukaan oli.

FILLER CAP/DIPSTICK

UPPER

LOWER

Tinggi permukaan harus antara garis tinggi permukaan "UPPER" (TERATAS) dan "LOWER" (TERBAWAH) dari oil filler cap/dipstick. Viskositas lain yang Other viscosities diperlihatkan pada peta shown in the chart dapat dipakai jika suhu may be used di when the rata-rata daerah average temperature pengendaraan anda in your riding daerah area is berada di dalam within the indicated jangkauan yang diperlihatkan. range.

Jika permukaan berada di level bawah dekat If thetinggi oil level is below oroli near the lower lineatau on the dipgaris tinggi permukaanoil terbawah dari dipstick, stick, add the recommended to the upper level. tambahkan oli yang dianjurkan sampai ke tinggi RECOMMENDED permukaan teratas. ENGINE OIL: Honda "4-stroke motorcycle oil" or equivalent motor oil classification: SG or higher OLIAPI MESIN YANG DIANJURKAN: (exceptOil oils Supreme labeled as energy the circular Federal Flick conserving atau oli on mesin 4 tak API service label) sejenis dengan klasifikasi API service SG, JASO T 903 standard: Viskositas: SAE 10W-30MB JASO MB Viscosity: SAE 10W-30

3-9

PERAWATAN Pastikan O-ring dalam kondisi baik it dan Make surebahwa the O-ring is inberada good condition and replace if ganti bila perlu. necessary. O-RING

Coat the O-ring with engine oil and install the oil filler cap/ Lapisi O-ring dengan oli mesin dan pasang oil filler dipstick. cap/dipstick. For engine oil change, see page 3-10. Untuk penggantian oli mesin, lihat hal. 3-10.

FILLER CAP/DIPSTICK

PENGGANTIAN OIL CHANGE OLI CATATAN: Ganti oli mesin dalam •? Change the mesin engine sewaktu oil with the engine warmkeadaan and the panas dan skuter di atas tanah mendatar scooter on level ground to assure complete draining.untuk memastikan pengeluaran secara menyeluruh. Support the scooter with its centerstand. Letakkan skuterwarm padaitstandard utamanya. Start the engine, up and stop it. Hidupkan mesin, panaskan dan matikan. Remove the oil filler cap/dipstick. Lepaskan oil filler cap/dipstick.

FILLER CAP/DIPSTICK Place an oilloyang drain pan under the engine collectmesin the oil,untuk then Letakkan pembuangan oli di to bawah remove the oil drain andlepaskan sealing washer. mengumpulkan oli,bolt dan oil drain bolt dan sealing washer. Slowly apply kickstarter and drain the engine oil. After draining the oil dengan completely, install new sealing Jalankan kickstarter pelan danthekeluarkan oli washer and oil drain bolt. mesin. Tighten the drain bolt to the specified torque. Setelah mengeluarkan oli secara menyeluruh, pasang TORQUE:24 N·m (2.4 kgf·m, 18 lbf·ft) sealing washer baru dan oil drain bolt. Kencangkan drain bolt torsi yang ditentukan. Fill the crankcase with thedengan recommended engine oil.

TORSI: N.m (2,4 kgf.m; 18 lbf.ft) ENGINE24 OIL CAPACITY: liter (0.7dengan US qt, 0.6 qt)yang after dianjurkan. draining crankcase Isi 0.7 oli lmp mesin 0.8 liter (0.8 US qt, 0.7 lmp qt) after disassembly KAPASITAS OLI MESIN: Check the oilpada level penggantian (page 3-9). 0,7 liter periodik 0,8 liter setelah pembongkaran mesin Make sure that there are no oil leaks. Periksa tinggi permukaan oli (hal. 3-9). Pastikan bahwa tidak ada kebocoran oli.

3-10

WASHER/DRAIN BOLT

PERAWATAN

ENGINE OIL OILSTRAINER STRAINERSCREEN SCREEN ENGINE the engine (see page 3-10). (SARINGAN Drain KASA OLIoil MESIN) Remove the strainer screen cap, O-ring, spring and oil Keluarkan olioil mesin (lihat hal. 3-10). strainer screen. Keluarkan oil strainer screen cap, O-ring, spring dan oil Wash the strainer screen thoroughly in non-flammable or strainer screen. high flash point cleaning untilmenyeluruh all accumulated dirt Cucilah strainer screensolvent secara dalam has been removed. larutan pembersih yang tidak dapat terbakar atau Blow dry it with compressed air to clean completely. mempunyai titik api tinggi sampai semua kotoran yang telah terkumpul dibersihkan. Before installingtelah the strainer screen, it should be examined closely for damage make sure the sealing udara rubber isdari in Keringkan denganandmeniupnya dengan good condition. kompressor untuk membersihkan secara menyeluruh. Make sure the O-ring is in good condition and replace it if Sebelum memasang strainer screen, periksalah dengan necessary. teliti terhadap kerusakan dan pastikan bahwa sealing Install the oil strainer andbaik. spring with the strainer sealrubber berada dalamscreen kondisi ing rubber toward the crankcase. Pastikan bahwa O-ring dalam kondisi baik dan ganti bila Coat the O-ring with engine oil and install the oil strainer perlu. screen cap. Pasang oil oil strainer dantospring dengan strainer Tighten the strainerscreen screen cap the specified torque. sealing rubber menghadap ke crankcase. TORQUE:20 N·m (2.0 oli kgf·m, 15 lbf·ft) Lapisi O-ring dengan mesin dan pasang oil strainer screen cap. Fill the crankcase with recommended engine oil and check Kencangkan oil strainer screen cap dengan torsi yang the engine oil level (page 3-9). ditentukan. Make sure that there are no oil leaks. TORSI: 20 N.m (2,0 kgf.m; 15 lbf.ft)

OIL STRAINER SCREEN

SPRING

OIL STRAINER SCREEN CAP

O-RING

Isi crankcase yang oli mesin yang dianjurkan dan periksa tinggi permukaan oli mesin (hal. 3-9). Pastikan bahwa tidak ada kebocoran oli.

PUTARAN STASIONER ENGINE IDLE SPEED MESIN CATATAN: Periksaand dan setelthe putaran stasioner setelah • ? Inspect adjust idle speed after all other semua engine bagian perawatan mesin lain telah maintenance items have beenyang performed and dijalankan are within dan adalah sesuai dengan spesifikasi. specifications. engineharus must bedalam warm forkeadaan accurate idle speed inspecMesin panas untuk • ? The tion and adjustment. minutes of stop-and-go riding is pemeriksaan danTen penyetelan putaran stasioner sufficient. yang akurat. Sepuluh menit pengendaraan jalandan-berhenti Support the scooteradalah with itscukup. centerstand.

ADJUSTING HOLE CAP

Warm up the engine about ten minutes. Letakkan skuter pada standard utamanya. Connect a tachometer and check the sepuluh idle speed. Panaskan mesin selama kira-kira menit. -1 IDLE SPEED: 1,700 ± 100 min (rpm) Hubungkan tachometer dan periksa putaran stasioner.

-1

PUTARAN 100 menit (rpm) If the engineSTASIONER: idle speed is out1.700 of specification, adjust as follows: Jika putaran stasioner mesin tidak sesuai dengan Unlock the seat with ignition key. spesifikasi, setel sebagai berikut: Open the seat. Buka penguncian tempat duduk Remove the adjusting hole cap and dengan turn the anak throttlekunci stop kontak. screw as required to obtain the specified idle speed. Naikkan tempat duduk. Lightly open the throttle 2 –dan 3 times, checkstop the Lepaskan adjusting holeforcap putarthen throttle engine idle speed again. screw sebanyak diperlukan untuk mendapatkan putaran stasioner ditentukan. Install the yang removed parts in the reverse order of removal.

THROTTLE STOP SCREW

Bukalah throttle 2 - 3 kali dengan ringan, kemudian periksa putaran stasioner mesin sekali lagi. Pasang parts yang telah dilepaskan dalam urutan terbalik dari pelepasan.

3-11

PERAWATAN

SECONDARY AIR SUPPLY SYSTEM SYSTEM PEMERIKSAAN INSPECTION Remove the cleanerhousing housing cover Lepaskan airaircleaner cover(page (hal. 3-6). 3-6). Remove thePAIR PAIRair aircleaner cleaner element. element. Lepaskan

ELEMENT

CATATAN: • ? Never Jangan memakai bensin atauforpelarut use sekali-kali gasoline or low flash point solvents cleandengan titik api rendah untuk membersihkan ing the element. A fire or explosion could result. element. Dapat mengakibatkan kebakaran atau Thoroughly wash the element in clean non flammable or high ledakan. flash point cleaning solvent. Cucilah dalam larutan pembersih yang tidak Allow theelement element to dry thoroughly. dapat terbakar atau mempunyai titik api tinggi. After drying, apply 1.0 – 1.5 g of clean engine oil to the entire surface of the element and rub it with hand to saturate the eleBiarkan element mengering secara menyeluruh. ment with oil. Setelah mengering, oleskan 1,0 – 1,5 g oli mesin bersih pada seluruh permukaan element RECOMMENDED ENGINE OIL: dan gosok dengan tangan untuk memenuhi element oli. motor oil Honda "4-stroke motorcycle oil"dengan or equivalent API classification: SG or higher OLI(except MESIN YANG DIANJURKAN: oils labeled as energy conserving on the circular Federal Oil Supreme Flick atau oli mesin 4 tak API service label) sejenis klasifikasi JASOdengan T 903 standard: MBAPI service SG, Viskositas: 10W-30 JASO MB Viscosity: SAE 10W-30

Peras larutan pembersih sepenuhnya

Cucilah dalam larutan pembersih

Penuhi element dengan oli

Oleskan 1,0 - 1,5 g oli mesin bersih

Install the element. Pasang element. Install the cleanerhousing housing cover cover (page Pasang airair cleaner (hal. 3-6). 3-6). Remove the bodycover cover(hal. (page2-9). 2-9). Lepaskan body Check theairairsuction suction joint cleaner housing housing Periksa joint between antara the air air cleaner and PAIRsaringan control valve for cracks, damage or (rumah udara) dan deterioration, PAIR control valve loose connections. terhadap retak-retak, pemburukan kondisi, kerusakan ika joint sambungan longgar. Check the air supply hose between the PAIR control valve If thememperlihatkan joint show any atau tanda-tanda signs of heat damage, kerusakan inspect theakibat PAIR panas, periksalah check valve (page 5 PAIR check valve. 24).

VACUUM HOSE

and air supply pipe for cracks, deterioration, damage or loose Periksa air supply hose antara PAIR control valve dan connections. air supply pipe terhadap retak-retak, pemburukan Check the air supplyatau pipesambungan between thelonggar. air supply hose and kondisi, kerusakan cylinder head for damage or loose fasteners. Periksa supply pipe antara air supply hose dan Check theair vacuum hose between the intake manifold vacuum cylinder head terhadap kerusakan atau pengikat joint and PAIR control valve for deterioration, damage or longgar. loose connections. Also check that hose is notantara kinkedintake or pinched. Periksa vacuum hose manifold vacuum oint dan PAIR control valve terhadap Install the removed parts in the reverse order of pemburukan removal. kondisi, kerusakan atau sambungan longgar.

Juga periksa bahwa hose (slang) tidak tertekuk atau terjepit. Pasang parts yang telah dilepaskan dalam urutan terbalik dari pelepasan.

3-12

AIR SUPPLY HOSE/PIPE

AIR SUCTION JOINT

PERAWATAN

DRIVE BELT BELT DRIVE Remove theleft leftcrankcase crankcase cover cover (page Lepaskan (hal. 8-5). 8-5). Check the drive belt for cracks, separationpemisahan or abnormal or Periksa drive belt terhadap retak-retak, atau excessive wear replaceatau it if necessary (page 8-12). keausan tidakand normal berlebihan dan ganti bila perlu (hal. 8-11).

DRIVE BELT

Dengan dua pelatmeasure datar, ukurlah Using themenggunakan suitable two flat plates, the drivelebar belt drive seperti diperlihatkan. widthbelt as shown.

DRIVE BELT

SERVICE LIMIT:17,5 17.5 mm BATAS SERVIS: mm (0.69 in)

Replace the drive belt iflebarnya it is less than the service limit servis (page Ganti drive belt jika kurang dari batas 8-12). (hal. 8-11).

DRIVE BELT

FINAL FINALDRIVE DRIVEOIL OIL PEMERIKSAAN TINGGI PERMUKAAN OLI OIL LEVEL CHECK Make sure bahwa that the final case has no oli oil leaks. Pastikan tidakreduction ada kebocoran pada final reduction case. Support the scooter with its centerstand.

SEALING WASHER

Remove the oil check Letakkan skuter padabolt. standard utamanya. Check whether the oilbolt. flows out from the check bolt hole. Lepaskan oil check If the level is lowoli(oil does notkeluar flow out), the recomPeriksa apakah mengalir dari add lubang check mended oil as described below. bolt.

Jika tinggi permukaan rendah (oli tidak mengalir RECOMMENDED FINAL REDUCTION OIL: keluar), tambahkan oli yang dianjurkan seperti diuraikan di Honda "4-stroke motorcycle oil" or equivalent motor oil bawah. API classification: SG or higher (except oils labeled as energy conserving on the circular

FINAL REDUCTION API service label) OIL YANG DIANJURKAN: Federal Oil Supreme Flick atau oli mesin 4 tak JASO T 903 standard: MB sejenis dengan klasifikasi API service SG, Viscosity: SAE 10W-30 Viskositas: SAE 10W-30 JASO MB Install the oil check bolt with a new sealing washer and Pasang check bolt torque. dengan sebuah sealing washer tighten it oil to the specified baru dan kencangkan dengan torsi yang ditentukan.

CHECK BOLT

LOWER LEVEL

TORQUE:13 N·m (1.3 kgf·m, 10 lbf·ft)

TORSI: 13 N.m (1,3 kgf.m; 10 lbf.ft)

3-13

PERAWATAN OIL CHANGE OLI PENGGANTIAN Place an oil drain pan underpembuangan the final reduction to collect Letakkan sebuah loyang oli dicase bawah fina the oil, then remove the oil check bolt, oil drain bolt and sealreduction case untuk menerima oli, kemudian lepaskan ingcheck washers. oil bolt, oil drain bolt dan sealing washers. Putar roda dengan pelanthe dan Slowly turnbelakang the rear wheel and drain oil.keluarkan oli. Setelah mengeluarkan oli secara menyeluruh, pasang After draining the oil completely, installwasher the oil drain oil drain bolt dengan sebuah sealing baru bolt dan with a new sealing washer and tighten the drain bolt to the kencangkan drain bolt dengan torsi yang ditentukan. specified torque. TORSI: 13 N.m (1,3 kgf.m; 10 lbf.ft) TORQUE:13 N·m (1.3 kgf·m, 10 lbf·ft)

Isilah casewith dengan oli yangoil dianjurkan Fill thefinal finalreduction reduction case recommended up to the sampai ke tinggi permukaan correct level (see page 3-13). yang tepat (lihat hal. 3-13). KAPASITAS FINAL REDUCTION OIL: FINAL REDUCTION CAPACITY: 0,10 liter padaOIL penggantian periodik 0.10 liter (0.11 US qt, 0.09 lmp qt) after draining 0,12 liter setelah pembongkaran 0.12 liter (0.13 US qt, 0.11 lmp qt) after disassembly Pasang oil check bolt dengan sealing washer baru dan Install the oil check bolt with a new sealing washer and kencangkan dengan torsi yang ditentukan. tighten it to the specified torque.

DRAIN BOLT

CHECK BOLT

SEALING WASHER

SEALING WASHER

TORSI: 13 N.m (1,3 TORQUE:13 N·m (1.3kgf.m; kgf·m,10 10 lbf.ft) lbf·ft)

FLUID (MINYAK REM) BRAKE FLUID CATATAN: Minyakfluid remcan yang tertumpah • ? Spilling damage painted,dapat plastic merusak or rubber parts parts. yanga dicat, atau dari plastik atau is karet. Place rag over theseterbuat parts whenever the system serviced. Tutupilah parts ini dengan kain lap setiap kali sistem diservis. ? Do not mix different types of fluid, as they are not com patible with each other. • ? Do Jangan mencampurkan jenis not allow foreign materialbermacam-macam to enter the system when minyak rem, oleh karena mereka tidak cocok satu filling the reservoir. sama lain. ? When the fluid level is low, check the brake pads for wear Jangan sampai benda-benda • (see page 3-15). A low fluid level mayasing be due memasuki to wear of sistem the brakeketika pads. mengisi reservoir. permukaan minyak rem piston terlaluisrendah, • IfJika the tinggi brake pads are worn, the caliper pushed periksalah pads keausan (lihat out, and thisbrake accounts forterhadap a low reservoir level. If hal. the brake are not worn and the fluid level low,terlalu check 3-15).pads Tinggi permukaan minyak rem is yang entire system fordiakibatkan leaks (page 3-15). rendah dapat oleh keausan dari brake pads. Support scooter withtelah its centerstand. Jikathe brake pads aus, caliper piston didorong dan ini menyebabkan tinggi permukaan Turnkeluar, the handlebar to the left so the reservoir is level and check the front brake fluid level Jika through the pads sight yang rendah di reservoir dalam reservoir. brake glass. tidak aus dan tinggi permukaan minyak rem rendah, periksalah keseluruhan sistem terhadap If the level is near the lower level mark, check the brake pads kebocoran (hal. 3-15). for wear (see page 3-15). Letakkan skuter pada standard utamanya. Putar handlebar (stang stir) ke kiri sehingga reservoir mendatar dan periksa tinggi permukaan minyak rem di dalam front brake reservoir melalui kaca pengintaian. Jika tinggi permukaan dekat tanda batas permukaan terendah, periksa brake pads terhadap keausan. (lihat hal. 3-15).

3-14

TANDA TINGGI PERMUKAAN TERENDAH

PERAWATAN

BRAKE SHOES/PADS WEAR KEAUSAN BRAKE SHOES/PADS FRONT DISC BRAKE PADS PADS FRONT DISC BRAKE (BRAKE PADS CAKRAM DEPAN) Check the brake pads for wear. Periksa brake pads terhadap keausan. Replace the brake pads if either pad is worn to the wear limit Ganti brake pads jika salah satu pad telah aus sampai groove. ke alur batas keausan. To replace the brake pad, see page 13-8. Untuk mengganti brake pad, lihat hal. 13-8.

REAR DRUM BRAKE SHOES (SEPATU REM TEROMOL BELAKANG) REAR DRUM BRAKE SHOES Periksa posisi keausan ketika handel rem Check the wear indikator indicator position when the brake lever is ditekan. applied.

ALUR-ALUR BATAS KEAUSAN

BELAKANG:

TANDA " "

If the indicator aligns with the " " mark, inspect the brake Jika indikator bertepatan dengan tanda "Δ", periksa drum (page 13-6). brake drum (hal. 13-5). Replace the brake shoes if the drum I.D. is within service limit. brake shoes jika D.D. drum masih di dalam batas Ganti servis.

BRAKE SYSTEM (SISTEM REM) BRAKE SYSTEM FRONT DISC BRAKE

INDIKATOR KEAUSAN

(REM CAKRAM DEPAN) FRONT DISC BRAKE Tekan rem dengan kuatcheck dan periksa bahwa tidak Firmlyhandel apply the brake lever and that no air has entered the system. ada udara yang telah memasuki sistem. If thehandel lever feels soft or spongy when operated, bleed ketika the air Jika terasa lunak atau seperti sepons from the system. dijalankan, buanglah udara palsu dari sistem. For air bleeding procedures (page 13-7). Untuk prosedur pembuangan udara palsu (hal. 13-7).

3-15

PERAWATAN Inspect the brakehose hose (slang and fittings deterioration, cracks, Periksa brake rem)fordan fittings (alat-alat or signs of leakage. pemasangan) terhadap pemburukan kondisi, retakTighten anytanda-tanda loose fittings.kebocoran. retak, atau Replace the hose and fittings as required. Kencangkan fittings yang longgar. Ganti hose dan fittings seperti diperlukan.

BRAKE HOSE

REAR DRUM BRAKE (REM BELAKANG) REARTEROMOL DRUM BRAKE Periksa brake rem) danfor brake (handel Check the brakecable cable(kabel and brake lever looselever connections, excessive play orsambungan other damage.longgar, jarak main bebas rem) terhadap Replace or repair if necessary. yang berlebihan atau kerusakan lain. Ganti atau perbaiki bila perlu. Measure the rear brake lever free play at the end of the lever.

10 – 20 mm (0.4 – 0.8 in)

Ukur jarak main bebas rear brake lever (handel rem FREE PLAY: 10 – 20 mm (0.4 – 0.8 in) belakang) pada ujung lever. JARAK MAIN BEBAS: 10 – 20 mm

bahwa Setel bebas brake dengan Make Pastikan sure the cut-out Adjust jarak the rearmain brake lever freerear play by turninglever the rear brake potongan pada rearnut. brake arm adjusting nut (mur penyetelan of the adjusting nut is memutar arm adjusting adjusting nut telah seated on the joint lengan rem belakang). duduk pada joint pin. pin.

ADJUSTING NUT

3-16

PERAWATAN

BRAKE LIGHT LIGHTSWITCH SWITCH BRAKE (SAKLAR LAMPU REM) ? The brake light switch on the brake lever cannot be CATATAN: If the brake pada light switch and dapat brake • adjusted. Brake light switch brake actuation lever tidak engagement arepenjalanan not synchronized, replace dan the disetel. Jika brake either light switch switch or malfunction parts of the system. pengenaan rem tidak sinkron, gantilah switch atau parts tidak light bekerja dengan baik daritosistem. Check thatyang the brake comes on just prior the brake actually being engaged. Periksa bahwa brake light (lampu rem) hidup tepat For brake light switch inspection (page 16-14). sebelum rem sebenarnya mulai bekerja.

Untuk pemeriksaan brake light switch (hal. 16-14).

REAR BRAKE

FRONT BRAKE

LIGHT SWITCH

LIGHT SWITCH

BRAKE LOCK OPERATION BRAKE LOCK OPERATION (CARA KERJA KUNCI REM) CATATAN: • ? Check Periksa brake lock thecara brakekerja lock operation aftersetelah the rear jarak brake main lever bebas brakeand lever telah(page diperiksa free playrear is checked adjusted 3-16).dan disetel (hal. 3-16). Squeeze the rear brake lever and set the lock lever.

LOCK LEVER

Tekan rear lever dan completely. tempatkan lock lever Check that the brake rear wheel is locked (handel kunci). Periksa bahwa roda belakang telah dikunci sama sekali.

BRAKE LEVER

3-17

PERAWATAN

HEADLIGHT AIM PENYETELAN ARAH SINAR LAMPU BESAR CATATAN: ? Adjust the headlight beam as specified by local laws and Setel arah sinar lampu besar seperti telah • regulations. ditentukan oleh undang-undang dan peraturan Place the scooter on a level ground. lokal. Adjust the headlight beam vertically by loosening the headLetakkan skuter dibolt. atas tanah mendatar. light aim adjusting Hold the headlight aim adjusting bolt and tighten it. Setel arah sinar lampu besar dalam arah vertikal dengan melonggarkan headlight aim adjusting bolt baut penyetelan arah sinar lampu besar). Tahan headlight aim adjusting bolt dan kencangkan. HEADLIGHT AIM ADJUSTING BOLT

KEAUSAN CLUTCH SHOES CLUTCH SHOES WEAR Lepaskan clutch (hal. 8-15). Remove the clutchassembly assembly (page 8-16). Periksa clutch shoes terhadap keausan Check the clutch shoes for abnormal wear. tidak normal. Ukur ketebalan dari masing-masing Measure the thickness of each shoe. shoe. BATAS SERVIS: 2,0 mm SERVICE LIMIT: 2.0 jika mm ketebalan (0.08 in) mereka kurang dari Ganti clutch shoes batas servis (hal. 8-17). Replace the clutch shoes if they are less than the service limit (page 8-18). Pasang clutch assembly (hal. 8-16). Install the clutch assembly (page 8-17). CLUTCH SHOE

SIDESTAND SIDESTAND (STANDARD SAMPING) Letakkan skuter pada utamanya. Support the scooter withstandard its centerstand. Periksa sidestand terhadap kerusakan Check thepegas sidestand spring for damage or loss of tension.atau kehilangan tegangan. Check the sidestand assembly for freedom of movement and lubricate the sidestand pivot if necessary. Periksa sidestand assembly terhadap kebebasan Check the sidestand ignition cut-off system: bila perlu. pergerakan dan lumasi engsel sidestand 1. Retract the sidestand. Periksa sistem sidestand ignition cut-off (sistem 2. Start the engine. pematian pengapian dari standard samping): 3. Move the sidestand full down. 1. Tarik sidestand atas. 4. The engine shouldke stop as the sidestand is lowered. 2. Hidupkan mesin. If there is a problem withsepenuhnya the system, check the sidestand 3. Gerakkan sidestand ke bawah. switch (page 15-9). 4. Mesin harus berhenti berputar sewaktu sidestand diturunkan.

Jika ada persoalan dengan sistem, periksa sidestand switch (saklar standard samping) (hal. 15-9).

3-18

SIDESTAND

PERAWATAN

SUSPENSI SUSPENSION DEPAN FRONT agian suspensi yang Loose, worn or longgar, aus atau damaged suspension rusak mempengarui parts impair scooter kestabilan dan stability and control. pengendalian skuter.

Check the action of the forks(garpu) by operating the front brake and Periksa cara kerja forks dengan menjalankan compressing the front suspension several times. rem depan dan menekan suspensi depan beberapa kali Check the entire assembly for signs of leaks, damage or loose ke bawah. fasteners.keseluruhan susunan terhadap tanda-tanda Periksa kebocoran, kerusakan atau pengikat longgar. Replace damaged components which cannot be repaired. Tightenkomponen-komponen all nuts and bolts. Ganti rusak yang tidak dapat diperbaiki. For fork service (page 11-11).

Kencangkan semua baut dan mur. Untuk service fork (hal. 11-11).

FRONT FORK

BELAKANG REAR Check thecara action of the shockabsorber absorber by compressing it Periksa kerja shock (peredam kejut) several times. dengan menekannya beberapa kali. Check the entire shock absorber assembly for signs of leaks, Periksa keseluruhan susunan shock absorber terhadap damage or loose fasteners. tanda-tanda kebocoran, kerusakan atau pengikat Replace damaged components which cannot be repaired. longgar. Tighten all nuts and bolts. Ganti komponen-komponen rusak yang tidak dapat For rear shock absorber service (page 12-5). diperbaiki.

Kencangkan semua baut dan mur. Untuk servis shock absorber belakang (hal. 12-5).

Dukung skuter kokoh naikkan Support the scooterdengan securely and raise dan the rear wheel offroda the belakang ground. lepas tanah.

REAR SHOCK ABSORBER ENGINE MOUNTING BUSHINGS

Check for worn engine mounting bushings by grabbing the Periksa terhadap engine mounting bushings (bos-bos engine and attempting to move the wheel side to side. pemasangan mesin) yang aus dengan memegang For engine service (page 12-6). mesin dan bushing mencoba untuk menggerakkan roda dari sisi ke sisi.

Untuk servis engine bushing (hal. 12-6).

3-19

PERAWATAN

NUTS,BAUT, BOLTS, FASTENERS MUR, PENGIKAT Check that all chassis nuts and boltsdan are tightened to theirtelah corPeriksa bahwa semua baut mur rangka rect torque values (page 1-9). dikencangkan dengan nilai torsi mereka yang benar Check that all cotter pins, safety clips, hose clamps and cable (hal. 1-9). stays are bahwa in place and properly secured. Periksa semua cotter pins, safety clips, hose clamps dan cable stays berada pada tempatnya dan telah dipasang dengan erat.

WHEELS/TIRES RODA/BAN

Support the scooter centerstand. Letakkan skuter di with atas its standard utamanya. Making sure that fork the fork not allowed to move, raiseroda the Pastikan bahwa tidakisdapat bergerak, naikkan front wheel and check for play. depan dan periksa terhadap kelonggaran. Check for worn front wheel bearings by grabbing the roda front Periksa terhadap front wheel bearings (bantalan wheel and attempting to move the wheel side to side. depan) yang aus dengan memegang roda depan dan Replace the frontmenggerakkan wheel bearings ifroda any dari looseness is sisi. noted. mencoba untuk sisi ke Ganti bearings jika smoothly diketahui Turn thefront wheel wheel and check that it rotates withada no kelonggaran. unusual noises.

WHEEL BEARINGS

If anyroda abnormal conditions are suspected, inspect thehalus front Putar dan periksa bahwa ia berputar dengan wheel adanya bearingssuara-suara (page 11-10).tidak normal. tanpa

Jika ada dugaan adaya kondisi-kondisi tidak normal, periksa front wheel bearings (hal. 11-10). Support the scooterdengan securely and raise the wheel. roda Dukung skuter kokoh danrearnaikkan belakang. Check for worn final gear shaft bearings by grabbing the rear Periksa terhadap final gear shaft bearings (bantalan wheel and attempting to move the wheel side to side. poros final gear) yang aus dengan memegang roda Replace the gear shaft bearings if anyroda looseness is belakang danfinal mencoba untuk menggerak dari sisi noted. ke sisi.

FINAL GEAR SHAFT BEARINGS

Turn the wheel and check that it rotates smoothly with no Ganti gear shaft bearings bila diketahui ada unusualfinal noises. kelonggaran. If anyroda abnormal conditions are ia suspected, thehalus final Putar dan periksa bahwa berputarcheck dengan reduction (pagesuara-suara 9-8). tanpa adanya tidak normal. Jika ada dugaan adanya kondisi-kondisi tidak normal, periksa final reduction (hal. 9-8).

Periksa tekanan udarawith banthe dengan air pressure gauge Check the tire pressure air pressure gauge when the (meter tekanan udara ban) sewaktu ban tires are pengukur cold. dalam keadaan dingin. RECOMMENDED TIRE PRESSURE: Driver only:UDARA BAN YANG DIANJURKAN: TEKANAN FRONT: 200 kPa (2.00 kgf/cm2, 29 psi) Pengendara saja: 2 2 REAR: 225 kPa200 (2.25 kgf/cm , kgf/cm 33 psi) ; 29 psi) DEPAN: kPa (2,00 2 BELAKANG: 225 kPa (2,25 kgf/cm ; 33 psi) Driver and passenger: 2 Pengendara dankPa pembonceng: FRONT: 200 (2.00 kgf/cm , 29 psi) 2 2 kgf/cm ; 29 psi) DEPAN: 200 kPa (2,00 REAR: 225 kPa (2.25 kgf/cm , 33 psi) 2 BELAKANG: 225 kPa (2,25 kgf/cm ; 33 psi)

PRESSURE GAUGE

3-20

PERAWATAN Check the ban tires for cuts, embedded other damage. Periksa terhadap sayatan,nails, pakuoryang tertancap, Check the front wheel atau kerusakan lain.and rear wheel for trueness. Periksa apakah roda depan dan roda belakang RECOMMENDED TIRE SIZE AND TIRE BRAND: berjalan lurus dalam satu bidang. UKURAN BAN DAN MEREK BAN YANG FRONT REAR DIANJURKAN: Tire size 80/90-14M/C40P 90/90-14M/C46P Tire brand SRI FT235 FT235 DEPAN BELAKANG Measure theban tread depth at the center of the tires. Ukuran 80/9090/90Replace the tires when the tread depth reaches the following 14M/C40P 14M/C46P limits. Merek SRI FT235 FT235 ban MINIMUM TIRE TREAD DEPTH: Ukur kedalaman alur telapak ban pada tengah-tengah FRONT/REAR: To the indicator ban. Ganti ban jika kedalaman telapak ban mencapai batas sebagai berikut. KEDALAMAN ALUR TELAPAK BAN MINIMUM: DEPAN/BELAKANG: Sampai ke indikator

INDICATOR

STEERING HEAD HEAD BEARINGS BEARINGS STEERING (BANTALAN KEPALA KEMUDI)

? Check that the control cables do not interfere with handleCATATAN: bar rotation. Periksa bahwa kabel-kabel pengontrol tidak • Support the scooterperputaran with its centerstand and raise the front mengganggu handlebar. wheel off the ground. Letakkan pada standard utamanya dan naikkan Check thatskuter the handlebar moves freely from side-to-side. If roda depan lepas tanah. the handlebar moves unevenly or binds, inspect the steering Periksa bahwa handlebar head bearings (page 11-21). bergerak dengan bebas dari sisi-ke-sisi. Jika handlebar bergerak secara tidak merata atau mengikat, periksa steering head bearings (hal. 1121).

Hold the scooter check the steering bearings for Peganglah skuterand dan periksa steeringhead head bearings wear by moving thedengan fork forward and backward. terhadap keausan menggerakkan fork ke depan dan belakang. If the steering stem has vertical movement, inspect the steer-

STEM BEARINGS

STEM BEARINGS

ing head bearing (page 11-21). Jika steering stem ada pergerakan vertikal, periksalah steering head bearing (hal. 11-21).

3-21

CATATAN

4. SISTEM PELUMASAN

4

DIAGRAM SISTEM PELUMASAN......... 4-2 LUBRICATION SYSTEM DIAGRAM????? 4-2

TROUBLESHOOTING ........................... 4-3 4-3 TROUBLESHOOTING ?????????????????

KETERANGAN SERVIS ........................ SERVICE INFORMATION ?????????????? 4-3 4-3

OIL .............................................. 4-4 OIL PUMP PUMP ???????????????????????????? 4-4

4-1

SISTEM PELUMASAN

LUBRICATION SYSTEM DIAGRAM DIAGRAM SISTEM PELUMASAN LUBRICATIONSYSTEM

ROCKER ARM SHAFT

CAM SHAFT

PISTON

CRANKSHAFT

OIL PUMP

OIL STRAINER SCREEN

4-2

SISTEM PELUMASAN

SERVICE INFORMATION KETERANGAN SERVIS UMUM GENERAL ! PERINGATAN Oli mesin bekas dapat menyebabkan kanker kulit jika berulangkali mengenai kulit untuk jangka waktu lama. Walaupun ini kecil Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely kemungkinannya terjadi anda menangani oli bekas hari,wash tetapyour dianjurkan untuk secara menyeluruh unless you handle usedkecuali oil on ajika daily basis, it is still advisable to setiap thoroughly hands with soap and water as soonmencuci as tangan dengan sabun dan air sesegera mungkin setelah menangani oli bekas. possible after handling used oil. • • • • •

• • • • •

Oil pump (pompa oli) dapat diservis mesin terpasang pada rangka. The oil pump can be serviced with thedengan engine installed in the frame. The service procedures in this sectionbab must performed withdengan the engine oil drained. Prosedur-prosedur servis di dalam ini be harus dijalankan oli mesin dikeluarkan. When and installing the oil pump, use berhati-hatilah care not to allow dust or dirt to kotoran enter thetidak engine. Ketikaremoving melepaskan dan memasang oil pump, agar debu atau memasuki mesin. If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly. Jika the adaoil bagian pump yang aus melampui batas yang ditentukan, gantilah oil pump sebagai sebuah susunan. After pumpdari has oil been installed, check that there are servis no oil leaks. Setelah oil pump telah dipasang, periksa bahwa tidak ada kebocoran o li.


Unit: mm (in) Satuan: mm SERVICE BAGIAN STANDARD BATAS SERVIS ITEM STANDARD LIMIT Kapasitas oli Pada penggantian 0,7 liter Engine oil capacity After draining 0.7 liter (0.7 US qt, 0.6 lmp qt) – mesin periodik After disassembly 0.8 liter (0.8 US qt, 0.7 lmp qt) – Pada pembongkaran 0,8 liter Recommended engine oil Honda "4-stroke motorcycle oil" or equivamesin lent motor oil Oli mesin yang dianjurkan Federal Oil Supreme Flick atau API classification: SGoli or mesin higher 4 tak sejenis dengan(except klasifikasi API service SG, oils labeled as energy conserving – Viskositas: SAE JASO on10W-30 the circular APIMB service label) JASO T 903 standard: MB Oil pump rotor Jarak renggang pada 0,15 0,20 Viscosity: SAE 10W-30 ujung rotor Oil pump rotor Tip clearance 0.20 (0.008) Jarak renggang antara 0,15 – 0,21 0.15 (0.006) 0,35 Body clearance 0.35 (0.014) 0.15 – 0.21 (0.006 – 0.008) rotor dan rumah clearance 0.12 (0.005) Jarak renggang Sideke 0,05 – 0,10 0.05 – 0.10 (0.002 – 0.004) 0,12 samping rotor pompa

TORQUE VALUES NILAI TORSI Oil pump plate screw Oil pump mounting bolt Oil pump plate screw Oil pump mounting bolt

3 N·m (0.3 kgf ·m, 2.2 lbf ·ft) 10 N·m (1.0 kgf ·m, 7 lbf ·ft) 3 N.m (0,3 kgf.m; 2,2 lbf.ft) 10 N.m (1,0 kgf.m; 7 lbf.ft)

TROUBLESHOOTING Engine oil level too low, high oil consumption TROUBLESHOOTING

• External oil leak piston ringsoli ormesin incorrect piston ring installation • Worn (page Tinggi permukaan terlalu rendah, pemakaian oli7-35) tinggi • Worn cylinder (page 7-33) Ada kebocoran oli di luar • Worn valve guide or seal (page 7-24) Piston rings aus atau p emasangan piston ring tidak benar (hal. 7-34) Oil contamination Cylinder aus (hal. 7-32) • Oil not changed often Valve guide atau sealenough aus (hal. 7-14) • Clogged oil strainer • Worn piston rings (page 7-36) Kontaminasi oli Oli jarang diganti Oil strainer tersumbat Piston rings aus (hal. 7-34) • • • •

• • •

4-3

SISTEM PELUMASAN

OIL PUMP POMPA OLI REMOVAL PELEPASAN • When the oiloil pump, do jagalah not allow atar dust or dirt Ketikaremoving melepaskan pump, debu to enter the engine. atau kotoran tidak memasuki mesin. Drain the engine oil (page 3-10). Keluarkan ollialternator mesin (hal. 3-10). Remove the (page 14-7). •

Lepaskan alternator (hal. 14-8). Remove the following: – Oil pump coverberikut: bolts Lepaskan sebagai – Oil pump cover - –OilO-ring pump cover bolts pump driven gear - –OilOil pump cover Oil pump bolts - –O-ring pump assembly - –OilOil pump driven gear - Oil pump bolts - Oil pump assembly

OIL PUMP ASSEMBLY

O-RING

OIL PUMP DRIVEN GEAR

OIL PUMP COVER

Lepaskan oil pump cover dengan menggunakan baut-baut 5 mm. OIL PUMP BOLTS

5 mm BOLTS

OIL PUMP COVER BOLTS

4-4

SISTEM PELUMASAN INSTALLATION PEMASANGAN • When the oil do berhati-hatilah not allow dust oragar dirt Ketikainstalling memasang oilpump, pump, to enter the engine. debu atau kotoran tidak memasuki mesin. Install the oil pump to the right crankcase.

•

OIL PUMP

Pasang oil pump pada crankcase. Install and tighten theright oil pump mounting bolts to the specified torque. Pasang dan kencangkan oil pump mounting bolts TORQUE:10 N·m ditentukan. (1.0 kgf·m, 7 lbf·ft) dengan torsi yang TORSI: 10 N.m (1,0 kgf.m; 7 lbf.ft)

BOLTS

Semprotkan oil pump gearoildan oil Apply engineolioilmesin to thepada oil pump drivendriven gear and pump pump shaft. shaft.

DRIVEN GEAR

Tepatkan

Install the oil pump driven gear to the oil pump by alignPasang oil pump pada oilcut-out. pump dengan ing the driven geardriven cut-outgear with oil pump mentepatkan potongan pada driven gear dengan potongan pada oil pump.

Oleskan oli mesin pada sebuah O-ring baru dan Apply engine oil to a new O-ring and install it topasang the oil alur oil cover pumpgroove. cover. pump Apply engine oil to the oil pump driven gear and oil pump Semprotkan mesin pada oil pump driven gear dan cover sliding oli surface. permukaan luncur oil pump cover. Install the oil pump cover to the right crankcase.

O-RING

Pasang oil pump cover pada right crankcase.

OIL PUMP COVER

Pasang dantighten kencangkan bolts. Install and the bolts. Install the alternator (page 14-9). Pasang alternator (hal. 14-10). Fillcrankcase the crankcase witholi engine (page 3-10). Isi dengan mesinoil (hal. 3-10).

BOLTS

4-5

SISTEM PELUMASAN PEMBONGKARAN/PERAKITAN DISASSEMBLY/ASSEMBLY Remove the following: Lepaskan sebagai berikut: – Dowel pins - Dowel pins – Screw - – Screw Pump plate - – Pump Outerplate rotor - – Outer Innerrotor rotor - •Inner rotor Apply engine oil to the inner rotor and outer rotor. Assembly is in theoli reverse disassembly. Semprotkan mesinorder padaofinner rotor dan outer rotor. TORQUE:OIL PUMP PLATE SCREW •

3 N·m (0.3 kgf·m, 2.2 lbf·ft) Perakitan adalah dalam urutan pembongkaran.

terbalik

dari

TORSI: OIL PUMP PLATE SCREW 3 N.m (0,3 kgf.m; 2,2 lbf.ft) DOWEL PINS PUMP PLATE

OUTER ROTOR

PUMP BODY

INNER ROTOR

4-6

SCREW 3 N·m (0.3 kgf ·m, 2.2 lbf ·t)

SISTEM PELUMASAN INSPECTION PEMERIKSAAN ? Measure at several points and use the largest reading Ukur pada the beberapa to compare service titik limit.dan pakailah pembacaan untukofmembandingkannya dengan batas ? Ifterbesar any portion the oil pump is worn beyond the specified servis. service limits, replace the oil pump and oil pump cover as andari assembly. Jika ada bagian oil pump yang aus melampaui servis yang ditentukan, gantilah oil pump dan Tip batas clearance oil pump cover sebagai sebuah susunan. Temporarily install the outer, inner rotors and oil pump driven gear into the oil pump body. Jarak renggang pada ujung inner rotor Measure the clearance between the outer rotor and the inner rotor with a feeler gauge.outer, inner rotors dan oil Untuk sementara pasanglah pump driven gear ke dalam oil pump body. SERVICE LIMIT: 0.20 mm (0.008 in) Ukur kerenggangan antara outer rotor dan inner rotor dengan feeler gauge. •

•

Kerenggangan pada ujung inner rotor :

BATAS SERVIS: 0,20 mm

Jarak renggang antara outer rotor dan badan Body clearance Ukur jarakthe renggang antara oil pump Measure clearance between the oil body pump dan bodyouter and the outer rotor with gauge. a feeler gauge. rotor dengan feeler

Kerenggangan antara outer dan badan :

SERVICE BATAS SERVIS: 0,35 mm LIMIT: 0.35 mm (0.014 in)

Jarak renggang ke samping rotor pompa Side clearance Ukur jarakthe renggang ke samping dengan menggunakan Measure side clearance using a straight edge and feeler lurus gauge. mistar dan feeler gauge.

Kerenggangan ke samping:

SERVICE BATAS SERVIS: 0,12 mm LIMIT: 0.12 mm (0.005 in)

4-7

CATATAN

5. SISTEM BAHAN BAKAR

5

LOKASI KOMPONEN .............................. COMPONENT LOCATION ?????????????5-2 5-2

PEMBERSIHAN KARBURATOR.............5-17 5-17 CARBURETOR CLEANING????????????

DIAGRAM SISTEM .................................. SYSTEM DIAGRAM ???????????????????5-3 5-3

PEMERIKSAAN KARBURATOR............. 5-18 CARBURETOR INSPECTION ?????????? 5-18

KETERANGAN SERVIS .......................... SERVICE INFORMATION ??????????????5-4 5-4

PENYETELAN SCREW................ 5-20 PILOT SCREWPILOT ADJUSTMENT ????????? 5-20

TROUBLESHOOTING TROUBLESHOOTING............................. ?????????????????5-5 5-5

INLET PIPE 5-22 INLET PIPE.............................................. ?????????????????????????? 5-22

AIR CLEANER HOUSING AIR CLEANER HOUSING....................... ??????????????5-6 5-6

SECONDARY AIR SUPPLY SUPPLYSYSTEM SYSTEM..... 5-23 SECONDARY AIR ??? 5-23

PELEPASAN KARBURATOR ................. 5-8 CARBURETOR REMOVAL ????????????? 5-8

TANGKI BAHAN BAKAR ........................5-26 5-26 FUEL TANK ?????????????????????????

PEMASANGAN 5-10 CARBURETORKARBURATOR INSTALLATION............. ??????? 5-10

FUEL 5-27 FUELAUTO AUTO VALVE VALVE ................................ ?????????????????? 5-27

PEMBONGKARAN/PERAKITAN CARBURETOR DISASSEMBLY/ KARBURATOR ........................................ 5-12 5-12 ASSEMBLY ??????????????????????????

5-1

SISTEM BAHAN BAKAR

COMPONENT LOCATION LOKASI KOMPONEN FUELSYSTEM

5-2

SISTEM BAHAN BAKAR

SYSTEM DIAGRAM DIAGRAM SISTEM

MAIN FUSE 15A

SUB FUSE 10A R/Bl

R

R

l B / R

l B / R

2P

R

G

4P

l B / R

O / G

6P

Br

G

l B

3P

Bl

O / G

l B

IGNITION CONTROL MODULE (ICM)

BATTERY

IGNITION SWITCH

STARTER ENRICHMENT (SE) THERMAL VALVE

5-3

SISTEM BAHAN BAKAR

SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM ? Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bind, resulting in loss of Menekuk atau memilin kabel pengontrol akan mengganggu kelancaran kerjanya dan dapat menyebabkan bahwa kabel macet vehicle control. atau in mengikat, sehinggaarea. mengakibatkan pengaturan atas ? Work a well ventilated Smoking or hilangnya allowing flames or sparks inkendaraan. the work area or where gasoline is stored can cause a fire Bekerjalah di ruangan dengan ventilasi baik. Merokok atau membiarkan lidah api atau percikan bunga api di tempat kerja atau • or explosion. ? When disassembling fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly. di tempat di mana bensin disimpan dapat mengakibatkan kebakaran atau ledakan. ? Before disassembling the carburetor, place a suitable container under the carburetor hose.yang Loosen thepada drainwaktu screw perakitan and drain • Sewaktu membongkar parts sistem bahan bakar, catatlah lokasi O-rings. Gantidrain dengan baru the carburetor. kembali. ? After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with pieces of tape to prevent any for• Sebelum membongkar karburator, letakkan penampung yang sesuai di bawah carburetor drain hose (slang pembuangan eign material from dropping into the engine. karburator). Longgarkan drain screw (sekrup pembuangan) dan kosongkan karburator. Setelah melepaskan karburator, bungkuslah lubang pemasukan mesin dengan kain lap atau tutuplah dengan pita perekat • SPECIFICATIONS untuk mencegah masuknya benda asing ke dalam mesin. •

ITEM

SPESIFIKASI Carburetor identification number

Main jet BAGIAN Slow jet Nomor identifikasi karburator SE thermal valve resistance Main Floatjet level Slow jet Pilot screw initial opening Tahanan listrik SE thermal valve Engine idle speed Tinggi pelampung PAIR control valve specified vacuum Throttle grip awal free play Pembukaan pilot screw Putaran stasioner mesin Vakuum PAIR control valve yang ditentukan TORQUE VALUES Jarak main bebas throttle grip Inlet pipe band screw

NILAI TORSI SE thermal valve body screw SE thermal valve setting plate screw Inlet pipe band screw cover screw SEVacuum thermal chamber valve body screw Slow jet SE thermal valve setting plate screw Main jet Vacuum chamber cover screw Needle Slow jet jet holder Float Main jet chamber screw Float jet chamber Needle holder drain screw PAIR check valve Float chamber screwcover screw Float chamber drain screw Fuel auto valve lock nut PAIR check valve cover screw Fuel auto valve lock nut

SPECIFICATIONS AVK2CH #100 SPESIFIKASI #35 AVK2CH 3.2 – 5.6 Ω (25°C/77°F) # 100 13.0 mm (0.51 in) # 35 See page 5-20 3,2 – 5,6 Ω (20° C) 1,700 ± 100 min-1 (rpm) 13,0 mm 60 kPa (450 mmHg) Lihat halaman 5-20 2 – 6 mm (0.1 – 0.2 in) -1 1.700 ± 100 menit (rpm) 60 kPa (450 mmHg) 2 – 6 mm

2 N·m (0.2 kgf ·m, 1.5 lbf ·ft) 3.4 N·m (0.4 kgf ·m, 2.5 lbf ·ft) 2.1 N·m (0.2 kgf ·m, 1.5 lbf ·ft) 2 N.m (0-,2 kgf.m; 1,5 lbf.ft) 2.1 (0.2 kgf ·m, 1.5 lbf ·ft) 3,4 N.m (0,4 N·m kgf.m; 2,5 lbf.ft) 1.5 N·m (0.2 kgf ·m, 1.1 lbf ·ft 2,1 N.m (0,2 kgf.m; 1,5 lbf.ft) 2.1 N·m (0.2 kgf ·m, 1.5 lbf ·ft) 2,1 N.m (0,2 kgf.m; 1,5 lbf.ft) 2.5 N·m (0.3 kgf ·m, 1.8 lbf ·ft) 1,5 N.m (0,2 kgf.m; 1,1 lbf.ft) 2.1 N·m (0.2 kgf ·m, 1.5 lbf ·ft) 2,1 N.m (0,2 kgf.m; 1,5 lbf.ft) 1.5 N·m (0.2 kgf ·m, 1.1 lbf ·ft) 2,5 N.m (0,3 kgf.m; 1,8 lbf.ft) 2.1kgf.m; N·m (0.2 ·m, 1.5 lbf ·ft) 2,1 N.m (0,2 1,5 kgf lbf.ft) 1,5 N.m (0,2 kgf.m; 1,1 lbf.ft) 22.5 N·m (2.3 kgf ·m, 17 lbf ·ft) 2,1 N.m (0,2 kgf.m; 1,5 lbf.ft) 22,5 N.m (2,3 kgf.m; 17 lbf.ft)

TOOLS TOOLS Pin driver 07744-0010100

5-4

Carburetor float level gauge 07401-0010000

SISTEM BAHAN BAKAR

TROUBLESHOOTING TROUBLESHOOTING Mesin Enginetidak won’tmau starthidup ? No fuel in tank • Tangki bahan bakar kosong ? No fuel to carburetor Bahan bakar tidak sampai ke karburator • ? Fuel strainer clogged Fuel strainer tersumbat ? Fuel hose clogged Fuel hose tersumbat ? Fuel tank breather hole clogged Lubang pernapasan ?- Faulty fuel auto valve tangki bahan bakar tersumbat ? Float level incorrect - Fuel auto valve tidak bekerja dengan baik ? Too much getting to the engine • Float levelfuel (tinggi pelampung) tidak sesuai ? Air cleaner clogged • banyak bahan bakar yang masuk ke dalam mesin ?Terlalu Flooded carburetor - Air cleaner ? Intake air leak tersumbat - Karburator banjir ? Fuel contaminated/deteriorated ? Faulty starting enrichment (SE) thermal valve Ada kebocoran udara masuk • ? Clogged starting enrichment (SE) circuit kondisinya Bahan bakar terkontaminasi/memburuk • ? Clogged carburetor slow circuit Starting enrichment (SE) thermal valve tidak bekerja dengan baik • ? Improper throttle operation Rangkaian starting enrichment (SE) tersumbat • ? No spark at plug (faulty ignition system – page 15-3) • Rangkaian stasioner karburator tersumbat Engine stall, hard to start, rough idling • Caraline kerja throttle tidak benar ? Fuel restricted Tidak ada percikan bunga api pada busi (sistem pengapian tidak bekerja dengan baik – hal. 15-3) • ? Fuel mixture too lean/rich ? Fuel contaminated/deteriorated ? Intake air leakmendadak, sulit dihidupkan, putaran stasioner kasar Mesin berhenti ? Idle speed misadjusted • Saluran bahan bakar terbatasi ? Pilot screw misadjusted • Campuran bahan hole bakar terlalu miskin/kaya ? Fuel tank breather clogged • ? Air cleaner clogged Bahan bakar terkontaminasi/memburuk kondisinya ? Slow clogged Ada circuit kebocoran udara masuk • ? Faulty starting enrichment (SE) thermal valve • Penyetelan putaran stasioner salah ? Ignition system malfunction (page 15-3) Penyetelan pilot screw salah • LeanLubang mixturepernapasan tangki bahan bakar tersumbat • ? Fuel jets clogged • Air cleaner tersumbat ? Float valve faulty Rangkaian stasioner tersumbat • ? Float level too low • Starting enrichment (SE) thermal valve tidak bekerja dengan baik ? Fuel line restricted ? Carburetor air vent hose • Sistem pengapian tidakclogged bekerja dengan baik (hal. 15-3) ? Fuel tank breather hole clogged ? Intake airbahan leak bakar terlalu miskin Campuran ? Vacuum piston faulty Fuel jets tersumbat • RichFloat mixture • valve tidak bekerja dengan baik ? Air jet clogged • Float level terlalu rendah ? Float valve faulty • Saluran bakar terbatasi ? Float levelbahan too high ? Starting enrichment valve stuck open • Carburetor air vent(SE) hosethermal tersumbat ? Air cleaner element contaminated • Lubang pernapasan tangki bahan bakar tersumbat ? Vacuum piston faulty Ada kebocoran udara masuk • Backfiring or piston misfiring during acceleration tidak bekerja dengan baik • Vacuum ? Fuel mixture too lean ? Ignition system malfunction (page 15-3) Campuran bahan bakar terlalu kaya Afterburn engine braking is used • Air jet when tersumbat ? Lean mixture in slow circuitdengan baik • Float valve tidak bekerja ? Faulty pulse secondary air injection (PAIR) system Float level terlalu tinggi • ? Faulty PAIR control valve • enrichment (SE) thermal valve macet terbuka ?Starting Faulty PAIR check valve cleanerhose element • ? Air Clogged of theterkontaminasi PAIR system system ? Ignition (page 15-3) baik • Vacuum pistonmalfunction tidak bekerja dengan Backfiring atau misfiring selama akselerasi • Campuran bahan bakar terlalu miskin • Sistem pengapian tidak bekerja dengan baik (hal. 15-3) Afterburn ketika engine braking dipakai • Campuran bahan bakar terlalu miskin pada rangkaian stasioner • Pulse secondary air injection (PAIR) system tidak bekerja dengan baik - PAIR control valve tidak bekerja dengan baik - PAIR check valve tidak bekerja dengan baik - Slang dari PAIR system tersumbat • Sistem pengapian tidak bekerja dengan baik (hal. 15-3)

5-5

SISTEM BAHAN BAKAR

AIR CLEANER CLEANER HOUSING HOUSING AIR REMOVAL PELEPASAN Remove the following: Lepaskan sebagai berikut: Luggagebox box(hal. (page 2-7) -? Luggage 2-7) Body cover ? (page 2-9) - Body cover (hal. 2-9) Left crankcasecover coverduct duct(hal. (page 2-12) -? Left crankcase 2-12) Remove the two PAIR valve mounting bolts bolts and Lepaskan kedua PAIRcontrol control valve mounting disconnect the valve from the air cleaner housing. (baut pemasangan PAIR control valve) Disconnect the crankcase breather hose dan fromlepaskan the air valve dari air cleaner housing. cleaner housing. Lepaskan crankcase breather hose (slang pernapasan bak mesin) dari air cleaner housing.

PAIR CONTROL VALVE

BOLTS

CRANKCASE BREATHER HOSE Loosen the connecting band screw. Longgarkan connectinghose hose band screw (sekrup pita Disconnect the vacuum piston hose from the air cleaner slang penyambung). housing.

BAND SCREW

Lepaskan vacuum piston hose dari air cleaner housing.

VACUUM PISTON HOSE

Tarik keluar finalreduction reduction breather hose air Pull out the final breather hose from dari the air cleaner housing. housing. cleaner Release the crankcase breather from the Lepaskan crankcase breather draindrain hose hose dari clamp. clamp. Lepaskan kedua air cleaner housing mounting bolts dari Remove the two air cleaner housing mounting bolts from sisi the kiri. left side.

BOLTS

BREATHER DRAIN HOSE

Be Hati-hati careful not to agar damage the air tidak merusak air cleaner cleanerconnecting connecting hose. hose.

BREATHER HOSE

CLAMP

Remove the bolt from right side. Lepaskan bolt dari sisithe kanan. Disconnect the connecting hose from the carburetor by Lepaskan connecting hose dari karburator dengan holding the carburetor and pulling the air cleaner housing memegang backward. karburator dan menarik air cleaner housing ke belakang. Remove the air cleaner housing from the right side of the frame. Lepaskan air cleaner housing dari sisi kanan dari rangka.

AIR CLEANER HOUSING BOLT

5-6

SISTEM BAHAN BAKAR PEMASANGAN INSTALLATION

Be careful not to Hati-hati agar damage the air tidak merusak air cleaner connecting cleaner connecting hose. hose.

Install the cleaner housing the right of the Pasang air air cleaner housing darifrom sisi kanan dariside rangka. frame. Sambungkan connecting hose ke karburator dengan Connect the connecting hose to the carburetor by holdmemegang karburator dengan hati-hati ing the carburetor and dan carefully pushing the mendorong air cleaner air cleaner housing ke depan. housing forward. Set the connecting hose band as shown. Tempatkan seperti diperlihatkan. Tighten the connecting band screwhose until band the band seats on the collar Kencangkan band screw sampai band duduk pada as shown. collar seperti diperlihatkan.

BAND SCREW

CONNECTING HOSE

75°

VACUUM PISTON HOSE

Hubungkan pada Connect thecrankcase crankcase breather breather hose hose to the air air cleaner cleaner housing. housing. Connect thePAIR PAIRcontrol controlvalve valveketoair the air cleaner housHubungkan cleaner housing. ing. Pasang dan kencangkan kedua PAIR control valve Install and tighten the two PAIR control valve mounting mounting bolts. bolts.

PAIR CONTROL VALVE

BOLTS

CRANKCASE BREATHER HOSE Set the air cleaner Tempatkan air housing cleanerin position. housing pada posisi pemasangannya. Install and tighten the bolt to the right side of air cleaner housing. Pasang dan kencangkan bolt pada sisi kanan dari air cleaner housing.

AIR CLEANER HOUSING BOLT Install and the two boltsbolts to the left sisi sidekiriofdari air Pasang dantighten kencangkan kedua pada cleaner housing. air cleaner housing. Set the crankcase breather drain hose to the clamp on Tempatkan crankcase breather drain hose pada clamp the air cleaner housing. pada cleaner Insertairthe final housing. reduction breather hose into the air Masukkan final cleaner housing.reduction breather hose ke dalam air cleaner housing. Install the following:

BOLTS

BREATHER HOSE

cover duct (page 2-12) ? Left crankcase Pasang sebagai berikut: ? Body cover (page 2-9) Luggage box cover (page 2-7) -? Left crankcase duct (hal. 2-12)

- Body cover (hal. 2-9) - Luggage box (hal. 2-7) BREATHER DRAIN HOSE

CLAMP

5-7

SISTEM BAHAN BAKAR

CARBURETOR REMOVAL PELEPASAN KARBURATOR Lepaskan sebagai berikut: Remove the following: Leftcrankcase crankcasecover coverduct duct(hal. (page 2-12) -? Left 2-12) Luggagebox box(hal. (page 2-7) -? Luggage 2-7) Place a suitable container carburetor drain Letakkan penampung yang under sesuai the di bawah carburetor hose and drain fuel from the carburetor by loosening the drain hose dan keluarkan bahan bakar dari karburator drain screw. dengan melonggarkan drain screw (sekrup Tighten the float chamber drain screw to the specified pembuangan). torque.

Kencangkan chamber screw dengan torsi TORQUE:1.5 float N·m (0.2 kgf·m, drain 1.1 lbf·ft) yang ditentukan. TORSI: 1,5 N.m (0,2 kgf.m; 1,1 lbf.ft)

Release the carburetor drain hose from the clamp. Lepaskan carburetor drain hose dari clamp.

FLOAT CHAMBER DRAIN SCREW

CLAMP


Lepaskan valvevalve 3P connector. DisconnectSE thethermal SE thermal 3P connector.

SE THERMAL VALVE 3P CONNECTOR

Lepaskan SEthermal thermal valve clamps dari Release thekedua two SE valve wirewire clamps from the frame. rangka. Release the SE thermal valvevalve wire dari fromwire the wire guide. Lepaskan kawat SE thermal guide.

WIRE GUIDE

WIRE CLAMPS

5-8

SISTEM BAHAN BAKAR Release the crankcase breather from the Lepaskan dari clamp. crankcase breather draindrain hose hose clamp. Lepaskan kedua air cleaner housing mounting bolts dari Remove the two air cleaner housing mounting bolts from sisi kiri. the left side of air cleaner housing. Lepaskan boltbolt darifrom sisi the kanan dari airof cleaner housing. Remove the right side air cleaner housing.

Kanan

Kiri: BOLTS

BREATHER DRAIN HOSE Loosen the lock the throttle Longgarkan dan disconnect lepaskan throttle dari lock nut nut and cablecable from the throttle drum. throttle drum. Release the air vent hose from the intake shroud. Lepaskan air vent hose dari intake shroud.

LOCK NUT

CLAMP THROTTLE CABLE

AIR VENT HOSE Disconnect the vacuum piston hose and fuel hose from Lepaskan vacuum piston hose dan fuel hose dari the carburetor. karburator. Loosen the air cleaner connecting hose band screw. Disconnect the connecting hose from the carburetor Longgarkan airthe cleaner connecting hose band screw. while holding carburetor and pulling the air cleaner Lepaskan connecting hose dari karburator sementara housing backward. memegang karburator danscrew menarik cleaner housing Loosen the inlet pipe band andair disconnect the carke belakang. buretor from the inlet pipe.

BAND SCREWS

Longgarkan inlet pipe band screw dan lepaskan karburator dari inlet pipe.

FUEL HOSE

VACUUM PISTON HOSE

5-9

SISTEM BAHAN BAKAR

CARBURETOR INSTALLATION PEMASANGAN KARBURATOR Connect the carburetor to the inlet pipe while aligning the

Sambungkan karburator pada inlet pipe sementara

agar Be Hati-hati careful not to tab of the carburetor with the groove of the inlet pipe. mentepatkan tab dari karburator dengan alur dari inlet tidak merusak inlet damage the inlet pipe. pipe. pipe.

Be careful to Hati-hati agarnot tidak damage the air merusak air cleaner connecting hose. cleaner connecting hose.

Connect the airair cleaner connecting hose to hose the carbureSambungkan cleaner connecting pada tor while holding the carburetor and carefully pushing the karburator sementara menahan karburator dan dengan air cleaner housing forward. hati-hati mendorong air cleaner housing ke depan. Tighten the inlet pipe band screw to the specified torque.

Tepatkan

CARBURETOR

CONNECTING HOSE

TORQUE:2 N·m kgf·m, lbf·ft) dengan torsi yang Kencangkan inlet(0.2 pipe band1.5screw ditentukan. Set the air cleaner connecting hose band by the specified angle. Tighten 2 the connecting hose TORSI: N.m (0,2 kgf.m; 1,5band lbf.ft)screw until the band seats on the collar as shown.

Tempatkan air cleaner connecting hose band dengan sudut yang ditentukan. Kencangkan connecting hose band screw sampai band duduk pada collar seperti diperlihatkan.

BAND SCREWS INLET PIPE BAND SCREW ATAS 75°

CONNECTING HOSE BAND SCREW

Sambungkan throttlecable cable pada throttle dan Connect the throttle to the throttle drum drum and install it to thepada cablecable holder. pasang holder. Connect the fuel hose and vacuum piston hose to the carburetor. fuel hose dan vacuum piston hose pada Sambungkan Set the carburetor air vent hose to the intake shroud as karburator. shown.

THROTTLE CABLE

Tempatkan carburetor air vent hose pada intake shroud seperti diperlihatkan.

AIR VENT HOSE

5-10

FUEL HOSE

VACUUM PISTON HOSE

SISTEM BAHAN BAKAR Tempatkan air housing cleanerin position. housing pada posisi Set the air cleaner Install and tighten the three air cleaner housing mounting pemasangannya. bolts. Pasang dan kencangkan ketiga air cleaner housing Secure the crankcase breather drain hose to the clamp. mounting bolts. Kokohkan pemasangan crankcase breather drain hose pada clamp.

Kanan

BOLTS

BOLT

Route the wire Alurkan wire harness properly harness (pagedengan 1-14). benar (hal. 1-14).

Secure thekedua two SE the Kokohkan SE thermal thermal valve valvewire wireclamps clampstopada frame. rangka. Set the SE thermal valve wirewire to the wirewire guide. Tempatkan SE thermal valve pada guide.

Kiri:

BREATHER DRAIN HOSE

CLAMP

WIRE GUIDE

WIRE CLAMPS Connect the SE Sambungkan SEthermal thermalvalve valve3P 3Pconnector. connector.

SE THERMAL VALVE 3P CONNECTOR Secure thepemasangan carburetor drain hose withdrain the clamp. Kokohkan carburetor hose dengan clamp. Adjust the throttle grip free play (page 3-5). Check the engine idle speed (page 3-11). Setel jarak main bebas throttle grip (hal. 3-5). Install the following: Periksa putaran stasioner mesin (hal. 3-11). ? Luggage box (page 2-7) Pasang sebagai berikut: ? Left crankcase cover duct (page 2-12) - Luggage box (hal. 2-7) - Left crankcase cover duct (hal. 2-12)

CLAMP


5-11

SISTEM BAHAN BAKAR

CARBURETOR DISASSEMBLY/ PEMBONGKARAN/PERAKITAN ASSEMBLY KARBURATOR • ?

Be carefulketika when melepaskan removing thevacuum vacuum chamber chamber cover cover Hati-hati as it iskarena under ia spring pressure. oleh berada di bawah tekanan pegas. ? Before removing the pilot screw, record the number of • Sebelum melepaskan pilot screw, catatlah jumlah turns until it seats lightly, then remove the pilot screw, putaran sampai ia O-ring. duduk dengan ringan, kemudian spring, washer and lepaskan pilot screw, spring, washer danifO-ring. ? Damage to the pilot screw seat will occur the screw tightened pilot against the seat. • is Dudukan screw akan mengalami kerusakan jika dikencangkan Hold thescrew carburetor and lightlyterhadap drive thedudukannya. float pin from the throttle drum side. Pegang karburator dan dengan ringan dorong masuk TOOL: float pin dari sisi throttle drum. Pin driver 07744-0010100 TOOL: Pin driver 07744-0010100

PIN DRIVER

FLOAT PIN

2.1 N·m (0.2 kgf ·m, 1.5 lbf ·ft)

DIAPHRAGM/ VACUUM PISTON

VACUUM CHAMBER COVER

FLOAT VALVE

FLOAT

FLOAT PIN SE THERMAL VALVE COVER

O-RING DRAIN SCREW 1.5 N·m (0.2 kgf ·m, 1.1 lbf ·ft)

FLOAT CHAMBER

SE THERMAL VALVE

O-RING

COMPRESSION SPRING

O-RING WASHER

NEEDLE HOLDER

SPRING

SPRING

NEEDLE JET

JET NEEDLE

SLOW JET 1.5 N·m (0.2 kgf ·m, 1.1 lbf ·ft)

2.1 N·m (0.2 kgf ·m, 1.5 lbf ·ft) SETTING PLATE

PILOT SCREW O-RING NEEDLE JET HOLDER 2.5 N·m (0.3 kgf ·m, 1.8 lbf ·ft)

MAIN JET 2.1 N·m (0.2 kgf ·m, 1.5 lbf ·ft)

5-12

2.1 N·m (0.2 kgf ·m, 1.5 lbf ·ft)

SE THERMAL VALVE BODY O-RING

3.4 N·m (0.4 kgf ·m, 2.5 lbf ·ft)

SISTEM BAHAN BAKAR FLOATCHAMBER CHAMBER FLOAT (RUANG PELAMPUNG) CATATAN: Handle Tangani jets dengan hati-hati. mudah sekali • ? the jets with care. TheyMereka can easily be scored or scratched. tergerus atau tergores. Pasang sebagai berikut: Install the following: Slow -? Slow jetjet Needle -? Needle jetjet ? Needle jet holder -? Needle jet holder Main jet - Main jet Tighten them to the specified torque. Kencangkan dengan torsi yang ditentukan. TORQUE: TORSI: Slow jet: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) Slow 1,5(0.2 N.m (0,2 kgf.m; 1,1 lbf.ft) Mainjet: jet: 2.1 N·m kgf·m, 1.5 lbf·ft) Main jet:jet holder: 2,12.5 N.m (0,2 kgf.m; Needle N·m (0.3 kgf·m,1,5 1.8lbf.ft) lbf·ft) Needle jet holder: 2,5 N.m (0,3 kgf.m; 1,8 lbf.ft)

NEEDLE JET

O-RING

WASHER MAIN JET PILOT SCREW

Kerusakan terjadi Damageakan to the pilot padaseat dudukan pilot screw will occur screw jika pilot screw if the pilot screw is dikencangkan terhadap tightened against the kedudukannya. seat.

Pasang O-ring, dan Install the O-ring,washer, washer,spring springdan and pilot pilot screw screw and kembalikan keoriginal tempatnya semula seperti telahremoval. dicatat return it to its position as noted during pada waktu prosedur penyetelan pilot Perform thepelepasan. pilot screw Jalan adjustment procedure if a new pilot screw is installed (page 5-20). screw seperti bila sebuah pilot screw baru telah dipasang Install the(hal. float5-20). and float valve in the carburetor body,

NEEDLE JET HOLDER

SPRING

FLOAT PIN

SLOW JET FLOAT VALVE

then install the float pin through the body and float. Pasang float dan float valve di dalam badan karburator, kemudian pasang float pin melalui badan dan float.

FLOAT Drive the masuk float pin lightly height from the float pin Dorong float until pin the dengan ringan sampai holder (SE thermal valve side) is 0.15 – 0.55 mm (0.006 ketinggian dari float pin holder (sisi SE thermal valve) 0.0220,15 in). – 0,55 mm. – adalah TOOL: TOOL: Pin driver driver Pin

PIN DRIVER

07744-0010100 07744-0010100

0.15 – 0.55 mm (0.006 – 0.022 in)

FLOAT PIN Install a new O-ring into the float chamber. Pasang sebuah O-ring baru ke dalam float chamber Install the float chamber. (ruang pelampung). Pasang float chamber.

FLOAT CHAMBER

O-RING

5-13

SISTEM BAHAN BAKAR Install and tighten the floatfloat chamber screws to thedengan speciPasang dan kencangkan chamber screws fied torque. torsi yang ditentukan. TORQUE:2.1 N·m (0.2 kgf·m, 1.5 lbf·ft) TORSI: 2,1 N.m (0,2 kgf.m; 1,5 lbf.ft)

SCREWS

VACUUM CHAMBER VACUUM CHAMBER Pasang jet needle, spring dan dalam Install the jet needle, spring andneedle needleholder holderkeinto the vacuum piston. piston. vacuum

VACUUM PISTON

JET NEEDLE SPRING

NEEDLE HOLDER

Dorong needle holder dalam piston vacuum Press the needle holdermasuk into thekevacuum andpiston turn the needle you jarum feel a click. dan putar holder needleclockwise holder until searah jam sampai terasa ada 'klik'.

Be careful not to damage theagar jet Hati-hati needle. tidak merusak jet needle.

Install the diaphragm/vacuum piston into the carburetor Pasang diaphragm/vacuum piston ke dalam badan body aligning the diaphragm tab with the groove on the karburator dengan mentepatkan diaphragm tab dengan carburetor body. alur pada badan karburator. Hold the vacuum piston almost full open to prevent the diaphragm from being pinched by the chamber cover. Tahan vacuum piston hampir terbuka penuh untuk Install the compression spring into the piston. menghindari dijepitnya diaphragm olehvacuum chamber cover. Set the boss of the vacuum chamber cover to the compressioncompression spring and install the cover. piston. Pasang kechamber dalam vacuum spring

NEEDLE HOLDER

Tempatkan

VACUUM CHAMBER COVER SPRING Tepatkan

Tempatkan boss dari vacuum chamber cover pada compression spring dan pasang chamber cover. DIAPHRAGM/ VACUUM PISTON

5-14

SISTEM BAHAN BAKAR Install and tighten the vacuumvacuum chamberchamber cover screws to Pasang dan kencangkan cover the specified torque. screws (sekrup-sekrup tutup ruang vakuum) dengan

SCREWS

torsi yang ditentukan. TORQUE:2.1 N·m (0.2 kgf·m, 1.5 lbf·ft) TORSI: 2,1 N.m (0,2 kgf.m; 1,5 lbf.ft)

Periksa bahwa spring telah dipasang benar Check that the spring is installed correctly dengan by pushing the bottom of the piston with your finger piston and make sure that dengan mendorong bagian bawah dengan jarithe piston returns back bahwa in place piston smoothly. ari dan memastikan kembali dengan lancar ke tempatnya semula.

SPRING

PISTON

STARTING ENRICHMENT STARTING ENRICHMENT (SE)(SE) THERMAL VALVE THERMAL VALVE Install a sebuah new O-ring into baru the groove on the thermal Pasang O-ring ke dalam alurSEpada SE valve body. thermal valve body. O-RING

SE THERMAL VALVE BODY Install the SE thermal valve body. Pasang SE thermal valve body. Install and tighten the SE thermal valve body screws to Pasang dan kencangkan SE thermal valve body screws the specified torque. dengan torsi yang ditentukan. TORQUE:3.4 N·m (0.4 kgf·m, 2.5 lbf·ft)

SE THERMAL VALVE BODY

TORSI: 3,4 N.m (0,4 kgf.m; 2,5 lbf.ft)

SCREW

5-15

SISTEM BAHAN BAKAR Pasang O-ring baru SE thermal Install asebuah new O-ring to the SEpada thermal valve. valve.

SE THERMAL VALVE

Install the thermal valve thekarburator carburetorsampai until it is Pasang SESE thermal valve ke into dalam ia fully seated. telah duduk sepenuhnya.

O-RING Set the SE thermal valve into thedalam carburetor body so that Tempatkan badan karburator SE thermal valve ke its center line is parallel with center line of carburetor sehingga garis tengahnya sejajar dengan garis tengah body as shown. seperti diperlihatkan. badan karburator

Install the setting Pasang setting plate withplate the dengan ujung yang telah chamfered edge dipotong menghadap ke facing up. atas.

Pasang setting plate pada Install the setting plate ontoalur the SE SE thermal thermal valve. valve groove. Install and tighten the setting plate screw the specified Pasang dan kencangkan setting plate to screw dengan torque. torsi yang ditentukan. TORQUE:2.1 N·m (0.2 kgf·m, 1.5 lbf·ft) TORSI: 2,1 N.m (0,2 kgf.m; 1,5 lbf.ft)

SETTING PLATE

Atur

SCREW

Pasang SE SE thermal valvevalve covercover pada to SEthe thermal valve Install the thermal SE thermal valve.

SE THERMAL VALVE COVER

5-16

SISTEM BAHAN BAKAR HOSES(SLANG-SLANG) HOSES Sambungkan airvent venthose hoseand dancarburetor carburetordrain drain hose. Connect the air hose.

AIR VENT HOSE


PEMBERSIHAN KARBURATOR CARBURETOR CLEANING Remove the following: Lepaskan sebagai berikut: ? SE thermal valve - SE thermal valve ? Diaphragm/vacuum piston - Diaphragm/vacuum piston ? Float/float valve -? Float/float valvejet/needle jet/needle jet holder Main jet/slow -? Main jet/slow jet/needle jet/needle jet in holder Pilot screw/spring/washer/O-ring Blow open all air and fuel passages the carburetor -body Pilotwith screw/spring/washer/O-ring compressed air. Do not use a piece of Jangan memakai wire to clean the air Tiuplah semua lubang terbuka dan lintasan bahan bakar seutas kawat and fuel passage untuk as it di dalam badan karburator dengan udara dari membersihkan saluran could damage the kompressor. lintasan bahan bakar carburetor body. oleh karena dapat merusak badan karburator.

5-17

SISTEM BAHAN BAKAR

CARBURETOR INSPECTION PEMERIKSAAN KARBURATOR SE VALVE SE THERMAL THERMAL VALVE VALVE/NEEDLE INSPECTION PEMERIKSAAN VALVE/NEEDLE

Lepaskan SESE thermal valve (hal. 5-12). Remove the thermal valve (page 5-12).

VALVE

Inspect valve the valve needle for stepped wearbertingkat or damPeriksa danand needle terhadap keausan age. atau kerusakan.

SE THERMAL VALVE

NEEDLE

PEMERIKSAAN VALVE THERMOWAX Pemeriksaan tahanan SE The SE thermal valve thermal valve dapat resistance inspection dengan candilakukan be done with the karburator terpasang carburetor installed pada mesin. to the engine.

VALVE THERMOWAX Measure the resistance atINSPECTION the connector terminals of the Ukur tahanan pada connector terminals dari sisi SE SE thermal valve side. thermal valve. CONNECTION: Black – Green/Orange HUBUNGAN: Hitam STANDARD: 3.2 – 5.6–ΩHijau/Jingga (at 25 °C/77°F) STANDARD: 3,2 – 5,6 (pada 25 C) If the resistance is abnormal, replace the SE thermal Jika tahanan tidak normal, gantilah SE thermal valve. valve.

PEMERIKSAAN CARA KERJA VALVE

Bl

G/O

Jika mesin telah dijalankan, biarkan mendingin (di bawah 35° C) selama 30 menit atau lebih. Lepaskan SE thermal valve body (hal. 5-12). Masukkan slang vinyl ke dalam fuel enrichment circuit (rangkaian pengkayaan bahan bakar) dan tiuplah ke VALVE OPERATION INSPECTION dalam hose. If the engine has been running, let it cool down (below °C (95 °F)) for ke 30 dalam minutes or more. Udara 35 harus mengalir rangkaian.


SE THERMAL VALVE

Remove the SE12 thermal valve (page valve 5-12). 3P Hubungkan baterai V pada SEbody thermal connector terminals 5 menit. Insert a vinyl dan hosetunggu into the fuel enrichment circuit and Masukkan slang vinyl ke dalam fuel enrichment circuit blow into the hose. dan tiuplah ke dalam Air should flow slang. into the circuit. Connect the 12 V battery to the SE thermal valve 3P conUdara nector tidak boleh mengalir ke dalam r angkaian. terminals and wait 5 minutes. Insert a tidak vinyl normal, hose into the SE fuelthermal enrichment Jika cara kerja ganti valve.circuit and blow into the hose. Pasang thermal (hal. 5-15). AirSE should notvalve flow into the circuit. If operation is abnormal, replace the SE thermal valve. Install the SE thermal valve (page 5-15).

5-18

FUEL ENRICHMENT CIRCUIT


SISTEM BAHAN BAKAR SYSTEM INSPECTION PEMERIKSAAN SISTEM

? Before performing the systempemeriksaan inspection, make sure Sebelum menjalankan sistem, that the following is normal. yang berikut adalah normal. ?pastikan Battery bahwa condition Kondisi baterai ?- Fuse - Sekring Remove the center body cover (page 2-8).

•

Lepaskan center body covervalve (hal.3P 2-8). Disconnect the SE thermal connector. Turn If the Jika engine has been SE thermal valve 3P connector. mesin telah Lepaskan running, letbiarkan it cool dijalankan, mendingin (di Putar kunci kontak ke "ON". down dulu (below bawah C) F)) selama 30 Ukur voltase pada sisi wire harness dari SE thermal 35 35 C (95 for 30 menit atau lebih. minutes or more. valve connector. °

°

°

HUBUNGAN: Hitam ( + ) - Hijau/Jingga ( - ) STANDARD: Tidak the ignition switch "ON". ada voltase baterai


Measure the voltage at the wire harness side of SE therHidupkan mesin. mal valve connector. Ukur voltase pada sisi wire harness dari SE thermal CONNECTION: (+) – Green/Orange (–) keadaan valve connector Black sementara mesin dalam panas. STANDARD: No voltage Start the engine. Hitam ( + ) - Hijau/Jingga ( - ) HUBUNGAN: Measure the voltage at the wire harness side of SE therSTANDARD: Ada voltase baterai mal valve connector while the engine is hot. Black (+) – Green/Orange (–) •CONNECTION: Jika ada voltase baterai pada setiap waktu,

TO MAIN FUSE R/Bl

periksa

STANDARD: Battery voltage sebagai berikut: - Hubungan singkat pada kawat Hijau/Jingga dari ? If there is battery voltage at all time, check the following:SE thermal valve • tidak ada in voltase bateraivalve pada Green/Orange setiap waktu, ?Jika Short circuit SE thermal wire sebagai berikut: periksa ? If- there is no voltage all time, check the following: Rangkaian terbukaatpada kawat Hitam ?- Open circuit in Black wire Rangkaian terbuka pada kawat Hitam dari S ? Open circuit in SE thermal valve Black wire and/or thermal valve dan/atau kawat-kawat Hijau/Jingga. Green/Orange wires • ? IfJika kawat-kawat adalah normal, gantilah ICM the wires are normal, replace the ICM with a new one, and yang recheck. dengan baru, dan periksa kembali.

Bl R R/Bl

R/Bl

G/O

ICM R R /B l


VACUUM CHAMBER (RUANGAN VAKUUM) Lepaskan vacuum chamber (hal. 5-12). Periksa sebagai berikut: -VACUUM Jet needle terhadap keausan bertingkat CHAMBER - Vacuum piston terhadap keausan atau kerusakan the vacuum chamber (page kecil, 5-12). pemburukan -Remove Diaphragm terhadap lubang kondisi kerusakan Check theatau following:

IGNITION SWITCH

VACUUM PISTON

? Jet needle for stepped wear ? Vacuum piston for wear or damage ? Diaphragm for pin holes, deterioration or damage

JET NEEDLE

DIAPHRAGM

5-19

SISTEM BAHAN BAKAR FLOATCHAMBER CHAMBER FLOAT Remove the float (page 5-12).(hal. 5-12). Lepaskan float (pelampung) Check the float for damage. Periksa float terhadap kerusakan. Replace the float if there is fuel in the float. Ganti float jika ada bahan bakar di dalam float. Inspect the float valve seat for scores, scratches, clogs and damage. Periksa float valve seat (dudukan katub pelampung) Check the tip of the float valve where it contacts the terhadap gerusan, goresan, sumbatan dan kerusakan. valve seat for stepped wear or contamination. Periksa ujung dariif the di mana ia floattipvalve Replace the valve is worndiortempat contaminated. mengadakan kontak dengan valve seat terhadap Check the operation of the float valve. keausan bertingkat atau k ontaminasi. Push valve the pin the floataus valve make sure that it Ganti bilaon ujungnya atauand terkontaminasi. returns smoothly.

PIN

FLOAT

FLOAT VALVE VALVE SEAT

Periksa cara kerja dari float valve. Dorong pin pada float valve dan pastikan bahwa ia kembali dengan lancar. Install the float valve and float (page 5-13). Pasang float valve dan float (hal. 5-13). Set the float level Letakkan float level gauge so that it is gauge sedemikian perpendicular to the sehingga ia tegaklurus float permukaan chamber face at pada float the highest point of chamber pada titik the float. tertinggi dari float.

With the float valve seated and the float arm just touchDengan float measure valve pada posisi duduk danspecial float arm ing the valve, the float level with the tool tepat menyentuh ukur (tinggi valve, float level as shown. pelampung) dengan special tool seperti diperlihatkan. FLOAT LEVEL: 13.0 mm (0.51 in)

FLOAT LEVEL: 13,0 mm TOOL: Carburetor float level gauge TOOL:

07401-0010000

Carburetor floatbe level gauge 07401-0010000 The float cannot adjusted. Replace the float assembly if the float level is out of specification. Float tidak dapat disetel. Ganti float assembly (susunan pelampung) bila float level tidak sesuai dengan spesifikasi.

FLOAT LEVEL GAUGE

PILOT PILOTSCREW/JETS SCREW/JETS Remove pilot screw jet (page 5-12). (hal. 5-12). Lepaskan pilot screwand daneach masing-masing jet Check the following: Periksa sebagai berikut: ? Pilot screw needle for wear or damage -? Pilot screw needle keausan atau kerusakan Pilot screw springterhadap for deterioration -? Pilot screw spring terhadap pemburukan kondisi Each jet for clogging -?Masing-masing jet Each passage forterhadap clogging penyumbatan - Masing-masing jalan lintasan terhadap penyumbatan

NEEDLE JET

NEEDLE JET HOLDER MAIN JET

SPRING PILOT SCREW

PILOT SCREWPILOT ADJUSTMENT PENYETELAN SCREW ? The pilot screw is factory pre-set and no adjustment is Pilot screw telahthe disetel awal is di replaced. pabrik dan tidak necessary unless pilot screw diperlukan penyetelan lagi kecuali jika pilot screw ? The engine must be warm for accurate adjustment. 10 minutes of baru. stop-and-go riding is sufficient. telah diganti a tachometer with graduations 50 min-1 (rpm) Mesin harus dalam keadaan of panas untuk • ? Use or smaller thatakurat. will accurately indicate a 50 min-1 (rpm) penyetelan 10 menit pengendaraan jalanchange. dan-berhenti adalah cukup. -1 Pakailah tachometer dengan skala 50 menit (rpm) • atau lebih kecil yang dapat dengan akurat -1 menujukkan perubahan sebesar 50 menit (rpm). •

5-20

SLOW JET

SISTEM BAHAN BAKAR IDLEDROP DROPPROCEDURE PROCEDURE IDLE (PROSEDUR PENURUNAN PUTARAN STASIONER) box (page 1. Remove the luggage 2-7).

Damage to the pilot Kerusakan akan screw seat pada will occur terjadi pilot if the seat pilotjika screw is 1. screw pilot tightened against the screw dikencangkan seat. terhadap dudukannya.

Turn the pilot screw clockwise until it seats lightly, and Lepaskan box (hal. 2-7). given. then back itluggage out to the specification This is an initial to jam the sampai final pilot screw Putar pilot screwsetting searahprior jarum ia duduk adjustment. dengan ringan, dan kemudian putar keluar sampai ke spesifikasi yang telah diberikan. INITIAL OPENING: @@@ turns out Ini merupakan penyetelan awal sebelum 2. Warm the engine up to screw. operating temperature. penyetelan akhir pilot 7 PEMBUKAAN AWAL: – /8 putaran keluar Stop-and-go riding for 101minutes is sufficient.

3. Stop the engine. 2. Panaskan mesin sampai suhu operasionil. Connect a tachometer according to the tachometer Pengendaraaninstructions. jalan-dan-berhenti selama 10 menit manufacturer’s adalah cukup.

3. Matikan mesin. 4. Disconnect vacuum hose from PAIR control valve Hubungkanthetachometer sesuai dengan petunjuk and connect the vacuum pump to the PAIR control pemakaian pabrik valve vacuum hose pembuatnya. joint. Plug the vacuum hose. 5. Apply the specified vacuum to the PAIR control valve 4. Lepaskan vacuum hose dari PAIR control valve dan vacuum hose more than 60 kPa (450 mm Hg). hubungkan vacuum pump (pompa vakuum) ke PAIR control valve vacuum hose joint. Sumbat vacuum hose.

5.

Terapkan vakuum yang ditentukan pada PAIR control valve vacuum hose lebih dari 60 kPa (450 mm Hg).

6.

Hidupkan mesin dan setel putaran stasioner dengan throttle stop screw. -1 PUTARAN STASIONER: 1.700 100 menit (rpm)

7.

Putar pilot screw masuk atau keluar dengan pelan untuk mendapatkan putaran mesin tertinggi.

6. Start the engine and adjust the idle speed with the 8. throttle Buka throttle 2 atau 3 kali dengan ringan, kemudian stop screw. setel putaran stasioner dengan throttle screw. IDLE SPEED: 1,700 ± 100 min -1 (rpm) -1 PUTARAN STASIONER: 1.700 100 menit 7. Turn the pilot screw in or out slowly to obtain the high(rpm) est engine speed.

PILOT SCREW

VACUUM PUMP

PAIR CONTROL VALVE

PLUG

THROTTLE STOP SCREW

8. Lightly open the throttle 2 or 3 times then adjust the 9. Putar pilot screw secara berangsur ke dalam idle speed with the throttle stop screw -1 sampai putaran mesin turun dengan 100 menit -1 ± IDLE SPEED: 1,700 100 min (rpm) (rpm). 9. Turn the pilot screw in gradually until the engine 10. speed Putar drops pilot by screw keluar sampai ke pembukaan @@@ min-1 (rpm) akhir. 10.Turn the pilot screw outward½ to the final opening. PEMBUKAAN AKHIR: putaran keluar dari FINAL OPENING: @@@ turns out from posisi yang diperoleh pada langkah 9 the position obtained in step 9 11. Lepaskan plug (sumbat) dari vacuum hose, 11.Disconnect the plug from the vacuum hose, then kemudian lepaskan vacuum pump dan hubungkan remove the vacuum pump and connect the vacuum kecontrol vacuum hose PAIR valve control valve vacuum hose hose to the PAIR vacuum hose joint. joint. 12.Readjust the idle speed with the throttle stop screw.

PILOT SCREW

± 100stasioner min -1 (rpm) 12. IDLE Setel SPEED: kembali 1,700 putaran dengan throttle stop screw. Install the luggage box (page 2-7).

PUTARAN STASIONER: (rpm)

1.700

100 menit

-1

Pasang luggage box (hal. 2-7).

5-21

SISTEM BAHAN BAKAR

INLETPIPE PIPE(PIPA MASUK) INLET PELEPASAN REMOVAL Lepaskan sebagai berikut: Remove the following: -? Left crankcase cover 2-12) Left crankcase coverduct duct(hal. (page 2-12) Luggage box(hal. (page 2-7) -? Luggage box 2-7)

Kanan

Kiri: BOLTS

Release the crankcase breather drain hose from the Lepaskan crankcase breather drain hose dari clamp. clamp. Lepaskan ketiga airair cleaner housing Remove the three cleaner housingmounting mountingbolts. bolts.

BREATHER DRAIN HOSE Disconnectfuel the fuel valve vacuumhose hose dan and PAIR Lepaskan autoauto valve vacuum PAIR control valve vacuum hose from the inlet pipe. control valve vacuum hose dari inlet pipe. Loosen the inlet pipe band screw. Longgarkan screw.the inlet pipe from the Remove theinlet nutspipe andband disconnect carburetor. Lepaskan nuts dan lepaskan inlet pipe dari karburator.

PAIR CONTROL VALVE VACUUM HOSE

FUEL AUTO VALVE VACUUM HOSE Tutuplah lubang pemasukan cylinder Seal the cylinder head head dengan kain lap intake port with a atau tutup dengan pita shop towel or cover it perekat untuk with a piece of tape to menghindari masuknya prevent any benda asing keforeign dalam materialmesin. from dropping into the engine.

Remove the gasket and clean any gasket material Lepaskan gasket dan bersikan sisa bahan gasketfrom dari the inlet pipe mating surface of the cylinder head. permukaan penyatuan inlet pipe dari cylinder head.

NUTS

BAND SCREW GASKET

PEMASANGAN INSTALLATION Install a new gasket to pada the cylinder head. Pasang gasket baru cylinder head.

Sambungkan inlet karburator dengan Connect the inlet pipepipe to thepada carburetor by aligning the tab of the carburetor the groove of the alur inlet pipe. mentepatkan tab dariwith karburator dengan dari inlet Install the inlet pipe mounting nuts and tighten them. pipe. Tighten inlet the inlet band screw to the specified torque. Pasang pipepipe mounting nuts dan kencangkan. TORQUE:2 N·m (0.2 kgf·m, 1.5 lbf·ft) Kencangkan inlet pipe band screw dengan torsi yang ditentukan. Connect the fuel auto valve vacuum hose and PAIR control valve vacuum hose to the inlet pipe. TORSI: 2 N.m (0,2 kgf.m; 1,5 lbf.ft)

Sambungkan fuel auto valve vacuum hose dan PAIR control valve vacuum hose pada inlet pipe.

5-22

CLAMP

PAIR CONTROL VALVE VACUUM HOSE

NUTS

Tepatkan FUEL AUTO VALVE VACUUM HOSE

BAND SCREW

SISTEM BAHAN BAKAR Set the air cleaner housing in housing position. pada Letakkan air cleaner tempat Install and tighten the three bolts. pemasangannya. Pasang ketiga bolts. Secure dan the kencangkan crankcase breather drain hose with the clamp. Kokohkan pemasangan crankcase breather drain hose Install the following: dengan clamp. ? Left crankcase cover duct (page 2-12) box berikut: ? Luggage (page 2-7) Pasang sebagai

Kiri:

Kanan:

BOLTS

- Left crankcase cover duct (hal. 2-12) - Luggage box (hal. 2-7)

BOLT

BREATHER DRAIN HOSE

CLAMP

SECONDARY AIR AIR SUPPLY SUPPLY SYSTEM SECONDARY PEMERIKSAAN SISTEM SYSTEM INSPECTION Hidupkan mesin and dan warm panaskan sampai suhu operasi Start the engine it up to normalkeoperating temperature and stop the engine. normal dan matikan mesin.

AIR INTAKE PORT

Remove the PAIR air cleaner element (page 3-12). Lepaskan PAIR air cleaner element (hal. 3-12). Check that the PAIR air intake port is clean and free of Periksa bahwa PAIR air intake port (lubang pemasukan carbon deposits. PAIR) adalah bersihfouled, dan bebas dari karbon. If the port is carbon check theendapan PAIR check valve.

Jika port kotor dengan karbon, periksa PAIR chec valve.

Remove the two bolts dan and lepaskan disconnectPAIR the PAIR Keluarkan kedua controlcontrol valve valve the air cleaner housing (see page 5-24). dari airfrom cleaner housing (lihat hal. 5-24). Disconnect the PAIR control valve vacuum hose and Lepaskan PAIR control valve vacuum hose dan sumbat plug the hose. hose. Connect the vacuum pump to the PAIR control valve vacuum hose joint. Hubungkan vacuum pump pada PAIR control valve Start the engine and open the throttle slightly to be cervacuum tain thathose air isjoint. sucked in through the joint of the PAIR control valve. Hidupkan mesin dan buka the sedikit throttle If the air is not drawn in, check joint and supply untuk hose for clogs. memastikan bahwa udara dihisap masuk melalui joint dari control running, valve. gradually apply vacuum to the WithPAIR the engine PAIRudara control valve. Jika tidak ditarik masuk, periksa joint dan slang Check that the joint of the PAIR control valve stops drawsaluran terhadap sumbatan. ing air, and that the vacuum does not bleed.

VACUUM PUMP

PAIR CONTROL VALVE

PLUG

Sementara dalam keadaan secara SPECIFIED mesin VACUUM: 60 kPa (450 mm hidup, Hg) berangsur terapkan vakuum pada PAIR control valve. If air is drawn or if dari the specified vacuum is notterhenti mainPeriksa bahwain, joint PAIR control valve tained, replace the PAIR control valve with a new one. menarik udara, dan bahwa vakuum tidak bocor. VAKUUM YANG DITENTUKAN: 60 kPa (450 mm Hg) Jika udara dihisap masuk, atau jika vakuum yang ditentukan tidak dapat dipertahankan, gantilah PAIR control valve dengan yang baru.

5-23

SISTEM BAHAN BAKAR PAIR CONTROL VALVE REMOVAL/ PELEPASAN/PEMASANGAN INSTALLATION PAIR CONTROL VALVE Remove the body cover (page 2-9). Lepaskan body cover (hal. 2-9). Disconnect the following: Lepaskan sebagai berikut: ? Air supply hose - Air supply hose ? PAIR control valve vacuum hose - PAIR control valve vacuum hose Remove the two PAIR control valve mounting bolts and pull out thekedua PAIR PAIR controlcontrol valve from cleaner housing. Lepaskan valveair mounting bolts dan Installation is in the reverse order removal. keluar PAIR control valve dariofair cleaner housing. Route the hoses tarik properly (page 1-14) lurkan hoses dengan Pemasangan benar (hal. 1-14)

adalah

dalam

urutan

terbalik

PAIR CONTROL VALVE

BOLTS

VACUUM HOSE

dari

pelepasan.

AIR SUPPLY HOSE

PEMERIKSAAN PAIR CHECK VALVE PAIR CHECK VALVE INSPECTION Lepaskan body cover (hal. 2-9). Remove the body cover (page 2-9). Lepaskan kedua control valve valve mounting mounting bolts bolts(page (hal. Remove the two PAIR PAIR control 5-24) dan putar valve sedikit ke atas untuk 5-24) and slightly turn the valve upward to gain access to mendapatkan akses PAIR check valve cover screws the PAIR check valveke cover screws. (sekrup-sekrup PAIR check valve cover). Remove the two screws and PAIR check valve cover. Lepaskan kedua screws dan PAIR check valve cover.

PAIR CHECK VALVE COVER

SCREW

Remove the PAIR check from control the PAIR control Lepaskan PAIR check valvevalve dari PAIR valve. valve.

PAIR CHECK VALVE

Ganti jika reed (buluh) rusak atau Replace the control PAIR control if the reed is damaged or PAIR valve valve deteriorated,kondisinya, rubber seat is cracked, deteriorated or memburuk rubber seat (dudukan karet) damaged, ormemburuk if there is clearance the reed retak-retak, kondisinyabetween atau rusak, atau and jika seat. ada kerenggangan antara reed dan seat. Installation is in the reverse order of removal. Pemasangan adalah dalam urutan terbalik dari TORQUE: pelepasan. Pair check valve cover screw:

RUBBER SEAT

2.1 N·m (0.2 kgf·m, 1.5 lbf·ft) TORSI: Pair check valve cover screw: 2,1 N.m (0,2 kgf.m; 1,5 lbf.ft)

REED

5-24

SISTEM BAHAN BAKAR PELEPASAN PAIR AIR SUPPLY PIPE PAIR AIR SUPPLY PIPE REMOVAL Disconnect the PAIR air supply from the pipe. Lepaskan PAIR air supply hose hose dari pipe.

PAIR AIR SUPPLY HOSE

Lepaskan ketiga bolts dan Remove the three bolts andPAIR PAIRairairsupply supplypipe. pipe. BOLTS

PAIR AIR SUPPLY PIPE Remove the gasket. Lepaskan gasket.

PAIR AIR SUPPLY PIPE INSTALLATION PEMASANGAN PAIR AIR SUPPLY PIPE Install a new gasket. Pasang sebuah gasket baru.

GASKET

Set the PAIR air supply in position. Letakkan PAIR air pipe supply pipe pada posisi pemasangannya. Apply locking agent to the PAIR air supply pipe mounting bolts as shown, then install and tighten them. Oleskan cairan pengunci pada PAIR air supply pipe mounting bolts seperti diperlihatkan, kemudian pasang dan kencangkan.

BOLTS

6.5 ± 1.0 mm (0.26 ± 0.04 in)

PAIR AIR SUPPLY PIPE

5-25

SISTEM BAHAN BAKAR Sambungkan PAIRairairsupply supply hose pada pipe dengan Connect the PAIR hose to the pipe so that the marked of the dari hosehose is facing out as shown. sisi yangside bertanda menghadap ke luar seperti diperlihatkan.

PAIR AIR SUPPLY HOSE

TANDA

PEMERIKSAAN INSPECTION Periksa PAIR terhadap Check the PAIRairairsupply supply pipe for bend or tekukan damage. atau kerusakan.

PAIR AIR SUPPLY PIPE

FUEL TANK TANK (TANGKI BAHAN BAKAR) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan body cover (hal. 2-9). Remove the body cover (page 2-9). Wipe off spilled out Sekalah bahan bakar fuel. yang tertumpah.

FUEL HOSE

Letakkan penampung di bawah fue Place an tempat approved container yang undersesuai the fuel auto valve and clamp the fuel hose. auto valve dan jepit fuel hose dengan clamp. Disconnectfuel the hose fuel hose vacuum hosedari fromfuel the auto fuel Lepaskan danand vacuum hose auto valve, then pull them out of the hole on the rear valve, kemudian tarik mereka keluar dari lubang pada fender. rear fender (spakbor belakang).

VACUUM HOSE

5-26

CLAMP

SISTEM BAHAN BAKAR Disconnectfuel the unit fuel unit 3P connector release wire the Lepaskan 3P connector danand lepaskan wire clamp from the fuel tank. clamp dari fuel tank. Remove the following: Lepaskan sebagai berikut: ? Two bolts ? Two bolts/collars - Dua bolts lift up the rear side of the luggage box and -Slightly Dua bolts/collars remove the fuel tank. Installation is in the reverse order of removal. Route the hoses and Angkat sisi belakang dari luggage box sedikit dan wire harness properly lepaskan fuel tank. (page 1-14). lurkan hoses dan wire Pemasangan harness dengan benar pelepasan. (hal. 1-14)

adalah

dalam

urutan

terbalik

BOLTS

FUEL TANK

BOLTS/COLLARS

dari

3P CONNECTOR

CLAMP

FUEL FUEL AUTO AUTO VALVE VALVE PEMERIKSAAN INSPECTION Lepaskan body cover (hal. 2-9). Remove the body cover (page 2-9). Sekalah bahan bakar penampung bakar yang di Place an approved fuelbahan container under the sesuai fuel auto Wipe off tertumpah. spilled out Letakkan yang valve and clamp the fuel hose. bawah fuel auto valve dan jepit fuel hose dengan clamp. fuel.

FUEL AUTO VALVE

FUEL HOSE

Disconnect thehose. fuel hose. Lepaskan fuel Check that the fuel does not come out from the joint of Periksa bahwa bahan bakar tidak mengalir keluar dari the fuel auto valve. oint dari fuel auto valve.

CLAMP

Sambungkan sebuah (slang fuel hose Connect a suitable fuel drain hosedrain to the fuel auto valve. pembuangan bahan bakar) yang sesuai pada fuel Place a suitable container under the fuel drain hose. auto valve. Disconnect the vacuum hose from the fuel auto valve and connect a commercially available vacuum pump to Letakkan tempat penampung the diaphragm vacuum outlet. yang sesuai di bawah fuel drain hose. Fuel should flow out from the fuel hose when vacuum is applied. Lepaskan vacuum hose dari fuel auto valve dan If fuel flow is restricted or does not flow, replace the fuel sambungkan sebuah vacuum pump yang dapat dibeli di auto valve. pasaran pada diaphragm vacuum outlet (saluran keluar vakuum diaphragm). Bahan bakar harus mengalir keluar dari fuel hose ketika vakuum diterapkan.

FUEL DRAIN HOSE

VACUUM PUMP

Jika aliran bahan bakar terbatasi atau tidak mengalir, gantilah fuel auto valve.

5-27

SISTEM BAHAN BAKAR PELEPASAN REMOVAL Remove the fuel tank (page 5-26). Lepaskan (hal. 5-26). fuel tank Place an approved fuel container and drain Wipe off spilled out Letakkan penampung bahan bakar yangfuel. sesuai dan Seka bahan bakar fuel. yang Loosen thebahan lock nut and remove the fuel auto valve. keluarkan bakar. tertumpah.

FUEL AUTO VALVE LOCK NUT

Longgarkan lock nut dan keluarkan fuel auto valve.

Lepaskan fuel strainer screen Remove the fuel strainer screendan andO-ring O-ring dari fromfuel the auto fuel auto valve. valve. Clean the fuel strainer screen with compressed air. Bersihkan fuel strainer screen dengan udara dari kompressor.

O-RING STRAINER SCREEN

FUEL AUTO VALVE

PEMASANGAN INSTALLATION Pasang O-ring baru pada fuel strainer Install a sebuah new O-ring to the fuel strainer screen. screen. STRAINER SCREEN

O-RING

Install the fuel strainer screenpada ontofuel the auto fuel auto as Pasang fuel strainer screen valvevalve seperti shown. diperlihatkan.

FUEL AUTO VALVE

STRAINER SCREEN

5-28

SISTEM BAHAN BAKAR Install the auto valve set it in the correct Pasang fuelfuel auto valve danand tempatkan pada sudutangle yang as shown. benar seperti diperlihatkan.

45 ± 3°

Tahan fuelfuel auto valve danand kencangkan Hold the auto valve tighten thelock locknut nutdengan to the specified torsi yang torque. ditentukan. TORQUE:22.5 N·m (2.3 kgf·m, 17 lbf·ft) TORSI: 22,5 N.m (2,3 kgf.m; 17 lbf.ft) Install the fuel tank (page 5-26). Pasang fuel tank (hal. 5-26).

FUEL AUTO VALVE LOCK NUT

5-29

CATATAN

6. PENURUNAN / PEMASANGAN MESIN

6 COMPONENT LOCATION ????????????? 6-2 LOKASI KOMPONEN ............................6-2

ENGINE REMOVAL ??????????????????? 6-4 PENURUNAN MESIN ............................6-4

SERVICE INFORMATION ?????????????? 6-3 6-3 KETERANGAN SERVIS ........................

ENGINE INSTALLATION ?????????????? 6-6 PEMASANGAN MESIN .........................6-6

6-1


COMPONENT LOCATION LOKASI KOMPONEN ENGINEREMOVAL/INSTALLATION

49 N.m (5.0 kgf.m, 36 lbf.ft)

6-2


SERVICE INFORMATION KETERANGAN SERVIS UMUM GENERAL • Support engine usingmenggunakan a jack or other dongkrak adjustableatau support ease of engine mounting removal. Topangthe mesin dengan alatto penopang lain yang dapatbolt disetel untuk mempermudah pelepasan • When removing/installing thepemasangan engine, tape the frame around the engine beforehand for frame protection. engine mounting bolt (baut mesin). • The following components require engine removal for service. menurunkan/memasang mesin, sebelumnya Cylinder head/camshaft/cylinder/piston – Ketika (page 7-10) bungkuslah rangka di sekitar mesin dengan pita untuk melindunginya. Komponen-komponen berikut ini memerlukan penurunan mesin agar dapat menservisnya. – Crankcase/crankshaft (page 10-5)) - Cylinder head/camshaft/cylinder/piston (hal. 7-10) • The following components(hal. can 8-15) be serviced with the engine installed in the frame. - Crankcase/crankshaft – Drive pulley (page 8-12) – Driven pulley/clutch (page 8-16) berikutnya dapat diservis dengan mesin terpasang pada rangka. Final reduction (page 9-6) – Komponen-komponen Drive pulley (hal. 8-11) – Stator/ignition pulse generator (page 14-7) Driven pulley/clutch – - Carburetor (page 5-8) (hal. 8-15) Final reduction (hal. 9-6) – Oil pump (page 4-4) - Stator/ignition pulse generator (hal. 14-7) - Karburator (hal. 5-8) SPECIFICATIONS - Oil pump (hal. 4-4)

•

• •

•

SPESIFIKASI

Engine dry weight Engine oil capacity BAGIAN Berat kosong mesin Kapasitas oli mesin

TORQUE VALUES

ITEM

After draining After disassembly Pada penggantian periodik Setelah pembongkaran mesin

Engine hanger link nut (Engine side)

NILAI TORSI

Engine hanger link nut (sisi Mesin)

SPECIFICATIONS 24.9 kg (54.9 lbs) 0.7 liter (0.7 US qt, 0.6 lmp qt) SPESIFIKASI 0.8 liter (0.8 US qt, 0.7 kg lmp qt) 24,9 0,7 liter 0,8 liter

49 N·m (5.0 kgf ·m, 36 lbf ·ft)

49 N.m (5,0 kgf.m; 36 lbf.ft)

6-3


ENGINE REMOVAL PENURUNAN MESIN Remove the following: Lepaskan sebagai berikut: Under cover(hal. (page 2-10) - – Under cover 2-10) Center body cover – (page 2-8) - Center body cover (hal. 2-8) Luggage box (page 2-7) – - Luggage box (hal. 2-7)

SPRING

ADJUSTING NUT

Remove the rear brake adjusting nut and joint pin from Lepaskan rear cable. brake adjusting nut dan joint pin dari rear the rear brake brake cable. Remove the return spring from the brake arm. Lepaskan return spring dari brake arm.

BRAKE CABLE Remove the cable clamp bolt. Lepaskan cable clamp bolt. Release the rear brake cable from the cable holder. Lepaskan rear brake cable dari cable holder.

JOINT PIN

BRAKE CABLE

CABLE CLAMP/ BOLT

CABLE HOLDER

Disconnect the spark plug cap. Lepaskan spark plug cap. Release the spark plug wire clamp from the frame. Lepaskan spark plug wire clamp dari rangka.

WIRE CLAMP

SPARK PLUG CAP

Remove the bolt and ground cables. Disconnect thedan following Lepaskan bolt groundconnectors: cables. – Alternator 3P connector Lepaskan connectors berikut ini: – Starter motor 2P connector SE thermal 3P connector - – Alternator 3P valve connector - Starter motor 2P connector - SE thermal valve 3P connector

BOLT/GROUND CABLES

ALTERNATOR 3P CONNECTOR

SE THERMAL VALVE 3P CONNECTOR STARTER MOTOR 2P CONNECTOR

6-4

PENURUNAN / PEMASANGAN MESIN Release the following clamps from the frame: wire clamps wire Lepaskan berikut ini dari rangka: thermal valve wire clamp thermal valve wire clamp - –SESE – Alternator wire clamp wire clamp - – Alternator Starter motor wire clamp - Starter motor wire clamp

SE THERMAL VALVE WIRE CLAMP

ALTERNATOR WIRE CLAMP STARTER MOTOR WIRE CLAMP Disconnect the following: Lepaskan sebagai berikut: – Fuel hose - –Fuel hose Fuel auto valve vacuum hose - Fuel auto valve vacuum hose Loosen the lock nut and disconnect the throttle cable. Longgarkan lock nut dan lepaskan throttle cable.

THROTTLE CABLE

FUEL HOSE

LOCK NUT VACUUM HOSE

Untuk menghindari To avoid damage to kerusakanthe pada ulirshock rear rear shock absorber absorber mounting mounting bolt,slightly angkat bolt threads, roda belakang sedikit. lift the rear wheel.

Lepaskan rearrear shock absorber lowerlower mounting bolt dan Remove the shock absorber mounting bolt and release the rear shock absorber from the engine. lepaskan rear shock absorber dari mesin.

SHOCK ABSORBER

MOUNTING BOLT Supportrangka the frame in upright position. Dukung pada posisi tegak. Hold the front wheel. Tahan roda depan. Remove the nut and engine hanger link bolt. Lepaskan nut dan engine hanger link bolt. Slightly pull the engine straight back and release it from the engine Tarik mesinhanger sedikit link. lurus ke belakang dan lepaskan dari Turn the rear side of the engine to the right andmesin). remove engine hanger link (penyambung penggantung the engine. Putar bagian belakang dari mesin ke kanan dan lepaskan mesin.

NUT/BOLT

6-5


PEMASANGAN MESIN ENGINE INSTALLATION Maneuver mesin the engine into therangka frame from sidedari of Gerakkan ke dalam dari the sisi right kanan the vehicle. kendaraan. Set the engine straight the frame the Tempatkan mesin lurus with dengan rangkaand danpush dorong engine forward so that the bolt holes are aligned. mesin ke depan sehingga lubang-lubang bolt telah Install the engine hanger link bolt from the left side of the disejajarkan. scooter. Install and tightenhanger the nut to thebolt specified Pasang engine link (bauttorque. penyambung penggantung mesin) dari sisi kiri dari skuter. TORQUE:49 N·m (5.0 kgf·m, 36 lbf·ft)

Pasang dan kencangkan nut dengan torsi yang ditentukan. TORSI: 49 N.m (5,0 kgf.m; 36 lbf.ft)

To ease installation of Untuk mempermudah the rear shock pemasangan rear shock absorber mounting absorber mounting bolt, bolt, slightly lift the angkat roda belakang rear sedikit. wheel.

NUT/BOLT

Tempatkan sedemikian Set the rearshock shockabsorber absorberbelakang so that the bolt holesrupa are sehingga aligned. lubang-lubang bolt telah disejajarkan. Install and tighten the rear shock absorber lower mountPasang ing bolt. dan kencangkan rear shock absorber lower mounting bolt (baut pemasangan bawah sokbreker belakang.

SHOCK ABSORBER

MOUNTING BOLT

Sambungkan throttle cable ke throttle throttledrum. drum (teromol Connect the throttle cable to the Adjust the throttle grip free play (page 3-5). kabel gas). Setel jarak main bebas throttle grip (putaran gas Connect the following: tangan) (hal. 3-5). – Fuel auto valve vacuum hose – Fuel hose Sambungkan sebagai berikut:

THROTTLE CABLE

FUEL HOSE

- Fuel auto valve vacuum hose - Fuel hose

VACUUM HOSE

Kokohkan clamps berikut ini pada Secure thepemasangan following wire wire clamps to the frame: rangka: – SE thermal valve wire clamp – Alternator wire clamp - SE thermal valve wire clamp – Starter motor wire clamp - Alternator wire clamp - Starter motor wire clamp


ALTERNATOR WIRE CLAMP STARTER MOTOR WIRE CLAMP

6-6

PENURUNAN / PEMASANGAN MESIN Sambungkan connectors berikut ini: Connect the following connectors:

Route the wire lurkan sire harness properly harness dengan benar(page (hal. 1-14). 1-14).

Alternator3P 3P connector - – Alternator connector – Starter motor wire 2Pconnector connector - Starter motor wire 2P – SE thermal valve 3P connector - SE thermal valve 3P connector Set the ground cables in position, then install and tighten Tempatkan kabel-kabel massa pada tempatnya, the bolt. kemudian pasang dan kencangkan bolt.

BOLT/GROUND CABLES

ALTERNATOR 3P CONNECTOR


STARTER MOTOR WIRE 2P CONNECTOR Secure the spark plug wire clamp to the frame. Kokohkan pemasangan spark plug wire clamp pada Connect the spark plug cap. rangka. Sambungkan spark plug cap.

WIRE CLAMP

Set theand brake cable through the cable holder. Tempatkan brake cable rem) melalui cable Install tighten the cable (kabel clamp/bolt. Route the rear brake holder.

SPARK PLUG CAP

BRAKE CABLE

lurkan rear brake cable properly cable dengan Pasang dan kencangkan cable clamp bolt. benar(page (hal. 1-14). 1-14).

CABLE CLAMP/ BOLT

Pasang joint pada brake Install the jointpin pindan andadjusting adjusting nut nut to the rear rear brake cable. cable. Set the return ujung-ujung spring ends intoreturn the hole on the left(pegas crankTempatkan spring case and pin on the brake arm. pengembalian) ke dalam lubang pada left crankcase Adjust the rear brake lever free play (page 3-16). dan pin pada brake arm (lengan rem).

SPRING

CABLE HOLDER

ADJUSTING NUT

Install the following: Setel jarak main bebas rear brake lever (hal. 3-16). – Under cover (page 2-10) Pasang sebagai berikut: body cover – Center (page 2-8) Luggage box (page 2-7) - – Under cover (hal. 2-10) - Center body cover (hal. 2-8) - Luggage box (hal. 2-7) BRAKE CABLE

JOINT PIN

6-7

CATATAN

7. CYLINDER HEAD/VALVES/CYLINDER/PISTON

COMPONENT LOCATION ····························7-2 LOKASI KOMPONEN-KOMPONEN......7-2

CYLINDER HEAD HEAD··········································7-14 CYLINDER ..................................7-14

SERVICE INFORMATION ·····························7-3 KETERANGAN SERVIS ........................7-3

CAMCHAIN CHAIN GUIDE...............................7-29 GUIDE······································7-29 CAM

TROUBLESHOOTING ····································7-6 TROUBLESHOOTING ...........................7-6

CAMCHAIN CHAIN TENSIONER TENSIONER SLIDER ···········7-30 CAM SLIDER .......7-30

CYLINDER COMPRESSION TEST ··············7-7 TEST KOMPRESSI CYLINDER.............7-7

CAMCHAIN CHAIN TENSIONER TENSIONER LIFTER ···········7-31 CAM LIFTER........7-31

CYLINDER COVER····························7-7 .................... 7-7 CYLINDER HEAD HEAD COVER

CYLINDER CYLINDER .............................................7-32 ······················································7-32

INTAKE/EXHAUST SHROUDS .............7-9 INTAKE/EXHAUST SHROUDS ·····················7-9

PISTON ..................................................7-34 PISTON ·························· ························ ··········· 7-34

CAMSHAFT ...........................................7-10 CAMSHAFT ························ ························· ···· 7-10

7-1

7

CYLINDER HEAD/VALVES/CYLINDER/PISTON

COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN CYLINDER HEAD/VALVES/CYLINDER/PISTON

0.8 N·m (0.1 kgf ·m, 0.6 lbf ·ft)

10 N·m (1.0 kgf ·m, 7 lbf ·ft)

4 N·m (0.4 kgf ·m, 3.0 lbf ·ft)

18 N·m (1.8 kgf ·m, 13 lbf ·ft)

12 N·m (1.2 kgf ·m, 9 lbf ·ft)

8 N·m (0.8 kgf ·m, 5.9 lbf ·ft) 12 N·m (1.2 kgf ·m, 9 lbf ·ft) 7 N·m (0.7 kgf ·m, 5.1 lbf ·ft)

7-2


SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM • This section covers service of the cylinder head, valves, rocker arms, camshaft, cylinder and piston. Babengine ini meliputi darifrom cylinder head,tovalves, arms, camshaft, cylinder dan piston. The must beservis removed the frame service rocker the cylinder head, valves, camshaft, cylinder and piston. • Mesin harus dilepaskan dari rangka untuk dapat menservis cylinder head, valves, camshaft, cylinder dan piston. • When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in their original locations. • Sewaktu pembongkaran, tandai dan solvent simpanlah parts yang dibongkar memastikan mereka dipasang kembali • Clean all disassembled parts with cleaning and dry them by blowing themuntuk off with compressed bahwa air before inspection. pada lokasi mereka. • Camshaft and semula rocker arm lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling cylinder head. Bersihkan semua parts yang dibongkar dengan larutan pembersih dan keringkan dengan meniup dengan udara dari • • Be careful not sebelum to damagepemeriksaan. the mating surfaces when removing the cylinder head cover and cylinder head. Do not tap the cylinder head cover kompressor and cylinder head too hard during removal. • Minyak pelumasan camshaft dan rocker arm disalurkan melalui jalan lintasan oli di dalam cylinder head. Bersihkan jalan • Take care not to damage the cylinder wallcylinder and piston. lintasan oli sebelum merakit kembali head. • When removing the piston, clean carbon and sludge from the penyatuan top of the cylinder. • Hati-hati agar tidak merusak permukaan-permukaan ketika melepaskan cylinder head cover dan cylinder head. Jangan mengetuk cylinder head cover dan cylinder head terlalu keras pada waktu pelepasan. • Hati-hati agar tidak merusak dinding cylinder dan piston. CYLINDER HEAD/VALVES SPECIFICATIONS • Ketika piston dilepaskan, bersihkan karbon dan kotoran dari bagian atas cylinder. Unit: mm (in) SPESIFIKASI CYLINDER HEAD/VALVES Satuan: mm SERVICE ITEM STANDARD BAGIAN STANDARD BATAS LIMIT SERVIS 2 2 Tekanan kompressi cylinder 1341 kPa (13,4 kgf/cm , 191 psi) Cylinder compression 1314 kPa (13.4 kgf/cm , 191 psi) – -1 menit -1 (rpm) pada 520 at 520 min (rpm) Perubahan bentuk melengkung cylinder head -– 0,05 Cylinder head warpage 0.05 (0.002) Rocker arm D.D. rocker arm IN/EX 10,000 – 10,015 10,04 Rocker arm Rocker arm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.04 (0.395) (MASUK/ 9.972 – 9.987 (0.3926 – 0.3932) Rocker arm shaft O.D. IN/EX 9.91 (0.390) BUANG) 0.013 – 0.043 (0.0005 – 0.0017) Arm to shaft clearance IN/EX 0.08 (0.003) D.L. rocker arm shaft IN/EX 9,972 – 9,987 9,91 Camshaft Cam lobe height IN 32.4006 – 32.6406 (1.27561 – 1.28506) 32.37 (1.274) Jarak renggang antara IN/EX 0,013––32.2464 0,043 (1.26009 – 1.26954) 0,08 EX 32.0064 31.97 (1.259) arm ke shaft Valve, valve Valve clearance IN 0.14 ± 0.02 (0.006 ± 0.001) – Camshaft Ketinggian cam lobe IN 32,4006 – 32,6406 32,37 guide ± 0.02 (0.006 ± 0.001) EX 0.14 – (bubungan) EX 32,0064 – (0.1959 32,2464– 0.1965) 31,97 4.90 (0.193) Valve stem O.D. IN 4.975 – 4.990 Valve, valve Jarak renggang klep IN ± 0,02 0,14 EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193) guide EX ± 0,02 0,14 Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.03-(0.198) D.L. valve stem IN 4,975 – 4,990 4,90 Stem-to-guide clearance IN 0.010 – 0.037 (0.0004 – 0.0015) 0.08 (0.003) EX 4,955 – 4,970 4,90 EX 0.030 – 0.057 (0.0012 – 0.0022) 0.10 (0.004) D.D. valve guide IN/EX – 5,012 5,03 Valve guide projection above IN/EX 9.15,000 – 9.3 (0.36 – 0.37) – Jarak renggang IN 0,010 – 0,037 0,08 cylinder head stem keValve guideseat width EX 0,10 1.5 (0.06) IN/EX 1.00,030 (0.04)– 0,057 Proyeksi valve guide IN/EX 9,1 – 9,3 Valve spring IN/EX 29.78 (1.172) 29.11- (1.146) di atas cylinder head free length Lebar valve seat IN/EX 1,0 1,5 Panjang bebas IN/EX 29,78 29,11 valve spring CYLINDER/PISTON SPECIFICATIONS • •

SPESIFIKASI CYLINDER/PISTON ITEM BAGIAN D.D. I.D. Kelonjongan Out-of-round Ketirusan Taper Perubahan bentuk melengkung Warpage Piston, piston D.L. piston Piston, piston Piston O.D. rings, piston Titik pengukuran D.L. piston rings, piston pin Piston O.D. measurement point pin D.D. lubang piston pin Piston pin bore I.D. D.L. piston pin Piston pin O.D. Jarak renggang antara piston-kepiston pin Piston-to-piston pin clearance Jarak renggang Ring paling atas Piston ring-to-ring Top antara piston Ring kedua groove clearance Second ring-ke-alurnya Piston ring end gap Ring paling Top atas Celah pada Second ujung piston ring Ring kedua Oil(side (side rail) rail) Ring oli Cylinder-to-piston clearance Jarak renggang antara cylinder-ke-piston Connecting rod small end I.D. rod D.D. kepala kecil connecting Connecting rod-to-piston pin clearancerod-ke-piston pin Jarak renggang antara connecting

Cylinder Cylinder

STANDARD STANDARD 50,005 – 50,015 50.005 – 50.015 (1.9687 – 1.9691) – – – 49,970 – 49,990 49.970 – 49.990 (1.9673 – 1.9681) 6 mm dari bagian bawah piston 6.0 (0.24) from bottom of skirt 13,002 – 13,008 13.002 – 13.008 (0.5119 – 0.5121) 12,994 – 13,000 12.994 – 13.000 (0.5116 – 0.5118) 0,002 – 0,014 0.002 – 0.014 (0.0001 – 0.0006) 0,015 – 0,050 0.015 – 0.050 (0.0006 – 0.0020) 0,015 – 0,050 0.015 – 0.050 (0.0006 – 0.0020) 0.10 – 0.25 (0.004 – 0.010) 0,10 – 0,25 0.10 – 0.25 (0.004 – 0.010) 0,10 – 0,25 0.20 – 0.70 (0.008 – 0.028) 0,20 – 0,70 0.015 – 0.045 (0.0006 – 0.0018) 0,015 – 0,045 13.010 – 13.028 (0.5122 – 0.5129) 13,010 – 13,028 0.010 – 0.034 (0.0004 – 0.0013) 0,010 – 0,034

Unit: mm (in) Satuan: mm SERVICE BATAS SERVIS LIMIT 50,10 50.10 (1.972) 0,05 0.05 (0.002) 0,05 0.05 (0.002) 0,05 0.05 (0.002) 49,95 49.95 (1.967) – 13,04 13.04 (0.513) 12,96 12.96 (0.510) 0,02 0.02 (0.001) 0,08 0.08 (0.003) 0,08 0.08 (0.003) 0.45 (0.018) 0,45 0.45 (0.018) 0,45 - – 0.09 (0.004) 0,09 13,05 13.05 (0.514) 0.05 (0.002) 0,05

7-3

CYLINDER HEAD/VALVES/CYLINDER/PISTON NILAI TORSI TORQUE VALUES Cylinder head Cylinder headcover coverspecial special bolt bolt Cam sprocket bolt Cam sprocket bolt Cylinder head Cylinder headnut nut Cylinder head bolt Cylinder head bolt Exhaust shroud mounting bolt Exhaust shroud mounting bolt Intake shroud mounting screw Intake shroud mounting screw Cam chain tensioner lifter screw Cam chaintensioner tensionerslider lifter screw Cam chain pivot pin bolt Cam chain tensioner slider pivot pin bolt

12 N.m (1,2(1.2 kgf.m; 9 lbf.ft) 12 N·m kgf·m, 9 lbf·ft) 8 N.m (0,8 kgf.m; 5,9 lbf.ft) mesin pada danthreads permukaan duduk. 8 N·m (0.8 kgf·m, 5.9 lbf·ft) Oleskan oli Apply engine oilulir to the and seating surface. 18 N.m (1,8 kgf.m; 13 lbf.ft) Oleskan oli mesin pada ulir dan permukaan duduk. 18 N·m (1.8 kgf·m, 13 lbf·ft) Apply engine oil to the threads and seating surface. 12 N.m (1,2 kgf.m; 9 lbf.ft) Oleskan oli mesin pada ulir dan permukaan duduk. 12 N·m (1.2 kgf·m, 9 lbf·ft) Apply engine oil to the threads and seating surface. 7 N.m (0,7 kgf.m; 5,1 lbf.ft) 7 N·m (0.7 kgf·m, 5.1 lbf·ft) 0,8 N.m (0,1 kgf.m, 0,6 lbf.ft) 0.8 N·m (0.1 kgf·m, 0.6 lbf·ft) 4 N.m (0,4 kgf.m; 3,0 lbf.ft) 4 N·m (0.4 kgf·m, lbf·ft) 10 N.m (1,0 kgf.m; 7 3.0 lbf.ft) 10 N·m (1.0 kgf·m, 7 lbf·ft)

TOOLS TOOLS Valve spring compressor 07757-0010000

Valve spring compressor attachment 07959-KM30101

Valve guide reamer, 5.0 mm 07984-MA60001

Valve guide driver, 5.0 mm 07942-MA60000

Valve guide adjusting driver 07743-0020000

Cam chain tensioner lifter stopper 070MG-0010100

Seat cutter, 27.5 mm (IN, 45°) 07780-0010200

Seat cutter, 24 mm (EX, 45°) 07780-0010600

Flat cutter, 27 mm (IN, 32°) 07780-0013300

7-4

CYLINDER HEAD/VALVES/CYLINDER/PISTON Flat cutter, 22 mm (EX, 32°) 07780-0012601

Interior cutter, 26 mm (IN, 60°) 07780-0014500

Interior cutter, 22 mm (EX, 60°) 07780-0014202

Cutter holder 5.0 mm 07781-0010400

7-5


TROUBLESHOOTING TROUBLESHOOTING ? Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test or by tracPersoalan pada bagian atasnoises mesin biasanya mempengaruhi unjuk kerja mesin. Persoalan-persoalan ini dapat didiagnosa ing engine to the top-end with a soun ding rod or stethoscope. dengan test kompressi dengan is menelusuri mesin padasmoke bagian dengan breather tangkai suara stethoscope. • If theatau performance poor at lowsuara-suara speeds, check for white in atas the crankcase hose. Ifatau the hose is smoky, • Jika unjuk kerja mesin buruk pada kecepatan rendah, periksalah terhadap asap putih pada crankcase breather hose (slang check for a seized piston ring. pernapasan bak mesin). Jika hose berasap, periksa terhadap piston ring yang macet. Compression too low, hard starting or poor performance at low speed • Valves: Kompressi terlalu rendah, mesin sulit dihidupkan atau unjuk kerja buruk pada kecepatan rendah – Incorrect valve adjustment • Valves (klep-klep): – Burned or bent valves - Penyetelan valve tidak benar – Incorrect valve timing - Valves terbakar – atau bengkok Broken valve spring - Tertib waktu klep –tidak benar Uneven valve seating - Valve spring patah – Valve stuck open - Valve seating (dudukan – Weak klep) valve tidak springmerata - Valve macet terbuka • Cylinder head: - Valve spring lemah – Leaking or damaged cylinder head gasket Cylinder head: • – Warped or cracked cylinder head - Cylinder head gasket bocor atau rusak – Loose spark plug - Ada perubahan melengkung atau retak-retak pada cylinder head ? bentuk Worn cylinder - Spark plug (busi) longgar ? Worn piston or piston rings Cylinder aus ? Bent connecting rod • • Piston atau piston rings aus too high, overheating or knocking Compression Connecting rod •bengkok • Excessive carbon build-up on piston head or on combustion chamber •

Excessive smoke Kompressi terlalu tinggi, overheating atau knocking • Worn valve stem or valve guide • Ada pembentukan karbon secara berlebihan pada piston head (kepala piston) atau di ruang pembakaran ? Damaged stem seal ? Worn cylinder Asap berlebihan ? Worn piston or piston rings • Valve stem atau ?valve guide aus Improper installation of piston rings • Stem seal rusak ? Scored or scratched piston or cylinder wall • Cylinder aus Excessive noise • Piston atau piston rings aus • Incorrect valve adjustment • Pemasangan piston rings tidak benar ? Sticking valve or broken valve spring Piston atau dinding cylinder tergerus atau tergores • ? Excessively worn valve seat ? Worn or damaged camshaft Mesin berisik ? Worn or damaged cam chain • Penyetelan klep ?tidak tepat Worn cam sprocket teeth • Valve macet atau valve ? Wornspring rocker patah arm and/or shaft Valve seat (dudukan klep) berlebihan • ? Worn or aus damaged cam chain tensioner • ? Worn Camshaft aus atau rusakcylinder Worn piston or piston rings Cam chain aus ? atau rusak • • Gigi-gigi cam sprocket aus Rough idle • Rocker arm dan/atau shaft aus compression • Low cylinder • Cam chain tensioner aus atau rusak Abnormal noise • Cylinder aus • Worn piston pin or piston pin hole • Piston atau piston rings aus • Worn connecting rod small end • Worn cylinder, piston or piston rings Putaran stasioner kasar Piston ring sticking/scuffing, bearing damage Tekanan kompressi cylinder rendah • • Clogged oil gallery or oil strainer screen Suara tidak normal • Internal oil leak Not using recommended engine oil Piston pin atau • lubang piston pin aus • • Kepala kecil connecting rod aus Cylinder, piston atau piston rings aus •

Piston ring macet/menggeser, kerusakan bearing (bantalan) Saluran oli atau oil strainer screen tersumbat • • Ada kebocoran oli di dalam Tidak menggunakan oli mesin yang dianjurkan •

7-6


CYLINDER COMPRESSION TEST TEST KOMPRESSI CYLINDER Warm the engine n ormalsuhu operating temperature. Panaskan mesinto sampai operasi normal. Stop the engine and remove the spark plugcap cap(topi and spark Matikan mesin dan lepaskan spark plug busi) plug (page 3-7). dan spark plug (busi) (hal. 3-7). Untuk mencegah To avoid discharging menghabiskan muatan thebaterai, battery,jangan do not listrik operate the starter menjalankan starter motor fordari more7 than motor lebih detik.7 seconds.

Install a compression gauge into the spark plug hole. Pasang compression gauge (meter pengukur Open the throttle all the way and kompressi) ke dalam lubang busi.crank the engine with the starterthrottle until the gauge reading rising. Buka seluruhnya danstops putar mesin dengan starter The maximum reading is usually reached sampai pembacaan gauge berhenti naik.within 4 – 7 seconds. Pembacaan maksimum maksimum biasanya biasanya dicapai dicapai dalam 4 – 7 detik. COMPRESSION PRESSURE: TEKANAN KOMPRESSI: 1,314 kPa (13.4 kgf/cm 2, 191 psi) at 520 min -1(rpm) 2 -1 1.314 kPa (13,4 kgf/cm ; 191 psi) pada 520 menit (rpm) If compression is high, it indicates that carbon deposits have Jika kompressi tinggi, ini menunjukkan bahwa telah accumulated on the combustion chamber and/or the piston crown. terkumpul endapan karbon pada ruang pembakaran dan/atau mahkota piston. mahkota piston. If compression is low, pour 3 – 5 cc (0.1 – 0.2 oz) of engine oil into the cylinder through the spark plug hole and recheck Jika kompressi kompressi rendah, tuangkan tuangkan 3 – 5 cc oli mesin ke the compression. dalam cylinder melalui lubang spark plug dan periksa If the compression kembali kompressi.increases from the previous value, check the cylinder, piston and piston rings. Jika kompressi naikhead darigas nilai • Lea Leakin king g cylin cylinder der head gasket ket sebelumnya, periksalah cylinder, piston dan piston dan piston rings. rings . • Wo Worn rn pi pist ston on ri ring ng • • Wor Kebocoran pada cylinder Worn n cyli cylinde nder r and and pis piston ton head gasket Piston ring aus • If compression is the same as the previous value, check the Cylinder dan piston dan piston aus • valves for leakage. Jika kompressi sama dengan nilai sebelumnya, periksalah valves (klep-klep) terhadap kebocoran.

COMPRESSION GAUGE

CYLINDER HEAD COVER CYLINDERREMOVAL HEAD COVER PELEPASAN Remove the center body cover (page 2-8). Disconnect the crankcase breather hose.

Jangan sampai samp aithe oli engine mesin Lepaskan Remove the special bolts, mounting rubbers and cylinder Do not let center body cover (hal. 2-8). menetes ke atas rangka oil drip down to the head cover. Lepaskan crankcase breather hose. dari frame cylinder head. from the cylinder head.


RUBBER SEAL

Lepaskan bolts, mounting rubbers dan cylinder Remove thespecial rubber seal from the cylinder head cover. head cover. Lepaskan rubber seal dari cylinder head cover.

SPECIAL BOLTS/ MOUNTING RUBBERS

PEMASANGAN INSTALLATION Make surebahwa the sealseal rubber is in good condition replace it Pastikan rubber berada pada and kondisi baik if necessary. dan ganti bila perlu. Apply adhesive (CEMEDINE 575 or Three Bond 1194 or Oleskan perekat (CEMEDINE 575mating atau area Three Bond equivalent) to the cylinder head cover as speci1194 atau sejenisnya) pada daerah penyatuan cylinder fied. head cover seperti ditentukan.

5 – 15 15 mm (0.2 – (0.2 – 0.6 0.6 in)

SEAL POINTS

CYLINDER HEAD COVER

7-7

CYLINDER HEAD/VALVES/CYLINDER/PISTON Install the seal rubberkeinto the groove on the cylinder head seal rubber cylinder head Pasang dalam alur pada cover. cover.

SEAL RUBBER

CYLINDER HEAD COVER Apply liquid sealant (Three bond perapat) 5211C or (Three SHIN-ETSUOleskan liquid sealant (cairan bond SILICONE or Three bond 1215KE45T or equivalent) to the 5211C atauKE45T SHINETSU-SILICONE atau Three semicircular seal rubber as pada shown.daerah setengah bond 1215 area atauof sejenisnya) lingaran dari seal rubber seperti diperlihatkan.

SEAL RUBBER

SEAL POINTS

Pasang mounting tanda Install the mountingrubbers rubbersdengan with their "UP""UP" markmereka facing up. menghadap ke atas.

TANDA "UP"

MOUNTING RUBBER

Tempatkan cylinder pada cylinder Set the cylinder head head cover cover onto the cylinder head.head. Pasang special dan tighten kencangkan torsi Install the specialbolts bolts and them to dengan the specified yang ditentukan. torque.


CYLINDER HEAD COVER

TORQUE:12 N·m (1.2kgf.m, kgf·m, lbf·ft) TORSI: 12 N.m (1,2 kgf. m, 99lbf.ft) lbf.f t)

Connect the crankcase hose. Hubungkan crankcasebreather breather hose. Install the centerbody bodycover cover (hal. (page2-8). 2-8). Pasang center

SPECIAL BOLTS

7-8


INTAKE/EXHAUST INTAKE/EXHAUSTSHROUDS SHROUDS (SELUBUNGREMOVAL/INSTALLATION PEMASUKAN/PENGELUARAN) PEMASUKAN/PENGELUARAN) Remove the following: PELEPASAN/PEMASANGAN

STARTER MOTOR WIRE CLAMP

Lepaskan berikut: – Center sebagai body cover (page 2-8) – Luggage box (page 2-7) 2-8) - Center body cover (hal. – Inlet pipe (page 5-22) - Luggage box (hal. 2-7) – Muffler 2-14) - Inlet pipe (page (hal. 5-22) – PAIR air supply (page 5-25) - Muffler (hal. 2-14)pipe (page -Release PAIR air pipe (hal. 5-25)from intake shroud: thesupply following wire clamps Lepaskan wirewire clamps berikut dari intake shroud: – Spark plug clamp – Alternator wire clamp clamp (penjepit kabel busi) clamp - Spark plug wire – SE thermal valve wire clamp - Alternator wire clamp clamp – Starter motor wire clamp clamp - SE thermal valve wire clamp threewire screws and a bolt. -Remove Starterthe motor clamp Remove the intake/exhaust shrouds by releasing the tabs of Lepaskan ketiga screws dan sebuah bolt. intake shroud from the slot of the exhaust shroud. Lepaskan shrouds dengan melepaskan Remove theintake/exhaust rubber seal. tabs dari intake shroud dari slot pada exhaust shroud. Be sure to align the Lepaskan Installationrubber is in theseal. reverse order of removal.

"IN" mark and "EX" Pastikan untuk mark on the rubber mentepatkan mentepatka n tanda seal with the inlet"IN" side dan "EX" pada rubber and exhaust side of seal dengan sisi masuk cylinder head. dan keluar dari cylinder head.

TORQUE: Pemasangan adalaha dalam urutan Intake shroud mounting screw: pelepasan. 0.8 N·m (0.1 kgf·m, 0.6 lbf·ft) TORSI: Intake shroud Exhaust shroudmounting mounting screw: bolt: 0,8 N.m(0.7 (0,1kgf·m, kgf.m; lbf.ft) 7 N·m 5.10,6 lbf·ft) Exhaust shroud mounting bolt: 7 N.m (0,7 kgf.m; 5,1 lbf.ft)

INTAKE SHROUD

terbalik


SPARK PLUG WIRE CLAMP

ALTERNATOR WIRE CLAMP

dari

SCREWS 0.8 N· N·m (0.1 kgf ·m, 0.6 lbf ·ft)

RUBBER SEAL

EXHAUST SHROUD BOLT 7 N· N·m (0.7 kgf ·m, 5.1 lbf ·ft)

7-9


CAMSHAFT CAMSHAFT PELEPASAN REMOVAL Lepaskan berikut: Remove thesebagai following: - Mesin (hal. (hal. 6-4) 6-4) – Engine (page 6-4) - Cylinder (hal. 7-7) – Cylinderhead headcover cover (page 7-7) – Coolingfan fancover cover(hal. (page2-12) 2-12) - Cooling – Intake/exhaust shroud shroud (page - Intake/exhaust (hal. 7-9) 7-9)

INDEX NOTCH

Rotatecrankshaft the crankshaft clockwise by rotating thejam cooling fan Putar searah perputaran jarum dengan slowly andcooling align thefan "T" dengan mark on the flywheel the index memutar pelan dan with mentepatkan notch on the pada right crankcase. tanda "T" flywheel dengan index notch (takik penunjuk) pada right crankcase. Make sure the piston is at TDC (Top Dead Center) on the compression stroke. Pastikan bahwa piston berada pada TDC (Top Dead This position can be confirmed by checking that there is slack Center) [TMA = Titik Mati Atas] pada langkah in the rocker arm. kompressi. If there is no slack, it is because the piston is moving through Posisi ini dapat dipastikan dengan memeriksa bahwa the exhaust stroke to TDC. ada kerenggangan pada rocker arm. Rotate the crankshaft one full turn by rotating the cooling fan Jika tidak ada kerenggangan, disebabkan oleh karena slowly and match up the "T" mark again. piston sedang bergerak melalui langkah pembuangan Make sure that the index line on the cam sprocket is flush ke TDC. TANDA " with the the top surfac surfacesatu e of cylinde cy linderr head and dengan that the "memutar that " mark Putar crankshaft putaran penuh on the cam facing up as mentepatkan shown (TDC ontanda the comcooling fansprocket denganis pelan dan "T" pression stroke). sekali lagi. If the cam cam sprocket sprocket " " mark is not facin facing g up, turn turn the cooling fan (crankshaft) one revolution and realign thepada "T" mark Pastikan bahwa index penunjuk) line (garis cam with the index notch on the right crankcase. sprocket adalah segaris dengan permukaan atas dari cylinder head dan bahwa tanda "O" pada cam sprocket menghadap ke atas seperti diperlihatkan (TDC pada langkah kompressi). Jika tanda "O" cam sprocket tidak menghadap ke atas, putar cooling fan (crankshaft) satu putaran dan tepatkan tanda "T" kembali dengan index notch pada right crankcase. Loosen the lock nutsnuts and adjusting screws fully. Longgarkan lock dan adjusting screws dengan penuh.

SCREWS

Remove thescrew screw dan and O-ring camchain chain tensioner tensioner Lepaskan O-ringfrom darithe cam SCREW lifter. lifter.

7-10

TANDA "T"

"

INDEX LINE

LOCK NUTS

O-RING

CYLINDER HEAD/VALVES/CYLINDER/PISTON Install the specialtool toolke into the tensioner body anddan turnputar the Pasang special dalam tensioner body tool clockwise until it stops turning. tool searah perputaran jarum jam sampai ia berhenti Hold the tensioner lifter by pushing the tool while aligning berputar. the tabs oftensioner the tool withlifter the grooves of themendorong tensioner lifter.tool Tahan dengan sementara mentepatkan tabs dari tool dengan alur-alur TOOL: dari tensioner Cam chain tenlifter. sioner 070MG-0010100 lifter stopper TOOL: Cam chain tensioner lifter stopper 0010100

LIFTER STOPPER

070MG-

Tepatkan

Putar cooling fanfan (crankshaft) (crankshaft ) satu dan tepatkan Turn the cooling (crankshaft) oneputaran revolution and realign kembali tanda dengan pada right the "T" mark with"T" the index notchindex on the notch right crankcase. crankcase. Make sure sure that that the cam sprocke sprockett " " mark is is not facing facing up. up. Remove the bolts, cam sprocket from the camshaft and tidak cam Pastikan bahwa tanda "O" pada cam sprocket chain off the cam sprocket. menghadap ke atas. Attach a piece of wire to the cam chain to prevent it from falling into thebolts, crankcase. Lepaskan cam sprocket dari camshaft dan cam

TANDA" "

BOLTS

Letakkan pada pada Place akain shoplap towel at bagianthe cranakcase yang opening of the terbuka untuktomenjaga crankcase prevent agar cam sprocket bolts the cam sprocket bolts chain lepas dari cam sprocket. tidak jatuh ke dalam from falling into the crankcase. Ikatkan seutas kawat pada cam chain agar ia tidak jatuh crankcase.

ke dalam crankcase.

CAM CHAIN CAM SPROCKET Remove the boltdari from the cylinder bolt cylinder head.head. Lepaskan

headwhile Lepaskan darithecylinder sementara Remove the camshaft camshaft from cylinder head holding the rocker rocker arms toarms ease removal. menahan untuk mempermudah pelepasan.

BOLT

ROCKER ARMS

CAMSHAFT

7-11

CYLINDER HEAD/VALVES/CYLINDER/PISTON INSTALLATION PEMASANGAN Apply engine oil to the camshaft bearings and decompressor Oleskan oli mesin pada camshaft bearings dan daerah cam rotating area. perputaran decompressor cam. Apply molybdenum solution to theoilcam lobes.cam lobes Oleskan larusan oil molybdenum pada (bubungan cam).

Pastikan tabs tabof ke dalam cylinder sementara Install thecamshaft camshaft into the cylinder head head while holding the Make surebahwa the tabs osf Pasang dari camshaft dan arms untuk mempermudah rocker arms torocker ease installation. the camshaft and menahan decompressor cam decompressor cam pemasangan. menghadap ke sisi ruang are facing the pembakaran. combustion chamber side.. side

ROCKER ARMS

CAMSHAFT

TAB Install and tighten the bolt. bolt. Pasang dan kencangkan

Putar searah perputaran Rotate crankshaft the crankshaft clockwise and align jarum the "T" jam markdan on tepatkan tanda pada notch flywheel index notch the flywheel with "T" the index on thedengan right crankcase. (takik penunjuk) pada right crankcase.

BOLT

INDEX NOTCH

TANDA"T"

7-12

CYLINDER HEAD/VALVES/CYLINDER/PISTON Apply engine to the pada cam chain cam sprocket teeth.cam Oleskan oli oil mesin camandchain dan gigi sprocket. Install the cam chain on the cam sprocket. Install the cam sprocket to the camshaft then make sure that Pasang cam sprocket. the indexcam line chain on thepada cam sprocket is flush with the cylinder Pasang cam sprocket camshaft head and that the " " mark pada on the cam sprocketkemudian is facing pastikan bahwa index lines (garis penunjuk) pada cam down as shown (TDC on the exhaust stroke). sprocket rata dengan cylinder head dan bahwa tanda "O" pada cam sprocket sedang menghadap ke bawah seperti diperlihatkan (TDC pada langkah pembuangan).

TANDA"

CAM SPROCKET

Oleskan oli mesin pada permukaan duduk dan dari Apply engine oil to the seating surface and thread of ulir the cam cam sprocket sprocket bolts. bolts. Install and tighten the cam sprocket bolts to specified torque Pasang dan kencangkan cam sprocket bolts dengan in the sequence shown. torsi yang ditentukan pada urutan yang diperlihatkan.

"

CAM CHAIN

INDEX LINES

BOLTS

2

Letakkan pada Place a kain shop lap towel at lubang dari crankcase the opening of the untuk mencegah crankcase to prevent jatuhnya cam sprocket TORQUE:8 N·m (0.8 kgf·m, 5.9 lbf·ft) sprocket bolt TORSI: 8 N.m (0,8 kgf.m; 5,9 lbf.ft) boltthe ke cam dalam crankcase. from falling into the crankcase.

1

Lepaskan cam dan install pasang Remove the camchain chaintensioner tensioner lifter lifterstopper stopper and a new O-ring to thebaru cam chain lifter.tensioner lifter. sebuah O-ring padatensioner cam chain Install anddan tighten the screw to screw the specified torque. Pasang kencangkan dengan torsi yang ditentukan. TORQUE:4 N·m (0.4 kgf·m, 3.0 lbf·ft)

STOPPER

SCREW

TORSI: N.m (0,4 kgf.m; 3,0 lbf.ft) Install the4following: Pasang sebagai berikut: – Intake/exhaust shroud (page 7-9) – Cooling fan cover (page 2-12) - Intake/exhaust shroud (hal. 7-9) – Cylinder head cover (page 7-7) - Cooling fan cover (hal. 2-12) Engine (page 6-6) (hal. 7-7) - – Cylinder head cover -Adjust Mesinthe (hal. 6-6) valve clearance (page 3-8). Setel jarak renggang klep (hal. 3-8).

O-RING

PEMERIKSAAN INSPECTION SISTEM DEKOMPRESSOR DECOMPRESSOR SYSTEM Letakkan camshaft dengan sisinya dengan Place the camshaft with its larger bearing sideyang facing down as bantalan shown. yang lebih besar menghadap ke bawah seperti diperlihatkan. Turn the decompressor cam with your finger. Make sure the decompressor cam only turn counterclockwise Putar decompressor cam dengan jari-jari. and does not turn clockwise. Pastikan bahwa decompressor cam hanya dapat berputar dalam arah berlawanan perputaran jarumasjam If the decompressor cam is faulty, replace the camshaft an assembly. dan tidak dapat berputar dalam arah perputaran jarum am.

DECOMPRESSOR CAM

Jika decompressor cam tidak bekerja dengan baik, ganti camshaft sebagai sebuah kesatuan.

7-13

CYLINDER HEAD/VALVES/CYLINDER/PISTON CAMSHAFT CAMSHAFT Turn the outerrace race (lingkaran of each camshaft with your finPutar outer luar) bearing dari masing-masing ger. The bearing should turn smoothly and qu ietly. jari-jari. camshaft bearing (bantalan camshaft) dengan Also check thatberputar the bearing inner race fitsdan tightly on the camBearing harus dengan halus tanpa suara. shaft. Juga periksa bahwa bearing inner race (lingkaran dalam Replace the camshaft assembly if thecamshaft. bearing does not turn bantalan) duduk dengan erat pada smoothly, quietly, or if they fit loosely on the tidak camshaft. Ganti camshaft assembly jika bearing berputar dengan halus, tanpa suara, atau jika mereka duduk dengan longgar pada camshaft.

BEARING

Periksa lobes (bubungan) Check thecam cam lobes for excessive wear terhadap and damage.keausan berlebihan dan kerusakan. Measure the height of each cam lobe. Ukur ketinggian dari masing-masing cam lobe. BATAS SERVIS: SERVICE LIMIT: IN: 32,37 mm IN: 32.37mm(1.274 in) EX: 31,97 mm EX: 31.97mm(1.259 in)

CYLINDER CYLINDERHEAD HEAD PELEPASAN REMOVAL ••

Ketikaremoving melepaskan cylinderhead headnuts, nutsalways (mur kepala When the cylinder replace silinder), selalu ganti cylinder head gasket dan the cylinder head gasket and cylinder gasket with new cylinder gasket dengan yang baru. ones.

Remove the following: Lepaskan sebagai berikut: – Engine (page 6-4) - – Mesin (hal.head 6-4)cover (page 7-7) Cylinder - – Cylinder cover(page (hal.2-12) 7-7) Coolinghead fan cover - – Cooling fan cover (hal.(page 2-12)7-9) Intake/exhaust shroud - Intake/exhaust shroud (hal. 7-9) Rotate the crankshaft clockwise by rotating the cooling fan slowly and align the "T" mark on the flywheel with the index Putar crankshaft searah dengan perputaran jarum jam notch on the right crankcase. dengan memutar cooling fan dengan pelan dan Make sure the tanda piston is TDC (Top Dead dengan Center) on the mentepatkan "T"at pada flywheel index compression stroke. notch pada right crankcase. This position can be confirmed by checking that there slack Pastikan bahwa piston berada pada TDC (TopisDead in the rocker arm. = Titik Mati Atas] pada langkah Center) [TMA If there is no slack, it is because the piston is moving through kompressi. the exhaust stroke to TDC. Rotate ini the crankshaft one full turn by rotating the cooling fan Posisi dapat dipastikan dengan memeriksa bahwa slowly and match up the "T" mark again. ada kerenggangan pada rocker arm. Jika tidak ada kerenganggan, disebabkan oleh karena piston sedang bergerak melalui langkah pembuangan ke TDC. Putar crankshaft satu putaran penuh dengan memutar cooling fan dengan pelan dan mentepatkan tanda "T" sekali lagi.

7-14

INDEX NOTCH

TANDA"T"

CYLINDER HEAD/VALVES/CYLINDER/PISTON Pastikan Make surebahwa that theindex indexline line pada on thecam cam sprocket sprocket isadalah flush rata permukaan atashead dariand cylinder dan with dengan the top surface of cylinder that thehead " " mark bahwa tanda "O" pada cam sprocket menghadap ke on the cam sprocket is facing up as shown (TDC on the com pression stroke). atas seperti diperlihatkan (TDC pada langkah kompressi). If the cam sprocket " " mark is not facing up, turn the cooling fan (crankshaft) one revolution andtidak realign the "T" mark Jika tanda "O" pada cam sprocket menghadap ke with the index notch on the right crankcase. atas, putar cooling fan (crankshaft) satu putaran dan tepatkan kembali tanda "T" dengan index notch pada right crankcase.

TANDA" "

INDEX LINE

Lepaskan O-ringfrom dari the cam Remove thescrew screw dan and O-ring camchain chaintensioner tensioner lifter. lifter.

SCREW

O-RING

Pasang special dalam tensioner body dan Install the specialtool toolke into the tensioner body and turnputar the tool jarum sampai ia berhenti berputar. tool searah clockwise untiljam it stops turning. Hold the tensioner tensioner lifter by pushing the tool while aligning Tahan lifter dengan mendorong tool the tabs of the tool with the tabs grooves the tensioner lifter. sementara mentepatkan darioftool dengan alur-alur dari tensioner lifter. TOOL: Cam chain tensioner 070MG-0010100 TOOL: lifter chain stopper Cam tensioner 070MG-0010100 lifter stopper

LIFTER

Tepatkan

Letakkan kain lap pada lubang crankcase Place adari shop towel at untuk menghindari the opening of the jatuhnya cam crankcase tosprocket prevent boltthe ke cam dalam crankcase. sprocket bolt from falling into the crankcase.

Lepaskan sprocketfrom darithe camshaft cam Remove thebolts, bolts,cam cam sprocket camshaftdan and cam chain sprocket. chain lepas off thedari cam cam sprocket.

CAM CHAIN

Attach a piece of wire to the cam chain to prevent it from fallIkat seutas kawat pada cam chain untuk mencegahnya ing into the crankcase. atuh ke dalam crankcase.

BOLTS

CAM SPROCKET

7-15

CYLINDER HEAD/VALVES/CYLINDER/PISTON Remove thecylinder cylinderhead head bolts. bolts. Lepaskan Loosen the cylinder head nutsnuts in a crisscross pattern in two or Longgarkan cylinder head dalam pola bersilangan three steps. dalam dua atau tiga langkah.

BOLTS

NUTS

Remove the nuts and plates. Lepaskan nuts dan plates.

PLATES

Lepaskan Remove thespring springdan plunger. and plunger.

PLUNGER

SPRING Remove thecylinder cylinderhead. head. Lepaskan

CYLINDER HEAD Remove the gasket and dowel pins.

INSTALLATION Clean the cylinder head mating surface. Lepaskan gasket and dancylinder dowel pins. Install the dowel pins and a new gasket onto the cylinder.

DOWEL PINS

PEMASANGAN Bersihkan permukaan penyatuan cylinder dan cylinder head. Pasang dowel pins dan sebuah gasket baru pada cylinder.

GASKET

7-16

CYLINDER HEAD/VALVES/CYLINDER/PISTON Alurkan chainthrough melaluithecylinder daninstall pasang Route thecam cam chain cylinderhead head and the cylinder head head onto thecylinder. cylinder. cylinder pada CAM CHAIN

CYLINDER HEAD Apply engine oil to the plunger whole surface. Oleskan mesinand pada seluruh permukaan plunger. Install theoli plunger spring. Pasang plunger dan spring.

PLUNGER

SPRING

Semprotkan ke permukaan duduk dan Apply engineoli oilmesin to the seating surface and threads of ulir the dari cylcylinder head plates dan kencangkan inder head nuts.nuts. InstallPasang the plates and tighten the cylinder cylinder nuts dalam polatobersilangan head nutshead in a crisscross pattern the specified dengan torque. torsi yang ditentukan. TORQUE:18 N?m (1.8 kgf?m, 13 lbf?ft) TORSI: 18 N.m (1,8 kgf.m; 13 lbf.ft) Apply engine oil to the seating surface and threads of the cylinder head mounting bolts, then install and tighten them to Semprotkan oli mesin pada permukaan duduk dan ulir the specified torque. dari cylinder head mounting bolts, kemudian pasang dan kencangkan dengan torsi yang ditentukan. TORQUE:12 N?m (1.2 kgf?m, 9 lbf?ft) TORSI: 12 N.m (1,2 kgf.m; 9 lbf.ft)

NUTS

BOLTS

PLATES Rotatecrankshaft the crankshaft clockwise align "T" mark on Putar searah jarumand jam danthe tepatkan tanda the flywheel with the index notchindex on the right crankcase. "T" pada flywheel dengan notch pada right crankcase.

INDEX NOTCH

TANDA"T"

7-17

CYLINDER HEAD/VALVES/CYLINDER/PISTON Apply engine oli oil to the cam chain andcam cam sprocket teeth.cam Semprotkan mesin pada gigi chain dan sprocket. Install the cam chain on the cam sprocket. Install the cam sprocket to the camshaft then make sure that Pasang cam sprocket. the indexcam linechain on thepada cam sprocket is flush with the cylinder Pasang cam sprocket pada camshaft kemudian head and " " mark is facing up as shown (TDC on the compastikan bahwa index line pada cam sprocket adalah pression stroke). rata dengan cylinder head dan tanda "O" menghadap ke atas seperti diperlihatkan (TDC pada langkah kompressi).

CAM CHAIN TANDA"

"

INDEX LINES CAM SPROCKET Letakkan kain lap menutupi lubang dari Place a shop towel at crankcase untuk the opening of the mencegah to agar cam crankcase prevent sprocket bolt tidak jatuh the cam sprocket bolt ke dalam crankcase. from falling into the crankcase.

Semprotkan pada permukaan duduk ulir Apply engine oli oil mesin to the seating surface and thread of dan the cam dari cam bolts. sprocket bolts. sprocket

BOLTS

Install and tighten the cam sprocket bolts to specified torque Pasang dan kencangkan cam sprocket bolts dengan in the sequence of the cam sprocket numbers. torsi yang ditentukan dalam urutan dari nomor cam sprocket. TORQUE:8 N?m (0.8 kgf?m, 5.9 lbf?ft) TORSI: 8 N.m (0,8 kgf.m; 5,9 lbf.ft)

NOMOR CAM SPROCKET

Lepaskan cam chain pasang Remove the cam chaintensioner tensionerlifter lifterstopper stopper dan and install a sebuah O-ring baru pada cam chain tensioner lifter. new O-ring to the cam chain tensioner lifter. Install anddan tighten the screw to screw the specified torque. Pasang kencangkan dengan torsi yang ditentukan. TORQUE:4 N?m (0.4 kgf?m, 3.0 lbf?ft)

STOPPER

SCREW

TORSI: N.m (0,4 kgf/m, 3,0 lbf.ft) Install the4following: Pasang sebagai berikut: – Intake/exhaust shroud (page 7-9) – Engine (page 6-6) - Intake/exhaust shroud (hal. 7–9) -Adjust Mesinthe (hal. 6-6) valve clearance (page 3-8). Setel jarak renggang klep (hal.3-8). O-RING

DISASSEMBLY PEMBONGKARAN ROCKER ARM/SHAFT ROCKER ARM/SHAFT Screw the 5mm bolt into the threaded hole in the rocker arm shaft and pull it out of the camshaft holder. Sekrupkan 5 mm bolt ke dalam lubang berulir di dalam Remove the rocker arms. rocker arm shaft dan tarik keluar dari camshaft holder. Keluarkan rocker arms.

ROCKER ARMS

BOLT

ROCKER ARM SHAFT

7-18

CYLINDER HEAD/VALVES/CYLINDER/PISTON CAMSHAFT CAMSHAFT Lepaskan boltand dan camshaft tab-nya Remove the bolt camshaft with its tabdengan facing down. menghadap ke bawah.

CAMSHAFT

BOLT

TAB

VALVE VALVE To prevent loss of Untuk mencegah tension, do not hilangnya tegangan, jangan tekan valve compress the valve springs lebihmore dari pada springs than yang diperlukan untuk necessary to remove melepaskan cotters. the cotters.

Remove thevalve valve cotters the valve spring compressor. Lepaskan cottersusing dengan menggunakan valve spring compressor.

Mark all parts Tandai semuaduring parts selama pembongkaran disassembly so they sehingga mereka dapat can be placed back in diletakkan kembali pada their original lokasi mereka semula. locations.

Lepaskan spring compressor dan the lepaskan Remove the valve valve spring compressor and remove followsebagai berikut: ing: - Valve spring retainers – Valve spring retainers - Valve springs – Valve springs - Valve spring seats – Valve spring seats - Valves – Valves - – Valve Valvestem stemseals seals

VALVE SPRING COMPRESSOR

TOOLS: TOOLS: Valve spring compressor 07757-0010000 Valve spring compressor 07757-0010000 Valve spring compressor attachment 07959-KM30101 Valve spring compressor attachment 07959-M30101

VALVE

VALVE STEM SEAL

VALVE SPRING SEAT VALVE SPRING VALVE SPRING RETAINER Avoiduntuk damaging the Lepaskan Remove the carbon deposits the combustion chamber endapan karbon form dari ruang pembakaran dan Hindari merusak permukaan penyatuan cylinder mating bersihkan and clean off thepermukaan cylinder head gasket head surface. dari cylinder g asket. cylinder surfacedan andpermukaan valve seat valve seat . surfaces.

COMBUSTION CHAMBER

7-19

CYLINDER HEAD/VALVES/CYLINDER/PISTON ASSEMBLY PERAKITAN COTTERS VALVE SPRING

SPRING RETAINER

SPRING SEAT VALVE STEM SEAL EXHAUST ROCKER ARME

VALVE GUIDE EXHAUST ROCKER ARM SHAFT

CLIP

INLET ROCKER ARM SHAFT BOLT

INLET ROCKER ARM

CAMSHAFT

INLET VALVE

EXHAUST VALVE

VALVE VALVE Blow through the oil passage the cylinder head with comTiuplah dengan udara dariin kompressor melalui jalan pressed air. lintasan oli di dalam cylinder head. Apply engine oil to the innerpermukaan surface of new valve dari stem seals. Oleskan oli mesin pada dalam valve Installseals the valve spring seats and new valve stem seals. stem baru. Pasang spring seatssurface dan valve Coat the valve valve stem sliding with stem engineseals oil. baru. Insert the valves into the valve guides while turning them Lapisi luncur valve stem dengan slowlypermukaan to avoid damage to the valve stem seals. oli mesin. Masukkan valves ke dalam valve guides sementara memutar mereka pelan-pelan untuk menghindari kerusakan pada valve stem seals.

VALVE

SPRING SEAT

STEM SEAL

7-20

CYLINDER HEAD/VALVES/CYLINDER/PISTON Install thevalve valve springs withdengan the tightly woundyang coils facing Pasang springs lilitan rapat the combustion menghadap ke chamber. ruang pembakaran.

Ke ruang pembakaran

Install the valvespring springretainer. retainer. Pasang valve Untuk mencegah To prevent loss of hilangnya tegangan, tension, do not jangan tekan compress the valve valve spring lebih more dari pada spring than yang diperlukan untuk necessary to install memasang cotters. the cotters.

Topang cylinder head di Support the cylinder atas permukaan meja head above the work kerja bench untuk mencegah surface to kerusakan pada valve. prevent valve damage.

VALVE SPRING COMPRESSOR

Install thevalve valve cotters using the valvemenggunakan spring compressor. Pasang cotters dengan valve spring compressor. TOOLS: TOOLS: Valve compressor 07757Valve spring spring compressor 07757-0010000 0010000 Valve spring compressor Valve spring compressor attachment 07959attachment 07959-KM30101 KM30101

Place a suitable tool onto thepada valve valve stem. stem. Letakkan tool yang sesuai TOOL YANG SESUAI

Tap the tool gently to seat the cotters firmly using a plastic Ketuk tool dengan ringan untuk mendudukkan cotters hammer. dengan erat dengan menggunakan palu plastik.

VALVE STEM

CAMSHAFT CAMSHAFT Oleskan – 1,0 mesin perputaran Apply 0.50,5 – 1.0 cc cc of oli engine oilpada to thedaerah decompressor cam decompressor dan camshaft rotating area andcam camshaft bearing. bearing. Apply molybdenum oil solution to the cam lobes. Oleskan larutan molybdenum oil pada cam lobes. Install the camshaft with its tab and tab of the decompressor Pasang camshaft dengan dan tab dari cam is facing combustion chambertab-nya side. decompressor cam menghadap ke sisi ruang pembakaran.

TAB TAB

7-21

CYLINDER HEAD/VALVES/CYLINDER/PISTON Install and tighten the bolt. bolt. Pasang dan kencangkan BOLT

ROCKER ROCKERARM ARM Semprotkan oli tomesin padasurface permukaan Apply engine oil the sliding and rollerluncur surfacedan of permukaan gelinding dari rocker arm. the rocker arm. Apply engine oli oil to the sliding of the luncur rocker arm Semprotkan mesin pada surface permukaan dari shaft. rocker arm shaft.

ROCKER ARMS

ROCKER ARM SHAFTS

Pasang rocker head. Install the rockerarms arms pada to the cylinder cylinder head. Pasang arm dari exhaus Install the exhaustrocker rockerarm armshaft shaft (poros into therocker exhaust rocker klep buang) ke dalam exhaust rocker arm dan cylinder arm and cylinder head until it is fully seated. head sampai ia telah duduk sepenuhnya. Insert the inlet rocker arm shaft into the cylinder head using a screwdriverinlet whilerocker aligning cut-out of the shaft arm with dari the Masukkan armtheshaft (poros rocker stud bolt hole on cylinder head. klep masuk) ke dalam cylilnder head dengan menggunakan obeng sementara mentepatkan potongan dari shaft dengan lubang stud bolt pada cylinder head.

ROCKER ARM SHAFTS

Tepatkan

7-22

CYLINDER HEAD/VALVES/CYLINDER/PISTON INSPECTION PEMERIKSAAN CYLINDERHEAD HEAD CYLINDER Check the spark plug valve areas cracks. retakPeriksa lubang busihole danand daerah valvefor terhadap Check the cylinder head for warpage with a straight edge and retak. a feeler gauge. Periksa cylinder head terhadap perubahan bentuk melengkung dengan sebuah mistar lurus dan feeler gauge. SERVICE LIMIT: 0.05 mm (0.002 in) BATAS SERVIS: 0,05 mm

ROCKERARM/SHAFT ARM/SHAFT ROCKER

Disassemble the cylinder head7-18). (page 7-18). Bongkar cylinder head (hal. Check the rockerarm armshafts shafts dan and rocker wear or Periksa rocker rockerarms armsforterhadap damage. keausan atau kerusakan. Turn the rocker arm roller with your finger. Putar rocker arm (penggelinding The roller should turn roller smoothly and quietly. rocker arm) dengan jari-jari. Measure the I.D. of each rocker halus arm. dan tanpa suara. Roller harus berputar dengan SERVICE Ukur D.D. dari masing-masing arm. in) LIMIT: IN/EX: 10.04rocker mm (0.395 BATAS SERVIS: IN/EX: 10,04 mm Measure the O.D. of each rocker arm shaft. Ukur D.L. dari masing-masing rocker arm shaft. SERVICE BATAS 9,91mm mm(0.390 in) LIMIT: SERVIS: IN/EX: IN/EX: 9.91

Hitung jarak rocker arm-ke-shaft. Calculate therenggang rocker arm-to-shaft clearance. BATAS SERVIS: IN/EX: 0,08 mm SERVICE LIMIT:

IN/EX: 0.08 mm (0.003 in)

VALVESPRING SPRING VALVE

Disassemble the cylinder head7-18). (page 7-18). Bongkar cylinder head (hal. Measure the free length of the valve springs. Ukur panjang bebas dari valve springs. SERVICE BATAS SERVIS: IN/EX: 29,11 mm LIMIT: IN/EX: 29.11 mm (1.146 in) Ganti springs jika mereka lebih pendek dari batas servis. Replace the springs if they are shorter than the service limit.

7-23

CYLINDER HEAD/VALVES/CYLINDER/PISTON VALVE/VALVE GUIDE VALVE/VALVE GUIDE Disassemble the cylinder head7-18). (page 7-18). Bongkar cylinder head (hal.

Check that the valve moves smoothly in the halus guide. di dalam Periksa bahwa valve bergerak dengan Check each valve for bend, burn, scratch or abnormal wear. guide. Periksa valve Measuremasing-masing each valve stem O.D. andterhadap record it. kebengkokan, keadaan terbakar, goresan atau keausan tidak normal. SERVICE LIMIT: IN/EX: valve 4.90 mm (0.193 Ukur D.L. masing-masing stem dan in) catat.

BATAS SERVIS: IN/EX: 4,90 mm

guide untuk menghilangkan pembentukan Selalu putar reamer Always rotate the Ream Ream valve the valve guide to remove any carbon build up before searah jam, karbon sebelum mengukur guide. reamer jarum clockwise, measuring the guide. jangan sekali-kali reamer dari ruang chamber pembakaran never Masukkan Insert the reamer from the sisi combustion side ofdari the berlawanan arah jarum cylinder head dan selalu putar reamer searah jarum counterclockwise cylinder head and always rotate the reamer clockwise. jam ketika when inserting, am. memasukkannya, TOOL: removing dan and mengeluarkannya Valve guide reamer, 5.0 mm 07984-MA60001 reaming. TOOL: selama pekerjaan Valve guide reamer, 5.0 MM 07984-MA60001 reaming.

Periksa reface D.D.each masing-masing valve Measure valve guide I.D. andguide recorddan it. catat. Inspect anddan reface the Ukur valve seats setiap kali valve seats whenever SERVIS: IN/EX: 5,03 mm valve guides diganti BATAS the valve guides are SERVICE (hal. 7-26). IN/EX: 5.03 mm (0.198 in) replaced (page 7-26). LIMIT:

Kurangi D.L. masing-masing valve stem dari D.D. guide Subtract each valve stem O.D. from the corresponding guide yang bersangkutan untuk mendapatkan jarak renggang I.D. to obtain the stem-to-guide clearance. stem-ke-guide SERVICE BATAS SERVIS: IN: 0,08 mm LIMIT: IN: 0.08 mm (0.003 in) EX: 0,10 mm EX: 0.10 mm (0.004 in)

Jika jarak renggang clearance stem-ke-guide If the stem-to-guide exceedsmelampaui the service batas limit, servis, tentukan apakah sebuah guide baru dengan determine if a new guide with standard dimensions would ukuran bring thestandard clearanceakan within membawa tolerance. jarak renggang ke If so, replace any guides as necessary and ream to fit (page 7dalam toleransi. 25). demikian, ganti guides yang diperlukan dan ream Jika If thepas stem-to-guide agar (hal. 7-25).clearance exceeds the service limit with new jarak guide, also replace stem-ke-guide the valve. Jika renggang melampaui batas servis dengan sebuah guide baru, ganti valve juga.

7-24

VALVE GUIDE REAMER

CYLINDER HEAD/VALVES/CYLINDER/PISTON VALVE GUIDEVALVE REPLACEMENT PENGGANTIAN GUIDE Disassemble the cylinder head 7-18). (page 7-18). Bongkar cylinder head (hal. Chill new valve guides in abaru freezer for about 1 hour. Dinginkan valve guides dalam bagian freezer dari lemari es selama kira-kira 1 jam. CATATAN: • Be sure to wear heavy gloves to avoid burns when han• Pastikan untukcylinder memakai sarung tangan berat untuk dling the heated head. menghindari luka-luka bakar sewaktu • Using a torch to heat the cylinder head maymenangani cause warcylinder head yang telah dipanaskan. page. • • Drive Jangan obor untuk memanaskan newmenggunakan guides from the camshaft side while the cylincylinder head karena dapat mengakibatkan der head is still heated. perubahan bentuk melengkung. Heat the cylinder head to 130 – 140°C (275 – 290°F) with a Dorong masuk guides baru dari sisi camshaft • hot plate or oven. Do not heat the cylinder head beyond sementara cylinder head masih dipanaskan. 150°C (300°F). Use temperature indicator sticks, available from welding supply stores, to be sure the cylinder head is Panaskan cylinder head sampai 130 - 140° C dengan heated to the proper temperature. kompor listrik atau oven. Jangan memanaskan cylinder Support the cylinder150 head and drive the valve guides out of ° C. Pakailah tongkat indikator head melampaui the cylinder head from the combustion suhu, yang dapat dibeli darichamber toko side. pemasok perlengkapan pengelasan, untuk memastikan bahwa TOOL: head telah dipanaskan sampai ke suhu yang cylinder Valve guide driver, 5.0 mm 07942-MA60000 tepat. Take outcylinder new valve guides from the freezer. Topang head dan dorong keluar valve guides dari cylinder head dari into sisi ruang pembakaran. Drive new valve guides the cylinder head to the specified TOOL: height from the cylinder head. Valve guide driver, 5,0 mm 07942-MA60000 TOOL: Keluarkan valve guides baru dari freezer. Valve guide adjusting driver 07743-0020000

VALVE GUIDE DRIVER

VALVE GUIDE

VALVE GUIDE ADJUSTING DRIVER

Dorong masuk valve guides baru ke dalam cylinder VALVE GUIDE PROJECTION: head sampai ke ketinggian yang ditentukan dari cylinder IN/EX: 9.1 – 9.3 mm (0.36 – 0.37 in) head.

9.1 – 9.3 mm (0.36 – 0.37 in)

Let the cylinder head cool to room temperature. TOOL: Valve guide adjusting driver 07743-0020000

PROJEKSI VALVE GUIDE: IN/EX: 9,1 – 9,3 mm Ream new valve guides after installation. Biarkan cylinder head menjadi dingin kembali sampai ke suhu ruangan. • Take care not to tilt or lean the reamer in the guide while reaming. Lakukan pekerjaan reaming pada valve guides baru. • Use cutting oil on the reamer during this operation. Hati-hati memiringkan • Insert the reamer agar from the tidak combustion chamber side ofatau the mencondongkan reamer di dalam sementara cylinder head and always rotate the reamerguide clockwise. meng-reaming. Gunakan cutting oil pada reamer selama •TOOL: Valve guide reamer, 07984-MA60001 pengerjaan ini. 5.0 mm

VALVE GUIDE VALVE GUIDE REAMER

Clean the cylinder head thoroughly to remove any metal dari parMasukkan dari sisi ruang pembakaran reamer ticles after reaming and reface the valve seat (page 7-26). cylinder head dan selalu putar reamer searah dengan arah perputaran jarum jam.

TOOL; Valve guide reamer, 5.0 mm

07984-MA60001

Bersihkan cylinder head secara menyeluruh untuk membuang partikel-partikel logam setelah pekerjaan reaming dan reface (bentuk kembali permukaan) valve seat (hal. 7-26).

7-25

CYLINDER HEAD/VALVES/CYLINDER/PISTON VALVE SEAT INSPECTION/REFACING PEMERIKSAAN/REFACING VALVE SEAT Disassemble the cylinder head7-18). (page 7-18). Bongkar cylinder head (hal. Clean the intake exhaustdan valves thoroughly to remove Bersihkan intakeand (masuk) exhaust (buang) valves carbon deposits. (klep) secara menyeluruh untuk menghilangkan

endapan karbon. Apply a light coat of Prussian Blue to the valve seats. Tap the valve against the valve seat several times using a Oleskan lapisan Blue pada valvea seats hand-lapping tool,ringan withoutPrussian rotating the valve to make clear (dudukan pattern. klep). Ketuk valve terhadap valve seat beberapa kali dengan menggunakan hand-lapping tool (alat skir klep dengan tangan), tanpa memutar valve agar mendapatkan pola elas.

Valves dapat The valvestidak cannot be digerinda. ground. IfJika the muka valve valve face terbakar, is burned,sangat badly aus atau jika ia worn or if it contacts engkontak seat secara the seat unevenly, tidak merata, gantilah replace the valve. valve.

Remove thevalve valvedan andperiksa inspect the valve seat face. Lepaskan valve seat face. The valve seatseat contact should be within theyang specified width Kontak valve harus di dalam lebar ditentukan and even all around the circumference. dan merata sepanjang kelilingnya. STANDARD: 1.0 mm (0.04 in) STANDARD: 1,0 mm SERVICE BATAS LIMIT: SERVIS: 1,5 1.5 mm mm (0.06 in)

Jika lebar valve seat di luar spesifikasi, reface valve If the valve seat width is not within specification, reface the seat (bentuk kembali permukaan dudukan klep) (lihat valve seat (see page 7-26). hal. 7-26). LEBAR SEAT

Inspect the valve seat seat face for: Periksa muka terhadap: valve • Damaged face: Kerusakan pada muka: –- Replace the valve reface the seat valve seat Ganti valve dan and reface valve • Uneven seat width: • Lebar seat tidak merata: – Bent or collapsed valve stem; Replace the valve and - Valve stem bengkok atau runtuh. Ganti valve dan reface the valve seat reface valve seat •

MUKA RUSAK

• •

LEBAR SEAT TIDAK MERAT

Contact (too (terlalu low or too high area): Daeraharea kontak rendah atau terlalu tinggi): –- Reface valveseat seat Refacethe valve

TERLALU RENDAH

7-26

TERLALU TINGGI

CYLINDER HEAD/VALVES/CYLINDER/PISTON • •

Follow the refacer manufacturer’s instructions. Ikuti petunjuk pemakaian pabrikoperating pembuat refacer. • Be careful not to grind the seat more than necessary. Hati-hati agar tidak menggerinda seat lebih • daripada yang diperlukan. 45°

60° 32°

Jika terlalu valve, seat harus If thedaerah contactkontak area is too hightinggi on thepada valve, the seat must be KONTAK TERLALU TINGGI lowered using a 32° flat cutter. diturunkan dengan menggunakan 32° flat cutter. If the contact area is too low on the valve, the seat must be Jika daerah kontak terlalu rendah pada valve, seat raised using a 60° interior cutter. harus dengan menggunakan 60° cutter. interior Refinishdinaikkan the seat to specifications, using a 4 5 ° finish cutter. Haluskan permukaan seat sesuai dengan spesifikasi, dengan menggunakan 45° finish cutter. KONTAK TERLALU RENDAH

LEBAR SEAT LAMA

32°

LEBAR SEAT LAMA

60° Reface Reface theseat seatdengan with a sebuah 45 cutter setiap 45 cutter whenever a kali sebuah valve guide valve guide is diganti. replaced. °

°

Pakailah 45° cutter, seat remove cutter, any hilangkan kekasaran atau Use a 45° seat roughness or irregularities ketidak-teraturan dari seat . from the seat. TOOLS: TOOLS: Seat cutter, 27.5 mm (45 IN) Seat cutter, 27.5 mm (45 ° IN) Seat cutter, 24 mm (45 EX) ° EX) Seat cutter, 24 mm Cutter holder, 5.0 (45 mm Cutter holder, 5.0 mm

KEKASARAN

07780-0010200 07780-0010200 07780-0010600 07780-0010600 07781-0010400 07781-0010400

° cutter, Pakailah flat cutter, hilangkan ¼ bagian teratasvalve dari Use a 32°32 flat remove the top 1/4 of the existing bahan valve seat yang ada sekarang. seat material.

TOOLS: TOOLS: Flat 27mm mm(32 (32 IN) ° IN) Flat cutter, cutter, 27 Flat 22mm mm(32 (32 EX) Flat cutter, cutter, 22 ° EX) Cutter 5.0mm mm Cutter holder, holder, 5.0

07780-0013300 07780-0013300 07780-0012601 07780-0012601 07781-0010400 07781-0010400

LEBAR SEAT LAMA

32°

7-27

CYLINDER HEAD/VALVES/CYLINDER/PISTON Use a 60° interior cutter, remove bottom 1/4 of existPakailah 60° interior cutter,thehilangkan ¼thebagian ing valve seat material. terbawah dari bahan valve seat yang ada sekarang.

TOOLS: TOOLS: Interior 26mm mm(60 (60 IN) ° IN) Interior cutter, cutter, 26 Interior 22mm mm(60 (60 EX) Interior cutter, cutter, 22 ° EX) Cutter holder, 5.0 mm Cutter holder, 5.0 mm

LEBAR DUDUKAN LAMA

07780-0014500 07780-0014500 07780-0014202 07780-0014202 07781-0010400 07781-0010400

60°

cutter, Dengan menggunakan ° seat ° seat cutter, cutsebuah Using a 45 the seat 45 to the proper width.potong seat sampai lebar yang benar. VALVE SEAT WIDTH: 1.0 mm (0.04 in) LEBAR VALVE SEAT: 1,0 mm Make sure that all pitting and irregularities are removed. Pastikan bahwa semua lubang-lubang dan ketidakteraturan telah dihilangkan.

1.0 mm (0.04 in)

45°

CATATAN: Tekanan skir klep yang berlebihan dapat merubah • bentuk atau merusak seat . ? Excessive lapping or damage the • Ubah sudut daripressure lappingmay tooldeform sering-sering untuk seat. mencegah keausan seat yang tidak merata. • Change angle lapping of lapping tool frequently to prevent • Jagalahtheagar compound (ambril) tidak uneven seat wear. memasuki guides. • Do not allow lapping compound to enter the guides. Setelah memotong oleskancompound lapping to compound After cutting the seat, seat, apply lapping the valve pada muka dan skirlight klep dengan menggunakan face, and lap valve, the valve using pressure. tekanan ringan. After lapping, wash any residual compound off the cylinder head and valve and recheck the seat contact. Setelah menskir klep, cucilah compound yang tersisa Assemble thehead cylinder head (page dari cylinder dan valve dan7-20). periksa kembali kontak seat.

7-28

HAND-LAPPING TOOL


CAM CAM CHAIN CHAINGUIDE GUIDE PELEPASAN REMOVAL Remove the cylinderhead head (hal. (page7-14). 7-14). Lepaskan cylinder

Lepaskan cam Remove the camchain chainguide. guide.

CAM CHAIN GUIDE

PEMASANGAN INSTALLATION Pasang dengan cam guideby bosses Install the camchain chain guide aligningmentepatkan the bosses of the cam dari cam chain dengan chain guide withguide grooves of the alur-alur cylinder. pada cylinder.

CAM CHAIN GUIDE

Install the cylinder head(hal. (page7-16). 7-16). Pasang cylinder head

Tepatkan

PEMERIKSAAN INSPECTION Periksa daerah terhadap camchain chain guide Check the slidingluncur area ofdari the cam guide for excessive keausan berlebihan atau kerusakan. wear or damage. CAM CHAIN GUIDE

7-29


CAM CHAIN CHAINTENSIONER TENSIONERSLIDER SLIDER CAM REMOVAL PELEPASAN Remove thesebagai following: Lepaskan berikut: – Drive pulley(hal. (page 8-12) - Drive pulley 8-11) – Cylinder head (page 7-14) - Cylinder head (hal. 7-14).

PIVOT PIN BOLT

Remove the pivotpin pinbolt. bolt. Lepaskan pivot

Lepaskan tensionerslider. slider. Remove theO-ring O-ringdan andcam cam chain chain tensioner

O-RING

TENSIONER SLIDER

PEMASANGAN INSTALLATION Install thecam cam chain chain tensioner slider to the left crankcase. Pasang tensioner slider pada sisi kiri dari crankcase. Coat a new O-ring with engine oil and install it into the pivot

O-RING

pin bolt groove. Lapisi sebuah O-ring baru dengan oli mesin dan pasang ke dalam alur pivot pin bolt.

TENSIONER SLIDER

Pasang pivot boltinto ke the dalam lubang cam slider chain Install the pivot pin pin bolt cam chain tensioner tensioner sliderit to dan kencangkan dengan torsi yang hole and tighten the specified torque. ditentukan. TORQUE:10 N·m (1.0 kgf·m, 7 lbf·ft) TORSI: 10 N.m (1,0 kgf.m; 7 lbf.ft) Install the following: Pasang sebagai berikut: – Cylinder head (page 7-16) - Cylinder head(page (hal. 8-13) 7-16) – Drive pulley - Drive pulley (hal. 8-12)

7-30

PIVOT PIN BOLT

CYLINDER HEAD/VALVES/CYLINDER/PISTON INSPECTION PEMERIKSAAN Check the slidingluncur area ofdari the cam slider for Periksa daerah camchain chaintensioner tensioner slider excessive wear or damage. terhadap keausan berlebihan atau kerusakan. TENSIONER SLIDER

CAM CHAIN CHAINTENSIONER TENSIONERLIFTER LIFTER CAM PELEPASAN REMOVAL Camcam chain dengan The chaintensioner tensioner lifter lifter dapat can be diservis serviced with the mesininstalled terpasang pada rangka. engine in the frame. Lepaskan luggage box (hal. 2-7). Remove the luggage box (page 2-7). Lepaskan tensioner screw dan O-ring. Remove the tensioner screw and O-ring. Pasang special tool ke dalam tensioner body dan putar Install the special tool into the tensioner body and turn the tool searah jarum jam sampai ia berhenti berputar. tool clockwise until it stops turning. Tahan tensioner lifter dengan mendorong tool Hold the tensioner lifter by pushing the tool while aligning sementara mentepatkan tabs dari tool dengan alur-alur the tabs of the tool with the grooves of the tensioner lifter. dari tensioner lifter. TOOL: TOOL: Cam chain tensioner Cam tensioner lifterchain stopper 070MG-0010100 lifter stopper 070MG-0010100 Remove the bolts and cam chain tensioner lifter. Lepaskan bolts dan cam chain tensioner lifter. Remove the gasketdari fromtensioner the tensioner lifter. Lepaskan gasket lifter. ••

SCREW

LIFTER STOPPER

GASKET

O-RING

TENSIONER LIFTER

BOLTS

PEMASANGAN INSTALLATION Pasang tensioner lifter stopper dantheputar Install thecam cam chain chain tensioner lifter stopper and turn tentensioner searah jamthedengannya untuk sioner shaftshaft clockwise with jarum it to retract tensioner fully. Install a new gasket,secara cam chain tensioner lifter and tighten the menarik tensioner penuh. bolts. sebuah gasket baru, cam chain tensioner lifter Pasang Remove the cam chain dan kencangkan bolts.tensioner lifter stopper. Lepaskan cam chain tensioner lifter stopper.

CAM CHAIN TENSIONER LIFTER

BOLTS

GASKET

7-31

CYLINDER HEAD/VALVES/CYLINDER/PISTON Install a new O-ring to the baru cam chain lifter. Pasang sebuah O-ring padatensioner cam chain tensioner Install and tighten the screw to the specified torque. lifter. Pasang dan kencangkan screw dengan torsi yang TORQUE:4 N·m (0.4 kgf·m, 3.0 lbf·ft) ditentukan. Install the luggage box (page 2-7). TORSI: 4 N.m (0,4 kgf.m; 3.0 lbf.ft)

SCREW

Pasang luggage box (hal. 2-7).

O-RING

PEMERIKSAAN INSPECTION Periksa cara chainlifter tensioner lifter: Check the camkerja chaincam tensioner operation: - Tensioner shaft boleh masuk kebody dalam – The tensioner shafttidak should not go into the whenbody it is pushed. ketika ia didorong. – When is turned clockwise withjam the dengan cam chain tensioner - Jika ia itdiputar searah jarum cam chain lifter stopper, the tensioner shaft should be pulled into the tensioner lifter stopper, tensioner shaft harus ditarik body. The shaft should protrude from the body as soon as ke dalam body. Shaft harus menonjol keluar dari body the cam chain tensioner lifter stopper is released. segera setelah cam chain tensioner lifter stopper dilepaskan.

TENSIONER SHAFT

TENSIONER LIFTER

CYLINDER CYLINDER PELEPASAN REMOVAL CATATAN: Ikatlaha piece seutas kawat cam chain ituntuk • • Attach of wire to the pada cam chain to prevent from mencegahnya jatuh ke dalam crankcase. falling into the crankcase. careful agar not totidak damage the mating surfaces penyatuan by using a Hati-hati merusak permukaan • • Be screwdriver when removing the cylinder. obeng karena mencongkel dengan ketika melepaskan cylinder. Remove the cylinder head (page 7-14). Remove the cylinder. Lepaskan cylinder head (hal. 7-14). Lepaskan cylinder.

7-32

CYLINDER

LIFTER STOPPER

CYLINDER HEAD/VALVES/CYLINDER/PISTON Lepaskan gasket dan dowel pins. INSTALLATION Clean the cylinder mating surface. PEMASANGAN Install dowel pins and a new gasket. cylinder. Bersihkan permukaan penyatuan

GASKET

Pasang dowel pins dan sebuah gasket baru.

DOWEL PINS Ikatlah seutasofkawat permukaan dalam Attach a piece wire Semprotkan Apply engineolioilmesin to thepada cylinder inner surface andcylinder piston pada cam chain untuk to the cam chain to dan piston rings. rings. mencegahnya agarfalling tidak prevent it from jatuh ke dalam Route the cam chain through the cylinder and install the cylinto the crankcase. Alurkan cam chain melalui cylinder dan pasang cylinder crankcase. inder over the piston while compressing the piston ring with

PISTON RINGS

CAM CHAIN

dari sementara menekan piston ring dengan youratas piston finger. ari-jari. Install the cylinder head (page 7-16). Pasang cylinder head (hal. 7-16).

CYLINDER

PEMERIKSAAN INSPECTION Lepaskan cylinder 7-32). Remove the cylinder(hal. (page 7-32). Periksa cylinder Inspect thediameter cylinder bore for wearterhadap or d amage.keausan atau kerusakan. Measure the cylinder I.D. in the X and Y axis at three levels. Ukur D.D. cylinder padato poros X dan Y pada tiga Take the maximum reading determine the cylinder wear. tingkat. SERVICE Ambil pembacaan maksimum untuk menentukan LIMIT: 50.10 mm (1.972 in) keausan cylinder. Calculate the taper and out-of-round at three levels in the X BATAS SERVIS: 50,10 mm reading to determine both and Y axis. Take the maximum measurements. Hitung ketirusan dan kelonjongan pada tiga tingkat pada poros X dan Y. Ambil pembacaan maksimum untuk SERVICE LIMIT: menentukan kedua pengukuran. Taper: 0.05 mm (0.002 in) Out ofSERVIS: round: 0.05 mm (0.002 in) BATAS Ketirusan: 0,05 mm The cylinder must be rebored and an oversize piston/piston Kelonjongan: 0,05 mm rings fitted if the service limits are exceeded. Cylinder harusoversize dikorterpistons/piston dan oversize piston/piston rings The following rings are available: dipasang jika batas servis dilampaui. 0.25 mm (0.0098 in) Oversize pistons/piston rings berikut tersedia: 0.50 mm (0.0197 in) 0,25 mm(0.0295 in) 0.75 mm 0,50 mm(0.0394 in) 1.00 mm 0,75 mm The piston 1,00 mmto cylinder clearance for the oversize piston must be: 0.015 – 0.045 mm (0.0006 – 0.0018 in). Jarak renggang antara piston-ke-cylinder untuk oversize Check the cylinder for warpage with a straight edge and piston harus sebesar: 0,015 – 0,045mm. feeler gauge in the directions as shown. Periksa cylinder terhadap perubahan melengkung dengan mistar lurus dan feeler gauge dalam arah-arah SERVICE seperti diperlihatkan. LIMIT: 0.05 mm (0.002 in) BATAS SERVIS: 0,05 mm

7-33

CYLINDER HEAD/VALVES/CYLINDER/PISTON STUD BOLT REPLACEMENT PENGGANTIAN STUD BOLT Remove the cylinder(hal. (page 7-32). Lepaskan cylinder 7-32). Threaddua two nuts the stud and tighten them together, and Putar nutsonto (mur) pada stud dan kencangkan use wrench on them to turn the stud bolt out. mereka satu sama lain, dan pakailah kunci pas pada

mereka untuk memutar boltthe keluar. Install new stud bolts A,stud B into crankcase and tighten them. Pasang stud bolts A, B baru ke dalam crankcase dan After crankcase stud bolts installation, check that the length kencangkan. from the bolt head to the crankcase surface is within specification. pemasangan crankcase stud bolts, periksa Setelah bahwa panjang dari kepala bolt sampai ke permukaan SPECIFIED LENGTH 177.5 – 178.5 mm (6.99 – 7.03 in) crankcase adalah sesuai dengan spesifikasi. Install the cylinder (page 7-33). PANJANG YANG DITENTUKAN: 177,5 – 178,5 mm

STUD BOLTS A 177.5 – 178.5 mm (6.99 – 7.03 in)

Pasang cylinder (hal. 7-33).

STUD BOLTS B 177.5 – 178.5 mm (6.99 – 7.03 in)

PISTON PELEPASAN REMOVAL Remove the cylinder(hal. (page 7-32). Lepaskan cylinder 7-32). Hati-hati agar piston pin Be careful to let clips tidaknot jatuh ke the piston pin clips dalam lubang dari fall into the opening crankcase. of the crankcase.

PISTON

Lepaskan piston pin clips dengan tang. Remove the piston pin clips with the pliers. Dorong piston pin keluar dari piston dan connecting rod, Push the piston pin out of the piston and connecting rod, then kemudian lepaskan piston. remove the piston.

PISTON PIN

PISTON PIN CLIP angan piston Do merusak not damage the Renggangkan Spread each piston ring and remove it byring lifting upkeluarkan at a point piston masing-masing dan ring dengan piston ring by dengan opposite mengangkatnya the gap. ke atas pada sebuah titik di merenggangkan ujung spreading the ends seberang celah. ujungnya terlalu jauh. too far.

PISTON RING

7-34

CYLINDER HEAD/VALVES/CYLINDER/PISTON ring endapan alur-alurwith dengan Clean carbon deposits karbon from the dari ring grooves a ring that Never sekali-kali use a wire Bersihkan Jangan memakai ia sebuah brush, sikat it willkawat, damage will be discarded. ring yang tidak dipakai lagi. akan merusak alur. the groove.

PEMASANGAN

Hati-hati agar tidak merusak piston dan rings. Be careful not to damage the piston and rings.

Semprotkan oli mesin pada masing-masing ring dan alur ring. INSTALLATION Pasang piston rings dengan hati-hati ke dalam alur-alur Apply ring engine oil to each ring and ring groove. ke atas. piston dengan tanda-tanda menghadap Jangan mempertukarkan ringthe paling dengan •Carefully install the piston rings into pistonatas ring grooves kedua. facing up. withring the markings • Untuk memasang oil ring, pasang spacer dulu, • Do not confuse the top and second rings. kemudian pasang side rails. ? To install the oilcelah ring, install the spacer first,ring thensejarak install Selang-selingkan pada ujung piston side rails. 120the derajat dari masing-masing. Selang-selingkan celah pada120 ujung side railfrom seperti Stagger the piston ring end gaps degrees apart each diperlihatkan. other. Stagger the side rail end gaps as shown. TANDA

RING TERATAS

TANDA

120°

RING KEDUA

120°

120°

RING TERATAS

RING KEDUA

RING OLI

SIDE RAIL

SPACER

20 mm atau lebih 20 mm atau lebih

7-35

CYLINDER HEAD/VALVES/CYLINDER/PISTON Apply engine oil connecting small end hole. kecil Semprotkan olito the mesin pada rod lubang kepala connecting rod.

CONNECTING ROD

Pasang piston tanda "IN" menghadap Install the piston dengan with the "IN" mark facing the intake ke side.sisi pemasukan. Apply engine oil to the piston pin and install it.

TANDA"IN"

PISTON PIN

Semprotkan oli mesin pada piston pin dan pasang.

Hati-hati agar piston pin Be careful not to let clips tidak jatuh ke the piston pin clips dalam lubang dari fall into the opening crankcase. of the crankcase.

Pasang piston pinpin clips baru. Install new piston clips. Pastikan pin clips telahsecurely. duduk dengan Make sure bahwa piston the piston pin clips are seated erat. ? Do not align the piston pin clip end gap with the piston Jangan mentepatkan celah pada ujung piston pin • cut-out. clip dengan potongan pada piston. Install the cylinder (page 7-33). • ?

Pasang cylinder (hal.7-33).

CLIP

PEMERIKSAAN INSPECTION Lepaskan piston 7-34). Remove the piston(hal. (page 7-34). Periksa piston terhadap dengan Inspect the piston rings rings for movementpergerakan by rotating the rings. memutar harus dapat dalam alurThe rings rings. shouldRings be able to move inbergerak their grooves without alur mereka tanpa menyangkut. catching. Dorong daripiston piston Push thering ring sampai until the permukaan outer surfaceluar of the ringring is hampir rata dengan piston dan ukur jarak renggang nearly flush with the piston and measure the ring-to-groove ring -ke-alur. clearance. BATAS SERVIS: SERVICE LIMIT: Atas/Kedua: 0,08 mm Top/Second: 0.08 mm (0.003 in)

7-36

CYLINDER HEAD/VALVES/CYLINDER/PISTON Insert eachmasing-masing piston piston ring into the bottom of the cylinder Masukkan ring secara tegaklurus squarely usingbagian the piston.bawah dari cylinder dengan ke dalam Measure the ring end gap. menggunakan piston. Ukur celah pada ujung ring. SERVICE LIMIT: Top/Second 0.45 mm (0.018 in) BATAS SERVIS: Atas/Kedua: 0,45 mm

Periksa permukaan piston terhadap Check the piston outer luar surface for scratches or goresan damage. atau kerusakan. Measure the piston pin hole. Take the maximum reading to determine I.D. Ukur lubang piston pin. Ambil pembacaan maksimum untuk menentukan D.D. SERVICE LIMIT: 13.04 mm (0.513 in) BATAS SERVIS: 13,04 mm Measure the piston pin O.D. at piston and connecting rod Ukur piston pin pada piston dan daerah luncur slidingD.L. areas. connecting rod. SERVICE LIMIT: SERVIS: 12.96 BATAS 12,96mm mm(0.510 in) Calculate the renggang piston-kepiston-to-piston pin clearance. Hitung jarak piston pin.

BATAS SERVIS: 0,02 mm SERVICE LIMIT: 0.02 mm (0.001 in) Ukur D.L.the piston 6,0mm mm(0.24 dariin) bagian Measure pistonpada O.D. titik at thesejauh point 6.0 from the bottom dan and 90 thelubang piston piston pin hole.pin. bawahnya 90°° to dari SERVICE BATAS SERVIS: 49,95 mm LIMIT: 49.95 mm (1.967 in) Hitung jarak renggang cylinder -kepiston (D.D. cylinder: Calculate the cylinder-to-piston clearance (cylinder I.D.: See Lihat hal. 7-33). page 7-33). BATAS SERVIS: 0,09 mm SERVICE LIMIT: 0.09 mm (0.004 in)

Measure thekepala connecting small endrod. I.D. Ukur D.D. kecil rod connecting

BATAS SERVIS: 13,05 mm SERVICE LIMIT: 13.05connecting mm (0.514 in) Hitung jarak renggang rod -kepiston pin. CalculateSERVIS: the connecting pin clearance. BATAS 0,05rod-to-piston mm SERVICE LIMIT:

0.05 mm (0.002 in)

7-37

CATATAN


7-39

8. KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH

LOKASI KOMPONEN-KOMPONEN......8-2

DRIVE BELT ..........................................8-11

KETERANGAN SERVIS ........................8-3

DRIVE PULLEY......................................8-11

SERVICE INFORMATION ·····························8-3

DRIVE PULLEY···································· ·········· 8-12

COMPONENT LOCATION ····························8-2

DRIVE BELT ···················································8-12

TROUBLESHOOTING ...........................8-4

CLUTCH/DRIVEN PULLEY ................... 8-15

TROUBLESHOOTING ····································8-4

CLUTCH/DRIVEN PULLEY ························ 8-16

8

LEFT CRANKCASE COVER .................8-5 LEFT CRANKCASE COVER ························· 8-5

8-1

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH

COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN KICKSTARTER/DRIVE PULLEY/DRIVENPULLEY/CLUTCH

108 N·m (11.0 kgf ·m, 80 lbf ·ft)

49 N·m (5.0 kgf ·m, 36 lbf ·ft)

8-2


SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM • ? ? ?

• • • •

This section covers maintenance of the kickstarter, drive pulley, driven pulley and clutch. Babservices ini meliputi perawatan kickstarter, drive pulley, driven pulley dan clutch. These can be done with dari the engine installed in the frame. Avoid getting servis grease ini anddapat oil on dilakukan the drive belt and drive/driven pulley faces order to prevent belt slippage. Pekerjaan dengan mesin terpasang padainrangka. DoJagalah not apply grease to thedan weight rollers. agar gemuk oli tidak mengenai drive belt dan drive/driven pulley faces supaya belt tidak slip. Jangan mengoleskan gemuk pada weight rollers.

SPECIFICATIONS SPESIFIKASI BAGIAN Lebar drive belt Movable drive face Drive belt width Movable drive face Clutch Clutch pulley Driven Driven pulley

ITEM D.D. bushing D.L. boss I.D. D.L. Bushing weight roller Boss O.D. Tebal lining D.D.Weight clutch roller outer O.D. Lining thickness Panjang bebas face spring Clutch outer D.L. driven face I.D. springdriven free length D.D.Face movable face Driven face O.D. Movable driven face I.D.

Satuan: mm STANDARD BATAS SERVIS 18,5 17,5 STANDARD 22,035 – 22,085 22,11 18.5 (0.73) 22,010 – 22,025 21,98 22.035 – 22.085 (0.8675 15,3 – 0.8695) 15,92 – 16,08 22.010 – 22.025 (0.8665 – 0.8671) 2,0 15.92– –112,2 16.08 (0.627 – 0.633) 112,0 112,5 – 121,4 124,2 112.0 – 112.2 (4.41 – 4.42) 33,965 33,985 33,94 124.2 – (4.89) 34,000 34,025 34,06 33.965 – 33.985 (1.3372 – 1.3380) 34.000 – 34.025 (1.3386 – 1.3396)

Unit: mm (in) SERVICE LIMIT 17.5 (0.69) 22.11 (0.871) 21.98 (0.865) 15.3 (0.60) 2.0 (0.08) 112.5 (4.43) 121.4 (4.78) 33.94 (1.336) 34.06 (1.341)

NILAI TORSI Left crankcase cover plate screw TORQUE VALUES Drive pulley face nut Left crankcase cover plate screw Clutch/driven pulley Drive pulley face nutnut Clutch outer nut Clutch/driven pulley nut Clutch outer nut

3 N.m (0,3 kgf.m; 2,2 lbf.t) 108 N.m (11,0 kgf.m; 80 lbf.ft) Oleskan oli mesin pada ulir dan 3 N·m (0.3 kgf·m, 2.2 lbf·ft)permukaan duduk 54 N.m (5,5108 kgf.m; lbf.ft) N·m40 (11.0 kgf·m, 80 lbf·ft) Apply engine oil to the threads and seating surface 49 N.m (5,0 kgf.m; 36 lbf.ft) 54 N·m (5.5 kgf·m, 40 lbt·ft) 49 N·m (5.0 kgf·m, 36 lbt·ft)

TOOLS TOOLS Clutch center holder 07724-0050002

Socket wrench, 39 x 41 mm 07GMA-KS40100

Clutch spring compressor 07LME-GZ40201

Driver 07749-0010000

Pilot, 28 mm 07746-0041100

Pilot, 20 mm 07746-0040500

8-3

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Flywheel holder 07725-0040001

Bearing remover, 20 mm 07931-MA70000

Attachment, 28 x 30 mm 07946-1870100

TROUBLESHOOTING TROUBLESHOOTING Mesin tapiscooter skuterwon’t tidakmove mau bergerak Enginehidup starts but Drivedrive belt belt aus ? Worn Ramp plate ? Damaged ramprusak plate ? Worn or shoe damaged shoe Clutch ausclutch atau rusak ? Broken face spring Drivendriven face spring patah • • • •

Engine stalls or scooter creeps Mesin maticlutch tiba-tiba atau skuter merangkak • Broken shoe spring Clutch shoe spring patah Poor performance at high speed or lack of power ? Wornkerja drive belt Unjuk buruk pada kecepatan tinggi atau ? Weak driven face spring kekurangan tenaga ? Worn weight rollers Drive belt aus ? Contaminated pulley faces Driven face spring lemah Weight rollers aus Pulley faces terkontaminasi •

• • • •

8-4

Fork seal driver attachment, 35.2 mm 07947-KA20200


LEFT CRANKCASE CRANKCASE COVER COVER LEFT PELEPASAN REMOVAL Remove the left crankcasecover cover duct duct (page 2-12) Lepaskan left crankcase (hal. 2-12) Remove the following: Lepaskan sebagai berikut:

CARBURETOR DRAIN HOSE CLAMP

BOLTS

Cover bolts - ?Cover bolts ? Carburetor drainhose hose clamp clamp - Carburetor drain ? Rear brake cable clamp - Rear brake cable clamp Vent holecover cover - ?Vent hole Remove the crankcase cover. cover. Lepaskan leftleft crankcase

REAR BRAKE CABLE CLAMP

Lepaskan dowel cover from gasket dari left Remove thekedua two dowel pins,pins, cover gasket the left crankcrankcase. case.

VENT HOLE COVER

GASKET

Clean the gasket mating surface. Bersihkan permukaan penyatuan gasket.

PEMASANGAN Bersihkan oli dan gemuk dari bearing bushing pada left crankcase cover. Pasang kedua dowel pins. Pasang cover gasket baru. DOWEL PINS

INSTALLATION Pasang crankcase cover pada bushing left crankcase Clean anyleft oil and grease from the bearing on the left crankcase cover. dengan mentepatkan dowel pins dengan lubang-lubang. Pasang carburetor drain hose clamp, rear brake cable Install the two dowel clamp, vent hole cover dan kencangkan left crankcase left crankcase cover onto the left crankcase aligning the cover bolts dalam pola bersilangan dalamby dua atau tiga dowel pins with the holes. langkah.

CARBURETOR DRAIN HOSE CLAMP

BOLTS

Install the carburetor drain hose clamp, rear brake cable Pasang left crankcase duct (hal. 2-12) clamp, vent hole cover cover and tighten the left crankcase cover bolts in a crisscross pattern in two or three steps. Install the left crankcase cover duct (page 2-12) REAR BRAKE CABLE CLAMP

VENT HOLE COVER

PEMBONGKARAN DISASSEMBLY Naikkan leftleft crankcase Raise thelock locktabs tabs dari of the crankcasecover cover plate plate dan and lepaskan screws. remove the screws.

LOCK TABS/SCREWS

8-5

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Lepaskan gear while sementara Remove thekickstarter kickstarter driven driven gear turning memutar the kickkickstarter spindle. starter spindle.

KICKSTARTER DRIVEN GEAR

Remove the thrust washer. Lepaskan thrust washer.

THRUST WASHER

Sebelum melepaskan kickstarter pedal, tandai pedal Before removing the kickstarter pedal, mark the pedal and dan spindle untuk posisi pemasangan yang benar. spindle for proper installation position.

KICKSTARTER PEDAL

TANDA

Remove the boltdan andkickstarter the kickstarter pedal. Lepaskan bolt pedal.

BOLT Remove the dustseal seal dari fromleft thecrankcase left crankcase cover. Lepaskan dust cover.

Lepaskan snap spindle. Remove the snapring ringdan andwasher washer dari fromkickstarter the kickstarter spindle.

DUST SEAL

WASHER

SNAP RING

8-6

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Unhook thekaitan returnreturn springspring from dari the pin the crankcase crankcase Lepaskan pin on pada cover. cover.

KICKSTARTER SPINDLE

RETURN SPRING

Remove the kickstarter spindle and return spring. Lepaskan kickstarter spindle dan return spring.

PIN Remove thespindle spindlebushing bushing and Lepaskan dancollar. collar. BUSHING

ASSEMBLY

COLLAR

PERAKITAN COLLAR

KICKSTARTER SPINDLE *1

BUSHING

3 N·m (0.3 kgf ·m, 2.2 lbf ·ft)

RETURN SPRING DRIVEN GEAR *2

COVER PLATE

FRICTION SPRING THRUST WASHER

LEFT CRANKCASE COVER

SNAP RING WASHER DUST SEAL

KICKSTARTER PEDAL

BOLT

*1: Oleskan 0.1 – 0.3 g *2: Oleskan 0.2 – 0.3 g

8-7

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Install thebushing bushing and intoke thedalam left crankcase cover. Pasang dancollar collar left crankcase cover.

BUSHING

COLLAR

Oleskan – g0,3 molybdenum disulfide Apply 0.10,1 – 0.3 of g molybdenum disulfide pastepaste to the pada kickkickstarter spindle. starter spindle.

Kaitkan pendek dari spring pada groove. alur spindle. Hook theujung short end of the spring to the spindle Install the spindle and return the crankcase while Pasang spindle dan spring return into spring ke dalamcover crankcase settingsementara the return meletakkan spring along return the guide on the crankcase cover spring di sepanjang cover.pada crankcase cover. guide

RETURN SPRING

Kaitkan

Hold the kickstarter spindle in position. Tahan kickstarter spindle pada posisinya.

KICKSTARTER SPINDLE

UJUNG PENDEK

Tetap Keep tahanholding kickstarter the Pasang Install thewasher washer pada onto the kickstarterspindle spindle dan and set the snap kickstarter tempatkan spindlekickstarter sampai snap ring ring to the kickstarter spindle groove. spindle snap ring pada alur kickstarter spindle. telah dipasang untuk until the snap ring is mencegah terlepasnya installed in order to spring dari guide. prevent the spring from coming off from the guide.

WASHER

8-8

SNAP RING

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Hook the longpanjang end of the spring to pada the pin the Kaitkan ujung darireturn return spring pinonpada crankcase cover. crankcase cover.

UJUNG PANJANG

PIN

Apply grease to apada new dust lip.seal baru. Oleskan gemuk bibirseal dust Install the dustseal sealsampai until it ia is flush with the left left crankcase crankcase Pasang dust rata dengan cover. cover. DUST SEAL

Sewaktu memasang kickstarter posisinya semula seperti When installing the Pasang Install the kickstarterpedal pedal pada in its original position as marked kickstarter pedal pada kickstarter pedal to telah duringditandai removal pada and tighten thepelepasan bolt. waktu dan kencangkan posisi standard, lihat the standard position, bolt. hal. 1-14. see page 1-14.

KICKSTARTER PEDAL

TANDA

BOLT

Pasang thrust crankcase Install the thrustwasher washer pada onto the crankcasecover. cover.

THRUST WASHER

8-9

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Apply 0.20,2 – – 0.30,3 g g of molybdenum molybdenum disulfide the Oleskan disulfide paste pastetopada driven gear gear shaft. driven shaft. Apply molybdenum disulfide paste to paste the friction spring slidOleskan molybdenum disulfide pada daerah ing area. luncur friction spring.

DRIVEN GEAR WELD BEAD

Depress the kickstarter pedal and hold it. Tekan kickstarter pedal dan tahan. Install the driven gear while aligning the friction spring hook with the groove the crankcase cover, and return thekaitan kickPasang driven ingear sementara mentepatkan starter spindle engagealur the pada drivencrankcase gear teeth and spindle friction spring to dengan cover, dan gear teeth before the weld spindle bead point. kembalikan kickstarter untuk menghubungkan gigi driven gear dan gigi spindle gear sebelum weld bead point (titik manik pengelasan).

Tepatkan FRICTION SPRING

Pasang crankcasecover cover dan kencangkan Install theleft left crankcase plateplate and tighten the screws to screws dengan torsi yang ditentukan. the specified torque. TORQUE:3 N·m (0.3kgf.m; kgf·m,2,2 2.2 lbf.ft) lbf·ft) TORSI: 3 N.m (0,3

Bend the lock tabs of the cover plate against the screw heads. Tekuk lock tabs dari cover plate terhadap kepala screw.

LOCK TABS/SCREWS

INSPECTION PEMERIKSAAN Inspect the following: Periksa sebagai berikut: Spindleterhadap for wear keausan or damageatau kerusakan -? Spindle ? Gear teeth for wear or damage - Gigi gear terhadap keausan atau kerusakan ? Return spring for weakness or damage - Return spring terhadap kelemahan atau kerusakan ? Bushing for wear or damage - Bushing terhadap keausan atau kerusakan

RETURN SPRING

COLLAR

SPINDLE

BUSHING Driven gearterhadap for wear or damageatau kerusakan -? Driven gear keausan ? Friction spring for weakness or damage - Friction spring terhadap kelemahan atau kerusakan ? Starter ratchet teeth for wear or damageatau kerusakan - Gigi starter ratchet terhadap keausan

FRICTION SPRING

DRIVEN GEAR

8-10

STARTER RATCHET TEETH

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH -? Journals crankcase terhadap Journals dari of the crankcase cover cover for wear orkeausan damage atau kerusakan.

JOURNALS

DRIVE DRIVEBELT BELT PENGGANTIAN REPLACEMENT CATATAN: Drive belt dapat ? The drive belt can bediservis serviceddengan with the mesin engine terpasang installed in pada rangka. the frame. •

Remove the drivepulley pulleyface face (hal. (page8-11). 8-11). Lepaskan drive Remove the drivebelt beltdan andganti replace it with yang a newbaru. one. Lepaskan drive dengan Install the drive pulley face (page 8-12). Pasang drive pulley face (hal. 8-12).

BELT

DRIVE PULLEY DRIVE PULLEY

PELEPASAN REMOVAL CATATAN: Drive pulley dapat diservis dengan mesin terpasang ? The drive pulley can be serviced with the engine installed pada rangka. in the frame. •

Lepaskan left crankcase (hal. 8-5). Remove the left crankcase cover cover (page 8-5). Tahan drive face pulley special tool dan Hold themuka drive pulley withdengan special tool and loosen the longgarkan pulley face nut. drive pulley drive face nut. TOOL: TOOL: Clutch center center holder Clutch holder

Remove the following: Lepaskan sebagai berikut: ? Nut -? Nut Washer -? Washer Starter ratchet plate -? Starter Drive ratchet face fin plate - Drive face fin

NUT/WASHER/ RATCHET PLATE

DRIVE PULLEY FACE

07724-0050002 07724-0050002

DRIVE FACE FIN

CLUTCH CENTER HOLDER

8-11

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Geser lepas drivebelt belt dari pulley boss boss Slide off the drive from thedrive drive pulley by dengan squeezmemencet drive ing the drive belt.belt.

BOSS

BELT

Lepaskan driveface face assembly Remove themovable movable drive assembly while sementara holding the menahan belakang daridrive face (ramp back of thebagian face (ramp plate) and face boss. plate) dan drive face boss.

MOVABLE DRIVE FACE ASSEMBLY

BOSS

PEMASANGAN INSTALLATION Hati-hati agar movable drive face not assembly Be careful to get tidak terbongkar dan the movable drive pastikan untuk face assembly memasang assembly disassembled and be sampai duduk dengan sure to install the penuh. assembly until fully seated.

Clean any oli oil dan and gemuk grease from the drive thebelt. drive Bersihkan dari drive faceface danand drive belt. Pasang movable drive face assembly pada crankshaft Install the movable drive face assembly onto the crankshaft sementara menahan ramp plate. while holding the ramp plate.

Compress the driven face spring by squeezing the drive drive belt belt Tekan driven face spring dengan memencet until there is enough to installuntuk the drive belt to the drive sampai ada cukup slack kekenduran memasang drive pulley boss. belt pada drive pulley boss.

8-12

MOVABLE DRIVE FACE ASSEMBLY

DRIVE BELT

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH belt drive boss pulley dengan Be careful to Tempatkan Set the drive drive belt onto thepada drive pulley by boss squeezing it to Hati-hati agarnot tidak untuk mendapatkan kerenggangan damage the spline. memencetnya obtain the clearance between the belt and shaft. merusak

DRIVE PULLEY FACE

antara dan shaft. Install belt the drive pulley face while aligning its splines with crankshaftdrive splines.pulley face sementara mentepatkan Pasang splines-nya dengan crankshaft splines.

Tepatkan

Pastikan sepenuhnya Make surebahwa that thedrive drivepulley pulley face face isduduk fully seated on the pada drive pulley boss. drive pulley boss.

Duduk sepenuhnya (Drive pulley face and Install the drive facefin findan andratchet ratchet plate. Pasang drive face plate.

RATCHET PLATE

DRIVE FACE FIN

Apply engine oil to the d riveulir pulley face nut threads Oleskan oli mesin pada drive pulley face and nut seatdan ing surface then install it with the washer. permukaan duduk kemudian pasang dengan washer. Hold the drive pulley face with the special tool and tighten Tahan pulley torque. face dengan special tool dan the nut todrive the specified kencangkan nut dengan torsi yang ditentukan. TOOL: Clutch center holder 07724-0050002 TOOL: Clutch center holder 07724-0050002 TORQUE:108 N·m (11.0 kgf·m, 80 lbf·ft) TORSI: 108 N.m (11,0 kgf.m; 80 lbf.ft) Install the left crankcase cover (page 8-5). Pasang left crankcase cover (hal. 8-5).

CLUTCH CENTER HOLDER

NUT WASHER

PEMERIKSAAN INSPECTION DRIVE DRIVEPULLEY PULLEYFACE FACE Check thedrive drivepulley pulley face scratches,goresan, scoring or gerusan damage. Periksa faceforterhadap atau kerusakan.

DRIVE PULLEY FACE

8-13

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH DISASSEMBLY/ASSEMBLY PEMBONGKARAN/PERAKITAN Remove the following: Lepaskan sebagai berikut: ? Drive face boss - Driven face boss ? Ramp plate - Ramp plate ? Slide pieces -? Slide pieces Weight rollers - Weight rollers Clean any oil and Assembly is in the reverse order of disassembly. adalah dalam urutan terbalik ersihkanfrom weight grease the Perakitan rollers dan movable weight rollers and pembongkaran.

dari

drive face dari oli movable drive face. dan gemuk.

MOVABLE DRIVE FACE

DRIVE FACE BOSS

Sisi left crankcase cover

RAMP PLATE WEIGHT ROLLERS SLIDE PIECES

PEMERIKSAAN INSPECTION WEIGHT WEIGHTROLLER ROLLER Periksa masing-masing rollerwear. terhadap keausan tidak Check each roller for abnormal Measure the weight roller O.D. normal. Ukur D.L. weight roller. SERVICE LIMIT:SERVIS: 15,3 15.3 mm BATAS mm(0.60 in)

MOVABLE FACE BOSS MOVABLEDRIVE DRIVE FACE BOSS Periksa face terhadap keausan atau Check thedrive drive face bossboss for wear or damage. Measure the drive face boss O.D. kerusakan. Ukur D.L. drive face boss. SERVICE BATAS mm(0.865 in) LIMIT:SERVIS: 21,98 21.98 mm

8-14

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MOVABLEDRIVE DRIVE FACE MOVABLE FACE

Check the movabledrive driveface face for scratches, scoringgerusan or damPeriksa terhadap goresan, movable age. atau kerusakan. Measure drive facebushing. bushing I.D. Ukur D.D.the drive face

MOVABLE DRIVE FACE

BATAS SERVIS: 22,11 mm SERVICE LIMIT: 22.11 mm (0.871 in)

CLUTCH/DRIVEN CLUTCH/DRIVENPULLEY PULLEY PELEPASAN REMOVAL CATATAN: Clutch/driven pulley dapat diservis dengan mesin ? The clutch/driven pulley can be serviced with the engine installed in the frame. terpasang pada rangka. •

Remove the left crankcase cover cover (page 8-5). Lepaskan left crankcase (hal. 8-5). Hold the clutchouter outerdengan with the special special tool the Pakailah special tool Tahan clutch tool and danremove lepaskan nut. ketika Use the melonggarkan special tool nut.

lock nut. when loosening the Menahan roda belakang lock nut. atau rem belakang Holding theakan rear merusak sistem final wheel or rear brake reduction. will damage the final reduction system.

CLUTCH OUTER

NUT/WASHER

TOOL: TOOL: Flywheel holder 07725-0040001 Flywheel holder 07725-0040001 Remove the washer and clutch outer. Lepaskan washer dan clutch outer.

FLYWHEEL HOLDER angan gemuk clutch/driven dan compress tekan drive Do notoleskan get grease on Tahan Hold the clutch/drivenpulley pulleyassembly assembly and the pada dengan memutar movable driven face the drive drive shaft shaft splines splines face drive spring face spring by turning movable driven face clockwise dari sebelah dalam jarum jam sampai ia berhenti. from the driven face searah until it stops. driven face. inside.

CLUTCH/DRIVEN PULLEY ASSEMBLY

8-15

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Untuk menghindari lukaTo avoid injury to luka pada jari-jari, your finger, do not jangan lepaskan release the driven driven pulley sementara pulley while removing melepaskan drive belt. the drive belt. If ika dilepaskan drive released drive face ace spring akan spring will extend memanjang dengan tiba suddenly and tiba dan movable driven movable driven face ace akan berputar, will turn, resulting in sehingga menimbulkan luka-luka pada jari-jari. injury to your finger.

Remove the clutch/drivenpulley pulleyassembly assembly dari from drive the drive Lepaskan clutch/driven belt belt by holding the movable movable driven dengan menahan drivenface. face.

BELT

Remove the drive belt from the clutch/driven pulley assemLepaskan drive beltthe dari clutch/driven pulley assembly bly while removing clutch/driven pulley assembly from sementara melepaskan clutch/driven pulley assembly the drive shaft. dari drive shaft.


PEMASANGAN INSTALLATION Bersihkan oli and dangrease gemuk darithe driven Clean any oil from drivenface facedan and drive drive belt. belt. Tahan clutch/driven dan compress tekan drive Hold the clutch/drivenpulley pulleyassembly assembly and the face dengan memutar movable driven face drive spring face spring by turning movable driven face clockwise searah jarum jam sampai ia berhenti. until it stops.


MOVABLE DRIVEN FACE

Untuk menghindari lukabelt pulley sementara To avoid injury to Tempatkan Set the drive drive belt onto the pada pulley alur groove while holding the luka pada jari-jari, your finger, do not menahan movable driven face.driven face. movable jangan lepaskan driven release the driven pulley sementara pulley while installing memasang drive belt. the drive belt. If ika dilepaskan drive released drive face ace spring akan springdengan will extend memanjang tiba suddenly and tiba dan movable driven movable driven face ace akan berputar, will turn,menimbulkan resulting in sehingga luka-luka pada jari-jari. injury to your finger.

BELT

MOVABLE DRIVEN FACE Jangan oleskan gemuk Pasang clutch/driven pulley assembly pada driveshaft. Do not get grease on Install the clutch/driven pulley assembly onto the driveshaft. pada drive shaft splines the drive shaft splines dari sebelah dalam from the driven driven face. face inside.

8-16


KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Clean any oil from clutch outer. Bersihkan oli and dangrease gemuk darithe clutch outer. Install theclutch clutchouter outer while aligning its splines with drivePasang sementara mentepatkan splinesshaftdengan splines.driveshaft splines. nya

Tepatkan

CLUTCH OUTER Install the washerdan and clutch clutch outer outer nut. Pasang washer nut.

FLYWHEEL HOLDER

Hold the clutch outer with the special tool andkencangkan tighten the Tahan clutch outer dengan special tool dan clutch outer outer nut the specified torque. clutch nutto dengan torsi yang ditentukan. TOOL: TOOL: Flywheel holder Flywheel holder

07725-0040001 07725-0040001

TORQUE:49 N·m (5.0kgf.m; kgf·m,36 36 lbf.ft) lbf·ft) TORSI: 49 N.m (5,0

Pasang left crankcase (hal. 8-5). Install the left crankcasecover cover (page 8-5).

NUT/WASHER

PEMBONGKARAN DISASSEMBLY CLUTCH/DRIVEN PULLEY CLUTCH/DRIVEN PULLEY Set the clutch spring compressor onto the clutch/driven pulTempatkan clutch spring compressor pada clutch/driven ley by aligning bosses of the compressor withcompressor the holes of pulley denganthe mentepatkan bosses dari the clutch. dengan lubang-lubang dari clutch. TOOL: TOOL: Clutch spring spring compressor Clutch compressor

CLUTCH SPRING COMPRESSOR CLUTCH/DRIVEN PULLEY

07LME-GZ40201 07LME-GZ40201

Untuk mencegah To prevent loss of Tahan Hold theclutch/driven clutch/driven pulley pulley by turning memutar the clutch spring dengan clutch hilangnya tegangan, compressor clockwise. tension, do not spring compressor searah jarum jam. jangan tekan driven face compress the driven spring lebih daripada face spring more than yang diperlukan untuk necessary to remove melepaskan the clutch/ driven clutch/driven pulley nut. pulley nut.

CLUTCH/DRIVEN PULLEY

8-17

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Hold the clutch springcompressor compressor in a vise. Tahan clutch spring pada sebuah catok. Remove the clutch/driven pulley nut using the specialdengan tool. Lepaskan clutch/driven pulley nut menggunakan special tool. TOOL: Socket wrench, 39 x 41 mm 07GMA-KS40100 TOOL: Socket wrench, 39 x 41 mm 07GMA-KS40100

SOCKET WRENCH

Longgarkan clutchspring springcompressor compressor secaraand berangsur Loosen the clutch gradually remove dan lepaskan sebagai berikut: the following: - Clutch assembly Clutch assembly -? Spring seat ? Spring seat - Driven face spring ? Driven face spring - Driven pulley assembly ? Driven pulley assembly

CLUTCH/DRIVEN PULLEY NUT

CLUTCH ASSEMBLY SPRING SEAT

DRIVEN PULLEY ASSEMBLY

DRIVEN FACE

CLUTCH CLUTCH

Remove the three E-clips E-clips and Lepaskan ketiga danwashers. washers. Remove the clutchshoes shoes dari fromdrive the drive plate. Lepaskan clutch plate. Remove the clutchshoe shoesprings. springs. Lepaskan clutch

E-CLIPS/WASHERS

Remove the damperrubbers rubbers from the drive plate. Lepaskan damper dari drive plate.

SPRINGS

DAMPER RUBBERS

8-18

DRIVE PLATE

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH DRIVEN DRIVENPULLEY PULLEY Remove the sealcollar. collar. Lepaskan seal

SEAL COLLAR

Remove the guidepins pinsdan and guide driven face. Lepaskan guide guiderollers rollersfrom darithe driven face. Remove the movabledriven drivenface face from the driven face. Lepaskan movable dari driven face.

O-RINGS

Remove theO-rings O-rings dan and oil movable driven driven Lepaskan oil seals sealsfrom darithemovable face. face. OIL SEALS

MOVABLE DRIVEN FACE GUIDE PINS DRIVEN FACE GUIDE ROLLERS

ASSEMBLY PERAKITAN GUIDE PINS GUIDE ROLLERS OIL SEALS O-RINGS SEAL COLLAR DRIVEN FACE

DRIVEN FACE SPRING

MOVABLE DRIVEN FACE SPRING SEAT WASHERS

E-CLIPS CLUTCH SHOES SPRINGS CLUTCH DRIVEN PULLEY NUT 54 N·m (5.5 kgf ·m, 40 lbf ·ft)

DAMPER RUBBERS DRIVE PLATE

DRIVEN PULLEY

Apply engine oil to new oil seal lips and install them into the DRIVEN PULLEY movable driven face. Oleskan oli mesin pada bibir oil seal baru dan pasang Coat new movable O-rings with engine ke dalam driven face.oil and install them into the movable driven face grooves. Lapisi O-rings baru dengan oli mesin dan pasang ke dalam alur-alur movable driven face.

O-RINGS OIL SEALS

8-19

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Bersihkan oli and dangrease gemuk dari pulley face. Clean any oil from the pulley face.

PINS/ROLLERS

Install the movabledriven drivenface face pada onto the driven face. Pasang movable driven face. Install the guiderollers rollersdan and guide guide pins. Pasang guide pins. Apply 2.0 – 2.5 g of grease (Shell ALVANIA R3 or Oleskan 2,0 – 2,5 g gemuk (Shell ALVANIA R3 atau IDEMITSU AUTOREX B or equivalent) to each guide IDEMITSU AUTOREX B atau sejenisnya) pada masinggroove. masing alur guide.

MOVABLE DRIVEN FACE

Pasang seal Install the sealcollar collarpada to thedriven drivenpulley. pulley. SEAL COLLAR

CLUTCH CLUTCH Pasang damper drive plate. Install the damperrubbers rubbers pada onto the drive plate.

DRIVE PLATE

DAMPER RUBBERS

Pasang springsinto kethe dalam Install theshoe shoe springs clutch clutch shoes asshoes shown.seperti diperlihatkan. Install the clutch shoes into the drive plate by aligning the shoe grooves and damper rubbers. Pasang clutch shoes ke dalam drive plate dengan mentepatkan alur-alur shoe dan damper rubbers.

CLUTCH SHOES

DRIVE PLATE

8-20

SPRINGS

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Install the washersdan and E-clips. E-clips. Pasang washers WASHERS/E-CLIPS

CLUTCH/DRIVEN PULLEY CLUTCH/DRIVEN PULLEY Rakit sebagai berikut: Assemble the following:

CLUTCH ASSEMBLY

-? Driven pulley Driven pulleyassembly assembly -? Driven face Driven facespring spring -? Spring Springseat seat -? Clutch Clutchassembly assembly

SPRING SEAT

DRIVEN PULLEY ASSEMBLY

To prevent loss of Untuk mencegah tension, do not hilangnya tegangan, compress the jangan tekan driven face driven face spring spring lebih daripada more untuk than yang diperlukan to merakitnecessary clutch/driven pulley nut. Jangan assemble the merusak clutch/driven ulir pulley nut. pulley nut. Do not damage the pulley nut threads.

Tempatkan clutch compressor spring over compressor di atas Set the clutch spring the clutch/driven pulclutch/driven pulley the assembly mentepatkan ley assembly aligning bosses of dengan the compressor with the bosses dariclutch. compressor dengan lubang-lubang dari holes of the clutch. TOOL: TOOL: Clutch spring compressor 07LME-GZ40201 Compress the driven face spring while 07LME-GZ40201 aligning the cutout of Clutch spring compressor the pulley nut threads with the drive plate hole and install the clutch/driven pulley nut.spring sementara mentepatkan Tekan driven face potongan dari ulir pulley nut dengan lubang drive plate dan pasang clutch/driven pulley nut.

Tepatkan (BOSSES/ HOLES

CLUTCH SPRING COMPRESSOR

Hold the spring compressor pada in a vice. Tahan spring compressor sebuah catok. Tighten the clutch/driven pulley nut using the socket wrench Kencangkan clutch/driven pulley nut dengan memakai to the specified torque. socket wrench dengan torsi yang ditentukan. TOOL: TOOL: Socket wrench, 39 x 41 mm Socket wrench, 39 x 41 mm

DRIVEN FACE

Tepatkan (CUTOUT/ PLATE HOLES

CLUTCH SPRING COMPRESSOR

07GMA-KS40100 07GMA-KS40100

TORQUE:54 N·m (5.5kgf.m; kgf·m,40 40 lbf.ft) lbf·ft) TORSI: 54 N.m (5,5

Lepaskan daritheclutch/driven Remove thespring spring compressor compressor from clutch/driven pulley pulley assembly. assembly.

SOCKET WRENCH

8-21

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH INSPECTION PEMERIKSAAN CLUTCH OUTER CLUTCH OUTER Check the clutch outer for wear or damage. Periksa clutch outer terhadap keausan atau kerusakan. Measure clutchouter. outer I.D. Ukur D.D.the clutch


DRIVEN DRIVENFACE FACESPRING SPRING Ukur panjang bebas driven face Measure the driven face spring freespring. length. BATAS SERVIS: 121,4 mm SERVICE LIMIT: 121.4 mm (4.78 in)

DRIVEN FACE DRIVEN FACE Check the driven face for scratches, scoring or damage. Periksa face Measure driven the driven faceterhadap boss O.D. goresan, gerusan atau kerusakan. Ukur D.L. driven face boss. SERVICE LIMIT: SERVIS: 33.94 BATAS 33,94mm mm(1.336 in)

8-22

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MOVABLE FACE MOVABLEDRIVEN DRIVEN FACE Check the movabledriven drivenface face terhadap for scratches, scoringgerusan or damPeriksa movable goresan, age. atau kerusakan. Check the guide grooves stepped wear or damage. Periksa alur-alur guideforterhadap keausan bertingkat Measure the movable driven face I.D. atau kerusakan. Ukur D.D. movable driven face. SERVICE LIMIT:SERVIS: 34,06 34.06 mm BATAS mm(1.341 in)

PEMERIKSAAN FACE BEARING DRIVEN FACEDRIVEN BEARING INSPECTION Juga bahwa bearingouter outerrace race Also periksa check that the bearing fitsduduk tightlydengan in the driven face. erat pada driven face. Install the driven face to the driveshaft. Pasang driven face pada driveshaft. Turn the driven face with your hand. The bearing should turn Putar driven face dengan tangan. Bearing harus smoothly and quietly. berputar dengan halus dando tanpa suara. Replace the bearings if they not turn smoothly, quietly, or Ganti tidak dengan halus, if theybearings jika fit loosely on mereka the driven faceberputar (page 8-23). tanpa suara, atau jika mereka duduk dengan longgar pada driven face (hal. 8-23).

DRIVEN FACE

DRIVEN FACE BEARING PENGGANTIAN DRIVEN FACE BEARING REPLACEMENT Lepaskan faceneedle needle Remove the driven driven face bearingbearing using thedengan special menggunakan special tools. tools. TOOLS: TOOLS: Bearing remover, 20 mm Bearing remover, 20 mm Fork seal driver attachment, Forkmm seal driver attachment, 35.2 35.2 mm

BEARING REMOVER

07931-MA70000 07931-MA70000

ATTACHMENT

07947-KA20200 07947-KA20200

NEEDLE BEARING

Lepaskan snap ball bearing Remove the snapring ringdan anddorong drive the ball bearingkeluar out ofdari the drivenface. face. driven

BEARING

SNAP RING

8-23

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Pack new bearing with greasegemuk (Shell ALVANIA R3 or Isilah ball ball bearing baru dengan (Shell ALVANIA IDEMITSU AUTOREX B or equivalent). R3 atau IDEMITSU AUTOREX B atau sejenisnya). sealed side of SisiThe tertutup dari ball ball bearing is facing bearing menghadap ke driven face. the driven face.

DRIVER

Pasang ball ke dalam driven Install the ballbearing bearing secara into the tegaklurus driven face squarely until it is face sampai ia the telah duduk fully seated, using special tools. sepenuhnya, dengan menggunakan special tools. TOOLS: TOOLS: Driver Pilot, 28 mm Driver Pilot, 28 mm

07749-0010000 07746-0041100 07749-0010000 07746-0041100

PILOT BALL BEARING

Pasang snap kokoh alur face pada driven Install the snapring ring dengan to the groove on pada the driven securely. face. Apply 7.0 – 8.0 g of grease (Shell ALVANIA R3 or IDEMITSU B or equivalent) to the driven face Oleskan 7,0AUTOREX – 8,0 g gemuk (Shell ALVANIA R3 atau inner surface. IDEMITSU AUTOREX B atau sejenisnya) pada permukaan dalam driven face.

SNAP RING Apply grease R3 atau or IDEMITSU Oleskan gemuk(Shell (Shell ALVANIA ALVANIA R3 AUTOREX B or equivalent) to a new needle bearing.bearing AUTOREX B atau sejenisnya) pada needle baru. The sealed side of Press the needle bearing into the driven face squarely as Sisi tertutup needle shown. needle bearing secara tegaklurus ke dalam needledari bearing is Dorong bearing menghadap ke facing the special driven face seperti diperlihatkan. special tools. tools. TOOLS: TOOLS: Driver 07749-0010000 Driver 07749-0010000 Attachment, 28 x 30 mm 07946-1870100 Attachment, 07946-1870100 Pilot, 20 mm 28 x 30 mm 07746-0040500 Pilot, 20 mm 07746-0040500

ATTACHMENT

DRIVER

1.0 mm (0.04 in)

PILOT

NEEDLE BEARING

8-24

9. FINAL REDUCTION

LOKASI KOMPONEN-KOMPONEN......9-2 FINAL REDUCTION CASE .........9-7 COMPONENT LOCATION ····························9-2PERAKITAN FINAL REDUCTION CASE ASSEMBLY ·····9-7 KETERANGAN SERVIS ........................9-3 FINAL REDUCTION CASE ...9-8 SERVICE INFORMATION ·····························9-3PEMERIKSAAN FINAL REDUCTION INSPECTION··············9-8 9

TROUBLESHOOTING ...........................9-5 PENGGANTIAN FINAL REDUCTION .............. TROUBLESHOOTING ····································9-5 FINAL REDUCTION BEARING BEARING ..........................................................9-10 REPLACEMENT·································· ··········· 9-10 PEMBELAHAN FINAL

FINAL REDUCTION CASE

REDUCTION CASE ...............................9-6 9-6 SEPARATION ···················································

9-1

FINAL REDUCTION

COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN FINALREDUCTION

9-2

FINAL REDUCTION

SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM

• The final reduction can be serviced with the engine installed in the frame. •• When installing the dapat driveshaft, be sure to usemesin the special tools; position the special tools on the bearing inner race Final reduction diservis dengan terpasang pada rangka. pull the driveshaft into the bearing until it is fullymemakai seated. Ketika memasang driveshaft, pastikan untuk special tools; tempatkan special tools pada bearing inner race dan • and tarik driveshaft ke dalam bearing sampai ia telah duduk sepenuhnya.

SPECIFICATIONS SPESIFIKASI ITEM Final reduction oil capacity BAGIAN After draining Kapasitas oli final Pada After penggantian periodik disassembly reduction Setelah pembongkaran Recommended final reduction oil Oli final reduction yang dianjurkan

NILAI TORSI Final reduction oil check bolt Final reduction oil drain bolt TORQUE VALUE Final reduction oil check bolt Final reduction oil drain bolt

Unit: mm (in) STANDARD SPESIFIKASI 0.10 liter (0.11 US qt, 0.09 lmp qt) 0,10(0.13 liter US qt, 0.11 lmp qt) 0.12 liter 0,12 liter Honda "4-stroke motorcycle oil" or equivalent motor oil Federalclassification: Oil SupremeSG Flick klasifikasi Service API service or dengan higher (except oilsAPI labeled as SG., Viskositas: SAE 10W-30 JASO MB energy conserving on the circular API service label) JASO T 903 standard: MB Viscosity: SAE 10W-30

13 N.m (1,3 kgf.m; 10 lbf.ft) 13 N.m (1,3 kgf.m; 10 lbf.ft) 13 N·m (1.3 kgf·m, 10 lbf·ft) 13 N·m (1.3 kgf·m, 10 lbf·ft)

TOOLS TOOLS Case puller 07SMC-0010001

Remover weight 07741-0010201

Bearing remover shaft, 10 mm 07936-GE00100

Bearing remover head, 10 mm 07936-GE00200

Bearing remover shaft, 12 mm 07936-1660120

Bearing remover head, 12 mm 07936-1660110

9-3

FINAL REDUCTION Bearing remover shaft, 15 mm 07936-KC10100

Attachment, 32 x 35 mm 07746-0010100

Attachment, 42 x 47 mm 07746-0010300

Pilot, 15 mm 07746-0040300

9-4

Bearing remover head, 15 mm 07936-KC10200

Attachment, 37 x 40 mm 07746-0010200

Driver 07749-0010000

Attachment, 40 x 42 mm 07746-0010900

Pilot, 10 mm 07746-0040100

Pilot, 12 mm 07746-0040200

Pilot, 20 mm 07746-0040500

Pilot, 22 mm 07746-0041000

FINAL REDUCTION Assembly collar 07965-GM00100

Assembly shaft 07965-1660200

Assembly collar attachment 07965-GM00200

TROUBLESHOOTING TROUBLESHOOTING Mesin bisa hidup tetapi skuter tidak mau bergerak Engine does start but scooter won’t move Final reduction rusak • • Damaged final reduction Final reduction macet • • Seized final reduction Drivedrive pulley dan driven pulley/clutch rusak • • Faulty pulley and driven pulley/clutch Abnormal noise Suara tidak normal • Worn, seized or chipped gears Gears aus, macet atau sumbing • • Worn or damaged final reduction bearing Final reduction bearing aus atau rusak • Oil leak • Oil level too Kebocoran oli high • Worn or damaged oil oli sealterlalu tinggi Tinggi permukaan • • Cracked crankcase and/or Oil seal aus atau rusak final reduction case • •

Crankcase dan/atau final reduction case retak

9-5

FINAL REDUCTION

FINAL REDUCTION PEMBELAHAN FINALCASE REDUCTION CASE SEPARATION PELEPASAN REMOVAL Final reduction dapat dengan mesin • The final reduction candiservis be serviced with the ter engine pasang pada rangka. installed in the frame.

•

BREATHER HOSE

Drain the final reduction oil (page 3-13). Keluarkan oli final reduction (hal. 3-13). Remove thesebagai following: Lepaskan berikut: – Clutch/drivenpulley pulley (hal. (page8-15) 8-16) - Clutch/driven – Rear wheel (page 12-4) - Roda belakang (hal. 12-4) – Rear brake shoes (page 13-5) - Rear brake shoes (hal. 13-5) Disconnect the final reduction case breather hose from the Lepaskan final reduction case breather hose dari final final reduction case hose joint. reduction case hose joint.

Remove thebolts boltsdan and final reduction reductioncase. case. Lepaskan


BOLTS

Lepaskan gasket. Remove thedowel dowelpins pins dan and gasket.

DOWEL PINS

GASKET

9-6

FINAL REDUCTION Remove the following: Lepaskan sebagai berikut: COUNTER GEAR

Countergear gear - –Counter Final gearshaft shaft - –Final gear Countershaft - –Countershaft

COUNTERSHAFT

FINAL GEAR SHAFT

FINAL REDUCTION CASE ASSEMBLY FINAL REDUCTION CASE ASSEMBLY Apply engineolioilmesin to each gearmasing-masing tooth and each bearing sliding Semprotkan pada gigi gear areamasing-masing of shaft. dan daerah luncur bearing dari shaft.

COUNTERSHAFT

Install the final gear shaft. Pasang final gear shaft. Install the countershaft into the counter gear while aligning Pasang countershaft ke with dalam the countershaft splines thecounter counter gear gear sementara splines and mentepatkan splines install them tocountershaft the final reduction case.dengan counter gear splines dan pasang mereka pada final reduction case.

SPLINES

FINAL GEAR SHAFT

COUNTER GEAR

9-7

FINAL REDUCTION Install the dowel pinsdan andgasket a new gasket. Pasang dowel pins baru.

DOWEL PINS

GASKET

Pasang final reduction kencangkan bolts. Install the final reductioncase case dan and tighten the bolts.


BOLTS

Sambungkan breather hose finalreduction reductioncase case Connect the breather hose to pada the final hose hose joint.joint.

BREATHER HOSE

Install the following: Pasang sebagai berikut: – Rear brake shoes (page 13-5) - –Rear rem belakang) (hal. 13-5) Rearbrake wheelshoes (page (sepatu 12-4) - –Roda belakang (hal. 12-4) Clutch/driven pulley (page 8-17) - Clutch/driven pulley (hal. 8-16) Fill the final reduction case with the recommended oil (page Isi final reduction case dengan oli yang dianjurkan (hal. 3-13). 3-13).

PEMERIKSAAN FINAL REDUCTION BEARING

FINAL REDUCTION INSPECTION LEFT CRANKCASE

BEARING

Periksa masing-masing bearing terhadap keausan atau LEFT CRANKCASE kerusakan. Putar race dari countershaft dan final gear shaft Checkinner each bearing for wear or damage. bearings (lingkaran dalam dari bantalan countershaft Turnfinal the inner of the countershaft and Bearing final gearharus shaft dan gearrace shaft) dengan jari-jari. bearings with your finger. The bearing should turn smoothly berputar dengan halus dan tanpa suara. Juga periksa and quietly. Also check that the bearing outer race fits tightly bahwa bearing outer race duduk dengan erat pada in the crankcase. crankcase. Replace the bearings if they do not turn smoothly, quietly, or Ganti bearings jika mereka tidak berputar dengan halus, if they fit loosely on the crankcase. tanpa suara, atau jika mereka duduk dengan longgar Turn crankcase. the driveshaft with your hand. The bearing should turn pada smoothly and quietly. Also check that the bearing outer race fits tightly in thedengan crankcase and the bearingharus inner berputar race fits Putar driveshaft tangan. Bearing tightly on the driveshaft. dengan halus dan tanpa suara. Juga periksa bahwa Replace the bearings do not turn smoothly, quietly, or bearing outer raceif they duduk dengan erat di dalam if they fit loosely on the crankcase and driveshaft. crankcase dan bearing inner race duduk dengan erat pada driveshaft. Ganti bearings jika mereka tidak berputar dengan halus, tanpa suara, atau jika mereka duduk dengan longgar pada crankcase dan driveshaft.

9-8

FINAL GEAR SHAFT BEARING

COUNTERSHAFT BEARING

DRIVESHAFT BEARING

FINAL REDUCTION FINAL CASE FINALREDUCTION REDUCTION CASE Check the finalreduction reduction case case bearings anddan finalfinal gear gear shaft Periksa final bearings oil seal for wear or damage. shaft oil seal terhadap keausan atau kerusakan.


Turn each bearing inner race with your finger. Putar masing-masing inner racefriction. dengan jari-jari. The bearing should turnbearing smoothly without Bearing harus berputar dengan halus tanpa gesekan. Check that there is no clearance between the outer race and Periksa the final bahwa reductiontidak case. ada kerenggangan antara outer race dan final reduction case.


FINAL GEAR SHAFT OIL SEAL

LEFT LEFTCRANKCASE CRANKCASECOVER COVER Lepaskan leftleft crankcase Remove the crankcasecover cover (hal. (page8-5). 8-5).

DRIVESHAFT BEARING

Putar inner race driveshaft bearing jari-jari. Turn the inner racedari of the driveshaft bearingdengan with your finger. Bearing harus berputar dan tanpa The bearing should turn dengan smoothlyhalus and quietly. Alsosuara. check Juga periksa bahwa bearing outerinrace duduk dengan that the bearing outer race fits tightly the crankcase cover. Replace bearing if cover. it does not turn smoothly, quietly, or if erat padathe crankcase it fits loosely on the crankcase cover. dengan halus, tanpa Ganti bearing jika ia tidak berputar suara, atau jika ia duduk dengan longgar pada crankcase cover.

GEAR/SHAFT GEAR/SHAFT DRIVESHAFT DRIVESHAFT Check thedriveshaft driveshaft for bend, wear or damage. Periksa terhadap tekukan, keausan atau kerusakan.

DRIVESHAFT

9-9

FINAL REDUCTION COUNTER GEAR/COUNTERSHAFT/FINALGEAR GEAR COUNTER GEAR/COUNTERSHAFT/FINAL SHAFT SHAFT Check the countershaft, counter gear and final gear shaft for Periksa countershaft, counter gear dan final gear shaft wear or damage. terhadap keausan atau kerusakan.

FINAL GEAR SHAFT

COUNTER GEAR

COUNTERSHAFT

FINAL REDUCTION BEARING PENGGANTIAN REPLACEMENTFINAL REDUCTION BEARING DRIVESHAFT BEARING 10 x 32

DRIVESHAFT

DRIVESHAFT BEARING (6204)

LEFT CRANKCASE COUNTERSHAFT BEARING (6201)

FINAL GEAR SHAFT BEARING (6022 UU) LEFT CRANKCASE COVER

OIL SEAL 20 x 32 x 6

COUNTERSHAFT BEARING (6301)

FINAL GEAR SHAFT BEARING (6302)

9-10

OIL SEAL 29 x 44 x 7


FINAL REDUCTION LEFTCRANKCASE CRANKCASE COVER LEFT COVER Remove the left crankcasecover cover (page 8-5). Lepaskan left crankcase (hal. 8-5). Remove the snap ring from the left crankcase cover groove. Lepaskan snap ring dari alur left crankcase cover.

SNAP RING

Lepaskan driveshaftbearing/bushing bearing/bushing Remove the driveshaft using the dengan special menggunakan special tools. tools. TOOLS: Bearing 07936-GE00200 TOOLS:remover head, 10 mm Bearing remover shaft, 10 mm 07936-GE00100 Bearing remover head, 10 mm 07936-GE00200 Remover weight 07741-0010201 Bearing remover shaft, 10 mm 07936-GE00100 Remover weight - Jika bearing tertinggal pada left07741-0010201 crankcase cover, lepaskan denganremains menggunakan sebagai berikut: – If the bearing in the lefttools crankcase cover, remove TOOLS: it using the following tools: Bearing remover head, 15 mm 07936-KC10200 TOOLS:remover shaft, 15 mm Bearing 07936-KC10100 Bearing remover 07936-KC10200 Remover weighthead, 15 mm 07741-0010201 Bearing remover shaft, 15 mm 07936-KC10100 Remover weight 07741-0010201

DRIVESHAFT BEARING/BUSHING Jika bearing tertinggal di dalam left crankcase cover:

DRIVESHAFT BEARING

Apply engineoli oilmesin to the bearing cavity.bearing. Semprotkan pada rongga Drive a new driveshaft into the left crankcase cover Dorong masuk sebuahbearing driveshaft bearing baru secara squarely until is fully seated, using the special tegaklurus keit dalam left crankcase cover tools. sampai ia telah duduk sepenuhnya, dengan menggunakan special tools. TOOLS: Driver 07749-0010000 TOOLS: Attachment, 32 x 35 mm 07746-0010100 Driver 07749-0010000 Pilot, 10 mm 07746-0040100 Attachment, 32 x 35 mm 07746-0010100 Pilot, 10 mm 07746-0040100

DRIVER

ATTACHMENT

DRIVESHAFT BEARING

PILOT

9-11

FINAL REDUCTION Install the snapring ringpada to thealur left left crankcase covercover. groove. Install the snap ring ring Pasang Pasang snap crankcase dengan yang with theujung chamfered dipotong menghadap edge facing the ke bearing. bearing.

SNAP RING

LEFT LEFTCRANKCASE CRANKCASE Separate thereduction final reduction Belah final case case (hal.(page 9-6). 9-6).

SET PLATE

Remove the two bolts setset plate. Lepaskan kedua boltsand dan plate.

BOLTS Hati-hati agar not tidak danfinal finalgear gear bearings Be careful to Lepaskan Remove thecountershaft countershaft and shaftshaft bearings using merusak permukaan menggunakan special tools. damage the final dengan the special tools. penyatuan final reduction case mating reduction case. TOOLS: surface. TOOLS:

Countershaft bearing: Countershaft bearing: Bearing remover 1212 mm Bearing removerhead, head, mm Bearing removershaft, shaft, mm Bearing remover 1212 mm Remover weight Remover weight Final bearing: Finalgear gear shaft shaft bearing: Bearing remover head, mm Bearing remover head, 1515 mm Bearing remover shaft, 15 mm Bearing remover shaft, 15 mm Remover weight Remover weight

07936-1660110 07936-1660110 07936-1660120 07936-1660120 07741-0010201 07741-0010201

07936-KC10200 07936-KC10200 07936-KC10100 07936-KC10100 07741-0010201 07741-0010201 FINAL GEAR SHAFT BEARING

9-12


FINAL REDUCTION

Sisi yang dariof The bertanda marked side masing-masing bearing each bearing is facing menghadap ke special the special tools. tools.

Apply engine oil topada each bearing cavity. rongga bearing. Oleskan oli mesin masing-masing Drive each new bearing into the left crankcase baru until Dorong masuk masing-masing secara bearing squarely it is fully seated, using the special tools. tegaklurus ke dalam left crankcase sampai ia duduk sepenuhnya, dengan menggunakan special tools. TOOLS: Countershaft bearing: TOOLS: Driver 07749-0010000 Countershaft bearing: Attachment, 37 x 40 mm 07746-0010200 Driver 07749-0010000 Pilot, 12 mm 07746-0040200 Attachment, 37 x 40 mm 07746-0010200 Final gear shaft bearing: Pilot, 12 mm 07746-0040200 Driver 07749-0010000 Final gear shaft bearing: Attachment, 42 x 47 mm 07746-0010300 Driver 07749-0010000 Pilot, 15 mm 42 x 47 mm 07746-0040300 Attachment, 07746-0010300

Pilot, 15 mm



07746-0040300

DRIVER

ATTACHMENT

PILOT

BEARING Clean and apply locking agent the set plate bolt ulir threads Bersihkan dan oleskan cairanto pengunci pada set from bolt its tip to 6.5 (0.26 ± 0.04 in) mm down. ± 1.0 mm plate dari ujungnya sampai 6,5 ke bawah. ± 1,0

SET PLATE TANDA"OUT"

Install the set plate with its "OUT" mark facing out. Pasang set plate dengan tanda "OUT" padanya Install and tighten the set plate bolts. menghadap ke luar.

Pasang dan kencangkan set plate bolts. 6.5 ± 0.1 mm (0.26 ± 0.04 in)

BOLTS

DRIVESHAFT DRIVESHAFT Remove the two bolts and set plate.

SET PLATE

Lepaskan kedua bolts dan set plate.

BOLTS

9-13

FINAL REDUCTION Remove the driveshaftdengan using the special tool. special tool. Lepaskan driveshaft menggunakan

TOOL: TOOL: Case puller Case puller

DRIVESHAFT

07SMC-0010001 07SMC-0010001

CASE PULLER

CASE PULLER

DRIVESHAFT Remove the snapring ringdari from thedriveshaft. driveshaft groove. Lepaskan snap alur

Remove thedriveshaft driveshaft bearing using a hydraulic press. Lepaskan bearing dengan menggunakan hydraulic press.

SNAP RING

BEARING

DRIVESHAFT

9-14

FINAL REDUCTION Lepaskan driveshaft Remove the driveshaftoiloilseal. seal.

DRIVESHAFT OIL SEAL

Apply engineolioilmesin to the pada bearing cavity.bearing. Sisi yang bertanda dari Semprotkan rongga Drive a new driveshaft bearing into the left crankcase masing-masing bearing squarely until it is fully seated,driveshaft using the special tools.secara The marked side of Dorong masuk sebuah bearing menghadap ke special each bearing is tools. facing tegaklurus ke dalam left crankcase sampai ia duduk TOOLS: the special tools. sepenuhnya, dengan menggunakan special tools. Driver Attachment, 42 x 47 mm TOOLS: Pilot, 20 mm Driver

07749-0010000 07746-0010300 07746-0040500 07749-0010000

Attachment, 42 x 47 mm Pilot, 20 mm

07746-0010300 07746-0040500

DRIVESHAFT BEARING

DRIVER

ATTACHMENT

DRIVESHAFT BEARING Install the driveshaftkeinto the bearing. Pasang dalam driveshaft bearing. Position the assembly collar on pada the driveshaft bearing inner Tempatkan assembly collar driveshaft bearing race and pull the drive shaft into the bearing until it is fully inner race dan tarik keluar drive shaft ke dalam bearing seated. sampai ia duduk sepenuhnya. TOOLS: TOOLS: Assembly shaft Assembly shaft Assembly collar Assembly collar Assembly collarattachment attachment Assembly collar

PILOT

ASSEMBLY COLLAR

DRIVESHAFT BEARING

ASSEMBLY SHAFT

07965-1660200 07965-1660200 07965-GM00100 07965-GM00100 07965-GM00200 07965-GM00200

ASSEMBLY COLLAR ATTACHMENT

DRIVESHAFT BEARING

ASSEMBLY COLLAR

ASSEMBLY COLLAR ATTACHMENT

ASSEMBLY SHAFT

9-15

FINAL REDUCTION Pasang Install thesnap snapring ring Pasang Install the snapring ringpada to thealur driveshaft groove. snap driveshaft. dengan ujungnya yang with the chamfered dipotong edge menghadap ke facing the bearing. bearing.

SNAP RING

Semprotkan pada bibir driveshaft Apply engineoli oilmesin to a new driveshaft oil seal lip.oil seal baru. Jangan Do notmasukkan insert theoil oil seal terlalu dalam seal too far .

DRIVESHAFT OIL SEAL

Pasang driveshaft rata with dengan left Install the driveshaftoiloilseal seal sampai until it isia flush the left crankcase. crankcase. TOOLS: TOOLS: Assembly shaft Assembly shaft Assembly collar Assembly collar Assembly collar attachment Assembly collar attachment

ASSEMBLY COLLAR

07965-1660200 07965-1660200 07965-GM00100 07965-GM00100 07965-GM00200 07965-GM00200

ASSEMBLY SHAFT

ASSEMBLY COLLAR ATTACHMENT ASSEMBLY COLLAR ATTACHMENT ASSEMBLY COLLAR

DRIVESHAFT OIL SEAL

Bersihkan dan locking oleskanagent cairan pengunci pada ulir set Clean and apply to the set plate bolt threads from tip to 6.5 sampai (0.26 ± 1.0 mm ± 0.04 plate bolt dariitsujungnya 6,5 mm in) ke down. bawah. ± 1,0

ASSEMBLY SHAFT

SET PLATE TANDA"OUT"

Install the set plate with its "OUT" mark facing out. Pasang set plate dengan tanda "OUT" menghadap Install and tighten the set plate bolts. keluar.

Pasang dan kencangkan set plate bolts. 6.5 ± 0.1 mm (0.26 ± 0.04 in)

BOLTS

9-16

FINAL REDUCTION FINAL REDUCTION CASE FINAL REDUCTION CASE Separate the final reduction case (page 9-6). Belah final reduction case (hal. 9-6). Be careful not to Remove the final gear shaft oil seal. Hati-hati agar tidak Lepaskan final gear shaft oil seal.



damage the final merusak permukaan Remove the final gear shaft bearing. reduction case mating penyatuan final Lepaskan final gear shaft bearing. surface. reduction cace Remove the countershaft bearing using the special tools.

Lepaskan countershaft bearing dengan menggunakan special tools. TOOLS: TOOLS: Bearing remover remover head, mm 07936-1660110 Bearing head,1212 mm 07936Bearing remover shaft, 12 mm 07936-1660120 1660110 Removerremover weight shaft, 12 mm 07741-0010201 Bearing 079361660120 Remover weight 077410010201

Apply engine oil the countershaft Semprotkan oli to mesin pada bearing ronggacavity. countershaft bearing. The marked side of Drive a new final gear shaft bearing into the final reduction Sisi yang di tandai dari Dorong masuk final gear shaft bearing baru secara bearing is facing the case squarely until it is fully seated, using the special tools. masing – masing tegaklurus ke dalam final reduction case sampai duduk tools. bantalan special menghadapi sepenuhnya, dengan menggunakan special tools. special tools. TOOLS: Driver 07749-0010000 TOOLS: Attachment, 32 x 35 mm 07746-0010100 Driver 077490010000 Pilot, 12 mm 07746-0040200 Attachment, 32 x 35 mm 077460010100 Pilot, 12 mm 077460040200

OIL SEAL

DRIVER

ATTACHMENT

PILOT


Semprotkan oli tomesin final cavity. gear shaft Apply engine oil the finalke gearrongga shaft bearing bearing. The marked of Drive a new final gear shaft bearing into the final reduction Hati-hati agarside tidak Dorong masuk final gear shaft bearing secara case squarely until it is fully seated, using the special tools. bearing is facing the merusak permukaan tegaklurus ke dalam final reduction case sampai ia special tools. penyatuan final duduk sepenuhnya, dengan menggunakan special reduction cace TOOLS: tools. Driver TOOLS: Attachment, 40 x 42 mm Driver Pilot, 22 mm

0010000 Attachment, 40 x 42 mm 0010900 Pilot, 22 mm 0041000

07749-0010000 07746-0010900 0774907746-0041000

ATTACHMENT

0774607746-

Apply engineoli oilmesin to a new finalbibir g earfinal shaftgear oil seal lip. oil sea Semprotkan pada shaft baru. Install the oil seal with the flat side facing the rear wheel side so that the depth from the final reduction case surface is 1.0 ± Pasang seal dengan sisinya yang datar menghadap 0.4 mm oil (0.04 ± 0.02 in) using the special tools. ke sisi roda belakang sehingga kedalamannya dari permukaan final reduction case adalah 1,0 ± 0,4 mm TOOLS: dengan menggunakan special tools. Driver 07749-0010000 Attachment, 42 x 47 mm 07746-0010300 TOOLS:

Driver 0010000 Attachment, 42 x 47 mm 0010300

DRIVER


PILOT

DRIVER

ATTACHMENT

0774907746-

1.0 ± 0.4 mm (0.04 ± 0.02 in) FINAL GEAR SHAFT OIL SEAL

9-17

CATATAN

10. CRANKCASE/CRANKSHAFT

LOKASI KOMPONEN ............................10-2

PEMBELAHAN CRANKCASE...............10-5

KETERANGAN SERVIS ........................10-3

PERAKITAN CRANKCASE ...................10-8

TROUBLESHOOTING ...........................10-4

PEMERIKSAAN CRANKSHAFT ........... 10-12

COMPONENT LOCATION ·························· 10-2

SERVICE INFORMATION ···························10-3

TROUBLESHOOTING ··································10-4

CRANKCASE SEPARATION ·······················10-5

CRANKCASE ASSEMBLY ···························10-8

CRANKSHAFT INSPECTION····················10-12

10

10-1

CRANKCASE/CRANKSHAFT

COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN CRANKCASE/CRANKSHAFT

10-2



• This section covers the crankcase separation to service the crankshaft. ?• The following parts pembelahan must be removed before separating the crankcase. Bab ini meliputi crankcase untuk menservis crankshaft. (page 6-4) Parts berikut ini harus dilepaskan sebelum membelah crankcase. • ? Engine ? Cylinder - Mesin head (hal. (page 6-4) 7-14) ? Cylinder (page 7-32) - Cylinder head (hal. 7-14) ? Piston (page 7-34) - Cylinder (hal. 7-32) ? Starter pinion - Piston (hal.(page 7-34)16-10) ? Drive pulley (page 8-12) - Starter pinion (hal. 16-10) ? Clutch/driven pulley - Drive pulley (hal. (page 8-11) 8-16) ? Starter motor (page 16-6)(hal. 8-15) - Clutch/driven pulley ? Flywheel/stator (page 14-7) - Starter motor (hal. 16-6) ? In addition to the parts listed above, remove the following parts when the left crankcase must be replaced. - Flywheel/stator (hal. 14-8) ? Final reduction (page 9-6) Selain parts yang disebut di a tas, lepaskan parts berikut ini jika left crankcase harus diganti. • ? In addition to the parts listed above, remove the following parts when the right crankcase must be replaced. Final reduction (hal. 9-6) ? Oil pump (page 4-4) disebut di a tas, lepaskan parts berikut ini jika right crankcasethe harus diganti. ?• BeSelain parts careful not toyang damage the crankcase mating surfaces when separating and assembling crankcase halves. Oil pump (hal. 4-4) ? Clean all disassembled parts with clean solvent and dry them using compressed air before inspection. Hati-hati agarthe tidak merusak penyatuan crankcase sewaktu merakit ?• When installing crankshaft, be permukaan sure to use the special tools; position the specialmembelah tools on thedan bearing innerbelahan race and crankcase. pull the crankshaft into semua parts yang dibongkar dengan cairan pelarut bersih dan keringkan dengan udara dari kompressor • theBersihkan bearing until it is fully seated. sebelum pemeriksaan. Sewaktu memasang crankshaft, pastikan untuk memakai special tools; tempatkan special tools pada bearing inner race • SPECIFICATIONS dan tarik crankshaft ke dalam bearing sampai ia duduk sepenuhnya.

SPESIFIKASI Crankshaft Crankshaft

Satuan: mm ITEM STANDARD BAGIAN STANDARD BATAS SERVIS Jarak renggang 0,10 – 0,35 Connecting rod ke sidesamping clearanceconnecting rod 0.10 – 0.35 (0.004 – 0.014) 0,55 Jarak renggang connecting rod – 0,012 0,05 Connecting rod radial radial clearance 0 –00.012 (0 – 0.0005) Keolengan 0,10 Runout –

Unit: mm (in) SERVICE LIMIT 0.55 (0.022) 0.05 (0.002) 0.10 (0.004)

TOOLS TOOLS Case puller 07SMC-0010001

Assembly shaft adaptor 07WMF-KFF0200

Assembly shaft 07965-VM00200

Assembly collar 07965-VM00100

Assembly collar 07931-KF00100

Attachment, 62 x 68 mm 07746-0010500

10-3

CRANKCASE/CRANKSHAFT Pilot, 35 mm 07746-0040800

Driver 07749-0010000

Fork seal driver attachment 41.2 mm 07947-KF00100

Universal bearing puller 07631-0010000

TROUBLESHOOTING TROUBLESHOOTING

Abnormal noise Suara tidak normal ? Worn crankshaft bearing Crankshaft bearing aus • ? Worn connecting rod big end bearing Connecting rod big end bearing (bantalan kepala • ? Worn connecting rod small end (page 7-37) besar connecting rod) Connecting rod small end (kepala kecil connecting • rod) aus (hal. 7-37)

10-4

Oil seal driver 07965-KE80200

Attachment, 24 x 26 mm 07746-0010700


CRANKCASE SEPARATION PEMBELAHAN CRANKCASE Refer keterangan to service information (page 10-3) for parts mana which Lihat servis (hal. 10-3) untukthe parts must be removed before separating the crankcase. yang harus dilepaskan sebelum membelah crankcase. Unhook the centerstand return spring. Lepaskan kaitan dari centerstand return spring (pegas pengembalian standard utama).

RETURN SPRING

Lepaskan cotter Remove the cotterpin pindan and washer. washer.

COTTER PIN

WASHER Remove the bolt andcollar collardari pivot from the pivot shaft. Lepaskan bolt dan shaft. Pull out the pivot shaft remove the centerstand. Tarik keluar pivot shaftand dan lepaskan centerstand.

COLLAR

BOLT

PIVOT SHAFT

Lepaskan crankcase dari right crankcase. Remove the crankcasebolts bolts from the right crankcase.

CENTERSTAND

BOLTS

10-5

CRANKCASE/CRANKSHAFT Place the crankcase the left facing down and Be careful to Letakkan Hati-hati agar not tidak crankcasewith dengan leftcrankcase crankcase menghadap merusak permukaan damage the ke separate leftpisahkan and right left crankcase. bawahthe dan dan right crankcase. penyatuan crankcase. crankcase mating surface.

RIGHT CRANKCASE

LEFT CRANKCASE

Lepaskan dowel left Remove the dowelpins pinsdari from thecrankcase. left crankcase.

DOWEL PINS

Lepaskan oiloil seal right Remove the sealdari from the crankcase. right crankcase.

OIL SEAL Release the cam from dari the timing sprocket on the crankLepaskan camchain chain timing sprocket pada shaft using a screwdriver as shown. crankshaft dengan menggunakan obeng seperti diperlihatkan.

SCREWDRIVER

TIMING SPROCKET

10-6

CAM CHAIN

CRANKCASE/CRANKSHAFT Sewaktu melepaskan When removing the crankshaft, crankshaft, beberhaticareful agar nothatilah to pinch thetidak cam menjepit cam chain chain between timing antara timing sprocket sprocket and left dan left crankcase. crankcase.

Hold the cam cam chain the timing sprocket remove dan the Pegang chainoffterlepas dari timingand sprocket crankshaft from the left crankcase usingcrankcase the case puller. keluarkan crankshaft dari left dengan menggunakan puller. Remove the camcase chain.

Lepaskan cam chain. TOOL: TOOL: Case puller Case puller

LEFT CRANKCASE CRANKSHAFT CASE PULLER

07SMC-0010001 07SMC-0010001

CAM CHAIN (Jangan di jepit)

CASE PULLER

CRANKSHAFT Remove snap ringring anddan oil seal. Lepaskan snap oil seal.

OIL SEAL

SNAP RING

10-7

CRANKCASE/CRANKSHAFT Lepaskan left crankshaft dengan Remove the left crankshaft bearing bearing using the menggunakan special tool. special tool.

CRANKSHAFT

BEARING

TOOL: Universal bearing puller 07631-0010000 TOOL: Universal bearing puller 07631-0010000 ? If the left crankshaft bearing remains in the crankcase, remove it to the right side. - Jika left crankshaft bearing tertinggal pada crankcase, lepaskan ke sisi kanan.

BEARING PULLER Jika left crankshaft bearing tertinggal pada crankcase:

LEFT CRANKSHAFT BEARING

PERAKITAN CRANKCASE CRANKCASE ASSEMBLY Hati-hati agar not tidak Be careful to Bersihkan Clean the inside and mating surface of the crankcases. bagian dalam dan permukaan penyatuan dari merusak permukaan damage the crankcases. Check for cracks or other damage. penyatuan crankcase. crankcase mating Periksa terhadap retak-retak atau kerusakan lain. Remove any roughness or irregularities with an oil stone. surface.

PERMUKAAN PENYATUAN

Buanglah kekasaran atau ketidak-teraturan dengan batu asah.

Apply 2 cc minimum to a pada new left crankcase Semprotkan minimumof2engine cc oli oil mesin sebuah left bearing. bearing baru. crankcase Drive the left crankcase bearing into the left crankcase Dorong crankcase bearing secaratool. tegaklurus squarelymasuk until it left is fully seated, using the special ke dalam left crankcase sampai ia duduk sepenuhnya, dengan menggunakan special tool. TOOLS: Driver 07749-0010000 TOOLS: Attachment, 62 x 68 mm 07746-0010500 Driver 07749-0010000 Pilot, 35 mm 62 x 68 mm 07746-0040800 Attachment, 07746-0010500 Pilot, 35 mm 07746-0040800

DRIVER

ATTACHMENT

PILOT LEFT CRANKCASE BEARING

10-8

CRANKCASE/CRANKSHAFT Install the crankshaftke into the left bearing. Pasang crankshaft dalam leftcrankcase crankcase bearing. Install the assemblyshaft shaftadaptor adaptor to the left Pasang assembly pada left crankshaft. crankshaft. Position the assembly A on left crankcase bearing Tempatkan assemblycollar collar A the pada left crankcase inner race and set the assembly collar B to the assembly colbearing inner race (lingkaran dalam bantalan crankcase lar A. kiri) dan tempatkan assembly collar B pada assembly collar InstallA.the assembly shaft to the assembly collar B and screw it onto the crankshaft while aligning the center of the assemPasang pada assembly collar B dan bly collarassembly B and the shaft assembly shaft. sekrupkan pada crankshaft sementara mentepatkan Pull thetengah crankshaft intoassembly the bearingcollar until itBis dan fully seated. When pulling the bagian dari assembly Sewaktu menarik crankshaft into the shaft. crankshaft bearing, ke be dalam careful TOOLS: bearing, berhati-hatilah not to damage the Tarik crankshaft ke dalam bearing sampai ia duduk Assembly shaft adaptor 07WMF-KFF0200 agar tidak merusak connecting rod . sepenuhnya. connecting rod. Assembly shaft 07965-VM00200 Assembly collar A 07965-VM00100 TOOLS: Assembly collar B 07931-KF00100 Assembly shaft adaptor 07WMF-KFF0200 Assembly shaft 07965-VM00200 Assembly collar A 07965-VM00100 Assembly collar B 07931-KF00100

ASSEMBLY SHAFT ADAPTOR

ASSEMBLY COLLAR B

ASSEMBLY SHAFT

ASSEMBLY COLLAR A ASSEMBLY COLLAR A

CRANKSHAFT

ASSEMBLY SHAFT ADAPTOR

ASSEMBLY COLLAR B

Apply engine oil topada a newbibir o il seal lip. Oleskan oli mesin oil seal. Install the sealsecara to the right crankcase squarely shown. Pasang oiloil seal tegaklurus pada right as crankcase seperti diperlihatkan. TOOLS: TOOLS: Driver 07749-0010000 Driver 07749-0010000 Attachment, 24 x 26 mm 07746-0010700 Attachment, 24 x 26 mm 07746-0010700

ASSEMBLY SHAFT

DRIVER OIL SEAL ATTACHMENT 10.4-10.9 mm (0.41-0.43 in)

OIL SEAL Apply liquid sealant (Three Bond 1207B or three bondBond 1215 Oleskan liquid sealant (cairan perapat) (Three or equivalent) to the crankcase mating surface. 1207B atau Three Bond 1215 atau sejenisnya) pada permukaan penyatuan crankcase.

10-9

CRANKCASE/CRANKSHAFT Apply 2 cc minimum of engine crankshaft Semprotkan minimum 2 cc oilolito right mesin pada bearright ing. crankshaft bearing. Apply 3 cc minimum of engine oil to connecting rod big end. Semprotkan minimum 3 cc oli mesin pada connecting Install dowel pins to the left crankcase. rod big the end.

Pasang dowel pins pada left crankcase.

DOWEL PINS

Rakit left dan crankcase. Assemble the right left and right crankcase.

RIGHT CRANKCASE

LEFT CRANKCASE Install the crankcasebolts bolts dan and tighten them indalam a crisscross Pasang crankcase kencangkan pola pattern in 2 -dalam 3 steps.2 – 3 langkah. bersilangan

timing and sprocket Semprotkan padasprocket dan cam Apply engineoli oil mesin to the timing cam chain. chain. Install the cam chain to the timing sprocket. Pasang cam chain pada timing sprocket.

BOLTS

CAM CHAIN

TIMING SPROCKET

10-10

CRANKCASE/CRANKSHAFT Apply engine oil to apada new bibir o il seal Oleskan oli mesin oil lip. seal baru.

OIL SEAL DRIVER

Install theoiloil sealsecara to the left crankcase squarely until it is Pasang seal tegaklurus pada left crankcase fully seated, using the special tool. dengan menggunakan sampai ia duduk sepenuhnya, special tool. TOOLS: TOOLS: Oil seal driver 07965-KE80200 Oil seal driver 07965-KE80200 Fork seal driver attachment, Fork seal driver attachment, 41.2 mm 07947-KF00100 41.2 mm 07947-KF00100

FORK SEAL DRIVER ATTACHMENT

OIL SEAL Set the snap ring into thepada left crankcase groove. Tempatkan snap ring alur left crankcase.

SNAP RING Apply thin coat of grease centerstand shaft surOleskan lapisan tipisto the gemuk padapivot permukaan face. centerstand pivot shaft (poros engsel standard utama). Install the centerstand and insert the pivot shaft from the left Pasang dan masukkan pivot shaft dari sisi crankcasecenterstand side. left crankcase. Install the collar to the pivot shaft. Pasang collar pada pivot pada pivotagent shaft. shaftto . the pivot shaft mounting Clean and apply locking

COLLAR PIVOT SHAFT

6.5 ± 0.1 mm (0.26 ± 0.04 in)

bolt threadsdan fromoleskan its tip to locking 6.5 ± 1.0 mm (0.26 0.04 in) Bersihkan agent (cat ± pengunci) down, then install and tighten it. pada ulir pivot shaft mounting bolt (baut pemasangan

poros engsel) dari ujungnya sampai 6,5 ± 1,0 mm kebawah, kemudian pasang dan kencangkan. CENTERSTAND

BOLT

Pasang washer pin baru. Install the washerdan and cotter new cotter pin. COTTER PIN

WASHER

10-11

CRANKCASE/CRANKSHAFT Hook thecenterstand centerstand return Kaitkan returnspring. spring (pegas pengembalian standard utama).information (page 10-3) Refer to service 10-3) for installation of parts removed to perform crankcase crankcase service. Bacalah keterangan servis (hal. 10-3) untuk pemasangan dari parts yang telah dilepaskan untuk menjalankan servis crankcase.

RETURN SPRING

PEMERIKSAAN CRANKSHAFT CRANKSHAFT INSPECTION Remove the crankshaft(hal. (page10-5). 10-5). 10-5). Lepaskan crankshaft

RIGHT CRANKCASE BEARING

Turn the outer racedari of theright rightcrankshaft crankshaft bearing your Putar outer race bearingwith dengan finger. The bearing should turn smoothly and quietly. Also ari-jari. Bearing harus berputar dengan halus dan tanpa check that bearingbahwa inner race fits tightly on theduduk right suara. Jugatheperiksa bearing inner race crankshaft. dengan erat pada right crankshaft. Replace the bearings if they do not turn or Ganti bearings apabila mereka tidaksmoothly, berputarquietly, dengan if they fit loosely on the right crankshaft. halus, tanpa suara, atau jika mereka duduk dengan

longgar pada right crankshaft.

Jika gigi timing sprocket aus rusak,sprocket periksa If atau the timing cam chain, tensioner dan teeth are worn or cam sprocket. damaged, check the cam chain, tensioner and cam sprocket.

Check the pump drive drive gear timing teeth for Periksa oiloilpump gearand dan gigi sprocket timing sprocket wear or damage. terhadap keausan atau kerusakan.

OIL PUMP DRIVE GEAR

TIMING SPROCKET

Ukur jarakthe renggang ke rod samping connecting rod big end Measure connecting big end side clearance with a dengan feeler gauge. feeler gauge. BATAS SERVIS: 0,55 mm SERVICE LIMIT: 0.55 mm (0.022 in)

10-12

FEELER GAUGE

CRANKCASE/CRANKSHAFT Set the crankshaft on V-blocks and measure theukur connecting Tempatkan crankshaft pada V-blocks dan jarak rod big end radial clearance. renggang radial connecting rod big end.


Set the crankshaft on V-blocks and measure the runout using a dial indicator. Actual runoutcrankshaft is 1/2 of total indicator reading. dan ukur Tempatkan pada V-blocks

keolengan dengan menggunakan dial indicator. Keolengan SERVICE sebenarnya adalah ½ dari pembacaan total indicator. LIMIT: 0.10 mm (0.004 in) BATAS SERVIS: 0,10 mm

65 mm (2.6 in)

35 mm (1.4 in)

10-13

CATATAN

11. RODA DEPAN/SUSPENSI/KEMUDI

LOKASI KOMPONEN-KOMPONEN......11-2 COMPONENT COMPONE NT LOCATION ················ ······················· ·········· ··· 11-2

FORK ................ ................................. .............................11-11 ............11-11 FORK ················· ········ ·················· ················· ··············· ··············· ················· ·············11-11 ····11-11

KETERANGAN SERVIS .................... ........................ ....11-3 11-3 SERVICE INFORMATION INFORMAT ION ··············· ······················· ············11-3 ····11-3

HANDLEBAR................. HANDLEBAR .................................11-19 ................11-19 HANDLEBAR HANDLEBAR ················ ······· ················ ··············· ················ ················ ·········· 11-19

TROUBLESHOOTING ...........................11-6 ...........11-6 TROUBLESHOOTING TROUBLESHOOTING................ ················ ························· ··················11-6 ·········11-6

STEERING STEM ................ ..........................11-21 ..........11-21 STEERING STEM········ ························· ········ 11-21

RODA DEPAN................................. DEPAN............. ...........................11-7 .......11-7 FRONT WHEEL····················· ························· 11-7

11

11-1

RODA DEPAN/SUSPENSI/KEMUDI

COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN FRONTWHEEL/SUSPENSION/STEERING

1 N· N·m (0.1 kgf ·m, 0.7 lbf ·ft)

4.5 N· N·m (0.5 kgf ·m, 3.3 lbf ·ft)

59 N· N·m (6.0 kgf ·m, 44 lbf ·ft)

64 N· N·m (6.5 kgf ·m, 47 lbf ·ft)

59 N· N·m (6.0 kgf ·m, 44 lbf ·ft)

11-2


SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM ! PERINGATAN Frequentmenghirup inhalation ofdebu brakebrake pad and shoe regardless material composition hazardous to your health. Seringkali pad dandust, shoe, apapunofkomposisi bahannya,could dapatbemembahayakan kesehatan. • Avoid breathing dust particles. Jangan menghirup partikel-partikel debu. • • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. Jangan sekali-kali memakai slang udara atau sikat untuk membersihkan susunan rem. Pakailah alat penghisap debu yang • baik. • This section covers the front wheel, fork, handlebar and steering stem. Bab ini meliputi fork or (garpu), handlebar (stang danusing steering (poros kemudi). • • When servicing theroda frontdepan, wheel, fork steering stem, support the stir) scooter a jackstem or other support. menservis roda depan, fork atau steering stem, dukung skuter dengan menggunakan dongkrakdisc atau alata pendukung •• AKetika contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated with high quality lain. brake degreasing agent. Brake yang terkontaminasi mengurangi pengereman. Buanglah pads yang terkontaminasi dan bersihkan • • After thedisc frontatau pad wheel installation, check the brake operation bydaya applying the brake lever. disc yang terkontaminasi dengan • For brake system service, refer to pagebahan 13-3. pembersih gemuk berkualitas tinggi untuk peralatan rem. Setelah pemasangan roda depan, periksa cara kerja rem dengan menarik brake lever (handel rem). • Untuk servis sistem rem, lihat hal. 13-3. •


ITEM BAGIAN Minimum tire tread depth Kedalaman minimum alur kembang ban Cold tire pressure Driver only Tekanan udara ban Pengendara saja Driver and passenger (dingin) Pengendara dan pembonceng Axle runout Keolengan poros roda Wheel rim runout Radial Keolengan pelek roda Radial Axial Aksial Fork Spring free length Fork Panjang bebas pegas Pipe runout Keolengan pipe Recommended fluid Fluida garpu yang dianjurkan Fluid level Tinggi permukaan fluida Fluid capacity Kapasitas fluida

NILAI TORSI TORQUE Front axle nutVALUES Front brake disc socket bolt Front axlepost nut nut Handlebar Front brakelever disc pivot socketbolt bolt Rear brake Handlebar post nut Rear brake lever pivot nut Rear brake lever pivot bolt Bottom bridge pinch bolt Rear brake bolt lever pivot nut Fork socket Bottomstem bridgetop pinch bolt Steering thread Fork socket bolt Steering stem lock nut Steering stem top thread Steering stem lock nut

STANDARD STANDARD – 2 200 kPa (2.00 kgf/cm , 29 psi) 2 200 kPa (2,00 kgf/cm , 29 2 psi) 200 kPa (2.00 kgf/cm , 29 psi) 2 200 kPa (2,00 kgf/cm , 29 psi) – – – 311.3 (12.26) 311,3 – Fork fluid Fluida garpu (minyak sokbreker) 50 (2.0) 50 3 75 ± 1 3 cm (2.5 ± 0.03 US oz, 75 ± 1 cm 2.6 ± 0.04 Imp oz)

59 N.m (6,0 kgf.; 44 lbf.ft) 42 N.m (4,3 kgf.m; 31 lbf.ft) 59 N·m kgf·m, lbf·ft) 59 N.m (6,0(6.0 kgf.m; 4444 lbf.ft) 42 N·m kgf·m, lbf·ft) 1 N.m (0,1 (4.3 kgf.m; 0,7 31 lbf.ft) 59 N·m (6.0 kgf·m, 44 lbf·ft) 4,5 N.m (0,5 kgf.m; 3,3 lbf.ft) 1 N·m (0.1 kgf·m, 0.7 lbf·ft) 64 N.m (6,5 kgf.m; 47 lbf.ft) 4.5 N·m kgf·m, lbf·ft) 20 N.m (2,0(0.5 kgf.m; 15 3.3 lbf.ft) 64hal. N·m11-22 (6.5 kgf·m, 47 lbf·ft) Lihat 20hal. N·m11-22 (2.0 kgf·m, 15 lbf·ft) Lihat See page 11-22 See page 11-22

Unit: mm (in) SERVICE Satuan: mm LIMIT BATAS SERVIS To the indicator Sampai ke indikator – – 0.2 (0.01) 0,2 2.0 (0.08) 2,0 2.0 (0.08) 2,0 305.1 (12.01) 305,1 0.2 (0.01) 0,20 – – – -

U-nut ALOC bolt; ganti dengan yang baru U-nut ALOC bolt; replace with new ones

Oleskan locking agent pada ulir Apply locking agent to the threads

11-3

RODA DEPAN/SUSPENSI/KEMUDI TOOLS Bearing remover shaft 07746-0050100

Bearing remover head, 12 mm 07746-0050300

Driver 07749-0010000

Pilot, 12 mm 07746-0040200

Fork seal driver body 07747-0010100

Fork seal driver attachment, 27.2 mm 07747-0010300

Pin spanner 07702-0020001

Socket wrench 07916-KM10000

Steering stem socket 07916-3710101

Ball race remover shaft 07GMD-KS40100

Ball race remover, 34.5 mm 07948-4630100

Attachment, 32 x 35 mm 07746-0010100

11-4

RODA DEPAN/SUSPENSI/KEMUDI Bearing driver attachment 07946-3710701

Oil seal driver, 53.5 mm 07947-SB00200

Fork seal driver attachment, 35.2 mm 07947-KA20200

Oil seal remover 07748-0010001

11-5


TROUBLESHOOTING TROUBLESHOOTING Hard steering Kemudi berattire pressure • Insufficient Tekanan • • Faulty tire udara ban kurang Ban rusak • • Steering stem lock nut too tight • Faulty steering head Steering stem lockbearing nut terlalu kencang • • Faulty steering head bearing race Steering head bearing rusak • • Bent steering stembearing race rusak Steering head • Steering stem • Steers to one side orbengkok does not track straight • Bent front axle Kemudi ke satu sisi atau tidak dapat berjalan lurus • Wheelmenarik installed incorrectly Front axle bengkok • • Worn or damaged front wheel bearings • Bent fork Roda tidak terpasang dengan benar • • Worn or damaged engineaus mounting bushings Bearings roda depan atau rusak • • Bent frame Fork bengkok • • Faulty steering head bushings bearing aus atau rusak Engine mounting • Rangka bengkok • Front wheel wobbles • Loose front axle fasteners Steering head bearing rusak • • Bent rim • Worn or damaged front wheel bearings Roda depan bergoyang Pengikat front axle • Front wheel turns hard longgar Pelek bengkok • • Front brake drag Bearings roda depan aus atau rusak • • Bent front axle • Faulty front wheel bearings Roda depan berat perputarannya Soft suspension Rem depan menyangkut • • Low tire pressure Front axle fork bengkok • • Deteriorated fluid Bearings roda depan rusak • • Incorrect fork fluid weight • Insufficient fluid in fork Suspensi lunak • Weak fork spring Tekanan udara ban rendah • Hard suspension Fork fluid memburuk kondisinya • • High tire pressure Berat fork fluidintidak • • Too much fluid fork benar Tidak ada cukup fluid di dalam fork • • Incorrect fork fluid weight Fork spring lemah • • Bent fork pipes • Clogged fork fluid passage Suspensi Keras Suspension noisy Tekanan udara ban tinggi • • Bent fork slider Terlalu banyak fluid di dalam fork • • Insufficient fluid in fork Beratfork forkfasteners fluid tidak benar • • Loose Fork pipes bengkok • Jalan lintasan fork fluid tersumbat •

Suspensi berisik Fork slider bengkok • Fluid di dalam fork kurang • Pengikat fork longgar •

11-6


FRONTDEPAN WHEEL RODA REMOVAL/INSTALLATION PELEPASAN/PEMASANGAN Raise and support the scooter using dengan safety stand. Naikkan dan dukung skuter menggunakan dongkrak. Remove/install the following: Lepaskan/pasang sebagai berikutnya: – Speedometer cable - Speedometer cable – O-ring O-ring – Axle nut - Axle nuaxle t – Front Front axle – Front wheel - Roda – Side depan collar Side collar – Speedometer gearbox - Speedometer gearbox CATATAN: • Replace the speedometer cable O-ring with a new one. • Ganti speedometer cable O-ring dengan yang baru. • Apply grease to the O-ring, front axle and speedometer • Periksaascara kerja rem setelah pemasangan ini. gearbox specified. • Check the brake operation after installation.

Lepaskan tab sementara mendorongnya ke dalam dan lepaskan sepeedometer

O-RING FRONT AXLE

Tepatkan alur speedometer gearbox dengan boss paka kaki

* SPEEDOMETER GEARBOX

AXLE NUT 59 N·m (6.0 kgf ·m, 44 lbf ·ft)

SIDE COLLAR Tepatkan speedometer tabs dengan alur-alur wheel hub.

RODA DEPAN *: Shell BEARING GREASE HD atau sejenisnya.

11-7

RODA DEPAN/SUSPENSI/KEMUDI DISASSEMBLY/ASSEMBLY PEMBONGKARAN/PERAKITAN Remove/install the following: Lepaskan/pasang sebagai berikut: – Dustseals seals - Dust – Socket bolts - Socket bolts – Brake disc - Brake disc – Wheel bearings - Wheel bearings – Distance collar - Distance collar Refer to page 11-9 for wheel bearing replacement. Lihat hal. 11-9 untuk penggantian wheel bearing. • Apply grease to the bearings, dust seal lips and distance collar as specified. • Replace the brake disc socket bolts with new ones.

RIGHT WHEEL BEARING (6201U)

DUST SEAL DUST SEAL

SOCKET BOLTS 42 N·m (4.3 kgf ·m, 31 lbf ·ft) Kencangkan baut-baut dalam pola bersilangan dalam 2 atau 3 langkah.

DISTANCE COLLAR

LEFT WHEEL BEARING (6201U) BRAKE DISC Pasang brake disc dengan sisi yang bertanda menghadap ke atas.

11-8

RODA DEPAN/SUSPENSI/KEMUDI BEARING REPLACEMENT PENGGANTIAN BEARING (BANTALAN) Install the bearingremover removerhead head into the bearing. Pasang bearing ke dalam bearing. From the opposite side, install the bearing removershaft shaft dan and Dari sisi berlawanan, pasang bearing remover drive the bearing out of the wheel hub. drive bearing keluar dari wheel hub. Remove thedistance distance collar drive out the keluar other bearing. Lepaskan collarand dan dorong bearing yang lain. TOOLS: TOOLS: Bearing remover head, 12 mm 07746-0050300 Bearing removershaft head, 12 mm 07746-0050300 Bearing remover 07746-0050100 Bearing remover shaft 07746-0050100

REMOVER SHAFT

REMOVER HEAD

REMOVER HEAD

BEARING

BEARINGS

REMOVER SHAFT

Jangan sekali-kali Never install the old memasang kembali bearings. Once the bearings lama. bearings haveSekali been bearings telah removed, the bearings dilepaskan, bearings must be replaced with harus diganti dengan new ones. yang baru.

Pack all bearing cavities with grease.gemuk. Isi semua rongga bearing dengan Drive in a new left bearing squarely with its sealed side facing up until it is fully seated. Dorong masuk sebuah bearing kiri baru dengan sisinya yang tertutup menghadap ke atas sampai ia duduk sepenuhnya. TOOLS: Driver 07749-0010000 TOOLS: Attachment, 32 x 35 mm 07746-0010100 Driver 07749-0010000 Pilot, 12 mm 07746-0040200 Attachment, 32 x 35 mm 07746-0010100 Pilot, 12 mm 07746-0040200

REMOVER HEAD

ATTACHMENT

BEARING Apply thin coat of tipis greasegemuk to the distance collar andcollar installdan it. Oleskan lapisan pada distance pasang. Drive in a new right bearing squarely with its sealed side facing up. Dorong masuk bearing kanan baru secara tegaklurus dengan sisinya yang tertutup menghadap ke atas. TOOLS: Driver 07749-0010000 TOOLS: Attachment, 32 x 35 mm 07746-0010100 Driver 07749-0010000 Pilot, 12 mm 32 x 35 mm 07746-0040200 Attachment, 07746-0010100 Pilot, 12 mm 07746-0040200

DISTANCE COLLAR

DRIVER

PILOT

BEARING

11-9

RODA DEPAN/SUSPENSI/KEMUDI INSPECTION PEMERIKSAAN AXLE(POROS) AXLE Place the axle on V-blocks and measure runoutkeolengan with a dial Letakkan axle pada V-blocks dantheukur indicator. dengan dial indicator. SERVICE BATAS 0,2 mm mm(0.01 in) LIMIT: SERVIS: 0.2

Keolengan sebenarnya ½ darireading. pembacaan total Actual runout is 1/2 of theadalah total indicator indicator.

WHEEL WHEELBEARING BEARING(BANTALAN RODA) Putar inner dari masing-masing bearing dengan Turn the innerrace race of each bearing with your finger, the bearari-jari, bearing harus berputar dengan halus dan tanpa ing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. suara. Juga periksa bahwa bearing outer race duduk dengan Replace the bearings Remove and discard the bearings if the races do not turn erat pada hub. in pairs. smoothly, quietly, or if they fit loosely in the hub. Keluarkan dan buanglah bearings jika races tidak Ganti bantalan dalam berputar dengan halus, tanpa suara, atau jika mereka pasangan. duduk dengan longgar pada hub.

WHEEL WHEELRIM RIM(PELEK RODA) Periksa keolengan dengan wheel Check the wheel rim wheel runout rim by placing themeletakkan wheel on a turning pada stand. turning stand (alat pegangan roda untuk stel Spin the wheel by hand and read the runout using a dial indipelek). cator. roda dengan tangan dan baca keolengan dengan Putar Actual runout isdial 1/2 indicator. the total indicator reading. menggunakan Keolengan sebenarnya adalah ½ dari pembacaan total indicator. SERVICE LIMIT: Axial: 2.0 mm (0.08 in) BATAS SERVIS: Radial: 2.0 mm (0.08 in) Aksial: 2,0 mm Radial: 2,0 mm

11-10


FORK (GARPU) FORK REMOVAL PELEPASAN Lepaskan sebagai berikut: Remove the following: - –Front upper Front uppercover cover(hal. (page2-4) 2-4) - –Front fender (spakbor depan) (hal. 2-7) Front fender (page 2-7) - –Front wheel Front wheel(roda (pagedepan) 11-7) (hal. 11-7) Remove the brake caliper (page 13-13). Support thebrake front Lepaskan brake caliper (hal. 13-13). Dukung front Remove the bottom bridge upper pinch bolts. caliper brake dengan caliper seutas with a Lepaskan bottom bridge upper pinch bolts. Loosen the bottom bridge lower pinch bolts and remove the kawat iathat tidakit piecesehingga of wire so Longgarkan bottom bridge lower pinch bolts dan fork legs. bergantung does not pada hang front from lepaskan fork legs. brake hose.

the front brake hose. Jangan memlintir brake Do not twist the brake hose. hose.

UPPER PINCH BOLT

INSTALLATION PEMASANGAN Install the fork pipe into the steering stem. Align the bolt hole with the groove of the fork pipe as shown. Pasang fork pipe ke dalam steering stem. Install the lubang bottom bridge upper pinch Tepatkan bolt dengan alur bolts. dari fork pipe seperti Tighten the bottom bridge pinch bolts to the specified torque. diperlihatkan.

LOWER PINCH BOLT

TORQUE:64 (6.5 upper kgf·m,pinch 47 lbf·ft) Pasang bottomN·m bridge bolts. Kencangkan bottom bridge pinch bolts dengan torsi Install the following: yang ditentukan. – Front wheel (page 11-7) – Front64 fender 2-7) TORSI: N.m(page (6,5 kgf.m; 47 lbf.ft) – Front upper cover (page 2-4) – Brake caliper berikut: (page 13-13) Pasang sebagai

-

Front wheel (hal. 11-7) Front fender (hal. 2-7) Front upper cover (hal. 2-4) Brake caliper (hal. 13-13)

GROOVE

FORK BOLT HOLE

11-11

RODA DEPAN/SUSPENSI/KEMUDI PEMBONGKARAN DISASSEMBLY Hold the fork fork slider slider indalam a vice catok with soft jaws orpenjepit a shop towel. Pegang dengan lunak atau dengan kain lap. Loosen the fork socket bolt but do not remove yet.

FORK SLIDER

SOCKET BOLT

Longgarkan fork socket bolt tetapi jangan lepaskan dulu.

Put the suitable tool ontool the spring Tempatkan suitable (kunciseat. perkakas yang sesuai) pada spring seat. Press the spring seat into the fork pipe using a suitable tool and hydraulic press, then remove the stopper ring using a Tekan spring seat ke dalam fork pipe dengan small screwdriver. menggunakan suitable tool dan hydraulic press, Remove the spring seat, O-ringring and spring from the fork pipe. kemudian lepaskan stopper dengan menggunakan obeng kecil.

To prevent loss of tension, do not Untuk mencegah compress the fork hilangnya tegangan, spring more than jangan tekan fork spring necessary. The spring lebih daripada yang diperlukan. Sprint seat seat is under berada bawah springdi pressure. Lepaskan spring seat, O-ring dan spring dari fork pipe. tekanan Use carepegas. when Berhati-hatilah ketika removing the fork melepaskan fork assembly from the assembly dari hydraulic hydraulic press. press.

SUITABLE TOOL SPRING SEAT

STOPPER RING

SPRING Pour out the fluid by pumping the fork pipedengan several Tuangkan forkfork fluid (minyak sokbreker) keluar times. memompa fork pipe beberapa kali.

Remove thedust dustseal. seal. Keluarkan DUST SEAL

11-12

O-RING

RODA DEPAN/SUSPENSI/KEMUDI Lepaskan oiloil seal Remove the sealstopper stopper ring. ring. STOPPER RING

Lepaskan socket washer. Remove the socketbolt boltdan and sealing sealing washer. SEALING WASHER

SOCKET BOLT

Remove the fork piston rebound spring from fork Lepaskan fork piston danand rebound spring dari forkthe pipe. pipe.

FORK PISTON

REBOUND SPRING

Tarik fork pipe keluar dari the fork slider. Pull the fork pipe out from fork slider. FORK SLIDER

FORK PIPE

11-13

RODA DEPAN/SUSPENSI/KEMUDI Remove theoil oilseal seal dengan using themenggunakan special tool. special tool. Keluarkan

TOOL: TOOL: Oil seall remover Oil seal remover atau sejenisnya

OIL SEAL REMOVER

07748-0010001 07748-0010001 or equivalent

OIL SEAL

ASSEMBLY

PERAKITAN DUST SEAL

FORK PIPE

FORK PISTON

FORK PISTON RING SPRING SEAT

STOPPER RING

STOPPER RING OIL SEAL

FORK SLIDER O-RING

FORK SPRING

SOCKET BOLT 20 N·m (2.0 kgf ·m, 15 lbf ·ft)

SEALING WASHER

REBOUND SPRING

Sebelum perakitan, cucilah semua parts dengan larutan Before assembly, wash all parts with high flash point or nonflammable solvent and wipe dry. pembersih dengan titik apithem tinggi atau yang tidak dapat terbakar dan seka kering. Install the fork pipe into the fork slider.

FORK SLIDER

Pasang fork pipe ke dalam fork slider.

FORK PIPE

11-14

RODA DEPAN/SUSPENSI/KEMUDI Make sure thatfork the Pasang Install therebound rebound spring spring and piston intoke thedalam fork pipe. Pastikan bahwa danfork fork piston for piston fork ringpiston telah ring duduk is pipe. alur. seateddiindalam the groove.

FORK PISTON

REBOUND SPRING

Bersihkan ulir bolt socket dan locking oleskan Clean the socket threadsbolt and apply agent cairan to the bolt threads. pada ulir bolt. penguncian

SEALING WASHER

Install and tighten the socket bolt with a new sealing washer Pasang dan kencangkan socket bolt dengan sebuah to the fork piston. sealing washer baru pada fork piston.

SOCKET BOLT

Apply fork fluid to pada the lipbibir of a sebuah new oil seal. Oleskan fork fluid oil seal baru.

FORK SEAL DRIVER

Pasang oil seal Drive themasuk oil sealoil intoseal the fork slider using special tools ke dalam forkthe slider dengan Install the dengan oil seal Dorong sisinya yang bertanda until it is fully seated. with its marked side menggunakan special tools sampai ia duduk menghadap ke atas. facing up. sepenuhnya.

TOOLS: TOOLS: Fork seal driver body Fork seal driver body Fork seal driver attachment, Fork seal driver attachment, 27.2 mm 27.2 mm

07747-0010100 07747-0010100 07747-0010300 07747-0010300

ATTACHMENT

OIL SEAL

Pasang oiloilseal ringinto ke the dalam alurring stopper Install the sealstopper stopper ring stopper groovering on pada fork slider. the fork slider. STOPPER RING

11-15

RODA DEPAN/SUSPENSI/KEMUDI Oleskan fork fluid seal baru. Apply fork fluid to pada a n ewbibir dust dust seal lip. Jangan bibir dust seal duduk sepenuhnya. Install the dust sealsampai until it isiafully seated. Do ketuk not tap the dust dust Pasang seal terlalu keras. seal lip too hard .

DUST SEAL

Tuangkan jumlah amount fork fluid yang dianjurkan dalam Pour the specified of recommended fork fluid into the forkyang pipe.ditentukan ke dalam fork pipe. umlah FORK FLUID CAPACITY: KAPASITAS FORK FLUID: 33 75 1 cm (2.5 0.03 US oz, 2.6 ± 0.04 Imp oz) ± ± 75 1 cm

Pump thefork forkpipe pipe several timeskali to remove air from Pompa beberapa untuk trapped mengeluarkan the lower portion of the fork pipe. udara yang terperangkap dari bagian bawah dari for pipe.

Pastikan bahwa tinggi forkthe legfork sepenuhnya ukur the tinggi permukaan Be sure the oil level is Tekan Compress leg fully anddan measure fluid level from permukaan fluida di dariofbagian same in the both fluid the top the forkatas pipe.dari fork pipe. dalam kedua forks. forks adalah sama. FORK FLUID

TINGGI PERMUKAAN FORK FLUID: 50 mm LEVEL: 50 mm (2.0 in)

50 mm (2.0 in)

Tarik forkfork pipepipe ke atas daninstall pasang Pull the up and the fork fork spring spring dengan with its sisinya meruncing taperedyang side facing down.menghadap ke bawah.

FORK SPRING

FORK PIPE

Sisi yang meruncing

11-16

RODA DEPAN/SUSPENSI/KEMUDI Coat aO-ring new O-ring fork fork fluid fluid and install it into the Lapisi baru with dengan dan pasang ke groove in the spring seat. dalam alur pada spring seat. Set the fork assembly, spring seat and stopper ring onto the Tempatkan fork assembly, spring seat dan stopper ring hydraulic press. pada hydraulic Put the suitable press. tool on the spring seat. Letakkan suitable tool pada spring seat. To prevent loss of Press the spring seat into the fork pipe until the stopper ring Untuk menghindari groove ismasuk visible.spring seat ke dalam fork pipe sampai tension, do not Dorong hilangnya tegangan, jangancompress tekan forkthe spring fork alur stopper ring tampak.

TOOL YANG SESUAI

STOPPER RING O-RING

lebih daripada spring moreyang than diperlukan. necessary.

SPRING SEAT Install the stopperring ringke intodalam the stopper ring groove the stopper ring on Pasang alur stopper pada forkpipe. pipe. fork

STOPPER RING Tahan fork slider catok dengan penjepit lunak atau Hold the fork sliderpada in a vise with soft jaws or a shop towel. dengan kain lap.

Tighten the fork socket bolt to the specified torque.

Kencangkan fork socket bolt dengan TORQUE:20 N·m (2.0 kgf·m, 15 lbf·ft) ditentukan. TORSI: 20 N.m (2,0 kgf.m; 15 lbf.ft)

torsi

FORK SLIDER

yang

SOCKET BOLT

PEMERIKSAAN INSPECTION FORKSPRING SPRING FORK Measure the fork spring free length. fork spring. Ukur panjang bebas SERVICE BATAS SERVIS: 305,1 mm LIMIT: 305.1 mm (12.01 in)

SPRING

11-17

RODA DEPAN/SUSPENSI/KEMUDI FORK FORK PIPE/SLIDER/PISTON PIPE/SLIDER/PISTON Periksa fork pipe, terhadap Check the fork pipe,fork forkslider sliderdan and fork fork piston piston for score mark, and excessive or abnormal wear. tanda-tanda gerusan, dan keausan berlebihan atau tidak normal. Check the fork piston ring for wear or damage. Check the rebound spring for fatigue or damage. Periksa fork piston ring terhadap keausan atau Replace the components if necessary. kerusakan. Periksa rebound spring terhadap keletihan atau kerusakan. Ganti komponen-komponen bila perlu.

FORK SLIDER

FORK PIPE REBOUND SPRING

Letakkan forkpipe pipeonpada V-block dan ukurthe keolengan. Place the fork V-block and measure runout. Keolengan sebenarnya adalah ½ dari pembacaan total Actual runout is 1/2 the total indicator reading. indicator. SERVICE BATAS SERVIS: 0,2 mm LIMIT: 0.2 mm (0.01 in)

11-18

FORK PISTON

FORK PISTON RING


HANDLEBAR HANDLEBAR (STANG STIR) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Longgarkan rear brake (kabel rem belakang) Loosen the rear brake cable cable by turning the adjusting nut. dengan memutar adjusting nut. Remove/install the following: Lepaskan/pasang sebagai berikut: – Front handlebar cover (page 2-5) - –Front handlebar cover (hal. 2-5) Rear handlebar cover (page 2-5) - –Rear handlebar cover (hal. 2-5) Front upper cover (page 2-4) - –Front upper cover (hal. 2-4) Rear brake lever pivot bolt/nut - –Rear pivot bolt/nut Rearbrake brakelever cable/lever - –Rear brake cable/lever Master cylinder/holder/bolts - –Master cylinder/holder/bolts Screw/upper throttle housing/lower throttle housing - –Screw/upper throttle housing/lower throttle housing Throttle cable/throttle pipe - –Throttle cable/throttle Left handlebar grip pipe - –Left handlebar grip Nut/collars/bolt/handlebar post - Nut/collars/bolt/handlebar post

ADJUSTING NUT

CATATAN: • Refer to page 11-20 for handlebar post/handlebar grip/ Lihat hal. 11-20 untuk pemasangan handlebar • throttle housing installation. post/handlebar grip/throttle • Route the wires/cables properlyhousing. (page 1-14). Alurkan dengan benar (hal. 1-14). • • Adjust thekawat/kabel rear brake lever free play (page 3-16). Setel jarak main bebas rear brake lever (hal. 3-16). •

Kencangkan baut atas dulu, kemudian baru baut bawah.

Tepatkan ujung master cylinder dengan tanda titik pada handlebar.

SCREW UPPER HOUSING

THROTTLE PIPE

Letakkan holder dengan tanda "UP" menghadap ke atas.

HOLDER BOLTS PIVOT BOLT 1 N·m (0.1 kgf ·m, 0.7 lbf ·ft)

MASTER CYLINDER

THROTTLE CABLE

PIVOT NUT COLLAR

COLLAR

4.5 N·m (0.5 kgf ·m, 3.3 lbf ·ft) REAR BRAKE LEVER

BOLT NUT

REAR BRAKE CABLE

59 N·m (6.0 kgf ·m, 44 lbf ·ft)

11-19

RODA DEPAN/SUSPENSI/KEMUDI PEMASANGAN HANDLEBAR POST HANDLEBAR POST INSTALLATION Install the handlebar post post onto steering stem stem while alignPasang handlebar padathesteering sementara ing the bolt holes. mentepatkan lubang-lubang bolt.

BOLT

Rear collar is taller Rear collar lebih tinggi Install the front/rear collars, bolt and nut. Pasang front/rear collars, bolt dan nut. thandari the front collar. front collar.

REAR COLLAR

Tighten the nut to the specified torque. Kencangkan nut dengan torsi yang ditentukan.

TORSI: 59 N.m (6,0 TORQUE:59 N·m (6.0kgf.m; kgf·m,44 44lbf.ft) lbf·ft)

FRONT COLLAR

NUT

PEMASANGAN HANDLEBAR GRIP HANDLEBAR GRIP INSTALLATION Jika gripswere telah dilepaskan, oleskan Honda If thehandlebar handlebar grips removed, apply Honda Bond A or equivalent to the inside of the gripbagian and to the cleandari surfaces Bond A atau sejenisnya pada dalam grip of the left permukaan handlebar. bersih dari left handlebar. dan pada

HANDLEBAR GRIP

Wait 3 – 5 minutes and install the grip. Tunggu 3 - 5 menit dan pasang grip. Allow to Rotate the grip for even application of the adhesive. iarkan the lemadhesive mengering Putar grip agar lem terbagi merata.

selama dry for11jam hoursebelum before memakainya. using.

LEFT HANDLEBAR

PEMASANGAN THROTTLE HOUSING THROTTLE HOUSING INSTALLATION Pasang throttle pipe. Install the throttle pipe. Oleskan 0,1 – 0,2 g gemuk pada daerah luncur throttle Apply 0.1 – 0.2 g of grease to the throttle cable sliding area cable dan hubungkan dengan throttle pipe. and connect it to the throttle pipe. Install thelower lower throttle throttle housing by dengan aligning the hole on the Pasang housing mentepatkan handlebar with the locating pin of the lower throttle housing. lubang pada handlebar dengan locating pin dari lower throttle housing.

Tepatkan

THROTTLE CABLE Install the upperhousing housing by aligningmentepatkan the groove of the Pasang upper dengan alurupper dari housing and tabdan of the upper housing tablower dari housing. lower housing.

SCREW

Install the screw and tighten it. Pasang screw dan kencangkan.

LOWER HOUSING

11-20

UPPER HOUSING


STEERING STEM STEM STEERING PELEPASAN REMOVAL Remove the following: Lepaskan sebagai berikut:

SPEEDOMETER CABLE

Fork (page 11-11) - – Fork (hal. 11-11) – Handlebar (page 11-19) - Handlebar (hal. 11-19)

BOLT

Remove the boltdan andbrake brake hose hose clamp. Lepaskan bolt clamp. Release the speedometer cable from cable guide. Lepaskan speedometer cable darithe cable guide.

CABLE GUIDE

Tahan toptopthread pinloosen spanner Hold the thread dengan using themenggunakan pin spanner and the dan longgarkan steering stem lock nut dengan steering stem lock nut using the socket wrench. menggunakan socket wrench. TOOLS: TOOLS: Socket wrench 07916-KM10000 Socket wrench 07916-KM10000 Pin spanner 07702-0020001 Pin spanner 07702-0020001 Remove the steering stem lock nut. Lepaskan steering stem lock nut.

SOCKET WRENCH STEM LOCK NUT PIN SPANNER

Hati-hati agar steering stem topthread threadusing dengan Hold the steering stemdan andlonggarkan loosen the top the Be careful not totidak drop Tahan menjatuhkan steering the steering stem. menggunakan stem socket. stem socket. stem.

TOOL: TOOL: Steering stem socket Steering stem socket

HOSE CLAMP

STEM SOCKET

07916-3710101 07916-3710101 TOP THREAD

Hati-hati agar Be careful not totidak drop Lepaskan Remove theupper upper bearing racerace and the upper steelsteel balls bearinginner inner dan upper menjatuhkan steering the steering stem and balls (23 balls) while sementara holding the steering stem.steering stem. (23 balls) memegang stem dan upper steel the upper steel balls. balls.

UPPER INNER RACE STEEL BALLS (23)

STEERING STEM

11-21

RODA DEPAN/SUSPENSI/KEMUDI Be Hati-hati careful not to tidak drop Lepaskan Remove the steeringstem stem and (29(29 balls). steering danlower lowersteel steelballs balls balls). agar the steering stem and menjatuhkan steering the lower stem dan steel lowerballs. steel balls.

STEERING STEM

STEEL BALLS (29)

INSTALLATION PEMASANGAN Lihat hal. 11-24 untuk penggantian stem Refer to page 11-24 for steering stem bearingsteering replacement. bearing. TOP THREAD

LOWER OUTER RACE

LOWER BEARING (29)

UPPER BEARING (23)

LOCK NUT

UPPER INNER RACE

LOWER INNER RACE

DUST SEAL WASHER UPPER OUTER RACE

BOLT STEERING STEM

FRONT BRAKE HOSE CLAMP

Apply 3g3gofgemuk grease dengan with extreme agent (recomOleskan bahanpressure tahan tekanan tinggi mended: EXCELIGHT by KYODO (dianjurkan: EXCELIGHTEP2 EP2manufactured yang dibuat oleh YUSHI, japan or Shell EP2 or equivalent) the YUSHI, Japan atauALVANIA Shell ALVANIA EP2 to atau lower bearing races. sejenisnya) pada lower bearing races.

Be careful not to drop Hati-hati the steeringagar stemtidak and menjatuhkanthe steering lower stem dan steel lowerballs. steel balls.

gemuk dengan bahan tahan tekanan tinggi (dianjurkan : EXCELIGHT EP2 yang di buat oleh KYODO YUSHI, japan atau Shell ALVANIA EP2 atau sejenisnya)

STEEL BALLS (29 balls)

Attach new steel balls (29 balls) to the lower bearing outer Letakkan steel balls baru (29 balls) pada lower bearing race. outer race. Insert the steering stem into the steering head pipe, being careful not to drop thestem steel balls. Masukkan steering ke dalam steering head pipe, dengan berhati-hati agar tidak menjatuhkan steel balls.

STEERING STEM

11-22


Hati-hati agar tidak menjatuhkan steering stem dan upper Be careful not to steel drop balls. the steering stem and the upper steel balls.

Apply 3g3gofgemuk grease dengan with extreme agent (recomOleskan bahanpressure tahan tekanan tinggi mended: EXCELIGHT EP2 manufactured by KYODO (dianjurkan: EXCELIGHT EP2 yang dibuat oleh YUSHI, japan or Shell EP2 or equivalent) the YUSHI, Japan atauALVANIA Shell ALVANIA EP2 to atau upper bearing races. sejenisnya) pada lower bearing races. Install new steel balls (23 balls) onto the upper bearing outer Letakkan steel balls baru (29 balls) pada lower bearing race. outer race. Install a new upper bearing inner race onto the stem. Masukkan steering stem ke dalam steering head pipe, dengan berhati-hati agar tidak menjatuhkan steel balls.

Pasang toptop thread. Install the thread. Tahan steering dantighten kencangkan top thread Hold the steeringstem stem and the stemstem top thread to the initial torque using dengan the special tool. dengan torsi awal menggunakan special tool. TOOL: TOOL: Steering stem Steering stemsocket socket

UPPER INNER RACE

STEEL BALLS (23 balls)

STEM SOCKET

07916-3710101 07916-3710101

TOP THREAD

TORSI: 25 N.m (2,5 TORQUE:25 N·m (2.5kgf.m; kgf·m,18 18lbf.ft) lbf·ft)

Putar steering stem kali dari times ujung-ke-ujung Turn the steering stembeberapa lock-to-lock several to seat the untuk mendudukkan bearing. bearing.

Loosen the top retightenkencangkan the top thread to the Longgarkan topthread, thread,then kemudian kembali specified torque using thetorsi special tool. ditentukan dengan top thread dengan yang menggunakan special tool. TOOL: Steering stem socket 07916-3710101 TOOL:

Steering stem socket 07916-3710101 TORQUE:2.5 N·m (0.3 kgf·m, 1.8 lbf·ft)

STEM SOCKET

TOP THREAD

TORSI: N.m (0,3 kgf.m; 1,8about lbf.ft) Turn the 2,5 thread counterclockwise 15 degrees. Recheck that the steering stemarah moves smoothly without Putar berlawanan perputaran jarum play jam thread or binding. sebanyak 15 derajat.

Periksa kembali bahwa steering stem bergerak dengan halus tanpa kelonggaran atau mengikat.

11-23

RODA DEPAN/SUSPENSI/KEMUDI Install the following: Pasang sebagai berikut: Fork (page 11-11) - –Fork (hal. 11-11) – Front wheel (page11-7) 11-7) - Roda depan (hal. Hold the top thread using the pin spanner and tighten the Tahan thread dengan menggunakan steeringtop stem lock nut to the specified torque. pin spanner dan kencangkan steering stem lock nut dengan torsi TOOLS: yang ditentukan. Socket wrench 07916-KM10000 TOOLS: Pin spanner 07702-0020001 Socket wrench 07916-KM10000 Pin spanner N·m (7.5 kgf·m, 55 lbf·ft) 07702-0020001 TORQUE:74

TORSI: N.m stem (7,5 kgf.m; 55 lbf.ft) Turn the 74 steering lock-to-lock several times. Make sure the steering stem moves smoothly without play Putar steering stem dari ujung-ke-ujung beberapa kali. or binding. Pastikan bahwa steering stem bergerak dengan halus

STEM LOCK NUT

SOCKET WRENCH PIN SPANNER

tanpa mengikat. Installkelonggaran the brake hoseatau clamp and tighten the bolt.

SPEEDOMETER CABLE

Route the speedometer cabledan through the cable guide. Pasang brake hose clamp kencangkan bolt. Install the handlebar (page 11-19). Alurkan speedometer cable melalui cable guide.

BOLT

Pasang handlebar (hal. 11-19).

CABLE GUIDE

HOSE CLAMP

STEERING STEM BEARINGS PENGGANTIAN STEERING STEM REPLACEMENT BEARINGS

• Always replace the steel balls and races as a set.

theganti steering stem (page Selalu steel balls dan11-21). races •Remove

sabagai satu set. Remove the upper bearing outer race using the following Lepaskan steering stem (hal. 11-21). tool. Lepaskan upper bearing outer race dengan menggunakan tool sebagai berikut. TOOL: Ball race remover shaft 07GMD-KS40100 TOOL: Ball race remover shaft

UPPER OUTER RACE

07GMD-KS40100

BALL RACE REMOVER SHAFT

Keluarkan lower bearing bearing race dengan Remove the lower outer outer race using the following tools. menggunakan tools sebagai beirkut. TOOLS: TOOLS: Ballrace race remover, mm Ball remover,34.5 34.5 mm Ballrace race remover Ball removershaft shaft

BALL RACE REMOVER SHAFT

07948-4630100 07948-4630100 07GMD-KS40100 07GMD-KS40100

BALL RACE REMOVER

11-24

LOWER OUTER RACE

RODA DEPAN/SUSPENSI/KEMUDI Remove thedust dustseal seal from steering stemlower lower bearing bearing Lepaskan dari the steering stem inner race. inner race. Remove the lower bearing inner race with a chisel or equivaLepaskan lower bearing race lent tool being careful not toinner damage thedengan stem. pahat atau tool sejenis, dengan berhati-hati agar tidak merusak Remove the washer from the steering stem. stem.

DUST SEAL

STEERING STEM

LOWER INNER RACE

WASHER

Lepaskan washer dari steering stem.

Install the washerpada steering to the steering stem. stem. Pasang washer Install alower new lower bearing usingmenggunakan the following Pasang bearing innerinner race race dengan toolberikut and hydraulic tool ini danpress. hydraulic press.

TOOL: TOOL: Fork driver attachment, attachment, Forkseal seal driver 35.2 35.2 mm mm

WASHER

LOWER INNER RACE

07947-KA20200 07947-KA20200

FORK SEAL DRIVER ATTACHMENT Apply 3g3gofgemuk grease dengan with extreme agent (recomOleskan bahanpressure tahan tekanan tinggi mended: EXCELIGHT EP2 manufactured by KYODO (dianjurkan: EXCELIGHT EP2 yang dibuat oleh YUSHI, japan or Shell EP2 or equivalent) to a YUSHI, Japan atau ALVANIA Shell ALVANIA EP2 atau new dust seal lip then install it to the lower bearing inner sejenisnya) pada bibir dust seal baru kemudian pasang race. lower bearing inner race. pada

DUST SEAL

Dorong masuk upper bearing race dalam head Drive a new upper bearing outer outer race into theke head pipe using pipe dengan menggunakan tools sebagai berikut. the following tools. TOOLS: TOOLS: Driver Driver driver attachment Bearing Bearing driver attachment

DRIVER/ATTACHMENT

07749-0010000 07749-0010000 07946-3710701 07946-3710701

UPPER OUTER RACE

11-25

RODA DEPAN/SUSPENSI/KEMUDI Drive a new lower bearing outer race thebaru head pipe using Dorong masuk lower bearing outerinto race ke dalam the following tools. menggunakan tools berikut ini. head pipe dengan TOOL: TOOL: Oilseal seal driver Oil driver 53.5 53.5mm mm

LOWER OUTER RACE

07947-SB00200 07749-SB00200

Install the steeringstem stem (hal. (page11-22). 11-22). Pasang steering

OIL SEAL DRIVER

11-26

12. RODA BELAKANG/SUSPENSI

LOKASI KOMPONEN-KOMPONEN... 12-2

RODA BELAKANG............................. 12-4

KETERANGAN SERVIS ..................... 12-3

SHOCK ABSORBER BELAKANG ..... 12-5

TROUBLESHOOTING ........................ 12-3

HANGER LINKAGE ............................ 12-6




REAR WHEEL ················································12-4

REAR SHOCK ABSORBER ·························· 12-5

HANGER LINKAGE ······································12-6

12

12-1

RODA BELAKANG/SUSPENSI

LOKASI KOMPONEN-KOMPONEN COMPONENT LOCATION REAR WHEEL/SUSPENSION

118 N·m (12.0 kgf ·m, 87 lbf ·ft)

69 N·m (7.0 kgf ·m, 51 lbf ·ft)

12-2


SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM ! PERINGATAN Frequentmenghirup inhalation ofdebu brakebrake shoe dust, regardless material composition could be hazardous to your health. kesehatan. Seringkali pad dan shoe,of apapun komposisi bahannya, dapat membahayakan • Jangan Avoid breathing dust particles. menghirup partikel-partikel debu. • Jangan Never use an air hose or brush slang to clean brake atau assemblies. Use anmembersihkan OSHA-approvedsusunan vacuum cleaner. sekali-kali memakai udara sikat untuk rem. Pakailah alat penghisap debu yang baik. • Use genuine Honda replacement bolts and nut for all suspension pivots and mounting points. Pakailah bolts dan nut asli Honda untuk semua titik engsel dan penggantungan suspensi. • For brake system service, refer to section 13. Untuk servis sistem rem, lihat Bab 13. • •

• •

SPECIFICATIONS SPESIFIKASI BAGIAN ITEM Kedalaman minimum alur kembang ban Minimum tire tread depth Tekanan udara ban Pengendara saja Cold tire pressure Driver only (dingin) Pengendara dan pembonceng Driver and passenger Keolengan pelek roda Radial Wheel rim runout Radial Aksial Axial

STANDARD STANDARD – 2 225 kPa (2,25 kgf/cm , 33 psi) 2 225 kPa (2.25 kgf/cm , 33 psi) 2 225 kPa (2,25 kgf/cm , 33 psi) 225 kPa (2.25 kgf/cm2, 33 psi) – –

Unit: mm (in) Satuan: mm SERVICE BATAS SERVIS LIMIT Sampai ke indikator To the indicator – – 2,0 2.0 (0.08) 2,0 2.0 (0.08)

TORQUE VALUES NILAI TORSI Rear axle Rear axlenut nut Engine hanger link nut (sisi rangka) Engine hanger link nut (Frame side)

118 N.m (12,0 kgf.m; lbf.ft)87 lbf·ft) 118 N·m (12.087kgf·m, 69 N.m (7,0 kgf.m; 51 lbf.ft) 69 N·m (7.0 kgf·m, 51 lbf·ft)

U-nut Oleskan oli mesin pada ulir U-nut Apply engine oil to the threads

TROUBLESHOOTING TROUBLESHOOTING Roda belakang bergoyang Rear wheel wobbles Pelek bengkok • Bent rim Ban rusak • Faulty tire Axle dan/atau enginemounting mounting bolt/nut penggantung mesin) tidak dikencangkan dengan benar • Axle nut and/or engine bolt/nut not(baut/mur tightened properly Final gear shaft bearing longgar atau aus • Loose or worn final gear shaft bearing Tekanan udara ban kurang • Insufficient tire pressure • • • • •

Soft suspension Suspensi lunak • Weak rear shock absorber spring Rear shock absorber • Oil leakage from damperspring unit lemah Adatire kebocoran • Low pressure oli dari damper unit Tekanan udara ban rendah Stiff suspension • Bent damper rod Suspensi Keras • High tire pressure Damper rod bengkok RearTekanan suspension noisy udara ban tinggi • Loose mounting fasteners Suspensi belakang berisik • Faulty shock absorber Pengikat penggantung longgar • Weak rear suspension bushings Shock absorber rusak Rear suspension bushings lemah • • •

• •

• • •

12-3


REAR RODA WHEEL BELAKANG REMOVAL PELEPASAN Support the scooter withstandard its centerstand. Letakkan skuter pada utamanya. Remove the exhaust pipe/muffler (page2-14). 2-14). Lepaskan exhaust pipe/muffler (hal. Remove the rear axle nut, washer and rear wheel. Lepaskan rear axle nut, washer dan roda belakang.

RODA BELAKANG

PEMASANGAN INSTALLATION Semprotkan oli mesin pada ulir rear axle nut dan Apply engine oil to the rear axle nut threads and seating surpermukaan duduk. face. Pasang roda finalgear gear shaft, dengan Install the rearbelakang wheel ontopada the final shaft, aligning its mentepatkan splines-nya dengan final gear shaft splines with the final gear shaft splines. Be careful not to Hati-hati agar tidak Install the washer onto the final gear shaft. damage the splines. splines. merusak Pasang washer pada Install the rear axle nut.final gear shaft. Kencangkan rear axle dengan torsitorque. yang ditentukan. Tighten the rear axle nutnut to the specified TORQUE:118 N·m (12.0kgf.m; kgf·m, 87 87 lbf·ft) TORSI: 118 N.m (12,0 lbf.ft)

Install the exhaustpipe/muffler pipe/muffler (hal. (page2-14). 2-14). Pasang exhaust Tepatkan (splines) WASHER AXLE NUT

PEMERIKSAAN INSPECTION Periksa keolengan dengan dial indicators. Check the wheel rimpelek runoutroda using dial indicators. Actual runout is 1/2 the total indicator readings. Keolengan sebenarnya adalah ½ dari pembacaan total indicator. SERVICE LIMITS: BATAS SERVIS: Radial: 2.0 mm (0.08 in) Radial: 2,0 mm Axial: 2.0 mm (0.08 in) Aksial: 2,0 mm

12-4


REAR SHOCK ABSORBER ABSORBER REMOVAL PELEPASAN Remove the bodycover cover(hal. (page2-9). 2-9). Lepaskan body Remove the bolts and rear shock absorber.

SHOCK ABSORBER

To avoid damage to Lepaskan bolts dan rear shock absorber. Untuk menghindari kerusakan pada ulirshock rear the rear shock absorber absorber mounting mounting bolt, slightly angkat bolt threads, rodalift belakang sedikit. the rear wheel. PEMASANGAN

Pasang shock absorber belakang dan kencangkan bolts. Pasang body cover (hal. 2-9). BOLTS

INSTALLATION Install the rear shock absorber and tighten the bolts. Install the body cover (page 2-9).

PEMERIKSAAN INSPECTION Periksa terhadap atau Check the damper damper unitunit for leakage or otherkebocoran damage. kerusakan lain. Check the shock absorber bushing for wear or damage.

BUSHING

Replaceshock the shock absorber assembly if necessary. Periksa absorber bushing terhadap keausan atau kerusakan.

Ganti shock absorber assembly bila perlu.

SHOCK ABSORBER Check the rear shockabsorber absorber mount wear or Periksa rear shock mount bushing bushingforterhadap damage. atau kerusakan. keausan

REAR SHOCK ABSORBER MOUNT BUSHING

12-5


HANGER LINKAGE LINKAGE (PENGHUBUNG PENGGANTUNG MESIN) REMOVAL Remove the engine (page 6-4). PELEPASAN Remove the nut and engine hanger link bolt. Lepaskan mesin (hal. 6-4). Remove the engine hanger link from the frame. Lepaskan nut dan engine hanger link bolt.

Lepaskan engine hanger link dari rangka. NUT

BOLT

ENGINE HANGER LINK

PEMASANGAN INSTALLATION Pasang engine rangka. Install the enginehanger hanger link link pada onto the frame. Pasang engine hanger bolt dari sisithe kirileft dariside rangka. Install the engine hangerlink link bolt from of the frame. Pasang engine hanger link nut dan washer dan kencangkan nut dengan torsinut yang Install the engine hanger link andditentukan. tighten it to the specified torque. TORSI: 69 N.m (7,0 kgf.m; 51 lbf.ft) TORQUE:69 N·m (7.0 kgf·m, 51 lbf·ft) Pasang mesin (hal. 6-6). Install the engine (page 6-6).

NUT

BOLT

ENGINE HANGER LINK

PEMERIKSAAN INSPECTION Check thehanger hanger link and dan stopper rubbers rubbers for wear Periksa linkbushings bushings stopper or damage. terhadap keausan atau kerusakan.

HANGER LINK BUSHINGS

STOPPER RUBBERS

Periksa engine terhadap Check the enginemount mount bushings bushings for wear or keausan damage. atau kerusakan.

ENGINE MOUNT BUSHINGS

12-6

13. SISTEM REM

LOKASI KOMPONEN-KOMPONEN... 13-2


PENGGANTIAN BRAKE FLUID/

BRAKE FLUID REPLACEMENT/AIR

AIR BLEEDING ................................... 13-6 BLEEDING····································· ·················· 13-6

KETERANGAN SERVIS ..................... 13-3


TROUBLESHOOTING ........................ 13-4


REAR DRUM BRAKE ......................... 13-5

REAR DRUM BRAKE····································13-5

BRAKE PAD/DISC.............................. 13-8

BRAKE PAD/DISC·························· ················ 13-8

BRAKE MASTER CYLINDER............. 13-11

BRAKE MASTER CYLINDER ···················13-11

BRAKE CALIPER ............................... 13-13

BRAKE CALIPER ········································13-13

13

13-1

SISTEM REM

COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN BRAKESYSTEM

FRONT BRAKE REM DEPAN

2 N·m (0.2 kgf·m, 1.5 lbf·ft)

34 N·m (3.5 kgf·m, 25 lbf·ft)

34 N·m (3.5 kgf ·m, 25 lbf ·ft) 30 N·m (3.1 kgf ·m, 22 lbf ·ft)

REAR BRAKE

REM BELAKANG

13-2

SISTEM REM

SERVICE INFORMATION KETERANGAN SERVIS GENERAL ! AWAS Seringkali menghirup debu brake pad dan shoe, apapun komposisi bahannya, dapat membahayakan kesehatan. Jangan menghirup partikel-partikel debu. Frequent inhalation of brake pad and shoe dust, regardless of material composition, could be hazardous to yo ur heal Jangan sekali-kali memakai slang udara atau sikat untuk membersihkan susunan rem. Pakailah alat penghisap debu yang • Avoid breathing dust particles. baik. • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. • •

CATATAN Minyak rem yang tertumpah akan membuat kerusakan parah pada lensa instrumen dan permukaan yang dicat. Ia juga b erbahaya Spilled brake fluid willdari severely bagi beberapa parts karet.damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be careful whenever you remove the reservoir cap; make sure the master cylinder horizontal first.posisi horisontal dulu. Berhati-hatilah setiap kali melepaskan reservoir cap; pastikan bahwa masterreservoir cylinderisreservoir pada • A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality Brakedegreasing disc atau pad brake agent. yang terkontaminasi mengurangi daya pengereman. Buanglah pads yang terkontaminasi dan bersihkan disc yang terkontaminasi denganthe bahan gemuk berkualitas tinggi untuk peralatan rem. • Check the brake system by applying brakepembersih lever after the air bleeding. • Never allow contaminants (dirt,menjalankan water, etc.) to handel get into rem an open reservoir. Periksa sistem rem dengan setelah proses air bleeding (pembuangan udara palsu). • Once the hydraulic system has been or ifair, thedsb.) braketidak feels masuk spongy,ke thedalam systemreservoir must be bled. Jagalah agar benda-benda asingopened, (kotoran, terbuka. • Always use fresh DOT 3 or DOT 4 brake fluid from a sealed container when servicing the system. Do not mixsistem. different types of fluid, they Sekali sistem hidraulik telah dibuka, atau jika rem terasa seperti sepons, buanglah udara palsu dari may not be compatible. Selalu pakai minyak rem baru DOT 3 atau DOT 4 dari kemasan yang belum pernah dibuka ketika menservis sistem. Jangan • Always check brake operation before riding scooter. mencampurkan bermacam-macam jenisthe minyak rem, mereka mungkin tidak cocok satu sama lain. Selalu periksa cara kerja rem sebelum mengendarai skuter. •

• • • •

•

SPECIFICATIONS SPESIFIKASI BAGIAN ITEM Jarak main bebas brake lever (handel rem) Rear brake lever free play D.D. rear brake drum Rear brake Minyak remdrum yangI.D. ditentukan Specified Brake discbrake fluid Ketebalan Brake disc Thickness bentuk melengkung Perubahan Warpage Master cylinder D.D. cylinder Master cylinder Cylinder I.D. D.L. piston Piston O.D. Caliper D.D. cylinder Caliper Cylinder I.D. D.L. piston Piston O.D.

STANDARD BATAS STANDARD 10 – 20 10 – 20 (0.4 – 0.8) 130,0 131,0 130.0DOT (5.12) 3 atau 4 DOT3,3 3 or–DOT 3,7 4 3,0 3.3 –- 3.7 (0.13 – 0.15) 0,10 11,000 – 11,043– 11,055 11.000 – 11.043 (0.4331 – 0.4348)10,945 10,957 – 10,984 10.957 – 10.984 (0.4314 – 0.4324)32,090 32,030 – 32,080 32.030 – 32.080 (1.2610 31,948 – 31,998 – 1.2630)31,94 31.948 – 31.998 (1.2578 – 1.2598)

Unit: mm (in) Satuan: mm SERVICE SERVIS LIMIT – 131.0 (5.16) – 3.0 (0.12) 0.10 (0.004) 11.055 (0.4352) 10.945 (0.4309) 32.090 (1.2634) 31.94 (1.257)

NILAI TORSI TORQUE VALUES Rear Rearbrake brakearm arm bolt bolt Brake caliper Brake caliperbleed bleed valve valve Brake master cylinder capscrew screw Brake master cylinder reservoir reservoir cap Brake pad pin Brake pad pin Front brake lever pivot bolt Front brake lever pivot bolt Front brake lever pivot nut Front brake lever pivot nut Front brake light switch screw Fronthose brakeoillight Brake boltswitch screw Brake hose oil bolt Brake caliper mounting bolt Brake caliper mounting bolt Brake caliper pin Brake caliper pin

10 N.m (1,0 7 lf.ft) ganti dengan yang 10 kgf.m; N·m (1.0 kgf·m, 7 lbf·ft) ALOC bolt; ALOC bolt; replace withbaru new one. 6 N.m (0,66 kgf.m; 4,4 lbf.ft) N·m (0.6 kgf·m, 4.4 lbf·ft) 2 N.m (0,2 kgf.m, 2 N·m 1,5 (0.2lbf.ft) kgf·m, 1.5 lbf·ft) 18 N.m (1,8 kgf.m; 13 lbf.ft) 18 N·m (1.8 kgf·m, 13 lbf·ft) 1 N.m (0,1 kgf.m; 0,7 lbf.ft) 1 N·m (0.1 kgf·m, 0.7 lbf·ft) 6 N.m (0,6 kgf.m; 4,4 lbf.ft) N·m (0.6 kgf·m, 4.4 lbf·ft) 1 N.m (0,16 kgf.m; 0,7 lbf.ft) 1 N·m (0.125 kgf·m, 34 N.m (3,5 kgf.m; lbf.ft)0.7 lbf·ft) 34 N·m (3.5 kgf·m, 30 N.m (3,1 kgf.m; 22 lbf.ft) 25 lbf·ft) ALOC bolt; ganti dengan yang baru 30 kgf.m; N·m (3.1 ALOC bolt; replace with new ones. 18 N.m (1,8 13kgf·m, lbf.ft) 22 lbf·ft) 18 N·m (1.8 kgf·m, 13 lbf·ft)

13-3

SISTEM REM TOOL TOOL Snap ring pliers 07914-SA50001

TROUBLESHOOTING TROUBLESHOOTING Front brake lever (handel rem depan) t erasa lunak atau seperti sepons Front brake lever soft or spongy Ada dalam sistem hidraulik • Air in udara hydraulic system Ada kebocoran pada • Leaking hydraulic systemsistem hidraulik terkontaminasi Brake pad/disc • Contaminated brake pad/disc Caliper piston seals aus • Worn caliper piston seals Master cylinder piston cups aus • Worn master cylinder piston cups • Worn brake pad/disc Brake pad/disc aus • Contaminated caliper Caliper terkontaminasi • Contaminated master cylinder Master cylinder terkontaminasi • Caliper not sliding properly Caliper tidak meluncur dengan benar • Low brake fluid level Tinggi permukaan minyak rem terlalu rendah • Clogged fluid passage Jalan lintasan fluid tersumbat • Warped/deformed brake disc Brake disc berubah bentuk melengkung/berubah bentuk • Sticking/worn caliper piston Caliper piston macet/aus • Sticking/worn master cylinder piston Master cylinder • Bent brake lever piston macet/aus Brake lever bengkok Front brake lever hard • Clogged/restricted brake system Brake lever depan keras • Sticking/worn caliper piston Sistemnot rem tersumbat/terbatasi • Caliper sliding properly Caliper piston macet/aus • Worn caliper piston seal Caliper tidakmaster meluncur dengan benar • Sticking/worn cylinder piston Caliper piston • Bent brake lever seal aus Master cylinder piston macet/aus Front brake drags Brake lever bengkok • Contaminated brake pad/disc • • • • • • • • • • • • • • •

• • • • • •

• Misaligned wheel Rem depan menyangkut • Badly worn brake pad/disc Brake pad/disc • Warped/deformedterkontaminasi brake disc Roda salah pasang • Caliper not sliding properly Brake pad/disc sangat aus • Clogged/restricted fluid passage • Sticking caliper piston bentuk melengkung/berubah bentuk Brake disc berubah tidakperformance meluncur dengan benar PoorCaliper rear brake Jalan lintasan fluidoftersumbat/terbatasi • Incorrect adjustment rear brake lever Caliper piston macet • Contaminated brake shoes • Worn brake shoes Unjuk kerja rem belakang buruk • Worn brake cam Penyetelan brake lever belakang tidak benar • Worn brake drum • Improperly installed brake arm Brake shoes terkontaminasi • Improperly engaged Brake shoes aus brake arm serrations Brake cam aus Brake drum aus Brake arm tidak terpasang dengan benar Gerigi brake arm tidak berhubungan dengan baik • • • • • • •

• • • • • • •

13-4

SISTEM REM

REAR DRUM DRUM BRAKE BRAKE (REM TEROMOL BELAKANG) BELAKANG) DISASSEMBLY/ASSEMBLY • Alway Alwayss replace replace the brake shoes as a set. PEMBONGKARAN/PERAKITAN

• Mark all all parts parts during disass disassembly embly so so they can can be placed placed Selalu ganti brakelocations. shoes sebagai satu set. back in the original Tandai semua parts selama pembongkaran Remove the rear wheel (page 12-4). sehingga mereka dapat diletakkan kembali pada Remove the adjusting nut and brake cable from the joint pin. posisinya semula. Remove theroda jointbelakang pin and return Lepaskan (hal.spring. 12-4). • •

Expand theadjusting brake shoes and brake removecable the brake shoes/shoe Lepaskan nut dan dari joint dari joint pin. springs from thepin brake panel. Lepaskan joint Lepaskan joint dan return spring. Remove the following: Renggangkan – Brake arm boltbrake shoes dan lepaskan brake dari shoes/shoe springs cam – Brake arm/brake ca m brake panel. Lepaskan sebagai berikut: – Dust seals

- Brake arm bolt Applyarm/brake grease tocam grease the dust seals, the seals, brake brake cam and and brake - • Brake anchor pin as specified. - Dust seals • Repla Replace ce the dust seals seals and and brake arm bolt bolt with new new ones. ones. Pasang yang dilepaskan dalam urutan Install the parts removed partstelah in the reverse order of removal. terbalik dari pelepasan. Adjust the rear brake lever free play (page 3-16). Setel jarak main bebas rear brake lever (hal. 3-16). *: Berikut 0.2 - 0.3 g gemuk. DUST SEAL

Tepatkan

* ANCHOR PIN

* BRAKE CAM BRAKE SHOES BRAKE ARM Pasang shoe springs dengan ujungnya yang terbuka menghadap keluar . BRAKE ARM BOLT 10 N· N·m (1.0 kgf ·m, 7 lbf ·ft)

ADJUSTING NUT SHOE SPRINGS JOINT PIN Letakkan ujung-ujung return spring ke dalam lubang pada brake panel dan pada pin pada brake arm.

RETURN SPRING

13-5

SISTEM REM PEMERIKSAAN INSPECTION Measure therear rearbrake brake drum drum I.D. Ukur D.D. (teromol rem belakang)


PENGGANTIAN BRAKE FLUID (MINYAK BRAKE FLUID REPLACEMENT/AIR REM) (PEMBUANGAN /AIR BLEEDING BLEEDING UDARA PALSU) BRAKE FLUID DRAINING PENGELUARAN BRAKE FLUID

• Do not mix mix different different types types of fluid, fluid, as they are are not comcom patible with each other. each Jangan mencampurkan bermacam-macam bermacam-macam jenis • Do notoleh allowkarena allow foreignmereka foreign material tidak material to enter to the system the syste when fluid, cocok satumsama filling the reservoir. lain. Jangan membiarkan benda asing memasuki sistem ketika mengisi reservoir.

•

•

Spilled fluid can damage painted, plastic or rubber parts.

CATATAN Place a rag over these these parts whenever whenever the system is serviced. Do not allow foreign material to enter the systemwhen filling the angan membiarkan reservoir. benda asing memasuki sistem ketika mengisi reservoir.

Fluid yang tertumpah dapat merusak parts yang dicat, Turn the handlebar until the reservoir is parallel to the ground atau terbuat dari plastik atau karet. Letakkan kain lap before removing the reservoir cap. menutupi parts ini ketika sistem diservis. Remove the screws, reservoir cap, diaphragm plate and diaPutar handlebar sampai reservoir parallel dengan tanah phragm. sebelum melepaskan reservoir cap. Lepaskan screws, reservoir cap, diaphragm plate dan diaphragm.

Sambungkan (slang pembuangan) pada Connect a bleedbleed hose tohose the caliper bleed valve. caliper bleed valve. Loosen the bleed valve and pump the brake lever until no more fluid flows out of the bleed valve. Longgarkan bleed valve dan pompa brake lever sampai fluid tidak mengalir keluar lagi dari bleed valve.

13-6

RESERVOIR CAP

SCREWS

DIAPHRAGM PLATE DIAPHRAGM

BLEED VALVE BLEED HOSE

SISTEM REM BRAKE FLUID FILLING/AIR PENGISIAN BLEEDINGBRAKE FLUID/AIR BLEEDING angan mencampurkan Do not mix different bermacam-macam jenis types of fluid. They fluida. Mereka tidak are not compatible. cocok satu sama lain.

Isi cylinder reservoir brake 3 Fillmaster the master cylinder reservoirdengan with DOT 3 or fluid DOT DOT 4 brake atau 4 dari kemasan pernah dibuka fluid DOT from the sealed containeryang to the belum upper level. sampai ke upper level (tinggi permukaan teratas). • Check the the fluid fluid level often often while while bleeding bleeding the the brake to to prevent air from being pumped into the system. Periksa tinggi permukaan fluid sering-sering sewaktu membuang udara dari sistem rem untuk mencegah dipompanya masuk udara ke dalam sistem.

UPPER LEVEL

•

Connect a commercially available bleed Hubungkan brake bleeder yang brake dapatbleeder dibeli to di the pasaran valve.bleed valve. pada

BLEED HOSE

Operate the brake bleeder and loosen the bleed valve. Jalankan brake bleeder dan longgarkan bleed valve. Perform the bleeding procedure until the system is comJalankan prosedur bleeding sampai sistem sama sekali pletely flushed/bled. dibilas. Close the bleed valve and operate the brake lever. Tutup bleed dan jalankan brakeagain. lever. If it still feelsvalve spongy, bleed the system Jika masih terasa seperti sepons, buanglah udara palsu After bleeding system completely, tighten the bleed v alve sekali lagi dari the sistem. to the specified torque. Setelah sistem telah di-bleeding di- bleeding sama sekali, TORQUE:6 N·m (0.6 kgf·m, 4.4 lbf·ft) kencangkan bleed valve dengan torsi yang ditentukan.

If air enters the Jika udara memasuki memasuki bleeder from around bleeder dari sekitar ulir the bleed bleed valve, rapativalve ulir threads, seal the dengan teflon tape. threads with tinggi teflon Periksa tape. permukaan fluid seringserin g sering Checksewaktu the fluidmemlevel bleeding sistem rem often while bleeding untuk menghindari the brake to prevent dipompanya air fromudara being masuk pumped ke dalam into sistem. kgf.m; 4,4 lbf.ft) lbf.ft) the TORSI: 6 N.m (0,6 kgf.m; system.

BLEED VALVE

Jika tersedia,perform jalankan prosedur If thebrake brake bleeder bleeder istidak not available, the following sebagai berikut. procedure. Pump up the system pressure with the brake lever until the Pompa tekanan sistem dengan brake lever (handel rem) lever resistance is felt. sampai terasa ada tahanan pada lever.

Check Periksa the fluidtinggi level permukaan fluidbleeding seringseringoften while sering sewaktu memthe brake to prevent bleeding sistem rem air from being untuk menghindari pumped into the dipompanya udara system. masuk ke dalam sistem. Do not release the angan melepaskan until the brakebrake lever lever sampai bleed bleed valve has been valve telah ditutup. closed.

Hubungkan bleed hose pada bleed dan the buanglah Connect a bleed hose to the bleed valvevalve and bleed system udara palsu dari sistem sebagai berikut: as follows:

BLEED VALVE

BLEED HOSE

1. Squeeze Squeeze the brake lever lever all all the way and loosen loosen the bleed bleed valve Tekan brake lever seluruhnya dan longgarkan 1/2 of a turn. Wait several seconds and then close bleed the bleedvalve valve. ½ putaran. Tunggu beberapa detik kemudian valve. 2. Rele Release ase the tutup brake bleed brake lever slowly sl owly and wait wait several several seconds seconds after Lepaskan brake pelan-pelan dan tunggu it reaches the endlever of its travel. beberapa detik mencapai ujung 3. Repea Repeat t the steps steps 1 andsetelah 2 until until there theiare are no air air bubbles bubble s in perjalanannya. the bleed hose. Ulangi langkah 1 dan 2 sampai tidak ada lagi After bleeding the system completely, tighten the bleed v alve gelembung-gelembung udara di dalam bleed hose. to the specified torque.

•

•

•

Setelah mem-bleeding mem-bleeding sistem sama sekali, kencangkan TORQUE:6 N·m (0.6 kgf·m, 4.4ditentukan. lbf·ft) bleed valve dengan torsi yang TORSI: 6 N.m (0,6 kgf.m; kgf.m; 4,4 lbf.ft) lbf.ft)

13-7

SISTEM REM Do not mix different Isi Fill the reservoir to the upper permukaan level with DOT 3 ordengan DOT 4 angan mencampurkan reservoir sampai ke tinggi teratas bermacam-macam jenis brake types of fluid. They brake fluid seal ed container. fluid from DOTa sealed 3 atau DOT 4 dari kemasan yang brake fluid. Mereka belum pernah dibuka sebelumnya. are not compatible. tidak cocok satu sama lain.

Pasang diaphragm, diaphragm Install the diaphragm, diaphragmplate platedan and reservoir reservoir cap, cap, kemudian kencangkan screws dengan then tighten the screws to the specified torque. torsi yang ditentukan.

UPPER LEVEL

RESERVOIR CAP

SCREWS

TORQUE:2 N·m (0.2 kgf·m, 1.5lbf.ft) lbf·ft) TORSI: 2 N.m (0,2 kgf.m; kgf .m; 1,5 lb f.ft)

DIAPHRAGM PLATE DIAPHRAGM

BRAKE BRAKE PAD/DISC PAD/DISC PENGGANTIAN BRAKE PAD BRAKE PAD REPLACEMENT Check Periksa the braketinggi fluid Dorong Push the caliper caliper pistons all the way in to allow installation of pistons seluruhnya ke dalam untuk permukaan brake brake fluid level in the reservoir memungkinkan new brake pads. pemasangan brake pads baru. di dalam reservoir as this operation sering-sering oleh causes operasi the levelini to karena rise. menyebabkan naiknya tinggi permukaan brake fluid.

BRAKE CALIPER Remove the padpin pinplug plugdari frombrake the brake caliper. Lepaskan pad Lepaskan pad caliper.

PAD PIN PLUG

13-8

SISTEM REM Remove the padpin pinplug fromdari the brake Lepaskan pad Lepaskan pad brakecaliper. caliper.

PAD PIN

Lepaskan brake caliper. Remove the brakepads pads dari frombrake the brake caliper.

BRAKE PADS

Selalu ganti brake Always replace the Pasang Install new brake padsbaru so that they are set on the ditempatkan brake caliper brake pads sehingga mereka pads dalam brake pads in pairs to pada bracket and bracket pi n. brake caliper pin. bracket dan bracket pin. pasangan untuk assure even disc memastikan pressure. tekanan

Tempatkan

BRACKET PIN

merata pada disc.

BRAKE PADS

Pasang pinby pushing dengan themendorong brakethepads Install the pad pad pin brake pads against pad spring to align pad pin holes o n the pads and caliper. terhadap pad the spring untuk mentepatkan lubang-lubang pad pin pada pads pada pads dan caliper.

PAD PIN

13-9

SISTEM REM Kencangkan pad Kencangkan pad dengan torsitorque. yang ditentukan. Tighten the pad pinpin to the specified TORSI: 18 N.m (1,8 kgf.m; kgf.m; 13 lbf.ft) TORQUE:18 N·m (1.8 kgf·m, 13 lbf·ft)

PAD PIN Setelah penggantian dan kencangkan kencangkan pad pad pin plug. After brakecara pad Pasang Install and tighten the pad pin plug. brake pad,the periksa replacement, check kerja rem dengan the brake operation menekan brake lever. by applying the brake lever.

PAD PIN PLUG

PEMERIKSAAN BRAKE DISC BRAKE DISC INSPECTION Visually brake inspect disc the brake disc visual for damage or cracks. Periksa secara terhadap kerusakan atau retak-retak. Measure the brake disc thickness at several points.

Ukur ketebalan brake disc pada beberapa titik. SERVICE BATAS 3,0 mm LIMIT: SERVIS: 3 .0 m m (0.12 in)

Periksa disc terhadap perubahan Check the brake brake disc for warpage. melengkung. SERVICE LIMIT: SERVIS: 0 .10 m m (0.004 in) BATAS 0,10 mm

bentuk

If theperubahan warpage exceeds service limit,melampaui check the wheel Jika bentukthe melengkung batas bearings for excessive pl ay. servis, periksa wheel play. bearings (bantalan roda) terhadap kelonggaran For brake discberlebihan. replacement, refer to page 11-8.

Untuk penggantian brake disc, lihat hal. 11-8.

13-10

SISTEM REM

BRAKE MASTER MASTER CYLINDER CYLINDER BRAKE REMOVAL/INSTALLATION PELEPASAN/PEMASANGAN Drain the brake fluid (page 13-6). Keluarkan brake fluid (minyak (hal. Remove the rear handlebar coverrem) (page 2-5).13-6). Lepaskan rear handlebar cover (hal. 2-5). Disconnect the brake light switch connectors. Lepaskan brake light switch connectors. Remove the oil bolt, brake hose and sealing washers. Lepaskan oil bolt, brake hose dan sealing washers. Install the removed parts in the reverse order of removal. Pasang parts yang telah dilepaskan dalam urutan terbalik dari pelepasan. • Replace the sealing washers with new ones. Isi bleedthe (buang udara palsu) Filldan and air air bleed hydraulic system (pagesistem 13-7). hidraulik (hal. 13-7). SCREW 2 N·m (0.2 kgf ·m, 1.5 lbf ·ft)

HOLDER

BOLTS

RESERVOIR CAP

Tepatkan ujung master cylinder dengan tanda titik pada handlebar. Kencangkan baut atas dulu, baru kemudian baut bawah.

DIAPHRAGM PLATE

Letakkan holder dengan tanda "UP" menghadap keatas.

DIAPHRAGM SEALING WASHERS

OIL BOLT 34 N·m (3.5 kgf ·m, 25 lbf ·ft)

MASTER CYLINDER CONNECTORS

BRAKE HOSE

Tepatkan brake hose eyelet terhadap stopper.

13-11

SISTEM REM DISASSEMBLY/ASSEMBLY PEMBONGKARAN/PERAKITAN Remove/install the following: Lepaskan/pasang sebagai berikut: Brakelever leverpivot pivotnut, nut,bolt bolt dan and brake - – Brake brakelever lever – Screw and brake light switch - Screw dan brake light switch Boot - – Boot Remove/install the snap ring using the special tool. TOOL: Snap ring pliers 07914-SA50001 TOOL: Snap ring washer, pliers master piston dan07914-SA50001 Lepaskan spring. Remove the washer, master piston spring. Pertahankan piston, cups, and spring, snap ring dan boot sebagai satu set; jangan mengganti parts secara terpisah. • Keep the piston, cups, spring, snap ring and boot as a set; Ketika memasang cups,parts. jaga agar bibirnya tidak do not substitute individual berputar terbalik bagian dalammaster di luar. • Apply brake fluid to the spring, piston and piston Pastikan bahwa snap ring telah duduk dengan erat cups. pada alurnya. • When installing the cups, do not allow the lips to turn inside out. • Apply silicone grease to the brake lever pivot bolt sliding surface and boot as specified. • Be sure that snap ring is firmly seated in the groove.

•

SNAP RING

SNAP RING PLIERS

•

•

* BOOT

SPRING WASHER PISTON CUPS

PIVOT BOLT 1 N·m (0.1 kgf ·m, 0.7 lbf ·ft) MASTER CYLINDER BODY

SNAP RING MASTER PISTON

BRAKE LIGHT SWITCH

BRAKE LEVER *: Oleskan 0.1 g silicone grease

PIVOT NUT 6 N·m (0.6 kgf ·m, 4.4 lbf ·ft)

PEMERIKSAAN INSPECTION Check the piston cups wear, deterioration damage. Periksa piston cupsforterhadap keausan,orpemburukan Check the master cylinder inner surface and piston outer surkondisi atau kerusakan. face for scratches or damage. Periksa permukaan dalam master cylinder dan permukaan luar cylinder piston I.D.terhadap goresan atau Measure the master kerusakan. SERVICE Ukur D.D. master cylinder. LIMIT: 11.055 mm (0.4352 in) MeasureSERVIS: the master 11,055 piston O.D. BATAS mm SERVICE Ukur D.L. master piston. LIMIT: 10.945 mm (0.4309 in) BATAS SERVIS: 10,945 mm

13-12

SCREW 1 N·m (0.1 kgf ·m, 0.7 lbf ·ft)

SISTEM REM

BRAKE CALIPER CALIPER BRAKE REMOVAL PELEPASAN Avoidagar spilling fluidrem on Jaga minyak painted, plastic, or tidak tertumpah atas rubber parts. parts yang dicat, atau Place terbuatadari shopplastik towel atau karet. over these parts Letakkan lap whenever thekain system menutupi parts ini is serviced. setiap kali sistem diservis.

Drain the brake fluid (page 13-6). Keluarkan brake fluid (hal. 13-6). Remove the following: Lepaskan sebagai berikut: – Oil bolt/sealing washers - Oil bolt/sealing washers – Pad spring - Pad spring – Brake pads (page 13-8) - Brake padsbolts (hal. 13-8) – Mounting - – Mounting bolts Brake caliper (baut pemasangan) - Brake caliper

INSTALLATION PEMASANGAN

Install the front brake caliper onto the left fork leg. Pasang front brake caliper pada kakithem kiri fork. Install new mounting bolts and tighten to the specified Pasang torque. mounting bolts baru dan kencangkan dengan torsi yang ditentukan. TORQUE:30 N·m (3.1 kgf·m, 22 lbf·ft)

Tighten the oil bolt Kencangkan oil bolt while pushing the sementara menekan brake hose eyelet brake hose eyelet joint joint against the terhadap stopper. stopper.

TORSI: 30 N.m 22 lbf.ft) Connect the brake(3,1 hosekgf.m; to the brake caliper with the oil bolt and new sealing washers. Sambungkan brake hose pada brake caliper dengan oil bolt danthe sealing washers baru. torque. Tighten oil bolt to the specified Kencangkan oil bolt dengan torsi yang ditentukan. TORQUE:34 N·m (3.5 kgf·m, 25 lbf·ft) TORSI: 34 N.m (3,5 kgf.m; 25 lbf.ft) Install the brake pads (page 13-9). Pasang brake pads (hal. 13-9). Fill the brake fluid and bleed the hydraulic system (page 13Isi brake fluid dan bleed (buang udara palsu) dari sistem 7). hidraulik (hal. 13-7).

BRAKE HOSE

OIL BOLT 34 N·m (3.5 kgf ·m, 25 lbf ·ft)

BRAKE CALIPER

SEALING WASHERS

BRAKE CALIPER MOUNTING BOLTS 30 N·m (3.1 kgf ·m, 22 lbf ·ft)

13-13

SISTEM REM DISASSEMBLY/ASSEMBLY PEMBONGKARAN/PERAKITAN

not useudara high Jangan Do memakai pressure air or bring bertekanan tinggi atau meletakkan nozzle the nozzle too terlalu dekat close to the pada inlet. lubang.

Remove/install the following: Lepaskan/pasang sebagai berikut: Caliper bracket - –Caliper bracket – Pin boots - Pin boots – Pad spring - Pad spring Place a shop towel over the piston. Letakkan kain lap di atas piston. Position the caliper body with the piston facing down and Tempatkan caliper body dengan piston menghadap ke apply small squirts of air pressure to the fluid inlet to remove bawah dan jalankan semprotan-semprotan kecil udara the piston. bertekanan pada lubang masuk fluid untuk Remove the dust seal/piston seal. mengeluarkan piston. Install the removed parts in the reverse order of removal. Keluarkan dust seal/piston seal.

Pasang parts yang telah dilepaskan dalam urutan • Replace piston seals and dust seals with new ones. terbalik dari the pelepasan. • Apply brake fluid to the piston and piston seals. • Apply silicone grease to the bracket pin boots and dust seals as specified. DUST SEAL

* BRACKET PIN BOOT

CALIPER BRACKET Pasang caliper piston dengan ujung yang terbuka menghadap ke brake pads.

PISTON SEAL

*

BRACKET PIN BOOT BLEED VALVE 6 N·m (0.6 kgf ·m, 4.4 lbf ·ft) PAD SPRING CALIPER BODY CALIPER PISTON

PEMERIKSAAN INSPECTION Periksa caliper cylinder gerusan, goresan atau Check the caliper cylinderterhadap for scoring, scratches or damage. kerusakan. Measure the caliper cylinder I.D. Ukur D.D. caliper cylinder. SERVICE LIMIT: 32.090 mm (1.2634 in) BATAS SERVIS: 32,090 mm Check the caliperpiston piston terhadap for scoring,gerusan, scratchesgoresan or damage. Periksa caliper atau kerusakan. Measure the caliper piston O.D. Ukur D.L. caliper piston. SERVICE LIMIT:SERVIS: 31,94 31.94 mm BATAS mm(1.257 in)

13-14

*: Oleskan minimum 0.4 g grease

14. BATERAI/SISTEM PENGISIAN/ALTERNATOR

LOKASI SISTEM ....................................14-2 SYSTEM LOCATION ····································14-2

FLYWHEEL / ALTERNATOR STATOR... 14-7 FLYWHEEL/ALTERNATOR STATOR······14-7

DIAGRAM ................................14-2 SYSTEMSISTEM DIAGRAM ······································14-2

PEMERIKSAAN ALTERNATOR.............. 14-11 ALTERNATOR INSPECTION···················· 14-12

LOKASI KOMPONEN-KOMPONEN......14-3 COMPONENT LOCATION ·························· 14-3

BATERAI.................................................. 14-12 BATTERY ······················································14-12

KETERANGAN SERVIS ........................14-4 SERVICE INFORMATION ···························14-4

SISTEM PENGISIAN................................ 14-13 CHARGING SYSTEM ························ ········· 14-13

TROUBLESHOOTING ...........................14-6 TROUBLESHOOTING ··································14-6

REGULATOR / RECTIFIER ..................... 14-14 REGULATOR/RECTIFIER ························· 14-14

14

14-1

BATERAI/SISTEM PENGISIAN/ALTERNATOR

SYSTEMSISTEM LOCATION LOKASI BATTERY/CHARGINGSYSTEM/ALTERNATOR

DIMMER SWITCH

LIGHTING SWITCH

BATTERY

REGULATOR/RECTIFIER

ALTERNATOR


Y W MAIN FUSE 15A

R

3P

R Y W G

4P

Y W

G

R: Red G: Green

G BATTERY

14-2

REGULATOR/ RECTIFIER

Y: Yellow W: White ALTERNATOR


COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN

6 N· N·m (0.6 kgf ·m, 4.4 lbf ·ft)

39 N· N·m (4.0 kgf ·m, 29 lbf ·ft)

10 N· N·m (1.0 kgf ·m, 7 lbf ·ft)

14-3


KETERANGAN SERVIS SERVICE INFORMATION UMUM GENERAL ! PERINGATAN • Baterai mengeluarkan gas-gas eksplosif; eksplosif; jauhkan percikan bunga api, lidah api dan rokok. Sediakan ventilasi • The battery gives off off explosive gases; keep sparks, flames and cigarettes away. away. Provide adequate ventilation ventilation when charging. charging. memadai ketika mengisi muatan listrik. • The battery contains contains sulfuric acid (electrolyte). (electrolyte). Contact Contact with skin or eyes may cause severe burns. burns. Wear Wear protective clothing and a face Baterai mengandung mengandung asam sulfat (elektrolit). Kontak dengan kulit atau mata dapat menyebabkan luka bakar parah. • shield. Pakailah pakaian – If electrolyte gets gets onpelindung your skin,dan flushpelindung with water.mata. Jika elektrolit mengenai kulit, bilas air. – If electrolyte gets gets in your eyes, flush with withdengan water for at least least 15 minutes and call a physician physician immediately. immediately. Jika elektrolit mengenai mata, bilas dengan air selama sekurangnya sekurangnya 15 menit dan mintalah • Electr Electroly olyte te is is poiso poisonou nous. s. bantuan dokter segera. – If swallowed, drink dengan large large quantities of of water or milk and call call your local Poison Control Center or a call call a physician physician immediately. immediately. • Electrolit beracun. - Jika tertelan, minumlah sejumlah besar air atau susu dan hubungilah Pusat Penanganan Keracunan dengan segera atau minta bantuan dokter dengan segera. • Always turn turn off the ignition switch before before disconnecting disconnecting any electrical component. • Some electri electrical cal components may be damaged if terminals or connectors are connected connected or disconnected while the ignition ignition switch is ON and CATATAN current is present.kunci kontak sebelum melepaskan komponen listrik. Selalu matikan •

Beberapa komponen listrik the dapat rusak jika atau connector dilepaskan sementara kuncithe For extended storage, remove remove battery, give it aterminal it full charge, and store it in disambungkan store a cool, dry space. space.atau For maximum servi service ce life, charge thekonta stored battery two weeks. weeks. pada posisi pevery osisi ON O N dan arus listrik listrik mengalir mengalir.. • For a battery battery remaining in in a stored scooter, scooter, disconnect the negative battery cable cable from the battery terminal. terminal. • The maintenanc maintenance e free batt battery ery must be replaced when it reaches the end of its service life. Untuk penyimpanan penyimpanan jangka panjang, lepaskan baterai, berikan muatan penuh, dan simpan di tempat kering yang sejuk. Untuk • • The battery can can be damaged if overcharged if or undercharged, undercha rged, oryang if leftdisimpan to discharge for long period.listrik Thesesetiap same conditions same contribute to shortcontribute mendapatkan umur pemakaian maksimum, isilah baterai dengan muatan dua minggu. ening the "life span" of the battery. Even under normal use, the performance of the battery deteriorates after 2-3 years. • Untuk baterai yang tetap dipasang pada skuter yang disimpan, lepaskan kabel negatif baterai dari terminal baterai. • Battery voltage voltage may recover after after battery charging, but under heavy load, load, battery voltage will drop quickly and eventually die out. out. For this Baterai maintenance free harus diganti jika ia mencapai akhir dari umur pemakaiannya. • reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in the battery itself, which may • Baterai dapat rusak jika di-overcharge di-overcharge (diisi muatan listrik berlebihan) atau di- undercharge (kurang pengisian muatan listrik), appear to be an overcharging symptom. If one o f the battery cells is shorted and battery voltage does not increase, the regulator/rectifier supatau excess bila iavoltage dibiarkan berkurang sendiri muatannya jangka lama.down Keadaan-keadaan sama ini ikut berperan dalam plies vol tage to the battery. Under battery. these conditions,untuk conditions, the electrolyte electrol ytewaktu level goes quickly. quickly. memperpendek umur pemakaian baterai. Bahkan pada pemakaian normal, unjuk kerja baterai memburuk setelahunder 2-3 • Before troubleshooting troubleshooting the charging system, check check for proper use and maintenance of the battery. Check Check ifakan the battery is frequently tahun. heavy load, such as having the headlight and taillight ON for long periods of time without riding the scooter. Voltase baterai dapat membaik membaik kem setelah listrik baterai, tetapi every di bawah beban beba voltase baterai • • The battery will self-discharge will whenkembali the bali scooter is notpengisian in use. Formuatan this reason, charge the battery two weeks we eksntoberat, prevent sulfation sulfation from akan turun dengan cepat dan akhirnya mati. Karena itu, sistem pengisian seringkali diduga sebagai penyebab persoalannya. occurring. Battery overcharge seringkali diakibatkan oleh dalam baterai sendiri, yang14-6). mungkin tampak sebagai gejala • When checki checking ng the charging charging system, always follow thepersoalan steps in thedi troubleshooting flow chart (page 14-6) . overcharging. Jika do salah satu sel hubungan voltase bertambah, regulator/rectifier • For battery charging, not exceed the baterai chargingada current and time time singkat specifieddan on the the battery.baterai Use of excessive etidak xcessive current or charging time may may damage the voltase battery. berlebihan ke baterai. Di bawah kondisi ini, tinggi permukaan elektrolit akan menurun dengan cepat. memasok flywheel, alternator and and ignition pulse generator services service s can beapakah done with the engine installed in thedengan installed frame. baik dan bagaimana • • The Sebelum troubleshooting sistem pengisian, periksalah baterai dipergunakan • Refe Refer r to page 15 15-7 -7 for igni ignition tion pu pulse lse gen generat erator or inspe inspectio ction. n. perawatannya. Periksa apakah baterai seringkali di bawah beban berat, seperti jika lampu besar dan lampu belakang menyala terus untuk jangka waktu lama tanpa mengendarai skuter. Baterai akan berkurang muatan listrik dengan sendirinya jika skuter tidak dipakai. Oleh karena itu, isilah baterai dengan dengan • BATTERY CHARGING muatan listrik setiap dua minggu untuk mencegah terjadinya sulfasi. the power the ON/OFF ON/OFF at the pengisian, at charger, notselalu charger, at the battery at bat tery terminal. termina l. Sewaktu memeriksa sistem ikuti langkah-langkah pada peta aliran troubleshooting (hal. 14-6). • • Turn battery charging, do notmuatan exceed the charging current and time timelampaui me specifiedarus on sthepengisian battery. Using current or extending the charging Pada waktu pengisian listrik baterai, jangan aru dan danexcessive waktu yang ditentukan pada baterai. baterai. • • For time may damage the battery. Pemakaian arus atau waktu pengisian berlebihan dapat merusak baterai. • Quic Quick k charging chargin g should only bealternator only done in andan emerg emergency; ency;pulse slow charging slow charg ing is preferred. pref erred. Pekerjaan servis flywheel, ignition generator dapat dijalankan dengan mesin terpasang pada rangka. • • Lihat hal. 15-7 untuk pemeriksaan ignition pulse generator. • •

BATTERY TESTING

PENGISIAN MUATAN LISTRIK BATERAI to the instruction o f the Operation the charger recommended battery tester for details battery testing. Hidup/matikan daya listrik denganManual saklar for pada (alat pengisian muatan listrikabout baterai), dan bukan pada terminal baterai. •Refer The recommended battery tester puts a "load" on the battery so that the actual battery condition of the load can be Sewaktu mengisi mengisi muatan listrik baterai, jangan jangan melampaui arus dan waktu pengisian seperti terterameasured. pada baterai. Pemakaian • arus listrik berlebihan atau memperpanjang waktu pengisian dapat merusak baterai. Recomm mmen ende ded d batt batter ery y tes teste ter: r: muatan BM-2 BM-210 10 ordengan BATT BATTER ERY Y MA MATE or equi eqboleh uiva vale lent nt •Reco Quick charging (pengisian listrik cepat) hanya dilakukan dalam keadaan darurat, lebih diutamakan pengisian muatan lsitrik dengan pelan). PENGETESAN BATERAI Bacalah petunjuk pemakaian di dalam Operation Manual untuk battery tester yang dianjurkan untuk detil-detil mengenai pengetesan baterai. Battery tester yang dianjurkan meletakkan "beban" pada baterai sehingga kondisi baterai sebenarnya dari beban dapat diukur. Battery tester yang yang dianjurkan:

14-4

BM-210 atau BATTERY MATE atau sejenisnya

BATERAI/SISTEM PENGISIAN/ALTERNATOR SPESIFIKASI SPECIFICATIONS BAGIAN Baterai Battery

Alternator Alternator

Kapasitas ITEM Capacarus ity Kebocoran C u r r e n t leakage Voltase Voltage Arus pengisian Charging current Kapasitas Capacity

NILAI TORSI TORQUE VALUES Cooling fan mounting bolt Flywheel nut Cooling fan mounting bolt Ignition pulse generator bolt Flywheel nut Ignition pulse generator bolt

Terisi penuh Fullydiisi chalistrik rged kembali Perlu Needs charging Normal Normal Cepat Quick

SPESIFIKASI SP3,5 ECAh IFICATIONS 12 V – 1 2 – 3mA .5 Ah maksimum V 0,5 0 . 5 m A Di atas 12,8 V max. bove V 12.8 V Di bawahA12,3 12.3 V 0,4 A / 5 Below – 10 jam 0.4jam A/5 – 10 h 3,0 A / 0,5 -1 0 A00 /0.5menit h 0,140 kW 3/ .5.000 5.0 (rpm) -1 0.111 kW/5,000 min (rpm)

10 N.m (1,0 kgf.m; 7 lbf.ft) 39N. (4,0 kgf.m; 29 lbf.ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 6 N.m (0,6 kgf.m; 4,4 lbf.ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 6 N·m (0.6 kgf·m, 4.4 lbf·ft)

TOOLS TOOLS Holder P.D. 32-92 07NAB-HAC0100

Flywheel puller 07733-0010000

14-5


TROUBLESHOOTING TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK BATERAI RUSAK ATAU LEMAH 1. Ba Batt tter ery y Te Test st • Test Baterai Remove the battery (page 14-12). 14-12). Lepaskan baterai (hal. 14-12). Check the battery condition using the recommended battery tester. Periksa kondisi baterai dengan menggunakan battery RECOMMENDED BATTERY TES-tester yang direkomendasikan. TE R: BMatau -210 oBATTERY r BATTERY MATatau E or esejenisnya. quivalent BATTERY TESTER YANG DIREKOMENDASIKAN: BM-210 MATE Is thekondisi battery inbaik? good condition? Apakah baterai dalam

YA TIDAK •

•

•

G O TO STEP 2. YES DENGAN – GO - LANJUTKAN DE NGAN LANGKAH 2.

- Baterai NO rusak – Faulty battery

2. Arus Curren Cur rent t Lea Leakag kagee Te Test st Test Kebocoran Listrik Install the battery (page 14-12). 14-12). Pasang baterai (hal. 14-12).

the battery current leakage ( page 14-12). Periksa kebocoran Check arus listrik baterai (hal. 14-13).( page 14-12). Is the current leakage below 0.5 mA? mA? Apakah kebocoran arus listrik di bawah bawah 0,5 mA? GO TO STEP 4. YES – GO YA - LANJUTKAN DENGAN DENGAN LANGKAH 4. NO – GO TO STEP 3. TIDAK - LANJUTKAN DENGAN LANGKAH LANGKAH 3. 3. Curr Current ent Leakage Leakage Test Test Without Without Regulator/ Regulator/rect rectifie ifierr Test Kebocoran Arus Listrik Tanpa Regulator/rectifier Disconnect the regulator/rectifier connector and recheck the battery current leakage. Lepaskan regulator/rectifier connector dan periksa kembali kebocoran arus listrik baterai. Is the current leakage below 0.5 mA? mA? Apakah kebocoran arus listrik di bawah bawah 0,5 mA? Faulty regulator/rectifi regulator/rectifier er YES – Faulty YA - Regulator/rectifier rusak Shor orte ted d wire wire har harne ness ss NO – • Sh TIDAK - • Ada hubungan •singkat wire Faul Fa ulty typada igniti igni tion on swharness swit itch ch • Ignition switch (kunci kontak) rusak 4. Alter Alternato natorr Chargin Charging g Coil Coil Inspec Inspection tion Pemeriksaan Kumparan Pengisian Alternator Check the alternator charging coil (page 14-11). 14-11).

Periksa kumparan Is pengisian alternator (hal.coil 14-11). the alternator charging resistance within 0.2 resistance 0.2 – 1.0 Apakah tahanan kumparan a5.lternator di antara 0,2 – 1,0 Gpengisian O TO STEP alternator YES – GO YA TIDAK •

(20° C/68° F)? Ω (20

(20 C)?

- LANJUTKAN DENGAN DE NGANcharging LANGKAH coil 5. NO – Faulty - Kumparan pengisian rusak 5. Cha Charg rging ing Volta Voltage ge Inspec Inspectio tion n

Measure and record the battery voltage using a digital multimeter (page 14-12). 14-12). Pemeriksaan Voltase Pengisian Startbaterai the engine. Ukur dan catat voltase dengan menggun akan digital multimeter (hal. 14-12). 14-12). Hidupkan mesin. Measure the charging voltage (page 14-12). Compare measurements to result of the following calculation. Ukur voltase pengisian (hal.the 14-13). STANDARD: Measured battery Voltage < Measured charging voltage < 15.5 V Bandingkan hasil pengukuran dengan hasil dari perhitungan berikut ini. Is the measured chadiukur charging rging voltage within within the standard voltdiukur voltage? age? STANDARD: Voltase baterai yang Voltase pengisian yang 15,5 V

•

Faulty battery YES – Faulty Apakah voltase pengisian yang diukur diukur di dalam voltase standard? NO – GO TO STEP 6. - Baterai rusak YA 6. Regu Regulato lator/rec r/rectifie tifierr System System Inspe Inspectio ction n TIDAK - LANJUTKAN DENGAN LANGKAH LANGKAH 6. Check the voltage and resistance at the regulator/rectifier connectors (page 14-14). 14-14). Pemeriksaan Sistem Regulator/Rectifier Are the results results of checked voltage voltage and resistance correct? correct? Periksa voltase dan tahanan pada regulator/rectifier connectors (hal. 14-14). Faulty regulator/rectifi regulator/rectifier er YES – Faulty Apakah hasil dari voltase dan tahanan yang diperiksa benar? Open n circu circuit it in in relate related d wire wire NO – • Ope YA - Regulator/rectifier • rusak Loose or poor conta contacts cts of of related related termin terminal al • Sh Shor orte ted d wire wire har harne ness ss TIDAK - • Rangkaian terbuka pada pada kawat yang bersangkutan atau buruk dari terminal yang bersangkutan • Kontak longgar atau • Ada hubungan singkat pada wire harness

14-6


FLYWHEEL/ALTERNATOR FLYWHEEL/A LTERNATOR FLYWHEEL/ALTERNATOR FLYWHEEL/ALTE RNATORSTATOR STATOR PELEPASAN REMOVAL Lepaskan cooling Remove the coolingfan fancover cover(hal. (page2-12). 2-12). Lepaskan bolts dan Remove themounting mounting bolts and(baut coolingpemasangan) fan. cooling fan.

BOLTS

COOLING FAN

Lepaskan crankcase breather drain (slang Release the crankcase breather drain hose fromhose the clamp. pembuangan pernapasan crankcase) dari clamp. Remove the two air cleaner housing mounting bolts from the Lepaskan left side. kedua air cleaner housing mounting bolts dari Remove sisi kiri. the bolt from the right side of air cleaner housing. Lepaskan bolt dari sisi kanan dari air cleaner housing.

BOLTS

DRAIN HOSE

CLAMP

housing sedikit air cleaner Be careful not to Angkat Slightlyair lift cleaner the air cleaner housing overditheatas air cleaner housbolt boss. ing bolt boss. disconnect the air housing cleaner housing Hold the flywheel with the special tool and loosen the flyconnecting hose from Tahan flywheel dengan special tool dan longgarkan wheel nut. the carburetor. flywheel nut. TOOL: TOOL: Holder 32-92 Holder P.D. P.D. 3 2-92

BOLT AIR CLEANER HOUSING BOLT BOSS

07NAB-HAC0100 07NAB-HAC0100

Lepaskan flywheel nut Remove the flywheel nutdan andwasher. washer.

HOLDER P.D. 32-92

NUT/WASHER

Lepaskan flywheel menggunakan Remove the flywheeldengan using the special tool. special tool. TOOL: TOOL: puller Flywheel Flywheel puller

07733-0010000 07733-0010000

FLYWHEEL PULLER

14-7

BATERAI/SISTEM PENGISIAN/ALTERNATOR Disconnect the alternator/ignition pulse generator 3P connecLepaskan alternator/ignition pulse generator 3P tor. connector. Release the alternator/ignition pulse generator wire band boss Lepaskan alternator/ignition pulse generator wire band from the frame. boss dari rangka.

ALTERNATOR/IGNITION PULSE GENERATOR 3P CONNECTOR

WIRE BAND BOSS

Lepaskan alternator/ignition Release the alternator/ignitionpulse pulsegenerator generator wire wire band band bosses dari intake shroud dan rangka. bosses from the intake shroud and frame.

WIRE BAND BOSS

Lepaskan bolt, wire Remove the bolt, wireholder holderdan and lepaskan release thewire wire grommet grommet from the crankcase. right crankcase. dari right

WIRE GROMMET

WIRE HOLDER Remove the two bolts plate from theignition ignitionpulse pulse Lepaskan kedua boltsand dansetset plate dari generator. generator.

WIRE BAND BOSS

BOLT

BOLTS

Remove the two mounting bolts, stator and ignition pulse Lepaskan kedua mounting bolts, stator dan ignition generator from the right crankcase. pulse generator dari right crankcase.

STATOR

BOLTS

SET PLATE IGNITION PULSE GENERATOR

14-8

BATERAI/SISTEM PENGISIAN/ALTERNATOR Remove the woodruff key. Be careful to Lepaskan Hati-hati agar not tidak woodruff key. merusak key dan damage the keyalur. and groove.

WOODRUFF KEY

PEMASANGAN Hati-hati agar tidak Pasang woodruff key ke dalam alur crankshaft key. merusak key dan alur.

INSTALLATION Be careful not to Install the woodruff key into the crankshaft key gro ove. damage the key and the groove.

Set the stator and ignition pulse generator onto the pada right Tempatkan stator dan ignition pulse generator crankcase. right crankcase. Install and tighten the statorstator mounting bolts. bolts. Pasang dan kencangkan mounting

BOLTS STATOR

Install the plate pada onto the ignition pulsegenerator generator dan and Pasang setsetplate ignition pulse tighten the mounting bolts tobolts the specified torque. kencangkan mounting dengan torsi yang ditentukan. TORQUE:6 N·m (0.6 kgf·m, 4.4 lbf·ft)

BOLT

TORSI: 6 N.m (0,6 kgf.m; 4,4 lbf.ft)

SET PLATE IGNITION PULSE GENERATOR Route thekawat wire properly set the dan wire grommet intowire the Alurkan denganandbenar tempatkan right crankcase groove. grommet ke dalam alur right crankcase.

WIRE GROMMET

Set the wire holder and tighten the holder bolt. Tempatkan wire holder dan kencangkan holder bolt.

WIRE HOLDER Alurkan Route thealternator alternator/ ignition pulse generator ignition pulse wire dengan benar generator(hal. wire 1-14). properly (page 1-14).

BOLTS

Set the alternator/ignition pulse generator wire band bosses to Tempatkan alternator/ignition pulse generator wire band the intake shroud and frame. bosses pada intake shroud dan rangka.

WIRE BAND BOSS

WIRE BAND BOSS

14-9

BATERAI/SISTEM PENGISIAN/ALTERNATOR Set the alternator/ignition pulsepulse generator wire band to Tempatkan alternator/ignition generator wireboss band the frame. boss pada rangka. Connect the alternator/ignition pulse generator 3P connector. Sambungkan alternator/ignition pulse generator 3P connector.

ALTERNATOR/IGNITION PULSE GENERATOR 3P CONNECTOR Install the flywheel ontocrankshaft the crankshaft by aligning the key Pasang flywheel pada dengan mentepatkan wayway on the(alur flywheel the key on the dengan crankshaft. key spie)with pada flywheel key pada crankshaft.

WIRE BAND BOSS

WOODRUFF KEY

KEY WAY

Tepatkan

Pasang washer Install the washerdan andflywheel flywheel nut. nut. WASHER

NUT

Tahan flywheel dengan special Hold the flywheel with the specialtool tooldan and kencangkan tighten the nutnut to dengan torsi torque. yang ditentukan. the specified TOOL: TOOL:P.D. 32-92 Holder 07NAB-HAC0100 Holder P.D. 32-92 07NAB-HAC0100 TORSI: 39 N.m (4,0 kgf.m; 29 lbf.ft) TORQUE:39 N·m (4.0 kgf·m, 29 lbf·ft)

HOLDER P.D. 32-92

14-10

FLYWHEEL NUT

BATERAI/SISTEM PENGISIAN/ALTERNATOR Set the airair cleaner housing in position. Letakkan cleaner housing pada tempatnya.

BOLTS

Install and tighten the bolt to the right side of air cleaner Pasang housing.dan kencangkan bolt pada sisi kanan dari air cleaner housing. Install and tighten the two bolts to the left side of air cleaner housing.dan kencangkan kedua bolts pada sisi kiri dari Pasang air cleaner housing.drain hose with the clamp. Secure the breather

DRAIN HOSE

CLAMP

Pasang cooling dan tighten kencangkan mounting bolts Install the coolingfan fan and the mounting bolts to the dengan torsi yang ditentukan. specified torque.

BOLT BOLTS

TORQUE:10 N·m (1.0 kgf·m,77lbf.ft) lbf·ft) TORSI: 10 N.m (1,0 kgf.m;

Pasang cooling fan cover Install the cooling fan cover(hal. (page2-12). 2-12).

COOLING FAN

PEMERIKSAAN ALTERNATOR ALTERNATOR INSPECTION Remove the centerbody bodycover cover (hal. (page2-8). 2-8). Lepaskan center Disconnectalternator the alternator 3P connector. Lepaskan 3P connector. Check the resistance between the following Periksa tahanan antara terminals berikut terminals. ini. STANDARD: STANDARD: Charging coil (White – (Putih ground): Kumparan pengisian – massa): °F) 0.2 – – 1,0 1.0 Ω (at 20 °C/68 0,2 (pada 20 C) Kumparan (Kuning – massa): Lighting coilpenerangan (Yellow – ground): 0,1 (pada 20 C) °F) 0.1 – – 0,8 0.8 Ω (at 20 °C/68

Replace the alternator stator if measuredyang readings arejauh far Ganti alternator stator jika pembacaan diukur ALTERNATOR 3P beyond the standard. di luar standard. CONNECTOR CHARGING COIL:

LIGHTING COIL:

14-11


BATTERY BATERAI PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION CATATAN: thekunci ignition switch ke "OFF" before removing Selalu turn putar kontak posisi "OFF" dulu • • Always the battery.melepaskan baterai. sebelum

Connect theterminal positive Sambungkan terminal first positif dulu and dan then the negative kemudian baru terminalterminal. negatif.

Remove the battery cover (page 2-13). Lepaskan battery cover (hal. 2-13). Remove the bolt and disconnect the negative (–) cable. Keluarkan negatif(+) ( -cable. ). Remove thebolt boltdan and lepaskan disconnectkabel the positive Keluarkan bolt dan lepaskan kabel positif ( + ). Remove the battery. Keluarkan baterai. Install the battery in the reverse order of removal. Pasang baterai dalam urutan terbalik dari pelepasan. After installing the battery, coat the terminals with clean Setelah grease. memasang baterai, lapisi terminal-terminal dengan gemuk bersih. Reinstall the removed parts.

Pasang kembali parts yang dilepaskan.

VOLTAGE INSPECTION PEMERIKSAAN VOLTASE Measure the battery voltage using a commercially available digital multimeter. Ukur voltase baterai dengan menggunakan digital multimeter yang dapat dibeli di pasaran. VOLTAGE (20⋅C/68⋅F): Fully charged: VOLTASE (20 C): Above 12.8 V Under charged: Below 12.3 V 12,8 V Bermuatan penuh: Di atas Muatan kurang: Di bawah 12,3 V

CHARGING SYST

CHARGING VOLTAGE INSPECTION •

14-12

BATTERY

BATTERY/NEGATIVE ( – ) TERMINAL

BATTERY/POSITIVE (+) TERMINAL


SISTEM PENGISIAN TEST KEBOCORAN ARUS LISTRIK Buka battery cover (hal. 2-13).

( – ) JARUM

(+) JARUM

Putar kunci kontak ke OFF dan lepaskan kabel negatif ( - ) dari baterai. Hubungkan jarum pemeriksaan ( + ) ammeter ke kabel negatif ( - ) dan jarum pemeriksaan ( - ) ammeter ke terminal ( - ) baterai. Dengan kunci kontak pada posisi OFF, periksa terhadap kebocoran arus listrik. CATATAN: • Ketika mengukur arus listrik dengan menggunakan tester, letakkan pada daerah jangkauan tinggi dulu, kemudian turunkan daerah jangkauan ke tingkat yang sesuai. Aliran arus listrik yang lebih tinggi dari daerah jangkauan yang dipilih dapat memutuskan sekring di dalam tester. • Sewaktu mengukur arus listrik, jangan putar arus kunci kontak ke ON. Lonjakan arus listrik dengan mendadak dapat memutuskan sekring di dalam tester.

( – ) KABEL

KETENTUAN KEBOCORAN ARUS LISTRIK: maksimum 0,5 mA. Make sure the battery is in good condition before perthis test. Jika forming kebocoran arus listrik melampaui nilai yang • Do not disconnect the battery or any cable in the charging ditentukan, kemungkinan ada hubungan singkat. system without first switching the dengan ignition switch to OFF. Carilah lokasi hubungan singkat melepaskan Failure to follow this precaution can damage the tester hubungan satu demi satu dan mengukur arus listrik. or electrical components. Warm up the engine to normal operating temperature.

PEMERIKSAAN VOLTASE PENGISIAN Stop the engine. To prevent a short, make absolutely certain which are the positive and negative terminals or cables.

Remove the battery cover (page 2-13) and connect the multiCATATAN: meter as shown. • Pastikan bahwa baterai dalam kondisi baik sebelum Connect a tachometer. menjalankan test ini. Jangan melepaskan baterai atauthe kabel apapun di • With the headlight on high beam, restart engine. dalam sistem onpengisian tanpa Measure the voltage the multimeter when terlebih the engine dulu runs mematikan kunci kontak ke OFF. Kegagalan untuk at 5,000 min-1 (rpm). mengikuti tindakan pencegahan ini dapat merusak tester atau komponen-komponen listrik. STANDARD:

Measured battery voltage (page 14-12) Panaskan mesin ke suhu operasi normal. < Measured charging voltage (page 14-12) Matikan mesin. < 15.5 V at 5,000 min -1 (rpm) Untuk menghindari Lepaskan battery cover (hal. 2-13) dan hubungkan hubungan singkat, multimeter seperti diperlihatkan.

REGULATOR/RECTIFIER

pastikan dengan benar manalah terminal atau Hubungkan REMOVAL/INSTALLATION tachometer. kabel positif dan negatif.

Remo lampu besar pada sinar lampu jauh, hidupkan Dengan mesin kembali. Ukur voltase pada multimeter sewaktu mesin berputar -1 pada 5.000 menit (rpm).

STANDARD: Ukur voltase baterai (hal. 14-12) Voltase pengisian yang diukur (hal. 14-13) -1 15,5 V pada 5.000 menit (rpm)

14-13


REGULATOR/RECTIFIER

e the body cover (page 2-9).

PELEPASAN/PEMASANGAN

BOLT

Turn the ignition switch to OFF. Lepaskan body cover (hal. 2-9). Disconnect the regulator/rectifier 4P connector. Putar kunci kontak ke OFF. Remove the bolt and the regulator/rectifier. Lepaskan regulator/rectifier 4P connector. Installation is in the reverse order of removal. Lepaskan bolt dan regulator/rectifier.


adalah

dalam

urutan

terbalik

dari 4P CONNECTOR

SYSTEM INSPECTION Remove the body cover (page 2-9). Disconnect the regulator/rectifier 4P connector and check it for loose contact or corroded terminals. PEMERIKSAAN SISTEM If the battery charging voltage reading (page 14-12) is out of Lepaskan body cover (hal. 2-9). the specification, inspect the connector terminals (wire harness side) asregulator/rectifier follows: Lepaskan 4P connector dan periksa terhadap kontak longgar atau terminal-terminal Item Terminal Specification berkarat. Battery charging Red (+) and Battery voltage line ground (–) should(hal. register Jika pembacaan voltase pengisian baterai 14-13) Ω Charging coil line White and 0.2 – 1.0 di luar spesifikasi, periksa terminal-terminal connector (sisi wire harness) ground sebagai berikut: (at 20°C/68°F) Ground line Green and ground Continuity should exist Bagian Terminal Spesifikasi

REGULATOR/RECTIFIER 4P CONNECTOR

Saluran of the charging Merah (+) dan are normal Harusandada omponents system there pengisian massa ( ) voltase are no loose connections, replace the regulator/rectifier baterai baterai unit. Saluran Putih dan 0,2 – 1,0 Ω kumparan massa (pada 20°C) pengisian Saluran massa Hijau dan Harus ada massa kontinuitas Jika semua komponen sistem pengisian adalah normal dan tidak ada sambungan longgar, gantilah regulator/rectifier unit.

REGULATOR/ RECTIFIER 4P CONNECTOR

REGULATOR/ RECTIFIER 4P CONNECTOR

REGULATOR/RECTIFIER 4P REGULATOR/ CONNECTOR RECTIFIER

14-14

REGULATOR/ RECTIFIER

BATERAI/SISTEM PENGISIAN/ALTERNATOR If thepembacaan lighting voltage reading is out of the specification. Jika voltase penerangan (hal. 14-15) di luar Disconnect the tail/brake light/rear turn signal light 6P conspesifikasi, lepaskan tail/brake light/rear turn signal 6P nector (page 2-9), then check the connector terminals (wire connector (hal. 2-9), kemudian periksa connector harness side) as wire follows: terminals (sisi harness) sebagai berikut: Terminal Specification Bagian Terminal Spesifikasi Yellow and 0.2 – 1.8 Ω Saluran kumparan (at 20 Kuning 0,2 – 1,8 Ω °C/68°F) ground penerangan dan (pada 20°C) Green and ground Continuity massa should exist Saluran massa Hijau dan Harus ada massa are normal kontinuitas If all components of the system and there are no loose connections at the regulator/rectifier connectors, replace the regulator/rectifier Jika semua komponen dariunit. sistem adalah normal dan tidak ada sambungan longgar pada regulator/rectifier connectors, gantilah regulator/rectifier unit.



14-15

CATATAN

15. SISTEM PENGAPIAN

LOKASI SISTEM...................................... 15-2 SYSTEM LOCATION ···································· 15-2

IGNITION COIL ......................................15-8 IGNITION COIL ············································· 15-8

DIAGRAM SISTEM .................................. 15-2

IGNITION SWITCH.................................15-8

KETERANGAN SERVIS .......................... 15-3

SIDESTAND SWITCH............................15-9

TROUBLESHOOTING ............................. 15-4

IGNITION CONTROL MODULE (ICM)...15-11

PEMERIKSAAN SISTEM PENGAPIAN... 15-5

IGNITION TIMING ..................................15-12

SYSTEM DIAGRAM ······································ 15-2 SERVICE INFORMATION ··························· 15-3 TROUBLESHOOTING ·································· 15-4 IGNITION SYSTEM INSPECTION·············15-5

IGNITION SWITCH·······································15-8 SIDESTAND SWITCH ··································· 15-9 IGNITION CONTROL MODULE (ICM) ·· 15-11

IGNITION TIMING······································15-12

15

15-1

SISTEM PENGAPIAN

SYSTEM LOCATION LOKASI SISTEM IGNITIONSYSTEM

MAIN FUSE 15A

IGNITION SWITCH BATTERY


SIDESTAND SWITCH IGNITION PULSE GENERATOR

IGNITION COIL


MAIN FUSE 15A

R

G

l / R B R

Y / u B

/ G W G

W / G

l Y / / l G B R B

IGNITION COIL

Br 2P

l B R / R

G

G

3P

W G / G

6P

4P

Y / u B

G


BATTERY

IGNITION SIDE STAND SWITCH SWITCH

15-2

3P

IGNITION PULSE GENELATOR

SPARK PLUG

SISTEM PENGAPIAN

SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM ! PERINGATAN If the engineharus must be run ning to do some woruntuk k, make sure the area is well ventilated. Never run thebahwa engine tempat in an enclosed The exhaust Jika mesin dalam keadaan hidup melakukan sesuatu pekerjaan, pastikan kerja area. berventilasi baik. contains poisonous carbon monoxide gas that may cause loss of consciousness and may Jangan sekali-kali menjalankan mesin di dalam tempat tertutup. Gas pembuangan mengandung gas karbon monoksida beracun lead dapat to death. yang mengakibatkan hilangnya kesadaran dan akhirnya dapat membawa kematian.

CATATAN • Beberapa komponen listrik dapat rusak jika terminal-terminal atau connector-connector disambungkan atau dilepaskan • Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and sementara kunci kontak pada posisi ON dan ada arus listrik yang mengalir. current is present. • Sewaktu menservis sistem pengapian, selalu ikuti langkah-langkah pada urutan troubleshooting pada hal. 15-4. •• When servicing the(waktu ignition system, always stepsoleh in thekarena troubleshooting sequence on page(ICM) 15-4. telah disetel awal di pabrik. Ignition timing pengapian) tidakfollow perluthe disetel Ignition Control Module •• The ignition timing does not normally need to be adjusted since the Ignition Control Module (ICM) is factory preset. arus listrik sedang Ignition Control Module (ICM) dapat rusak jika dijatuhkan. Juga jika connector dilepaskan sewaktu • The Ignition Control Module (ICM) may be damaged if dropped. Also if the connector is disconnected when current is flowing, the excessive mengalir, voltase berlebihan dapat merusak module. Selalu matikan kunci kontak sebelum menservis. voltage may damage the module. Always turn off the ignition switch before servicing. • Sistem pengapian yang tidak bekerja dengan baik seringkali disebabkan oleh sambungan buruk. Selalu periksa • A faulty ignition system is often related to poor connections. Check those connections before proceeding. Make sure the battery is adequately sambungan ini sebelum melanjutkan. Pastikan bahwa baterai bermuatan listrik cukup. Menggunakan starter motor dengan charged. Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at the spark plug. baterai lemah mesin lebih rendah maupun tidak • Use spark plug of menghasilkan the correct heat kecepatan range. Usingperputaran spark plug with an yang incorrect heat range can damage the adanya engine. percikan bunga api pada busi. • Pakailah busi dengan derajat panas yang tepat. Pemakaian busi dengan derajat panas yang tidak tepat dapat merusak mesin. SPECIFICATIONS

SPESIFIKASI

ITEM Standard For extended high speed riding

Spark plug BAGIAN Busi Spark plugStandard gap Untuk lama pada kecepatan tinggi Ignition coil peakpengendaraan voltage Jarak renggang busi Ignition pulse generator peak voltage Peak voltage Ignition timing(voltase puncak) ignition coil Peak voltage ignition pulse generator Ignition timing (pengaturan waktu pengapian)

SPECIFICATIONS CPR8EA-9 (NGK) / U24EPR9 (DENSO) SPESIFIKASI CPR9EA-9 (NGK) CPR 8EA -0.80 9 (NGK), – 0.90U24EPR9 mm (0.031 (DENSO) – 0.035 in) CPR 9EA – 9 (NGK) 100 V minimum 0,80 – 0,90 mm 0.7 V minimum minimum 100 V14° BTDC at idle speed minimum 0,7 V 14° sebelum TMA pada putaran stasioner

TORQUE VALUE Key shutter socket bolt NILAI TORSI

Key shutter socket bolt

10 N·m (1.0 kgf·m, 7 lbf·ft.)

10 N.m (1,0 kgf.m; 7 lbf.ft.)

TOOL TOOL Imrie diagnostic tester (model 625) atau Peak voltage adaptor 07HGJ-0020100

Dengandigital digitalmultimeter multimeter (indepedDengan (indepedansi ansi minimum WM/DCv)yang minimum 10 MΩ10 /DCV )yang dapatdapat di beli beli di pasaran. didipasaran.

15-3

SISTEM PENGAPIAN

TROUBLESHOOTING TROUBLESHOOTING • Inspect the following before diagnosing the system. • – Faulty Periksa sebagai spark plug berikut ini sebelum mendiagnosa sistem. - Spark plug (busi) rusak. – Loose spark plug cap or spark plug wire connection Spark plug cap (topi busi) atau sambungan kabel busi longgarvoltage) – Water got into the spark plug cap (Leaking the ignition coil secondary - Air memasuki spark plug cap (Voltase sekunder ignition coil bocor) No spark at spark plug Unusual Tidak ada percikan bunga apicondition pada busi. Ignition coil Low peak voltage. primary voltage Kejadian luar biasa

Probable cause (Check in numerical order) 1. The multimeter impedance is too low; below 10 MΩ/ DCV. 2. Cranking speed is penyebab too slow. (Battery is undercharged or operatKemungkinan ing force of the kickstarter is weak) (periksa menurut urutan angka) 3. The sampling time of the tester Peak voltage 1. Impedansi multimeter terlalu rendah; di bawah 10and MΩmeasured /DCV. pulse were not Voltase synchronized. (System is normal if measured voltagepada is over the primer (voltase puncak) rendah 2. Putaran start mesin terlalu rendah (Baterai lemah atau gaya dorong standard voltage at least once.) ignition kickstarter lemah) 4. contoh Poorly connected or d aniukur opentidak circuit in the ignition coil 3. Waktu pengambilan tester danconnectors pulsa yang sinkron system. (Sistem adalah normal bila voltase yang diukur adalah sekurangnya sekali di atas voltase standard.) 5. Faulty ignition coil. 4. Connectors tersambung dengan buruk atau ada rangkaian terbuka 6. Faulty ignition control module (ICM) (in case whenpada above No. 1 ignition system (sistem – 5pengapian). are normal). 5. Ignition coil tidak bekerja dengan No peak voltage. 1. Incorrect peakbaik. voltage adaptor connections. 6. Ignition control module (ICM) tidak switch. bekerja dengan baik (dalam hal bila No. 2. Faulty ignition 1-5 di atas adalah3.normal). Loose or poorly connected ICM connectors. Open adapter circuit ortidak poor benar. connection in the Red/Black wire of the Tidak ada peak voltage 1. Sambungan peak4.voltage 2. Ignition switch (kunciICM. kontak) tidak bekerja dengan baik. 5. Open circuit or poor connection in the Green wire of the ICM. 3. ICM connectors longgar atau buruk sambungannya. 6. atau Open circuit in theburuk Green/White wire or Green wire ofdari the side4. Rangkaian terbuka sambungan pada kawat Merah/Hitam stand switch. ICM. 7. atau Faulty sidestand switch. 5. Rangkaian terbuka sambungan buruk pada kawat Hijau dari ICM. 8. Faulty peak voltage adaptor (page 15-5). 6. Rangkaian terbuka pada kawat Hijau/Putih atau kawat Hijau dari sidestand 9. Faulty ignition pulse generator. (Measure the peak voltage.) switch. 10. Faulty ICM (in case when above No.1 – 9 are normal). 7. Sidestand switch tidak bekerja dengan baik. Peak voltage is normal, but no spark jumps 1. Faulty spark plug or leaking ignition coil secondary current. 8. Peak voltage adapter (hal. 15-5) tidak bekerja dengan baik. at the plug. 2. Faulty ignition coil. 9. Ignition pulse generator tidak bekerja dengan baik (Ukur peak voltage). Ignition pulse Low peak voltage. The multimeter impedance too1-9 low.di atas adalah 10. ICM tidak bekerja1. dengan baik (dalam hal bilaisNo. generator 2. Cranking speed is too slow. (Operating force of the kickstarter is normal). weak) Peak voltage normal, 1. Busi tidak bekerja dengan baik atau ada kebocoran pada arus sekunder 3. The sampling time of the tester and measured pulse were not ignition coil. tetapi tidak ada synchronized. (System is normal if measured voltage is over the 2. Ignition coil tidak bekerja dengan baik. percikan bunga api standard voltage at least once.) pada busi 4. Faulty ignition pulse generator (in case when above No.1 – 3 are Ignition Peak voltage rendah 1. Impedansi multimeter terlalu rendah. normal). pulse 2. Putaran start mesin terlalu rendah (Gaya dorong pada kickstarter lemah). No peak voltage. 1. Faulty peak voltage adapter (page 15-5). 3. Waktu pengambilan contoh dari tester dan pulsa yang diukur tidak sinkron generator 2. Faulty ignition pulse generator. (Sistem adalah normal bila voltase yang diukur adalah sekurangnya sekali di atas voltase standard.) 4. Ignition pulse generator tidak bekerja dengan baik (dalam hal bila No. 1-3 di atas adalah normal). Tidak ada peak voltage. 1. Peak voltage adapter tidak bekerja dengan baik (hal. 15-5). 2. Ignition pulse generator tidak bekerja dengan baik.

15-4

SISTEM PENGAPIAN

IGNITION SYSTEM INSPECTION PEMERIKSAAN SISTEM PENGAPIAN CATATAN: theretidak is no spark plug, check all connections for busi, loose Jika ada at percikan bunga api pada • • If or poor contact before measuring peak voltage. periksa semua sambungan terhadap kontak • Use commercially available digital multimeter longgar atau buruk sebelum mengukurwith peaan Ω impedance of 10 M /DCV minimum. voltage (voltase puncak). • The display value differs depending upon the internal Pakailah digital multimeter dengan impedansi • impedance of the multimeter. minimum 10 MΩ/DCV yang dapat dibeli di pasaran. • If using Imrie diagnostic tester (model 625), follow the Nilai yang ditayangkan • manufacturer’s instructions.berbeda tergantung pada impedansi internal dari multimeter. Connect the peak voltage adaptor to the digital multimeter, or Imrie diagnostic •use Jika the Imrie diagnostic tester. tester (model 625) yang dipakai, ikutilah petunjuk pabrik pembuatnya. TOOLS: Imrie diagnostic testervoltage (model 625) or Hubungkan peak adaptor pada digital multimeter, atau pakailah Imrie diagnostic tester. Peak voltage adaptor 07HGJ-0020100 with Commercially available digital multimeter (impedTOOLS: ance 10 MΩ/DCV minimum) Imrie diagnostic tester (model 625) atauPeak voltage adaptor 07HGJ-0020100 dengan digital multimeter yang PEAK VOLTAGE ADAPTORdapat dibeli di pasaran (dengan impedansi minimum 10 M /DCV) INSPECTION

DIGITAL MULTIMETER

PEAK VOLTAGE ADAPTOR

When

PEMERIKSAAN PEAK VOLTAGE ADAPTOR Sewaktu mengetes tegangan tinggi pada sisi sekunder testing the high tension on the ignition coil secondary side ignition denganadaptor, menggunakan peak voltage using the coil peak voltage the inner diode may be damadaptor, di adaptor sebelahwill dalam dapat rusak. Oleh aged. As adiode damaged cause incorrect peak voltage readings, alwaysadaptor consideryang a defective if the peak vo ltkarena sebuah rusak adaptor akan mengakibatkan age readings are all abnormal. pembacaan peak voltage yang tidak benar, selalu The adaptor diode can be easilyadaptor checkedyang by therusak following pertimbangkan kemungkinan jika procedure. Therefore, be sure to check the adaptor before pembacaan peak voltage semuanya tidak normal. replacing the parts that display an abnormal testing value. Diode adaptor dapat diperiksa dengan mudah dengan Set the multimeter to the AC voltage range and measure the prosedur sebagai berikut. Oleh karena itu, pastikan If you touch the local line voltage. untuk memeriksa adaptor sebelum mengganti parts adaptor jack Then, connect the peak voltage adaptor to the multimeter, memperlihatkan pengetesan normal. measure the same AC nilai voltage with DC tidak voltage range and immediately after yang

PEAK VOLTAGE ADAPTOR

disconnecting the compare it to AC voltage measured previously. ika adaptor jack adaptor, you may get Pasang multimeter pada daerah jangkauan voltase AC • The normal if the DC voltage measured via the disentuh segera setelah dan ukuradaptor voltaseissaluran lokal. electrical shock. adaptor ishubungkan 1.4 times of AC voltage. melepaskan adaptor, Kemudian peak voltage adaptor ke Be sure to disconnect anda mungkin terkena • The adaptor is defective if the DC voltage measured via multimeter, ukur voltase AC yang sama dengan daerah the adaptor after kejutan listrik. the adaptor is 0 V. angkauan voltase DC dan bandingkan dengan voltase allowing the voltage Pastikan untuk AC yang diukur sebelumnya. to decrease melepaskan adaptor sufficiently. • Adaptor adalah normal jika voltase DC yang diukur setelah membiarkan melalui adaptor adalah 1,4 kali voltase AC (sekitar voltase turun sendiri dengan cukup. 300V). •

Adaptor adalah rusak jika voltase DC yang diukur melalui adaptor adalah 0 V.

15-5

SISTEM PENGAPIAN IGNITION COIL PRIMARY PEAK IGNITION COIL PRIMARY PEAK VOLTAGE VOLTAGE (VOLTAGE PUNCAK PRIMER COIL PENGAPIAN) CATATAN: • Check all system connections before inspection. If the system is disconnected, incorrect peak voltage sebelum might be semua sambungan sistem • Periksa measured. Jika sistem terlepas, peak voltage yang pemeriksaan. • diukur Checkmungkin cylinder tidak compression benar. and check that the spark plug is installed correctly. • Periksa kompressi cylinder dan periksa bahwa busi telahthe dipasang dengan benar. on a level surface. Place scooter with its centerstand Remove the skuter body cover (page 2-9). Letakkan dengan standard utama pada permukaan mendatar. Release the spark plug wire clamp boss from the intake shroud. Lepaskan body cover (hal. 2-9).

Lepaskan spark plug wire clamp boss dari intake shroud.

WIRE CLAMP

Lepaskan plug cap busi) dari spark plug Disconnectspark the spark plug cap (topi from the spark plug. (busi). Connect a known-good spark plug to the spark plug cap and ground the spark plug to the cylinder as done in a spark test. Sambungkan busi yang diketahui dalam keadaan baik pada spark plug cap dan hubungkan busi dengan massa pada cylinder seperti dilakukan pada test percikan api busi.

BUSI BAGUS

With the ignition primary wire connected, connect the Dengan ignitioncoilcoil primary wire tersambung, peak voltage peak adaptorvoltage or tester adaptor probes to the ignition coil prihubungkan atau jarum-jarum mary wire terminal andpada ground.ignition coil primary wire pemeriksaan tester terminal dan massa. TOOLS: Imrie diagnostic tester (model 625) or TOOLS: Peak diagnostic voltage adaptor Imrie tester (model 625)07HGJ-0020100 atau with commercially available digital07HGJ-0020100 multimeter (impedPeak voltage adaptor Ω/DCV ance 10 M minimum)(impedansi minimum 10 dengan digital multimeter M /DCV) CONNECTION: Black/Yellow (–) – Body ground (+) HUBUNGAN: Hitam/Kuning ( - ) - Massa badan ( + ) IGNITION COIL PRIMARY Retract the sidestand. WIRE TERMINAL (Bl/Y) Turn the ignition switch "ON" then squeeze the brake lever Tarik sidestand ke atas. fully. Putar kunci kontak ke "ON" kemudian tekan handel rem JARUM IGNITION COIL Crank the engine with the starter motor and measure the igni- PEMERIKSAAN( – ) Avoid touching the sepenuhnya. tester probes to tion coil primary peak voltage. angan menyentuh prevent electric Putar mesin dengan starter motor dan ukur ignition coil jarum pemeriksaan PEAK VOLT shock. primary peak voltage (voltase puncak primer coil tester untuk menghindari AGE: 100 V minimum kejutan listrik. pengapian). BI/Y G If the peak voltage is abnormal, check each item following PEAK VOLTAGE (VOLTASE PUNCAK): the troubleshooting chart (page 15-4). minimum 100 V Connect the spark plug cap to the spark plug. Dari ICM Jika peak voltage tidak normal, periksa masing-masing BUSI BAGUS Set the spark plug wire clamp boss to the intake shroud. bagian mengikukti peta troubleshooting (hal. 15-4) Install the body cover (page 2-9). JARUM Sambungkan spark plug cap pada spark plug. PEMERIKSAAN(+) Tempatkan spark plug wire clamp boss pada intake shroud. Pasang body cover (hal. 2-9).

15-6

SISTEM PENGAPIAN IGNITION PULSE GENERATOR PEAK IGNITION PULSE GENERATOR PEAK VOLTASE VOLTAGE (VOLTASE PUNCAK IGNITION PULSE GENERATOR) • Check cylinder compression and make sure the spark plug CATATAN: is installed correctly. Periksa kompressi cylinder dan pastikanIf bahwa • • Check all system connection before inspection. the system is disconnected, incorrect peak voltage might be measpark plug terpasang dengan benar. sured. Periksa semua sambungan sistem sebelum • Jika to sistem terlepas sambungannya, Turnpemeriksaan. the ignition switch "OFF". maka voltase puncak yang salah yang akan Remove the battery cover (page 2-13). terukur. Disconnect the ICM 6P connector. Putar kunci kontak ke "OFF". Connect the peak voltage adaptor or tester probes to the ICM Lepaskan battery cover (hal. 2-13). 6P connector. Lepaskan TOOLS: ICM 6P connector. Imrie diagnostic (model 625) or atau jarum-jarum Hubungkan peaktester voltage adaptor Peak ke voltage 07HGJ-0020100 tester ICM adaptor 6P connector. TOOLS: with commercially available digital multimeter (impedImrie diagnostic tester (model 625) atau ance 10 MΩ/DCV minimum) Peak voltage adaptor 07HGJ-0020100 CONNECTION:Blue/yellow – Body ground (–) dengan digital multimeter (+) (impedansi minimum 10 M /DCV) yang dapat dibeli di pasaran Turn the ignition switch "ON" and squeeze the brake lever fully. HUBUNGAN: Biru/kuning ( + ) - Massa badan ( - ) angantouching menyentuh Crank kunci the engine withke the "ON" kickstarter measure the igni Avoid the Putar kontak dan and tekan handel rem jarum-jarum tester probes to tion pulse generator peak voltage. sepenuhnya. emeriksaan testerelectric untuk prevent menghindari kejutan PEAK VOLT shock . listrik. Putar AGE:mesin dengan 0.7kickstarter V minimumdan ukur ignition pulse

generator peak voltage. If the peak voltage minimum 0,7 V PEAK VOLTAGE: Jika peak voltage yang diukur pada ICM connector adalah tidak normal, ukur peak voltage measuthe pada ignition measured at the ICM connector is abnormal, igni pulse generator 3P3P connector. tin pulse generator connector.


6P CONNECTOR

Bu/ Y

Bu/ Y

ICM 6P CONNECTOR IGNITION PULSE GENERATOR

Remove the centerbody bodycover cover (hal. (page2-8). 2-8). Lepaskan center Connect the peak voltage tester or adaptor probes to the 3P Hubungkan peak voltage tester atau jarum-jarum connector terminal of the ignition pulse generator side. pemeriksaan adaptor pada 3P connector terminal dari In the samepulse manner as at the ICM connector, measure the sisi ignition generator. peak voltage and compare it to the v oltage measured at the ICM connector. Dengan cara sama seperti pada ICM connector, ukurlah peak voltage dan bandingkan dengan yang • If the peak voltage measured at the ICM isvoltase abnormal and diukur pada ICM connector. the one measured at the ignition pulse generator is normal, the wire harness has an open or short circuit, or loose Jika peak voltage yang diukur pada ICM tidak connection. normal danvoltages yang measure diukur are pada ignition • If both peak abnormal, checkpulse each generator adalah normal, maka wire harness ada item in the troubleshooting chart (page 15-4). rangkaian atauthe adaignition hubungan atau If all items terbuka are normal, pulsesingkat, generator is hubungan longgar. faulty. See page 14-7 for ignition pulse generator replaceJika kedua peak voltages yang diukur tidak normal, • ment. periksalah masing-masing bagian pada peta Install the removed parts in the reverse order of removal. troubleshooting (hal. 15-4). Jika semua bagian adalah normal, maka ignition pulse generator rusak. Lihat hal. 14-7 untuk penggantian ignition pulse generator. •

IGNITION PULSE GENERATOR 3P CONNECTOR 3P CONNECTOR

Pasang parts yang telah dilepaskan dalam urutan terbalik dari pelepasan.

IGNITION PULSE GENERATOR

15-7

SISTEM PENGAPIAN

IGNITIONCOIL COIL(COIL PENGAPIAN) IGNITION PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Remove the bodycover cover(hal. (page2-9). 2-9). Lepaskan body Disconnectspark the spark releasespark spark plug plug wire Lepaskan plug plug cap cap dan and lepaskan clamp from the intake shroud. clamp dari intake shroud.

CLAMP Disconnectignition the ignition coil primary connectors. Lepaskan coil primary wirewire connectors.

SPARK PLUG CAP

PRIMARY WIRE CONNECTORS

Release thespark sparkplug plugwire wire clamp clamp from the frame. Lepaskan dari rangka.

IGNITION COIL

Remove the two mounting bolts and ignition coil. Lepaskan kedua mounting bolts dan ignition coil. Installation is in adalah the reversedalam order of urutan removal. terbalik Route the wire Pemasangan lurkan wire harness dengan benar (hal. pelepasan. harness properly (page 1-14). 1-14).

dari

CLAMP

BOLTS

IGNITION IGNITIONSWITCH SWITCH(KUNCI KONTAK) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Remove the steeringstem stem (hal. (page11-21). 11-21). Lepaskan steering

BOLT

Disconnectignition the ignition switch 2P connector. Lepaskan switch 2P connector.

IGNITION SWITCH

SCREWS

Remove the socketbolt boltdan and key key shutter. shutter. Lepaskan socket Remove the screwsdan and ignition ignition switch. switch. Lepaskan screws Installation is in adalah the reversedalam order of urutan removal. terbalik Pemasangan pelepasan.

dari

TORQUE: TORSI: Key shutter socket bolt: 10 N·m (1.0 kgf·m, 7 lbf·ft) Key shutter socket bolt: 10 N.m (1,0 kgf.m; 7 lbf.ft)

2P CONNECTOR

15-8

KEY SHUTTER

SISTEM PENGAPIAN INSPECTION PEMERIKSAAN Remove the front uppercover cover(hal. (page2-4). 2-4). Lepaskan front upper Disconnect the ignition switch 2P connector. Lepaskan ignition switch 2P connector.

IGNITION SWITCH 2P CONNECTOR

Periksa switchforterhadap antara Check theignition ignition switch continuitykontinuitas between the connector terminals in each switch position. connector terminals pada setiap posisi switch.

IGNITION SWITCH IGNITION SWITCH B AT 1

B AT

R/Bl

R

ON OFF LOCK COLOR

SIDESTAND SWITCH (SAKLAR STANDARD SAMPING) SIDESTAND SWITCH PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Remove the centerbody bodycover cover (hal. (page2-8). 2-8). Lepaskan center Disconnectsidestand the sidestand switch connector. Lepaskan switch 3P3P connector.

SIDESTAND SWITCH 3P CONNECTOR

15-9

SISTEM PENGAPIAN Release thekawat sidestand switch switch wire from theframe frameclamps. clamps. Lepaskan sidestand dari

SIDESTAND SWITCH WIRE

CLAMPS

Lepaskan bolt dan Remove the bolt andsidestand sidestand switch. switch. Install thesidestand sidestand switch whilesementara aligning its groove with the Pasang switch mentepatkan spring pin, making sure that tabs arememastikan positioned as bahwa shown. alurnya dengan spring pin,the dengan tabs telah ditempatkan seperti diperlihatkan. Install and tighten the sidestand switch bo lt.

SPRING PIN

BOLT GROOVE

lurkan wire harness kencangkan sidestand switch bolt. Connectdan the sidestand switch 3P connector. Route the wire Pasang dengan benar (hal. harness properly sidestand switch 3P2-8). connector. Install the center body cover (page 1-14). Sambungkan (page 1-14).

Pasang center body cover (hal. 2-8). • Do not reuse the broken sidestand switch. CATATAN: • Remove sidestandkembali switch before retightening theyang side• Jangan the memakai sidestand switch stand pivot nut. patah. Lepaskan sidestand switch sebelum • mengencangkan kembali sidestand pivot nut.

INSPECTION Remove the battery cover (page 2-13). PEMERIKSAAN Turn the ignition Lepaskan batteryswitch cover"OFF". (hal. 2-13).

SIDESTAND SWITCH

TABS


Disconnect theswitch ICM 6P Putar keconnector. "OFF". ignition

Lepaskan ICM 6P connector.

6P CONNECTOR

15-10

SISTEM PENGAPIAN Periksa terhadap kontinuitas antara 6P connector Check for continuity between the ICM ICM 6P connector of the wiresisi harness and ground. dari wire side harness dan massa. CONNECTION:Green/White – Body badan ground HUBUNGAN: Hijau/Putih – Massa

There should be continuitydengan with thesidestand sidestand retracted, and Harus ada kontinuitas ditarik, dan there should continuity with the sidestand tidak bolehbe no ada kontinuitas dengan applied. sidestand diturunkan. If there is no continuity with the sidestand retracted, the wire harness is broken or the sidestand switch is faulty. Jika tidak ada kontinuitas dengan sidestand ditarik ke atas, wire harness patah atau sidestand switch rusak.

SIDESTAND Kontinuitas (Sidestand ditarik):

Tidak ada Kontinuitas (Sidestand diturunkan):

ICM 6P CONNECTOR

ICM 6P CONNECTOR

G/W G

G/W G

UP

SIDESTAND SWITCH

UP

SIDESTAND SWITCH

IGNITION (ICM) IGNITIONCONTROL CONTROLMODULE MODULE (ICM) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan battery Remove the batterycover cover(hal. (page2-13). 2-13).


Putar ignition switch ke"OFF". "OFF". Turn the ignition switch DisconnectICM the ICM 4P/6P connectors. Lepaskan 4P/6P connectors. Installation is in the reverse order ofurutan removal. terbalik Pemasangan dalah dalam pelepasan.

dari

4P/6P CONNECTORS

15-11

SISTEM PENGAPIAN POWER/GROUND LINE INSPECTION PEMERIKSAAN POWER/GROUND LINE (SALURAN POWER LINEDAYA/MASSA) Remove the batterycover cover(hal. (page2-13). 2-13). Lepaskan battery Disconnect the ICM 4P connector. POWER LINE (SALURAN DAYA)


Turn the ignition switch "ON". Lepaskan ICM 4P connector. Measure the battery voltage between the ICM 4P connector Putar ignition switch ke "ON". of the wire harness side and ground. Ukur voltase baterai antara ICM 4P connector dari sisi CONNECTION:Red/Black wire harness dan massa. (+) – Body ground (–) There should be battery voltage with the ignition switch HUBUNGAN: Merah/Hitam ( + ) - Massa badan ( - ) "ON".

Harus ignition switch pada If thereada is novoltase voltage baterai with the dengan ignition switch "ON", check the "ON". following: Jika tidak ada voltase dengan ignition switch pada "ON", – Wire harness between the battery and ICM periksa sebagai berikut: – Ignition switch - Wire harness antara baterai dan ICM – Fuse - Ignition switch - GROUND Sekring LINE

4P CONNECTORS POWER LINE: ICM 4P CONNECTOR

Turn the ignition switch "OFF".MASSA) GROUND LINE (SALURAN Disconnect theswitch ICM 4P Putar ignition keconnector. "OFF". Check for ICM continuity between the ICM 4P connector of the Lepaskan 4P connector. wire harness side and ground. Periksa terhadap kontinuitas antara ICM 4P connector CONNECTION:Green – Body ground dari sisi wire harness dan massa. HUBUNGAN: – Massa badan There should beHijau continuity at all time.

Harus ada kontinuitas setiap waktu.

lurkan Route wire harness the wire If there is no continuity, check the open circuit in green wire. dengan benar (hal. Jika tidak ada kontinuitas, periksa rangkaian terbuka harness properly (page 1-14). 1-14). pada kawat hijau.

GROUND LINE: ICM 4P CONNECTOR

R/Bl

IGNITION SWITCH

G

FUSE 15A

IGNITION (WAKTU PENGAPIAN) IGNITIONTIMING TIMING CATATAN: • • The Ignition timing telah disetelpreset awaland di need pabrik dan ignition timing is factory only be hanya perlu diperiksa jika sebuah komponen dari checked when an electrical system component is replaced. sistem telah diganti. • Read thelistrik instructions for timing light operation. • Bacalah petunjuk pemakaian timing light. Remove the cooling fan cover (page 2-12). Lepaskan cooling fan cover (hal. 2-12). Connect the timing light to the spark plug wire.

NOTCH

Hubungkan timing light "ON". pada kabel lbusi. Turn the ignition switch Putar ignition switch Start the engine and letkeit "ON". idle. -1 Hidupkan dan biarkan berputar stasioner. ± 100 min (rpm) ENGINE mesin IDLE SPEED:1,700 -1 PUTARAN STASIONER MESIN: 1.700 100 menit The ignition timing is correct if the index notch on the right (rpm) crankcase aligns with the "F" mark on the flywheel as shown.

If the ignition is incorrect, inspect the ignition pulse Ignition timingtiming adalah tepat jika index notch (takik generator (page penunjuk) pada15-7). right crankcase bertepatan dengan tanda "F" pada flywheel seperti diperlihatkan.

Jika ignition timing tidak tepat, periksa ignition pulse generator (hal. 15-7).

15-12

TANDA "F"

TIMING LIGHT

16. SISTEM STARTER LISTRIK

LOKASI SISTEM ....................................16-2 SYSTEM LOCATION ····································16-2

DIAGRAM SISTEM ................................16-2 SYSTEM DIAGRAM ······································16-2

KETERANGAN SERVIS ........................16-3 SERVICE INFORMATION ···························16-3

TROUBLESHOOTING ...........................16-4 TROUBLESHOOTING ··································16-4

STARTER PINION .................................16-10 STARTER PINION ·······································16-10

STARTER RELAY..................................16-11 STARTER RELAY········································16-11

STARTER SWITCH................................16-14 STARTER SWITCH ·····································16-14

BRAKE LIGHT SWITCH ........................16-14 BRAKE LIGHT SWITCH····························16-14

STARTER MOTOR ................................16-6 STARTER MOTOR ········································ 16-6

16

16-1


SYSTEMSISTEM LOCATION LOKASI ELECTRICSTARTERSYSTEM

REAR BRAKE LIGHT SWITCH STARTER SWITCH MAIN FUSE 15A

FRONT BRAKE LIGHT SWITCH

SUB FUSE 10A IGNITION CONTROL MODULE (ICM) BATTERY

IGNITION SWITCH STARTER RELAY

STARTER MOTOR

DIAGRAM SISTEM SYSTEM DIAGRAM MAIN FUSE 15A R R/Bl

STARTER RELAY

l B

R

BATTERY

SUB FUSE 10A

l B / R

R

5P 4P

l R B / / / R W R Y R

W / R

2P

6P

l B

2P

l B / G R

W / R

G / Y

G

Y G / / Y G

Y l / G B

Y l / G B

l B / R

R

Br 4P

6P

Bl

W / G

STARTER MOTOR

16-2


BRAKE LIGHT SWITCHES STARTER SWITCH

IGNITION SWITCH


SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM • • • • • •

Always turn the ignition switch "OFF" before servicing the starter motor. The motor could suddenly start, causing serious injury. putarmay ignition switch ke the "OFF" sebelum menservis starter motor. Motorignition dapatcurrent. dihidupkan dengan tiba-tiba, dan A Selalu weak battery be unable to turn starter motor quickly enough, or supply adequate menyebabkan luka-luka parah. The starter motor can be serviced with the engine in the frame. When checking themungkin starter system, follow the stepsstarter in the troubleshooting Baterai lemah tidak always sanggup memutar motor dengan (page cukup16-4). cepat, atau memasok arus pengapian yang If mencukupi. the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be damaged. Refer to the following information. Starter motor dapatcomponent diservis dengan mesin terpasang pada rangka. – Ketika Ignitionmemeriksa switch (pagesistem 15-8) starter, selalu ikuti langkah-langkah pada troubleshooting (hal. 16-4). Jika arus listrik dibiarkan mengalir melalui starter motor untuk memutarnya sementara mesin tidak berputar, starter motor dapat rusak. SPECIFICATION Bacalah informasi komponen berikut ini. - Ignition switch (hal. 15-8) Unit: mm (in) SERVICE ITEM STANDARD LIMIT Starter motor brush length 7.0 (0.28) 3.5 (0.14) SPESIFIKASI Satuan: mm BAGIAN STANDARD BATAS SERVIS TORQUE VALUE Panjang sikat starter motor 7,0 3,5 •

•

• • •

•

Starter motor case screw

2 N·m (0.2 kgf·m, 1.5 lbf·ft)

NILAI TORSI Starter motor case screw

2 N.m (0,2 kgf.m; 1,5 lbf.ft)

16-3


TROUBLESHOOTING TROUBLESHOOTING Starter motor not turn Starter motordoes tidak berputar 1. Standard Inspection 1. Pemeriksaan Standard

Check forterhadap following:berikutnya: Periksa –- Kondisi Battery condition baterai –- Sekring Burned fuse putus terbakar

2. 2.

3. 3.

Are the above itemsdiinatas gooddalam condition? Apakah hal-hal kondisi baik? YES – GO TO STEP 2. YA - LANJUTKAN DENGAN LANGKAH 2. NO – Replace or repair the malfunction part(s). TIDAK - Ganti atau perbaiki parts yang tidak bekerja dengan baik. Starter Relay Operation Cara Kerja Starter Relay Turn the ignition switch "ON". Putar kunci kontak kefully "ON". Squeeze the brake lever and push the starter switch. Tekan handel rem sepenuhnya tekan starter switch. You should hear the relay "CLICK"dan when the starter switch is depressed. Harus terdengar bunyi "KLIK" dari relay ketika starter switch ditekan. Is the "CLICK" heard? Apakah bunyi "KLIK" terdengar? YES – GO TO STEP 3. YA - LANJUTKAN DENGAN LANGKAH 3. NO – GO TO STEP 5. TIDAK - LANJUTKAN DENGAN LANGKAH 5. Starter Motor Cable Inspection Pemeriksaan Starter Motor Cable Turn the ignition switch "OFF". Putar for kunci kontak Check open circuitke in "OFF". starter motor cable and starter motor ground cable. Periksa terhadap rangkaian terbuka pada starter motor cable dan starter motor ground cable (kabel massa Are the above cables in good condition? starter motor). YES – GO TO STEP 4. Apakah kabel-kabel di atas dalam kondisi baik? NO – • Loose or poorly connected starter motor cable. YA LANGKAH 4. (Green) and battery negative terminal. •- LANJUTKAN Open circuit inDENGAN starter motor ground cable • Open circuit in starter motor Red/White cable between the starter relay and starter motor. TIDAK Starter motor cable longgar atau tersambung dengan buruk. Starter Motor Inspection Rangkaian terbuka pada starter motor ground cable (Hijau) dan terminal negatif baterai. Rangkaian terbuka pada kabel and Merah/Putih starter motor antara starter relay dan starter Apply battery voltage to the starter motor directly check the operation. motor. Does the starter motor turn? Pemeriksaan Starter Motor YES – • Open circuit in Red wire between the starter relay and battery. Hubungkan voltase baterai langsung ke starter motor dan periksa cara kerja. • Faulty starter relay. •

4.

• •

4.

Apakah starterstarter motor berputar? motor. NO – Faulty 5. YA Starter Relay Circuit Inspection - Coil Rangkaian terbuka pada kawat Merah antara starter relay dan baterai. Starter relay rusak. Disconnect the ICM 4P connector. •

•

Turn the ignition switch "ON". TIDAK - Starter motor tidak bekerja dengan baik. Measure the battery voltage between the ICM connector of the wire harness side and ground. 5. Pemeriksaan Rangkaian Starter Relay Coil CONNECTION:Yellow/Red (+) – Ground (–) Lepaskan ICM 4P connector.

Putarthe kunci kontak ke "ON". Does battery voltage exist? Ukur voltase baterai antara ICM connector dari sisi wire harness dan massa. YES – GO TO STEP 6. HUBUNGAN: Kuning/Merah ( + ) - Massa ( - ) NO – • Loose or poorly connected connector. Apakah • adaOpen voltase baterai? circuit in battery cable between the battery and ignition switch. • Open circuit in starter relayLANGKAH Red/Black 6. wire between the ignition switch and starter relay. YA - LANJUTKAN DENGAN • Open circuit in starter relay Yellow/Red wire between the ICM and starter relay. ignitionyang switch (page 15-8).dengan buruk. TIDAK •- Faulty Connector tersambung • Faulty starter relay coil. Rangkaian terbuka pada kabel baterai antara baterai dan kunci kontak. Rangkaian terbuka pada kawat Merah/Hitam starter relay antara kunci kontak dan starter relay. Rangkaian terbuka pada kawat Kuning/Merah starter relay antara ICM dan starter relay. Kunci kontak tidak bekerja dengan baik (hal. 15-8). Starter relay coil tidak bekerja dengan baik. •

• •

• • •

16-4

SISTEM STARTER LISTRIK Brake Light Switch/Starter SwitchLight Circuit Inspection 6.6. Pemeriksaan Rangkaian Brake Switch/Starter Switch

Turn the ignition switch "ON". Putar kunci kontak ke "ON". Squeeze the brake fully and push starter switch. Tekan handel remlever sepenuhnya dan the tekan starter switch. Measure the battery voltage between the ICM connector of theharness wire harness side and ground. Ukur voltase baterai antara ICM connector dari sisi wire dan massa.

HUBUNGAN: Kuning/Hijau ((+) + )– -Ground Massa(–) (- ) CONNECTION:Yellow/Green Apakah voltase Does the ada battery voltagebaterai? exist? YA LANJUTKAN TO STEP 7. DENGAN LANGKAH 7. YES – -GO TIDAK NO – - • • • • • •

• • • • •

Connector longgar atau connector. tersambung dengan buruk. Loose or poorly connected Brakebrake light switch tidak bekerja dengan baik. Faulty light switch. Open circuit in Black wire between sub antara fuse andsekring brake light switch. dan brake light switch. Rangkaian terbuka pada kawat the Hitam tambahan Open circuit in Green/Yellow wire between the brake light switch and starter switch. Starter switch tidak bekerja dengan baik. Faulty starter switch. Rangkaian terbuka pada kawat Kuning/Hijau antara ICM dan starter switch. Open circuit in Yellow/Green wire between the ICM and starter switch.

7. Starter Relay Continuity Inspection

Check the starterKontinuitas relay for continuity 16-13). Pemeriksaan Starter(page Relay Is there continuity? Periksa starter relay terhadap kontinuitas (hal. 16-13) YES – • Open circuit in ICM Red/Black wire. Apakah ada kontinuitas? • Open circuit in ICM Green wire. ICM. terbuka pada kawat Merah/Hitam ICM. YA - • Faulty Rangkaian Rangkaian terbuka pada kawat Hijau ICM. starter relay. NO – Faulty ICM tidak bekerja dengan baik. Starter motor turns engine slowly TIDAK - Starter • Low battery voltage.relay tidak bekerja dengan baik. • Poorly connected battery terminal cable. • Poorly connected starter motor cable. Starter motor memutar • Faulty starter motor. mesin dengan pelan •Voltase Poorlybaterai connected battery ground cable. rendah. Battery terminal cable dengan Starter motor turns, but tersambung engine does not turn buruk. tersambung dengan buruk. •Starter Startermotor motorcable is running backwards. Starter motor tidak bekerja dengan baik. – Case assembled improperly. Battery groundconnected cable tidak tersambung dengan baik. – Terminals improperly. • Faulty starter pinion. Starter motor berputar, tetapi mesin tidak berputar Starter relay "CLICK", but engine does not turn motordoes berputar terbalik. •Starter Crankshaft not turn due to engine problems. Case telah dirakit dengan salah. • Faulty starter pinion. - Terminals disambung dengan salah. Starter pinion tidak bekerja dengan baik.

7.

•

• •

• • • • •

•

•

Starter relay berbunyi "KLIK", tetapi mesin tidak berputar Crankshaft tidak berputar disebabkan persoalan di dalam mesin. Starter pinion tidak bekerja dengan baik. • •

16-5


STARTER MOTOR MOTOR PELEPASAN REMOVAL Lepaskan airair cleaner Remove the cleanerhousing housing (hal. (page5-6). 5-6). Tarik lepas dustcover. cover. Pull off the dust Lepaskan screw startermotor motorcable cable dari Remove the screwdan and starter from the starter starter motor. motor.

SCREW/STARTER MOTOR CABLE

MOUNT BOLT

Remove the mounting bolts, ground cable and starter motor. Lepaskan mounting bolts, ground cable dan starter Remove the starter motor case screw and ground cable. motor.

Lepaskan starter motor case screw dan ground cable.

DUST COVER

MOUNT BOLT/ GROUND CABLE Remove the O-ring from the starter motor. Lepaskan O-ring dari starter motor.

PEMASANGAN

SCREW/GROUND CABLE

STARTER MOTOR

Lapisi sebuah O-ring baru dengan oli mesin dan pasang ke dalam alur starter motor.

O-RING

Route the starter lurkan starter motor cable dan ground cable motor cable and dengan benarcable (hal. ground 1-14). properly (page 1-14).

Set the ground cable cable and tighten the starter motor case motor screw Tempatkan ground dan kencangkan starter to thescrew specified torque. dengan torsi yang ditentukan. case

SCREW/STARTER MOTOR CABLE

MOUNT BOLT

TORQUE:2 N·m (0.2 kgf·m,1,5 1.5lbf.ft) lbf·ft) TORSI: 2 N.m (0,2 kgf.m;

Install the startermotor motorpada to themesin. engine. Pasang starter Set the groundground cable andcable tightendan the starter mounting bolts. Tempatkan kencangkan starter mounting bolts. Install the starter motor cable and tighten the screw. Put the dust cover back in the appropriate position. Pasang starter motor cable dan kencangkan screw. Install the air cleaner housing (page 5-7). Letakkan dust cover kembali pada posisi yang sesuai.

DUST COVER

Pasang air cleaner housing (hal. 5-7). MOUNT BOLT/ GROUND CABLE

16-6

SCREW/GROUND CABLE

SISTEM STARTER LISTRIK DISASSEMBLY PEMBONGKARAN Remove the screwsdan andstarter starter motor Lepaskan screws motor case. case. Remove the following: Lepaskan sebagai berikut: Armature - – Armature – Bracket - Bracket – Springs - Springs Gasket - –Gasket MOTOR CASE

ARMATURE SPRING

SCREW

GASKET

BRACKET

PERAKITAN ASSEMBLY Pasang springs diindalam brush holders. Install the springs the brush holders.

BRUSH HOLDERS

SPRINGS

16-7

SISTEM STARTER LISTRIK Pasang ke the dalam bracket sementara Install thearmature armature into bracket while holding the brushes. brushes. menahan

ARMATURE

BRUSHES Coil dapat rusak jika Pasang Install agasket new gasket thebracket. bracket. baruonto pada magnet Install thebracket bracket and armature to the motor while case holdThe coilmenarik may be Pasang dan armature pada case motor armature terhadap ing the bracket side armature shaft tightly. damaged case. if the sementara memegang armature shaft dari sisi bracket magnet pulls the dengan erat. armature against the case.

BRACKET

MOTOR CASE

GASKET

Pasang motor screwsand dan kencangkan dengan Install the motorcase case screws tighten them to the specitorsi yang ditentukan. fied torque. TORSI: 2 N.m (0,2 kgf.m; 1,5 lbf.ft) TORQUE:2 N·m (0.2 kgf·m, 1.5 lbf·ft)

PEMERIKSAAN INSPECTION BRUSH BRUSH Periksa brushes terhadap kerusakan danthe ukur panjang Inspect the brushes for damage and measure brush length. brush. SERVICE LIMIT:

BATAS SERVIS: 3,5 mm

16-8

3.5 mm (0.14 in)

SCREWS

ARMATURE

SISTEM STARTER LISTRIK ARMATURE ARMATURE

Jangan menggunakan commutator armaturefor terhadap Do not use emery or Periksa Inspect the commutator bars bars ofdari the armature discolorkertas amplas pada sand commutator. paper on the perubahan ation. warna. commutator.

COMMUTATOR BARS

Bars discolored in pairs indicate shorted coils. Bars yang berubah warna dalam pasangan menunjukkan coils yang ada hubungan singkat.

Periksa masing-masing Check forterhadap continuity kontinuitas between each antara pair of commutator bars. pasangan commutator bars. There should be continuity.

KONTINUITAS:

Tidak boleh ada kontinuitas.

Check forterhadap continuitykontinuitas between eachantara commutator bar and the Periksa masing-masing armature shaft. commutator bar dan armature shaft. Thereboleh shouldada be no continuity. Tidak kontinuitas.

TIDAK ADA KONTINUITAS:

16-9


STARTER PINION PINION STARTER PELEPASAN REMOVAL Lepaskan leftleft crankcase (hal. 8-5). Remove the crankcasecover cover (page 8-5). Remove the starterpinion pinionholder. holder. Lepaskan starter

Remove the starterpiniion. pinion. Lepaskan starter

STARTER PINION HOLDER

STARTER PINION

PEMASANGAN INSTALLATION Oleskan 0,1– –0.3 0,3gg ofgemuk R3R3 atau Apply 0.1 grease(Shell (ShellALVANIA ALVANIA or IDEMITSUAUTOREX AUTOREX BB atau or equivalent) to the endsujungof the IDEMITSU sejenisnya) pada starterstarter pinion.pinion. ujung

STARTER PINION

Install the starter pinion into the left crankcase. Pasang starter pinion ke dalam left crankcase.

Pasang starter dalam left crankcase. Install the starterpinion pinionholder holder ke into the left crankcase. Pasang leftleft crankcase Install the crankcasecover cover (hal. (page8-5). 8-5).

16-10

STARTER PINION HOLDER

SISTEM STARTER LISTRIK PEMERIKSAAN INSPECTION Check that the starter pinion operates smoothly. Periksa bahwa starter pinion bekerja dengan halus.

DRIVEN GEAR

Check the pinion geargear teeth and forterhadap wear or damage. Periksa gigi pinion danshaft shaft keausan atau kerusakan. Check the starter driven gear teeth of the drive pulley face for wear or damage. Periksa gigi starter driven gear dari muka drive pulley terhadap keausan atau kerusakan.

PINION GEAR

STARTER STARTER RELAY RELAY PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan battery Remove the batterycover cover(hal. (page2-13). 2-13).

5P CONNECTOR

Lepaskan starter holder stay. Remove the starterrelay relaydari frombattery the battery holder stay. Lepaskan relay 5P connector. Disconnectstarter the starter relay 5P connector. Pemasangan Installation is in adalah the reversedalam order of urutan removal. terbalik pelepasan.

dari

STARTER RELAY

PEMERIKSAAN CARA KERJA OPERATION INSPECTION Remove the batterycover cover(hal. (page2-13). 2-13). Lepaskan battery Turn the ignition switch "ON". Putar kunci kontak ke "ON". Squeeze the brake lever fully and push the starter switch. Tekan handel rem sepenuhnya dan tekan starter switch. The system is normal if the starter relay clicks. Sistem adalah normal jika starter relay berbunyi klik. If yourelay don’t hear relay "CLICK", inspect the Jika tidaktheberbunyi "KLIK", periksa sebagai following: berikut:

- –Rangkaian starter relay coil (hal. 16-12) Starter relay coil circuit (page 16-12) - –Rangkaian light switch/starter switch Brake lightbrake switch/starter switch circuit (page(hal.16-12) 16-12) - –Rangkaian ICM power/ground 15-12) ICM power/ground circuit (page(hal. 15-12) If you hear the suara relay "CLICK", but starter turn, Jika terdengar "KLIK" dari relay, does tetapinotstarter inspect the starter relay continuity (page 16-13). kontinuitas tidak berputar, periksa starter relay terhadap (hal. 16-13).

STARTER RELAY

16-11

SISTEM STARTER LISTRIK PEMERIKSAAN RANGKAIAN STARTER RELAY COIL CIRCUIT STARTER RELAY COIL INSPECTION Remove the batterycover cover(hal. (page2-13). 2-13). Lepaskan battery DisconnectICM the ICM 4P connector. Lepaskan 4P connector. Turn the ignition switch "ON". Putar kunci kontak ke "ON". Measure the voltage between ICM connector the wire Ukur voltase antara ICM the connector dari of sisi wire harness side and ground. harness dan massa. CONNECTION:Yellow/Red (+) – Ground (–) HUBUNGAN: Kuning/Merah ( + ) - Massa ( - ) If the battery voltage appears only when the ignition switch is Jika voltase baterai hanya tampak sewaktu kunci kontak "ON", the circuit is normal. pada posisi "ON", rangkaian adalah normal. IGNITION CONTROL MODULE (ICM) 4P CONNECTOR ICM 4P CONNECTOR

Dari BATTERY R/Bl Y/R

IGNITION SWITCH

STARTER RELAY

PEMERIKSAAN RANGKAIAN BRAKE LIGHT SWITCH/STARTER BRAKE LIGHT SWITCH/STARTER SWITCH SWITCH CIRCUIT INSPECTION Lepaskan battery Remove the batterycover cover(hal. (page2-13). 2-13). Lepaskan ICM 6P connector. Disconnect the ICM 6P connector. Putar kunci kontak ke "ON". Turn the ignition switch "ON". Tekan handel remlever sepenuhnya dan tekan starter switch. Squeeze the brake fully and push the starter switch. Ukur voltase antara ICM the connector dari of sisi Measure the voltage between ICM connector the wire harness dan and massa. harness side ground. CONNECTION:Yellow/Green HUBUNGAN: Kuning/Hijau ( (+) - ) –- Ground Massa ((–) -)

If thevoltase battery voltage whenketika the ignition is Jika baterai appears hanya only tampak kunciswitch kontak "ON", the brake lever is fully squeezed and the starter switch pada posisi "ON", handel rem telah ditekan sepenuhnya is pushed, circuit is normal. dan starterthe switch ditekan, rangkaian adalah normal.

IGNITION CONTROL MODULE (ICM) 6P CONNECTOR ICM 6P CONNECTOR

Dari BATTERY FRONT BRAKE LIGHT SWITCH

Y/G G/Y

STARTER SWITCH

Bl

G/Y

REAR BRAKE LIGHT SWITCH Bl

16-12

SISTEM STARTER LISTRIK PEMERIKSAAN KONTINUITAS STARTER RELAY CONTINUITY STARTER RELAY INSPECTION Remove the starterrelay relay(hal. (page16-11). 16-11). Lepaskan starter Connect a fully charged V battery wire penuh to the Hubungkan kawat positif12 baterai 12 Vpositive bermuatan relay switch terminal A and negative wire to the terminal B. pada terminal A relay switch dan kawat negatif pada terminal B.continuity at the terminal C and terminal D. Check for There should be continuity between the C and D terminals Periksa terhadap kontinuitas pada terminal C dan while the battery is connected, and no continuity when the terminal D. battery is disconnected.

Harus ada kontinuitas antara terminal C dan D sewaktu baterai dihubungkan, dan tidak ada kontinuitas ketika baterai dilepaskan.

A

C

B

D

STARTER RELAY A

B

C

D

16-13


STARTER STARTER SWITCH SWITCH PEMERIKSAAN INSPECTION Remove the front handlebarcover cover (page 2-5). Lepaskan front handlebar (hal. 2-5). Turn the ignition switch "OFF". Putar kunci kontak ke "OFF". Disconnect the starter switch connector. Lepaskan starter switch connector. Check for continuity between the connector terminals in each Periksa terhadap kontinuitas antara connector terminals switch position. pada masing-masing posisi switch. Continuity should exist between the color coded wire termiHarus kontinuitas antara terminal-terminal kawat nals as ada follows: dengan kode warna sebagai berikut:

STARTER SWITCH

STARTER SWITCH CONNECTOR

STARTER SWITCH ST

ICM

G/Y

Y/G

FREE PUSH COLOR

BRAKE BRAKE LIGHT LIGHTSWITCH SWITCH PEMERIKSAAN INSPECTION Lepaskan front handlebar (hal. 2-5). Remove the front handlebarcover cover (page 2-5).

DEPAN:

BELAKANG:

BRAKE LIGHT SWITCH CONNECTORS

BRAKE LIGHT SWITCH WIRE CONNECTORS

Disconnect the brake light switch wire wire connectors (Green/ Lepaskan brake switch connectors Yellow and Black) and check for continuity between the (Hijau/Kuning dan Hitam) dan periksa terhadap switch side antara terminals. kontinuitas terminal-terminal pada sisi switch. There should be continuity with the brake lever squeezed, Harus ada kontinuitas dengan handel rem ditekan, dan and there should be no continuity with the brake lever tidak boleh ada kontinuitas sewaktu handel rem released. dilepaskan.

16-14

17. LAMPU/METER/SAKLAR-SAKLAR

LOKASI SISTEM............................................ 17-2 SYSTEM LOCATION ····································17-2

KETERANGAN SERVIS ................................17-3 SERVICE INFORMATION ···························17-3

PEMERIKSAAN SISTEM PENERANGAN ....17-4 LIGHTING SYSTEM INSPECTION············ 17-4

LAMPU BESAR ............................................. 17-6 HEADLIGHT ··················································· 17-6

LAMPU SENJA .............................................. 17-7 POSITION LIGHT··········································17-7

LAMPU SEIN .................................................17-8 TURN SIGNAL LIGHT··································17-8

RELAY LAMPU SEIN ...................... 17-10

TURN SIGNAL RELAY ·······························17-10

LAMPU REM/BELAKANG............... 17-11

TAIL/BRAKE LIGHT ·································· 17-10

FUEL LEVEL SENSOR.................... 17-13

SPEEDOMETER ···········································17-11

FUEL METER................................... 17-14

FUEL LEVEL SENSOR ·······························17-13

KLAKSON ........................................ 17-15

FUEL METER ···············································17-14

HORN····························· ·························· ······· 17-15

SAKLAR LAMPU SEIN..................................17-9 TURN SIGNAL SWITCH······························· 17-9

17

17-1

LAMPU/METER/SAKLAR-SAKLAR

SYSTEMSISTEM LOCATION LOKASI LIGHTS/METERS/SWITCHES

DIMMER SWITCH TURN SIGNAL SWITCH

HORN SWITCH

SPEEDOMETER

TURN SIGNAL RELAY

FUEL LEVEL SENSOR

LIGHTING SWITCH

HORN

17-2



• Check the battery condition before performing any inspection that requires proper battery voltage. Periksa kondisi sebelum menjalankan sesuatu pemeriksaan yang memerlukan voltase baterai yang memadai. •• Route the wires and baterai cables properly after servicing each component (page 1-14). •• The following color codesdan are used throughout this section. Alurkan kawat-kawat kabel-kabel dengan benar setelah menservis masing-masing komponen (hal. 1-14). • Kode warna berikut ini dipakai sepanjang bab ini. Bu==Blue Blue (biru) Bu Bl = Black Bl = Black (hitam) Brown (coklat) BrBr==Brown G = Green (hijau)

G = Gr Green Lg = Light green = Gray (abu-abu) Gr =Lb Gray O =muda) Orange = Light blue (biru Lb =Lg Light blue R = Red = Light green (hijau muda) O = Orange (jingga)

W (merah) = White R = Red Y = W = White Yellow (putih) Y = Yellow (kuning)

SPECIFICATIONS SPESIFIKASI Bulbs Bola lampu

Fuse Sekering

ITEM BAGIAN Headlight Lampu besar Position light Lampu senja light Tail/brake Lampu rem/belakang Front turn signal light Lampu sein depan Rear turn signal light Lampu sein belakang Instrument light Lampu instrumen High beam indicator Lampu indikator sinar jauh Turn signal indicator Lampu indikator lampu sein Main fuse Sekering utama Sub fuse

Sekering tambahan

SPECIFICATIONS SPESIFIKASI 12 V – 32/32 W 12 V 12–V32/32 – 3.4 W W 12 V – 3,4 W 12 V – 5/18 W 1212VV– –5/18 10 WWx 2 1212 VV –– 1010WWx x22 1212VV – –10 WWx x2 2 1.7 12 V12– V 1,7 W xW2 – 1.7 12 V – 1,7 W 12 V – 3.4 W 12 V – 3,4 W 15 A x 1 15 A x 1 10 A x 1

10 A x 1

17-3


LIGHTING SYSTEM INSPECTION PEMERIKSAAN SISTEM PENERANGAN LAMPU BESARDOES TIDAKNOT MENYALA HEADLIGHT COME ON OR ATAU REDUP NYALANYA IS WEAK Standard Inspection Pemeriksaan Standard Check the following Periksa sebagai berikut

Burned out bulb or terbakar bulb with atau unspecified wattagedengan - – Bola lampu putus bola lampu – Loose connector watt yang tidak sesuai – Lighting switch - Connector longgar – Dimmer switch - Lighting switch (saklar lampu) - IfDimmer switch dim)check as follows: the above items (saklar are normal, Lighting Circuit Inspection Jika hal-hal di atas adalah normal, periksa sebagai berikut: Remove the followings: Pemeriksaan Rangkaian Penerangan – Front upper cover (page 2-4) Lepaskan berikut: – Centersebagai body cover (page 2-8) - Front upper cover (hal. 2-4) - Center body cover (hal. 2-8)

HEADLIGHT 6P CONNECTOR

Disconnect the alternator/ignition pulse generator 3P connecLepaskan alternator/ignition pulse generator 3P tor. connector.


Putar lighting switch ketoposisi dan dimmer switch ke Turn the lighting switch H andHdimmer switch to Hi posiHi. tion.


Check the continuity between the Blue terminal of the headPeriksa kontinuitas antara terminal Biru dari headlight light 6P connector and yellow terminal of the alternator/igni6P connector dan terminal Kuning dari alternator/ignition tion pulse generator 3P connector. pulse generator 3P connector. If there is continuity, check the following: Jika ada kontinuitas, periksa sebagai berikut: Bu Bu/W

Y

DIMMER SWITCH LIGHTING SWITCH

17-4


LAMPU/METER/SAKLAR-SAKLAR Lepaskan body cover 2-9). Remove the body cover(hal. (page 2-9). Lepaskan 4P connector. Disconnectregulator/rectifier the regulator/rectifier 4P connector.

REGULATOR/RECTIFIER 4P CONNECTOR Check thekontinuitas continuity between Yellow terminals the Periksa antara theterminal Kuning ofdari regulator/rectifier 4P and dan alternator/ignition pulse regulator/rectifier 4Pconnector connector alternator/ignition generator 3P connector. pulse generator 3P connector.


If there is continuity, check the following: Jika ada kontinuitas, periksa sebagai berikut:

Y


Pemeriksaan Massa Ground Inspection Check the continuity antara betweenterminal the GreenHijau terminal the headPeriksa kontinuitas dariofheadlight light 6P connector ground. 6P connector dan and ground (massa).


If there is continuity, check the lighting coil (page 14-12). Jika ada kontinuitas, periksa lighting coil (kumparan If the lighting coil is normal, check the regulator/rectipenerangan) (hal. 14-11). fier(page 14-14). Jika lighting coil adalah normal, periksa regulator/rectifier (hal. 14-14).

G

17-5


HEADLIGHT HEADLIGHT(LAMPU BESAR) PENGGANTIAN BULB (BOLA LAMPU) BULB REPLACEMENT Lepaskan front upper Remove the front uppercover cover(hal. (page2-4). 2-4). Remove the dustcover. cover. Lepaskan dust Slightly headlight push the headlight socket and turn it counterTekan bulb bulb socket sedikit dan putar clockwise. berlawanan arah jarum jam. Remove the headlightbulb bulbdan and ganti replace it with yang a new baru. one. Lepaskan headlight dengan Install a new headlight bulb by aligning the tab on the headPasang headlight bulb baru dengan mentepatkan tab light bulb with the groove on the headlight unit. pada bulb dengan alurthe pada unit. Installheadlight the bulb socket by aligning tabsheadlight on the bulb socket Pasang bulb socket dengan mentepatkan tabs pada with the slots on the headlight unit. bulb socket dengan slots pada headlight unit. Push the bulb socket in, turn it clockwise. Tekan bulb socket ke dalam, putar searah jarum jam. Install the dust cover cover Install the dust cover tightly on the headlight unit. Pasang Pasang dust cover dengan erat pada headlight unit. dengan "TOP" with itstanda "TOP" mark Install the front upper cover (page 2-4). menghadap ke atas. facing up. Pasang front upper cover (hal. 2-4).

HEADLIGHT BULB

TANDA "TOP"

DUST COVER

BULB SOCKET

LIGHTING SWITCH INSPECTION PEMERIKSAAN LIGHTING SWITCH Lepaskan front handlebar (hal. 2-5). Remove the front handlebarcover cover (page 2-5). Turn the ignition switch "OFF". Putar kunci kontak ke "OFF". Disconnectlighting the lighting switch connector. Lepaskan switch connector.

LIGHTING SWITCH

Check for continuity between the connector terminals in each Periksa terhadap kontinuitas antara connector terminals switch position. pada masing-masing posisi switch. Continuity exist between color coded wire termiHarus ada should kontinuitas antara the terminal kawat dengan nals as follows: kode warna sebagai berikut:

LIGHTING SWITCH CONNECTORS

LIGHTING SWITCH HL

C1

TL

Bu/W

Y

Br

(N) P (N) H COLOR

17-6

LAMPU/METER/SAKLAR-SAKLAR PEMERIKSAAN DIMMER SWITCH DIMMER SWITCH INSPECTION Remove the front handlebarcover cover (page 2-5). Lepaskan front handlebar (hal. 2-5). Turn the ignition switch "OFF". Putar kunci kontak ke "OFF". Disconnectdimmer the dimmer switch connector. Lepaskan switch connector.

DIMMER SWITCH

Check for continuity between the connector terminals in each Periksa terhadap kontinuitas antara connector terminals switch position. pada masing-masing posisi switch. Continuity exist between color coded wire kawat termiHarus ada should kontinuitas antara the terminal-terminal nals as follows: dengan kode warna sebagai berikut:

DIMMER SWITCH CONNECTOR

DIMMER SWITCH Hi

Lo

HL

Bu

W

Bu/W

HI (N) LO COLOR

POSITION POSITIONLIGHT LIGHT(LAMPU SENJA) PENGGANTIAN BOLA LAMPU BULB REPLACEMENT Lepaskan front upper Remove the front uppercover cover (hal. (page2-4). 2-4). Tarik keluar position lightbulb bulb socket dari Pull out the position light socket from theheadlight headlightunit. unit. Keluarkan position light bulb dan ganti dengan Remove the position light bulb and replace it with a newyang one. baru. Install the position light bulb socket in the reverse order of removal. Pasang position light bulb socket dalam urutan terbalik

BULB SOCKET

POSITION LIGHT BULB

dari pelepasan.

17-7


TURN SIGNAL SIGNAL LIGHT LIGHT(LAMPU SEIN) PENGGANTIAN BULB (BOLA LAMPU) BULB REPLACEMENT DEPAN FRONT Remove the front uppercover cover (hal. (page2-4). 2-4). Lepaskan front upper Turn the front signal light bulb socketberlawanan counterclockwise Putar front turnturn signal light bulb socket arah and remove it from the light unit. arum jam dan lepaskan dari light unit. Remove the bulb from the socket and replace with abaru. new Keluarkan bulb dari socket dan ganti denganityang one. Pasang turn signal light bulb socket dalam urutan Install the turn signal light bulb socket in the reverse order of terbalik dari pelepasan. removal.

FRONT TURN SIGNAL LIGHT BULB

BELAKANG REAR Lepaskan tail/brake Remove the tail/brakelight lightlens lens (hal. (page17-10). 17-10).

REAR TURN SIGNAL LIGHT LENS

rear Remove the rearturn turnsignal signallight light lens. lens. Be careful to Lepaskan Hati-hati agarnot tidak menggores permukaan scratch the reflector reflector. surface. Hati-hati agarnot tidak Be careful to merusak lens. damage the lens.

Remove therear rearturn turn signal signal light socket dan and Lepaskan lightbulb bulbfrom darithesocket Installation is in the reverse order of removal. replace it with a new one. ganti dengan yang baru.


17-8

adalah

dalam

urutan

BULB SOCKET

terbalik

dari

REAR TURN SIGNAL LIGHT BULB


TURN SIGNAL SWITCH (SAKLAR LAMPU SEIN)

TURN SIGNAL SWITCH

PEMERIKSAAN INSPECTION Lepaskan front handlebar cover (hal. 2-5).

Remove the front handlebar cover (page 2-5). Putar kunci kontak ke "OFF". Turn the ignition switch "OFF". Lepaskan turn signal switch connector. Disconnect the turn signal switch connector. Periksa terhadap kontinuitas antara connector terminals Check for continuity between the connector terminals in each pada masing-masing posisi switch. switch position. Harus ada kontinuitas antara terminal kawat dengan Continuity exist between the color coded wire termikode warnashould sebagai berikut: nals as follows:

TURN SIGNAL SWITCH

TURN SIGNAL SWITCH CONNECTOR

TURN SIGNAL SWITCH R

W

L

Lb

Gr

O

R N L COLOR

17-9


TURN SIGNAL SIGNALRELAY RELAY TURN PEMERIKSAAN INSPECTION Lepaskan front handlebar Remove the front handlebarcover cover (hal. (page2-5). 2-5). Check the following: Periksa sebagai berikut: Batterybaterai condition - –Kondisi Burned out bulb non-specified - –Bola lampu putusor terbakar atauwattage dengan watt yang – tidak Burned fuse sesuai Ignition switch and turn signal switch function - –Sekring putus terbakar – Loose connector - Fungsi ignition switch dan turn signal switch - IfConnector longgar the above items are normal, check as follows:

Jika hal-halthediturn atas adalah normal, periksa sebagai Disconnect signal relay 2P connector from the relay. berikut: Short the turn signal relay connector terminals of the wire harness side with a jumper Lepaskan turn signal relaywire. 2P connector dari relay. CONNECTION:Black Gray relay connector terminals Hubungkan singkat turn–signal dari sisithe wire harness dengan kawatthe penghubung. Check turn signal light by turning switch ON.

If the light comes on, the– turn signal relay is faulty or the conHUBUNGAN: Hitam Abu-abu nector has poor connection. Periksa lampu sein dengan memutar switch ke ON. If the light does not come on, the wire harness is broken. Jika lampu sein menyala, maka turn signal relay rusak atau connector sambungannya buruk.

Jika lampu sein tidak menyala, maka wire harness putus.

TURN SIGNAL RELAY KAWAT PENGHUBUNG

Dari MAIN FUSE

IGNITION SWITCH

TURN SIGNAL RELAY 2P CONNECTOR

O Bl

Gr Lb

TURN SIGNAL SWITCH

G

TURN SIGNAL LIGHT

TAIL/BRAKE LIGHT (LAMPU BELAKANG/REM) TAIL/BRAKE LIGHT PENGGANTIAN BULB BULB REPLACEMENT

Tekan bagian atas dari Lepaskan screws dan tail/brake light lens. Slightly press down rear fender sedikit ke Remove the screws and tail/brake light lens. the upperbawah side ofuntuk rear mempermudah fender to ease pelepasan. removal. Hati-hati agarnot tidak Be careful to merusak damagelens the dan lensrear and ender. rear fender.

SCREWS

TAIL/BRAKE LIGHT LENS

Tekan danand putar arah berlawanan Slightlybulb presssedikit the bulb turndalam it counterclockwise, then arum jam, dan the lepaskan dari light unit. remove it from light unit. Ganti tail/brake light bulb baru. Replace the tail/brake lightdengan bulb withyang a new one. Installation is in adalah the reversedalam order of urutan removal. terbalik Make sure that the Pemasangan lens packing is in pelepasan. place.

17-10

dari

TAIL/BRAKE LIGHT BULB


SPEEDOMETER SPEEDOMETER PENGGANTIAN BULB BULB REPLACEMENT Lepaskan front handlebar Remove the front handlebarcover cover (hal. (page2-5). 2-5). Tarik keluar bulbsocket socketfrom darithe speedometer Pull out the bulb speedometerunit. unit. Remove the bulb from the socket and dengan replace ityang with baru. a new Lepaskan bulb dari socket dan ganti one. Pemasangan adalah dalam urutan terbalik dari Installation is in the reverse order of removal. pelepasan.

BULB

BULB SOCKET

PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan rear (hal. 2-5). Remove the rearhandlebar handlebar cover cover (page 2-5). Lepaskan berikut: Disconnectsebagai the following:

CONNECTORS

- –Starter switch Starter switchconnector connector - –Lighting switch connectors Lighting switch connectors - –Dimmer switch connector Dimmer switch connector - –Turn signal switch Turn signal switchconnector connector - –Horn switch connector Horn switch connector

Remove the three screws dan screws and speedometer unit. Lepaskan ketiga speedometer unit. Installation is in adalah the reversedalam order of urutan removal. terbalik Pemasangan pelepasan.

dari

SCREWS SPEEDOMETER

17-11

LAMPU/METER/SAKLAR-SAKLAR PEMBONGKARAN/PERAKITAN DISASSEMBLY/ASSEMBLY Remove thesebagai following: Lepaskan berikut: – Turnsignal signalrelay relay - Turn – Meterlens lens - Meter – Four bulb - Empat bulbsockets sockets – Three terminal screwsdan and wire wire terminals terminals - Tiga terminal screws – Two screws and speedometer/fuel meter unitunit - Dua screws dan speedometer/fuel meter – Meter case - Meter case Assembly is inadalah the reverse order of urutan disassembly. Perakitan dalam terbalik

dari

pembongkaran. TURN SIGNAL RELAY

SCREWS

TERMINAL SCREWS

SPEEDOMETER/ HANDLEBAR SWITCH WIRE

METER CASE

SPEEDOMETER/ FUEL METER UNIT

METER LENS

INSTRUMENT LIGHT (BI and G) TURN SIGNAL INDICATOR (O and Lb)

HI BEAM INDICATOR (Bu and G) INSTRUMENT LIGHT (BI and G)

TERMINAL (BI)

TERMINAL (Bu/W)

TERMINAL (Y/W)

17-12


FUEL LEVEL LEVELSENSOR SENSOR FUEL PELEPASAN REMOVAL Unlockkunci and open the seat usingdan the ignition Buka tempat duduk naikkankey. tempat duduk Disconnect the fuel unit 3P connector. dengan menggunakan anak kunci kontak. Lepaskan fuel unitsensor 3P connector. Turn the fuel level holder plate counterclockwise with a pair offuel needle nose pliers andholder align theplate tabs ofdalam the fuel arah tank Putar level sensor and grooves of the fuel sensortang holder plate. berlawanan jarum jamlevel dengan lancip dan tepatkan tabs dari fuel tank dan alur-alur pada fuel level sensor Remove the fuel level sensor holder plate. Removeplate. the fuel level sensor and the O-ring. holder Be careful not to Hati-hati agar tidak Lepaskan fuel level sensor holder plate.

damage the float arm. merusak float arm.

Lepaskan fuel level sensor dan O-ring.

INSTALLATION PEMASANGAN Install the new O-ring to the fuel tank. Install theO-ring fuel level thetank. fuel tank. Pasang barusensor padatofuel Hati-hati agar not tidak Be careful to Set the holder plate by aligning the tabs of the fuel tank and merusak damage the float float arm. arm. Pasang fuel level sensor pada fuel tank.

grooves of the holder plate. Tempatkan holder dengan tabs Turn the holder plateplate clockwise untilmentepatkan the arrow marks on dari the fuel tank dan alur-alur dari holder plate. holder plate and the fuel tank are aligned. Puter holder plate searah jarum jam sampai tandatanda panah pada holder plate dan fuel tank telah ditepatkan. Pelepasan:

HOLDER PLATE

Tepatkan

HOLDER PLATE

HOLDER PLATE

FUEL LEVEL SENSOR

Pemasangan: FUEL LEVEL SENSOR

Tepatkan HOLDER PLATE

TANDA PANAH

O-RING

Tepatkan

17-13

LAMPU/METER/SAKLAR-SAKLAR PEMERIKSAAN INSPECTION Ukur tahanan antara terminal-terminal connector Measure the resistance between the connector terminals with the floatfloat at upper (full) and lower dengan (pelampung) pada(empty) posisi positions. teratas (penuh) dan paling bawah (kosong). (20°C/68°F) CONNECTION FLOAT POSITION (20° C) FULL EMPTY HUBUNGAN POSISI PELAMPUNG Blue/White - Green 25 – 45 Ω 400 – 700 Ω PENUH KOSONG Yellow/White – Green 400 – 700 Ω 25 – 45 Ω Biru/Putih – Hijau 25 – 45 Ω 400 – 700 Ω Yellow/White – Blue/ 450 – 750 Ω 450 – 750 Ω Kuning/Putih – 400 – 700 Ω 25 – 45 Ω White Hijau Kuning/Putih 450 450 – 750 Ω Replace the fuel– level sensor if it– is750 outΩ of specification. Biru/Putih

G

Y/W

Bu/W

FUEL LEVEL SENSOR

FUEL METER METER CIRCUIT INSPECTION FUEL METER DOES NOT MOVE

• Before performing the system inspection, make sure that the following items are normal. – Battery condition – Fuse PEMERIKSAAN RANGKAIAN METER – Meter indicators • Sebelum sistem, Unlock and open menjalankan the seat using the pemeriksaan ignition key. pastikan bahwa bagian-bagian berikut ini adalah Disconnect the fuel level sensor 3P connector. normal. Short the fuel level sensor connector terminals of the wire Kondisi baterai harness side with the jumper wire. - Sekring CONNECTION:Blue/White – Green - Meter indicators

FUEL METER

FUEL LEVEL SENSOR 3P CONNECTOR

Jangan Do nottinggalkan leave the terminal-terminal terminals connected tersambung dengan with the jumper wire kawat listrik untuk waktu for a long time, as it Turn the METER TIDAK ignition switchBERGERAK "ON" and check the fuel meter. lama, oleh karena FUEL causes damage to the menyebabkan kerusakan Buka meter gaugeduduk moves dan to thenaikkan "F", it is tempat normal. duduk kunci tempat fuel meter. If the fuel pada fuel meter.

dengan anak kunci kontak. • If the above inspection is normal, check the fuel level sensor (see page 17-14). Lepaskan fuel level sensor • If the meter gauge moves3P to connector. "E" with connector shorted, check the following: Hubungkan singkat fuel level sensor connector – Fuel level circuitdengan kawat terminals dari sensor sisi wire wirefor open harness – Fuel meter Black wire for open circuit penghubung. If the wire harness is normal, replace the speedometer/ fuel HUBUNGAN: – Hijau meter unit with aBiru/Putih new one, and recheck. Putar kunci kontak ke "ON" dan periksa fuel meter.

FUEL METER


Jika fuel meter gauge bergerak ke "F", ia adalah normal. • •

Jika pemeriksaan di atas adalah normal, periksa fuel level sensor (lihat hal. 17-14). Jika meter gauge bergerak ke "E" dengan connector dihubungkan singakt, periksa sebagai berikut: - Rangkaian terbuka pada kawat fuel level sensor - Rangkaian terbuka pada kawat Hitam fuel meter

Jika wire harness adalah normal, ganti speedometer/fuel meter unit dengan yang baru, dan periksa kembali.

17-14

Dari MAIN FUSE

IGNITION SWITCH BI

Bu/ W Y/ W G

KAWAT PENGHUBUNG

LAMPU/METER/SAKLAR-SAKLAR FUEL "F" FUELMETER METERTETAP STAYSPADA AT "F" Lepaskan handlebar (hal. 2-5) dan Remove the rear rear handlebar covercover (page 2-5) and connect the handlebar switch/speedometer 4P/6P connectors. sambungkan handlebar switch/speedometer 4P/6P connectors. Turn the ignition switch "OFF". Disconnect fuel ke level sensor 3P connector (page 17-14). Putar kunci the kontak "OFF". Check for fuel continuity between3P theconnector fuel level sensor connector Lepaskan level sensor (hal. 17-14). of the wire harness side and meter terminal. Periksa terhadap kontinuitas antara fuel level sensor CONNECTION:Yellow/White Yellow/White connector dari sisi wire harness– dan meter terminal. • If there is no continuity, there is open circuit in Yellow/ HUBUNGAN: Kuning/Putih – Kuning/Putih White wire. there is continuity, check the fuel sensor (page 17• • If Jika tidak ada kontinuitas, ada level rangkaian terbuka 14). pada kawat Kuning/Putih. • Jika levelthe sensor (hal. If the ada fuel kontinuitas, level sensor isperiksa normal,fuel replace speedome17-14). ter/fuel meter unit with a new one (page 17-12) and Jika fuel level sensor adalah normal, ganti recheck. speedometer/fuel meter unit dengan yang baru (hal. 17-12) dan periksa kembali.

FUEL METER Y/W TERMINAL

FUEL METER

Dari MAIN FUSE

IGNITION SWITCH Bu/ W Y/W G


HORN HORN (KLAKSON) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Remove the front uppercover cover(hal. (page2-4). 2-4). Lepaskan front upper

HORN

CONNECTORS

Disconnecthorn the horn connectors the horn. Lepaskan connectors darifrom horn. Remove the bolt, washer,rubber rubber dan and horn. Lepaskan bolt, washer, horn. Installation is in adalah the reversedalam order of urutan removal. terbalik Pemasangan pelepasan.

dari

BOLT/WASHER/RUBBER

PEMERIKSAAN HORN HORN INSPECTION Remove the front uppercover cover(hal. (page2-4). 2-4). Lepaskan front upper Disconnecthorn the horn connectors the horn. Lepaskan connectors darifrom horn. Connect a 12V battery to the horn terminals. Hubungkan baterai 12V pada horn terminals. The horn is normal if it sounds when the 12V battery is 12V conHorn adalah normal jika berbunyi sewaktu baterai nected to the horn terminals. dihubungkan ke horn terminals.

17-15

LAMPU/METER/SAKLAR-SAKLAR PEMERIKSAAN HORN SWITCH HORN SWITCH INSPECTION Remove the front handlebarcover cover (page 2-5). Lepaskan front handlebar (hal. 2-5). Turn the ignition switch "OFF". Putar kunci kontak ke "OFF". Disconnect the horn switch connector. Lepaskan horn switch connector. Check for continuity between the connector terminals in each Periksa terhadap kontinuitas antara connector terminals switch position. pada masing-masing posisi switch. Continuity exist between colorterminals coded wire termiHarus adashould kontinuitas antarathe wire dengan nals as follows: kode warna sebagai berikut:

HORN SWITCH

HORN SWITCH CONNECTOR

HORN SWITCH BAT

HO

Bl

Lg

FREE PUSH COLOR

17-16

18. DIAGRAM LISTRIK

WIRING DIAGRAM······························· ········ 18-2 DIAGRAM LISTRIK.......................... 18-2

18

18-1

DIAGRAM LISTRIK

WIRING DIAGRAM DIAGRAM LISTRIK T H G I L L A R N A G E I ) R S W 0 T N 1 H R V G 2 I U 1 R T ( b L

T H G I L E ) K A W R 8 1 B / & 5 L I V 2 A 1 T ( r Y B G / G

G

N R T U H T G R I ) L A E L W R 0 A 1 T N V F G I 2 E 1 L S (

0 0 6 9 Y V K Z 0 3 0 0

G O

N O I T I L I N O G I C

Y r O / B b L G G I N I M

K G R A U P L S P

P 6

r b O Y / G B L G

D N A H ) T C E S T S I ( E D W T I S N S E L R M A E H M T E C I R R V R E L A T N H A S E T V

G

P U

W / G

O / G l B

/ R O R T E I A F L I U T C G E E R R

P 4 G

P I 3 N I G M

Y / l B l B / R R / Y G

G W / G

P 3 I N I l M B

W / G G / Y Y / u B O / G

O / G

Y P W 3 Y / u B

I N I M

L O R T ) N M O C I C ( N E O I L U T I D N O G I M R O T A N R E T L

Y W Y / u B

N O I E T I S L N U G I P

R R

R E T Y R A L A T E S R

R W / R l B / R R / Y

P 5

R O T O M R E T R A T S

A

G

G

X O B E S U F N H O I C T T I I N W G I S

P 4

r B P 6

l B

G Y W R

Y H R E A 5 T . T 3 V A 2 B 1

I N I M

W / R

P 2

G

D E N N U I O G R N E G

W / R

A 5 1 R R

A 0 1

D N E U M O A R R F G

W / G G G

l B l B / R

N E E U E E L R N G B G T T W N H Y H K A A O N R G I G I R R I B O L L P G

r r b g B O L L P G G N I K R A M / D W N E N K O E E T U C L I A L U E D O L E L R E H R B Y B G R W G : B l u B Y B G

1 T A B

P 2

l B / R R

T A B

L E V R E L O L S E N E U F S

I P 3 N I l M B

l B / R R

M O C R W R O L O C

W / u B W / Y G H C T I W S R E T R A T S

W l r b / Y G / / B B Y L O G G W u / Y Y B

I N I M

P 6

4 I N I M P

G / Y

M C I

Y / G

T S

E E R F

H S U P

R O L O C

W l r Y G / / W / B B Y b L O / u Y G G Y B

g L

R H E T C T R I A T W S S L A Y N A N R L G I E U T S R H C T I W S G N I T H G I L

T S

G / Y

O H

g L

E l

Y / G

B

l B

P 2

r G l B

L T

r G O b L

r B Y

1 C

W / u B u B W

R

1 C

b G L

T H G I L L T A N N O ) G R I F W S 0 T 1 N H V R G 2 I U 1 R T (

18-2

l T A B B

W L W W R R

L H I H O L

Y W / u B

L H

b r u W L B B G O

I N I M

r B

G

T H G I L ) N W O I 4 . T 3 I V S 2 O 1 P (

H C T I W S N R O H

N R O H

G

H C N T I R O W H S L A N G I H S C N T I R W U T S R H E C M T I M I W D S

H C T I W S R E M M I D

O H

g L

T A B

l B

E E R F

H S U P

R O L O C

L H

W / u B

o L

W

i H

u B

I H

) N (

O L

R O L O C

H C T I W S L A N G I S N R U T

L

O

W

r G

H C T I W S N O I T I N G I

T A B

R

1 T A B

l B / R

b L

R

R

N

L

R O L O C

P 6

u G B W

) W T 2 H 3 / G I W L 2 3 D V A 2 E 1 H (

G O

T H G I L L A T N N G O I ) R W S F 0 1 N T V R F U E 2 1 L T (

Y l / G B

H E C K T A I R W B S T T N H O G R I F L

R E T E M O D E E L P A S N ) R G I O W T 4 S . A 3 N C I V R D 2 U 1 N T I (

l / Y B G

R E L T E E U F M

N N O I O I T ) T ) R ) A A O W N W M W N T I 7 I 7 7 . . . A A 1 1 M 1 E M C I V V U V B U 2 L 2 I D 2 L 1 I 1 H 1 L L N I ( ( I (

H C E T K I A W R S B T R H A G E I R L

H C T I W S G N I T H G I L

N O

F F O

K C O L

R O L O C

L T

r B

1 C

Y

W / u B

L H

) N (

P

) N (

H

R O L O C

19. TROUBLESHOOTING

MESIN TIDAK MAU HIDUP ATAU

UNJUK KERJA BURUK PADA ENGINE LACKS POWER19-3

SULIT DIHIDUPKAN..............................19-2

KECEPATAN TINGGI ............................19-6 POOR PERFORMANCE AT LOW

MESIN KEKURANGAN TENAGA .........19-3

AND IDLE SPEED19-5 PENGENDALIAN BURUK .....................19-6

UNJUK KERJA BURUK PADA GIGI

POOR PERFORMANCE AT

SATU DAN PUTARAN STASIONER.....19-5

HIGH SPEED19-6

ENGINE DOES NOT START

POOR HANDLING19-6

OR IS HARD TO START ·······························19-2

19

19-1

TROUBLESHOOTING

ENGINE DOESMAU NOTHIDUP STARTATAU OR ISSULIT HARDDIHIDUPKAN TO START MESIN TIDAK TROUBLESHOOTING

1. Spark Plug Inspection 1. Pemeriksaan Busi Remove and inspect spark plug. Lepaskan dan periksa busi. Is the spark plug wet? Apakah busi basah? YES – • Flooded carburetor YA Karburator banjir •- Faulty starting enrichment (SE) thermal valve • Throttle open (SE) thermal valve tidak bekerja dengan baik Startingvalve enrichment • Dirty air cleaner Throttle valve terbuka • Improperly adjusted pilot screw Air cleaner kotor STEP 2. tidak disetel dengan baik NO – GO TO Pilot screw •

• • • •

2. Spark TIDAKTest - LANJUTKAN DENGAN LANGKAH 2.

Perform spark test. Test Percikan Bunga Api Busi Is there weak or no spark? Jalankan test percikan bunga api busi. YES – • Faulty spark plug Apakah percikan api lemah atau tidak ada? • Fouledbunga spark plug • Loose or disconnected ignition system wires YA Busi tidak bekerja dengan baik • Broken or shorted spark plug wire Busi kotor • Faulty ignition coil Kabel-kabel pengapian longgar atau terlepas • Faulty igniting sistem pulse generator • Faulty ignition switch Kabel busi putus atau ada hubungan singkat • Faulty ignition control module (ICM)baik Ignition coil tidak bekerja dengan • Faulty sidestand switch Ignition pulse generator tidak bekerja dengan baik • Broken sidestand switch wire Ignition switch tidak bekerja dengan baik NO – GO TO STEP 3. Ignition control module (ICM) tidak bekerja dengan baik 3. Carburetor Inspection Sidestand switch tidak bekerja dengan baik Kawat Check carburetor for sidestand clogging. switch putus

2.

•

• • • • •

• • • •

- LANJUTKAN TIDAK Is the carburetor clogged? DENGAN LANGKAH 3. 3.

not serviced frequently enough Pemeriksaan Karburator YES – Carburetor GO TO STEP 4. NO Periksa– karburator terhadap sumbatan.

4. Apakah Fuel Linekarburator Inspection tersumbat?

Disconnect fuel hose at carburetor and apply vacuum teratur pressure to the fuel auto valve. YA - the Karburator kurang mendapatkan perawatan Does fuel flow freely? TIDAK - LANJUTKAN DENGAN LANGKAH 4. YES – GO TO STEP 5. Pemeriksaan Saluran Bahan Bakar NO – • Clogged fuel line Lepaskan •fuel hose (slang bahan bakar) pada karburator dan terapkan tekanan vakuum pada fuel auto Clogged fuel auto valve valve. • Clogged fuel tank breather • Clogged fuel strainer Apakah bahan bakar mengalir dengan bebas? 5. Cylinder Compression Inspection YA - LANJUTKAN DENGAN LANGKAH 5. Check the cylinder compression. TIDAK Fuelwithin line (saluran bahan bakar) tersumbat Is the compression specification? Fuel auto valve tersumbat YES – GO TO STEP 6. Fuel tank breather tersumbat open NO – • Valve Fuel stuck strainer tersumbat • Worn cylinder and piston rings 5. Pemeriksaan Kompressi Cylinder • Damaged cylinder head gasket • Seized valve Periksa kompressi cylinder • Incorrect valve.seat contact • Improper valve timing Apakah kompressi sesuai dengan spesifikasi?

4.

•

• • •

YA TIDAK

- LANJUTKAN DENGAN LANGKAH 6. -

Valve macet terbuka Cylinder dan piston rings aus Cylinder head gasket rusak Valve macet Kontak valve seat tidak benar Valve timing tidak sesuai

•

• • • • •

19-2

TROUBLESHOOTING 6 Kondisi Start Mesin 6. Engine Starting Condition Start by following Hidupkan mesin normal denganprocedure. mengikuti prosedur normal. Apakah mesin hidup kemudian mati lagi? Does the engine start then stops?

YA YES

– • • • • • •

SE thermal valvevalve tidak bekerja dengan baik Faulty SE thermal Leaking inletbocor pipe Inlet pipe Incorrectly adjusted carburetor Karburator tidak disetel dengan benar Clogged carburetor Karburator tersumbat Improper ignition timing (Faulty ICM or ignition pulse generator) Ignition timing tidak benar (ICM atau ignition pulse generator rusak) Contaminated fuel Bahan bakar terkontaminasi

• • • • • •

ENGINE LACKS POWER MESIN KEKURANGAN TENAGA 1. Engine Oil Inspection 1. Pemeriksaan Oli Mesin

Periksa tinggi permukaan oli dan kondisinya. Apakah tinggi permukaan oli benar dan oli berada dalam kondisi baik? Check level and condition. YA the -oilLANJUTKAN DENGAN LANGKAH 2. IsTIDAK the oil level the oil in oli good condition? - correct Tinggiand permukaan terlalu tinggi/rendah Oli terkontaminasi YES – GO TO STEP 2. •

•

2. NO Pemeriksaan Penggerak level too high/low – • Oil Peralatan • Contaminated oil Naikkan roda lepas tanah dan putar dengan tangan. 2. Drive Train Inspection Apakah roda berputar dengan bebas? Raise the wheel off the ground and spin it by hand. YA - LANJUTKAN DENGAN LANGKAH 3. Does the wheel spin freely? TIDAK Rem menyangkut YES – GO TO STEP 3. Final reduction dan driven pulley bearings aus atau rusak NO – • Brake Finaldragging shaft bengkok • Worn or damaged final reduction and driven pulley bearings • Bent final shaft 3. Pemeriksaan Tekanan Udara Ban •

• •

3. Tire Pressure Inspection Periksa tekanan udara ban depan dan belakang. Check front and rear tire pressure. Apakah tekanan udara ban rendah? Is the tire pressure low? YA Tire valve tidak bekerja dengan baik tire valve YES – • Faulty Ban bocor • Punctured tire TIDAK - LANJUTKAN DENGAN LANGKAH 4. NO – GO TO STEP 4. 4. Pemeriksaan Busi 4. Spark Plug Inspection Lepaskan dan periksa Remove and inspect thebusi. spark plug. •

•

Apakah busi baik? Is the spark plugdalam in goodkondisi condition? YA YES

TO STEP 5. DENGAN LANGKAH 5. – G-OLANJUTKAN

TIDAK– •- Plug Busi mendapatkan perawatan teratur notkurang serviced frequently enough NO • Incorrect range Derajatspark panasplug busiheat tidak sesuai • Faulty plug Busi spark tidak bekerja dengan baik Carburetor Inspection Pemeriksaan Karburator Check carburetor for clogging. Periksa karburator terhadap sumbatan. Is the carburetor clogged? Apakah karburator tersumbat? YES – Carburetor not serviced frequently enough YA - Karburator kurang mendapatkan perawatan teratur NO – GO TO STEP 6. TIDAK - LANJUTKAN DENGAN LANGKAH 6. Ignition Timing Inspection Pemeriksaan Ignition Timing Check the ignition timing. ignition timing. IsPeriksa the ignition timing correct? •

• •

5. 5.

6. 6.

Apakah ignition timing O TO STEP 7. benar? YES – G YA NO

LANGKAH Faulty ignitionDENGAN control module (ICM) 7. – •- LANJUTKAN • Faulty ignition pulse generator TIDAK Ignition control module (ICM) tidak bekerja dengan baik Ignition pulse generator tidak bekerja dengan baik •

•

19-3

TROUBLESHOOTING 7. Cylinder compression Inspection 7. Pemeriksaan Kompressi Cylinder Test the cylinder compression. Test kompressi cylinder . Is the compression within specification? Apakah kompressi sesuai dengan spesifikasi? YES – GO TO STEP 8. YA - LANJUTKAN DENGAN LANGKAH 8. NO – • Valve stuck open TIDAK • - Worn Valve macet and terbuka cylinder piston rings Cylinder dan piston rings aus • Damaged cylinder head gasket • Seized valve Cylinder head gasket rusak • Incorrect valve seat contact Valve macet • Improper valve timing Kontak valve seat tidak benar 8. Overheating Inspection Valve timing tidak tepat Check for engine overheating. 8. Pemeriksaan Overheating Is the engine overheating? Periksa terhadap engine overheating. YES – • Excessive carbon build-up in combustion chamber Apakah mesin • Useoverheating? of poor quality fuel • Lean fuel mixture YA Pembentukan karbon secara berlebihan di ruang pembakaran STEP 9. bahan bakar berkualitas rendah NO – GO TO Pemakaian Campuran bahan bakar miskin 9. Engine Knocking Inspection •

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•

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TIDAK - or LANJUTKAN DENGAN LANGKAH 9. Accelerate run at high speed. the engine knocking? 9. Is Pemeriksaan Engine Knocking (mesin mengelitik)

piston andpada cylinder YES – • Wornatau Berakselerasilah jalan kecepatan tinggi. • Wrong type of fuel Apakah mesin knocking? • Excessive carbon build-up in combustion chamber • Ignition timing too advanced (faulty ICM) YA Piston cylinder aus •- Lean fueldan mixture Jenis bahan bakar tidak sesuai NO – GO TO STEP 10. Pembentukan karbon secara berlebihan di ruang pembakaran 10. Valve Timing Inspection Ignition timing terlalu maju (ICM tidak bekerja dengan baik) Campuran Check the valve timing. bahan bakar miskin •

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TIDAK - timing LANJUTKAN Is the valve correct?DENGAN LANGKAH 10. STEPTiming 11. – GO TO 10. YES Pemeriksaan Valve Cam timing sprocket not buka installed properly NO Periksa– valve (tertib klep). 11. Apakah Drive Train Inspection valve timing benar?

Check thedrive train. YA LANJUTKAN DENGAN LANGKAH 11. Is the drive train normal? TIDAK - Cam sprocket tidak terpasang dengan benar NO – • Fouled or faulty drive belt 11. Pemeriksaan DriveorTrain • Fouled faulty(Peralatan drive pulleypenggerak) • Fouled Periksa drive train. or faulty driven pulley • Worn clutch shoes Apakah drive train normal?

TIDAK

-

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19-4

Drive belt kotor atau tidak bekerja dengan baik Drive pulley kotor atau tidak bekerja dengan baik Driven pulley kotor atau tidak bekerja dengan baik Clutch shoes aus

TROUBLESHOOTING

POOR PERFORMANCE AT LOW AND IDLE SPEED UNJUK KERJA BURUK PADA GIGI SATU DAN PUTARAN 1. Idle Adjustment Inspection STASIONER Check the idle speed. Pemeriksaan Penyetelan Putaran Stasioner Is the idle speed correct? Periksa putaran stasioner. YES – GO TO STEP 2. Apakah putaran stasioner benar? NO – Adjust the idle speed 2. YA Spark Test- LANJUTKAN DENGAN LANGKAH 2.

1.

TIDAK spark - Setel putaran stasioner Perform test. 2. Is Test Percikan Api spark? Busi there weak or Bunga intermittent • Faulty spark plug api busi. Jalankan percikan bunga YES – test • Fouled spark plug Apakah percikan • Faulty bunga ignitionapi coillemah atau tidak teratur? • Faulty ignition control module (ICM) YA Busi tidak bekerja dengan baik STEP 3. NO – GO TO Busi kotor Ignition coil tidak bekerja dengan baik 3. Intake Air Leaking Inspection Ignition control module (ICM) tidak bekerja dengan baik Check for air leaks at the inlet pipe. TIDAK LANJUTKAN DENGAN LANGKAH 3. Is there air- leaking? •

• • •

3.

Pemeriksaan Kebocoran inlet pipeUdara Pemasukan YES – • Loose • Damaged inlet pipe Periksa terhadap kebocoran udara pada inlet pipe. • Damaged inlet pipe gasket Apakah kebocoran GO TO STEP 4. udara pemasukan? NO – ada

Inlet pipe longgar 4. YA Starting Enrichment (SE) Thermal Valve Inspection Inlet pipe rusak Check the SE thermal valve (page 5-18). Inlet pipe gasket rusak Is the SE Thermal valve OK? TIDAK - LANJUTKAN DENGAN LANGKAH 4. YES – GO TO STEP 5. 4. Pemeriksaan Starting Enrichment (SE) Thermal Valve NO – Faulty SE thermal valve Periksa SE thermal valve (hal. 5-18). 5. Ignition Timing Inspection Apakah SE thermal valve OK? Check the ignition timing. YA - LANJUTKAN DENGAN LANGKAH 5. Is the ignition timing correct? TIDAK - SE thermal valve tidak bekerja dengan baik. YES – Improper valve timing 5. NO Pemeriksaan Ignition Timing ignition control module (ICM) – • Faulty • Faulty ignition pulse generato Periksa ignition timing (waktu pengapian). •

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Apakah ignition timing benar? YA TIDAK

- Valve timing tidak benar -

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Ignition control module (ICM) tidak bekerja dengan baik Ignition pulse generator tidak bekerja dengan baik.

19-5

Buku Pedoman Reparasi Beat

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