Buku Pedoman Reparasi Blade

DAFTAR ISI

HOW MEMAKAI TO USEBUKU THISINIMANCARA UAL Buku Pedoman Reparasi ini menguraikan This service manual describes the service procedures for the ANF110. prosedur servis untuk sepedamotor BLADE. Follow the Maintenance Schedule (Section 4) recommendations to ensure that the vehicle is in peak operating condition.

Ikuti petunjuk pada Jadwal Perawatan (Bab 4) Performing the first scheduled maintenance is very important. It compensates untuk mempertahankan sepedamotor pada for the initial wear that occurs during the break-in period. kondisi operasional puncak.

KETERANGAN UMUM

1

FITUR TEKNIK

2

RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS

Sections 1 and 4 apply to the whole motorcycle. Section 3 illustrates procedures for removal/installation of components that may be required to Adalah sangat penting untuk menjalankan perform service described in the following sections. Section 5 throughberkala 18 describe1parts of the motorcycle, grouped according to perawatan dan 2 pada waktunya. Servis location.

ini mengadakan penyesuaian terhadap keausan Find theyang section terjadi you want on this page, then turn to the table of contents awal dalam masa pemakaian mula.on

3

PERAWATAN

4

SISTEM PELUMASAN

5

SISTEM BAHAN BAKAR

6

PENURUNAN/PEMASANGAN MESIN

7

CYLINDER HEAD/VALVES HEAD/VALVES

8

CYLINDER/PISTON

9

the first page of the section.

Most 1 sections start with an untuk assemblyseluruh or systemsepedamotor. illustration, service Bab dan 4 berlaku information and troubleshooting for the section. The subsequent pages give Bab 3 menggambarkan prosedur untuk detailed procedure. pelepasan/pemasangan komponen-komponen If you don't know the source of the trouble, go to section 20 Troubleshooting. yang mungkin diperlukan untuk menjalankan pekerjaan servis yang diuraikan dalam bab-bab berikutnya. Bab 5 safety, melalui 18safety mengura menguraikan bagia n-bagian dari Your and the of others,ikan is verybagian-bagia important. To help n you make informed decisions we have provided safety messages and other sepedamotor, yang dikelompokkan menurut information throughout this manual. Of course, it is not practical or lokasi. possible to warn you about all the hazards associated with servicing

N I S E M

this vehicle. You must use your own good judgement. Carilah bab yang Anda inginkan pada halaman You will find important safety information in a variety of forms includini,ing:kemudian bacalah daftar isi pada halaman • Safet Safety y Labels – on on the vehiclebersangkutan. vehicle pertama dari bab yang • Safety Messages – preceded by a safety alert symbol and one of three signal words, DANG ER, WARNING, WARNING, or CAUTION. Kebanyakan bab dengan gambar These signal words mean: dimulai You WILL be KILLED or SERIOUSLY susunan atau gambar sistem, keterangan servis HURT if you don’t follow instructions.

dan troubleshooting untuk bab itu. HalamanYoumemberikan CAN be KILLED or SERIOUSLY halaman berikutnya prosedur servis HURT if you don’t follow instructions. secara mendetil. You CAN be HURT if you don’t follow instructions.

Jika Anda tidak mengetahui sumber penyebab • Instructions – how to service thisbab vehicle correctly safely. kesukaran, bacalah 21, andTROUBLESHOOTING. As you read this manual, you will find information that is preceded by a Semua keterangan, gambar, petunjuk dan symbol. The purpose of this message is to help prevent damage to dior the environment. dalam publikasi ini your spesifikasi vehicle, other property,

berdasarkan data-data produk terakhir yang tersedia pada waktu persiapan untuk ALL INFORMATION, ILLUSTRATIONS, pencetakan. DIRECTIONS AND SPECIFICATIONS INCLUDED IN THIS PUBLICATION ARE PT Astra Honda Motor berhak membuat BASED ON THE LATEST PRODUCT INFORperubahan pada setiap waktu tanpa MATION AVAILABLE AT THE TIME OF pemberitahuan dan tanpa ikatan apapun. APPROVAL FOR PRINTING. Honda Motor Co., Ltd. RESERVES THE RIGHT TO MAKE Dilarang mengutip atau mencetak ulang CHANGES AT ANY TIME WITHOUT NOTICE bagian dari penerbitan ini tanpa tertulis AND WITHOUT INCURRING ANYijin OBLIGApenerbit. TION WHATSOEVER. NO PART OF THIS PUBLICATION MAY BE REPRODUCED WITHOUT Buku Pedoman ini ditulisTHIS untukMANUAL orang yang WRITTEN PERMISSION. IS WRITTEN FOR PERSONS WHO dasar HAVE telah memiliki pengetahuan ACQUIRED KNOWLEDGE perawatan BASIC sepedamotor Honda. OF MAINTENANCE ON Honda MOTORCYCLES, PT ASTRA HONDA MOTOR

MOTOR SCOOTERS OR ATVS.o., Ltd. SERVICE PUBLICATION OFFICE

Date of Issue: May, 2008 © Honda Motor Co., Ltd.

A K G N A R

N A K I R T S I L E K

CLUTCH/GEARSHIFT LINKAGE

10

ALTERNATOR

11

CRANKSHAFT/TRANSMISSION/KICKSTARTER

12

RODA DEPAN/SUSPENSI/KEMUDI

13

RODA BELAKANG/REM/SUSPENSI

14

REM HIDRAULIK

15

BATERAI/SISTEM PENGISIAN

16

SISTEM PENGAPIAN

17

SISTEM STARTER LISTRIK

18

LAMPU-LAMPU/METER-METER/SAKLAR-SAKLAR

19

DIAGRAM LISTRIK

20

TROUBLESOOTING

21

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 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 kerja ataupun ataupun kunci perkakas, balk yang yang dianjurkan dianjurkan oleh Honda maupun tidak, harus meyakinkan dirinya sendiri dengan pasti bahwa keamanan pribadi maupun keamanan kendaraan tidak terancam oleh cara pelaksanaan servis ataupun kunci perkakas yang dipilih.

1. KETERANGAN UMUM 1

SERVICE RULES··············································1-2 PERAT PE RATURAN URAN SERV SE RVIS... IS......... ............ ............ ............ ............. ..........1-2 ...1-2

REAR SPESWHEEL/BRAKE/SUSPENSION IFIKASI IFIKASI RODA BELAKANG/ SPECIFICATIONS············································1-7 REM/SU RE M/SUSPEN SPEN SI ............. ................... ............. .............. ............. ........1-7 ..1-7

MODEL IDEN IDENTIFIC TIFICATION ATION ······· ··············· ··············· ············1-2 ·····1-2 IDENTIFIKASI MODEL....................................1-2 HYDRAULIC BRAKE SPE SIFIKASI REM R EM HIDRAUL HSPECIFICATIONS···1-8 IDRAUL IK.... IK....... ...... ....... ....1-8 1-8 SPES SP ESIFIKAS IFIKASI I UMUM ............ .................. ............ ............ ............. .........1-4 ..1-4 GENERAL SPECIFICATIONS·······················1-4 SPE SIFIKASI SISTE M PELUMASAN PEL UMASAN ...... ......... ....1-5 .1-5 LUBRICATION SYSTEM

BATTERY/CHARGING SYSTEM SPES IFIKASI IFIKASI BATERAI/ B ATERAI/ SPECIFICATIONS············································1-8 SISTEM PENGISIAN..................................1-8

SPECIFICATIONS············································1-5 SPESIFIKASI SISTEM BAHAN BAKAR......1-5

IGNITION SYSTEM SPECIFICATIONS······1-8 SPESIFIKA SPES IFIKASI SI SISTEM PENGA PEN GAPIAN... PIAN...... ...1-8 1-8

FUEL SYSTEM SPECIFICATIONS···············1-5 SPESIFIKASI CYLINDER HEAD/VAL HE AD/VALVE VES S ............ .................. ............ ............ ............ ............ ............. .......1-5 1-5 CYLINDER HEAD/VALVES

ELECTRIC STARTER SYSTEM SPESIFIKA SPES IFIKASI SI SISTEM SPECIFICATIONS············································1-8 STARTE ST ARTE R LISTRIK ............. .................... ............ ............ ...........1-8 ....1-8

SPECIFICATIONS············································1-5 SPESIFIKASI CYLINDER/PISTON...............1-6

CYLINDER/PISTON SPECIFICATIONS ····· 1-6

LIGHTS/METERS/SWITCHES SPESIFIKA SPES IFIKASI SI LAMPU-LAMPU/ LAMPU-LAMPU/ SPECIFICATIONS············································1-8

METER-METER/SAKLAR-SAKLAR .....1-8

SPES IFIKASI IFIKASI CLUTCH/

CLUTCH/GEARSHIFT GEARS HIFT HIF T LINKAGE LIN KAGELINKAGE ............ .................. ............ ............. ...........1-6 ....1-6

STANDARD TORQUE VALUES····················1-9 NILAI TORSI TOR SI STANDARD STAN DARD ....... .......... ...... ....... ....... ...... ...1-9 1-9

SPECIFICATIONS············································1-6 SPESIFIKA SPES IFIKASI SI ALTERN ATOR/STARTER ATOR/STARTER

ENGINE ENGIN E & FRAME TORQU TORQUE E VALUES ······1-9 NILAI TORSI MESIN & RANGKA ..... ....... ..... ....1-9 .1-9

ALTERNATOR/STARTER CLUTCH CLUTC CL UTCH H .............................................................1-6 SPECIFICATIONS············································1-6

LUBRICATIO LUBRI CATION N& SEAL POIN POINTS ···············1-12 ········1-12 TITIK-TITIK TITIK-TITI K PELUMASAN PE LUMASAN &TS ·······

SPES IFIKASI IFIKASI CR ANKSHAFT/ ANKSHAFT/

PERAP PE RAPATAN........... ATAN.................. ............. ............ ............. ............. ..........1-12 ....1-12

CRANKSHAFT/TRANSMISSION/KICKTRANSMISSI/KICK TRAN SMISSI/KICKSTAR STARTER TER... ...... ...... ...... ...... ...... ....... .....1-7 .1-7

CABLE & HARNESS ROUTING··················1-14

STARTER SPECIFICATIONS························1-7 SPES IFIKASI IFIKASI RODA DEPAN/ FRONT WHEEL/SUSPENSION/ SUSPEN SU SPEN SI/KE MUDI ............ .................. ............ ............ ............. ..........1-7 ...1-7

STEERING SPECIFICATIONS SPECIFICATIONS······················ ······················ 1-7

PERLETAKAN K ABEL & HARNESS... HARNESS..... ..1-14 1-14

EMISSION CONTROL SYSTEMS···············1-21 SISTE M PENGATUR PE NGATURAN AN EMISI ...... ......... ...... ......1-21 ...1-21

1-1

KETERANGAN UMUM

SERVICE RULES PERATURAN SERVIS GENERALINFORMATION

1. 1. 2. 2. 3. 4. 3. 5.

4. 6. 5. 7. 8. 6. 7.

Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications specifications Pakailah parts to dan asli Honda atau yang direkomendasikan oleh Honda atau sejenisnya. Parts yang tidak may cause damage the pelumas motorcycle. memenuhi spesifikasi rancangan kerusakan pada sepedamotor. Use the special special tools designed for this Honda product dapat to avoid avoimengakibatkan d damage and incorrect assembly. assembly. Pakailah special tools yang telah dirancang untuk produk ini untuk menghindari kerusakan dan yang tidak Use only metric tools when servicing the the motorcycle. Metric Metric bolts, nuts and and screws are not interchangeable interchangeable with pemasangan English fasteners. benar. Install new new gaskets, O-rings, cotter cotter pins, and lock plates when when reassembling. reassembling. Hanya pergunakan toolswith ketika menservis sepedamotor. Baut, mur dan to sekrup metric tidak dapat dipertukarkan When tightening bolts ormetric nuts, begin wit h the larger diameter or inner bolt first. first . Then tighten the specified speci fied torque diagonally in incremental incremental dengan pengikat sistem Inggris. steps unless a particular sequence is specified. Pasanglah pin,ssembly. dan lock dan lock plates baru pada waktu perakitan Clean parts ingasket, cleaningO-ring, solvent cotter upon disassembly. disa Lubricate any sliding surfaces surfaces before reassembly. rekembali. assembly. Ketika mengencangkan mengencan gkan bautfor atau mur, mur,installation mulailah and dengan baut dengan diameter yang lebih besar baut besar atau baut di sebelah sebelah dalam After reasse reassembly, mbly, check all parts proper installation operation. Route electrical wires as shown dengan in the Cable Cable and Harness Routingyang (pagetelah 1-14).ditentukan secara bersilang dalam langkah-langkah dulu.all Kemudian kencangkan torsi pengencangan peningkatan kecuali bila telah ditentukan urutan tertentu. Bersikan parts Bersikan parts yang telah dilepaskan dalam larutan pembersih. Lumasi semua permukaan luncur sebelum perakitan kembali. Setelah perakitan kembali, periksalah semua parts semua parts terhadap terhadap pemasangan dan pengoperasian yang ben ar. Alurkan semua kawat kawat listrik seperti seperti diperlihatkan dalam dalam Perletakan Kabel Kabel dan Harness (hal. 1-15).

MODEL IDENTIFICATION

8.

IDENTIFIKASI MODEL

1-2

KETERANGAN UMUM SERIAL NUMBERS NOMOR SERI

LihathalamanLihathalamanLihathalamanLihathalamanLihathalamanLihathalamanLihathalamanLihathalamanLihathalamanLihathalamanLihathalamanLihat halamanLihathalamanLihathalamanLihathalamanLihathalamanLihathalamanLihathalaman

The frame serial number is stamped on the kiri left dari side kepala of the steering head. Nomor seri rangka di cetak di sebelah kemudi

NOMOR SERI RANGKA

Nomor seriserial mesin dicetak pada bagian sisi kiri crankcase (bak The engine number is stamped on the lower leftbawah side ofdari the crankcase. mesin).

NOMOR SERI MESIN

Nomor identifikasi karburator di is cetak pada samping kanan body The carburetor identification number stamped on the right side of thedari carburetor body. karburator

NOMOR IDENTIFIKASI KARBURATOR

1-3

KETERANGAN UMUM

GENERAL SPECIFICATIONS SPECIFICATION S SPESIFIKASI UMUM BAGIAN DIMENSI DIMENSIONS

RANGKA FRAME

MESIN ENGINE

KARBURATOR PERALATAN CARBURETOR PENGGERAK DRIVE TRAIN

KELISTRIKAN

ELECTRICAL

1-4

ITEM Panjang menyeluruh Overall length Lebar menyeluruh Overall width Tinggi menyeluruh Overall height Jarak sumbu roda WheelbTinggi ase tempat duduk Seat heiTinggi ght pijakan kaki FootpegJarak heighterendah t ke tanah GroundBerat clearamotor nce siap pakai Curb weJenis ight rangka Frame tSuspensi ype depan Front suJarak spensipergerakan on poros depan Front axSuspensi le travel belakang Rear susJarak pensiopergerakan n poros belakang Rear axDamper le travel (peredam kejut) belakang ban depan Rear daUkuran mper Ukuran Front tire size ban belakang Depan Rear tireMerek size ban Belakang Tire brand F ront Rem depan Rear Rem belakang Front brake Sudut caster Rear brake Panjang trail Caster angle Kapasitas tangki bahan bakar Trail length Diameter dan langkah Fuel tank capacity Volume langkah Bore anPerbandingan d stroke kompressi DisplacPeralatan ement penggerak klep CompreKlep ssionmasuk ratio membuka ] Valve train menutup ] pada pengangIntake vKlep alve buang op ens at 1 m1m (0.04 in) lift membuka ] katan mm clmenutup oses ] at 1 mm (0.04 in) lift ExhaustSistem valve pelumasan opens at 1 mm (0.04 in) lift Jenis pompa oli closes at 1 mm (0.04 in) lift LubricaSistem tion systpendinginan em Saringan udara Oil pump type Jenis crankshaft Cooling system Air filtrBerat ation kosong mesin Susunan cylinder Crankshaft type Engine Jenis dry wekarburator ight Diameter Cylinder arrangemthrottle ent CarbureSistem tor Typekopeling ThrottleSistem bore pengoperasian kopeling Transmissi Clutch system Clutch oPrimary perationreduction system Final reduction Transmission Perbandingan gigi gigi 1 Primary reduction gigi 2 Final reduction gigi 3 Gear ratio gigi 14st 2nd Pola pengoperan gigi 3rd 4th GearshiSistem ft patternpengapian Sistem starter Sistem pengisian Regulator/rectifier Ignition system StartingSistem system penerangan Charging system Regulator/rectifier Lighting system

SPESIFIKASI

SPECIFICATIONS 1.885 mm 1,885 mm (74.2 in) 709 mm 709 mm (27.9 in) 1.071 mm 1,071 mm (42.2 in) 1.221 mm 1 ,221 mm (48.1 in) 669 mm 69 mm (26.3 in) 2686mm 68 mm (10.6 in) 1472mm 1 7 mm (5.8 in) 96,8 4 kg 96back .8 kg (bone 213.4(tulang lbs) Jenis belakang) Bacteleskopik k bone type Garpu Telescopic fork 81 mm 81 m m ((lengan 3.2 in) ayun) Swing arm Swingarm 83 mm Jenis satu sisi 83pipa mm (pengoperasian 3.3 in) 70/90-17 M/C 38P One side operation tube type 80/90-17 70/90-M/C 17 M44P /C 38P NF63B (IRC) 80/90-17 M/C 44P NR78Y(IRC) NF63B (IRC) Rem Ncakram R78Y (IRhidraulik C) Mekanis, mendahului-mengikut mendahului-mengikutii Hydraulic disc brake 26°00' Mechanical leading trailing 67 mm 26°00’ 3,7 liter 67 mm (2.6 in) 50,0 x 55,6 mm 3.7 lite3r (0.98 US gal, 0.81 lmp gal) 109,1 cm 9,0 :50 1.0 x 553.6 mm (1.97 x 2.19 in) cu-in) rantai tunggal 109.1SOHC cm (6.66 2 valve, digerakkan 9 . 0 : 1 5° BTDC (sebelum (sebelu m TMA) 2 valve,(setelah single chaTMB) in driven SOHC 30° ABDC ° 5 BTDC 34° BBDC (sebelum TMB) 0° ABDC 0° 3ATDC (setelah TMA) 34° BBDC Di bawah tekanan paksaan dgn bak oli basah 0° ATDC Trochoid Forced preudara ssure and wet sump Pendinginan Trochkertas oid kental Elemen Jenis Airakitan r cooled 22,6Vkg iscous paper element SatuAcylinder ssembledmiring type 80 ° dari vertikal Tipe22 Valve .6 kg Piston (49.8 lbs) 18 mm Single cylinder inclined 80° from vertical Pelat-majemuk, Piston valve tybasah pe Jenis 18sentrifugal mm (0.7 in)otomatis Bertautan Multi-ptetap, late, w4-kecepatan et 4,059 (69/17) Automatic centrifugal type 2,642 (37/14) Constant mesh, 4-speed 2,615 (34/13) 4.059 (69/17) 1,555 (28/18) 2.642 (37/14) 1,136 (25/22) 2.6(22/24) 15 (34/13) 0,916 1 . 5 (28/18) Sistem55 pengembalian digerakkan kaki kiri 1 . 1 3 6 ( 25/22) hanya sewaktu sepedamotor (sistem rotary; 16 (22/24) N – 1 – 2 – 3 – 4 (- N) tidak0.9 bergerak) L e f t foot operated return system DC-CDI (rotary Kickstartersystem; only when the motorcycle is not running) Single phase output alternator 1 - 2 - 3 - 4 (- N) phase, SCR N - opened/single half wave DC-CDI rectification Kickstarter with electric starter motor Alternator Single phase output alternator SCR opened/single phase, half wave rectification Alternator

KETERANGAN UMUM

LUBRICATION SYSTEM SPECIFICATIONS SPESIFIKASI SISTEM PELUMASAN BAGIAN

ITEM Kapasitas oli mesin Pada penggantian oli Pada pembongkaran mesin Engine oil capacity At draining Oli mesin yang dianjurkan At disassembly Recommended engine oil

Oil pump rotor

Oil pump rotor

STANDARD

0,8 liter STANDARD 1,0 (0.8 liter US qt, 0.7 lmp qt) 0.8 liter Oli mesin dengan 1.0 liter (1.1 US 4 qt,tak 0.9 lmp qt) klasifikasi service SJ. API API classification: SE, SF or SG Viskositas: SAE 10W-30 JASO MA (except oils labeled as energy conserving on Jarak renggang pada ujung rotor the circular API service label) 10W-30 Jarak renggang antara rotor dan rumah Viscosity: 0,15 –SAE 0,21 JASO T 903 standard: MA Jarak renggang ke samping rotor pompa 0,03 – 0,09 Tip clearance – Body clearance 0.15 – 0.21 (0.006 – 0.008) Side clearance 0.03 – 0.09 (0.001 – 0.004)

Satuan: mm(in) Unit: mm BATAS SERVIS SERVICE LIMIT – – 0,15 0,26 0,15

0.15 (0.006) 0.26 (0.010) 0.15 (0.006)

SPESIFIKASI SISTEM BAHAN BAKAR BAGIAN

FUEL SYSTEM Nomor identifikasi karburatorSPECIFICATIONS Putaran stasioner

ITEM Jarak main bebas putaran gas tangan Carburetor identification number Main Jetidle speed Engine Throttle Slow Jet grip freeplay MainLevel jet Float (tinggi permukaan Pelampung) Slow jet Pembukaan awal pilot screw Float level Vacum yang di tentukan untuk pair control valve Air screw initial opening PAIR control valve specified vacuum

–

SPESIFIKASI PB7UA -1

1400 ±100 min (rpm) SPECIFICATIONS 2 - 6 mm PB7UA #88

1,400 ± 100 min-1 (rpm) 2 – 6 mm (0.1 – 0.2 in) #35 #88 11,7 mm #35 Lihat hal. 6-15 11.7 mm (0.46 in) 60 kPa (450 mmHg) See page 6-15 60 kPa (450 mmHg)

SPESIFIKASI CYLINDER HEAD/VALVES CYLINDER HEAD/VALVES SPECIFICATIONS BAGIAN STANDARD Kompressi cylinder ITEMpada cylinder head Perubahan bentuk melengkung Valve, Valve clearance IN/EX Cylinder compression valve guide (jarak renggang klep) (masuk/ buang) Cylinder head warpage D.L. valve stem IN Valve, Valve clearance IN/EX EX valve guide Valve stem O.D. IN D.D. valve guide IN/EX EX Jarak renggang stemIN Valve guide I.D. IN/EX ke-guide EX Stem-to-guide clearance IN Proyeksi valve guide di IN/EX EX atas cylinder head Valve guide projection IN/EX Lebar valve seat IN/EX seat width IN/EX Panjang bebas valveValve spring IN/EX Valve spring free length IN/EX Rocker arm/ D.D. rocker arm IN/EX Rocker arm/ Rocker arm I.D. IN/EX shaft D.L. rocker arm shaft IN/EX shaft Rocker arm shaft O.D. IN/EX Jarak renggang rocker IN/EX Rocker arm-to-shaft cleararm-ke-shaft IN/EX ance Camshaft Tinggi cam lobe IN Camshaft Cam lobebubungan) height IN (cuping EX EX Cam chain D.L. push rod Cam chain tenPush rod O.D. tensioner Panjang bebas spring sioner Spring free length

Satuan: mm

BATAS SERVIS 2

1.245 kPa (12,7 kgf/cm , 181 psi) -1 pada 600 menit (rpm) STANDARD -

-

Unit: mm (in) SERVICE 0,05 LIMIT

1,245 kPa (12.7 kgf/cm2, 181 psi) ± 0,02-1 0,10 at 600 min (rpm) – 4,975 – 4,990 0.10 ± 0.02 (0.004 ± 0.001) 4,955 – 4,970 4.975 – 4.990 (0.1959 – 0.1965) 5,000 – 5,012 4.955 – 4.970 (0.1951 – 0.1957) 0,010 – 0,037 5.000 – 5.012 (0.1969 – 0.1973) 0,030 – 0,057 0.010 – 0.037 (0.0004 – 0.0015) 9,1 – 9,3 0.030 – 0.057 (0.0012 – 0.0022) 9.1 – – 9.3 (0.36 – 0.37) 0,90 1,10 0.90 – 1.10 (0.035 – 0.043) 30,67 30.67 (1.207) 10,000 – 10,015 10.000 – 10.015 (0.3937 – 0.3943) 9,972 – 9,987 9.972 – 9.987 (0.3926 – 0.3932) 0,013 – 0,043

0.05 (0.002) 4,965 – 4,945 4.965 (0.1955) 5,03 4.945 (0.1947) 0,065 5.03 (0.198) 0,085 0.065 (0.0026) 0.085 (0.0033) – 1,6 29,70 1.6 (0.06) 10,1029.70 (1.169) 9,91 10.10 (0.398) 0,0449.91 (0.390)

0.013 – 0.043 (0.0005 – 0.0017) 32,194 – 32,434 32.194––32,230 32.434 (1.2675 – 1.2769) 31,990 31.990 – 32.230 (1.2594 – 1.2689) 11,985 – 12,000 11.985 – 12.000 (0.4718 – 0.4724) 111,3 111.3 (4.38)

0.044 (0.0017) 32,16 31,9632.16 (1.266) 11,9431.96 (1.258) 109 11.94 (0.470) 109 (4.3)

-

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1-5

KETERANGAN UMUM

CYLINDER/PISTON SPECIFICATIONS SPESIFIKASI CYLINDER/PISTON BAGIAN

STANDARD

STANDARD D.D. ITEM 50,005 – 50,015 Kelonjongan - (1.9687 – 1.9691) I.D. 50.005 – 50.015 Ketirusan Out-of-round – Perubahan bentuk melengkung Taper – Piston, Arah tanda piston Tanda – "IN" menghadap ke Warpage piston rings, sisi pemasukan Piston, piston Piston mark direction "IN" mark facing toward the intake side piston rings pin D.L. piston 49,980 – 49,995 Piston O.D. 49.980 – 49.995 (1.9677 – 1.9683) Titik pengukuran D.L. piston 10from mmbottom dari of bagian Piston O.D. measurement point 10 mm (0.4 in) skirt bawah piston Piston pin bore I.D. 13.002 – 13.008 (0.5119 – 0.5121) D.D. lubang piston pin 13,002 – 13,008 Piston pin O.D. 12.994 – 13.000 (0.5116 – 0.5118) D.L. piston pin pin clearance Piston-to-piston 0.002 – 0.01412,994 (0.0001––13,000 0.0006) Jarak renggang antara piston-ke-piston pin 0.015 – 0.0500,002 – 0,014 Piston ring-to-ring Top (0.0006 – 0.0020) Jarak renggang piston ringRing paling atas 0,015 – 0,050 groove clearance SecondRing kedua 0.015 – 0.0500,015 (0.0006 – 0.0020) ke-alurnya – 0,050 (Riken) (Riken) Piston ring-to-ring Top 0.015 – 0.045 (0.0006 – 0.0018) Jarak renggang Ring paling atas 0,015 – 0,045 groove clearance Second 0.015 – 0.045 (0.0006 – 0.0018) piston ring-ke-alurnya Ring kedua 0,015 – 0,045 (Teikoku) (Teikoku) Piston ring end gap Top 0.10 – 0.25 (0.004 – 0.010) Celah pada ujung 0,10 – 0,25 (Riken) SecondRing paling atas 0.10 – 0.25 (0.004 – 0.010) piston ring (Riken) Ring kedua 0,10 – 0,25 Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) Ring oli (side rail) 0,20 – 0,70 Piston ring end gap Top 0.10 – 0.25 (0.004 – 0.010) Celah pada ujung 0,10 – 0,25 (Teikoku) SecondRing paling atas 0.10 – 0.25 (0.004 – 0.010) piston ring (Teikoku) Ring kedua 0,10 – 0,25 Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) Ring oli (side rail) 0,20 – 0,70 Cylinder-to-piston clearance 0.010 – 0.035 (0.0004 – 0.0014) Jarak renggang antara 0,010 – 0,035 Connecting rod small endcylinder-ke-piston I.D. 13.016 – 13.034 (0.5124 – 0.5131) D.D. kepala kecil connecting rod 13,016 – 13,034 Connecting rod-to-piston pin clearance 0.016 – 0.040 (0.0006 – 0.0016) Jarak renggang antara connecting rod-ke-piston pin 0,016 – 0,040

Cylinder Cylinder

CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS SPESIFIKASI CLUTCH/GEARSHIFT LINKAGE BAGIAN Manual Manual clutch clutch

Centrifugal clutch Centrifugal clutch

ITEM

Ketebalan disc Disc thickness Plate warpage Perubahan bentuk melengkung plate Tinggi bebas clutch Clutch spring freespring height Clutch outer guide Clutch outer guide I.D. O.D. D.D.Primary primarydriven driven gear gear I.D. D.L.Mainshaft mainshaftO.D. pada clutchouter outerguide guide at clutch D.D.Clutch clutchdrum drumI.D. Clutch weight Ketebalan clutch lining weightthickness lining drum I.D. D.D.One-way one-wayclutch clutch drum O.D. D.L.One-way one-wayclutch clutchroller roller gear I.D. D.D.Primary primarydrive drive gear at primary primary drive D.L.Crankshaft crankshaftO.D. pada drive gear gear

STANDARD STANDARD

2,00 – 2,20 2.00 – 2.20 (0.079 – 0.087) – 5.01 (0.197) 5,01 D.D. – 17.009 16,991 – 17,009 16.991 (0.6689 – 0.6696) D.L. – 22.980 22,959 – 22,980 22.959 (0.9039 – 0.9047) 23,000 – 23,021 23.000 – 23.021 (0.9055 – 0.9063) 16,966 – 16,984 16.966 – 16.984 (0.6680 – 0.6687) 104,2 104.0 – 104.2104,0 (4.09 – 4.10) 1.5 (0.06) 1,5 42.000 – 42.020 (1.6535 – 1.6543) 42,000 – 42,020 4.990 – 5.0004,990 (0.1965 – 0.1969) – 5,000 19.030 – 19.058 (0.7492 – 0.7503) 19,030 – 19,058 18,967 – 18,980 18.967 – 18.980 (0.7467 – 0.7472)

Satuan: mm Unit: mm (in) BATAS SERVIS SERVICE 50,05 LIMIT 0,1050.05 (1.970) 0,10 0.10 (0.004) 0,05 0.10 (0.004) 0.05 (0.002) – 49,91 49.91 (1.965) – 13.03 (0.513) 13,03 12.98 (0.511) 12,98 0.075 (0.0030) 0,0750.09 (0.004) 0,09 0,09 0.09 (0.004) 0.09 (0.004) 0,09 0.09 (0.004) 0,09 0.5 (0.02) 0,5 0.5 (0.02) 0,5 1.1 (0.04) 1,1 0.5 (0.02) 0,5 0.5 (0.02) 0,5 1.1 (0.04) 1,1 0.10 (0.004) 0,1013.05 (0.514) 13,050.07 (0.003) 0,07

Unit: mm (in) Satuan: mm SERVICE BATAS SERVIS LIMIT 1,82 1.82 (0.072) 0,200.20 (0.008) 4,63 4.63 (0.182) 17,049 17.049 (0.6712) 22,940 22.940 (0.9031) 23,07 23.07 (0.908) 16,87 16.87 (0.664) 104,3104.3 (4.11) 1,0 1.0 (0.04) 42,0442.04 (1.655) 4,97 4.97 (0.196) 19.11 (0.752) 19,11 18,92 18.92 (0.745)

SPESIFIKASI ALTERNATOR/STARTER CLUTCH ALTERNATOR/STARTER CLUTCH SPECIFICATIONS

Satuan: mm

BAGIAN

STANDARD

BATASUnit: SERVIS mm (in)

ITEM Starter driven gear boss O.D.

STANDARD 45,660 – 45,673

45,2

Starter driven gear boss O.D.

1-6

45.660 – 45.673 (1.7976 – 1.7981)

SERVICE LIMIT 45.2 (1.78)

KETERANGAN UMUM

CRANKSHAFT/TRANSMISSION/KICKSTARTER SPECIFICATIONS SPESIFIKASI CRANKSHAFT/TRANSMISSION/KICKSTARTER BAGIAN Crankshaft Crankshaft

Transmission Transmission

Shift fork/ Shift drum Shift fork/ Shift drum Kickstarter Kickstarter

STANDARD

STANDARD JarakITEM renggang ke samping connecting rod 0,10 – 0,35 Jarak renggang radial connecting rod 0 – 0,008 Connecting rod side clearance 0.10 – 0.35 (0.004 – 0.014) Keolengan Connecting rod radial clearance 0 – 0.008 (0 –- 0.0003) D.D. gear M2, M3 17,000 –– 17,018 Runout C1 18,000 – 18,018 Gear I.D. M2, M3 17.000 – 17.018 (0.6693 – 0.6700) C4 20,000 – 20,021 C1 18.000 – 18.018 (0.7087 – 0.7094) D.L. bushing C120.000 – 20.021 17,966 – 17,984 C4 (0.7874 – 0.7882) D.D. bushing C1 15,000 – 15,018 Bushing O.D. C1 17.966 – 17.984 (0.7073 – 0.7080) Jarak renggang gear-ke-bushing C1 0,016 – 0,052 Bushing I.D. C1 15.000 – 15.018 (0.5906 – 0.5913) D.L. mainshaft M30.016 – 0.05216,966 Gear-to-bushing clearance C1 (0.0006––16,984 0.0020) D.L. countershaft C1 14,966 – 14,984 Mainshaft O.D. M3 16.966 – 16.984 (0.6680 – 0.6687) Jarak renggang gear-ke-shaft M3 0,016 – 0,052 Countershaft O.D. C1 14.966 – 14.984 (0.5892 – 0.5899) Jarak renggang bushing-ke-shaft C10.016 – 0.0520,016 – 0,052 Gear-to-shaft clearance M3 (0.0006 – 0.0020) D.D. shift fork 34,075 – 34,100 Bushing-to-shaft clearance C1 0.016 – 0.052 (0.0006 – 0.0020) Ketebalan shift fork claw 4,85 – 4,95 Shift fork I.D. 34.075 – 34.100 (1.3415 – 1.3425) D.L. shift drum Kanan 33,950 – 33,975 Shift fork claw thickness 4.85 – 4.95 (0.191 – 0.195) Kiri 23,940 – 23,980 Shift drum O.D. Right 33.950 – 33.975 (1.3366 – 1.3376) D.D. pinion 20,000 – 20,021 Left 23.940 – 23.980 (0.9425 – 0.9441) D.L. spindle 19,959 – 19,980 Pinion I.D. 20.000 – 20.021 (0.7874– 0.7882) Spindle O.D. 19.959 – 19.980 (0.7858 – 0.7866)

SPESIFIKASI RODA DEPAN/SUSPENSI/KEMUDI

Satuan: mm Unit: mm (in) BATAS SERVIS SERVICE 0,60 LIMIT 0,05 0.60 (0.024) 0,10 0.05 (0.002) 17,04 0.10 (0.004) 18,04 17.04 (0.671) 20,04 18.04 (0.710) 17,94 20.04 (0.789) 15,04 17.94 (0.706) 0,10 15.04 (0.592) 16,95 0.10 (0.004) 14,95 16.95 (0.667) 0,09 14.95 (0.589) 0,09 0.09 (0.004) 34,14 0.09 (0.004) 4,60 34.14 (1.344) 33,93 4.60 (0.181) 23,92 33.93 (1.336) 20,08 23.92 (0.942) 19,94 20.08 (0.791) 19.94 (0.785) Satuan: mm

BAGIAN STANDARD BATAS SERVIS FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS

Kedalaman minimum alur telapak ban Sampai ke indikator 2 Unit: mm (in) Tekanan udara ban Pengendara saja 200 kPa (2.00 kgf/cm , 29 psi) 2 SERVICE (dingin) Pengendara dan pembonceng 200 kPa (2.00 kgf/cm , 29 psi) ITEM STANDARD LIMIT Keolengan axle (poros roda) 0,20 Minimum tire tread depth – To indicator Keolengan wheel rim Radial 2,0 2 Cold tire pressure Driver 200- kPa (2.00 kgf/cm , 29 psi) – (pelek roda) Aksialonly 2,0 2 Driver and passenger 200 kPa (2.00 kgf/cm , 29 psi) – Jarak wheel hub-ke-rim Axle runout – 0.20 (0.008) Fork Panjang bebas spring 306,8 297,6 Wheel rim runout Radial – 2.0 (0.08) Arah spring Kumparan dengan lilitan yang Axial – 2.0 (0.08) rapat menghadap ke bawah Fork Spring free length 306.8 (12.08) 297.6 (11.72) Keolengan pipe 0,20 Spring direction With the tightly wound coil sideOil facing down– Fork fluid yang dianjurkan Honda Ultra Cushion 10W Pipe runout – 0.20 (0.008) atau sejenisnya Recommended fork fluid fluid – Fluid level (fork masuk penuh keFork 73,0 Fluid level (full bottom) 73.0 (2.87) – bawah) 3 3 ± 1 cm Fluid capacityfluid 66.066,0 Kapasitas ± 1 cm – (2.23 ± 0.03 US oz, 2.32 ± 0.04 lmp oz)

REAR WHEEL/BRAKE/SUSPENSION SPECIFICATIONS SPESIFIKASI RODA BELAKANG/REM/SUSPENSI BAGIAN

ITEM

Kedalaman minimum alur telapak ban Minimum tire tread depth Tekanan udara ban Pengendara saja Cold tire pressure Driver only (dingin) Pengendara dan pembonceng Driver and passenger Keolengan axle (poros roda) Axle runout Keolengan wheel rim Radial Radial Wheel rim runout (pelek roda) Aksial Axial Jarak Drivewheel chain hub-ke-rim Size – link DID Drive chain Size - link DID RK RK Slack Kekenduran Brake Brake drum I.D. Rem D.D. brakefreeplay drum Brake pedal Jarak main bebas brake pedal

STANDARD STANDARD – 2 2 kgf/cm , 33 psi) 225225 kPa kPa (2.25(2.25 kgf/cm , 33 psi) 2 2 kgf/cm , 33 psi) 225225 kPa kPa (2.25(2.25 kgf/cm , 33 psi) – – – 420DX – 102 420DX 420SL – 102- 102 30 –420SL 40 (1.2- –102 1.6) 30 40 (4.33 – 4.34) 110.0 ––110.2 – 110,2 20 –110,0 30 (0.8 – 1.2) 20 - 30

Unit: mm Satuan: mm(in) SERVICE BATAS SERVIS LIMIT Sampai ke To indikator indicator – – 0,20 0.20 (0.008) 2,0 2.0 (0.08) 2,0 2.0 (0.08) – – – 111.0 (4.37) 111,0 – -

1-7

KETERANGAN UMUM

SPESIFIKASI REM HIDRAULIK HYDRAULIC BRAKE SPECIFICATIONS BAGIAN

Satuan: mm Unit: mm (in)

STANDARD

ITEM Brake fluid (minyak rem) yang dianjurkan Recommended brake fluidpad Indikator keausan brake Brake pad brake wear indicator Ketebalan disc Brake disc thickness Keolengan brake disc Brake disc runout D.D. master cylinder Master cylinder I.D. D.L. master piston Master piston O.D. D.D. caliper cylinder Caliper cylinder I.D. Caliper piston O.D. D.L. caliper piston

BATAS SERVIS SERVICE

STANDARD DOT 3 atau DOT4 DOT - 3 or DOT 4 – 3,3 – 3,7 3.3 – 3.7 (0.13 – 0.15) – 11,000 – 11,043 11.000 – 11.043 (0.4331 – 0.4348) 10,957 – 10,984 10.957 – 10.984 (0.4314 – 0.4324) 33,96 – 34,01 33.96 – 34.01 (1.337 – 1.339) 33.878 – 33.928 (1.3338 – 1.3357) 33,878 – 33,928

LIMIT Sampai ke–alur 3,0 To the groove 3.0 (0.12) 0,30 0.30 (0.012) 11,055 11.055 (0.4352) 10,945 10.945 (0.4309) 34,0234.02 (1.340) 33,8733.87 (1.333)

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

Alternator Alternator

SPESIFIKASI SPECIFICATIONS

ITEM Kapasitas Capacity Current leakage Kebocoran arus listrik °C/ Voltage Fully charged penuh Bermuatan ° C) Voltase(20 (20 68°F) Needs Perlucharging diisi listrik kembali Charging current Normal Arus pengisian Normal Quick Cepat Capacity Kapasitas Charging resistance (20°C/68°(20 F) ° C) Tahanancoil kumparan pengisian

12 V – 3,5 Ah12 V – 3.5 Ah 20 MA Ma x. 20 mA max. 13,0 – 13,2 V 13.0 – 13.2 V 12.4 V Di bawah 12,4Below V 0.4 A/5 – 10 h 0,4 A / 5 – 10 h 3,0 A / 0,5 h 3.0 A/0.5 h -1 -1 0.120 kW/5,000 (rpm) 0,120 kW / 5.000 menitmin (rpm) Ω 0.3– 1.0 0,3 – 1,0 Ω

IGNITION SYSTEM SPECIFICATIONS SPESIFIKASI SISTEM PENGAPIAN BAGIAN Busi Spark plug

ITEM

SPESIFIKASI SPECIFICATIONS CPR6EA-9S U20EPR9S (DENSO) CPR6EA-9S(NGK) (NGK) U20EPR9S (DENSO) CPR7EA-9S U22EPR9S (DENSO) CPR7EA-9S(NGK) (NGK) U22EPR9S (DENSO) 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 10 ° sebelum TMA pada putaran stasioner 10° BTDC at idle

Standard Standard PilihanOptional

Jarak Sparkrenggang plug gap busi Peak voltage (voltas e puncak) ignition coil Ignition coil peak voltage Peak voltage CKP sensor Ignition pulse generator peak voltage Ignition Ignitiontiming timing(pengaturan ("F" mark) waktu p engapian)(tanda "F")

SPESIFIKASI SISTEM STARTER LISTRIK ELECTRIC STARTER SYSTEM SPECIFICATIONS BAGIAN STANDART Panjang Sikat Starter motor ITEM

7,0

BATAS SERVIC E 3,5

STANDARD

Unit: mm (in) SERVICE LIMIT 3.5 (0.14)

SPESIFIKASI Starter motor brush lengthLAMPU-LAMPU/METER-METER/SAKLAR-SAKLAR 7.0 (0.28) BAGIAN Bola lampu

SPESIFIKASI Lampu besa r (High/Low = jauh /dekat) Lampu rem/belakang Lampu sein depan Lampu sein belakang ITEM Headlight (High/Low)instrumen Lampu penerangan Indikator lampu se in Position light Indikator Brake/taillampu light jauh Indikator Front turnposisi signalgigi lighttransmissi Indikator Rear turnneutral signal light Sekring utama Meter light Sekring tambahan Turn signal indicator High beam indicator Gear position indicator Neutral indicator Main Sub

12 V – 32/32 W 12 V – 3,4 W x 2 12 V – 18,5 W 12 V – 10 W x 2 SPECIFICATIONS 12 V – 32/32 W 12 V – 1,7 W x 2 12 V – 3,4 W x 2 12 V – 3.4 W x 2 12 V – 1,7 W 12 V – 18/5 W 12 V – 1,7 W x 4 12 V – 10 W x 2 12 V - 1,7 W 12 V – 10 W x 2 10 A 12 V – 1.7 W x 2 7,5 A 12 V – 3.4 W x 2 12 V – 1.7 W 12 V – 1.7 W x 4 12 V – 1.7 W 10 A 7.5 A

LIGHTS/METERS/SWITCHES SPECIFICATIONS Bulbs

Sekring

Fuse

1-8

KETERANGAN UMUM

NILAI TORSITORQUE STANDARD STANDARD VALUES JENIS PENGIKAT FASTENER TYPE andand nut nut (baut & 55 mm mmbolt bolt 6 mm bolt and nut mur) SHand flange 6(Include mm bolt nut bolt) (termasuk SH nut flange bolt) 8 mm bolt and 810mm mmbolt boltand and nut nut 10 bolt and andnut nut 12 mm mm bolt 12 mm bolt and nut

TORQUE JENIS PENGIKAT TORQUE TORSI FASTENER TYPE TORSI N·m lbf.ft) (kgf·m, lbf·ft) (kgf·m, lbf·ft) N.m (kgf.m; N.m (kgf.m;N·m lbf.ft) 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1) 5,2 (0,5; 3,8) 5 mm screw (sekrup) 4,2 (0,4; 3,1) 6 mm screw 6 mm screw 9,0 (0,9; 6,6) 9.0 (0.9, 6.6) 6 mm flange bolt 10 (1,0; 7) 10 (1.0, 7) 6 mm flange bolt mmflange head, small 22 (2,2; 16) 22 (2.2, 16)(kepala 8(8 mm, kecil)flange) 10 (1,0; 7) 10 (1.0, 7) 34 (3,5; 25) 34 (3.5, 25)6 mm flange bolt (kepala 10 mm) 6 mm flange bolt 55 (5,6; 41) 55 (5.6, 41)and nut (8 mm head, large flange) 12 (1,2; 9) 12 (1.2, 9) 8 mm flange bolt and nut 27 (2,8; 20) 6 mm flange bolt (10 mm head) 10 mm flange bolt and nut 39 (4,0; 29) and nut 12 (1.2, 9) 8 mm flange bolt and nut 27 (2.8, 20) 10 mm flange bolt and nut 39 (4.0, 29)

TORSI PENGENCANGAN MESIN & RANGKA • Spesifikasi torsi yang dicantumkan di bawah adalah untuk pengikat tertentu. ENGINE & FRAME TORQUE VALUES

Pengikat lain harus dikencangkan dengan torsi pengencangan standard yang dicantumkan di atas. • • Torque specifications listed below are for specified fasteners. •RANGKA/BODY Others should be tightened to standard torque values listed above. PANELS/SISTEM PEMBUANGAN GAS BAGIAN JUMLAH FRAME/BODY PANELS/EXHAUST SYSTEM Exhaust pipe joint ITEM nut Exhaust pipe stud bolt Exhaust pipe joint nut Exhaust pipe stud bolt

2 2

PERAWATAN

BAGIAN MAINTENANCE ITEM Oil Drain bolt Valve adjusting lock nut Oil drain bolt Valve adjusting filter lock cover nut bolt Oil centrifugal

Oil centrifugal Clutch adjusterfilter lockcover nut bolt Spark plug (busi) Clutch adjuster lock nut Spark plug SISTEM PELUMASAN

BAGIAN LUBRICATION SYSTEM Oil pump cover screw ITEM Oil pump cover screw SISTEM BAHAN BAKAR

BAGIAN FUEL SYSTEM

DIAMETER ULIR (mm) THREAD Q'TY 8 DIA. (mm) 8 2 8 2 8

JUMLAH 1 2 3 1 1

DIAMETER ULIR (mm) THREAD Q'TY 12 DIA. (mm) 5 1 12 2 5 5 3 1 1

8 10

5 8 10

JUMLAH 3

DIAMETER ULIR (mm) THREAD Q'TY 5 DIA. (mm) 3 5

JUMLAH

DIAMETER ULIR (mm) THREAD Inlet pipe band screw 1 ITEM Q'TY Fuel valve screw 2 3 DIA. (mm) Inlet pipe band screw 1 – Air cut off valve screw 2 4 Fuel valve 2 3 Slow jet screw 1 Air cut-off valve screw 2 4 Main jet 1 Slow jet 1 – Needle jet holder 1 Main chamber jet 1 – Float screw 2 4 Needle jet holderdrain screw 1 – Float chamber 1 Fuel 1 Float strainer chambercup screw 2 4 Throttle cable holder screw 1 5 Float chamber drain screw 1 – Fuel Valve lever 1 4 Fuel strainer cup screw 1 – Inlet pipecable mounting 2 6 Throttle holder bolt screw 1 5 PAIR check valve cover screw 2 4 Fuel valve lever screw 1 4 Inlet pipe mounting bolt 2 6 PELEPASAN/PEMASANGAN MESIN PAIR check valve cover screw 2 4 BAGIAN JUMLAH DIAMETER ULIR (mm) Drive sprocket fixing plate bolt 2 6 Engine hanger nut 3 10

TORSI N.m (kgf.m; lbf.ft) TORQUE 27 (2,8; 20) N·m (kgf·m, lbf·ft) 27 (2.8, 20) – TORSI N.m (kgf.m; lbf.ft) TORQUE 24 (2,4; 18) N·m (kgf·m, lbf·ft) 9 (0,92; 6,6) 24 (2.4, 18) 9 (0.92, 5 (0,51; 3,7) 6.6) 5 (0.51, 12 (1,2; 9) 3.7) 16 (1,6; 12) 12 (1.2, 9) 16 (1.6, 12)

CATATAN REMARKS Lihat hal. 3-17

See page 3-17

CATATAN REMARKS Semprotkan oli pada ulir dan permukaan duduk. Applycairan oil to the threads and Oleskan pengunci pada seating surface. ulir: Lihat hal. 4-11 Apply locking agent to the threads: See page 4-12

TORSI N.m (kgf.m; lbf.ft) TORQUE 5 (0,51; 3,7) N·m (kgf·m, lbf·ft) 5 (0.51, 3.7)

CATATAN

TORSI N.m (kgf.m; lbf.ft) TORQUE N·m (kgf·m, lbf·ft) 0,88 (0,090; 0,65) – 2,1 (0,21; 1,5) (0.090, 1,50.88 (0,15; 1,1) 0.65) 2.1 (0.21, 1,5 (0,15; 1,1) 1.5) 1.5 (0.15, 2,5 (0,25; 1,8) 1.1) 1.5 (0.15, 2,1 (0,21; 1,5)1.1) 2.5 (0.25, 1,5 (0,15; 1,1) 1.8) 5,9 (0,60; 4,4) 1.5) 2.1 (0.21, 3,4 (0,35; 2,5) 1.1) 1.5 (0.15, 2,1 (0,21; 1,5) 4.4) 5.9 (0.60, 12 (1,2; 9) 3.4 (0.35, 2.5) 2,1 (0,21; 1,5) 1.5) 2.1 (0.21, 12 (1.2, 9) 2.1 (0.21, 1.5) TORSI N.m (kgf.m; lbf.ft) 12 (1,2; 9) 59 (6,0; 44)

CATATAN

REMARKS

Lihat hal. 6-13 REMARKS See page 6-13

CATATAN

1-9

KETERANGAN UMUM CYLINDER HEAD/VALVES ENGINE REMOVAL/INSTALLATION BAGIAN ITEM Cylinder head cover special bolt Drive sprocket fixing plate bolt Cylinder head nut Engine hanger nut

JUMLAH Q'TY 2 2 4 3

DIAMETER THREAD ULIR (mm) DIA. (mm) 6 6 7 10

TORSI TORQUE N.m (kgf.m; lbf.ft) N·m (kgf·m, lbf·ft) 10 (1,0; 7) 12 (1.2, 9) 13 (1,3; 10) 59 (6.0, 44)

Cam sprocket bolt CYLINDER HEAD/VALVES

2

5

8 (0,82; 5,9)

THREAD 14 8DIA. (mm) 6 7

TORQUE 22 (2,2; 16) N·m (kgf·m, 16 (1,6; 12) lbf·ft) 10 (1.0, 7) 13 (1.3, 10)

DIAMETER 5 ULIR (mm)

TORSI 8 (0.82, 5.9) N.m (kgf.m; lbf.ft)

Apply oil to the threads and seating surface. CATATAN Apply locking agent to the threads: See page 8-11

22 (2.2, 16) 10 (1,0; 7) 16 (1.6, 12) -

Lihat hal. 9-8

Cam chain tensioner sealing bolt ITEM Cam chain tensioner arm pivot bolt Cylinder head cover special bolt Cylinder head nut

1 1

BAGIAN Cam sprocket bolt

JUMLAH 2

Cam chain tensioner sealing bolt Cam chain guide roller pin bolt Cam chain tensioner Cylinder stud bolt arm pivot bolt

1 4

CYLINDER/PISTON

Q'TY

2 4

1 1

8 7

14 8

CATATAN REMARKS Semprotkan oli pada ulir dan permukaan duduk. Oleskan cairan pengunci pada ulir: Lihat hal. 8-11 REMARKS

CYLINDER/PISTON

CLUTCH/GEARSHIFT LINKAGE BAGIAN

ITEM

Cam chain guide roller pin bolt Shift drum stopper Cylinder stud bolt arm bolt

Shift return spring pin LINKAGE CLUTCH/GEARSHIFT Gearshift cam plate bolt ITEM Centrifugal clutch lock nut Shift drum stopper arm bolt Clutch center lock nut Shift return spring pin Gearshift camplate platebolt bolt Clutch Lifter

Q'TY JUMLAH

1

1 4

1 1 Q'TY

1 1 4

Centrifugal clutch lock nut ALTERNATOR

1 1 1

TORQUE TORSI N·m (kgf·m, lbf·ft) N.m (kgf.m; lbf.ft) 10 (1.0, 7) 10 (1,0; 7)–

8 6 THREAD DIA. (mm) 14 6

30 (3,1; 22) 17 (1,7; 13) TORQUE N·m (kgf·m, lbf·ft) 54 (5,5; 40) 10 (1.0, 7)

14

8 6

54 (5,5; 40) 30 (3.1, 22) 17 12(1.2 ,(1.7, 9) 13)

14

54 (5.5, 40)

6

1

BAGIAN Clutch center lock nut

JUMLAH 1

Flywheel nut Clutch lifter plate bolt

1

Starter clutch mounting CLUTCH ALTERNATOR/STARTER

THREAD DIAMETER DIA. (mm) ULIR (mm) 8 6 7

4

6

DIAMETER ULIR14 (mm) 10 6

TORSI (5.5, 40) N.m 54 (kgf.m; lbf.ft) 40 (4,1; 30) 12 (1.2, 9)

Oleskan cairan pengunci See page 9-8 pada ulir: Lihat hal. 10-29 Oleskan cairan pengunci pada ulir:REMARKS Lihat hal. 10-28 Semprotkan oli pada ulir Apply locking agent to the dan permukaan duduk. threads: See page 10-30 Semprotkan oli pada ulir dan permukaan duduk. Apply locking agent to the threads: See page 10-29 Apply oil to the threads and seating surface. CATATAN Apply oil to the threads and seating surface. Semprotkan oli pada ulir dan permukaan duduk.

6

ITEM Q'TY CRANKSHAFT/TRANSMISSION/KICKSTARTER

BAGIAN Flywheel nut

JUMLAH 1

Cam chain guide sprocket spindle Starter clutch mounting torx bolt

1

6

RODA DEPAN /SUSPENSI/KEMUDI CRANKSHAFT/TRANSMISSION/KICKSTARTER BAGIAN JUMLAH ITEM Q'TY Steering stem lock nut 1 Cam chain guide sprocket spindle 1

THREAD DIA. (mm) DIAMETER 10 ULIR (mm)

TORQUE N·m (kgf·m, lbf·ft) TORSI 40 (4.1, 30) N.m (kgf.m; lbf.ft)

6

10 (1,0; 7) 12) 16 (1.6,

6

DIAMETER THREAD ULIR (mm) DIA. (mm) 26 6

TORSI TORQUE N.m (kgf.m; lbf.ft) N·m (kgf·m, lbf·ft) 10 (1.0, 7)

Steering stem top thread

1

26

-

Bottom bridge pinch bolt Handlebar post mounting nut Front axle nut Front brake disc socket bolt

4 1 1 4

10 10 12 8

64 (6,5; 47) 59 (6,0; 44) 59 (6,0; 44) 42 (4,3; 31)

Fork socket bolt

2

8

20 (2,0; 15)

Brake hose guide bolt

1

6

12 (1,2; 9)

1-10

REMARKS CATATAN

REMARKS

CATATAN Apply oil to the threads and seating surface. Apply locking agent to the threads: See page 11-11 CATATAN REMARKS Untuk urutan pengencangan; Lihat hal. 13-24 Untuk urutan pengencangan; Lihat hal. 13-24 U-nut U-nut ALOC bolt; ganti dengan yang baru. Oleskan cairan pengunci pada ulir. ALOC bolt; ganti dengan yang baru.

KETERANGAN UMUM FRONTBELAKANG/REM/SUSPENSI WHEEL/SUSPENSION/STEERING RODA

BAGIAN

ITEM

Rear axle stem nut lock nut Steering Driven sprocket nut Driven flange bolt Steering stemstud top thread Rear brake stopper arm nut Rear brake armpinch nut bolt Bottom bridge Shock absorber upper mounting bolt Handlebar post mounting nut Shock absorber lower mounting cap Front axle nut nut Front brake disc socket bolt Swingarm pivot nut

JUMLAH Q'TY 1 4 4 2 1 2 2 1

Fork socket bolt

1 1 4 1 1 4 2

REM HIDRAULIK Brake hose guide bolt BAGIAN REAR CaliperWHEEL/BRAKE/SUSPENSION bleed valve Pad pin ITEM Caliper bracket pin bolt Caliper mounting bolt Rear axle nut Driven sprocket nut Brake hose oil stud bolt bolt Driven flange Master cylinder reservoir cap screw Rear brake stopper arm nut Front brake light switch screw Rear brake arm nut Brake lever pivot bolt Shock absorber upper mounting bolt Brake lever pivot nut Shock absorber lower mounting cap nut/nut Swingarm pivot nut

1 JUMLAH

1 1 1 2 2 2 1 1 1

Q'TY

1 4 4 2 1 2 2 1

DIAMETER THREAD ULIR (mm) DIA. (mm) 12 26 8 8 26 8 6 10 10 10 12 10 8 12 8

TORSI TORQUE N.mN·m (kgf.m; lbf.ft) (kgf·m, lbf·ft) 59 (6,0; 44) – 32 (3,3; 24) – 22 (2,2; 16) 10 (1,0;64 7)(6.5, 47) 24 (2,4;59 18) (6.0, 44) 59 (6.0, 44) 24 (2,4; 18) 42 (4.3, 31) 59 (6,0; 44) 20 (2.0, 15)

CATATAN

REMARKS

U-nut For tightening sequence; See U-nut page 13-25 LihatFor hal. 14-11 sequence; See tightening page 13-25 U-nut U-nut U-nut ALOC bolt; replace with new U-nut ones. Apply locking agent to the threads. ALOC bolt; replace with a CATATAN new one.

6 DIAMETER ULIR (mm) 8 10 THREAD 8 DIA. (mm) 8 12 8 10 8 4 8 4 6 6 10 6 10 12

12 (1.2, 9) TORSI N.m (kgf.m; lbf.ft) 5,4 (0,56; 4,0) 17 (1,7; TORQUE 13) REMARKS 17 (1,7; N·m 13) (kgf·m, lbf·ft) 30 (3,1;59 22) ALOC bolt, ganti dengan yang (6.0, 44) U-nut baru.U-nut 32 (3.3, 24) 34 (3,5; 25) – See page 14-11 1,5 (0,15; 22 1,1) (2.2, 16) 1,2 (0,12; 0,9) 10 (1.0, 7) U-nut 1,0 (0,10; 0,7) 24 (2.4, 18) 5,9 (0,60; 4,4) 24 (2.4, 18) 59 (6.0, 44) U-nut

DIAMETER THREAD ULIR (mm) DIA. (mm) 8 14 10 8 8 DIAMETER ULIR (mm) 10 4 4 5 4 6 6 DIAMETER ULIR (mm) 10 THREAD 10 DIA. (mm) 14

TORSI TORQUE N.mN·m (kgf.m; lbf.ft) (kgf·m, lbf·ft) 5.4 (0.55, 4.0) 1,5 (0,15; 1,1) 17 (1.7, 13) 17 (1.7, 13) 30 (3.1, 22) TORSI N.m (kgf.m; lbf.ft) 34 (3.5, 25) 2,0 (0,20; 1,5) 1.1) 1.5 (0.15, 4,2 (0,43; 3,10) 0.9) 1.2 (0.12, 1.0 (0.10, 0.7) 5.9 (0.60, 4.4) TORSI N.m (kgf.m; lbf.ft) 18 (1,8; TORQUE 13) 44 (4,5; N·m 32) (kgf·m, lbf·ft) 1.5 (0.15, 1.1)

THREAD DIA. (mm) 4 5

TORQUE N·m (kgf·m, lbf·ft) 2.0 (0.20, 1.5) 4.2 (0.43, 3.1)

THREAD DIA. (mm) 10 10

TORQUE N·m (kgf·m, lbf·ft) 18 (1.8, 13) 44 (4.5, 32)

HYDRAULIC BRAKE SISTEM PENGAPIAN

BAGIAN

ITEM

Caliperhole bleed valve Timing cap Pad pin Caliper bracket pin bolt SISTEM ELEKTRIK STARTER Caliper mounting bolt BAGIAN Brake hose oil bolt Starter cable screwcap screw Mastermotor cylinder reservoir Starter motorlight case screw Front brake switch screw Brake lever pivot bolt

LAIN-LAIN Brake lever pivot nut BAGIAN IGNITION SYSTEM

Sidestand pivot bolt ITEM Sidestand pivot nut Timing hole cap

JUMLAH Q'TY 1 1 1 2 JUMLAH

1

2 2 1 1 1 JUMLAH

1 3

1 1

Q'TY

1

CATATAN

REMARKS

ALOC bolt; replace with new CATATAN ones.

CATATAN REMARKS

ELECTRIC STARTER SYSTEM ITEM

Starter motor cable screw Starter motor case screw

Q'TY

1 3

REMARKS

OTHERS ITEM

Sidestand pivot bolt Sidestand pivot nut

Q'TY

1 1

REMARKS

1-11

KETERANGAN UMUM

LUBRICATION & SEAL POINTS TITIK-TITIK PELUMASAN & PERAPATAN ENGINE

MESIN BAHANMATERIAL

LOKASI LOCATION Cylinder bore Bagian dalam cylinder Permukaan luarsurface pistonand danpiston alur-alur Piston outer ring piston groovesring Permukaan lubang piston pin Piston pindalam hole inner surface Permukaan piston pin Piston pinluar outer surface Piston rings Piston rings Permukaan dalam kepala kecil connecting rod Connecting rod small end inner surface Kepala besar connecting rod Connecting rod big end Permukaan luar IN/EX valve stem IN/EX valve stem outer surface Seluruh permukaan camshaft Camshaft whole surface Seluruh permukaan cam chain Cam chain whole surface Seluruh permukaan camshaft plunger Camgelinding sprocket teeth Daerah decompressor cam Rocker arm shaftlubang hole inner surface Permukaan dalam rocker arm shaft Rocker arm shaft whole Seluruh permukaan rockersurface arm shaft Rocker arm roller rolling area Daerah gelinding rocker arm roller Oil pump and outer rotor sliding Daerah luncurinner oil pump inner dan outerarea rotor Seluruh cam chain guide sprocket spindle Campermukaan chain guide sprocket spindle whole surface Permukaan luarguide clutch outer guide Clutch outer outer surface Clutch discs Clutch discs Gearshift spindle journal Gearshift spindle journal Permukaan luncur shift fork inner Shift fork inner sliding surface Seluruh permukaan shift drum Shift drum whole surface Daerah perputaran countershaft shift drum lock plate Countershaft shift drum lock plate rotating area Gigi-gigi gear (primary, transmission, kickstarter) Gear teeth (primary, transmission, kickstarter) Bagian dalam cam chain tensioner push rod Cam chain tensioner push rod inside Injector seal ring Starter clutchpermukaan rolling surface Masing-masing gelinding bantalan Starter reduction gear both journal and gear teeth Masing-masing O-ring Starter reduction gear shaft bearingplate rolling surface Cairan pengunci Ulir Each oil stopper bolt Each O-ringbearing set plate bolt Ulir mainshaft Locking agent disulfide oil Permukaan Oil stopper platekickstarter bolt threadspinion gear Molybdenum dalam Mainshaftdalam bearing set plate boltgear threads (campuran dari ½ oli Permukaan primary drive Liquid dan sealant Cylinder head matingmasing-masing surface (semicircular area) berputar mesin ½ (recommended: molybdenum Permukaan dalam gear Three bond 5211C or SHIdisulfide grease) transmission NETSU-SILICONE KE45T or Seluruh permukaan C1 gear bushing Three bond 1215 or equivalent) Alur M4, C3 gear shift fork Molybdenum disulfide (a Kickstarter pinion gear surface Sealant (Three bond oil 1215 Permukaan penyatuan leftinner crankcase mixture of 1207B 1/2 engine oilatau and 1/ Permukaan Primary drive gear inner surface atau duduk alternator wire grommet 2 molybdenum disulfide sejenisnya) Cylinder head cover rubber (daerah setengah Each transmission rotating gear seal inner surface grease) lingkaran) C1 gear bushing whole surface Multi-purpose grease BibirM4, gearshift oil groove seal C3 gearspindle shift fork BibirLeft countershaft oil sealsurface Sealant (Three bond 1215 or crankcase mating 1207B or LOCTITE or equiva- Bibir kickstarter spindle oil seal Bersikan dari gemuk Flywheel dan daerah kontak left crankshaft lent) Sealant (Three bond 1215 or Alternator wire grommet seating surface 1207B or equivalent) Multi-purpose grease Gearshift spindle oil seal lip Countershaft oil seal lip Kickstarter spindle oil seal lip Degreasing Flywheel and left crankshaft contact areas

CATATAN

REMARKS

Engine oil Oli mesin

1-12

3

1,0 – 2,0 cm 1.0 – 2.0 cm3

0,5 – 1,0 cm

3

4.0 – 5.0 cc

4,0 – 5,0 cc

Lihat hal. 8-26 Lihat hal. 12-16 See page 8-26 See page 12-16 See page 8-7

Lihat hal. 12-19

See page 12-19

KETERANGAN UMUM FRAME RANGKA MATERIAL

BAHAN Urea based multipurpose Multipurpose grease bergrease with extreme pressure dasarkan (example: urea Kyodoyang Yushitahan tekanan EXCELITEsangat EP2, Shell tinggi ALVA NIA EP2 orKyodo equivalent) (contoh: Yushi EXCELITE Multi-purpose EP2, grease Shell ALVANIA EP2 atau sejenisnya) Multi-purpose grease

LOCATION

REMARKS

LOKASI Steering stem dust seal lips

CATATAN Apply 3 g minimum

Bibir-bibir sealraces Uppersteering inner andstem outerdust bearing Upper innerinner danand outer bearing races Lower outer bearing races Lower inner dan outer bearing races

Apply 3 g minimum Berikan minimum 3g Apply 3 g minimum Berikan minimum 3 g

Brake panel anchor pin Brake cam sliding surface Brake cam (brake shoe contact area) Brake panel anchor pin Front/rear axle surface Permukaan luncur brake cam Front/rear wheel distance collar Brake cam (daerah kontak Front wheel dust seal lipsbrake shoe) Permukaan axle Throttle front/rear pipe surface, flange groove and slot Bibir-bibir front wheel dust Rear wheel driven flangeseal dust seal lips Permukaan throttle pipe dan alur flange Rear wheel hub O-ring Bibir-bibir rear wheel driven flange dust seal Speedometer cable inside Rear wheel hub O-ring Speedometer cable O-ring Gigi-gigi speedometer gear Kickstarter pedalspeedometer sliding area and steel ball Permukaan dalam gear Steering handle lock sliding area pinion shaft Seluruh permukaan speedometer Seat lock sliding area Bagian dalam speedometer cable Sidestand sliding surface Daerah luncurpivot kickstarter pedal dan steel ball Rearluncur brake pedal/centerstand pivot sliding surface Daerah steering handle lock Eachluncur wheelseat bearing Daerah lock Speedometer gear teeth Permukaan luncur sidestand pivot Permukaan luncur rear brake pedal/center stand pivot Speedometer gear inner surface Masing-masing wheel bearing Silicone grease Front brake lever pivot bolt sliding surface Front brake lever-to-master Silicone grease Permukaan luncur front brakepiston lever contacting pivot bolt surface Brake caliper bracket sliding surface Permukaan kontak front pin brake lever-ke-master piston Brake caliper dust seal Permukaan luncur brake caliper bracket pin Brake caliper dust seal Pad pin O-ring pin O-ring Brake fluid DOT 3 or DOT 4 Pad Brake master piston, spring and piston cups Brake fluid DOT 3 atau Brake master piston, spring dan piston cups Brake caliper piston DOT 4 Brake master piston Brake caliper piston seal caliper piston seal inside Honda Bond A or equivalent Brake Handlebar grip rubber Honda Bond A atau Bagian dalam handlebar grip rubber Fork fluid Fork oil seal lips sejenisnya Fork dust seal lips Honda Ultra Cushion Oil Bibir-bibir forkO-ring oil seal Fork cap 10W atau sejenisnya Bibir-bibir fork SAE #80 or 90 gear oil or drive Drive chaindust seal Fork cap O-ring chain lubricant SAE chain Gear #80 oil atau 90 gear oil DriveRear brake cam felt seal atau drive chain lubricant Gear oil Rear brake cam felt seal Cable lubricant Bagian dalam throttle cable

Apply 0.2 – 0.3 g Apply 0.2 – 0.3 g Apply 0.2 – 0.3 g Berikan 0,2 – 0,3 g Berikan 0,2 – 0,3 g Berikan 0,2 – 0,3 g

Berikan 3 g Berikan 0,5 – 1,0 g Berikan 0,1 g

Apply 3 g Apply 0.5 – 1.0 g Apply 0.1 g

Berikan 0,1 g Apply 0.4 g minimum Berikan minimum0,4g

1-13

KETERANGAN UMUM

PERLETAKAN KABEL & HARNESS CABLE & HARNESS ROUTING FRONT BRAKE LIGHT SWITCH WIRE FRONT BRAKE LIGHT SWITCH WIRE (Black, Green/Yellow) CONNECTORS

LEFT HANDLEBAR SWITCH WIRE HORN WIRE

DIMMER SWITCH 3P CONNECTOR TURN SIGNAL LIGHT SWITCH 3P (Red) CONNECTOR

HORN SWITCH 3P (Black) CONNECTOR LIGHTING SWITCH 3P CONNECTORS

CHOKE CABLE

STARTER SWITCH 3P (Black) CONNECTOR THROTTLE CABLE

FRONT BRAKE HOSE

IGNITION SWITCH 2P CONNECTOR

COMBINATION METER SUB HARNESS SPEEDOMETER CABLE

FRONT BRAKE HOSE HEADLIGHT 4P CONNECTOR

CHOKE CABLE RIGHT FRONT TURN SIGNAL LIGHT 2P CONNECTOR

COMBINATION METER SUB HARNESS SPEEDOMETER CABLE

CONNECTORS: – COMBINATION METER 9P CONNECTOR – COMBINATION METER 6P CONNECTOR

1-14

LEFT FRONT TURN SIGNAL LIGHT 2P (Black) CONNECTOR

SPEEDOMETER CABLE

KETERANGAN UMUM

FRONT BRAKE HOSE

COMBINATION METER SUB HARNESS

THROTTLE CABLE SPEEDOMETER CABLE CARBURETOR AIR VENT HOSE COMBINATION METER SUB HARNESS

CHOKE CABLE

AIR SUPPLY HOSES

FUEL HOSE

SPEEDOMETER CABLE

CARBURETOR DRAIN HOSE

CRANKCASE BREATHER HOSE

1-15

KETERANGAN UMUM

THROTTLE CABLE


CHOKE CABLE

CONNECTORS: – COMBINATION METER 9P CONNECTOR – COMBINATION METER 6P CONNECTOR

AIR SUPPLY HOSE

MAIN WIRE HARNESS

FRONT BRAKE HOSE

SPARK PLUG WIRE

1-16

CARBURETOR AIR VENT HOSE

KETERANGAN UMUM

CHOKE CABLE

AIR SUPPLY HOSE

AIR SUPPLY HOSE CARBURETOR AIR VENT HOSE


CARBURETOR DRAIN HOSE

FUEL HOSE

MAIN WIRE HARNESS

ICM

FUEL HOSE

IGNITION PULSE GENERATOR/ ALTERNATOR WIRE IGNITION CONTROL MODULE (ICM) 2P/3P CONNECTORS


ALTERNATOR 2P CONNECTOR

GEAR POSITION SWITCH 6P (Black) CONNECTOR

1-17

KETERANGAN UMUM IGNITION CONTROL MODULE (ICM) REAR BRAKE LIGHT SWITCH WIRE (Black, Green/Yellow) CONNECTORS

IGNITION PULSE GENERATOR WIRE (Blue/Yellow) CONNECTOR ALTERNATOR WIRE (Yellow) CONNECTOR

GROUND TERMINAL

REGULATOR/RECTIFIER 4P CONNECTOR

MAIN WIRE HARNESS

MAIN WIRE HARNESS

VACUUM HOSE

SPARK PLUG WIRE

REAR BRAKE LIGHT SWITCH WIRE

BATTERY WIRE HARNESS

BATTERY WIRE HARNESS 2P/3P CONNECTORS

START MOTOR 2P CONNECTOR

BATTERY BATTERY POSITIVE (+) CABLE

BATTERY NEGATIVE (–) CABLE

MAIN FUSE 10 A SUB FUSE 7.5 A

STARTER RELAY

1-18

KETERANGAN UMUM

BRAKE/TAIL LIGHT UNIT 6P CONNECTOR

FUEL LEVEL SENSOR 3P (Black) CONNECTOR

FUEL HOSES

MAIN WIRE HARNESS

BRAKE/TAIL LIGHT WIRE

RIGHT REAR TURN SIGNAL LIGHT WIRE

LEFT REAR TURN SIGNAL LIGHT WIRE

1-19

KETERANGAN UMUM IGNITION PULSE GENERATOR

ALTERNATOR WIRE

1-20

KETERANGAN UMUM

EMISSION CONTROL SYSTEMS EMISSI SISTEM-SISTEM PENGATURAN SUMBER SOURCE EMISSI OF EMISSIONS

Proses pembakaran menghasilkan karbon monoksida (CO), oksida-oksida dari nitrogen (Nox) dan hidrokarbon (HC). Pengaturan The combustion process produces carbon Controlling hydrocarbon emissionpada is verykondisi-kondisi important because, under karbon monoksida, oksida-oksida darimonoxide nitrogen and danhydrocarbons hidrokarbon(HC). adalah sangat penting oleh karena, tertentu, certain conditions, they react to form photochemical smog when subject to sunlight. Carbon monoxide does not react in the same way, but it is mereka bereaksi membentuk photochemical smog ketika terkena cahaya matahari. Karbon monoksida tidak bereaksi dengan cara toxic. yang sama, tetapi ia beracun. Honda Motor Co., Ltd menggunakan bermacam-macam sistem untuk mengurangi monoksida, Honda Motor Co., Ltd. utilizes lean carburetor settings as well as (hal. other 1-23), systems, to reduce carbonkarbon monoxide, oxides ofoksida-oksida nitrogen and dari nitrogen dan hidrokarbon. hydrocarbons.

CRANKCASE EMISSION CONTROL SYSTEM SISTEM PENGATURAN EMISSI CRANKCASE The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned Mesin dilengkapichamber denganthrough sistem (bak mesin) tertutup untuk mencegah pengeluaran emissi crankcase ke dalam to the combustion thecrankcase air cleaner and carburetor. 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. AIR CLEANER HOUSING


CARBURETOR

UDARA SEGAR BLOW-BY GAS

1-21

KETERANGAN UMUM EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDARY AIR INJECTION SYSTEM) THREE-WAY CATALYTIC CONVERTER The exhaust emission control system consists of athree-way secondary catalytic air supplyconverter system which introduces filtered airtiga-arah). into the exhaust gases in the exhaust Sepedamotor ini dilengkapi dengan sebuah (katalisator pengubah port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system. This change of fresh air promotes burning of the unburned exhaust gases and changes a considerable amount of hydrocarbons and carbon monoxide into relatively harmless carbon Three-way catalytic converter ada dalam sistem pembuangan gas. Melalui reaksi kimia, mereka mengubah HC, CO dan NOx di dioxide and water vapor. dalam gas pembuangan mesin menjadi karbon dioksida (CO2), nitrogen (N2) dan uap air. This model has the pulse secondary air injection (PAIR) control valve and PAIR check valve. PAIR check valve prevents reverse air flow through the system. The PAIRpada control valve reacts ini to walaupun high inlet pipe vacuum and will cut the supply of the fresh air during engine Tidak diperlukan penyetelan sistem-sistem pemeriksaan periodik darioff komponen-komponen dianjurkan. deceleration, thereby preventing afterburn in the exhaust system. No adjustment to the pulse secondary air injection system should be made, although periodic inspection of the components is recommended.

SEPARATE AIR FILTER

PAIR CONTROL VALVE

PAIR CONTROL VALVE VACUUM HOSE

CARBURETOR PAIR CHECK VALVE

UDARA SEGAR VACUUM AIR

NOISE EMISSION CONTROL SYSTEM (SISTEM PENGATURAN EMISSI KEBISINGAN) DILARANG MENGUTAK-ATIK SISTEM SYSTEM PENGATURAN EMISSI KEBISINGAN: Undang-undang melarang tindakan-tindakan NOISE EMISSION CONTROL berikut atau penyebab daripada: (1) Pelepasan atau dibuat tidak bekerjanya oleh seseorang, selain untuk tujuan perawatan, TAMPERING WITH THE NOISE CONTROL SYSTEM IS PROHIBITED: Local law may prohibit the following acts or the causing thereof: perbaikan atau penggantian, dari setiap peralatan atau elemen rancangan yang telah dipasang pada sebuah kendaraan untuk (1) The removal or rendering inoperative by any person, other than for p urposes of maintenance, repair or replacement, of any device or element tujuan pengaturan kebisingan sebelum penjualan atau penyerahannya kepada pelanggan akhir atau sementara ia dipergunakan; 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; (2) Pemakaian peralatan atauofelemen rancangan sedemikian telah dilepaskan dibuat tidak dapat bekerja (2) the use of the kendaraan vehicle aftersetelah such device or element design has been removed or rendered inoperative by atau any person. oleh seseorang. AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW: DI TINDAKAN-TINDAKAN YANG DIANGGAP MERUPAKAN PENGUTAK-ATIKAN TINDAKAN-TINDAKAN 1. ANTARA Removal of, or puncturing of the muffler, baffles, header pipes or any other component which conductsADALAH exhaust gases. SEPERTI DIof, BAWAH INI: of any part of the intake system. 2. Removal or puncturing 1. Melepaskan atau melubangi knalpot, komponen pengaturan aliran, pipa pendahulu atau setiap komponen lain yang 3. Lack of proper maintenance. menyalurkan gas pembuangan. 4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer. 2. Melepaskan atau melubangi setiap bagian dari sistem pemasukan udara. 3. Tidak menjalankan perawatan yang layak. 4. Mengganti bagian bergerak dari kendaraan, atau bagian dari sistem pembuangan atau pemasukan, dengan part lain daripada yang telah ditentukan oleh pabrik.

1-22

2. FITUR-FITUR TEKNIK

2

SISTEM KOPELING MANUAL .........................2-2

MANUAL CLUTCH SYSTEM················ 2-2

2-1

FITUR-FITUR TEKNIK

SISTEM KOPELING MANUAL MANUAL CLUTCH SYSTEM TECHNICALFEAT URES

GARIS BESAR OUTLINE Sepedamo tor mema diaphragm clutch spring (pegas kopeling coil jenis diafragma) sebagai gantinya conventional coil springs This motorcycle adoptskai a diaphragm clutch spring instead of conventional springs. (pegas gulungan konvensional). LOKASI KOM PONENKOMPONEN COMPONENT LOCATION

CLUTCH CENTER

CLUTCH SPRING SPRING SEAT

CLUTCH OUTER

CLUTCH LIFTER PLATE

THRUST WASHER PRESSURE PLATE CLUTCH OUTER

CLUTCH DISCS/PLATES

PRESSURE PLATE CLUTCH SPRING SPRING SEAT

CLUTCH LIFTER PLATE

CLUTCH CENTER

CLUTCH DISCS/PLATES

2-2

FITUR-FITUR TEKNIK MEKANISME KOPELING CLUTCH MECHANISM OPERATION CARA KERJA

Ketika liftercam camplate platemoves bergerak sewaktu gearshift pedal (pedal gigi) ditekan dan gearshift spindle ke As the lifter during the gearshift pedal applied andpemindah the gearshift spindle is shi fting to the next gear memindahkan position, the balls posisi berikutnya, pada clutch keluarThis darioperation ceruk-ceruk pada lifter cam plate. Dengan on the gigi clutch lifter boss balls derail (bola-bola) from the recesses on thelifter lifterboss cam plate. lifts the pressure plate, reducing the demikian pressure applied to the clutch discs/platesplate, and the engine power is notpada transmitted the crankshaft to mainshaft. mereka mengangkat pressure mengurangi tekanan clutch from discs/plates dan daya dorong mesin tidak diteruskan dari crankshaft ke mainshaft. CRANKSHAFT

CLUTCH DISCS/PLATES CLUTCH SPRING

MAINSHAFT

Derailed

CLUTCH LIFTER BOSS

GEARSHIFT SPINDLE

LIFTER CAM PLATE CLUTCH LIFTER PLATE Setelah pemindahan gigi telahand selesai dan on balls lifter are boss terpasang ceruk-ceruk pada lifter plate, When the shifting is complete the balls thepada clutchclutch lifter boss engaged withpada the recesses on the lifter camcam plate, the pressure plate kembali returns tokeitsposisinya original position engine power is transmitted from crankshaft the crankshaft to mainshaft. plate semula and dan the daya dorong mesin diteruskan dari ke mainshaft. CRANKSHAFT

CLUTCH SPRING

Engaged

MAINSHAFT

CLUTCH LIFTER PLATE

CLUTCH DISCS/PLATES

2-3

MEMO

3. RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS

3

BODY PANEL ············· 3-2 LOKASI BODYLOCATIONS·············· PANEL............................... 3-2

GRAB RAIL............................................3-7

BODY PANEL REMOVALBODY CHART ··············3-2 DIAGRAM PELEPASAN PANEL .... 3-2

BODY COVER........................................3-8

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

LUGGAGE BOX.....................................3-9

TROUBLESHOOTING ····································3-3 TROUBLESHOOTING ................................ 3-3

REAR FENDER......................................3-10

FRONTTOP TOPCOVER COVER ·······································3-4 FRONT .................................. 3-4

HANDLEBAR COVER ...........................3-10

LOWERSIDE SIDECOVER COVER····································· 3-5 LOWER ................................ 3-5

FOOTPEG BAR .....................................3-15

FRONT FRONTFENDER......................................... FENDER ··············································3-53-5

PASSENGER FOOTPEG HOLDER.......3-15

MAIN PIPE MAIN PIPESIDE SIDECOVER/ COVER/MAIN PIPE COVER ·······························································3-6 MAIN PIPE COVER ............................... 3-6

LEFT CRANKCASE REAR COVER ......3-16 EXHAUST PIPE/MUFFLER ...................3-16

SEAT ··································································· 3-73-7 SEAT ........................................................... GRAB RAIL ·······················································3-7

BODY COVER····························· ······················ 3-8

LUGGAGE BOX·················· ·························· ···· 3-9

REAR FENDER················································· 3-9

HANDLEBAR COVER···································3-10

FOOTPEG BAR································ ··············· 3-14

PASSENGER FOOTPEG HOLDER············· 3-14

RIGHT PIVOT COVER ·································3-14

LEFT CRANKCASE REAR COVER ···········3-15

EXHAUST PIPE/MUFFLER ························· 3-15

3-1


LOKASI BODYLOCATIONS PANEL BODY PANEL FRAME/BODYPANELS/EXHAUSTSYSTEM

(11)

(12)

(1)

(4) (13)

(3)

(10)

(9)

(7)

(6)

(2)

(5) Front cover (1) (1) Front toptop cover (hal. 3-4) (page 3-4) (2) (2) Lower si de cover (hal. 3-5) Lower side cover (page 3-5) (3) (3) Main pipe side cover/main 3-6) Main pipe side cover/mainpipe pipecover cover(hal. (page 3-6) (4) (4) Front fender (hal. 3-5) Front fender (page 3-5) (5) (5) Footpeg bar (hal. 3-14) Footpeg bar (page 3-15) (6) (6) Body co ver (hal. 3-8) Body cover (page 3-8) (7) Rear fender (hal. 3-9) (7) Rear fender (page 3-10)

(14)

(8)

(8) footpeg holder (8) Passenger Pass enger footpeg holder (hal. 3-14) (page 3-15) (9) Grab Grab rail (hal. 3-7) rail (page 3-7) (10) Seat (page (hal. 3-7) (10) Seat 3-7) (11) Luggagebox box(page (hal. 3-9) 3-9) (11) Luggage (12) Handlebar front cover (hal. 3-10) 3-10) (12) Handlebar front cover (page (13) Handleba r rear cover (hal. 3-11) (13) Handlebar rear cover (page 3-11) (14) Left crankcase rear cover (hal.3-15) (14) Left crankcase rear cover (page 3-16)

BODY PANEL REMOVAL CHART DIAGRAM PELEPASAN BODY PANEL • This chart shows removal order of frame covers. Diagram ini memperlihatkan urutan pelepasan dari frame covers (penutup rangka).

•

(1) FRONT TOP COVER

(12) HANDLEBA R FRON T COVER

(2) LOWER S IDE COVER

(9) GRAB RAIL

(13) HANDLEBAR REAR COVER

(3) MA IN PIPE S IDE COVER/MAIN PIPE COVER (4) FRONT FENDER (6) BODY COVER (5) FOOTPEG BAR

(10) SEAT

3-2

(11) LUGGAGE BOX

(7) REAR FENDER

(8) PASSENGER FOOTPEG HOLDER (14) LEFT CRANKCASE REAR COVER


KETERANGAN SERVIS SERVICE INFORMATION GENERAL UMUM • This section covers removal and installation of the body panels and exhaust system. Serious may result if the exhaust system dari is not allowed to cool before components removed or serviced. Bab ini burns meliputi pelepasan dan pemasangan body panels dan sistem pembuanganare gas. • Always replace the exhaust pipe gasket after removing the exhaust pipe from the engine. Luka bakar parah kemungkinan dapat terjadi jika sistem pembuangan gas tidak dibiarkan menjadi dingin dulu sebelum • • When installing the exhaust system, loosely install all of the muffler fasteners. Always tighten the exhaust joint first, then tighten the komponen-komponen dilepaskan atau diservis. mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly. Selalu inspect ganti exhaust pipe gasket melepaskan exhaust pipe dari mesin. • • Always the exhaust systemsetelah for leaks after installation. Sewaktu memasang sistem pembuangan gas, pasanglah semua pengikat muffler dengan longgar dulu. Selalu kencangkan • exhaust joint (sambungan pipa knalpot) dulu, kemudian kencangkan mounting fasteners (pengikat pemasangan). Jika TORQUE VALUES dikencangkan dulu, exhaust pipe (pipa knalpot) mungkin tidak akan duduk dengan benar. pengikat pemasangan Setelahpipe pemasangan pembuangan gas terhadap kebocoran. • Exhaust joint nut selesai, selalu periksa sistem 27 N·m (2.8 kgf·m, 20 lbf·ft) • •

Exhaust pipe stud bolt

–

TORSI PENGENCANGAN Exhaust pipe joint nut Exhaust pipe stud bolt

27 N.m (2,8 kgf.m; 20 lbf.ft) -

TROUBLESHOOTING

See page 3-17

Lihat hal. 3-16

Excessive exhaust noise • Broken exhaust system • Exhaust gas leak

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

3-3


FRONT FRONT TOP TOP COVER COVER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan sebagai berikut: Remove the following: – Twoscrews bolts and licence plate holder fromholder the front - Dua (sekrup) dan licence plate dariside sisi depan – Two special screws from the lower front side - Dua special screws (sekrup khusus) dari sisi depan bawah – Six special screws from the rear side - Enam special screws dari sisi belakang Be careful not to Remove the front top cover while releasing its boss from front top frame coverby sementara melepaskan boss (tonjolan pemasangan)nya the grommet on the pulling it forward. Hati-hati tidak Lepaskan damageagar the boss. grommet pada rangka dengan menariknya merusak boss-nya. dari Disconnect the headlight 4P connector and front ke turndepan. signal 2P connectors. Lepaskan headlight 3P connector (connector 3P lampu besar) dan front turn signal 2P connectors (connector 2P lampu sein depan). Pemasangan adalah dalam urutan terbalik dari pelepasan. Installation is in the reverse order of removal. SPECIAL SCREWS BOLTS

LICENCE PLATE HOLDER FRONT TOP COVER

BOSS

CONNECTORS GROMMET

PEMBONGKARAN/PERAKITAN DISASSEMBLY/ASSEMBLY Lepaskan sebagai berikut: Remove the following: – Six screws - Enam screws – Right/left frontturn turnsignal signalunits units - Right/left front – Headlight adjusting bolt - Headlight adjusting bolt – Headlight retainers - Headlight – Headlightretainers unit - Headlight unit Assembly is in the reverse order of disassembly. Perakitan adalah dalam urutan terbalik dari pembongkaran. Adjust the headlight aim (page installing the frontfront top cover. Setel arah sinar headlight (hal.4-18) after 4-18) setelah memasang top cover. FRONT TOP COVER SCREWS RETAINERS

FRONT TURN SIGNAL UNITS

3-4

BOLT

HEADLIGHT UNIT


LOWER LOWER SIDE SIDE COVER COVER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION

Lepas kan s ebagai berikut: Remove the following: - Screw/washer – Screw/washer - Screw – Screw - Dua s pecial w – Two specialscre screws

hook (kaitan) pada cover dari Hati-hati agarnot tidak Release the boss on the rearbagian side ofdepan lowerdari sidelower cover Be careful to Lepaskan merusak from (lubang the grommet on the frame and remove lower pemasangan) pada main pipethe side cover dan damageboss-nya. the boss. slot side cover. (tonjolan pemasangan) pada bagian belakang dari lower bosses side cover dari grommets pada rangka.

Installation is in the reverse order of removal. Pemasangan adalah dalam uru tan terbalik dari pelepasan. GROMMET Sisi kiri di perlihatkan:

BOSS

SCREW

SPECIAL SCREWS LOWER SIDE COVER SCREW/WASHER

FRONT FRONT FENDER FENDER (SPAKBOR DEPAN) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION

Lepaskan speedometer cable guide dari lubang pada front fender. Release the speedometer cable guide from the hole on the front fender. Lepaskan sebagai berikut: Remove the following: - Dua bolts/collars – Twoscrews/collars bolts/collars - Dua – Two fender screws/collars - Front – Front fender Installation is in the reverse ofterbalik removal. Pemasangan adalah dalamorder urutan dari pelepasan. FRONT FENDER

SCREWS/COLLARS

BOLTS/COLLARS

SPEEDOMETER CABLE GUIDE

3-5


MAIN MAINPIPE PIPE SIDE SIDE COVER/MAIN COVER/MAINPIPE PIPE COVER COVER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION

Lepaskan sebagai berikut: thecover following: -Remove Front top (hal. 3-4) - – Lower cover (page (hal. 3-5) Frontside top cover 3-4) Lower sidescrews cover (page 3-5)kanan dan kiri - – Tiga special dari sisi Two special - – Screw dari sisiscrews depan from the right and left side – Screws from the front and upper side Lepaskan tabs (lidah pemasangan) pada sisi bawah dari main pipe side cover dari slots (lubang-lubang pemasangan) pada air cleaner housing dan lepaskan main pipe side cover/main pipe cover.

Hati-hati agar tidak Be careful not to merusak tabs dan damage the tabs and slots. slots. Untuk mencegah To prevent damage terjadinya kerusakanto the body body panel ada p ermukaan surfaces, tape them as Pemasangan panel, lapisilah dengannecessary. pita bila pelepasan. perlu.

adalah

dalam

urutan

terbalik

dari

SCREW

MAIN PIPE SIDE COVER/ MAIN PIPE COVER

SPECIAL SCREWS SLOTS

SCREW

TABS

DISASSEMBLY/ASSEMBLY PEMBONGKARAN/PERAKITAN

Remove the ten screws and separate the main pipe side covers from the main pipe cover. Lepaskan kesepuluh screws dan pisahkan main pipe side dari covers main pipe cover. Assembly is in the reverse order of disassembly. Perakitan adalah dalam urutan terbalik dari pembongkaran. RIGHT MAIN PIPE SIDE COVER

SCREWS

3-6

MAIN PIPE COVER

LEFT MAIN PIPE SIDE COVER


SEAT SEAT (TEMPAT DUDUK) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Buka seat seat dengan menggunakan anak kunci kontak. Open thethe using the key. Remove two nuts andignition the seat. Support the seat while Installation is in the reverse order of removal. Peganglah seat Lepaskan kedua nuts dan seat . removing the nuts.

sementara melepaskan Pemasangan nuts.

adalah

dalam

urutan

terbalik

dari

pelepasan.

SEAT

NUTS

GRAB GRAB RAIL RAIL PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Buka dengan menggunakan anak kunci kontak. Openseat the seat using the ignition key. Remove the four mounting and grab the grab Support the grab grab rail rail Lepaskan keempat mounting bolts bolts dan rail. rail by Peganglah releasing the tabs on the rear si de of body cover from the while removing the sementara melepaskan Pemasangan adalah dalam urutan terbalik dari grab rail slots. bolts. bolts. pelepasan. Installation is in the reverse order of removal.

BOLTS

GRAB RAIL

SLOTS

TABS

3-7


BODY COVER COVER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Remove the following: Lepaskan sebagai b erikut: Grab rail(hal. (page 3-7) - – Grab rail 3-7) Main pipe side cover/mainpipe pipecover cover(hal. – (page3-6) 3-6) - Main p ipe side cover/main – Four special screws - Empat special screws Release the tabs on front and rear side of the body cov Right left body Right and dan left bod y Lepaskan tabs dari sisi d epan dari body covers. ers. covers can be covers da pat Lepaskan boss dari grommet pada rangka dan lubang Release the boss from the grommet on the frame and the removed in the same dilepaskan dengan screw rangka, screw dari holesbosses from thepada bosses on the kemudian frame, thenlepaskan remove manner. cara yang sama. body the body cover. cover. Pemasangan dalam urutan terbalik dari Installation is inadalah the reverse order of removal. pelepasan. Sisi kanan di perlihatkan: GROMMET BODY COVER

BOSSES

TABS

SPECIAL SCREWS

BOSS

TABS

PEMBONGKARAN/PERAKITAN DISASSEMBLY/ASSEMBLY Lepaskan ke-tujuh Remove the sevenscrews, screws. Separate center the center cover Pisahkan bodybody covercover dan and rear rear lowerlower cover dari frombody rear cover. body cover. rear Assembly is in the reverse order of disassembly. Perakitan adalah dalam urutan terbalik dari pembongkaran.

CENTER BODY COVER

SCREWS

3-8

REAR BODY COVER

REAR LOWER COVER


LUGAGE BOX (KOTAK BAGASI) LUGGAGE BOX PELEPASAN/PEMASANGAN PELEPASAN/PEMASANGAN Lepaskansebagai sebagaiberikut berikut:: Lepaskan - – Battery Baterai (page (Hal. 16-5) 16.5) - – Seat Tempat duduk (page 3-7) ( Hal. 3-7) - – Body Body cover cover (page (Hal. 3-8) 3-8) Buka ikatan dan lepaskan konektor wire harness baterai Release the startermotor wire band and the battery wire dan konektor 2P disconnect dari wire harness utama. harness connectors and starter motor 2P connector from Lepaskan bolt, harness. dua special bolt dan tiga collar. the main wire Remove the bolt, two special bolts and threewire collars. Angkat luggage box sambil menarik keluar harness

lurkan Route wire harness the wire dengan benar 1harnesses (Hal. properly 14) (page 1-14). Hati-hati jangan Be careful not to sampai wire harness pinch wire terjepit di the antara harness between the luggage box dan luggage box and rangka/frame. frame.

Raise the luggage box while pulling out the battery wire baterai. harness. Pemasangan dalam terbalik dari Installation is inadalah the reverse order urutan of removal. pelepasan.

BATTERY WIRE HARNESS

BOLT/COLLAR

SPECIAL BOLTS/ COLLARS

LUGGAGE BOX WIRE BAND

CONNECTORS

3-9


REAR FENDER FENDER (SPAKBOR BELAKANG) REMOVAL/INSTALLATION PELEPASAN/PEMASANGAN: Lepaskan sebagai berikut: Remove the following: - Brake/tail light unit (hal. 19-5) Brake/tail light6-16) unit (page 19-8) - –Fuel tank (hal. – Luggage box (page 3-9) Lepaskan dari main harness wire Remove the fourwire bolts, then pull upketiga the rear sideguides. of the fuel Lepaskan kedua bolts, dua special bolts dan rear tank. fender. Release the main wire harness from the three wire guides. Lepaskan spring, retainer dan key cylinder. Remove the two bolts, two special bolts and rear fender. Pemasangan adalah dalam urutan terbalik dari Remove the spring, retainer and key cylinder. pelepasan. Installation is in the reverse order of removal.

WIRE GUIDES

MAIN WIRE HARNESS

BOLTS

SPECIAL BOLT

SPRING RETAINER

FUEL TANK

BOLTS

REAR FENDER

SPECIAL BOLT KEY CYLINDER

HANDLEBAR COVER COVER HANDLEBAR FRONT COVER PELEPASAN/PEMASANGAN HANDLEBAR REMOVAL/INSTALLATION FRONT COVER Longgarkan locknuts nuts pengunci) dan mirrors lepaskan Loosen the lock and(mur remove the rearview by rearview mirrors (kaca spion) dengan memutar mereka turning them counterclockwise. berlawanan arah jarum jam.

REARVIEW MIRRORS

LOCK NUTS

3-10

RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS Lepaskan ke-enam screws. Remove the six screws. Remove the handlebar cover by releasing the Lepaskan handlebar frontfront cover dengan melepaskan bossesdan fromtabs dari the handlebar rear rear cover. bosses handlebar cover. cover. Installation is in the reverse order of removal. Pemasangan adalah dalam urutan terbalik dari pelepasan. HANDLEBAR FRONT COVER

Hati-hati agar tnot idakto Be careful merusakdamage handlebathe r front cover. handlebar front

BOSSES

SCREWS

PELEPASAN HANDLEBAR REAR COVER HANDLEBAR REAR COVER REMOVAL Lepas kan sebagai berikut: the following: - Remove Front top cover (hal. 3-4) Front topfront covercover - – Handlebar (page(hal. 3-4) 3-10) – Handlebar front cover (page 3-10) Lepaskan speedometer cable dari speedometer unit. Disconnect the speedometer cable from the combination meter assembly. Lepaskan wire boss dari rangka. Release the wire boss from the frame. Lepaskan connectors sebagai berikut: Disconnect the following connectors: - Front brake light switch connectors – Front brake light switch connectors - –Turn signal switch 3P3Pconnector (merah) Turn signal switch (Red) connector - –Horn switch 3P3P connector (Hitam ) Horn switch (Black) connector - –Horn connectors Horn connectors Combination meter sub harness9P/6P 9P/6Pconnectors connectors - –Combination meter sub harness

BRAKE LIGHT SWITCH CONNECTORS

TURN SIGNAL/HORN SWITCH CONNECTORS

HORN CONNECTORS

Release the combination meter sub harness from the Lepaskan combination meter sub harness dari cable cable guide. guide.

CABLE GUIDE

WIRE BOSS

COMBINATION METER SUB HARNESS CONNECTORS

SPEEDOMETER CABLE

3-11

RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS Disconnect the choke from the choke lever. Lepaskan kabel choke cable dari choke lever

CHOKE CABLE

Lepaskan kedua screws screws depan screw Remove the two front screws and thedan rearspecial special screw. belakang. belakang . Release the handlebar rear cover from the handlebar. Lepaskan handlebar rear cover dari handlebar.

HANDLEBAR REAR COVER

SPECIAL SCREW

SCREWS

Lepaskan screw dan throttle upper upper housing dengan Remove the screw and the throttle housing by unhooking the lower housing melepaskan lower housing tabtab. dari kaitannya.

SCREW

UPPER HOUSING

TAB Disconnect the throttle from the throttle pipe. Lepaskan throttle cable cable dari throttle pipe. Loosen the throttle cable lock nut and pull the cable out Longgarkan throttle cable lock nut dan tarik keluar cable from the throttle lower housing. dari throttle lower housing.

THROTTLE PIPE

THROTTLE CABLE

LOCK NUT

3-12

LOWER HOUSING

RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS Remove the handlebar cover by pulling the keluar choke Lepaskan handlebar rearrear cover dengan menarik and le throttle out of its throttle thrott cab cab lecables dari l ubangnya. ubangny a.holes.

CHOKE CABLE

THROTTLE CABLE


PEMASANGAN REAR HANDLEBAR HANDLEBAR REAR COVER INSTALLATION COVER Letakkan handlebarrear rearcover coverinpada posisinya. Set the handlebar position. Route the chokecable and throttle cables through holes on Alurkan throttle melalui lubang padathe handlebar the handlebar rear cover. rear cover.

CHOKE CABLE

THROTTLE CABLE


CHOKE CABLE

3-13

RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS throttle cable throttle lower housing Alurkan ARoute lurkanthe melalui dan throttle cable through the throttle lower housing and tighten lock nut. kencangkan lock lockthe nut. Apply grease to the throttlepada pipe alur flange groove andflange throtgrease throttle pipe Berikan (gemuk) tle pipe slot. dan slot pipe throttle . Connect the throttle cable to the throttle pipe. Hubungkan throttle cable pada throttle pipe. Install the throttle lower housing in position by aligning the pin with the hole on the handlebar. Pasang throttle lower housing pada posisinya dengan mentepatkan pin dengan lubang pada handlebar.

THROTTLE PIPE

Tepatkan

LOCK NUT

throttle Pasang dengan mentepatkan Install the throttleupper upper housing housing by aligning its slot with the nya lowerdengan housinglower tab, then installtab, and kemudian tighten the pasang screw. slothousing dan kencangkan screw .

SCREW

THROTTLE CABLE

LOWER HOUSING UPPER HOUSING

TAB Alurkan wire the harness handlebar rear incover pada Route wire Letakkan Set the handlebar rear cover position, then posisinya, install and dengan benar (hal. kemudian tighten thepasang two front screws and thekedua rear special screw. dan kencangkan screws depan harness properly 1-15). (page 1-14). dan special screw belakang.


SPECIAL SCREW

SCREWS

Hubungkan choke chokelever. Connect thekabel choke cableke to leher the choke

CHOKE CABLE

3-14


Route the wire Alu rkan rkan wire harness harness properly dengan benar (hal. (page 1-14). 1-14) . 1-14).

Hubungkan speedometer cable padatospeedometer unit. Connect the speedometer cable the combination meter unit.combination meter sub harness pada cable Letakkan guide. Set the combination meter sub harness to the cable guide. Sambungkan connectors sebagai berikut: - Connect Front brake light switch connectors the following connectors: - Turn signal switch 3P connector (m (m erah) – Horn connectors - –Horn switch swit ch 3P conne ctor (Hitam) Turn signal switch 3P (Red) connector - –Horn connectors Horn switch 3P (Black) connector - –Combination meter sub harness 9P/6P Combination meter sub harness 9P/6Pconnectors connectors – Front brake light switch connectors Pasang wir b ossboss dengan erat pada ran gka. Secure wire theewire to the frame. Pasang s ebagai berikut: Install the following: - Handlebar front cover (hal. 3-10) Handlebar front cover - – Front top cover (hal. 3-4)(page 3-10) – Front top cover (page 3-4)


TURN SIGNAL/HORN SWITCH CONNECTORS

HORN CONNECTORS

CABLE GUIDE

WIRE BOSS

COMBINATION METER SUB HARNESS CONNECTORS

SPEEDOMETER CABLE

FOOTPEG BAR BAR FOOTPEG PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepas kan s ebagai Remove the four berikut: bolts and footpeg bar while pushing down the rear brake pedal. - Empat bolts is in the reverse order of removal. - Installation Footpeg bar Pemasangan pelepasan.

adalah

dalam

urutan

terbalik

BOLTS

dari

FOOTPEG BAR

PASSENGER FOOTPEG PASSENGER FOOTPEG HOLDER HOLDER REMOVAL/INSTALLATION PELEPASAN/PEMASANGAN Remove the muffler mounting bolt, washer, nut, collar, Lepaskan and mountsebagai rubber berikut: (right side only) (page 3-16). 3-16). - Remove Exhaust pipe/muffler (hanya sisi kanan saja) (hal.3-16) the two socket bolts and passenger footpeg - holder. Dua socket bolts - Installation Passengerisfootpeg holder in the reverse order of removal.

Pemasangan pelepasan.

adalah

dalam

urutan

terbalik

BOLTS

dari

FOOTPEG HOLDER

3-15


LEFT LEFT CRANKCASE CRANKCASE REAR COVER COVER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Remove the two bolts dan and left crankcase Lepaskan kedua crankcase rear rear cover. cover. Installation is inadalah the reverse order of removal. Pemasangan dalam urutan terbalik dari

BOLTS

pelepasan.

REAR COVER

EXHAUST PIPE/MUFFLER EXHAUST REMOVAL PIPE/MUFFLER Remove the exhaust pipe joint nuts. Lepaskan exhaust pipe joint nuts.

JOINT NUTS Remove the muffler mounting bolt, nut, and Lepaskan muffler m ounting ount ing b olt, olt , washer danwasher. nut. Remove the muffler mounting bolt. Lepaskan muffler mounting bolt sementara mendorong

NUT/WASHER

Remove exhaust pipe/muffler while pushing down rear brakethe pedal peda l ke bawah. the rear brake pedal. Lepaskan exhaust pipe/muffler.

MOUNTING BOLT

MOUNTING BOLT

Remove the gasket from the exhaust of the cylinder Keluarkan dari exhaustportport (lubang head. pembuangan) dari cylinder head.

GASKET

3-16

RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS INSTALLATION PEMASANGAN WASHER

NUT

MOUNT RUBBER COLLAR

EXHAUST PIPE/ MUFFLER GASKET

27 N· N·m (2.8 kgf ·m, 20 lbf ·ft) BOLTS

EXHAUST PIPE STUD EXHAUST PIPE STUDBOLT BOLT Putar duatwo nutsnuts padatostud kencangkan mereka Thread the bolt studdan bolt and tighten them satu samathen lain, pakailah pas pada together, usekemudian a wrench on them tokunci turn the stud bolt out. untuk memutar stud bolt keluar. mereka Install and tighten new stud bolts into the cylinder head Pasang dan kencangkan stud bolts baru ke dalam to the specified torque. cylinder head dengan yang ditentukan. TORQUE:11 N·m (1.1torsi kgf·m, 8 lbf·ft) TORSI: 11 N.m the (1,1stud kgf.m; kgf.m ; 8 lbf.ft) After tightening bolts, check that the length from the bolt head to the cylinder head surface is within speciSetelah fication. mengencangkan stud bolts, periksa bahwa panjang dari kepala bolt sampai ke permukaan cylinder head adalah sesuai dengan spesifikasi. spesifikasi.

29.5 ± 1.0 mm (1.16 ± 0.04 in)

Selalu ganti gasket baru ke dalam exhaustport portofdari Always replace the Pasang Install agasket new gasket into the exhaust the cylinder cylinder dengan yang head. gasket withbaru. a new head. one.

GASKET

3-17

RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS Pasang exhaust pipe/muffler, pipe joint nuts, Push down the brake pedal andexhaust install the exhaust pipe/ muffler,mounting exhaust bolts, pipe joint nuts, muffler muffler washer dan nut. mounting bolts, washer and nut. Kencangkan exhaust pipe joint nuts dengan torsi yang Tighten the exhaust pipe joint nuts to the specified ditentukan. torque.

EXHAUST PIPE/ MUFFLER

TORQUE:27 N·m (2.8 kgf·m,20 20lbf.ft) TORSI: 27 N.m (2,8 kgf.m; llbf·ft) bf.ft)

Tekan brake pedal mounting ke bawahbolt. dan kencangkan muffler Tighten the muffler mounting bolt dengan ditentukan. Hold the mounting bolttorsi andyang tighten the nut. TORSI: 44 N.m (4,5 kgf.m; 32 lbf.ft) lbf.ft) Tahan mounting bolt dan kencangkan nut. JOINT NUTS

NUT/WASHER

BOLT

3-18

MOUNTING BOLT

4.

PERAWATAN

4

KETERANGAN SERVIS .......................... 4-2

SECONDARY AIR SUPPLY SYSTEM..... 4-13 MAINTENANCE SCHEDULE ························ 4-4

JADWAL PERAWATAN .......................... 4-4

DRIVE CHAIN .......................................... 4-13 FUEL LINE ························································ 4-5

SALURAN BAHAN BAKAR .................... 4-5

BRAKE FLUID (MINYAK REM) ............... 4-16 THROTTLE OPERATION ······························4-5

CARA KERJA THROTTLE ...................... 4-5

KEAUSAN BRAKE SHOES/PADS.......... 4-16 AIR CLEANER·················································· 4-6

CHOKE OPERATION .............................. 4-6

SISTEM REM ........................................... 4-17

AIR CLEANER ......................................... 4-6

BRAKE LIGHT SWITCH .......................... 4-18

CRANKCASE BREATHER...................... 4-7

PENYETELAN ARAH LAMPU BESAR ... 4-18

SPARK PLUG (BUSI) .............................. 4-7

SISTEM KOPELING................................. 4-19

JARAK RENGGANG KLEP..................... 4-9

SIDESTAND............................................. 4-19

OLI MESIN ............................................... 4-10

SUSPENSI ............................................... 4-19

ENGINE OIL STRAINER SCREEN.......... 4-11

MUR, BAUT, PENGIKAT ......................... 4-20

ENGINE OIL CENTRIFUGAL FILTER..... 4-11

RODA/BAN .............................................. 4-20

PUTARAN STASIONER MESIN.............. 4-12

STEERING HEAD BEARINGS ................ 4-21

CRANKCASE BREATHER ·····························4-6

SPARK PLUG ····················································4-7

VALVE CLEARANCE ·····································4-8

ENGINE OIL······················································4-9

ENGINE OIL STRAINER SCREEN·············4-10

ENGINE OIL CENTRIFUGAL FILTER ·····4-10

ENGINE IDLE SPEED ···································4-11

DRIVE CHAIN ························· ······················· 4-12

BRAKE FLUID ················································ 4-15

BRAKE SHOES/PADS WEAR ······················4-15

BRAKE SYSTEM············································4-16

BRAKE LIGHT SWITCH······························4-17

SERVICE INFORMATION ·····························4-2

HEADLIGHT AIM······················· ··················· 4-17

4-1

PERAWATAN

KETERANGAN SERVIS SERVICE INFORMATION MAINTENANCE

UMUM GENERAL

• Letakkan sepedamotor pada tanah mendatar sebelum memulai sesuatu pekerjaan. the sangat motorcycle on a terbakar level ground anypada work.kondisi tertentu. Bensin mudah danbefore dapatstarting meledak • • Place • Gasoline is extremely flammable and is explosive under certain conditions. • Bekerjalah di tempat dengan ventilasi baik. Merokok atau membiarkan api atau percikan bunga api di tempat kerja atau di • Work in a well ventilated area. Smoking or allowing flames or sparks inatau the work area or where the gasoline is stored can cause a fire or tempat di mana bensin disimpan dapat menyebabkan kebakaran ledakan. explosion. • Gas pembuangan mengandung gas karbon monoksida beracun yang dapat menghilangkan kesadaran dan dapat membawa • The exhaust contains poisonous carbon monoxide gas that may cause loss of consciousness and may lead to death. Run the engine in and kematian. Jalankan mesin di tempat terbuka atau di tempat tertutup yang dilengkapi dengan sistem pengeluaran gas open area or with an exhaust evacuation system in and enclosed area. pembuangan.

SPECIFICATIONS SPESIFIKASI ITEM Throttle grip freeplay Jarak main bebas throttle grip Spark plug Standard Spark plug (busi) Standard Optional Pilihan Spark renggang plug gap busi Jarak Engine oil oli capacity At draining Kapasitas mesin Pada penggantian periodik At disassembly Pada pembongkaran mesin Recommended oil Oli mesin yangengine dianjurkan

BAGIAN

Putaran stasioner mesin Jarak renggang IN (Masuk) / EX (Buang) klep Engine idle speed Drive chain Size - link DID Valve clearance IN/EX (rantai roda) RK Drive chain Size – link DID Kekenduran RK Panjang drive chain pada 41 pins (40 links) Slackdianjurkan Brake fluid (minyak rem) yang Drive chain length at 41 pins (40 (pedal links) rem) Jarak main bebas brake pedal Recommended brake fluid Ukuran ban (Merk) Depan Brake pedal freeplay Belakang Tire size (Brand) Tekanan udara ban Pengendara saja Depan Front dingin Belakang Rear Cold tire pressure Driver only Pengendara & Depan Front pembonceng Belakang Rear and passenger Kedalaman minimum alurDriver telapak ban Depan Front Belakang Rear Minimum tire tread depth Front Rear

SPECIFICATIONS 2 – 6 mm (0.1 – 0.2 in) 2 – 6 mm U20EPR9S (DENSO) CPR6EA-9S (NGK) CPR6EA-9S (NGK) U20EPR9S (DENSO) U22EPR9S (DENSO) CPR7EA-9S (NGK) CPR7EA-9S (NGK) U22EPR9S (DENSO) 0.80 – 0.90 mm (0.031 – 0.035 in) 0,80 – 0,90 mm 0.8 liter (0.8 US qt, 0.7 lmp qt) 0,8 liter 1.0 liter (1.1 US qt, 0.9 lmp qt) 1,0 liter API classification: SE, SF or SGAPI service SJ, Oli mesin 4 tak dengan klasifikasi (exceptSAE oils labeled as JASO energy MA conserving on the circular API service Viskositas: 10W-30 -1 label) 1.400 ± 100 menit (rpm) SAE 10W-30 0,10 Viscosity: ± 0,02 mm JASO T 903 standard: MA 1,400 ± 100 min-1 (rpm) 420DX – 102 0.10 ± 0.02 mm (0.004 ± 0.001 in) 420SL – 102 420DX – 102 30 – 40 mm 420SL – 102 508 mm 30 – 40 mm (1.2 – 1.6 in) DOT 3 atau DOT 4 508 mm (20.0 in) 20 – 30 mm DOT 3 or DOT 4 70/90-17 M/C 33P (IRC: NF63B) 20 – 30 mm (0.8 – 1.2 in) 80/90-17 M/C 43P (IRC: NR78Y) 270/90-17 M/C 38P (IRC: NF63B) 200 kPa (2,00 kgf/cm ; 29 psi) 2 225 kPa (2,25 kgf/cm80/90-17 ; 33 psi)M/C 44P (IRC: NR78Y) 2 200 kPa (2.00 kgf/cm2, 29 psi) 200 kPa (2,00 kgf/cm ; 29 psi) 2 kPa (2.25 kgf/cm2, 33 psi) 225 kPa (2,25 kgf/cm ; 225 33 psi) 200 kPa (2.00 kgf/cm2, 29 psi) Sampai ke indikator 2 Sampai ke indikator 225 kPa (2.25 kgf/cm , 33 psi) To indicator To indicator

SPESIFIKASI

TORSI PENGENCANGAN

TORQUE VALUES Oil drain bolt Valve adjusting Oil drain bolt lock nut Oil centrifugal filter cover bolt Valve adjusting lock nut Clutch adjuster lock nut Oil centrifugal filter cover bolt Spark plug (busi) Clutch adjuster lock nut Wheel spoke Spark plug Rear axle nut Rear axle nut

4-2

24 N.m (2,4 kgf.m; 18 lbf.ft) 9 N.m (0,9224kgf.m; 6,6 kgf·m, lbf.ft) 18 lbf·ft)Semprotkan oli ke ulir dan permukaan duduk N·m (2.4 5 N.m (0,51 kgf.m; 3,7 lbf.ft) Oleskan cairan pengunci pada ulir 9 N·m (0.92 kgf·m, 6.6 lbf·ft) Apply oil to the threads and seating surface 12 N.m (1,2 kgf.m; 9 lbf.ft) 5 N·m (0.51 kgf·m, 3.7 lbf·ft) Apply locking agent to the threads: See page 4-12 16 N.m (1,6 kgf.m; 12 lbf.ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 3,2 N>m (0,33 kgf.m; 2,4 lbf.ft) N·m (1.6 kgf·m, 12 lbf·ft)U-nut 59 N.m (6,016kgf.m; 44 lbf.ft) 59 N·m (6.0 kgf·m, 44 lbf·ft) U-nut

PERAWATAN TOOL Valve adjusting wrench 07708-0030400

4-3

PERAWATAN

MAINTENANCE SCHEDULE JADWAL PERAWATAN Jalankan Pemeriksaan SebeluminJalan di dalam Buku Pedoman Pemilik pada masing-masing Perform the Pre-ride inspection the Owner’s Manual at each scheduled maintenance period. periode perawatan yang dijadwalkan. P: Periksa dan Bersihkan, Setel, Lumasi atau Ganti bila perlu. B: Bersihkan. G: Ganti. L: Lumasi. PB: Perawatan Berkala. I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate. Bagian-bagian berikut memerlukan pengetahuan mekanis tertentu. Beberapa bagian (terutama yang ditandai * dan **) dapat The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more technimemerlukan lebih banyak informasi teknis dan perkakas khusus. Hubungi AHASS Anda. cal information and tools. Consult an authorized Honda dealer. FREQUENCY YANG LEBIH WHICHEVER → PEMBACAAN ODOMETER (km) - CATATAN 1 COMES FIRST ODOMETER READING (NOTE 1) FREKUENSI DULU DIX1,000 1 4 8 12 PB I PB II PB km III CAPAI ↓ X1,000 mi 0.6 2.5 5 7.5 500 2.000 4.000 8.000 12.000 Km BAGIAN YANG DISERVIS ITEMS Months 1218 18 Bulan 6 12 6 * FUEL LINE I I I * SALURAN BAHAN BAKAR P P P P * THROTTLE OPERATION I I I * CARA KERJA GAS TANGAN P P P P * CHOKE OPERATION I I I AIR CLEANER Catatan 2 SETIAP 16.000 km: G AIR CLEANER NOTE2 EVERY 16,000 km (9,600 mi) R CRANKCASE BREATHER Catatan 3 B B B B CRANKCASE BREATHER NOTE3 C 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 MESIN G G SETIAP 4.000 km: G R R R ENGINE OIL R * * ENGINE OIL STRAINER SCREEN B B B B B ENGINE OIL STRAINER SCREEN C * * ENGINE OIL CENTRIFUGAL CENTRIFUGAL FILTER B B B B B ENGINE OIL C FILTER ** ENGINE IDLE SPEED I I I I *** PUTARAN STASIONER MESIN SYSTEM P P P P P SECONDARY AIR SUPPLY I DRIVE P SETIAP 500 km: L DRIVECHAIN CHAIN EVERY 1,000 km (600 mi) I, L BRAKE FLUID (MINYAK REM) Catatan 4 P P BRAKE FLUID NOTE4P I IP I KEAUSAN SEPATU REM WEAR P P P BRAKE SHOES/PADS I IP I SISTEM REM P P P P P BRAKE SYSTEM I I I I * * SAKELAR LAMPU SWITCH REM P P P BRAKE LIGHT I IP I * * ARAH SINAR LAMPU P P P P HEADLIGHT AIM BESAR I IP I SISTEM CLUTCH (KOPELING) P P P CLUTCH SYSTEM I P I IP I SIDESTAND I IP I STANDARD SAMPING P P P * SUSPENSION I I I * SUSPENSI P P P P NUTS, BOLTS, FASTENERS I P IP * * MUR, BAUT, PENGIKAT P ** WHEELS/TIRES I I IP I ** RODA/BAN P P P P STEERING HEADKEMUDI BEARINGS I P I **** BANTALAN KEPALA P P

LIHAT REFER TO HALAMAN PAGE 4-5 4-5 4-5 4-5 4-6 4-6 4-6 4-6 4-7 4-7 4-7 4-8 4-9 4-9 4-10 4-10 4-11 4-10 4-11 4-12 4-11 4-13 4-12 4-13 4-15 4-16 4-15 4-16 4-16 4-17 4-17 4-18 4-17 4-18 4-17 4-19 4-18 4-19 4-18 4-19 4-19 4-20 4-19 4-20 4-21 4-21

Should be serviced by an authorized Honda dealer, unless the owner hasTEPAT proper tools and service data and is mechanically * *HARUS DISERVIS OLEH AHASS, KECUALI BILA PEMILIK MEMPUNYAI TOOLS YANG DAN DATA qualified. SERVIS YANG DIPERLUKAN, DAN MEMPUNYAI KETRAMPILAN MEKANIS UNTUK MENGERJAKANNYA. InKEAMANAN, the interestKAMI of safety, we recommend items be servicedINI only by anDILAKUKAN authorizedOLEH Honda dealer. ** **DEMI MENGANJURKAN AGARthese PEKERJAAN-PEKERJAAN HANYA AHASS. Honda recommends that an authorized Honda dealer should road test your motorcycle after each periodic maintenance is carried out. NOTES: CATATAN: 1. At higher odometer readings, repeat at the frequency interval here. yang ditentukan di atas. 1. Pada pembacaan odometer lebih tinggi, ulangilah padaestablished interval frekuensi 2. Service more frequently when riding in unusually wet or dusty areas. 2. Servis sering when jika dikendarai di daerah luar biasa basah atau berdebu. 3. Service morelebih frequently riding in rain or at fullyang throttle. 3. Servis lebih sering jika dikendarai dalam hujan atau dengan gas penuh. 4. Replace every 2 years. Replacement requires mechanical skill. 4. Ganti setiap 2 tahun. Penggantian memerlukan ketrampilan mekanis.

4-4

PERAWATAN

FUEL LINEBAHAN BAKAR SALURAN Lepaskan b ody cover (hal. 3-8). (page 3-8). Remove the body cover

FUEL LINE

Check the fuel line for deterioration, damagepemburukan or leakage. Periksa saluran bahan bakar terhadap Replacekerusakan the fuel line if necessary. kondisi, atau kebocoran. Ganti bahan bakar Installsaluran the body cover (page(fuel 3-8).line) bila perlu.

Pasang body cover (hal. 3-8).

FUEL LINE

CARA KERJA THROTTLE (GAS TANGAN) THROTTLE OPERATION Periksa terhadap pemburukan kerusakan Check for any deterioration or kondisi damageatau to the throttle cable.throttle Checkcable. the throttle for smooth operation. pada Periksagrip throttle grip (putaran gas Check that the throttle opens and automatically closes in tangan) terhadap kelancaran cara kerja. Periksa bahwa all steering positions. throttle membuka dan secara otomatis menutup kembali If thesemua throttleposisi grip does not return properly, lubricate the pada kemudi. throttle cable, and overhaul and lubricate the throttle grip housing. Jika throttle grip tidak kembali dengan benar, lumasi For cable lubrication: Disconnect throttlethrottle cable atgrip its throttle cable, dan bongkar danthe lumasi upper end. Thoroughly lubricate the cable and its pivot housing. point a commercially cable lubricant or a If the with throttle grip still doesavailable not return properly, replace lightweight oil. the throttle cable. Untuk melumasi cable: Lepaskan throttle cable pada Reusing a damaged, ujung With the engineLumasi idling, turn the dan handlebar all the way to atasnya. cable titik perputarannya the right and left to ensure that the idle speed does not abnormally bent or secara menyeluruh dengan pelumas kabel yang dapat change. If idle speed increases, check the throttle grip kinked throttle cable dibeli di pasaran ataucable oli dengan berat ringan. freeplay and throttle connection.

can prevent proper throttle operation and Pemakaian kembali may leadcable to a loss throttle yangof throttle control atau while rusak, tertekuk kusut secarariding. tidak normal dapat mengganggu cara kerja throttle yang benar dan dapat mengakibatkan kehilangan pengontrolan sewaktu mengendarai sepedamotor.

2 – 6 mm (0.1 – 0.2 in)

Measure the throttle grip freeplay at the throttle grip Jika throttle grip tetap tidak dapat kembali dengan flange. benar, gantilah throttle cable. FREEPLAY: 2 – 6 mm (0.1 – stasioner, 0.2 in) Sementara mesin berputar putar handlebar (stang stir) sama sekali ke kanan dan ke kiri untuk memastikan bahwa putaran stasioner tidak berubah. Jika putaran stasioner naik, periksa jarak main bebas throttle grip dan perletakan throttle cable.

Ukur jarak main bebas throttle grip pada throttle grip flange. JARAK MAIN BEBAS: 2 – 6 mm

4-5

PERAWATAN Jarak main bebas throttle dapat disetel pada ujung Throttle grip freeplay cangrip be adjusted at throttle cable adjuster. bawah dari throttle cable. Longgarkan (mur pengunci) dan putar adjuster Remove thelock dustnut cover from the adjuster. (penyetel) Loosen thesebanyak lock nut. yang diperlukan dan kencangkan Adjust freeplay by turning the adjuster. lock nutthe sementara menahan adjuster. Periksa kembali cara kerja throttle. Recheck the throttle operation. Replace any damaged parts, if necessary. Ganti parts yang rusak, bila perlu.

ADJUSTER

LOCK NUT

DUST COVER

CARA KERJA CHOKE (CUK) CHOKE OPERATION Periksa terhadap kerja and choke lever Check for smoothkelancaran choke levercara operation lubricate the choke cable (handel cuk) danif required. lumasi choke cable (kabel cuk) bila perlu. Inspect the cable for cracks which could allow moisture to enter. Replacecable the choke cable if necessary. Periksa terhadap retak-retak yang memungkinkan masuknya kelembaban. Ganti choke cable bila perlu.

CHOKE LEVER

AIR CLEANER • The viscous paper element connect be cleaned

because the element contains a dust adhesive. AIR CLEANER

• If the motorcycle is used in unusually wet or dusty PELEPASAN/PEMASANGAN areas, more frequent inspections are required. Lepaskan screws, cleanerhousing housing cover dan Remove the screws, air air cleaner cover and gaskets. gaskets. Lepaskan dandiscard buanglah air cleaner cleanerelement elementin sesuai Remove and the air accordengan jadwal perawatan (hal. 4-4). dance with the maintenance schedule (page 4-4). Ganti element setiap waktu bila ia sangat kotor atau Replace the element any time if it is excessively dirty or rusak. damaged. Pasang part s yang telah dilepaskan dalam urutan terbalik dariremoved pelepasan. Install the parts in the reverse order of removal.

AIR CLEANER ELEMENT

GASKETS

4-6

AIR CLEANER HOUSING COVER

SCREWS

PERAWATAN

BREATHER CRANKCASE BREATHER CATATAN: Servis sering bilamana dalam Servicelebih more frequently whendikendarai ridden in rain or hujan, at full pada gasService penuh, a throttle. if tau thesetelah depositsepedamotor level can be telah seen dicuci. in the drain cap. Servis bila tinggi permukaan endapan dapat terlihat pada drain Check the cap. crankcase breather drain cap. If deposits has collected, remove the clip and crankcase breather drain cap.breather drain cap. Periksa crankcase Drain deposits the terkumpul, suitable container. Bila endapan into telah lepaskan clip dan Install the crankcase breather drain cap and clip. crankcase breather drain cap. Keluarkan endapan dan buang ke dalam penampung yang sesuai. Pasang crankcase breather drain cap dan clip.

CLIP

DRAIN CAP Remove the lower side cover (page 3-5). Lepaskan left left lower side cover (hal. 3-5). Check crankcase the crankcase breather for deterioration, Periksa breather hose hose terhadap pemburukan damage or leakage. kondisi, kerusakan atau kebocoran.

BREATHER HOSE

SPARK PLUG (BUSI) PELEPASAN REMOVAL Disconnect the spark plugcover cap. (hal. 3-5). Lepaskan right lower side Remove the spark plug. Clean around the spark plug base with Bersihkan daerah di compressed air before sekitar dasar removing the busi plug dengan udara dari and make sure no kompressor sebelum debris is allowed to melepaskan busi dan enter bahwa the combustion pastikan kotoran chamber. tidak memasuki ruang pembakaran.

SPARK PLUG CAP

SPARK PLUG

Lepaskan spark plug cap. Inspect or replace as described in the maintenance schedule (page 4-4). Lepaskan spark plug. Periksa dan ganti sesuai dengan jadwal perawatan (hal. 4-4).

4-7

PERAWATAN INSPECTION PEMERIKSAAN Clean the spark electrodes with a(kutub-kutub wire brush orbusi) speBersihkan sparkplug plug electrodes cial plugsikat cleaner. dengan kawat atau dengan alat special plug Check the insulator for cracks or damage, and the eleccleaner. trodes for wear, fouling or discoloration. Periksa insulator terhadap keretakan atau kerusakan, Replace the plugterhadap if necessary. dan electrodes keausan, pengotoran atau warna. SPARK PLUG (OR EQUIVALENT): RECOMMENDED Always use the perubahan Standard: NGK: CPR6EA-9S specified spark plug Ganti busi bila perlu. on this motorcycle. DENSO: U20EPR9S Selalu pakai busi yang Optional: NGK: CPR7EA-9S telah ditentukan untuk BUSI YANG DIANJURKAN (ATAU EKUIVALENNYA): DENSO: Standard: NGK: U22EPR9S CPR6EA-9S sepedamotor ini.

Pilihan:

DENSO: NGK: DENSO:

CENTER ELECTRODE

U20EPR9S CPR7EA-9S U22EPR9S

INSULATOR

SIDE ELECTRODE

Measure spark gapbusi between center dan and side Ukur jaraktherenggang antarathecenter electrodes with a feeler tengah gauge. dan samping) dengan electrodes (elektrode feeler gauge. SPARK PLUG GAP: 0.80 – 0.90 mm (0.031 – 0.035 in) JARAK RENGGANG BUSI: 0,80 – 0,90 mm If necessary, adjust the gap by bending the side electrode carefully. Bila perlu, setel jarak renggang busi dengan menekuk side electrode dengan hati-hati.

0.80 – 0.90 mm (0.031 – 0.035 in)

PEMASANGAN INSTALLATION Pasang danhand kencangkan dengan pada Install and tighten thebusi spark plug totangan the cylinder head, then tighten the spark plug to the specified torque. cylinder head, kemudian kencangkan dengan torsi yang ditentukan. TORQUE:16 N·m (1.6 kgf·m, 12 lbf·ft) TORSI: (1,6 kgf.m; Connect16 theN.m spark plug cap. 12 lbf.ft) Pasang spark plug cap.

4-8

SPARK PLUG

SPARK PLUG CAP

PERAWATAN

VALVE RENGGANG CLEARANCEKLEP JARAK CATATAN: Periksa and dan adjust setel jarak renggang klep while sewaktu • • Inspect the valve clearance the engine is cold (below 35°C/95°F). mesin dalam keadaan dingin (di bawah 35° C).

INSPECTION PEMERIKSAAN

Remove the following: Lepaskan sebagai berikut: – Left lower side cover (page 3-5) Spark plug (page (hal. 4-7) 3-5) - – Lower side covers Cylinder head cover – - Spark plug (busi) (hal. (page 4-7) 8-6) - Shift Cylinder head cover (hal. 8-6)or 4th gear. the transmission into 3rd Selalu putar roda belakang dalam arah berlawanan dengan jarum jam. ika diputar dalam arah jarum jam, decompressor akan beroperasi dan posisi yang tepat tidak dapat diperoleh.

Masukkan transmissi dalam gigi 3 atau 4. by little, in a Turn the rear wheel ke counterclockwise little quick motion. Putar rodathe belakang berlawanan jam sedikit Position cam sprocket so thatarah the jarum cylinder head top demi sedikit, dengan gerakan surface comes between thecepat. "ll" and "l" lines on the sprocket. cam sprocket sehingga permukaan atas Tempatkan cylinder head beradais at antara garisDead "II" dan "I" on pada Make sure the piston TDC (Top Center) the sprocket. compression stroke. This position can be obtained by confirming that there is slack in the rocker arms.berada If there is no slack, theDead rear Pastikan bahwa piston pada TDC turn (Top wheel again until the correct position is obtained. Center = TMA – Titik Mati Atas) pada langkah kompressi. Posisi ini dapat diperoleh dengan memastikan bahwa ada kerenggangan pada rocker arms. Jika tidak ada kerenggangan, putar roda belakang sekali lagi sampai posisi yang tepat diperoleh.

GARIS"I"

GARIS "Il"

Check each valve clearance inserting aklep feeler gauge Periksa masing-masing jarakbyrenggang dengan between the valve adjusting screw and valve stem. memasukkan feeler gauge (lidah pengukur) antara valve adjusting screw (sekrup penyetelan klep) dan VALVE CLEARANCE: valve stem (tangkai klep). IN/EX:0.10 ± 0.02 mm (0.004 ± 0.001 in)

JARAK RENGGANG KLEP: IN/EX: 0,10 0,02 mm

FEELER GAUGE

PENYETELAN ADJUSTMENT Setel melonggarkan lock (murthepengunci) Adjustdengan by loosening the lock nut andnut turning adjusting dan memutar adjusting screw (sekrup penyetel) sampai ADJUSTING SCREW screw until there is a slight drag on a feeler gauge. ada tahanan pada feeler Apply enginesedikit oil to the lock nut. gauge. Hold the adjusting screw and tighten the lock nut to the Semprotkan oli mesin pada lock nut. specified torque. Tahan adjusting screw dan kencangkan lock nut dengan TOOL: torsi yang ditentukan. Valve adjusting wrench 07708-0030400

LOCK NUT

TOOL: TORQUE:9 N·m (0.92 kgf·m, 6.6 lbf·ft) Valve adjusting wrench 07708-0030300 Recheck the valve clearance. TORSI: 9 N.m (0,92 kgf.m; 6,6 lbf.ft) Install the following: Periksa kembali jarak renggang klep. – Cylinder head cover (page 8-7) Pasang sebagai berikut: plug (page – Spark 4-8) Left lower side cover – (page - Cylinder head cover (hal. 8-6)3-5)

VALVE ADJUSTING WRENCH

- Spark plug (hal. 4-7) - Lower side covers (hal. 3-5)

4-9

PERAWATAN

ENGINE OIL OLI MESIN PEMERIKSAAN TINGGI PERMUKAAN OLI OIL LEVEL INSPECTION Start the engine and let it idle berputar for 3 – 5 minutes. Hidupkan mesin dan biarkan stasioner selama Stop the engine and wait 2 – 3 minutes. 3-5 menit. Hold themesin motorcycle in an upright position. Matikan dan tunggu 2-3 menit. Remove sepedamotor the oil filler cap/dipstick wipe oil from the Letakkan pada posisiand tegak. dipstick withoil a clean Lepaskan fillercloth. cap/dipstick (tutup pengisian Insert the oil filler cap/dipstick without screwing it in, oli/tangkai pengukur) sekalah oli dari dipstic remove it and check thedan oil level. dengan kain bersih. Masukkan oil filler cap/dipstick tanpa menyekrupkannya ke dalam, lepaskan dan periksa tinggi per mukaan oli.

O-RING UPPER LEVEL

OIL FILLER CAP/ DIPSTICK

LOWER LEVEL

If the level is below near the lower level on thebatas dipJika permukaan oli diorbawah atau dekat dengan stick, add the recommended oil toLEVEL) the upper level. permukaan terendah (LOWER pada dipstick, tambahkan oli yang dianjurkan RECOMMENDED ENGINE OIL: sampai ke batas permukaan tertinggi (UPPER LEVEL). API classification: SE, SF or SG (except oils labeled as energy conserving on the circular OLIAPI MESIN YANG service label)DIANJURKAN: Oli mesin 4 tak dengan klasifikasi API service SJ, Viscosity: SAE 10W-30 Viskositas: SAE 10W-30 JASO T 903 standard: MAJASO MA Check that the O-ring on the oil filler cap is in good condition, and replace it if necessary. Install the oil filler cap/dipstick.

PENGGANTIAN OLI ENGINE OIL CHANGE Panaskan mesin. Warm up the engine. Matikan lepaskan filler dan seka Stop themesin, engine, removeoilthe oil cap/dipstick filler cap/dipstick and wipe from the dipstick with a clean cloth. oli darioildipstick dengan kain bersih. Remove the drain bolt and sealing washer. Lepaskan drain bolt (baut pembuangan) dan sealing Drain oil completely. washer. Install the oil drain bolt with a new sealing washer and Keluarkan semuanya. tighten it toolithe specified torque. TORQUE:24 N·m (2.4 kgf·m, 18 lbf·ft) Pasang oil drain bolt dengan sealing washer baru dan kencangkan dengan torsi yang ditentukan.

TORSI: 24 N.m (2,4 kgf.m; 18 lbf.ft) DRAIN BOLT/SEALING WASHER

Isi dengan olirecommended mesin yang dianjurkan. Fillmesin the engine with engine oil.

O-RING

KAPASITAS MESIN: ENGINE OILOLI CAPACITY: 0,8 liter pada penggantian 0.8 liter (0.8 US qt, 0.7 lmp qt)periodik at draining 1,0 liter pada pembongkaran 1.0 liter (1.1 US qt, 0.9 lmp qt) atmesin disassembly Check that the O-ring the oil in good dalam condiPeriksa bahwa O-ringon pada oilfiller fillercap capis berada tion, and replace it if necessary. kondisi baik, dan ganti bila perlu. Install the oil filler cap/dipstick. Pasang oil filler cap/dipstick. Make sure there are no oil leaks. Pastikan bahwa tidak ada kebocoran Check the engine oil level (page 4-10).oli.

Periksa tinggi permukaan oli mesin (hal. 4-10). OIL FILLER CAP/DIPSTICK

4-10

PERAWATAN

ENGINEOIL OILSTRAINER STRAINERSCREEN SCREEN ENGINE Lepaskan right crankcase cover (hal. 10-5). Remove the right crankcase cover (page 10-5). Lepaskan oiloilstrainer danclean bersihkan dalam Remove the strainer screen and it in non-flammable orpembersih high flash point larutan yangsolvent. tidak dapat terbakar atau mempunyai titik api tinggi. Install the oil strainer screen with its tapered side facing the crankcase side and thinner edge facing up as shown. Pasang screen dengan sisinya yang Install theoil rightstrainer crankcase cover (page 10-8). meruncing menghadap ke sisi crankcase dan pinggirannya yang lebih tipis di sebelah atas seperti diperlihatkan pada gambar.

SISI CRANKCASE

Pasang right crankcase cover (hal. 10-8).

OIL STRAINER SCREEN

ENGINEOIL OILCENTRIFUGAL CENTRIFUGALFILTER FILTER ENGINE MEMBERSIHKAN CLEANING Remove the right crankcase cover (page 10-5). Lepaskan right crankcase cover (hal. 10-5).

GASKET

BOLTS

Remove the bolts, oil centrifugal filter cover and gasket. Lepaskan bolts, oil centrifugal filter cover dan gasket.

OIL CENTRIFUGAL FILTER COVER

Bersihkan Clean the oil oilcentrifugal centrifugal filter filtercover cover dan and bagian inside dalam of the drivedrive plateplate usingdengan a clean menggunakan lint-free cloth. kain yang tidak dari mudah terurai.

gasket Pasang dengan yang Install a sebuah new gasket with baru its sealed side sisinya facing the oil tertutup menghadap ke oil centrifugal filter cover. centrifugal filter cover.

GASKET

4-11

PERAWATAN Oleskan cairanagent pengunci ulir oil centrifugal Apply locking to thepada oil centrifugal filter c overfilter bolt threads shown. cover boltasseperti diperlihatkan.

4.5 ± 1.0 mm (0.18 ± 0.04 in)

Install the centrifugal filter cover and bolts. oil oil centrifugal filter cover bolts. Pasang dan Tighten the bolts to the specified torque. Kencangkan bolts dengan torsi yang ditentukan. TORQUE:5 N·m (0.51 kgf·m, 3.7 lbf·ft) TORSI: 5 N.m (0,51 kgf.m; 3,7 lbf.ft) Install the right crankcase cover (page 10-8). Pasang right crankcase cover (hal. 10-8).

BOLTS

OIL CENTRIFUGAL FILTER COVER

ENGINE IDLE SPEED MESIN PUTARAN STASIONER CATATAN: the engine idle speed all Periksa and dan adjust setel putaran stasioner mesin after setelah • • Inspect other engine maintenance items have been persemua bagian perawatan mesin yang lain telah formed and are within specifications. dijalankan dan adalah sesuai dengan spesifikasi. • The engine must be warm for accurate engine idle Mesin inspection harus and dalam keadaan panas untuk • speed adjustment. -1 pemeriksaan danwith penyetelan putaran stasioner • Use a tachometer graduations of 50 min (rpm) yang akurat. or smaller that will accurately indicate a 50 min-1 (rpm) -1 change. Pakailah tachometer dengan skala 50 menit (rpm) • atau lebih kecil yang 10dapat memperlihatkan Warm up the engine for about minutes. -1 perubahan sebesar 50 menit (rpm) dengan akurat. Connect a tachometer according to the tachometer manufacturer’s operating instructions. Panaskan mesin selama kira2 10 menit. Check the engine idle speed. Hubungkan tachometer sesuai dengan petunjuk IDLE SPEED: 1,400 ± 100 min -1 (rpm) pemakaian pabrik tachometer. Turn the throttle stop screw as required to obtain the Periksa putaran mesin. specified enginestasioner idle speed.

PUTARAN STASIONER: 1.400

-1

100 menit (rpm)

Putaran stasioner mesin yang rendah dapat disebabkan oleh saluran udara yang tertahan atau idle air screw yang kotor. Untuk pemeriksaan idle air screw (hal. 6-15). Putar idle air screw sebanyak diperlukan untuk mendapatkan putaran stasioner mesin yang ditentukan.

4-12

THROTTLE STOP SCREW

PERAWATAN

SECONDARY AIR AIR SUPPLY SUPPLY SYSTEM SECONDARY Remove the main pipe side cover/main pipe cover (page (SISTEM PEMASOKAN UDARA SEKUNDER)

VACUUM HOSE

3-6). Lepaskan main pipe side cover/main pipe cover (hal. 3Check the air supply hose and pipe between the PAIR 6). control valve and exhaust port for cracks, deterioration, Periksa hose dan pipe antara PAIR contro damageair or supply loose connections. valve dan lubang pembuangan terhadap retak-retak, Check the vacuum hose between the PAIR control valve pemburukan kondisi, kerusakan atau hubungan longgar. and inlet pipe vacuum joint for cracks, deterioration, damage or loose connections. Periksa vacuum hose antara PAIR control valve dan inlet pipe vacuum joint terhadap keretakan, pemburukan kondisi, kerusakan atau hubungan longgar.

AIR SUPPLY HOSE/PIPE Check the air supply hoses for deterioration, damage or Periksa air supply hoses terhadap pemburukan kondisi, loose connections. kerusakan atau hubungan longgar. Also periksa check bahwa that hoses cracked, kusut kinked or Juga hoses are tidaknot retak-retak, atau pinched. terjepit. Pastikan bahwa tidak retak-retak. hoses Make sure that the hoses are not cracked. Lepaskan dan periksa air supply Remove and check the air supplyhoses. hoses. Jika ada endapan karbon pada air supply hoses, If therePAIR are check carbonvalve deposits in the air supply hoses, periksa (hal. 6-18). check the PAIR check valve (page 6-18).

AIR SUPPLY HOSES

DRIVE CHAIN DRIVE CHAIN (RANTAI RODA) CATATAN: Never inspect and adjust the drive chain while the engine is running. Jangan sekali-kali memeriksa dan menyetel drive chain sementara mesin dalam keadaan hidup.

DRIVE CHAIN SLACK INSPECTION

Support the motorcycle KEKENDURAN with its centerstand andDRIVE shift the PEMERIKSAAN transmission into neutral. CHAIN

Measure the drive chain slack, on the chain run midway between the sprockets. Letakkan sepedamotor pada standard utamanya dan CHAIN SLACK: 30 –ke 40dalam mm (1.2 – 1.6 in) masukkan transmissi netral. Ukur kekenduran drive chain, di tengah-tengah rantai antara sprockets. Excessive chain slack, 50 mm (2.0 in) or more, may damage KEKENDURAN RANTAI: 30 – 40 mm the frame.

PERHATIAN Kekenduran rantai yang berlebihan, 50 mm atau lebih, dapat merusak rangka.

30 – 40 mm (1.2 – 1.6 in)

4-13

PERAWATAN ADJUSTMENT PENYETELAN Longgarkan rear axle axle nut nut and dan both kedua lock nuts. Loosen the rear lock nuts. Turn kedua both drive the correct drive Putar drivechain chainadjusters adjustersuntil sampai kekenduran chain slack is obtained. drive chain yang benar telah diperoleh.

ADJUSTER

LOCK NUT

Pastikan bahwa adjuster plates Make sure the ujung front depan end of dari bothkedua adjuster plates are aligned withdengan the samegaris-garis index lines penunjuk on the swingarm. bertepatan yang sama pada swingarm.

AXLE NUT ADJUSTER PLATE

INDEX LINES

Kencangkan rearaxle axlenut nuttodengan torsi yang ditentukan. Tighten the rear the specified torque. TORSI: 59 N.m (6,0 kgf.m; TORQUE:59 N·m (6.0 kgf·m,44 44lbf.ft) lbf·ft)

LOCK NUT

Kencangkan kedua drive chain dan lock nut Tighten the both drive chain lockadjusters nuts securely. dengan erat. Recheck the drive chain slack and free wheel rotation. Check kembali the rearkekenduran brake pedaldrive freeplay 4-17) and Periksa chain (page dan kebebasan adjust it if necessary. perputaran roda.

Periksa jarak main bebas rear brake pedal (pedal rem belakang) (hal. 4-17) dan setel bila perlu.

AXLE NUT

CLEANING, LUBRICATION AND PEMBERSIHAN, PELUMASAN DAN INSPECTION PEMERIKSAAN Letakkan sepedamotor padaitsstandard utamanya Support the motorcycle with centerstand and shiftdan the transmission into neutral. masukkan transmissi ke dalam netral. If the drive chain becomes extremely dirty, it should be Jika drive and chain dalamprior keadaan sangat kotor, ia harus removed cleaned to lubrication. dilepaskan dan dibe rsihkan sebelum Remove the left crankcase rear coverdilumasi. (page 3-16).

RETAINING CLIP

MASTER LINK

Carefully remove the retaining clip with Lepaskan left crankcase rear cover (hal.pliers. 3-16). Remove the master link and link plate, and disconnect the drive chain. Lepaskan retaining clip dengan hati-hati dengan Remove the drive chain. menggunakan tang.

Lepaskan master link dan link plate, dan lepaskan sambungan drive chain. Lepaskan drive chain.

4-14

LINK PLATE RETAINING CLIP

PERAWATAN Bersihkan larutan pembersih tidak LARUTAN PEMBERSIH YANG TIDAK DAPAT Clean the chain chain dengan with non-flammable or high yang flash point solvent and wipe it dry. dapat terbakar atau mempunyai titik api tinggi dan seka Be sure the chain has dried completely before lubricat- TERBAKAR ATAU MEMPUNYAI TITIK API TINGGI sampai kering. ing. Pastikan bahwa chain telah mengering sama sekali Inspect the drive chain for possible damage or wear. sebelum melumasinya. Replace any chain that has damaged rollers, loose fitting BERSIHKAN Periksa chainappears terhadap kemungkinan kerusakan links, ordrive otherwise unserviceable. Installing a new chain on badly worn sprockets will cause atau keausan. the new chain to wear quickly. rollers (penggelinding) Ganti chain yang mempunyai Inspect and replace the sprocket as necessary. yang rusak, links yang longgar pemasangannya, atau selain itu tampaknya tidak dapat diservis lagi. Pemasangan sebuah chain baru pada sprockets yang SEKA DAN KERINGKAN sudah sangat aus akan mengakibatkan bahwa chain lekas menjadi aus. Periksa dan ganti sprocket bila perlu. Lubricate thechain drive dengan chain with or drive – 90 gear Lumasi drive oli #80 transmissi #80oil – 90 atau chain lubricant. Wipe off any excess oil or chain lubridrive chain lubricant (pelumas rantai roda). Sekalah oli cant.chain lubricant yang berlebihan. atau

Lumasi

#80 – 90 GEAR OIL ATAU DRIVE CHAIN LUBRICANT Measure distance between a span 41 pins (40 Ukur jarak the antara bentangan 41 pins (40 of links) dari titik links) from pin center to pin center by holding so that all pusat pin ke titik pusat pin dengan memegangnya links are straight. sehingga semua links dalam keadaan lurus. DRIVE CHAIN LENGTH (41 pins/40 links) PANJANG DRIVE CHAIN (41 pins/40 STANDARD: 508 mm (20.0 in) links) STANDARD: 508 mm SERVICE BATAS mm LIMIT:SERVIS: 518 mm518 (20.4 in)

BATAS SERVIS : 518 mm

PEMERIKSAAN SPROCKET SPROCKET INSPECTION Remove the crankcase rear cover (page 3-16). Lepaskan left left crankcase rear cover (hal. 3-16). Inspectgigi the drive drivesprocket and driven teeth forterhadap wear or Periksa dansprocket driven sprocket damage, replace them if necessary. keausan atau kerusakan, ganti bila perlu. Never use a new drive chain on worn sprockets. Both chain and sprockets mustdrive be in chain good condition, or Jangan sekali-kali memakai baru pada the new replacement chain will wear rapidly. sprockets yang aus. Baik chain dan sprockets harus dalam keadaan baik, atau chain pengganti yang baru akan menjadi cepat aus.

AUS

RUSAK

NORMAL

4-15

PERAWATAN Install the drive chain onto the sprockets. Pasang drive chain pada sprockets. Install the master and plate. Pasang master linklink dan linklink plate. Install the retaining with itsujungnya open endyang opposite the Pasang retaining clipclipdengan terbuka direction of chain travel. berlawanan dengan arah pergerakan rantai. Adjust the drive chain slack (page 4-14). Setel kekenduran drive chain (hal. 4-14).

RETAINING CLIP

MASTER LINK

LINK PLATE

BRAKE FLUID (MINYAK REM) BRAKE FLUID CATATAN

RETAINING CLIP

Minyak rem yang tertumpah dapat merusak parts yang dicat, atau terbuat dari plastik atauplastic karet. or Tutupilah Spilled fluid can damage painted, rubber parts parts. ini dengan kain lap setiap kali sistem diservis. Place a rag over these parts whenever the system is serviced. CATATAN: not mix different typesbermacam-macam of fluid, as they are not Jangan mencampurkan jenis • • Do compatible with each other. minyak rem, oleh karena mereka tidak cocok satu • Do not allow foreign material to enter the system sama lain. when filling the reservoir. Jangan sampai benda-benda asing memasuki • Turn the handlebar so that the reservoir is level and sistem ketika mengisi reservoir. check the front brake fluid level through the sight glass.

JENDELA PENGINTAIAN

Whenhandlebar the front brake fluid level ispada low, posisi check mendatar the brake Putar sampai reservoir pad wear (page 4-16). dan periksa tinggi permukaan minyak rem depan A low fluid levelpengintaian. may be due to wear of the brake pads. If melalui jendela the brake pads are worn the caliper pistons are pushed out, tinggi and this accounts for a low rem reservoir level. If the Jika permukaan minyak depan rendah, brake pads are not worn and the fluid level is low, check periksalah keausan brake pad (hal. 4-16). the entire system leaks (page 4-17).dapat diakibatkan Permukaan minyakforrem yang rendah

oleh keausan brake pads. Jika brake pads aus, caliper pistons terdorong keluar, dan ini menyebabkan tinggi permukaan yang rendah di dalam reservoir. Jika brake pads tidak aus dan tinggi permukaan minyak rem rendah, periksalah keseluruhan sistem terhadap kebocoran (hal. 4-16).

TANDA BATAS TERENDAH

BRAKE SHOES/PADS WEAR KEAUSAN FRONT BRAKE SHOES/PADS BRAKE PADS Check thePADS brake pads for wear. BRAKE DEPAN

Replace the brake pads if either pad is worn to the wear limit groove. Periksa brake pads terhadap keausan. Ganti brake pads apabila salah satu pad telah aus Always replace the For brake pad replacement (page 15-7). brake pads as a set to sampai ke alur batas keausan. assure even disc Selalu ganti brake pads Untuk penggantian brake pad (hal. 15-7). pressure. sebagai sebuah set untuk memastikan tekanan merata pada disc.

ALUR-ALUR BATAS KEAUSA

4-16

PERAWATAN REAR BRAKE SHOES BRAKE SHOES BELAKANG Check the wear wear indicator position when the brake pedal Periksa posisi indicator (indikator keausan) is applied. sewaktu b rake pedal ditekan. If the indicator plate aligns with the " tanda " mark the Jika indicator plate bertepatan dengan " Δ"on pada brakerem, panel, inspectbrake the brake (page rem) 14-14). panel periksa drumdrum (teromol (hal. 1414). If the brake drum I.D. is within the service limit, replace the brake shoes (page 14-14). Jika D.D. brake drum berada di bawah batas servis, gantilah b rake shoes (hal. 14-14).

TANDA" "

INDICATOR PLATE

SISTEM REM BRAKE SYSTEM PEMERIKSAAN REM HIDRAULIK HYDRAULIC BRAKE INSPECTION Tekan lever (handel rem)check dengan kuat Firmly brake apply the brake lever and that no air dan has enteredbahwa the system. periksa tidak ada udara yang telah memasuki sistem. If the lever feels soft or spongy when operated, bleed the

BRAKE HOSE

air from the system (page 15-5). Jika handel terasa lunak atau seperti sepons ketika Remove the handlebar frontpalsu coverdari (page 3-10).(hal. 15-5). dijalankan, buanglah udara sistem Inspect the brake hose and fittings for deterioration, Lepaskan handlebar front cover (hal. 3-10). cracks and signs of leakage. Tighten any loose fittings. Periksa (slang as rem) dan fittings (peralatan Replacebrake hoseshose and fittings required. pemasangan) terhadap pemburukan kondisi, keretakan dan tanda2 kebocoran. Kencangkan fittings yang longgar. Ganti hoses dan fittings bila perlu. BRAKE HOSE

JARAK MAIN BEBAS BRAKE PEDAL BRAKE PEDAL FREEPLAY Ukur jarak bebaspedal brake pedalat the (pedal Measure themain rear brake freeplay tip ofrem) the brake pedal. belakang pada ujung dari brake pedal. FREEPLAY: 20 – 30 mm (0.8 – 1.2 in) JARAK MAIN BEBAS: 20 – 30 mm

20 – 30 mm (0.8 – 1.2 in)

4-17

PERAWATAN Pastikan main bebas brake pedal dengan Make sure thebahwa cut-out Setel Adjustjarak the brake pedal freeplay by turning the memutar adjusting po tongan pada nut. nut. of the adjusting nut is adjusting adjusting nutthe dudu seated on joint Recheck the freeplay, then check and adjust the rear pada joint pin. Periksa kembali pin. brake light switchjarak (page main 4-18). bebas, kemudian periksa

dan s etel rear brake l ight switch (saklar belakang lampu rem) (hal. 4-18).

ADJUSTING NUT

JOINT PIN

BRAKE BRAKE LIGHT LIGHTSWITCH SWITCH (SAKLAR LAMPU REM) • The front brake light switch on the master cylinder CATATAN: cannot be adjusted. If the front brakecylinder light switch • Brake light switch depan pada master tidak actuation and brake engagement are not synchrodapat disetel. Jika penjalanan brake light switch nized, either replace the switch unit or the malfuncdepan parts dan pengenaan rem tidak sinkron, gantilah tioning of the system. switch unit atau parts yang tidak dengan • Adjust the rear brake light switch afterbekerja the brake pedal freeplay baik dariadjustment. sistem. •Check Setel rakebrake light belakang that bthe lightswitch comes on just priorsetelah to the penyetelan jarak main bebas brake pedal telah brake actually being engaged. If the light fails to come on, adjust the switch by turning the dilakukan. adjusting nut so that the light comes on at the proper time. Periksa bahwa lampu rem menyala tepat sebelum rem Recheck the brake light switch operation. sebenarnya mulai bekerja.

BRAKE LIGHT SWITCH

Hold the switch body and turnbadan the adjusting Tahan switch nut. dan putar adjusting Do not turn the switch nut. body while turning Jangan memutar the adjusting nut. Periksa kembali cara kerja brake light switch. badan switch sewaktu memutar adjusting nut.

PENYETELAN ARAH SINAR LAMPU HEADLIGHT AIM BESAR Letakkan sepedamotor pada tanah mendatar di

ADJUSTING NUT

Place the motorcycle on the level ground using the atas centerstand.utama. standard Adjust the headlight Adjust the headlight beam vertically by loosening the bolt Setel arah sinar Setel arah the sinar lampu unit, besar vertikal headlight thendalam tighten arah the bolt. beam specified by and moving lampuas besar seperti dengan melonggarkan bolt dan menggerakkan local lawsoleh and telah ditentukan regulations. headlight unit, kemudian kencangkan bolt. undang-undang dan peraturan lokal.

BOLT

4-18

PERAWATAN

CLUTCHSYSTEM SYSTEM (SISTEM KOPLING) CLUTCH Longgarkan adjuster lock lock nut nutand danturn putar Loosen the clutch adjuster the clutch clutch adjuster clockwise one full turn; do not turn excessively. adjuster searah jarum jam satu putaran penuh; jangan Slowly turn the adjuster counterclockwise until resistance memutar secara berlebihan. is felt. Dengan pelan putar adjuster berlawanan arah jarum From this point, turn the adjuster clockwise 1/8 turn, and Hold the adjuster am sampai terasa ada tahanan. tighten the lock nut to the specified torque. while tightening the

LOCK NUT

ADJUSTER

lock nut. Dari Tahan adjuster titik ini, putar searah jarum jam sebanyak TORQUE:12 N·m adjuster (1.2 kgf·m, 9 lbf·ft) sementara 1/8 putaran, dan kencangkan lock nut dengan torsi yang • Check for clutch operation after adjustment. mengencangkan lock ditentukan. nut.

TORSI: 12 N.m (1,2 kgf.m; 9 lbf.ft) •

Periksa cara kerja penyetelan selesai.

clutch

(kopling)

setelah

SIDESTAND (STANDARD SAMPING) Support the motorcyclepada with its centerstand. Letakkan sepedamotor standard utamanya. Check the sidestand springs for damage or loss of atau tenPeriksa pegas sidestand terhadap kerusakan sion. kehilangan Check the tegangan. sidestand assembly for freedom of movement Periksa sidestand assembly (susunan standard and lubricate the sidestand pivot if necessary. samping) terhadap kebebasan pergerakan dan lumasi sidestand pivot (engsel standard samping) bila perlu.

SIDESTAND

SUSPENSI SUSPENSION PEMERIKSAAN SUSPENSI DEPAN FRONT SUSPENSION INSPECTION Periksa cara kerja (garpu) denganthe menarik rem Check the action of forks the forks by operating front brake and compressing the front suspension times. depan dan menekan suspensi depan several beberapa kali ke Check the entire assembly for signs of leaks, damage or bawah. loose fasteners. Periksa keseluruhan susunan terhadap tanda-tanda Replace damaged components which cannot be Loose, worn or kebocoran, kerusakan atau pengikat longgar. damaged suspension repaired. parts impair Tighten all nuts and bolts. komponen2 yang rusak yang tidak dapat Parts suspensi yang Gantilah motorcycle stability longgar, aus atau rusak diperbaiki. For fork service (page 13-11).

SUSPENSI DEPAN:

and control. mempengaruhi stabilitas dan Kencangkan semua nuts dan bolts. pengendalian atas sepedamotor. Untuk menservis fork (hal. 13-11).

4-19

PERAWATAN REAR SUSPENSION INSPECTION PEMERIKSAAN SUSPENSI BELAKANG Periksa cara kerjaof shock absorbers (peredam Check the action the rear shock absorbers by kejut) combelakang menekannya pressing dengan them several times. beberapa kali ke bawah. SUSPENSI BELAKANG: Check the entire shock absorber assembly forterhadap signs of Periksa keseluruhan susunan shock absorber leaks, damage or loose fasteners. tanda-tanda kebocoran, kerusakan atau pengikat yang Tighten all nuts and bolts. longgar. For rear shock absorber (page 14-22). Kencangkan semua nuts service dan bolts. Untuk menservis shock absorber belakang (hal. 14-22).

Letakkan sepedamotor standard utamanya. Support the motorcyclepada with its centerstand. Check for worn swingarm by(bos grabbing theayun) rear Periksa terhadap swingarmbushings bushings lengan ends of the swingarm and attempting to move the swingyang aus dengan memegang ujung-ujung belakang dari arm side to side. swingarm dan mencoba untuk menggerakkan swingarm Replace dari sisi kethe sisi.swingarm bushings if any looseness is noted (page 14-17). Gantilah swingarm bushings jika ada kelonggaran (hal. 14-17).

SWINGARM BUSHINGS:

NUTS, BOLTS, FASTENERS (MUR, BAUT, PENGIKAT)

NUTS, BOLTS, FASTENERS Periksa bahwa semua nuts dan bolts dari rangka telah dikencangkan dengan torsi pengencangan mereka yang Check that all chassis nuts and bolts are tightened to benar (hal. 1-10). their correct torque values (page 1-9). Periksa bahwa semua cotter pins, safety clips, hose Check that all cotter pins, safety clips, hose clamps and clamps dan are cable stays and adaproperly pada tempatnya cable stays in place secured. dan telah dipasang dengan erat.

WHEELS/TIRES RODA/BAN Support the motorcycledengan securelykokoh and raise front Letakkan sepedamotor pada the standard wheel off the utamanya danground. naikkan roda depan lepas tanah. Hold the fork leg and move the front wheel sideways with force tofork seeleg if the wheel bearings worn. roda depan Tahan (kaki garpu) dan are gerakkan dengan kuat ke samping untuk melihat apakah wheel bearings (bantalan roda) adalah aus.

4-20

FRONT WHEEL BEARINGS:

PERAWATAN Periksa terhadap wheelbearings bearings roda) yang Check for worn wheel by(bantalan holding the swingarm and dengan move themenahan rear wheelswingarm sideways. dan menggerakkan aus roda belakang ke samping. Replace the wheel bearings if any looseness is noted (page 14-9). Ganti wheel bearings jika ada kelonggaran (hal. 14-9).

REAR WHEEL BEARINGS:

Periksa udara ban tire pressure Check tekanan the tire pressure withdengan a tire pressure gaugegauge when the tires are cold. (alat pengukur tekanan udara ban) sewaktu ban dalam keadaan dingin. RECOMMENDED TIRE PRESSURE AND SIZE: 2 Unit: kPaBAN (kgf/cm , psi) TEKANAN UDARA DAN UKURAN YANG FRONT REAR DIANJURKAN: 2 Cold tire pressure Satuan: kPa (kgf/cm ; psi) Driver only: 200 (2.00, 29)BELAKANG 225 (2.25, 33) DEPAN Driver and Passenger: 200 (2.00, 29) 225 (2.25, 33) Tekanan udara Tire dingin size 80/90-17 ban 20070/90-17 (2,00; 29) 225 (2,25; 33) M/C 38P M/C 44P Pengendara saja: Tire brand IRC: NF63B IRC: NR78Y Pengendara dan 200 (2,00; 29) 225 (2,25; 33) pembonceng: Ukuran ban 70/90-17 80/90-17 M/C 38P M/C 43P Merek ban DUNLOP: DUNLOP: Check the tires for cuts, embedded nails, or other damD104FAJ D104G age. IRC: NF55for trueness. IRC: NR70Z Check the front and rear wheels

Measure the depth at thesayatan, center of the tires. yang Periksa bantreadterhadap paku Replace the tires when the tread depth reaches the foltertancap,atau kerusakan lain. lowing limits. Periksa roda depan dan belakang apakah segaris. MINIMUM TIRE TREAD Ukur kedalaman alur ban pada bagian tengah ban. DEPTH: To indicator Ganti ban jika kedalaman alur ban mencapai batasbatas berikut ini:

KEDALAMAN ALUR BAN MINIMUM: Sampai ke indikator

STEERING HEAD BEARINGS STEERING KEPALA HEAD BEARINGS (BANTALAN KEMUDI) Support the motorcycledengan securely and dan raise the roda front Dukunglah sepedamotor kokoh angkat wheel off the ground. depan lepas tanah. Check that the handlebar moves freely from side to side. Make sure the handlebar control cables do notdengan interferebebas with hanPeriksa bahwa bergerak dari dlebarkerotation. ujung ujung. Pastikan bahwa control cables (kabelkabel pengaturan) tidak mengganggu perputaran handlebar.

4-21

PERAWATAN Periksa stem bearings (bantalan poros kemudi) Check steering for steering stem bearings by grabbing the fork legs andmemegang attempting to move front fork garpu) forward dan and dengan fork legsthe(kaki-kaki backward. mencoba untuk menggerakkan front fork (garpu depan) dari sisihandlebar ke sisi. moves unevenly, binds, or has vertical If the movement, inspect the steering head bearings (page 13Jika 22).handlebar bergerak secara tidak merata, mengikat, atau ada pergerakan vertikal, periksa steering head bearings (hal. 13-21).

4-22

STEERING STEM

5. SISTEM PELUMASAN

5

DIAGRAM SISTEM PELUMASAN.............. LUBRICATION SYSTEM DIAGRAM···········5-2 5-2

TROUBLESHOOTING ........................ 5-3 TROUBLESHOOTING ····································5-3

KETERANGAN SERVIS ............................. SERVICE INFORMATION ·····························5-3 5-3

OILPUMP··························································5-4 PUMP ........................................... 5-4 OIL

5-1

SISTEM PELUMASAN

LUBRICATION SYSTEM DIAGRAM DIAGRAM SISTEM PELUMASAN LUBRICATIONSYSTEM

CAMSHAFT

PISTON

OIL PUMP

CRANKSHAFT

MAINSHAFT OIL CENTRIFUGAL FILTER

COUNTERSHAFT

OIL STRAINER SCREEN

5-2

SISTEM PELUMASAN

SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM ! 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 bekastosetiap hari, wash tetap your dianjurkan secara mencuci unless you handle usedkecuali oil on ajika daily basis, it is still advisable thoroughly hands untuk with soap andmenyeluruh water as soon as tangan dengan sabun dan air sesegera mungkin setelah menangani oli bekas. possible after handling used oil. Babsection ini meliputi servis dariofoilthe pump (pompa oli). This covers service oil pump. The pump can diservis be serviced with mesin the engine installed in the frame. Oil oil pump dapat dengan terpasang pada rangka. The service procedures in this sectionbab must performed with dengan the engine oil drained. Prosedur-prosedur servis di dalam inibe harus dijalankan oli mesin dikeluarkan. When removing and installing the oil pump, use care not to allow dust or dirt to enter the engine. melepaskan dan memasang oil pump, berhati-hatilah atauthe kotoran tidak mesin. If Sewaktu any portion of the oil pump is worn beyond the specified service agar limits,debu replace oil pump asmemasuki an assembly. Jikathe ada dari oil installed, pump yang austhat melampaui batas servis yang ditentukan, gantilah oil pump sebagai sebuah After oil bagian pump has been check there are no oil leaks. susunan. Setelah oil pump telah dipasang, periksa bahwa tidak ada kebocoran oli.

• • • • • •

• • • • •

•

SPECIFICATIONS SPESIFIKASI

ITEM

BAGIAN Engine oil capacity Kapasitas oli mesin Recommended engine oil Oli mesin yang dianjurkan

Oil pump rotor Oil pump rotor

At draining Pada penggantian periodik At disassembly Pada pembongkaran mesin

Jarak renggang pada ujung Tip clearance rotor Body clearance Jarak renggang antara rotor dan rumah Side clearance Jarak renggang ke samping rotor pompa

TORQUE VALUE TORSI PENGENCANGAN Oil pump cover screw Oil pump cover screw

Unit: mm (in) SERVICE Satuan: mm LIMIT BATAS SERVIS – – -

STANDARD STANDARD 0.8 liter (0.8 US qt, 0.7 lmp qt) 0,8 liter 1.0 liter (1.1 US qt, 0.9 lmp qt) 1,0 liter API classification: SE, SF or SG Oli mesin tak dengan klasifikasi API (except4oils labeled as energy conserving service SJ, on the circular API service label) Viskositas: SAE 10W-30 JASO MA Viscosity: SAE 10W-30 JASO T 903 standard: MA 0,15 – 0,150.15 – – 0,21 0.21 (0.006 – 0.008) 0,26 0.03 – 0.09 (0.001 – 0.004) 0,03 – 0,09 0,15

– 0.15 (0.006) 0.26 (0.010) 0.15 (0.006)

5 N·m (0.51 kgf ·m, 3.7 lbf ·ft) 5 N.m (0,51 kgf.m; 3,7 lbf.ft)

TROUBLESHOOTING TROUBLESHOOTING Engine oil level too low permukaan oli terlalu rendah •Tinggi Oil consumption Konsumsi oli • External oil leak rings oli • Worn (page 9-7) Ada piston kebocoran di luar installed piston rings (page 9-9) • Improperly Piston rings aus (hal. 9-7) valve guide or stem seal • Worn (page 8-14) Piston rings tidak dipasang dengan benar (hal. 9-9) • Worn cylinder (page 9-6) Valve guide atau stem seal aus (hal. 8-14) Oil contamination Cylinder aus (hal. 9-6) • Worn piston rings (page 9-7) • Improperly installed piston rings (page 9-9) Worn valve oli guide or stem seal (page 8-14) •Kontaminasi Piston rings aus (hal. 9-7)enough • Oil not changed frequently Piston rings tidak dengan screen (page • Clogged oil strainer dipasang 4-11)benar (hal. 9-9) Valve guide atau stem seal aus (hal. 8-14) Oli jarang diganti Oil strainer screen tersumbat (hal. 4-10) • • • • • •

• • • • •

5-3

SISTEM PELUMASAN

OIL OILPUMP PUMP(POMPA OLI) PELEPASAN REMOVAL Keluarkan oli mesin Drain the engine oil (hal. (page4-10). 4-10).

OIL PUMP

Remove the following: Lepaskan sebagai berikut: Right crankcase cover(hal. (page 10-5) - – Right crankcase cover 10-5) – Three bolts - Tiga bolts – Oil pump - Oil pump

BOLTS

Lepaskan gasket darifrom oil pump. Remove the gasket the oil pump. GASKET

OIL PUMP

DISASSEMBLY/ASSEMBLY PEMBONGKARAN/PERAKITAN OIL PUMP BODY

OIL PUMP SHAFT SCREWS 5 N·m (0.51 kgf ·m, 3.7 lbf ·ft)

OUTER ROTOR

OIL PUMP COVER

5-4

INNER ROTOR

SISTEM PELUMASAN Semprotkan permukaan inner rotor dan Apply engineolioilpada to the inner rotorluncur and outer rotor sl iding outer rotor . surfaces. Install the inner and outer rotors to the oil pump body. Pasang inner rotor shaft dan aligning outer rotor pada rumah oi Install the oil pump the flat surfaces of the pump. oil pump shaft and the inner rotor. Pasang oil pump shaft dengan mentepatkan permukaan-permukaan mendatar dari oil pump shaft dan inner rotor.

INNER ROTOR

OIL PUMP SHAFT

Tepatkan

OUTER ROTOR

Pasang oil oil pump cover. Install the pump cover. Install and the three screws to dengan the specified Pasang dan tighten kencangkan ketiga screws torsi torque. yang ditentukan. TORQUE: 5 N·m (0.51 kgf·m, 3.7 lbf·ft) TORSI: 5 N.m (0,51 kgf.m; 3,7 lbf.ft) Install the oil pump (page 5-6). Pasang oil pump (hal. 5-6).

SCREWS

OIL PUMP COVER

PEMERIKSAAN INSPECTION Jika Ifada dari oil anybagian portion of the pump yang aus oil pump is worn melampaui batas servis, beyond the service gantilah oil pump limit, replace the oil sebagai sebuah pump as an assembly. assembly.

Disassemble the oil pump Bongkar oil pump (hal. 5-4).(page 5-4). Temporarily installpasang the outer androtor innerdan rotors into the ke oil Untuk sementara outer inner rotor pump body. dalam rumah oil pump. Install the pump shaft. Pasang oil oil pump shaft. Measure the tip clearance between the inner and outer rotors. Ukur jarak renggang antara pada ujung rotor antara inner rotor dan outer0.15 rotor. SERVICE LIMIT: mm (0.006 in)

TIP CLEARANCE:

BATAS SERVIS: 0,15 mm

Ukur jarakthe renggang antara outer rotor dan rumah oi Measure pump body clearance between the outer rotor and the oil pump body. pump.

BODY CLEARANCE:

SERVICE LIMIT: 0.26 mm (0.010 in) BATAS SERVIS: 0,26 mm

5-5

SISTEM PELUMASAN Ukur jarakthe renggang ke samping menggunakan Measure side clearance usingdengan a straight edge and a feeler lurus gauge. mistar dan sebuah feeler gauge.

SIDE CLEARANCE:

SERVICE LIMIT: 0.15 mm (0.006 in) BATAS SERVIS: 0,15 mm Assemble the oil pump Rakit oil pump (hal. 5-4).(page 5-4).

PEMASANGAN INSTALLATION Pasang gasket pada oil oil pump. Install the new baru gasket to the pump. Install the oil pump the crankcase aligning the oil Pasang oil pump padatocrankcase dengan mentepatkan pump shaft groove with the cam chain guide sprocket alur oil pump shaft dengan cam chain guide sprocket spindle. spindle.

Tepatkan

GASKET

OIL PUMP Install and the three bolts. Pasang dantighten kencangkan ketiga bolts. Clean the oil oil strainer strainer screen screen (page 4-11). Bersihkan (hal. 4-11).

OIL PUMP

Install the right crankcase cover (page 10-8) Pasang right crankcase cover (hal. 10-8). After installation, fill the crankcase with recommended Setelah pemasangan, isilah crankcase dengan oli mesin engine oil (page 4-10). yang dianjurkan (hal. 4-10) dan periksa bahwa tidak ada Start the engine kebocoran oli. and check that there are no oil leaks.

BOLTS

5-6

6. SISTEM BAHAN BAKAR

6

KOMPONEN-KOMPONEN SISTEM ........ 6-2 COMPONENT LOCATION ····························6-2

PENYETELAN AIR SCREW ..................6-15 AIR SCREW ADJUSTMENT ························ 6-15

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

FUELTANK TANK ...........................................6-16 FUEL ····················································6-16

TROUBLESHOOTING ............................. 6-4 TROUBLESHOOTING ····································6-4

FUELFILTER FILTER ......................................... 6-17 FUEL ················································· 6-17

AIR HOUSING ....................... 6-5 AIR CLEANER CLEANER HOUSING······························6-5

FUELSTRAINER STRAINER SCREEN ................... 6-17 FUEL SCREEN ··························6-17

PELEPASAN CARBURETOR ................. 6-5 CARBURETOR REMOVAL ··························· 6-5

SECONDARY AIR SUPPLY SYSTEM...6-18 SECONDARY AIR SUPPLY SYSTEM ········6-18

PEMBONGKARAN/PEMERIKSAAN CARBURETOR DISASSEMBLY/

SEPARATE AIR FILTER ······························6-20

SEPARATE AIR FILTER .......................6-20

CARBURETOR ........................................ 6-7 INSPECTION ························· ························· ··· 6-7 AIR SUPPLY PIPE.................................6-20

AIR SUPPLY PIPE··········································6-20

PERAKITAN CARBURETOR .................. 6-10 CARBURETOR ASSEMBLY ························ 6-10 INLET PIPE ............................................6-21

PEMASANGAN CARBURETOR ............. 6-13 CARBURETOR INSTALLATION················ 6-13

INLET PIPE ·····················································6-21

6-1

SISTEM BAHAN BAKAR

COMPONENT LOCATION SISTEM KOMPONEN-KOMPONEN FUELSYSTEM

12 N·m (1.2 kgf ·m, 9 lbf ·ft)

6-2

SISTEM BAHAN BAKAR

KETERANGAN SERVIS SERVICE INFORMATION GENERAL UMUM • Bending or twisting the throttle cable will impair smooth operation and could cause the cable to stick or bind, resulting in loss of vehicle conMenekuk atau memilin throttle cable (kabel gas) akan mengganggu kelancaran cara kerjanya dan dapat menimbulkan • trol. kemacetan pengikatan pada cable, sehingga mengakibatkan kehilangan atas • Work in a wellatau ventilated area. Smoking or allowing flames or sparks in the work area pengendalian or where gasoline is kendaraan. stored can cause a fire or explo• sion. Bekerjalah di tempat dengan ventilasi baik. Merokok atau memperbolehkan adanya api atau percikan bunga api di tempat atau di tempat di mana bensin dapat kebakaran atau • If kerja the vehicle is to be stored for more than disimpan one month, drainmenyebabkan the float chamber. Fuel left in the ledakan. float chamber may cause clogged jets, resulting akan disimpan selama lebih dari satu bulan, kosongkan float chamber (ruang pelampung). Bahan bakar yang • inJika hard kendaraan starting or poor driveability. tertinggal di dalamthe float chamberplace dapat tersumbatnya jets, sehingga mesin atauthe sepedamotor • Before disassembling carburetor, an mengakibatkan approved fuel container under the carburetor, loosen the sulit draindihidupkan screw and drain carburetor. sulit disassembling dikendalikan.the fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly. • When Sebelum membongkar karburator, di bawah karburator, longgarkan drain screw •• After removing the carburetor, wrap the letakkan intake portpenampung of the engineyang with sesuai a shop towel or cover it with a piece of tape to prevent any (sekrup foreign pembuangan) dan kosongkan karburator. material from dropping into the engine. Be sure to remove the cover when reinstalling the carburetor. Sewaktu membongkar parts sistem bahan bakar, catatlah lokasi dari O-rings. Gantilah dengan yang baru pada waktu • perakitan kembali. Setelah melepaskan karburator, bungkuslah intake port (lubang pemasukan) dari mesin dengan kain lap atau tutuplah dengan • SPECIFICATIONS pita perekat untuk mencegah masuknya benda asing ke dalam mesin. Jangan lupa melepaskan penutup pada waktu ITEM SPECIFICATIONS pemasangan kembali karburator. Carburetor identification number PB7UA Engine idle speed 1,400 ± 100 min-1 (rpm) SPESIFIKASI Throttle grip freeplay 2 – 6 mm (0.1 – 0.2 in) BAGIAN SPESIFIKASI Main jet #88 Nomor identifikasi karburator PB7UA -1 Slow jet stasioner mesin #35 Putaran 1.400 ± 100 menit (rpm) Float level 11.7 mm (0.46 in) Jarak main bebas throttle grip 2 – 6 mm Air screw initial opening See page 6-15 Main jet # 88 PAIR control valve specified vacuum 60 kPa (450 mmHg) Slow jet # 35 Float level (tinggi pelampung) 11,7 mm PembukaanVALUE awal air screw TORQUE

Lihat halaman 6-15 60 kPa (450 mmHg)

Vakuum PAIR control valve yang ditentukan Inlet pipe band screw – Fuel valve screw 0.88 N·m (0.090 kgf·m, 0.65 lbf·ft) Air cut-off valve screw 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft) TORSI PENGENCANGAN Slow jet 1.5 N·m (0.15 kgf·m, 1.1 lbf·ft) Inlet Mainpipe jet band screw 1.5 N·m (0.15 kgf·m, 1.1 lbf·ft) Fuel valve screw 0,88 N.m (0,090 kgf.m; Needle jet holder 2.5 N·m (0.25 kgf·m, 1.8 0,64 lbf·ft)lbf.ft) Air cu t-off val ve scre w 2,1 N.m (0,20 kgf .m; 1,5 lbf.ft) Float chamber screw 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft) Slow jet 1,5 N.m (0,20 kgf.m; 1,1 lbf.ft) Float chamber drain screw 1.5 N·m (0.15 kgf·m, 1.1 lbf·ft) Main jet 1,5 N.m (0,20 kgf.m; 1,1 lbf.ft) Fuel strainer cup 5.9 N·m (0.60 Needle jet holder 2,5 N.m (0,30 kgf·m, kgf.m;4.4 1,8lbf·ft) lbf.ft) Throttle cable holder screw 3.4 N.m N·m (0.35 Float chamber screw 2,1 (0,20 kgf·m, kgf.m;2.5 1,5lbf·ft) lbf.ft) Fuel valve lever drain screwscrew 2.1 N.m N·m (0.21 Float chamber 1,5 (0,20 kgf·m, kgf.m;1.5 1,5lbf·ft) lbf.ft) Inlet pipe mounting 12 N·m Fuel strainer cup bolt 5,9 N.m (1.2 (0,6kgf·m, kgf.m;94lbf·ft) lbf.ft) Throttle cable holder screw 3,4 N.m (0,35 kgf.m; 2,5 lbf.ft) PAIR check valve cover screw 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft) Fuel valve lever screw 2,1 N.m (0,20 kgf.m; 1,5 lbf.ft) Inlet pipe mounting bolt 12 N.m (1,2 kgf.m; 9 lbf.ft) PAIR check valve cover screw 2,1 N.m (),20 kgf.m; 1,5 lbf.ft)

See page 6-13

Lihat hal. 6-13

TBD

TO TOOL OL

Carburetor float level gauge 07401-0010000

6-3

SISTEM BAHAN BAKAR

TROUBLESHOOTING TROUBLESHOOTING Engine won’t start Mesin tidak mau hidup • Too much fuel getting to the engine banyak bahan bakar yang masu k ke dalam mesin • –Terlalu Air cleaner clogged Air cleaner tersumbat – Flooded carburetor • Intake air leak banjir - Karburator • Fuel contaminated/deteriorated Ada kebocora n udara masuk • • No fuel to carburetor Bahan bakar terkontaminasi/memburuk kondisinya • – Fuel filter clogged bakar tidak sampai ke karburator • –Bahan Fuel strainer clogged Fueltank filtercap tersumbat –- Fuel breather hole clogged –- Fuel clogged/bent Fuelline strainer tersumbat –- No fuel tank Luba nginpernapasan fuel tank cap tersumbat Saluran bahan bakar tersumbat/tertekuk Lean mixture Fuel tank kosong • Fuel jets clogged • Float valvetidak faulty - Choke bekerja dengan baik • Float level too low - Throttle tidak bekerja dengan baik • Fuel line ada restricted - Tidak pe rcikan bunga api pada busi (sistem pengapian tidak bekerja dengan baik) • Carburetor air vent hose clogged • Intake air leak Campuran baka r terlalu miskin • Throttle bahan valve faulty Fuel jets tersumbat • Rich mixture Float valvechoke tidak stuck bekerja dengan baik • • Carburetor Floatvalve level faulty terlalu rendah • • Float levelbahan too high Saluran bakar terbatasi • • Float • Air jets clogged Carbu retor air vent hose tersumbat • • Air cleaner element contaminated Ada kebocoran udara masuk • • Flooded carburetor Throttle valve tidak bekerja dengan baik • Engine stall, hard to start, rough idling • Fuel line restricted Campuran bahan baka r terlalu kaya • Ignition system malfunction Carburetor macet • • Fuel mixture choke too lean/rich Floatcontaminated/deteriorated valve tidak bekerja dengan baik • • Fuel air leak Float level terlalu tinggi • • Intake • Idle speed misadjusted Air jets tersumbat • • Air screw misadjusted Air cleaner element terkontaminasi • • Slow circuit clogged Karburator banjir • • Improper choke operation • Low cylinder compression • Air berhenti cleaner clogged Mesin mendadak, sulit d ihidupkan, putaran stas ioner kasar Saluran bahan bakar terbatasi •Afterburn when engine braking is used mixture in slowrusak circuit Sistem pengapian • • Lean • Faulty pulsebahan secondary airterlalu injection (PAIR) system Campuran bakar miskin/kaya • – Faulty PAIR control valve bakar terkontaminasi/kondisinya memburuk • –Bahan Clogged hose of the PAIR system Ada kebocora n udara masuk • • Ignition system malfunction air cut-off penyetelan valve Ada kesalahan putaran stasioner • • Faulty Ada kesalahan penyetelan air screw • Backfiring or misfiring during acceleration Rangkaian pelan tersumbat • • Ignition system malfunction mixture lean dengan baik Choke tidaktoo bekerja • • Fuel kompressi cylinderand rendah •PoorTekanan performance (driveability) poor fuel economy Air cleaner tersumbat • • Fuel system clogged • Ignition system malfunction • Air cleaner clogged Afterburn ketika engine brak ing dipakai Campuran bahan bakar terlalu miskin pada slow circuit (rangkaian pelan) • Pulse secondary air injection (PAIR) system tidak bekerja dengan baik • - PAIR control valve tidak bekerja dengan baik - Hose dari PAIR system tersumbat Kerusakan pada sistem pengapian • Air cut-off valve tidak bekerja dengan baik •

Backfiring atau misfiring selama akselerasi Sistem pengapian rusak • Campuran bahan bakar terlalu miskin • Unjuk kerja (kemampuan berkendaraan) lema h dan pemakaian bahan bakar boros Sistem bahan bakar tersumbat • Sistem pengapian rusak • Air cleaner tersumbat •

6-4

SISTEM BAHAN BAKAR

AIR AIR CLEANER CLEANER HOUSING HOUSING PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Remove the main cover/main cover (page Lepaskan main pipepipe sideside cover/main pipepipe cover (hal. AIR VENT HOSE 3-6). 3-6). Lepaskan air the ventair hose dan crankcase breather breather hose. Disconnect vent hose and crankcase Lepaskan bolt. hose. Remove the bolt.

BOLT

CRANKCASE BREATHER HOSE Loosen the connecting hose Longgarkan hose band band screw. screw. Remove the bolt and air cleaner housing assembly. Lepaskan bolts cleaner housing assembly. Installation is indan the air reverse order of removal. Tighten the connecting hose band screw Pemasangan so that the gap pelepasan. between the band ends is 5 mm (0.2 in).

adalah

dalam

urutan

terbalik

BOLT

AIR CLEANER HOUSING

dari 5 mm (0.2 in.)

SCREW

PELEPASAN KARBURATOR CARBURETOR REMOVAL THROTTLE VALVE THROTTLE VALVE Lepaskan right lower side cover (hal. 3-5). Remove the right lower side cover (page 3-5). Lepaskan carburetor top dan throttle valve dari Remove the carburetor top and throttle valve from the karburator. carburetor.

Lepaskan throttle cable dari throttle valve valve sementara Remove the throttle cable from the throttle while compressing the valve throttle valve spring. menekan throttle spring.

CARBURETOR TOP

THROTTLE CABLE

SPRING

THROTTLE VALVE

6-5

SISTEM BAHAN BAKAR Lepaskan retainer, jetneedle needle sementara Remove the retainer,spring spring dan and jet while pushing the retainer retainer with a sedikit screwdriver slightly and kemudian turning it mendorong dengan obeng, counterclockwise. putar berlawanan arah jarum jam. Check the throttle valve and jet needle for scratches, wear or throttle damage. Periksa valve dan jet n eedle terhadap goresan, keausan atau kerusakan. Replace them if necessary.

THROTTLE VALVE

SCREW DRIVER

Ganti mereka bila perlu. JET NEEDLE SPRING RETAINER

BADAN KARBURATOR CARBURETOR BODY Remove the lower side cover (page 3-5). Lepaskan left left lower side cover (hal. 3-5). Turn fuel the fuel valve "OFF". Putar valve ke 'OFF'. Place a suitable container under the carburetor drain Letakkan yang di bawah carbureto hose andpenampung drain fuel from thesesuai carburetor by loosening the drain hose (slang pembuangan karburator) dan drain screw. keluarkan bahan bakar dari karburator dengan Tighten the float chamber drain screw. melonggarkan drain screw (sekrup pembuangan). TORQUE:1.5 N·m (0.15 kgf·m, 1.1 lbf·ft) Kencangkan float chamber drain screw (sekrup pembuangan ruang pelampung) .

DRAIN SCREW

Jepit dengan fuel clamp. Pinch thehose fuel hose withhose the hose clamp. Disconnect the following: Lepaskan sebagai berikut: – Fuel hose - Fuel hose – Drain hose - –Drain hosehose Air vent - Air vent hose

SCREWDRIVER AIR VENT HOSE

CLAMP

DRAIN HOSE

FUEL HOSE

Longgarkan connecting hose hose band band screw. screw. Loosen the air cleaner connecting Remove the carburetor mountingbolts, bolts,insulator, insulator,O-rings O-rings Lepaskan carburetor mounting and carburetor from the inlet pipe. dan carburetor dari inlet pipe.

BOLTS

CARBURETOR

SCREW INSULATOR/O-RINGS

6-6

SISTEM BAHAN BAKAR Lepaskan choke cable dari clamp dan lepaskan choke Release the choke cable from the clamp and disconnect cable. the choke cable.

CHOKE CABLE

CLAMP

CARBURETOR DISASSEMBLY/ PEMBONGKARAN/PEMERIKSAAN INSPECTION KARBURATOR FUEL VALVE FUEL VALVE Remove the screws, fuel valve and O-ring. Lepaskan screws, fuel valve dan O-ring.

FUEL VALVE

SCREWS

O-RING

AIR CUT-OFF VALVE AIR CUT-OFF VALVE Lepaskan screws danand air air cut-off valve cover. Remove the screws cut-off valve cover. SCREWS

AIR CUT-OFF VALVE COVER

Lepaskan spring, diaphragm dan O-ring. Remove the spring, diaphragm and O-ring.

O-RING

SPRING

DIAPHRAGM

6-7

SISTEM BAHAN BAKAR Periksa sebagai berikut: Check the following: Diaphragm for pin holes, deterioration orpemburukan damage - –Diaphragm terhadap lubang-lubang kecil, –kondisi Springatau for deterioration kerusakan. – Needle of diaphragm for wear - Spring terhadap pemburukan kondisi – Air passages for clogging - Needle dari diaphragm terhadap keausan - Jalan lintasan udara terhadap penyumbatan.

SPRING

AIR PASSAGES

NEEDLE

AIR CUT-OFF VALVE DIAPHRAGM

FLOAT CHAMBER FLOAT CHAMBER Remove the screws float chamber. Lepaskan screws danand float chamber. Remove the O-ring from the float chamber. Lepaskan O-ring dari float chamber.

FLOAT CHAMBER

O-RING

SCREWS

Check the the float valve. Periksa caraoperation kerja darioffloat valve. Lepaskan float pinpin danand float. Remove the float float. Periksa float terhadap perubahan bentuk Inspect the float for deformation or damage. kerusakan.

FLOAT VALVE

atau

FLOAT

6-8

FLOAT PIN

SISTEM BAHAN BAKAR Lepaskan float valve. Remove the float valve. Inspect the float valve seatvalve for scratches, clogging and Periksa dudukan float terhadap goresan, damage. penyumbatan dan kerusakan. Check the tip of the float valve where it contacts the valve seat for stepped wear or contamination. Periksa ujung dari float valve di mana ia mengkontak Check thevalve float valve operation by pushing its end pin. dudukan terhadap keausan bertingkat atau The pin should return smoothly. kontaminasi.

FLOAT VALVE

Replace the valve if the tip is worn or contaminated. Periksa cara kerja float valve dengan menekan pin pada ujungnya. Pin harus kembali dengan lancar.

Ganti valve jika ujungnya aus atau terkontaminasi.

Pemeriksaan Float valve tip:

Normal:

Aus:

Pemeriksaan cara kerja:

PIN

Kembali dengan lancar: Remove the following: Lepaskan se bagai berikut: Main - –Main jetjet – Needle jet holder - –Need le jetjet holder Needle - –Need le jet Slow jet - –Slow jet stop screw/spring Throttle - Turn Throttle stop screw/spring the air screw in and record the number of turns until Damage to the air it seats lightly. screw seat will occur Tangani semua jetsnumber dengan Mereka dapat Make a note of the to hati-hati. use as a reference whenif the air screw is reinstalling the air screw. mudah tergerus atau tergores. tightened against the Remove the air screw, spring, washer and O-rings. Handle all jets with care. They can easily be scored or scratched.

seat.

Inspect jet for or damage andjumlah replaceputaran them if Putar aireach screw ke wear dalam dan catat necessary. sampai ia duduk dengan ringan. Catatlah angka ini untuk dipakai sebagai referensi ketika memasang kembali air screw. Lepaskan screw, washer daninO-rings. Blow openaireach air spring, and fuel passage the carburetor body with compressed air. Periksa masing-masing jet terhadap keausan atau kerusakan dan ganti mereka bila perlu.

NEEDLE JET HOLDER

Macet: MAIN JET SLOW JET

NEEDLE JET

THROTTLE STOP SCREW/SPRING AIR SCREW/SPRING/WASHER/O-RINGS

Tiuplah terbuka setiap jalan lintasan udara dan bahan bakar di dalam badan karburator dengan udara dari kompressor.

6-9

SISTEM BAHAN BAKAR

PERAKITAN KARBURATOR CARBURETOR ASSEMBLY DIAPHRAGM

O-RING

FLOAT PIN

0.88 N·m (0.090 kgf ·m, 6.5 lbf ·ft)

WASHER FLOAT VALVE

AIR SCREW

SPRING

FLOAT O-RING

O-RINGS

THROTTLE STOP SCREW

RETAINER

O-RING

SLOW JET 1.5 N·m (0.15 kgf ·m, 1.1 lbf ·ft)

FUEL VALVE

2.1 N·m (0.21 kgf ·m, 1.5 lbf ·ft) AIR CUT-OFF VALVE COVER

NEEDLE JET

2.1 N·m (0.21 kgf ·m, 1.5 lbf ·ft)

JET NEEDLE

NEEDLE JET HOLDER 2.5 N·m (0.25 kgf ·m, 1.8 lbf ·ft)

FLOAT CHAMBER FUEL STRAINER SCREEN

O-RINGS

FUEL STRAINER CUP 5.9 N·m (0.60 kgf ·m, 4.4 lbf ·ft)

MAIN JET 1.5 N·m (0.15 kgf ·m, 1.1 lbf ·ft)

THROTTLE VALVE

DRAIN SCREW 1.5 N·m (0.15 kgf ·m, 1.1 lbf ·ft)

FLOATCHAMBER CHAMBER FLOAT Handle all jets with care. They can easily be scored or scratched.

Install the following: Pasang sebagai b erikut: – Throttle stop screw/spring - –Throttle stop screw/spring Slow jet Needle - –Slow jet jet Needle - –Needle jetjet holder – Main jet - Needl e jet holder - Tighten Main jetthem to the specified torque. TORQUE: Slow jet mereka dengan 1.5 N·m (0.15 kgf·m, 1.1 lbf·ft) Kencangkan torsi yang ditentukan. Needle jet holder 2.5 N·m (0.25 kgf·m, 1.8 lbf·ft) TORSI: Main jet 1.5 N·m (0.15 kgf·m, 1.1 lbf·ft) Slow jet 1,5 N.m (0,20 kgf.m ; 1,1 lbf.ft) Needle holder 2,5 N.m (0,30 kgf.m; 1,8 lbf.ft) Install thejet following: jet 1,5 N.m (0,20 kgf.m; 1,1 lbf.ft) –Main Spring – Washer – Newair O-rings screw sebagai berikut: Pasang the air screw and return it to its original position as - Install Spring noted during removal. - Washer - O-rings baru

Pasang air screw dan kembalikan pada posisinya semula seperti telah dicatat pada waktu pelepasan.

6-10

WASHER SLOW JET

SPRING AIR SCREW

MAIN JET

SPRING NEEDLE JET NEEDLE JET HOLDER

THROTTLE STOP SCREW

O-RINGS

SISTEM BAHAN BAKAR Install the float valve onto the float. float valve float. Pasang pada Install the float and floatvalve valvepada in thebadan carburetor body, float float Pasang dan karburator, then install the float pin through the body and float. kemudian pasang float pin melalui badan dan float.

FLOAT PIN

FLOAT VALVE

FLOAT FLOAT LEVEL FLOAT INSPECTION PEMERIKSAAN LEVEL With thefloat floatvalve valvedalam seatedkeadaan and the duduk float arm touchDengan danjust float arm ing the valve, measure float float level level with the float level tepat menyentuh valve, the ukurlah dengan float gauge as shown. level gauge seperti diperlihatkan. FLOAT FLOAT LEVEL: 11.7 11,7mm mm LEVEL: (0.46 in)

TOOL: TOOL: Carburetor levelgauge gauge Carburetor float float level

FLOAT LEVEL GAUGE

07401-0010000 07401-0010000

The float be adjusted. Float levellevel tidakcannot dapat disetel. Replace float the float assembly the float out of Gantilah assembly jika if float level level tidakis sesuai specification. dengan spesifikasi.

Pasang ebuah O-ring barufloat pada alur float chamber. Install asnew O-ring in the chamber groove. Pasang Install the float float chamb chamber. er.

FLOAT CHAMBER

O-RING

Pasang dantighten kencangkan chamber screws Install and the floatfloat chamber screws to thedengan specified yang torque. torsi ditentukan. TORQUE:2.1 N·m (0.21 kgf·m, 1.5 lbf·ft) TORSI: 2,1 N.m (0,20 kgf.m; 1,5 lbf.ft)

SCREWS

6-11

SISTEM BAHAN BAKAR AIR VALVE AIRCUT-OFF CUT-OFF VALVE Install a new O-ring with itsbaru flat side facing sisinya the carburetor Pasang sebuah O-ring dengan yang body. mendatar menghadap ke badan karburator. Install the diaphragm to set the diaphragm rib in the Pasang (membran) untuk menempatkan groove indiaphragm the carburetor body properly. diaphragm rib (tulang membran) dengan benar pada alur di dalam badan karburator.

FLAT SIDE

O-RING DIAPHRAGM Install the spring and valve cover. Be careful not to Pasang spring dan valve cover. Install and tighten the screws to the specified torque. pinch the diaphragm Pasang dan kencangkan screws dengan torsi yang and O-ring between ditentukan. TORQUE:2.1 N·m (0.21 kgf·m, 1.5 lbf·ft) the body and valve cover when tightening TORSI : 2,1 N.m (0,20 kgf.m; 1,5 lbf.ft) the cover screws.

SCREWS

DIAPHRAGM/SPRING AIR CUT-OFF VALVE COVER

FUEL FUELVALVE VALVE Install as new O-ring and fueldan valve. Pasang ebuah O-ring baru fuel valve.

FUEL VALVE

O-RING

Pasang dan kencangkan screws dengan torsi yang Install and tighten the screws to the specified torque. ditentukan. TORQUE:0.88 N·m (0.090 kgf·m, 0.65 lbf·ft) TORSI : 0,88 N.m (0,090 kgf.m; 0,64 lbf.ft)

6-12

SCREWS

SISTEM BAHAN BAKAR

PEMASANGAN KARBURATOR CARBURETOR INSTALLATION BADAN KARBURATOR CARBURETOR BODY Hubungkan cabletopada karburator clamp Connect the choke choke cable the carburetor anddan clamp the cable. dengan klem) cable. (pasang

Pasang O-rings baru body ke dalam dan alur-alur Install the carburetor to the insulator air cleaner connecting hose. karburator. badan Install the insulator Install new O-rings into the insulator and carburetor body with the boss facing grooves.

CHOKE CABLE

CLAMP

CARBURETOR BOSS

up.

O-RINGS

Pasang badan karburator air cleaner Install the carburetor body pada and insulator to theconnecting inlet pipe hose. and tighten the bolts. Tighten badan the connecting hose band screw pada so that thepipe gap Pasang karburator dan insulator inlet between the band ends is 5 mm (0.2 in). dan kencangkan bolts dengan erat.

BOLTS

INSULATOR CARBURETOR

Kencangkan connecting hose band screw sehingga lebar jarak renggang pada ujung-ujung bands adalah 5 mm.

SCREW 5 mm (0.2 in.)

INSULATOR

Connec

6-13

SISTEM BAHAN BAKAR Sambungkan sebagai berikut: t the following: vent hose - –AirAir vent hose – Drain hose - Drain hose – Fuel hose - Fuel hose Remove the hose clamp. Turn the fuel valve "ON". Lepaskan hose clamp. Installfuel thevalve left lower side cover (page 3-5). Putar ke "ON".

AIR VENT HOSE CLAMP

Pasang left lower side cover (hal. 3-5). DRAIN HOSE

FUEL HOSE

THROTTLE VALVE THROTTLE VALVE Install the jet needle thethrottle throttle valve. valve. Pasang jet needle ke into dalam Secure the jet needle with retainer and spring Kokohkan pemasangan jet needle dengan retainerwhile dan pushing the retainer with a screwdriver slightly and turnsementara mendorong sedikit dengan spring retainer ing it clockwise. sebuah obeng, dan m emutarnya s earah jarum jam.

THROTTLE VALVE

SCREWDRIVER

JET NEEDLE SPRING RETAINER Install the throttle valve spring ontothrottle the throttle Pasang throttle valve spring pada cable.cable. Connect the throttle cablecable to the throttle while valve comSambungkan throttle pada valve throttle pressing the throttle valve spring. sementara m enekan throttle valve spring.

THROTTLE CABLE

SPRING

THROTTLE VALVE

Pasang valve into ke the dalam badan karburator Install thethrottle throttle valve carburetor body by aligndengan mentepatkan padanya ing its cut-out with thepotongan throttle stop screw.dengan throttle stop scre w.

THROTTLE VALVE

CUT-OUT

THROTTLE STOP SCREW

6-14

SISTEM BAHAN BAKAR Tighten the carburetor Kencangkan carburetortop. top dengan erat. After installing the carburetor, check for the following: Setelah memasang karburator, periksalah terhadap – Throttle berikut ini: grip free play (page 4-5) Engine idle speed – (page 4-12) - Jarak main bebas throttle grip (hal. 4-5) Air screw adjustment – (page - Putaran stasioner mesin (hal.6-15) 4-12) - Install Penyetelan air screw (hal. 6-15) the right lower side cover (page 3-5).

CARBURETOR TOP

Pasang right lower side cover (hal. 3-5).

AIR SCREW ADJUSTMENT IDLE AIR DROPSCREW PROCEDURE PENYETELAN • The air screw is factory pre-set and no adjustment is

PROSEDUR PENURUNAN PUTARAN necessary unless the carburetor is overhauled or the air screw is replaced. STASIONER • •

• •

•

• •

Air screw disetel awal di pabrik dan tidak diperlukan penyetelan lagi kecuali jika karburator telah dibongkar atau air screw diganti baru. -1 Pakailah tachometer dengan skala 50 menit (rpm) atau lebih kecil yang dapat dengan akurat Use a tachometer with graduations of 50 min-1 (rpm) -1 memperlihatkan perubahan sebesar 50 menit or smaller that will accurately indicate a 50 min-1 (rpm) (rpm). change.

Remove the lower side covers (page 3-5). Lepaskan lower side covers (hal. 3-5). 1. Damage to the air 1. screw seat will occur if the air screw is tightened against the seat.

Turn screw clockwise until lightly, then Putarthe airair screw searah jarum jamit seats sampai ia duduk back it out to specification given. dengan ringan, kemudian putar kembali keluar This is an initial setting prior to the final air screw sampai ke spesifikasi yang diberikan. adjustment. Ini merupakan penyetelan awal sementara sebelum INITIAL OPENpenyetelan akhir air screw. ING: 1-7/8 turns out PEMBUKAAN AWAL: 1 – 7/8 putaran keluar 2. Warm up the engine to operating temperature. Stop and go riding for 10 minutes is sufficient. 2. Panaskan mesin sampai suhu operasional. 3. Stop the engine jalan-dan-berhenti and connect the tachometer Pengendaraan selama 10accordmenit ing to its manufacturer’s instructions. adalah cukup. 4. Disconnect the vacuum hose of PAIR control valve, then connect it to the vacuum pump and plug the vac3. Matikan mesin dan hubungkan tachometer sesuai uum port. dengan petunjuk pemakaian pabrik pembuatnya.

4.

THROTTLE STOP SCREW AIR SCREW

VACUUM HOSE

Lepaskan vacuum hose dari PAIR control valve, dan hubungkan ke vacuum pump (pompa vakum) dan sumbat vacuum port (lubang vakum).

6-15

SISTEM BAHAN BAKAR the specified to the PAIR pada control PAIR valve 5.5. Apply Terapkan vakum vacuum yang ditentukan vacuum hose more thanhose 60 kPa (450 mmHg). control valve vacuum lebih dari 60 kPa (450 6. Start the engine and adjust the idle speed with the mmHg). throttle stop screw. 6. Hidupkan mesin dan setel putaran stasioner IDLE SPEED:TBD TBD min -1 (rpm) dengan throttle stop±screw. -1

7. 7. 8.

Turn the air STASIONER:1.300 screw in or out slowly 100 to obtain highPUTARAN menitthe (rpm) est engine speed.masuk atau keluar dengan pelan Putar air screw Lightly open the throttle 2 or mesin 3 times, then adjust the untuk mendapatkan putaran tertinggi. idle speed with the throttle stop screw. 8. Buka throttle 2 atau 3 kali dengan r ingan, kemudian air screw out until the engine speed 9. Turn setel the putaran stasioner dengan throttle stop drops screw.by TBD min-1 (rpm). 9. Putar air screw keluar sampai putaran mesin turun 10.Turn the 50 air menit screw-1clockwise to the final opening from dengan (rpm). the position obtained step 9.

VACUUM PUMP VACUUM HOSE

PLUG

FINALair OPEN10. Putar screw searah jarum jam ke pembukaan ING: dari posisi yang TBD turns in pada langkah 9. akhir diperoleh

PEMBUKAAN 1/4 putaran dari 11.Disconnect the AKHIR: plug from the vacuumkeluar port, then remove the vacuum pump and connect9 the vacuum posisi yang diperoleh pada langkah hose of PAIR control valve. 11. Lepaskan plug (sumbat) dari vacuum port, 12.Readjust the idle speed with the throttle stop screw. kemudian lepaskan vacuum pump dan hubungkan IDLE SPEED:1,400 min -1 (rpm) ± 100 vacuum hose dari PAIR control valve. 12. Setel stasioner Install the kembali lower sideputaran cover (page 3-5). dengan throttle stop screw. PUTARAN STASIONER: (rpm)

1.400

-1

100 menit

Pasang lower side cover (hal. 3-5).

FUEL TANK

FUEL TANK (TANGKI BAHAN BAKAR) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan b ody cover (hal. 3-8). Remove the body cover (page 3-8). Lepaskan (Hitam). fuel level sensor 3P connector Disconnect the fuel level sensor 3P (Black) connector. Release the wire from the clamp.

WIRE CLAMP

3P CONNECTOR (Hitam)

Lepaskan mounting bol bolts. ts. Remove the mounting BOLTS

6-16

SISTEM BAHAN BAKAR Klem fuel hose narikup fuel atas. Clamp the fuel dengan hose byme pulling thetank fuelke tank. Disconnect thehose fuel dan hoselepaskan and remove fuel tank. Lepaskan fuel fuel the tank. Installation is in the reverse order of removal. Pemasangan adalah dalam urutan terbalik pelepasan.

FUEL TANK

dari

FUEL HOSE CLAMP

FUEL FUEL FILTER FILTER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Remove the body cover (page 3-8). Lepaskan body cover (hal. 3-8).

FUEL FILTER

Clamp the fuel dari hosesisi of the tank side. Klem fuel hose fuelfuel tank. Disconnect the fuel hoses and remove fuel filter. Lepaskan fuel hoses dan lepaskan fuel the filter. Wipe off spilled out Place an approved fuel container and drain the fuel. fuel. Letakkan tempat penampung bahan bakar yang sesuai Check the fuel filter for damage or contamination. the fuel filter necessary. diReplace bawah fuel tank daniflepaskan fuel filter. Installation is in the reverse order of removal. Periksa fuel filter terhadap kerusakan atau kontaminasi. Gantilah fuel filter bila perlu.


adalah

dalam

urutan

terbalik

dari FUEL HOSES KE SISI FUEL TANK

FUEL FILTER

TANDA ARAH

FUEL FUEL STRAINER STRAINER SCREEN SCREEN Lepaskan right lower side cover (hal. 3-5). Remove the right lower side cover (page 3-5). Putar valve ke "OFF". Turn fuel the fuel valve "OFF". Remove the strainer cup, strainer screen and OLepaskan fuel fuel strainer cup, strainer screen dan O-rings. rings.

STRAINER SCREEN/O-RINGS

Bersihkan strainer screen screenand dan strainer cup dalam Clean the strainer strainer cup in non-flammable or high flash point solvent. larutan pembersih yang tidak dapat terbakar atau Replace thetitik strainer screen if necessary. mempunyai api tinggi. Gantilah strainer screen bila perlu.

STRAINER CUP

6-17

SISTEM BAHAN BAKAR Pasang O-rings baru, strainer screen dan strainer cup. Install new O-rings, strainer screen and strainer cup. Tighten the strainer the specified torque. Kencangkan strainercup cuptodengan torsi yang di tentukan.

O-RINGS

TORQUE:5.9 N·m (0.60 kgf·m, 4.4 lbf·ft) TORSI: 5,9 N.m (0,6 kgf.m; 4 lbf.ft)

Turn the valve surebahwa that there areada no Putar fuelfuel valve ke "ON" "ON"and danmake pastikan tidak fuel leakage. kebocoran bahan bakar. Install the right lower side cover (page 3-5). Pasang right lower side co ver (hal. 3-5).

STRAINER SCREEN

STRAINER CUP

SECONDARY AIR SUPPLY SYSTEM SYSTEM PEMERIKSAAN PAIR (PULSE AIR PAIR (PULSE SECONDARY INJECTION) CHECK VALVECHECK SECONDARY AIR INJECTION) INSPECTION VALVE

Remove the right lower side cover (page 3-5). Lepaskan right lower side cover (hal. 3-5). Lepaskan screws, check cover PAIR control Remove the screws andvalve check valvedari cover from the valve PAIRbody. control valve body.

PAIR CONTROL VALVE BODY

SCREWS

CHECK VALVE COVER

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

PAIR CHECK VALVE

Periksa reed terhadap kerusakan ataureplace keletihan, ganti Check the reed for damage or fatigue, if necessary. bila perlu. Replace thecheck PAIR valve check jika valve if theseat rubber seat is Ganti PAIR rubber retak-retak, cracked, deteriorated or damaged, or if there is memburuk kondisinya atau rusak, atau jika clearada ance between the reed and seat kerenggangan antara reed dan seat. Installation is in the reverse order of removal.

REED

Pemasangan adalah dalam urutan terbalik dari TORQUE: pelepasan. PAIR check valve cover screw 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft) TORSI: PAIR check valve 2,1 N.m (0,20 kgf.m; 1,5 lbf.ft) cover scr ew RUBBER SEAT

6-18

CHECK VALVE

SISTEM BAHAN BAKAR PELEPASAN/PEMASANGAN PAIR PAIR CONTROL VALVE REMOVAL/ INSTALLATION CONTROL VALVE Remove the right lower side cover (page 3-5). Lepaskan right lower side cover (hal. 3-5). PAIR CONTROL VALVE Lepaskan vacuum hose dan air supply hose hose dari PAIR Disconnect the vacuum hose and air supply from control valve. the PAIR control valve. Lepaskan bolts dan PAIR control valve body . Remove the bolts and PAIR control valve body. Pemasangan adalah dalam urutan terbalik dari Installation is in the reverse order of removal. pelepasan.

BOLTS

AIR SUPPLY HOSE

VACUUM HOSE

PEMERIKSAAN SISTEM SYSTEM INSPECTION Remove the lower side covers (page 3-5). Lepaskan lower side covers (hal. 3-5). Start the engine and warm it up to normal operating temHidupkan mesin dan panaskan sampai ke suhu operasi perature and stop the engine. normal dan matikan mesin. Disconnect the air supply hose from the separate air filter Lepaskan air supply hose dari separate air filter (hal. 6(page 6-20). 20 ). Remove the PAIR check valve (page 6-18) and check the inside of PAIR clean6-18 and free of periksa carbon Lepaskan PAIRcontrol checkvalve valveis (hal. ) dan deposits. bahwa bagian dalam dari PAIR control valve adalah Checkdan the bebas PAIR check valve if the inside of PAIR control bersih dari endapan karbon. valve is carbon fouled. Periksa PAIR check valve jika bagian dalam dari pair Disconnect PAIR control valve vacuum hose from the control valvethe kotor dengan karbon. inlet pipe and plug the hose joint. Connect the vacuum pump to the PAIR control valve Lepaskan PAIR control valve vacuum hose dari inlet vacuum hose. pipe dan sumbat hose joint. Start the engine and open the throttle slightly to be cerHubungkan kethePAIR control tain that air isvacuum sucked inpump through air supply hose.valve vacuum hose. If the air is not drawn in, check the air supply hose for clogging. Hidupkan mesinrunning, dan buka throttle sedikit to untuk With the engine gradually apply vacuum the memastikan bahwa udara dihisap masuk melalui air PAIR control valve vacuum hose. Checkhose. that the air supply hose stops drawing air, and supply that udara the vacuum does notmasuk, bleed. periksa air supply hose Jika tidak dihisap terhadap sumbatan. SPECIFIED VACUUM:60 kPa (450 mmHg)

VACUUM HOSE

AIR SUPPLY HOSE VACUUM PUMP

PLUG

If the airmesin is drawn in keadaan or if the specified vacuum is not Dengan dalam jalan, secara berangsur maintained, install a new PAIR control valve. terapkan vakum pada PAIR control valve vacuum hose. If afterburn occurs deceleration, even when the secPeriksa bahwa airon supply hose berhenti menghisap ondary air supply system is normal, check the air cut-off udara, valve. dan bahwa tidak ada kebocoran vakum. Install the removed parts in the reverse removal. VAKUM YANG DITENTUKAN: 60 kPaorder (450 of mmHg)

Jika udara ditarik masuk atau jika vakum yang ditentukan tidak dapat dipertahankan, pasang sebuah PAIR control valve baru. Jika terjadi peristiwa afterburning pada deselerasi, bahkan jika secondary air supply system adalah normal, periksalah air cut-off valve. Pasang parts yang dilepaskan dalam urutan terbalik dari pelepasan.

6-19

SISTEM BAHAN BAKAR

SEPARATE AIR FILTER FILTER Lepaskan main pipe side cover/main pipe cover (hal. 3Remove the main pipe side cover/main pipe cover (page 3-6). 6). Lepaskan air supply hose dari Remove the hose bands and clamp. disconnect the air supply Lepaskan clamps dan lepaskan air supply dari hoses from the separate air filter and removehoses the sepaseparate air filter dan lepaskan separate air filter. rate air filter.

BANDS

Check the separate air filter and replace it if necessary. Periksa separate air filter dan ganti bila perlu. Installation is in the reverse order of removal. Pemasangan adalah dalam urutan terbalik dari pelepasan. SEPARATE AIR FILTER

AIR SUPPLY HOSES SEPARATE AIR FILTER TANDA ARAH

KE PAIR CONTROL VALVE

AIR AIR SUPPLY SUPPLY PIPE PIPE PELEPASAN REMOVAL Remove the right lower side cover (page 3-5). Lepaskan right lower side cover (hal. 3-5). AIR SUPPLY Remove the bolts. HOSE Lepaskan bolts. Disconnect the air supply hose and remove the air supLepaskan air supply hose dan lepaskan air supply pipe. ply pipe. Lepaskan gasket bersihkan kedua Remove the gasket dan and clean the both matingpermukaan surface. penyatuan.

AIR SUPPLY PIPE

PEMERIKSAAN INSPECTION Bersihkan air supply supplypipe pipe terhadap retak-retak atau Check the air for crack or damage. kerusakan.

6-20

BOLTS

GASKET

SISTEM BAHAN BAKAR INSTALLATION PEMASANGAN Pasang ebuah gasket baruairpada air pipe. supply pipe. Install as new gasket to the supply

GASKET

AIR SUPPLY PIPE

Hubungkan Connect theair airsupply supplyhose. hose. Install and tighten pipe the bolts. Pasang air supply dan bolts. Kencangkan dengan Install the rightbolts lower side cover langkah-langkah (page 3-5). ditentukan seperti diperlihatkan.

yang

AIR SUPPLY HOSE

BOLTS

Pasang right lower side cover (hal. 3-5).

AIR SUPPLY PIPE

GASKET

INLET INLETPIPE PIPE PELEPASAN REMOVAL Remove the lower side covers (page 3-5). Lepaskan lower side covers (hal. 3-5). Disconnect the vacuum Lepaskan vacuum hose. hose. Remove the following: Lepaskan sebagai berikut: – Bolts - –Bolts Insulator - –Insulator O-rings Inlet pipe - –O-rings - Inlet pipe

INLET PIPE

O-RINGS

INSULATOR

VACUUM HOSE

BOLTS

PEMASANGAN INSTALLATION Pasang ebuah gasket barucylinder pada cylinder Install as new gasket to the head. head.

GASKET

6-21

SISTEM BAHAN BAKAR Pasang inlet pipe dan bolts pada cylinder head. Install the inlet pipe and bolts to the cylinder head. Tighten the bolts the specified torque. Kencangkan boltsto dengan torsi yang ditentukan.

INLET PIPE

TORQUE:12 N·m (1.2 kgf·m, 9 lbf·ft) TORSI: 12 N.m (1,2 kgf.m; 9 lbf.ft)

BOLTS O-rings baru insulator dan alur-alur Install the insulator Pasang Install new O-ring into ke thedalam insulator and carburetor body grooves. karburator. with the boss facing badan up.

BOSS

INSULATOR O-RINGS

Pasang insulator dan bolts badan karburator Install the insulator and boltspada to the carburetor body dan and tighten the bolts. kencangkan bolts dengan erat. Connect the vacuum hose to the inlet pipe. Hubungkan vacuum hose pada inlet pipe. Install the lower side covers (page 3-5). Pasang lower side covers (hal. 3-5).

BOLTS

INSULATOR

VACUUM HOSE

6-22

7. PENURUNAN/PEMASANGAN MESIN

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

ENGINE REMOVAL········································7-4 PENURUNAN MESIN ......................... 7-4

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

ENGINE INSTALLATION ······························7-7 PEMASANGAN MESIN ...................... 7-6

7

7-1


LOKASI KOMPONEN ENGINEREMOVAL/INSTALLATION

59 N·m (6.0 kgf ·m, 44 lbf ·ft)

59 N·m (6.0 kgf ·m, 44 lbf ·ft)

12 N·m (1.2 kgf ·m, 9 lbf ·ft)

12 N·m (1.2 kgf ·m, 9 lbf ·ft)

7-2


SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM • During engine removal and installation, support the motorcycle with its centerstand. Selama penurunan dan pemasangan mesin, letakkan standard utamanya. • Support the engine using a jack or other adjustable support tosepedamotor ease of enginepada hanger bolts removal. Topang mesin dengan menggunakan dongkrak atauinstalled alat penopang lain yang dapat disetel untuk mempermudah pelepasan • The following components can be serviced with the engine in the frame. hanger – engine Alternator (pagebolts 11-6)(baut penggantung mesin). – Komponen-komponen Manual clutch (page 10-9) berikut ini dapat diservis dengan mesin terpasang pada rangka. – - Centrifugal (page 10-9) Alternatorclutch (hal. 11-6) – - Gearshift linkage(kopling (page 10-27) Manual clutch manual) (hal. 10-9) – - Cylinder head (page 8-12) Centrifugal clutch (kopling sentrifugal) (hal. 10-9) – - Cylinder/piston (page 9-5) Gearshift linkage (peralatan pemindah gigi) (hal. 10-27) – - Oil pump (page 5-4) Cylinder head (kepala silinder) (hal. 8-12) – - Starter motor (page 18-6) Cylinder/piston (hal. 9-5) Oil pump (hal. 5-4) • The following components require engine removal for service. Starter motor (hal. 18-6) – - Crankshaft/transmission/kickstarter (page 12-6) – Shift forks/shift drum (page 12-9) berikut memerlukan penurunan mesin agar dapat menservisnya. – Komponen-komponen Cam chain guide sprocket (page ini 12-18) - Crankshaft/transmission/kickstarter (hal. 12-6) - Shift fork/shift drum (hal. 12-9) SPECIFICATIONS - Cam chain guide sprocket (hal. 12-18)

• •

•

•

ITEM

Engine dry weight SPESIFIKASI Engine oil capacity

Berat kosong mesin Recommended engine oil Kapasitas oli mesin

At draining BAGIAN At disassembly

Pada penggantian periodik Pada pembongkaran mesin

Oli mesin yang dianjurkan

SPECIFICATIONS 22.6 kg (49.8 lbs) 0.8 liter (0.8 US qt, 0.7 lmp qt) SPESIFIKASI 1.0 liter (1.1 US qt, 0.9 lmp qt) 22,6 kg API classification: SE, SF or SG 0,8 liter on the circular API service (except oils labeled as energy conserving 1,0 liter label) Oli mesin 4 tak dengan klasifikasi API service SJ, Viscosity: SAE 10W-30 Viskositas: SAE 10W-30 JASO MA JASO T 903 standard: MA

TORSI PENGENCANGAN TORQUE VALUES Engine hanger Engine hangernut nut Drive sprocket Drive sprocketfixing fixing plate platebolt bolt Inlet pipe mounting bolt Throttle body insulator mounting bolt Swingarm pivot pivot nut nut Swinfarm

N·m(6,0 (6.0kgf.m; kgf·m,44 44 lbf.ft) lbf·ft) 5959N.m 12 N·m (1.2 kgf·m, 9 lbf·ft) 12 N.m (1,2 kgf.m; 9 lbf.ft) N·m(1,2 (1.2kgf.m; kgf·m,99lbf.ft) lbf·ft) 1212N.m N·m(6,0 (6.0kgf.m; kgf·m,44 44lbf.ft) lbf·ft) 5959N.m

U-nut U-nut

7-3


PENURUNAN MESIN ENGINE REMOVAL Support the motorcycle with itsstandard centerstand. Letakkan sepedamotor pada utamanya. Drain the engine oil (page Keluarkan oli mesin (hal. 4-10). 4-10). Remove the following: Lepaskan sebagai berikut: Body covers(hal. (page 3-8) - –Body covers 3-8) – Left crankcase rear cover (page 3-16) - Left crankcase rear cover (hal. 3-16) – Exhaust pipe/muffler (page 3-16) - Exhaust pipe/muffler (hal. 3-15) PAIR control valve(hal. (page 6-19) - –PAIR 6-19) control valve Disconnect the spark plug cap. Lepaskan spark plug cap.

SPARK PLUG CAP Disconnectsebagai the following: Lepaskan berikut:

WIRE BAND BOSS

Starter motor2P 2Pconnector connector - –Starter motor – Alternator wire (Yellow) - Alternator wire connector connector (Kuning) Ignition pulse generator wire wire connector (Blue/yellow) connector - –Ignition pulse generator (Biru/kuning) Remove the wire band boss.

CONNECTORS

Disconnectsebagai the following: Lepaskan berikut:

6P CONNECTOR (HITAM)

Alternator connector - – Alternator 2P2Pconnector – Gear position switch 6P connector (Black) connector - Gear position switch 6P (Hitam)

2P CONNECTOR

Lepaskan hosefrom darithe lower Release thecarburetor carburetor drain drain hose lowerside side cover cover stay. stay.

DRAIN HOSE

7-4

PENURUNAN/PEMASANGAN MESIN Disconnect the crankcase breather Lepaskan crankcase breather hose.hose.

CRANKCASE BREATHER HOSE Remove the inlet pipe mounting bolts and gasket. Lepaskan inlet pipe mounting bolts dan gasket.

BOLTS

GASKET Loosen the lock chain adjusters and dan axle nut. Longgarkan locknuts, nuts,drive drive chain adjusters axle Push the rear wheel forward. nut. Dorong roda belakang ke depan.

LOCK NUTS

AXLE NUT ADJUSTERS Remove the drive sprocket fixing plate bolts. Lepaskan drive sprocket fixing plate bolts. Turn dan and lepaskan remove the fixing plate. Putar fixing plate. Remove the drive sprocket from the countershaft and drive chain. Lepaskan drive sprocket dari countershaft dan drive chain.

BOLTS

DRIVE SPROCKET

FIXING PLATE

7-5

PENURUNAN/PEMASANGAN MESIN Remove the following: Lepaskan sebagai berikut: Pivot nut/washer - –Pivot nut/washer – Bolt - –Bolt Plate - Plate

PIVOT NUT/WASHER

PLATE

BOLT

Remove the collar from the pivot bolt. Lepaskan collar dari pivot bolt. COLLAR

Support mesin the engine usingmenggunakan a jack or other adjustable supTopang dengan dongkrak atau port. alat penopang lain yang dapat disetel. Lepaskan engine nut (mur penggantung mesin) Remove the front hanger engine hanger nut. depan. Remove the rear upper engine hanger nut and rear lo wer engine hanger nut. Lepaskan engine hanger nut bolts belakang danfrom engine Remove the engine hanger and atas engine the hanger frame. nut belakang bawah. • Wrap the inlet pipe port with a shop towel or cover it Lepaskan hanger bolts dan engine dari rangka. with a engine piece of tape to prevent any foreign material Bungkuslah lubang inlet pipe (pipa pemasukan) from dropping into the engine. dengan kain lap bersih atau tutuplah dengan pita perekat untuk mencegah jatuhnya benda-benda asing ke dalam mesin. •

7-6

ENGINE HANGER BOLTS/NUTS


ENGINE INSTALLATION PEMASANGAN MESIN CATATAN: Perhatikan arah dari hanger bolts. • Note the direction of the hanger bolts. • Use a floordongkrak jack or other support,lain carefully Pakailah atauadjustable alat penopang yang place engine into the frame tempatkan and maneuver it into dapat the disetel, dengan hati-hati mesin ke place. dalam rangka dan gerakkan ke posisi • Route the wires and hoses properly (page 1-14). pemasangannya. Alurkan wires (kawat listrik) dan hoses (slangslang) dengan benar (hal. 1-14). • •

•

Pada waktu rangka topang mesin During engine Letakkan Place themesin engineke intodalam the frame anddan support the engine pemasangan mesin, using a jack or other adjustable support. installation, hold the dengan menggunakan dongkrak atau alat penopang peganglah mesin yang dapat disetel. engine securely and lain Install the engine hanger bolts and nuts. dengan erat dan be careful not to berhati-hatilah agar Tighten the rear upper engine hanger nut to the specified frame Pasang tidakdamage merusakthe rangka torque. engine hanger bolts dan nuts. and engine. dan mesin.

Kencangkan hanger belakang atas dengan TORQUE:59engine N·m (6.0 kgf·m,nut 44 lbf·ft) torsi yang ditentukan. Tighten 59 theN.m rear (6,0 lower engine44 hanger TORSI: kgf.m; lbf.ft) nut to the specified torque. Kencangkan engine hanger nut belakang bawah TORQUE:59 N·m (6.0 kgf·m, 44 lbf·ft) dengan torsi yang ditentukan. TORSI: (6,0 kgf.m;hanger 44 lbf.ft) Tighten 59 theN.m front engine nut to the specified torque. Kencangkan engine hanger nut depan dengan torsi TORQUE:59 N·m (6.0 kgf·m, 44 lbf·ft) yang ditentukan. TORSI: 59 N.m (6,0 kgf.m; 44 lbf.ft) Install the collar to pivot bolt. Pasang collar pada pivot bolt.

Install the following: Pasang sebagai berikut: – Plate - Plate – Pivot nut/washer - –Pivot Boltnut/washer - Bolt Tighten the swingarm pivot nut to the specified torque while holding swingarm the pivot bolt. Kencangkan pivot nut dengan torsi yang ditentukan sementara menahan pivot TORQUE:59 N·m (6.0 kgf·m, 44 lbf·ft)bolt.

ENGINE HANGER BOLTS/NUTS

COLLAR

PIVOT NUT/WASHER

Tighten 59 theN.m bolt. (6,0 kgf.m; 44 lbf.ft) TORSI:

Kencangkan bolt.

PLATE

BOLT

7-7

PENURUNAN/PEMASANGAN MESIN Install the drive chain onto the sprocket. drive sprocket. Pasang drive chain pada drive Install the drive sprocket onto the countershaft. Pasang drive sprocket pada countershaft.

FIXING PLATE

DRIVE CHAIN

Install the fixing plate to the countershaft while aligning their teeth. Pasang fixing plate pada countershaft sementara Rotate the fixing platemereka. and align their bolt holes. mentepatkan gigi-gigi Install fixing and tighten sprocket fixing plate bolts Putar plate the dandrive tepatkan lubang-lubang bolt alternately to the specified torque. mereka. TORQUE:12 N·m (1.2 kgf·m, 9 lbf·ft) Pasang dan kencangkan drive sprocket fixing plate bolts secara bergantian dengan torsi yang ditentukan.

TORSI: 12 N.m (1,2 kgf.m; 9 lbf.ft) BOLTS

DRIVE SPROCKET Install agasket new gasket to thecylinder cylinderhead. head. Pasang baru pada Install and tighten the mounting bolts to dengan the specified Pasang dan kencangkan mounting bolts torsi torque. yang ditentukan. TORQUE:12 N·m (1.2 kgf·m, 9 lbf·ft) TORSI: 12 N.m (1,2 kgf.m; 9 lbf.ft)

BOLTS

GASKET

Hubungkan crankcase breather hose.

C o n

nect the crankcase breather hose.


carburator drain hose lower Alurkan melalui Route the carburetor drain hose through the side lowercover side stay. cover stay.

DRAIN HOSE

7-8

PENURUNAN/PEMASANGAN MESIN Hubungkan berikut: Connect thesebagai following:

6P CONNECTOR (HITAM)

Alternator connector 2P2P connector - – Alternator – Gear position switch6P 6Pconnector (Black) connector - Gear positiion switch (Hitam)

2P CONNECTOR Connect thesebagai following: Hubungkan berikut: – Starter motor 2P connector - –Starter motorwire 2P connector Alternator (Yellow) connector - –Alternator wire Ignition pulseconnector generator (Kuning) wire (Blue/yellow) connector - Ignition pulse generator wire connector (Biru/kuning) Install the wire band boss. Pasang wire band boss.

WIRE BAND BOSS

CONNECTORS Connect the spark plug cap. Pasang spark plug cap. Install the following: Pasang sebagai berikut: – PAIR control valve (page 6-19) - – PAIR control valve (hal.(page 6-19)3-17) Exhaust pipe/muffler - – Exhaust pipe/muffler (hal. Left crankcase rear cover3-17) (page 3-16) - – Left crankcase rear cover Body covers (page 3-8) (hal. 3-16) - Body covers (hal. 3-8) Fill the recommended engine oil up to the proper level Isi oli4-10). mesin yang dianjurkan sampai ke tinggi (page permukaan yangchain ditentukan Adjust the drive slack (hal. (page4-10). 4-14). Setel kekenduran drive chain (hal. 4-14).

SPARK PLUG CAP

7-9

MEMO

8. CYLINDER HEAD/VALVES

LOKASI KOMPONEN-KOMPONEN......8-2 COMPONENT LOCATION ····························8-2

CAMSHAFT ...........................................8-8 CYLINDER HEAD COVER ····························8-6

KETERANGAN SERVIS ........................8-3 SERVICE INFORMATION ·····························8-3

CYLINDER HEAD ..................................8-12 CAMSHAFT ·························· ························· ···· 8-8

TROUBLESHOOTING ...........................8-5 TROUBLESHOOTING ····································8-5

CAM CHAIN HEAD··········································8-12 TENSIONER .....................8-23 CYLINDER

TEST KOMPRESSI CYLINDER.............8-6 CYLINDER COMPRESSION TEST ··············8-6

OIL STOPPER PLATE...........................8-25 CAM CHAIN TENSIONER ···························8-24

8

CYLINDER HEAD COVER ....................8-6

8-1

CYLINDER HEAD/VALVES

COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN CYLINDERHEAD/VALVES

8 N·m (0.82 kgf ·m, 5.9 lbf ·ft) 10 N·m (1.0 kgf ·m, 7 lbf ·ft) 13 N·m (1.3 kgf ·m, 10 lbf ·ft)

16 N·m (1.6 kgf ·m, 12 lbf ·ft) 22 N·m (2.2 kgf ·m, 16 lbf ·ft)

8-2


KETERANGAN SERVIS SERVICE INFORMATION GENERAL UMUM • • • • • • • • •

This section covers service of the cylinder head, valves, camshaft and cam chain tensioner. The head, valves, camshaft cam chaincamshaft tensioner dan services can betensioner. done with the engine installed in the frame. Babcylinder ini meliputi servis dari cylinderand head, valves, cam chain When disassembling, mark and store the disassembled parts to ensure that they are reinstalled in theirdengan original locations. Pekerjaan servis dari cylinder head, valves, camshaft dan cam chain tensioner dapat dilakukan mesin terpasang Clean all disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection. pada rangka. Camshaft lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling cylinder head. Sewaktu pembongkaran, dan simpanlah parts yangthe dibongkar Be careful not to damage thetandai mating surfaces when removing cylinder untuk head. memastikan bahwa mereka dipasang kembali pada lokasi mereka semula. Bersihkan semua parts yang dibongkar dengan larutan pembersih dan keringkan dengan meniup dengan udara dari • SPECIFICATIONS kompressor sebelum memeriksanya. • mm (in) Minyak pelumasan camshaft disalurkan melalui jalan lintasan oli di dalam cylinder head. Bersihkan jalan lintasan Unit: oli sebelum merakit kembali cylinder head. SERVICE ITEM STANDARD LIMIT • Hati-hati agar tidak merusak permukaan-permukaan penyatuan ketika melepaskan cylinder head. Cylinder compression 1,245 kPa (12.7 kgf/cm2, 181 psi) – at 600 min-1 (rpm) SPESIFIKASI Cylinder head warpage 0.05 (0.002) – Satuan: mm Valve, Valve clearance IN/EX 0.10 ± 0.02 (0.004 ± 0.001) – BAGIAN STANDARD BATAS SERVIS valve guide 2 Valve stem O.D. IN 4.975 – 1.245 4.990 kPa (0.1959 – Tekanan kompressi cylinder (12,7 0.1965) kgf/cm : 181 psi) - 4.965 (0.1955) -1 EX 4.945 (0.1947) 4.955 – pada 4.970600 (0.1951 – menit 0.1957) (rpm) Valve guide I.D. IN/EX 5.03 (0.198) 5.000 – 5.012 (0.1969 – 0.1973) Perubahan bentuk melengkung cylinder head 0,05 Stem-to-guide clearance IN 0.010 – 0.037± (0.0004 – 0.0015) Valve, Jarak renggang klep IN/EX - 0.065 (0.0026) 0,10 0,02 mm EX 0.030 – 0.057 (0.0012 – 0.0022) 0.085 (0.0033) valve guide (MASUK/BUANG) Valve guide projection IN/EX 9.1 – 9.3 (0.36 – 0.37) – D.L. valve stem IN 4,975 – 4,990 4,965 Valve seat width IN/EX 0.90 – 1.10 (0.035 – 0.043) 1.6 (0.06) EX 4,955 – 4,970 4,945 Valve spring free length IN/EX 30.67 (1.207) 29.70 (1.169) D.D. valve IN/EX 5,000 – 5,012 5,03 Rocker arm/ Rocker armguide I.D. IN/EX 10.10 (0.398) 10.000 – 10.015 (0.3937 – 0.3943) Jarak renggang stem-keIN 0,010 – 0,037 0,065 shaft Rocker arm shaft O.D. IN/EX 9.91 (0.390) 9.972 – 9.987 (0.3926 – 0.3932) guide arm-to-shaft clearEX 0,030 – 0,057 0,085 Rocker IN/EX 0.013 – 9,1 0.043 (0.0005 – 0.0017) Proyeksi valve guide IN/EX – 9,3 - 0.044 (0.0017) ance Lebarlobe valve seat IN/EX 0,90 – 1,10 1,6 Camshaft Cam height IN 32.16 (1.266) 32.194 – 32.434 (1.2675 – 1.2769) Panjang bebas valve spring IN/EX 30,62 29,70 EX 31.96 (1.258) 31.990 – 32.230 (1.2594 – 1.2689) Rocker arm/ D.D. rocker arm IN/EX 10,000 – 10,015 10,10 Cam chain tenPush rod O.D. 11.94 (0.470) 11.985 – 12.000 (0.4718 – 0.4724) sioner shaft D.L. rocker arm shaft IN/EX 9,972 – 9,987 9,91109 (4.3) Spring free length 111.3 (4.38) Jarak renggang rocker IN/EX 0,013 – 0,043 0,044 arm-ke-shaft TORQUE Camshaft VALUES Ketinggian cam lobe IN 32.194 – 32,434 32,16 (bubungan) EX 31,990 – 32,230 31,96 Cylinder boltrod 10 N·m (1.0 kgf ·m, 7 lbf ·ft) 11,985 – 12,000 Cam chainhead cover special D.L. push 11,94 Cylinder head nut Apply oil to the threads and seating surface. 13 N·m (1.3 kgf ·m, 10 lbf ·ft) tensioner Panjang bebas spring 111,3 109 Cam sprocket bolt Apply locking agent to the threads: 8 N·m (0.82 kgf ·m, 5.9 lbf ·ft) See page 8-11 Cam chain tensioner sealing bolt 22 N·m (2.2 kgf ·m, 16 lbf ·ft) TORSI PENGENCANGAN Cam chain tensioner arm pivot bolt 16 N·m (1.6 kgf ·m, 12 lbf ·ft)

Cylinder head cover special bolt Cylinder head nut Cam sprocket bolt

10 N.m (1,0 kgf.m; 7 lbf.ft) 13 N.m (1,3 kgf.m; 10 lbf.ft) 8 N.m (0,82 kgf.m; 5,9 lbf.ft)

Cam chain tensioner sealing bolt Cam chain tensioner arm pivot bolt

22 N.m (2,2 kgf.m; 16 lbf.ft) 16 N.m (1,6 kgf.m; 12 lbf.ft)

Semprotkan oli pada ulir dan permukaan duduk. Oleskan cairan pengunci pada ulir: Lihat hal. 8-11

8-3

CYLINDER HEAD/VALVES TOOLS Valve spring compressor 07757-0010000

Valve spring compressor attachment 07959-KM30101

Valve guide driver, 5.0 mm 07942-MA60000

Valve guide reamer, 5.0 mm 07984-MA60001

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

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

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

Flat cutter, 22 mm (32° EX) 07780-0012601

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

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

Cutter holder, 5.0 mm 07781-0010400

8-4


TROUBLESHOOTING TROUBLESHOOTING • Engine top-end problems usually affect engine performance. These problem can be diagnosed by a compression test or by tracing Persoalan pada bagian atas mesin biasanya engine noises to the top-end with a sounding rodmempengaruhi stethoscope. unjuk kerja mesin. Persoalan ini dapat didiagnosa dengan test kompressi atau dengan menelusuri suara-suara bagian dengan tangkaihose. suaraIfatau stethoscope. white pada smoke in the atas crankcase breather the hose is smoky, check for a • If the performance is poor at low speeds, check formesin • Jika unjuk buruk pada kecepatan rendah, periksalah terhadap asap putih pada crankcase breather hose (slang seized pistonkerja ring mesin (page 9-7). 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 mesin sulit dihidupkan atau unjuk kerja buruk pada kecepatan rendah – Incorrect valverendah, clearance • –Valves Burned(klep-klep): or bent valves –- Incorrect valve timing Jarak renggang klep tidak benar –- Broken spring Valvesvalve terbakar atau bengkok –- Valve open Tertibstuck waktu klep tidak benar • Cylinder head: Valve spring – Uneven valve patah seating Valve macet terbukacylinder head gasket –- Leaking or damaged • –Cylinder Warpedhead: or cracked cylinder head cylinder, piston or piston rings • Worn (page 9-6) - Valve seating (dudukan klep) tidak merata - Cylinder head bocor or atau rusak Compression too high,gasket overheating knocking Ada perubahan bentuk melengkung atau retak-retak pada cylinder head • Excessive carbon build-up on piston head or combustion chamber Cylinder, piston atau piston rings aus (hal. 9-5) • Excessive smoke • Cylinder head: 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, piston or piston rings (page 9-6) Asap berlebihan Excessive noise • Cylinderhead: head: • Cylinder Valve stem atau valve guide aus – Incorrect valve clearance Ada kerusakan stem seal –- Sticking valve or pada broken valve spring – Damaged or worn camshaft Cylinder, piston atau piston rings aus (hal. 9-5) • – Loose or worn cam chain – Worn or damaged cam chain guide roller/sprocket Mesin berisik – Worn or damaged cam chain tensioner • –Cylinder head: Worn cam sprocket teeth Jarakrocker renggang klep tidak benar –- Worn arm and/or shaft cylinder, or piston rings • Worn (page 9-6) - Valve macetpiston atau valve patah spring - Camshaft rusak atau aus Rough idle Cam chain longgar atau aus • Low cylinder compression Cam chain guide roller/sprocket aus atau rusak • Faulty fuel system (page 6-3) - Cam chain tensioner aus atau rusak - Gigi-gigi cam sprocket aus - Rocker arm dan/atau shaft aus • Cylinder, piston atau piston rings aus (hal. 9-5) •

Putaran stasioner kasar Tekanan kompressi cylinder rendah • Sistem bahan bakar tidak bekerja dengan baik (hal. 6-3) •

8-5


CYLINDER COMPRESSION TEST TEST KOMPRESSI CYLINDER Panaskan mesin sampai suhu operasi normal. Warm up the engine to normal operating temperature.

COMPRESSION GAUGE

Stop themesin engine and disconnect theplug spark plug cap. Matikan dan lepaskan spark cap (topi busi). Remove the spark plug (page 4-7). Lepaskan spark plug (busi) (hal. 4-7). Install the compression in the spark hole. Pasang compression gauge gauge (meterplugpengukur Turn the ignition switch ON. kompressi) pada lubang busi. Shift the transmission into neutral. Open the transmissi throttle all the way and crank the engine with ke dalam neutral. To avoid discharging Masukkan the battery, do not the starter until the gauge reading stops rising. Buka throttle seluruhnya dan putar mesin dengan The maximum reading is usually reached within 4 – 7 operate the starter kickstarter seconds. sampai pembacaan gauge berhenti naik.

motor for more than 7 seconds. STANDARD: STANDARD:

2 2 -1 -1 1,245 kPa kPa (12.7 psi)psi) at 600 min600 (rpm) 1.245 (12,7kgf/cm kgf/cm, 181 ; 181 pada menit If (rpm) compression is high, it indicates that carbon deposits have accumulated on the combustion chamber and/or Jika kompressi the piston head. tinggi, ini menunjukkan bahwa telah terkumpul endapan karbon pada ruang pembakaran If compression is low, pour 3 – 5 cc (0.1 – 0.2 oz) of dan/atau mahkota piston. engine oil into the cylinder through the spark plug hole

and recheck the compression. Jika kompressi rendah, tuangkan 3 – 5 cc oli mesin ke If the cylinder compression increases fromdan the periksa previous value, dalam melalui lubang busi kembali check the cylinder, piston and piston rings for the followkompressi. ing: – Leaking cylinder Jika kompressi naikhead dari gasket nilai sebelumnya, periksalah – Worn piston ring cylinder, piston dan piston rings terhadap: – Worn cylinder and piston - Kebocoran pada cylinder head gasket the compression is the same as the previous value, - IfKeausan piston ring check the valves for leakage. - Keausan cylinder dan piston

Jika kompressi sama dengan nilai sebelumnya, CYLINDER HEAD COVER periksalah valves (klep-klep) terhadap kebocoran.

REMOVAL

CYLINDERRemove HEAD COVER the special bolts, mounting rubbers and cylinder head cover. PELEPASAN

SPECIAL BOLTS/ MOUNTING RUBBERS

Lepaskan special bolts, mounting rubbers dan cylinde head cover. .

CYLINDER HEAD COVER

Lepaskan rubber seal dari cylinder head cover Remove the rubber seal and dowel pin from the cylinder head cover.

RUBBER SEAL

CYLINDER HEAD COVER

8-6

DOWEL PIN

CYLINDER HEAD/VALVES INSTALLATION PEMASANGAN Tiuplah terbuka lintasaninolithe di dalam cylinder head Blow open the jalan oil passage cylinder head cover with the compressed air. cover dengan udara dari kompressor.

Make sure the rubber rubber seal seal berada is in good and Pastikan bahwa dalamcondition kondisi baik replace if necessary. dan gantiitbila perlu. Install the rubber seal into the groove on the cylinder head cover. Pasang rubber seal ke dalam alur pada cylinder head cover. Install the dowel pin.

CYLINDER HEAD COVER

RUBBER SEAL

DOWEL PIN

Pasang pin dowel

CYLINDER HEAD COVER

Oleskan liquidsealant sealant(Three (Three bond 5211C Three Apply liquid bond 5211C or atau SHINETSU SILICONE or Three bond 1215 or equivalent) to bond 1215 KE45T atau sejenisnya) pada daerah setengah the semicircular areaseal of rubber seal as shown. lingkaran dari rubber seperti diperlihatkan.

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

TITIK PERAPATAN

TANDA "UP"

MOUNTING RUBBER

8-7

CYLINDER HEAD/VALVES Tempatkan cylinder head cover cylinderhead. head. Set the cylinder head cover ontopada the cylinder Install the specialbolts bolts and them todengan the specified Pasang special dan tighten kencangkan torsi torque. yang ditentukan. TORQUE:10 N·m (1.0 kgf·m, 7 lbf·ft) TORSI: 10 N.m (1,0 kgf.m; 7 lbf.ft)

SPECIAL BOLTS

CYLINDER HEAD COVER

CAMSHAFTEMOVALhaft can be serviced CAMSHAFT with the engine installed on the frame. Remove the following: PELEPASAN side covers – Lower sebagai (page 3-5) Lepaskan berikut: – Cylinder head cover (page 8-6) - – Lower side coverscover (hal.(page 3-5) 11-4) Left crankcase - –Cylinder headtensioner cover (hal. 8-6) washer/bolt Cam chain sealing - Left crankcase cover (hal. 11-4) - Cam chain tensioner sealing washer/bolt

SEALING WASHER/BOLT

Putar crankshaft berlawanan arah jarum jam sampai Turn the crankshaft counterclockwise until the index lines index penunjuk) pada sprocket on thelines cam(garis sprocket is aligned withcam the top surfacesejajar of the dengan atas dari cylinder head. cylinderpermukaan head. Make sure the piston is at TDC (Top Dead Center) on the Pastikan bahwa piston berada pada TDC (Top Dead compression stroke. This position can obtained confirming thatlangkah there is Center) [TMA =beTitik Matiby Atas] pada slack in the rocker arms. If there is no slack, turn the kompressi. crankshaft again until the correct position is obtained. Posisi ini dapat diketahui dengan mengkonfirmasikan Remove thekerenggangan bolts, cam sprocket from the camshaft and bahwa ada pada rocker arms. Jika tidak camkerenggangan, chain off the cam sprocket. ada putar crankshaft sekali lagi sampai posisi benar telahto diperoleh. Attachyang a piece of wire the cam chain to prevent it from falling into the crankcase. Lepaskan bolts, cam sprocket dari camshaft dan lepaskan cam chain dari cam sprocket.

INDEX LINES

CAM CHAIN

CAM SPROCKET

Ikatlah cam dengan sepotong kawat Remove the chain bolt/washer from the cylinder he agar tidak dapat terjatuh ke dalam crankcase. ad. Lepaskan bolt/washer dari cylinder head.

8-8

BOLT/WASHER

BOLTS

CYLINDER HEAD/VALVES Lepaskan camshaft cylinder head Remove the camshaft dari from the cylinder head sementara while holding the rocker tountuk ease removal. menahan rockerarms arms mempermudah pelepasan.

ROCKER ARMS

CAMSHAFT

CAMSHAFT INSPECTION Putar outer race (lingkaran luar) daribearing masing-masing Turn the outer race of each camshaft with your camshaft bearing dengan jari-jari. Bearing harus finger. The bearing should turn smoothly and quietly. Also check that the bearing inner race fits tightly on the berputar dengan halus dan tanpa suara. camshaft. Juga periksa bahwa bearing inner race (lingkaran dalam Replace the camshaft assembly if the bearing does not bantalan) duduk dengan erat pada camshaft. turn smoothly, quietly, or if they fit loosely on the camGanti shaft. susunan camshaft jika bearing tidak berputar dengan halus, tanpa suara, atau jika mereka duduk dengan longgar pada camshaft.

BEARINGS

Periksa cam bubungan) terhadap Check the cam lobes for(telinga excessive wear and damage. keausan berlebihan dan kerusakan. Measure the height of each cam lobe.

CAM LOBES

SERVICE LIMIT: Ukur tinggi masing-masing cam lobe. IN: 32.16 mm(1.266 in) BATAS SERVIS: EX: 31.96 mm(1.258 in) IN: 32,16 mm EX: 31,96 mm

PEMASANGAN INSTALLATION Semprotkan olioil mesin camshaft bearings Apply engine to thepada camshaft whole surface.(bantalan camshaft), cam lobes dan daerah perputaran Install the camshaft into the cylinder head with its tab facdecompressor cam. the rocker arms to ease installation. ing up while holding

ROCKER ARMS

CAMSHAFT

TAB

8-9

CYLINDER HEAD/VALVES Install and the bolt/washer. Pasang dantighten kencangkan bolt/washer.

Putar berlawanan arah jarum jamthesampai Rotatecrankshaft the crankshaft counterclockwise until index line online the (garis flywheel is aligned pada with the index notch the index penunjuk) flywheel (rodaongila) left crankcase. bertepatan dengan index notch (takik penunjuk) pada left crankcase.

BOLT/WASHER

INDEX NOTCH

INDEX LINE

Semprotkan chain cam Apply engineolioilmesin to thepada camcam chain and dan cam gigi sprocket sprocket. teeth. Install the cam chain on the cam sprocket with its stamp Pasang cam up, chain padasure camthat sprocket dengan tanda mark facing making the index lines on the cam sprocket are flushke withatas, the top surfacememastikan of the cylincetakan menghadap dengan der head as shown on the compression stroke). bahwa index lines (TDC (garis-garis penunjuk) pada cam Install the cam sprocket to the camshaft. sprocket sama tingginya dengan permukaan atas dari cylinder head seperti diperlihatkan (TDC pada langkah kompressi). Pasang cam sprocket pada camshaft.

CAM CHAIN

TANDA CETAKAN

CAM SPROCKET Apply locking to the pada cam sprocket threadsbolt as Oleskan cairanagent pengunci ulir cambolt sprocket shown.diperlihatkan. seperti Install and tighten the cam sprocket bolts to specified torque. dan kencangkan cam sprocket bolts dengan Pasang torsi yang ditentukan. TORQUE:8 N·m (0.82 kgf·m, 5.9 lbf·ft)

Lebar pelapisan: 6.5 ± 1.0 mm dari ujung

TORSI: 8 N.m (0,82 kgf.m; 5,9 lbf.ft)

BOLTS

8-10

INDEX LINES

CYLINDER HEAD/VALVES Pour 4.0 – 5.0 cc of oil ke into the cam chain Tuangkan 4,0 – 5,0 ccengine oli mesin dalam push rod. tensioner push rod as shown. Pasang sebuah sealing washer baru dan bolt, kemudian Install a new sealing washer and the bolt, then tighten it. kencangkan.

SEALING WASHER/BOLT

Install the following: Pasang sebagai headberikut: cover (page 8-7) – Cylinder - – Cylinder head cover (hal. 8-7) Left crankcase cover (page 11-5) - – Left crankcase cover (hal. 11-5) Lower side covers (page 3-5) - Lower side covers (hal. 3-5)

4.0 – 5.0 cc

8-11


CYLINDER HEAD HEAD CYLINDER REMOVAL PELEPASAN Lepaskan sebagai berikut: • Cylinder head can be serviced with the engine - Cam sprocket (hal. 8-8) installed on the frame. - Remove Exhaustthe pippe/muffler following: (hal. 3-16) - Insulator mounting bolts/O-ring (hal. 6-6) Camair sprocket (page(hal. 8-8) 6-20) - – PAIR supply pipe – Exhaust pipe/muffler (page 3-16) mounting – Inlet pipe (page 6-21) Lepaskan O2 sensor 1Pbolts/gasket connector (Hitam) dan lepaskan – PAIR air supply pipe (page 6-20) kawat dari clamp (hal. 6-44).

NUTS

BOLTS

Remove the cylinder head bolts. Lepaskan cylinder head bolts. Loosen the cylinder head nuts in a crisscross pattern in two or three steps. Longgarkan cylinder head nuts dalam pola bersilangan Remove four nuts, two washers and a plate. dalam duathe atau tiga langkah. Lepaskan ke-empat nuts, dua washers dan sebuah plate. PLATE Lepaskan cylinder head. Remove the cylinder head.

NUTS/WASHERS CYLINDER HEAD

Lepaskan gasket danand dowel pins. Remove the gasket dowel pins. DOWEL PINS

GASKET

8-12

CYLINDER HEAD/VALVES DISASSEMBLY PEMBONGKARAN ROCKERARM/SHAFT ARM/SHAFT ROCKER Remove the rocker shaft stopper bolt. Lepaskan rocker armarm shaft stopper bolt.

Screw the sebuah 5 mm bolt into bolt the threaded in the rocker Sekrupkan 5 mm ke dalamhole lubang berulir di arm shaft and arm pull itshaft out ofdan the cylinder head.dari cylinder dalam rocker tarik keluar Remove the rocker arms. head. Keluarkan rocker arms.

BOLT

ROCKER ARMS 5 mm BOLT

ROCKER ARM SHAFT

CAMSHAFT CAMSHAFT Keluarkan bolt/washer dan camshaft. Remove the bolt/washer and camshaft. BOLT/WASHER

CAMSHAFT

VALVE VALVE Untuk menghindari valve cotters menggunakan Remove the valve cottersdengan using the valve spring valve comTo prevent loss of Lepaskan hilangnya tegangan, pressor. compressor. tension, do not spring

VALVE SPRING COMPRESSOR

jangan tekan compress the valve valve springs lebih daripada TOOLS: springs more than TOOLS: yang diperlukan untuk Valve spring compressor 07757-0010000 necessary to remove Valve spring compressor 07757-0010000 mengeluarkan cotters. Valve spring compressor attachment 07959-KM30101 the cotters. Valve spring compressor 07959-KM30101

attachment

COTTERS

ATTACHMENT

8-13

CYLINDER HEAD/VALVES Tandai parts Mark all semua parts during selama pembongkaran disassembly so they sehingga merekaback dapat can be placed in ditempatkan kembali their original pada lokasi mereka locations. semula.

Lepaskan valve dan remove keluarkan Remove the valvespring spring compressor compressor and the following: sebagai berikut: - –Valve spring retainers Valve spring retainers Valve springs - –Valve springs Valve spring seats - –Valve spring seats – Valves - Valves – Valve stem seals - Valve stem seals

VALVE VALVE STEM SEAL

VALVE SPRING SEAT VALVE SPRING VALVE SPRING RETAINER Hati-hati agar tidak endapan ruang pembakaran dan Avoid damaging the Keluarkan Remove the carbon karbon depositsdari form the combustion chammerusak permukaan bersihkan off the cylinder surface. permukaan cylinderhead headgasket gasket. mating surface and ber and clean penyatuan dan valve seat surfaces. permukaan duduk valve.

COMBUSTION CHAMBER

INSPECTION CYLINDER HEAD PEMERIKSAAN Check the spark plug hole and valve areas for cracks. CYLINDER HEAD Check the cylinder head for warpage with a straight edge and a feeler gauge. Periksa lubang busi dan daerah valve terhadap retakretak. SERVICE Periksa head LIMIT: cylinder 0.05 mmterhadap (0.002 in) perubahan bentuk melengkung dengan mistar lurus dan feeler gauge.


ROCKERARM/SHAFT ARM/SHAFT ROCKER

Disassemble the head cylinder head (page 8-13). Bongkar cylinder (hal. 8-13). Check the rocker armshafts shafts dan and rocker wear or Periksa rocker arm rockerarms armsforterhadap damage. keausan atau kerusakan. Turn the rocker rollers with your finger. Putar rocker armarm rollers dengan jari-jari. The rollers should turn dengan smoothly and dan quietly. Rollers harus berputar halus tanpa suara. Measure the I.D. of each rocker arm. Ukur D.D. dari masing-masing rocker arm. SERVICE LIMIT:SERVIS: IN/EX: IN/EX: 10.10 BATAS 10,10mm mm(0.398 in)

ROLLERS

Ukur D.L. the dariO.D. masing-masing rocker shaft. Measure of each rocker arm arm shaft. SERVICE BATAS SERVIS: IN/EX: 9,91 mm LIMIT: IN/EX: 9.91 mm (0.390 in) Hitung jarak renggang rocker arm-ke-shaft. Calculate the rocker arm-to-shaft clearance. BATAS SERVIS: IN/EX: 0,044 mm SERVICE LIMIT:

8-14

IN/EX: 0.044 mm (0.0017 in)

ROCKER ARM SHAFTS

CYLINDER HEAD/VALVES VALVE VALVESPRING SPRING Disassemble the head cylinder head (page 8-13). Bongkar cylinder (hal. 8-13). Measure the free length ofsprings. the valve springs. Ukur panjang bebas valve SERVICE BATAS SERVIS: IN/EX: 29,70 mm LIMIT: IN/EX: 29.70 mm (1.169 in) Ganti springs jika mereka lebih pendek dari batas Replace the springs if they are shorter than the service servis. limit.

VALVE/VALVE GUIDE VALVE/VALVE GUIDE Disassemble the head cylinder head (page 8-13). Bongkar cylinder (hal. 8-13).

Check that the valve smoothly in the guide. Periksa bahwa valvemoves bergerak dengan halus di dalam Check each valve for bend, burn, scratch or abnormal guide. wear. Periksa masing-masing valve terhadap tekukan, Measure each valve stem O.D. and record it. keadaan terbakar, goresan atau keausan tidak normal. SERVICE LIMIT: IN: 4.965 mm stem (0.1955 in)catat. Ukur D.L. masing-masing valve dan EX: 4.945 mm (0.1947 in) BATAS SERVIS: IN: 4,965 mm EX: 4,945 mm

Selalu putar reamer Always rotate the searah jarum jam, reamer clockwise, jangan sekali-kali putar never berlawanan jarum counterclockwise sewaktu memasukkan, when inserting, mengeluarkan dan removing and melakukan pekerjaan reaming. reaming.

Lakukan pekerjaan reaming padaany valve guide untuk Ream the valve guide to remove carbon build up membuang pembentukan before measuring the guide.karbon sebelum mengukur Insert the reamer from the combustion chamber side of guide. the cylinderreamer head and rotate pembakaran the reamer clockMasukkan darialways sisi ruang dari wise. head dan selalu putar reamer searah jarum jam. cylinder TOOL: TOOL: Valve guide reamer, 5.0 mm 07984-MA60001 Valve guide reamer, 5.0 mm 7984-MA60001

Periksa dan lakukan Inspect and reface the pekerjaan refacing pada valveseats seatssetiap whenever valve kali the valve guides are valve guides diganti replaced (page 8-21). (hal. 8-21).

Ukur D.D. each masing-masing guide dan it. catat. Measure valve guidevalve I.D. and record

VALVE GUIDE REAMER

BATAS SERVIS: IN/EX: 5,03 mm SERVICE LIMIT:D.L. masing-masing IN/EX: 5.03valve mm (0.198 in) D.D. guide Kurangi stem dari yang bersangkutan untuk mendapatkan jarak renggang Subtract each valve stem O.D. from the corresponding stem-ke-guide. guide I.D. to obtain the stem-to-guide clearance. SERVICE BATAS SERVIS: IN: 0,065 mm LIMIT: IN: 0.065 EX: 0,085mm mm(0.0026 in) EX: 0.085 mm (0.0033 in) Jika renggangclearance stem-ke-guide melampaui If thejarak stem-to-guide exceeds the servicebatas limit, servis, tentukan apakah sebuah guide dengan determine if a new guide with standardbaru dimensions ukuran standard akan membawa jarak renggang di would bring the clearance within tolerance. If so, toleransi. replace any guides as necessary and ream to fit dalam (pagedemikian, 8-20). Jika gantilah guides yang diperlukan dan If the stem-to-guide clearance service limit lakukan pekerjaan reaming agarexceeds pas (hal.the 8-20). with new guide, also replace the valve. Jika jarak renggang stem-ke-guide melampaui batas servis dengan guide yang baru, gantilah valve juga.

8-15

CYLINDER HEAD/VALVES ASSEMBLY PERAKITAN COTTERS VALVE SPRING

SPRING RETAINER

EXHAUST ROCKER ARM SPRING SEAT INLET ROCKER ARM

VALVE STEM SEAL

VALVE GUIDE EXHAUST ROCKER ARM SHAFT

CLIP

INLET ROCKER ARM SHAFT

ROCKER ARM SHAFT STOPPER BOLT BOLT/WASHER

EXHAUST VALVE CAMSHAFT

INLET VALVE

VALVE VALVE Tiuplah melaluithe jalan dalam cylinder Blow through oil lintasan passageoli in dithe cylinder headhead with compressed air. dengan udara dari kompressor. Install the valve spring seats and newstem valveseals stembaru. seals. Pasang valve spring seats dan valve Coat the valve stem sliding surface with engine oil. Insertpermukaan the valves into the valve valve stem guides while turning them Lapisi luncur dengan oli mesin. slowly to avoid damage to the valve seals. Masukkan valves ke dalam valve stem guides sementara memutar mereka dengan pelan untuk menghindari kerusakan pada valve stem seals.

VALVE SPRING SEAT

STEM SEAL

8-16

CYLINDER HEAD/VALVES Pasang springs with dengan lilitan yang Install thevalve valve springs the tightly wound coilsrapat facmenghadap ke ruang pembakaran. ing the combustion chamber.

Ke ruang pembakaran

To prevent loss of Untuk menghindari tension, do not hilangnya tegangan, jangan tekan compress thevalve valve spring lebih more daripada spring than yangnecessary diperlukan untuk to install memasang thecotters. cotters.

Install the valve spring retainer. Pasang valve spring retainer. Install the valve cotters using the valve spring compresPasang valve cotters dengan menggunakan valve sor. spring compressor. TOOLS: Valve spring compressor 07757-0010000 TOOLS: Valve spring spring compressor Valve compressor 07757-0010000 attachment 07959-KM30101 Valve spring compressor 07959-KM30101 attachment

VALVE SPRING COMPRESSOR

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

Place a suitable toolsuitable onto the tool valve(alat stem.perkakas yang Letakkan sebuah sesuai) valve stem. Tap thepada tool gently to seat the cotters firmly using a hammer. Ketuk tool dengan ringan untuk mendudukkan cotters dengan erat dengan menggunakan palu plastik.

SUITABLE TOOL

COTTER

VALVE STEM

CAMSHAFT CAMSHAFT 3

Semprotkan 1,0 cm oliwhole mesin pada daerah Apply engine 0,5 oil to–the camshaft surface. perputaran decompressor cam, cam lobes dan Install the camshaft with its tab facing up. camshaft bearings.

CAMSHAFT

Pasang camshaft dengan tab-nya menghadap ke atas dan tab dari decompressor cam menghadap ke sisi ruang pembakaran.

TAB

8-17

CYLINDER HEAD/VALVES Install and the bolt/washer. Pasang dantighten kencangkan bolt-washer.

BOLT/WASHER

ROCKER ROCKERARM ARM Semprotkan mesin pada spermukaan luncur dan Apply engineoli oil to the sliding urface and roller surface of the rocker arm.dari rocker arm. permukaan roller Apply engineoli oil mesin to the sliding o f theluncur rocker arm Semprotkan pada surface permukaan dari shaft. rocker arm shaft.

INLET ROCKER ARM EXHAUST ROCKER ARM

ROCKER ARM SHAFTS Install the rocker arms to the cylinder head. Pasang rocker arms pada cylinder head. Install the exhaust rocker arm shaft into the exhaust Pasang exhaust rockerhead arm until shaft dalam exhaust rocker arm and cylinder it iske fully seated. rocker arm dan cylinder head sampai ia telah duduk Insert the inlet rocker arm shaft into the cylinder head sepenuhnya (exhaust = untuk klep buang). using a screwdriver while aligning the bolt holes of the shaft and cylinder head. Masukkan inlet rocker arm shaft ke dalam cylinder head dengan menggunakan obeng minus sementara menjajarkan lubang-lubang bolt dari shaft dan cylinder head (inlet = untuk klep masuk).

ROCKER ARMS

ROCKER ARM SHAFTS INLET ROCKER ARM SHAFT

Tepatkan (bolt holes)

8-18

CYLINDER HEAD/VALVES Pasang dantighten kencangkan rocker shaft stopper Install and the rocker armarm shaft stopper bolt.bolt.

BOLT

PEMASANGAN INSTALLATION Bersihkan cylinder cylinder Clean the permukaan cylinder and penyatuan cylinder head matingdan surface. head. Install the dowel pins and a new gasket onto the cylinder. Pasang dowel pins dan sebuah gasket baru pada cylinder.

DOWEL PINS

GASKET

Alurkan camcam chain melalui cylinder head dan pasang Route the chain through the cylinder head and install the cylinder onto the cylinder. cylinder head pada head cylinder.

CAM CHAIN

CYLINDER HEAD

Semprotkan permukaan duduk dan Apply engineoli oilmesin to the pada seating surface and threads of ulir the cylinder headhead nuts.nuts. Install the plate anddan two dua washers and dari cylinder Pasang plate washers tighten the cylinder cylinder head nutshead in a crisscross pattern to dan kencangkan nuts dalam pola the specified torque. bersilangan dengan torsi yang ditentukan. TORQUE:13 N·m (1.3 kgf·m, 10 lbf·ft) TORSI: 13 N.m (1,3 kgf.m; 10 lbf.ft) Install and tighten the cylinder head mounting bolts. Pasang danfollowing: kencangkan cylinder head mounting bolts. Install the

NUTS

BOLTS

– Cam sprocket (page 8-10) Hubungkan O2 sensor (page 1P 3-17) connector (Hitam) dan – Exhaust pipe/muffler amankan kawat dengan clamp (hal. 6-45).6-21) – Gasket/inlet pipe mounting bolts (page – PAIR air supply pipe (page 6-21) Pasang sebagai berikut:

-

Cam sprocket (hal. 8-8) Exhaust pippe/muffler (hal. 3-16) Insulator mounting bolts/O-ring (hal. 6-13) PAIR air supply pipe (hal. 6-20)

PLATE

NUTS/WASHERS

8-19

CYLINDER HEAD/VALVES VALVE GUIDEVALVE REPLACEMENT PENGGANTIAN GUIDE Disassemble thehead cylinder head (page 8-13). Bongkar cylinder (hal. 8-13). Chill new valve guides in a freezer for about 1 hour. Dinginkan valves guides baru di dalam bagian freeze dari lemari es selama kira-kira 1 jam. CATATAN: • Be sure to wear heavy gloves to avoid burns when handling heated cylinder sarungan head. • Pastikan the untuk memakai tangan tebal • Using torch to heat the cylinder bakar head may cause untuk a menghindari luka-luka sewaktu warpage. menangani cylinder head yang telah dipanaskan. • Drive new guides from the camshaft side while the • Jangan head menggunakan obor untuk memanaskan cylinder is still heated. cylinder head karena dapat mengakibatkan Heat the cylinder head to 130 – 140°C (275 – 290°F) with perubahan ben tuk melengkung. a hot plate or oven. Do not heat the cylinder head Dorong masuk guides baru dari sisi camshaft • beyond 150°C (300°F). Use temperature indicator sticks, sementara cylinder h ead masih dipanaskan. available from welding supply stores, to be sure the cylinPanaskan head 130 – 140°C dengan der head iscylinder heated to the sampai proper temperature. kompor listrik atau oven. Jangan memanaskan cylinde Support the cylinder head and drive the valve guides out ° C. Pakailah tongkat indikator head melampaui 150 of the cylinder head from the combustion chamber side. suhu, yang dapat dibeli dari toko pemasok TOOL: perlengkapan pengelasan, untuk memastikan bahwa Valve guide driver, mm 07942-MA60000 cylinder head telah5.0 dipanaskan sampai ke suhu yang tepat. Take out new valve guides from the freezer. Topang cylinder head dan dorong keluar valve guide Drive new clips guidespembakaran. into the cylinder head dari cylinder headand darivalve sisi ruang to the specified height from the cylinder head. TOOL: Valve guide driver, 5.0 mm 07942-MA60000 TOOL: Valve guide driver, 5.0 mm 07942-MA60000 Keluarkan valve guides baru dari freezer. Dorong masuk clips baru dan valve guides ke dalam VALVE GUIDE PROJECTION: cylinder h ead sampai ke ketinggian yang ditentukan dari IN/EX: 9.1 – 9.3 mm (0.36 – 0.37 in) cylinder head. TOOL: Let the cylinder head cool to room temperature. Valve guide adjusting driver 07743-0020000

PROYEKSI VALVE GUIDE: IN/EX: 9,1 – 9,3 mm Biarkan cylinder head menjadi dingin kembali sampai ke suhu ruangan. Lakukan pekerjaan reaming pada valve guides baru Ream new valve guides after installation. s etelah pem asangan. CATATAN: care not to tilt or lean the reamer in the guide Hati-hati agar tidak memiringkan atau • • Take while reaming. mencondongkan ream er di dalam guide sewaktu • Use cutting oil on the reamer during this operation. meng-reaming. the reamer from the chamber side of Pakailah cutting oil combustion pada ream er selama • Insert the pengerjaan cylinder head i ni. and always rotate the reamer clockwise. Masukkan reamer dari sisi ruang pembakaran dari cylinder head dan selalu putar reamer searah dengan TOOL: perpu taran jarum jam. Valve guide reamer, 5.0 mm 07984-MA60001 TOOL: Valve ream er, 5.0 thoroughly mm 07984-MA60001 Cleanguide the cylinder head to remove any metal particles after reaming and reface the valve seat (page 8Bersihkan cylinder head secara menyeluruh untuk 21) membuang partikel-partikel logam setelah pekerjaan reaming dan jalankan pekerjaan refacing (pembentukan kembali permukaan) pada valve seat (hal. 8 -21).

8-20

VALVE GUIDE DRIVER

VALVE GUIDE

VALVE GUIDE DRIVER VALVE GUIDE/ CLIP

9.1 – 9.3 mm (0.36 – 0.37 in)

VALVE GUIDE REAMER

CYLINDER HEAD/VALVES VALVE SEAT INSPECTION/REFACING PEMERIKSAAN/REFACING VALVE SEAT Disassemble thehead cylinder head (page 8-13). Bongkar cylinder (hal. 8-13). Clean the intake and exhaust valves thoroughly to Bersihkan intake valves (klep pemasukan) dan exhaust remove carbon deposits. valves (klep pembuangan) secara menyeluruh untuk Apply a light coat of Prussian Blue to the valve s eats. menghilangkan endapan karbon. Tap the valve against the valve seat several times using a hand-lapping tool, without rotating the valve to make a Oleskan lapisan tipis Prussian Blue pada valve seats clear pattern. (dudukan klep). Ketuk valve terhadap valve seat beberapa kali dengan menggunakan hand-lapping tool (alat skir klep dengan tangan), tanpa memutar valve agar mendapatkan pola yang jelas.

Valves tidak dapat The valves cannot be digerinda. Jika ground. If themuka valve valve sangat faceterbakar, is burned, badly aus atau jika ia worn or if it contacts mengkontak seat secara the seat unevenly, tidak merata, gantilah replace the valve. valve.

HAND-LAPPING TOOL

Lepaskan valve danand periksa muka Remove the valve inspect the valve seat. seat face. The valve should within theditentukan specified Kontak valveseat seatcontact harus di dalambe lebar yang width and even all around the circumference. dan merata sepanjang kelilingnya. STANDARD: 0.90 – 1.10 mm (0.035 – 0.043 in) STANDARD: 0,90 - 1,10 mm SERVICE BATAS 1,6mm mm LIMIT:SERVIS: 1.6 (0.06 in) If thelebar valvevalve seat seat width di is luar not within specification, Jika spesifikasi, reface reface valve the valve seat (page 8-21). seat (bentuk kembali permukaan dudukan klep) (hal. 821). LEBAR SEAT

Inspectmuka the valve seat face for: Periksa valve seat terhadap: • •

Damaged Kerusakanface: pada muka: – Replace the valve and reface the valve seat - Gantilah valve dan reface valve seat • Uneven seat width: Lebar tidak merata: • – Bentseat or collapsed valve stem; Replace the valve - and Valve stem bengkok atau roboh; Ganti valve dan reface the valve seat reface valve seat.

MUKA RUSAK • •

LEBAR SEAT TIDAK MERATA

Contact (too low orrendah too high area): Daerah area kontak (terlalu atau terlalu tinggi): –- Reface valve Reface the valve seatseat

TERLALU RENDAH

TERLALU TINGGI

8-21

CYLINDER HEAD/VALVES • •

Ikuti penunjuk pemakaian pabrik pembuat refacer. • Follow the refacer manufacturer’s operating instructions. Hati-hati agar tidak menggerinda seat lebih • Be carefulyang not to grind the seat more than necessary. daripada diperlukan. 45°

60° 32°

Jika daerah kontak tinggi valve, If the contact area isterlalu too high on pada the valve, theseat seatharus must be 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 Jika daerah kontak terlalu rendah be raised using a 60° interior cutter. pada valve, seat harus dinaikkan dengan menggunakan 60° finish ° interior Refinish the seat to specifications, using a 45 cutcutter. ter. Haluskan permukaan seat sesuai dengan spesifikasi, dengan menggunakan 45 ° finish cutter.

KONTAK TERLU TERLALU T TINGGI OLD LEBAR SEATSEAT WIDTH LAMA

32°

KONTAK TERLALU RENDAH CONTACT TOO LOW SEAT LAMA OLDLEBAR SEAT WIDTH

60° Reface the seat with a Pakailah Use a 4545 ° seat cutter, remove any roughness or irregucutter, hilangkan kekerasan atau ° seat 45 cutter whenever a ketidak-teraturan larities from the seat. dari seat . valve guide is TOOLS: replaced. TOOLS: °

° IN) Seat cutter, cutter, 27.5 Seat 27.5mm mm(45 (45 IN) ° EX) Seat cutter, cutter, 24 Seat 24mm mm(45 (45 EX) Cutter 5.0mm mm Cutterholder, holder, 5.0

KEKASARAN

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

Pakailah cutter,remove hilangkan ¼ bagian teratas dari ° flat Use a 3232 ° flat cutter, the top 1/4 of the existing bahan valvematerial. seat yang ada sekarang. valve seat TOOLS: TOOLS: Flatcutter, cutter, 27 Flat 27 mm mm(32 (32° IN) IN) Flat cutter, 22 mm (32 Flat cutter, 22 mm (32° EX) EX) Cutterholder, holder, 5.0 Cutter 5.0mm mm

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

OLD SEAT WIDTH LEBAR SEAT LAMA

32°

8-22

CYLINDER HEAD/VALVES Use a 60°60 interior cutter,cutter, removehilangkan the bottom¼1/4bagian of the ° interior Pakailah existing valve seat material. terbawah dari bahan valve seat yang ada sekarang. TOOLS: TOOLS: Interiorcutter, cutter, 26 Interior 26 mm mm(60 (60° IN) IN) Interior cutter, 22 mm (60 Interior cutter, 22 mm (60° EX) EX) Cutterholder, holder, 5.0 Cutter 5.0mm mm

OLD SEAT WIDTH LEBAR SEAT LAMA 07780-0014500 07780-0014500 07780-0014202 07780-0014202 07781-0010400 07781-0010400

60°

Dengan menggunakan 45°theseat potongwidth. seat Using a 45 ° seat cutter, cut seatcutter, to the proper sampai lebar yang benar. VALVE SEAT WIDTH:0.90 – 1.10 mm (0.035 – 0.043 in) LEBAR VALVE SEAT: 0,90 – 1,10 mm Make sure that all pitting and irregularities are removed. Pastikan bahwa semua lubang-lubang dan ketidakteraturan telah dihilangkan.

0.90 – 1.10 mm (0.035 – 0.043 in)

45°

• Excessive lapping pressure may deform or damage the seat. CATATAN: Tekanan skir klep yang berlebihan dapat merubah • • bentuk atau merusak seat. Ubah sudut dari lapping tool sering-sering untuk • menghindari keausan seat yang tidak merata. • Jagalahthe agar compound (ambril) tidak • • Change anglelapping of lapping tool frequently to prevent memasuki uneven seatguides. wear. • Do not allow lapping compound to enter the guides. Setelah memotong seat, oleskan compound After cutting the seat, apply lappinglapping compound to the pada valve, skir klep dengan menggunakan valvemuka face, and lapdan the valve using light pressure. tekanan ringan.wash any residual compound off the cylin After lapping, der head and valve and recheck the seat contact. Setelah menskir klep, cucilah compound yang tersisa Assemble the cylinder head (page 8-16). dari cylinder head dan valve dan periksa kembali kontak seat .

HAND-LAPPING TOOL

Rakit cylinder head (hal. 8-16).

8-23


CAM CHAIN CHAINTENSIONER TENSIONER CAM PELEPASAN REMOVAL Remove the flywheel (page 11-7). Lepaskan flywheel (hal. 11-7). Remove the cam chaintensioner tensionersealing sealing washer/bolt, washer/bolt, Lepaskan cam chain tensioner spring and the push rod. tensioner spring dan push rod.

TENSIONER SPRING

PUSH ROD

SEALING WASHER/BOLT

Lepaskan pivot bolt, dan Remove the pivot bolt,washer, washer,tensioner tensioner arm/collar arm/collar and the tensioner roller. tensioner roller.

TENSIONER ROLLER

TENSIONER ARM/COLLAR

INSPECTION PEMERIKSAAN Measure the tensioner spring free length. Ukur panjang bebas tensioner spring. SERVICE LIMIT: 109 mm (4.3 in) BATAS SERVIS: 109 mm

Periksa push rodrod terhadap keausan atau kerusakan. Check the push for wear or damage. Measure the push Ukur D.L. push rod.rod O.D. SERVICE LIMIT:11,94 11.94 mm BATAS SERVIS: mm (0.470 in)

8-24

PIVOT BOLT/ WASHER

CYLINDER HEAD/VALVES Inspect the check valvediin the push push rod forrod wearterhadap or damPeriksa check valve dalam age. keausan atau kerusakan.

CHECK VALVE

INSTALLATION Install the cam chain tensioner PEMASANGAN

roller, collar, tensioner arm and the pivot bolt/washer, then tighten it to the specified torque. Pasang cam chain tensioner roller, collar, tensioner arm dan pivot bolt/washer, kemudian kencangkan dengan TORQUE: 16 N·m (1.6 kgf·m, 12 lbf·ft) torsi yang ditentukan.

TENSIONER ROLLER

COLLAR

TORSI: 16 N.m (1,6 kgf.m; 12 lbf.ft)

TENSIONER ARM Install the push rod. Pasang sebagai berikut: Install the tensioner spring with its tapered side facing - down. Push rod - Install Tensioner and spring tighten the sealing bolt with a new sealing washer to the specified torque. Pasang dan kencangkan sealing bolt dengan sebuah TORQUE: 22 N·m kgf·m, 16 lbf·ft) sealing washer baru(2.2 dengan torsi yang ditentukan.

Sisi berulir

PIVOT BOLT/WASHER PUSH ROD

TORSI: 22 N.m (2.2 kgf.m; 16 lbf.ft)

TENSIONER SPRING Remove cam the chain cam tensioner chain tensioner sealing bolt and Lepaskan sealing bolt dan washer. washer. Tuangkan 4,0 – 5,0 cc oli mesin ke dalam push rod. Pour 4.0 – 5.0 cc of engine oil into the push rod.

SEALING WASHER/BOLT

4.0 – 5.0 cc

Pasang dan tighten kencangkan sealing Install and the sealing boltbolt withdengan a new sebuah sealing washer. sealing washer baru. Install the flywheel (page 11-12). Pasang flywheel (hal. 11-8).

SEALING WASHER/BOLT

8-25


OILSTOPPER STOPPER PLATE PLATE OIL PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Remove the flywheel Lepaskan flywheel (hal. 11-7). (page 11-7). Remove the stopper plate. Lepaskan boltbolt danand oil oil stopper plate. Apply locking agentpengunci to the bolt pada threadsulir as specified. Oleskan cairan bolt seperti Install the oil stopper plate and tighten the bolt. ditentukan. Install the (page dan 11-12). Pasang oil flywheel stopper plate kencangkan bolt.

Lebar pelapisan: 6.5 ± 1.0 mm ±dari ujung

Pasang flywheel (hal. 11-8).

BOLT

8-26

PLATE

9. CYLINDER/PISTON

LOKASI KOMPONEN .............................. 9-2 COMPONENT LOCATION ····························9-2

TROUBLESHOOTING ............................. 9-4 TROUBLESHOOTING ····································9-4

KETERANGAN SERVIS .......................... 9-3 SERVICE INFORMATION ·····························9-3

CYLINDER/PISTON ................................. 9-5 CYLINDER/PISTON ········································9-5 9

9-1

CYLINDER/PISTON

COMPONENT LOCATION LOKASI KOMPONEN CYLINDER/PISTON

10 N·m (1.0 kgf ·m, 7 lbf ·ft)

9-2

CYLINDER/PISTON

KETERANGAN SERVIS SERVICE INFORMATION GENERAL UMUM • •• • • •• •

This section covers service of the cylinder and piston. These services can be performed with the engine installed in the frame. Babcare ini meliputi servisthe dari cylinder dan piston. Pekerjaan servis ini dapat dilakukan dengan mesin terpasang pada r angka. Take not to damage cylinder wall and piston. Hati-hati agar tidak merusak dinding cylinder dan piston. Be careful not to damage the mating surfaces when removing the cylinder. Do not tap the cylinder too hard during removal. Hati-hati agar tidak merusak permukaan penyatuan cylinder. in Jangan mengetuk cylinder terlalu keras When disassembling, mark and store the disassembled parts toketika ensuremelepaskan that they are reinstalled their original locations. sewaktu pelepasan.parts with cleaning solvent and dry them by blowing them off with compressed air before inspection. Clean all disassembled Sewaktu pembongkaran, tandai dan simpanlah parts yang dibongkar untuk memastikan bahwa mereka dipasang kembali • pada lokasinya semula. SPECIFICATIONS • Bersihkan semua parts yang dibongkar dengan larutan pembersih dan keringkan dengan meniup dengan udara dari kompressor sebelum pemeriksaan. Unit: mm (in)

SPESIFIKASI

ITEM

STANDARD

Cylinder BAGIAN Cylinder

I.D. 50.005 – 50.015 (1.9687 – 1.9691) STANDARD Out-of-round – D.D. 50,005 ––50,015 Taper Kelonjongan Warpage – Ketirusan Piston, piston Piston mark direction "IN" mark facing toward the intake side rings Perubahan - (1.9677 – 1.9683) Piston O.D.bentuk melengkung 49.980 – 49.995 Piston, Arah tanda piston point Tanda "IN" menghadap ke Piston O.D.pada measurement 10 mm (0.4 in) from bottom of skirt piston rings sisi (0.5119 pemasukan Piston pin bore I.D. 13.002 – 13.008 – 0.5121) D.L. piston 49,980 – 49,995 Piston pin O.D. 12.994 – 13.000 (0.5116 – 0.5118) Titik pengukuran pin D.L. piston mm –dari bagian bawah Piston-to-piston clearance 0.002 – 0.01410 (0.0001 0.0006) Piston ring-to-ring Top 0.015 – 0.050piston (0.0006 – 0.0020) D.D. lubang piston pin 13,002 – 13,008 groove clearance Second 0.015 – 0.050 (0.0006 – 0.0020) (Riken) D.L. piston pin 12,994 – 13,000 Piston ring-to-ring Top (0.0006 – 0.0018) Jarak renggang antara piston-ke-piston pin 0.015 – 0.0450,002 – 0,014 groove clearanceantara piston ring- Paling atas Jarak renggang 0,015 –0,050 Second 0.015 – 0.045 (0.0006 – 0.0018) (Teikoku) (Riken) ke-alurnya Kedua 0,015 – 0,050 Piston ring end gap Top 0.10 – 0.25 (0.004 Jarak renggang antara piston ring- Paling atas 0,015––0.010) 0,045 (Riken) Second ke-alurnya (Teikoku) Kedua 0.10 – 0.25 (0.004 0,015––0.010) 0,045 Oil (side 0.20 – 0.70 (0.008 0.028) Celah pada ujung piston ringrail)Paling atas 0,10 –– 0,25 Piston ring end gap Top 0.010) (Riken) Kedua 0.10 – 0.25 (0.004 0,10 –– 0,25 (Teikoku) Second 0.35 0.020) Oli (side rail)– 0.50 (0.014 0,20 –– 0,70 Oil (side 0.20 – 0.70 (0.008 0.028) Celah pada ujung piston ringrail)Paling atas 0,10 –– 0,25 Cylinder-to-piston clearance (0.0004 – 0.0014) (Teikoku) Kedua 0.010 – 0.0350,10 – 0,25 Connecting rod small end I.D. 13.016 Oli (side rail) – 13.034 0,20(0.5124 – 0,70– 0.5131) Connecting rod-to-piston pin clearance 0.016 – 0.0400,010 (0.0006 – 0.0016) Jarak renggang antara cylinder-ke-piston – 0,035 D.D. kepala kecil connecting rod 13,016 – 13,034 Jarak renggang antara connecting rod-ke-piston pin 0,016 – 0,040

TORQUE VALUES

Cam chain guide roller pin bolt

TORSI CylinderPENGENCANGAN stud bolt Cam chain guide roller pin bolt Cylinder stud bolt

10 N·m (1.0 kgf·m, 7 lbf·ft) –

10 N.m (1,0 kgf.m; 7 lbf.ft) -

SERVICE LIMIT Satuan: mm 50.05 (1.970) BATAS 0.10SERVIS (0.004) 50,050.10 (0.004) 0,10 0.05 (0.002) 0,10 – 0,05 49.91 (1.965) – 13.03 (0.513) 49,9112.98 (0.511) 0.075 (0.0030) 0.09 (0.004) 13,03 0.09 (0.004) 12,98 0,0750.09 (0.004) 0,09 0.09 (0.004) 0,09 0,09 0.5 (0.02) 0,09 0.5 (0.02) 0,5 1.1 (0.04) 0,5 0.5 (0.02) 1,1 0.75 (0.030) 0,5 1.1 (0.04) 0,5 0.10 (0.004) 1,1 13.05 (0.514) 0,10 0.07 (0.003)

13,05 0,07

See page 9-8

Lihat hal. 9-8

9-3

CYLINDER/PISTON

TROUBLESHOOTING TROUBLESHOOTING Compression too low, hard starting or poor performance at low speed Kompressi terlalu rendah, mesin sulit dihidupkan atau unjuk kerja buruk • Leaking cylinder head gasket pada kecepatan • Worn, stuck orrendah broken piston ring Cylinder head gasket bocor • • Worn or damaged cylinder and piston connecting • • Bent Piston ring aus,rod macet atau patah Cylinder dan piston aus atau rusak •Compression too high, overheating or knocking • • Excessive Connecting rod bengkok carbon built-up on piston head or combustion chamber Excessive smoke Kompressi terlalupiston tinggi, • Worn cylinder, or overheating piston rings atau knocking • • Improper Ada pembentukan karbon secara installation of piston rings berlebihan pada piston head (kepala piston) atau di ruang pembakaran • Scored or scratched piston or cylinder wall head/valve problem (page 8-5) • Cylinder Asap berlebihan Cylinder, piston atau piston rings aus •Abnormal noise • • Worn Pemasangan piston rings piston pin or piston pintidak holebenar • Worn cylinder, piston or piston rings atau tergores • Piston atau dinding cylinder tergerus • Worn connecting rod small end • Ada persoalan pada cylinder head/valve (hal. 8-5) • Excessive carbon build-up

Suara tidak normal Piston pin atau lubang piston pin aus • • Cylinder, piston atau piston rings aus • Kepala kecil connecting rod aus Ada pembentukan karbon secara berlebihan •

9-4

CYLINDER/PISTON

CYLINDER/PISTON CYLINDER/PISTON PELEPASAN CYLINDER CYLINDER REMOVAL Be careful not to drop Hati-hati agar tidak the guide roller into menjatuhkan guide the crankcase. roller ke dalam crankcase.

Remove the following: Lepaskan sebagai berikut: EOT sensor (page8-12) 6-42) - – Cylinder head (hal. Cylinder - – Cam chain head guide(page roller8-12) pin bolt/sealing washer – Cam chain guide roller pin bolt/sealing washer - Guide roller – Guide roller

GUIDE ROLLER

ROLLER PIN BOLT/ SEALING WASHER Be careful not to Lepaskan Remove the cylinder. Hati-hati agar tidak cylinder. damage the mating merusak permukaan penyatuan. surface.

CYLINDER Remove the gasket dowel pins. Lepaskan gasket danand dowel pins.

GASKET

DOWEL PINS

PELEPASAN PISTON PISTON REMOVAL Place clean shop Letakkan kaina lap bersih towel over the di atas crankcase agar crankcase prevent clip tidak dapattojatuh ke the clip from falling dalam crankcase. into the crankcase.

Remove the piston with pliers. Lepaskan piston pinpin clipclip dengan tang. Push the piston pin out of the piston and connecting rod, Dorong piston pin keluar dari piston dan connecting rod, and remove the piston. dan keluarkan piston.

PISTON PIN

PISTON

CLIP

9-5

CYLINDER/PISTON Jangan piston masing-masing pistonitring dan lepaskan Spread each piston ring and remove by lifting it up at a Do merusak not damage the Renggangkan ring dengan ke atas pada sebuah titik di piston ring by dengan point justmengangkatnya opposite the gap. merenggangkan ujung- seberang celah. spreading the ends ujungnya terlalu jauh. too far.

Jangan Neversekali-kali use a wire Bersihkan Clean carbon deposits from the piston ring grooves endapan karbon dari alur-alur piston with ring memakai ia dengan a used piston ring that will be bekas discarded. brush;sikat it willkawat, damage sebuah piston ring yang tidak dipakai akan merusak alur. lagi. the groove.

PISTON RING BEKAS

Blow the oil passage with compressed air, if necessary.

Tiuplah jalan lintasan oli dengan udara dari kompressor, bila perlu.

ALUR-ALUR PISTON RING


CYLINDER CYLINDER Inspect the cylinder wall for scratches and wear. Measure and record theterhadap cylinder goresan I.D. at three levels in Periksa dinding cylinder dan keausan. both the X and Y axis. Take the maximum reading to Ukur dan catat D.D. cylinder pada tiga tingkat pada determine the cylinder wear. poros X dan Y. Ambil bacaan maksimum untuk SERVICE keausan cylinder. menentukan LIMIT: 50.05 mm (1.970 in) BATAS SERVIS: 50,05 mm Calculate the cylinder-to-piston clearance. Hitung jarak renggang cylinder-ke-piston. For measurement of the piston O.D. (page 9-7).

Untuk pengukuran D.L. piston (hal. 9-7). SERVICE LIMIT: SERVIS: 0.10 BATAS 0,10mm mm(0.004 in)

Hitung ketirusan dan for kelonjongan cylinder pada tiga Calculate the cylinder taper and out-of-round at three levels in an Xporos and YXaxis. the maximum reading to tingkat pada dan Take Y. Ambil bacaan maksimum determine the taperkedua and out-of-round. untuk menentukan pengukuran. SERVICE LIMITS: BATAS SERVIS: 0.10 mm (0.004 in) Taper: Ketirusan: 0,10 mm Out-of-round: 0.10 mm (0.004 in) Kelonjongan: 0,10 mm The cylinder must be rebored and an oversize piston fitted if the service are exceeded. Cylinder harus limits dikorter dan oversize piston harus dipasang jika batas servis dilampaui. These parts numbers The following oversize pistons are available: may be change 0.25 mm (0.010 in): 13102-KWB-305 Nomor-nomor parts ini Oversize pistons berikut tersedia: without written 0.50 mm (0.020 in): 13103-KWB-305 dapat berubah tanpa permission. 13102-KWB-305 0.75mm: mm (0.030 in): 13104-KWB-305 pemberitahuan tertulis. 0,25

0,50 13103-KWB-305 1.00mm: mm (0.040 in): 13105-KWB-305 0,75 mm: 13104-KWB-305 1,00 13105-KWB-305 The mm: cylinder must be rebored so that the clearance for an oversize piston is 0.010 – 0.035 mm (0.0004 – 0.0014 in). Cylinder harus dikorter sehingga jarak renggang untuk sebuah oversize piston adalah 0,010 – 0,035 mm.

9-6

Y ATAS

TENGAH

BAWAH

X

CYLINDER/PISTON Periksa terhadap perubahan bentuk Check thecylinder cylinder for warpage by placing a straight edge and a feeler gauge across thesebuah stud holes as shown. melengkung dengan meletakkan mistar lurus dan feeler gauge antara lubang-lubang stud seperti SERVICE diperlihatkan. LIMIT: 0.05 mm (0.002 in) BATAS SERVIS: SERVIS: 0,05 mm

Selalu ganti piston rings Always replace the sebagai sebuah set. piston rings as a set.

PISTON/PISTON PISTON/PISTONRING RING Periksa rings kehalusan Inspect piston the piston ringsterhadap for smooth movementpergerakan by rotating them. The rings should be Rings able toharus move dapat in theirbergerak grooves dengan memutar mereka. without catching. dalam alurnya tanpa menyangkut. Push the ring until the outer surface of the piston ring is nearly ring flush sampai with the permukaan piston and measure clearance Tekan luar darithe piston ring using a feeler gauge. hampir rata dengan piston dan ukur jarak renggang dengan menggunakan SERVICE LIMITS: feeler gauge. Top: 0.09 mm (0.004 in) BATAS SERVIS: Seco Se cond nd: : 0. 0.09 09 mm (0. (0.00 004 4 in) in) Atas: 0,09 mm Kedua: 0,09 mm

Masukkan ring into secara tegaklurus ke cylinder dalam Insert the piston piston ring the bottom of the squarelybawah using the piston crown.dengan mendorongnya bagian dari cylinder Measure the ring piston. end gap. dengan mahkota piston. mahkota Ukur celah pada ujung ring. SERVICE LIMITS: Top: BATAS SERVIS: Seco Se cond nd (R (Riike ken n): Atas: Second Sec ond (T (Teik eikoku oku): ): Kedua (Riken): Oil (s (side ra rail): Kedua (Teikoku): Oli (side rail):

PISTON RING

0.5 mm (0.02 in) 0.5 mm (0 (0.0 .02 2 in) in) 0,5 mm 0.75 0.7 5 mm (0.0 (0.030 30 in) in) 0,5 mm 1.1 mm mm (0.04 in) 0,75 mm 1,1 mm

Ukur D.L. piston pada sebuah titik 10 10 mm mm (0.4 dari in) bagian Measure the piston O.D. at a point from ° dari bawah dan 90 lubang piston lubang pistonpin pin. the bottom and 90° to the piston hole. SERVICE BATAS SERVIS: SERVIS: 49,91 mm LIMIT: 49.91 mm (1.965 in) Untuk pengukuran D.D. cylinder (hal. 9-6). For measurement of the cylinder I.D. (page 9-6). 9-6). Hitung jarak renggang cylinder - ke- piston. piston. Calculate the cylinder-to-piston clearance. BATAS SERVIS: SERVIS: 0,10 mm SERVICE LIMIT: 0.10 mm (0.004 in)

90° 10 mm (0.4 in)

9-7

CYLINDER/PISTON Ukur D.D. piston lubang piston lubangpin piston Measure bore pin I.D.pada in anporos X andXYdan axis.Y. Take bacaan the maximum reading to determine I.D. D.D. Ambil maksimum maksimum untuk menentukan SERVICE BATAS mm LIMIT:SERVIS: 13,03 13.03 m m (0.513 in) Ukur D.L. piston D.L. piston pin pada tiga titik. Measure the piston pin O.D. at three points. BATAS SERVIS: 12,98 mm SERVICE LIMITjarak : 12.9 piston-ke8 mm (-ke0.5 piston 1 1 in) pin. Hitung renggang renggang piston piston

Calculate the piston-to-piston BATAS SERVIS: 0,075 mm pin clearance. SERVICE LIMIT:

0.075 mm (0.0030 in)

CONNECTING ROD

CONNECTING ROD Measure the connecting rod small end I.D. Ukur D.D. kepala kecil connecting rod. SERVICE LIMIT: 13.05 mm (0.514 in) BATAS SERVIS: 13,05 mm Calculate the connecting rod-to-piston pin piston clearance. Hitung jarak renggang connecting rod -ke-ke piston pin. SERVICE BATAS SERVIS: 0,07 mm LIMIT: 0.07 mm (0.003 in)

CYLINDER STUD BOLT PENGGANTIAN CYLINDER STUD BOLT REPLACEMENT Sewaktu mengganti stud bolts, pasanglah If replacing the cylindercylinder stud bolts, be sure to install them as shown. sebagai berikut. Thread two nuts onto the stud bolt, and tighten them together, then usepada a wrench on them tokencangkan turn the studsatu bolt Pasang dua nuts stud bolts, dan out. lain, kemudian pakailah kunci pas padanya untuk sama memutar stud bolt keluar. Install and tighten new stud bolts to the specified torque. TORQUE:11 N·m (1.1 kgf·m, 8 lbf·ft) Pasang dan kencangkan stud bolts baru dengan torsi yang Afterditentukan. tightening the stud bolts, check that the length from the bolt head to the crankcase surface is within specification. TORSI: 6 N.m (0,61 kgf.m; 4,4 lbf.ft)

Setelah mengencangkan stud bolts, periksa bahwa panjang dari kepala bolt sampai permukaan crankcase adalah sesuai dengan spesifikasi.

9-8

176.0 ± 1.0 mm (6.93 ± 0.04 in)

CYLINDER/PISTON PEMASANGAN PISTON PISTON INSTALLATION Clean thekepala piston, piston piston, heads, ring grooves Bersihkan kepala alur-alur ringand danskirts. skirts (rok). Carefully piston install the piston rings onto the piston their TANDA RING KEDUA Pasang rings dengan hati-hati padawith piston ("RN" atau "T") markings facing up. dengan tanda-tandanya menghadap ke atas.

Do not align the gaps of the oil ring side rails. angan sejajarkan celah-celah dari oil ring side rails.

• Be careful careful not to to damage damage the piston piston and and piston piston rings CATATAN: during installation. • Hati-hati agar tidak merusak piston merusak piston dan piston dan piston rings • Do not confuse not conf use the the top top and secon second d rings. rings. selama pemasangan. • When installing installing the oil ring, install install the the spacer spacer first first and • Jangan rings paling atas dengan yang then the pertukarkan side rails. kedua. Stagger the piston ring end gaps 120 degrees apart from Ketika memasang pasang spacer dulu, • each other as shown. oil ring, pasang kemudian pasang side rails. Stagger the side rails gaps as shown. After installation, the pis ton rings should be free to rotate Selang-selingkan celah pada ujung piston ring sejarak in the groove. 120 derajat dari masing-masing seperti diperlihatkan. Selang-selingkan celah pada ujung side rail seperti diperlihatkan.

TANDA RING ATAS ("R" atau "1T")

RING ATAS 120° 120°

RING KEDUA

120°

Setelah pemasangan, piston pemasangan, piston rings harus dapat berputar bebas di dalam alur-alurnya. SPACER

SIDE RAILS

20 mm (0.8 in) ATAU LEBIH

Letakkan kain lap menutupi crankcase untuk mencegah Place a clean shop towel over the crankcase to prevent the dirt, dust or piston pin clips from entering crankmasuknya kotoran, debu atau piston pin clips the ke dalam case. crankcase. Be careful not to Clean the gasket mating surfaces of the crankcase and Hati-hati tidak Bersihkan cylinder thoroughly. permukaan-permukaan penyatuan gasket damageagar the gasket merusak permukaandari crankcase cylinderrod secara mating surfaces. Apply oil to thedan connecting smallmenyeluruh. end inner surface.

permukaan penyatuan penyatuan gasket.

Semprotkan oli pada permukaan dalam kepala kecil connecting rod.

Semprotkan oli pada dalam lubang Apply oil to the pistonpermukaan pin hole inner surface and piston p iston pin permukaan luar piston pin. pindan outer surface. luar piston Install the pistondengan with thetanda "IN" mark the intakke e side. Pasang piston "IN"facing menghadap sisi Instal the piston pin. pemasukan. Pasang piston Pasang piston pin.

TANDA "IN"

PISTON PIN

PISTON

9-9

CYLINDER/PISTON Pasang piston Pasang piston clips clipspin baru. Install the newpin piston clips. CATATAN: • Make sure sure the the piston piston pin clips are are seated seated securely. securely. Pastikan bahwa piston bahwa piston pinclip telah dengan • • Do not align the piston the pisto n pin clclips ip end gap duduk gap with the piston piston kokoh. cutout. Jangan mentepatkan celah pada ujung piston pin • clip dengan potongan pada piston. pada piston.

CLIP

PEMASANGAN CYLINDER CYLINDER INSTALLATION angan dowel pins dan sebuah Do notmemakai reuse the Pasang Install the dowel pins and a newgasket gasket.baru. kembali gasket, gantilah gasket, replace with a dengan yang baru. new one.

GASKET

DOWEL PINS Apply oil to the bore, piston surface, piston, boreouter Semprotkan oli cylinder pada cylinder (lubang cylinder) ring groovesluar and piston, piston rings. permukaan alur-alur piston ring dan piston rings. Route the cam chain through the cylinder.

CAM CHAIN

PISTON RINGS/GROOVES

Be careful not to Install the cylinder over the piston while compressing the Alurkan cam chain melalui cylinder. damage the piston piston rings with your fingers. rings and cylinder Hati-hati agar tidak Pasang cylinder di atas piston sementara menekan bore. merusak piston rings piston rings dengan jari-jari. dan lubang dalam cylinder.

CYLINDER BORE/PISTON OUTER SURFACE Hati-hati agartotidak camcam chain guide roller, sealing dan Be careful not drop Pasang Install the chain guide roller, newwasher sealingbaru washer menjatuhkan guide and chain the cam chain guide guide roller pin roller bolt. pin bolt. the guide roller into cam roller ke dalam Tighten the roller pin bolt to the specified torque. the crankcase. Kencangkan roller pin bolt dengan torsi yang ditentukan. crankcase.

GUIDE ROLLER

ROLLER PIN BOLT

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 berikut: sensor (page – EOTsebagai 6-42) – Cylinder head (page 8-19) - Cylinder head (hal. 8-19)

SEALING WASHER

9-10

10. CLUTCH/GEARSHIFT LINKAGE

LOKASI KOMPONEN-KOMPONEN......10-2 COMPONENT COMPONE NT LOCATION ········ ················ ··············· ·········· ··· 10-2

RIGHT CRANKCASE COVER...............10-5 RIGHT CRANKCASE COVER·········· COVER····················· ··········· 10-5

KETERANGAN SERVIS .................... ........................ ....10-3 10-3 SERVICE INFORMAT INFORMATION ION ··············· ········ ··············· ············10-3 ····10-3

CLUTCH.................................................10-8 CLUTCH···························································10-8

TROUBLESHOOTING ................... ...........................10-4 ........10-4 TROUBLESHOOTING TROUBLES HOOTING ······· ················ ·················· ··················10-4 ·········10-4

GEARSHIFT GEARSHIFT GEARSHI FTLINKAGE..........................10-26 LINKAGE ······· ··············· ··············· ···············10-26 ········10-26 10

10-1


COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN CLUTCH/GEARSHIFTLINKAGE

17 N· N·m (1.7 kgf ·m, 13 lbf ·ft)

10 N· N·m (1.0 kgf ·m, 7 lbf ·ft) 54 N· N·m (5.5 kgf ·m, 40 lbf ·ft)

54 N· N·m (5.5 kgf ·m, 40 lbf ·ft)

5 N· N·m (0.51 kgf ·m, 3.7 lbf ·ft)

10-2


SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM • This section covers service of the clutch (centrifugal clutch and manual clutch) and gearshift linkage. These service can be done • with Bab meliputi service dari clutch (kopling) (centrifugal clutch dan manual clutch) dan gearshift linkage (peralatan theini engine installed in the frame. • Engine oil viscosity, oil level and the useservis of oil additives an effect on clutch Oil additives of any kind are specifically pemindah gigi). Pekerjaan-pekerjaan ini dapat have dilakukan dengan mesinoperation. terpasang pada rangka. recommended. When the permukaan clutch does oli notdan disengage or the oil motorcycle with clutch disengaged, the engine oil Viskositas oli mesin, tinggi penggunaan additivescreeps (campuran penambahan padainspect oli) mempengaruhi • not and oil level before servicing the clutch system. cara kerja clutch. Khususnya oil additives dari jenis apapun tidak boleh dipakai. Jika clutch tidak bisa dilepaskan atau sepedamotor merangkak maju sewaktu clutch dilepaskan, periksalah oli mesin dan tinggi permukaan oli sebelum menservis clutch system. SPECIFICATIONS

SPESIFIKASI ITEM

BAGIAN Manual clutch Manual

Centrifugal clutch clutch Centrifugal

STANDARD

STANDARD Disc thickness 2.00 – 2.20 (0.079 – 0.087) Ketebalan disc 2,00 – 2,20 Plate warpage – Clutch spring free height Perubahan bentuk melengkung plate 5.01 (0.197) Clutch outer guideclutch spring I.D. 16.991 – 17.0095,01 (0.6689 – 0.6696) Ketinggian bebas O.D. 22.959 – 22.98016,991 (0.9039 – 0.9047) Clutch outer guide D.D. – 17,009 Primary driven gear I.D. 23.000 – 23.02122,959 (0.9055 – 0.9063) D.L. – 22,980 D.D. primary driven gearouter 23,000 – 23,021 Mainshaft O.D. at clutch 16.966 – 16.984 (0.6680 – 0.6687) guide D.L. mainshaft pada clutch outer guide 16,966 – 16,984 Clutch drumdrum I.D. 104.0 – 104.2 (4.09 – D.D. clutch 104,0 –4.10) 104,2 Clutch weight lining thickness 1.5 (0.06) Ketebalan clutch weight lining 1,5 One-way clutch drum I.D. 42.000 – 42.020 (1.6535 – 1.6543) D.D. one-way clutch drum 42,000 – 42,020 One-way clutch roller O.D. 4.990 – 5.000 (0.1965 – 0.1969) D.L. one-way clutch roller 4,990 – 5,000 Primary drivedrive gear gear I.D. 19.030 – 19.05819,030 (0.7492 – 0.7503) D.D. primary – 19,058 Crankshaft O.D. at primary drive D.L. crankshaft pada primary drive gear – 18,980 18.967 – 18.98018,967 (0.7467 – 0.7472) gear

Unit: mm (in) SERVICE Satuan: mm LIMIT BATAS SERVIS 1.82 (0.072) 1,820.20 (0.008) 0,204.63 (0.182) 17.049 (0.6712) 4,63 22.940 (0.9031) 17,049 23.07 (0.908) 22,940 23,07 16.87 (0.664) 16,87 104.3 (4.11) 104,3 1.0 (0.04) 1,0 42.04 (1.655) 42,04 4.97 (0.196) 4,97 19.11 (0.752) 19,11

18,92 18.92 (0.745)

TORSI PENGENCANGAN TORQUE VALUES Oil centrifugal centrifugalfilter filtercover coverbolt bolt Shift drum stopper arm bolt Shift drum stopper arm bolt Shift return return spring springpin pin Shift Gearshift cam camplate platebolt bolt Gearshift Centrifugal clutch lock nut Centrifugal clutch lock nut Clutch center lock nut Clutch center lock nut Clutch lift er plate bolt

N·m(0,51 (0.51kgf.m; kgf·m,3,7 3.7lbf.ft) lbf·ft) 55N.m 10 N.m (1,0 kgf.m; 7 lbf.ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 30 30N.m N·m(3,1 (3.1kgf.m; kgf·m,22 22lbf.ft) lbf·ft) 17 17N.m N·m(1,7 (1.7kgf.m; kgf·m,13 13lbf.ft) lbf·ft) 54 N.m (5,5 kgf.m; 40 lbf.ft) 54 N·m (5.5 kgf·m, 40 lbf·ft) 54 54N.m N·m(5,5 (5.5kgf.m; kgf·m,40 40lbf.ft) lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·f t)

Apply locking to the threads; See page Oleskan cairan agent pengunci pada ulir; Lihat hal. 4-11 4-11 Oleskan cairan pengunci pada ulir; Lihat hal. 10-29 Apply locking agent to the threads; See page 10-29

Oleskan cairan pengunci pada ulir; Lihat hal. 10-28 10-28 Apply locking agent to the threads; See page Oleskan oli pada ulir dan permukaan duduk Apply oil to the threads and seating surface Oleskan olito pada ulir dan and permukaan duduk Apply oil the threads seating surface

10-3

CLUTCH/GEARSHIFT LINKAGE TOOLS Universal holder 07725-0030000

Clutch center holder 07HMB-HB70100

Lock nut wrench 20 x 24 mm 07716-0020100

Extension bar 07716-0020500

Gear holder, M1.5 07724-0010200

TROUBLESHOOTING TROUBLESHOOTING Faulty clutch operation can usually be corrected by adjusting the clutch system. Cara kerja clutch yang tidak benar biasanya dapat diperbaiki dengan menyetel clutch system. Clutch slips when accelerating Clutch slip sewaktu berakselerasi • Incorrect clutch adjustment clutch disc • • Worn Penyetelan clutch tidak benar • Weak clutch springs • Clutch disc aus • Faulty clutch weight Clutch springs lemah additive • • Molybdenum or graphite • Clutch weight tidak bekerja dengan baik Motorcycle creeps with clutch disengaged Ada additive molybdenum atau graphite • • Incorrect clutch adjustment • Clutch plate warped Sepedamotor maju sewaktu clutch dilepaskan • Faulty clutchmerangkak lifter clutch weight • • Faulty Penyetelan clutch tidak benar Clutch plate berubah bentuk melengkung •Hard to shift • • Damaged Clutch lifter tidak bekerja gearshift spindledengan baik • Damaged stopper plate and pin Clutch weight tidak bekerja dengan baik • • Loose stopper plate bolt • Incorrect clutch adjustment Transmissi sulit dipindahkan • Loose gearshift cam plate bolt Gearshift spindle rusak • Transmission jumps out of gear dan pin rusak • Stopper plate • Damaged stopper arm • Stopper plate bolt longgar • Damaged gearshift cam plate Penyetelan clutch • • Loose gearshift camtidak platebenar bolt • Gearshift cam plate bolt longgar Gearshift pedal will not return • Weak or broken gearshift spindle return spring Transmissi meloncat keluar dari gigi • Bent gearshift spindle Stopper arm rusak • • Gearshift cam plate rusak Gearshift cam plate bolt longgar •

Gearshift pedal tidak mau kembali Gearshift spindle return spring lemah atau patah • • Gearshift spindle bengkok

10-4


RIGHT CRANKCASE CRANKCASE COVER COVER RIGHT REMOVAL PELEPASAN Drain the engine oil (hal. (page4-9). 4-9). Keluarkan oli mesin Remove the following: Lepaskan sebagai berikut:

BOLT

– Exhaust pipe/muffler (page 3-15) - Footpeg bar (hal. 3-14) – Footpeg bar (page 3-14) - Bolt the bolt and kickstarter pedal. Kickstarter pedal When removing the - Remove Sewaktu melepaskan Lepaskan bolt dan kickstarter pedal. kickstarter pedal, kickstartermark pedal, thetandai pedal posisi pedal untuk position to ensure the memastikan lokasinya original location. semula.

KICKSTARTER PEDAL

Lepaskan bolts danand dua clamps dalam pola bersilangan Remove the bolts two clamps in a crisscross pattern in several steps.langkah. dalam beberapa Be careful not to Remove the right crankcase cover. Hati-hati agar tidak Lepaskan right crankcase cover. damage the mating

RIGHT CRANKCASE COVER

CLAMPS

merusak permukaan surface. penyatuan.

BOLTS

Lepaskan gasket danand dowel pins. Remove the gasket dowel pins.

DOWEL PINS

GASKET

DISASSEMBLY PEMBONGKARAN Remove the following: Lepaskan sebagai berikut: – Clutch adjuster lock nut - –Clutch adjuster lock nut Washer - –Washer O-ring - –O-ring Clutch adjuster/lifter boss - Clutch adjuster/lifter boss

NUT/WASHER/O-RING

ADJUSTER/ LIFTER BOSS

10-5

CLUTCH/GEARSHIFT LINKAGE KICKSTARTER SPINDLE OIL OIL SEALSEAL KICKSTARTER SPINDLE

Periksa bahwa oil seal seal is berada dalam Check that the kickstarter kickstarter spindle spindle oil in good condition, replace it if bila necessary. kondisi baik, ganti perlu. Jika mengganti oil seal, seal,install pasang sampai ia telah duduk If replacing the oil it until it is fully seated. sepenuhnya.

KICKSTARTER SPINDLE OIL SEAL

JALAN LINTASAN OLI OIL PASSAGES Tiuplah terbuka jalan lintasan oli right dari crankcase right crankcase Blow open the oil passage of the cover cover dengan udara with compressed air.dari kompressor. Check the oil passage for clog. Periksa jalan lintasan oli terhadap penyumbatan.

PERAKITAN ASSEMBLY Pasang bossintokethedalam right Install theclutch clutch adjuster/lifter adjuster/lifter boss right crankcase covercover aligning its boss with the hole in thedengan crankcrankcase dengan mentepatkan boss-nya case cover. lubang pada crankcase cover. Apply oil to aolinew O-ring. Semprotkan pada O-ring baru. Install the O-ring onto the clutch adjuster/lifter boss. Pasang O-ring pada clutch adjuster/lifter boss.

Tepatkan

ADJUSTER/ LIFTER BOSS Install the washer and clutch adjuster lock nut. Pasang washer dan clutch adjuster lock nut. Adjust the clutch installingright the (page setelah 4-17) after Setel clutch systemsystem (hal. 4-17) memasang right crankcase cover. crankcase cover.

LOCK NUT

WASHER

10-6

O-RING

CLUTCH/GEARSHIFT LINKAGE INSTALLATION PEMASANGAN Apply grease the kickstarter spindlespindle oil sealoil li ps. Oleskan gemuktopada bibir kickstarter seal.

KICKSTARTER SPINDLE OIL SEAL

penyatuan crankcase Hati-hati Be careful agar not totidak drop Bersihkan Clean thepermukaan gasket mating surface gasket of the dari crankcase and menjatuhkan benda- dan rightright crankcase cover,cover, being careful notberhati-hati to damage them. crankcase dengan agar any foreign materials benda asing ke engine. dalam tidak merusak mereka. into the Install the dowel pins and a new gasket onto the crankmesin.

DOWEL PINS

case. Pasang doweloil pins sebuah gasket baru Apply engine to thedan gearshift spindle journal area.pada crankcase.

Semprotkan oli mesin pada daerah gearshift spindle ournal.

GASKET Be careful not to Install the right crankcase cover. Hati-hati agar tidak Pasang right crankcase cover. the Install the two clamps and tighten the right crankcase merusak bibir damage kickstarter Pasang kedua clamps dan kencangkan right crankcase kickstarteroil oilseal. seal cover bolts in a crisscross pattern in several steps. cover bolts dalam pola bersilangan dalam beberapa lips.

RIGHT CRANKCASE COVER

CLAMPS

langkah.

BOLTS Install the kickstarter pedal its original position as Pasang kickstarter pedal padatoposisinya semula seperti marked during removal. telah ditandai pada waktu pelepasan. Install and the boltbolt securely. Pasang dantighten kencangkan dengan erat. Install the following: Pasang sebagai bar berikut: – Footpeg (page 3-14) Exhaust pipe/muffler – - Footpeg bar (hal. 3-14)(page 3-16)

BOLT

- Fill Exhaust pipe/muffler (hal. 3-16) engine oil (page 4-9). the engine with recommended Isilah dengan yang dianjurkan ( hal.4-9). Makemesin sure there areoli nomesin oil leaks. Pastikan bahwa tidak ada kebocoran oli. Check the clutch system adjustment (page 4-17). Periksa penyetelan clutch system (hal. 4-17).

KICKSTARTER PEDAL

10-7


CLUTCH CLUTCH (KOPLING) REMOVAL PELEPASAN CATATAN: be serviced the engine Clutch system system can dapat diservis with dengan mesin • • Clutch installed onpada the frame. terpasang rangka. Remove the following: Lepaskan sebagai berikut: – Right crankcase cover (page 10-5) - – Right crankcase cover (hal. Engine oil centrifugal filter 10-5) cover (page 4-10) - Engine oil centrifugal filter cover (hal. 4-10) Remove the clutch lever and the clutch lifter cam plate. Lepaskan clutch lever dan clutch lifter cam plate.

LIFTER CAM PLATE

CLUTCH LEVER

Tekuk tabof dari membebaskan Bend ke up atas the tab thelock lockwasher washeruntuk to clear the lock nut groove. alur lock nut.

Pasang clutch center menggunakan Install the clutch centerholder holderdengan using proper bolts or screws. bolts atau screws yang tepat. Remove the centrifugal clutch lock nut using the special Lepaskan centrifugal clutch lock nut dengan tools. menggunakan special tools. TOOLS: Lock nut wrench, 20 x 24 mm TOOLS: Extension bar Lock nut wrench, 20 x 24 mm Clutch center Extension barholder Clutch center holder

TAB

LOCK NUT WRENCH

CENTRIFUGAL CLUTCH LOCK NUT

07716-0020100 07716-0020500 07716-0020100 07HMB-HB70100 07716-0020500

07HMB-HB70100

EXTENSION BAR

Lepaskan washer danand lock washer. Remove the washer lock washer.

10-8

LOCK NUT

LOCK WASHER

CLUTCH CENTER HOLDER WASHER

CLUTCH/GEARSHIFT LINKAGE Remove the clutch weight assembly. Lepaskan clutch weight assembly.

CLUTCH WEIGHT ASSEMBLY Remove the clutch lifter bearing. Lepaskan clutch lifter bearing.

CLUTCH LIFTER BEARING

Hold the primarydrive drive and withdengan gear holder, Tahan primary dan driven drivengear gear gear remove the clutch center nut using the nut special tool. holder, lepaskan clutchlock center lock dengan menggunakan special tool. TOOLS: Universal holder TOOLS: Lock nut wrench, 20 x 24 mm Universal holder Extension bar Lock nut wrench, 20 x 24 mm Gear holder M1.5 Extension bar Gear holder M1.5

CLUTH CENTER LOCK NUT LOCK NUT WRENCH

07725-0030000 07716-0020100 07725-0030000 07716-0020500 07716-0020100 07724-0010200 07716-0020500

07724-0010200 GEAR HOLDER UNIVERSAL HOLDER

Remove the washer. Lepaskan washer. Loosen the clutch lifter plate bolts. Longgarkan clutch lifter plate bolts.

EXTENSION BAR

BOLTS

WASHER

10-9

CLUTCH/GEARSHIFT LINKAGE Remove the two oil separator plate Lepaskan kedua plate mounting mounting bolts. bolts.

BOLTS Remove the centrifugal clutch outer, manual clutch Lepaskan centrifugal clutch outer, manual clutch danand oil the oil separator plate as an assembly. separator plate sebagai sebuah assembly (susunan).

MANUAL CLUTCH

CENTRIFUGAL CLUTCH OUTER

OIL SEPARATOR PLATE Remove the collar from the crankshaft. Lepaskan collar dari crankshaft. Remove the clutch outer guide and collar from the mainLepaskan clutch outer guide dan collar dari mainshaft. shaft.

COLLAR

CLUTCH OUTER GUIDE

10-10

COLLAR

CLUTCH/GEARSHIFT LINKAGE PEMBONGKARAN/PEMERIKSAAN NTRIFUGAL CLUTCH DISASSEMBLY/ CENTRIFUGAL INSPECTION CLUTCH CE

ONE-WAYCLUTCH CLUTCH ONE-WAY Temporarily installpasang the centrifugal the Untuk sementara centrifugalclutch clutchouter outertopada crankshaft. crankshaft. Hold the crankshaftdan and putar turn the centrifugalclutch clutch outer Tahan crankshaft centrifugal outer by hand. dengan tangan. Make sure that centrifugal the centrifugal only turns Pastikan bahwa clutchclutch outerouter hanya berputar counterclockwise as shown and does not turn clockwise. berlawanan jarum jam seperti diperlihatkan dan tidak Remove the centrifugal clutch outer from the crankshaft. dapat berputar dalam arah jarum jam.

Lepaskan centrifugal clutch outer dari crankshaft.

Remove the snap retainer. Lepaskan snap ringring danand retainer.

SNAP RING

RETAINER Be careful agar not totidak lose Hati-hati the clutch rollers and kehilangan clutch rollers clutch springs. springs. dan clutch

Remove the following: Lepaskan sebagai berikut: – Rollers Springs - –Rollers – One-way clutch inner - –Springs Washer - One-way clutch inner - Washer

SPRING

CLUTCH INNER Ganti clutch keausan rollers Replace therollers clutch Periksa Check the rollers terhadap for excessive wear or berlebihan damage. sebagai sebuah rollers as a set. set. kerusakan. Measure the one-way clutch roller O.D.

SERVICE Ukur D.L. one-way clutch roller. LIMIT: 4.97mm (0.196 in) BATAS SERVIS: 4,97 mm Replace thesprings clutch Check the springs for fatigue or damage. Ganti clutch springs as a set. Periksa springs terhadap keletihan atau kerusakan.

ROLLER

WASHER

atau ROLLER

sebagai sebuah set.

SPRING

10-11

CLUTCH/GEARSHIFT LINKAGE Periksa one-way terhadap Check the one-wayclutch clutchinner inner for wear orkeausan damage. atau kerusakan.

CLUTCH INNER CLUTCHOUTER/SUB-GEAR OUTER/SUB-GEAR CLUTCH Be careful agar not totidak lose Remove the spring retainer and spring. Hati-hati Lepaskan spring retainer dan spring.

PIN

the pin. pin. kehilangan

Remove the pin, snap ring and sub-gear. Lepaskan pin, snap ring dan sub-gear. Check the sub-gear for wear or damage. Periksa sub-gear terhadap keausan atau kerusakan.

PIN

SPRING RETAINER/SPRING

SNAP RING

SUB-GEAR Check the sliding surfaces of the luncur centrifugal outer Periksa permukaan-permukaan dariclutch centrifugal for excessive or damage. clutch outer wear terhadap keausan berlebihan atau Measure the one-way clutch drum I.D. kerusakan. SERVICE Ukur D.D. one-way42.04 clutch drum. LIMIT: mm (1.655 in) BATAS SERVIS: 42,04 mm Check the inside of the centrifugal clutch drum for scratches or excessive wear. Periksa bagian dalam centrifugal clutch drum terhadap goresan keausan berlebihan. Measureatau the centrifugal clutch drum I.D. SERVICE Ukur D.D. centrifugal clutch LIMIT: 104.3 mm drum. (4.11 in) BATAS SERVIS: 104,3 mm

10-12

CLUTCH/GEARSHIFT LINKAGE CLUTCH WEIGHT CLUTCH WEIGHT Check the clutch weight assembly for damage. Periksa clutch weight assembly terhadap kerusakan. Measure the clutch weight lining thickness. Ukur ketebalan clutch weight lining. SERVICE BATAS mm (0.04 in) LIMIT:SERVIS: 1,0 1.0 mm

Remove the E-clips. Lepaskan E-clips.

E-CLIPS

Lepaskan sideside plate, friction spring dan spring seat. Remove the plate, friction spring and spring seat.

SPRING SEAT

FRICTION SPRING

SIDE PLATE

Secara bergantian angkat clutchthen weights, Alternately lift the clutch weights, remove kemudian the c lutch weights and springs. lepaskan clutch weights dan springs.

CLUTCH WEIGHTS

SPRINGS

10-13

CLUTCH/GEARSHIFT LINKAGE Remove the damper rubbers from theplate. drive plate. Lepaskan damper rubbers dari drive

RUBBERS

DRIVE PLATE

Periksa drive terhadap keausan atau Check the driveplate plate bosses for wear or damage. Check each clutch weight for wear or damage. kerusakan. Periksa masing-masing clutch weight terhadap keausan atau kerusakan.

BOSS

CLUTCH WEIGHT PRIMARY DRIVE GEAR

Measure the primary drive gear I.D. PRIMARY DRIVE GEAR SERVICE Ukur D.D. primary drive gear LIMIT: 19.11 mm (0.752 in) BATAS SERVIS: 19,11 mm

PRIMARY DRIVE GEAR CRANKSHAFT

CRANKSHAFT Measure the crankshaft O.D. Ukur D.L. crankshaft. SERVICE LIMIT: 18.92 mm (0.745 in) BATAS SERVIS: 18,92 mm

10-14

CLUTCH/GEARSHIFT LINKAGE CENTRIFUGAL CLUTCH ASSEMBLYCLUTCH PERAKITAN CENTRIFUGAL E-CLIP

SPRING SEAT CLUTCH WEIGHT DAMPER RUBBER

SPRING

DRIVE PLATE

SIDE PLATE SPRING RETAINER FRICTION SPRING

SPRING

WASHER SPRING

RETAINER

SNAP RING PIN

SNAP RING

CLUTCH ROLLER

CLUTCH INNER

SUB-GEAR


CLUTCH CLUTCHWEIGHT WEIGHT Install the damper rubbers to the drive plate. Pasang damper rubbers pada drive plate.

RUBBERS

DRIVE PLATE Hook the springspada to theclutch clutch weights weights so that theirujungopen Kaitkan springs sehingga ends facing the drive plate side. ujung mereka yang terbuka menghadap ke sisi drive plate. Install the clutch weights and springs onto the drive plate as shown. Pasang clutch weights dan springs pada drive plate seperti diperlihatkan.

CLUTCH WEIGHTS

SPRINGS

10-15

CLUTCH/GEARSHIFT LINKAGE Pasang spring seat, plate to pada Install the spring seat,friction frictionspring springdan and side plate the clutchweight weightassembly assembly seperti as shown. clutch diperlihatkan.

CLUTCH WEIGHT

SIDE PLATE SIDE PLATE SPRING SEAT FRICTION SPRING Tepatkan ujung E-clips baru sementara menekan the sideside plate. Align the openterbuka end of Pasang Install the new E-clips while compressing plate. dari E-clips dan bosses the E-clips and bosses dari side plate. of the side plate.

BOSS

E-CLIPS

SIDE PLATE

CLUTCH CLUTCHOUTER/SUB-GEAR OUTER/SUB-GEAR Install the sub-gear by aligning its hole and primary drive Pasang sub-gear dengan mentepatkan lubangnya dan gear cut-out. potongan pada primary drive gear. Periksa bahwa snap ring Pasang snap ring. snap ring. Check that the snap Install the

PIN

duduk pada alur. ring is seated in the groove. Install the pin. Be careful not lose Pasang pin. Hati-hati agartotidak the pin. pin. kehilangan

Tepatkan

SNAP RING

Masukkan ujungend yang tertekuk ke on dalam Insert the bent of the springdari intospring the hole the spring pada retainer. lubang spring retainer. Coil the spring into ke the dalam spring retainer, making sure that Gulungkan spring spring retainer, dengan the spring is bahwa set between theditempatkan retainer andantara tab. memastikan spring retainer dan tab.

SPRING RETAINER

SUB-GEAR SPRING

Masukkan (UJUNG TERTEKUK DAN LUBANG) TAB

10-16

CLUTCH/GEARSHIFT LINKAGE Pasang retainer/springto the pada clutch Install thespring spring retainer/spring clutch outer outer while aligning thementepatkan straight end of spring into dari the hole on the sementara ujung lurus spring ke sub-gear and aligning the retainer groove with the pin. dalam lubang pada sub-gear dan mentepatkan alur retainer dengan pin.

Tepatkan (ALUR dan PIN)

Tepatkan (UJUNG LURUS DAN LUBANG)

SUB GEAR Check cara the sub-gear operation by moving it and make Periksa kerja sub-gear dengan menggerakkannya sure that it returns without binding. tanpa mengikat. dan memastikan bahwa ia kembali

SUB-GEAR

ONE-WAY ONE-WAYCLUTCH CLUTCH Pasang washer clutchinner innerinto kethe dalam Install the washerdan and one-way one-way clutch centrifugal clutch outer. centrifugal clutch outer.

CLUTCH INNER

WASHER Install the springs and rollers as shown. Pasang springs dan rollers seperti diperlihatkan.

SPRING

ROLLER

10-17

CLUTCH/GEARSHIFT LINKAGE Pasang retainer. Install the retainer. Install the snap ringdengan into theerat groove of the one-way Periksa bahwa Check that the snap Pasang snap ring ke dalam alur dariclutch oneouter securely. ringisduduk dengan ring seated in the way clutch outer. benar pada alurnya. groove.

SNAP RING

RETAINER Temporarily installpasang the centrifugal the Untuk sementara centrifugalclutch clutchouter outertopada crankshaft. crankshaft. Tahan crankshaft centrifugal outer Hold the crankshaftdan and putar turn the centrifugalclutch clutch outer by hand. dengan tangan. Make sure that centrifugal the centrifugal turns Pastikan bahwa clutchclutch outerouter hanyaonly berputar counterclockwise as shown and does not turn clockwise. dalam arah berlawanan jarum jam seperti diperlihatkan Remove the centrifugal outer from the crankshaft. dan tidak dapat berputarclutch searah jarum jam.

Lepaskan centrifugal clutch outer dari crankshaft.

MANUAL CLUTCH DISASSEMBLY PEMBONGKARAN MANUAL CLUTCH Remove the clutch lifter plateassembly assembly dan and washer Lepaskan clutch lifter plate washer from dari the clutch outer. clutch outer.

WASHER

CLUTCH LIFTER PLATE

CLUTCH OUTER Remove the following: Lepaskan sebagai berikut: – Bolts - –Bolts Clutch lifter plate - –Clutch lifter plate Spring - –Spring Clutch center Clutch discs - –Clutch center Clutch plates - –Clutch discs

CLUTCH LIFTER PLATE

SPRING

- Clutch plates

BOLTS

10-18

CLUTCH CENTER/ DISCS/PLATES

CLUTCH/GEARSHIFT LINKAGE Putar clutch spring seat bertepatan Turn the clutch spring seatsampai until itsslots-nya slots is aligned with the tabstabs on the clutch lifter plate, then remove it. dengan pada clutch lifter plate, kemudian lepaskan.

SLOTS

TABS

SPRING SEAT

CLUTCH LIFTER PLATE

PEMERIKSAAN MANUAL CLUTCH MANUAL CLUTCH INSPECTION CLUTCH BEARING CLUTCHLIFTER LIFTER BEARING Temporarily installpasang the clutch lifter bearing to the clutch Untuk sementara clutch lifter bearing ke dalam lifter plate. clutch lifter plate. Turn the inner race of the clutch lifter bearing with your finger.inner race dari clutch lifter bearing dengan jari-jari. Putar The bearing should turn smoothly and quietly. Bantalan harus berputar dengan halus dan tanpa suara. Also check that the bearing outer race of thedari bearing fits Juga periksa bahwa bearing outer race bearing tightly in the clutch lifter plate. duduk dengan erat pada clutch lifter plate. Replace the bearing if the inner race does not turn smoothly, quietly, or if the outer race fits loosely in the Ganti jika inner race tidak berputar dengan clutch bearing lifter plate. halus, tanpa suara, atau jika outer race duduk dengan longgar di dalam clutch lifter plate.


CLUTCH LIFTER PLATE

CLUTCH CLUTCHSPRING SPRING Check the grooves andtabs tabs dari of cl utch spring for damage. Periksa alur-alur dan clutch spring terhadap kerusakan. Check the spring for fatigue or other damage. Periksa spring terhadap keletihan atau kerusakan lain. Measure the clutch spring free height. Ukur ketinggian bebas clutch spring. SERVICE LIMIT:SERVIS: 4,63 4.63 mm BATAS mm(0.182 in)

CLUTCH SPRING

CLUTCH CLUTCHCENTER CENTER centercenter Periksa alur-alur dariofclutch terhadap kerusakan Check the grooves the clutch for damage or wearkeausan caused by thedisebabkan clutch plates. atau yang oleh clutch plates. Replace necessary. Ganti bilaifperlu.

CLUTCH CENTER

GROOVES

10-19

CLUTCH/GEARSHIFT LINKAGE CLUTCH CLUTCHDISC DISC Ganti clutch the discs dan Ganti Replace clutch Replace the clutch discsmereka if they show signs of scoring or memperlihatkan tandaclutch discs jika discoloration. plates satuas set. discssebagai and plates a tanda gerusan atau perubahan warna. set. Measure the thickness of each clutch disc.

Ukur ketebalan masing-masing clutch disc. SERVICE LIMIT:SERVIS: 1,82 1.82 mm BATAS mm(0.072 in)

CLUTCH CLUTCHPLATE PLATE Ganti clutch the discs dan Periksa Replace clutch Check each clutch plate for warpage a surface plate clutch on plate masing-masing terhadap plates satuas set. using a feeler gauge. discssebagai and plates a perubahan bentuk melengkung di atas surface plate set. (pelat pengukur kedataran) dengan menggunakan

SERVICE feeler gauge. LIMIT:

0.20 mm (0.008 in)


CLUTCH OUTER GUIDE CLUTCHOUTER/CLUTCH OUTER/CLUTCH OUTER GUIDE primary driven gear Periksa gigi-gigi terhadap keausan Check the primary driven gear teeth for wear or damage. Check the slots of the clutch outer for damage or wear atau kerusakan. caused by the clutch discs. Periksa slots dari clutch outer terhadap kerusakan atau keausan disebabkan Measureyang the primary drivenoleh gearclutch I.D. discs. SERVICE gear. Ukur D.D. primary driven LIMIT: 23.07 mm (0.908 in) BATAS SERVIS: 23,07 mm Measure the clutch outer guide I.D. and O.D. Ukur D.D. dan D.L. clutch outer guide. SERVICE LIMITS: I.D.: SERVIS: 17.049 mm (0.6712 in) BATAS O.D.: 22.940 mm (0.9031 in) D.D.: 17,049 mm D.L.: 22,940 mm

MAINSHAFT

MAINSHAFT Measure the mainshaft O.D. at clutch outer guide. Ukur D.L. mainshaft pada clutch outer guide. SERVICE LIMIT: 16.87 mm (0.664 in) BATAS SERVIS: 16,87 mm

10-20

CLUTCH/GEARSHIFT LINKAGE MANUAL CLUTCH ASSEMBLY PERAKITAN MANUAL CLUTCH CLUTCH SPRING

CLUTCH CENTER

SPRING SEAT PRESSURE PLATE

LIFTER PLATE

WASHER CLUTCH OUTER

CLUTCH PLATES

BOLTS

CLUTCH DISC B (TANDA IDENTIFIKASI:CAT BIRU)

CLUTCH DISC A

Ganti clutch discs dan Replace the clutch plates sebagai satu as set.a discs and plates Jangan mempertukarkan set. disc A dengan disc the B. Do not confuse disc A with disc B.

Coat the clutch discs with oil. Lapisi clutch discs dengan oli. Install the items in the following sequence: Pasang bagian-bagian dalam urutan berikut: – Clutch spring - –Clutch spring Clutch center - –Clutch center Clutch disc A Clutch plate - –Clutch disc A Clutch disc B (ID mark: Blue paint on a tab) - –Clutch plate Clutch plate - –Clutch disc B (tanda Identifikasi: cat Biru pada sebuah – Clutch disc A tab) – Pressure plate - Clutch plate - Clutch disc A - Pressure plate

CLUTCH SPRING CLUTCH CENTER

DISC A CLUTCH PLATES

DISC A DISC B(TANDA IDENTIFIKASI : CAT BIRU)

PRESSURE PLATE

10-21

CLUTCH/GEARSHIFT LINKAGE Set the spring seat with chamfered edge facingyang the Tempatkan spring seat itsdengan pinggirannya clutch liftermenghadap plate as shown aligning tab with the dipotong ke while clutch lifter its plate seperti slot on the plate. diperlihatkan sementara mentepatkan tab-nya dengan Turn the clutch spring seat about 45°. slot pada plate. Putar clutch spring seat sebanyak kira-kira 45°.

Tepatkan (TABS dan SLOTS)

SPRING SEAT

CLUTCH LIFTER PLATE

SPRING SEAT Putar 45°

Pinggiran yang di potong CLUTCH LIFTER PLATE Install the clutch lifter plate. Pasang clutch lifter plate. Temporarily install the bolts. Untuk sementara pasang bolts. Align the tabs of the clutch discs.

CLUTCH LIFTER PLATE

BOLTS

Tepatkan tabs dari clutch discs.

Tepatkan Install the washer ontoclutch the clutch Pasang washer pada outer.outer. Install the clutch center assembly into the clutch outer. Pasang clutch center assembly ke dalam clutch outer.

CLUTCH CENTER ASSEMBLY

WASHER

10-22

CLUTCH OUTER

CLUTCH/GEARSHIFT LINKAGE PEMASANGAN INSTALLATION Install the collar onto the mainshaft. Pasang collar pada mainshaft. Apply oil to the clutch outer guide outer surface. Semprotkan oli pada permukaan luar clutch outer guide. Install the clutch outer guide. Pasang clutch outer guide. Install the collar onto the crankshaft.

COLLAR

COLLAR

Pasang collar pada crankshaft.

CLUTCH OUTER GUIDE

Semprotkan molybdenum disulfide oil primary pada permukaan Apply molybdenum disulfide oil to the drive gear inner surface. drive gear. dalam primary

Align the cut-outs of the primarydari drive gear and sub-gear Tepatkan potongan-potongan primary drive gear MANUAL CLUTCH as shown, then engage the primary drive/driven gears. dan sub-gear seperti diperlihatkan, kemudian saling Install the manual clutch, centrifugal hubungkan primary drive/driven gears.clutch outer and oil separator plate as assembly. Pasang manual clutch, centrifugal clutch outer dan oil separator plate sebagai sebuah kesatuan.

OIL SEPARATOR PLATE

Tepatkan


Pasang dantighten kencangkan kedua oil separator plate Install and the two oil separator plate mounting mounting bolts. bolts.

BOLTS

10-23

CLUTCH/GEARSHIFT LINKAGE Pasang washer pada Install the washer ontomainshaft. the mainshaft. Tighten the clutch Kencangkan clutchlifter lifterplate platebolts. bolts.

BOLTS

WASHER

Semprotkan oli clutch pada ulir-ulir clutch dan Apply oil to the center lock nutcenter threadslock andnut seating surface. permukaan duduk. Install the clutch center lock nut. Pasang clutch center lock nut. Hold the primary drive and driven gear with the gear Tahan primary drive dan driven gear dengan gear holder, tighten the clutch center lock nut to the specified holder, torque. kencangkan clutch center lock nut dengan torsi yang ditentukan. TOOLS: Universal holder 07725-0030000 TOOLS: Lock nut wrench, 07716-0020100 Universal holder 20 x 24 mm 07725-0030000 Extension bar 07716-0020500 Lock nut wrench, 20 x 24 mm 07716-0020100 Extension bar 07716-0020500 Gear holder, M1.5 07724-0010200 Gear holder, M1.5 07724-0010200 TORQUE:54 N·m (5.5 kgf·m, 40 lbf·ft) TORSI: 54 N.m (5,5 kgf.m; 40 lbf.ft) Install the clutch lifter bearing. Pasang clutch lifter bearing.

Pasang clutch weight assembly keinto dalam Install the clutch weight assembly the clutch clutch outer outer while aligning the splines of the clutch weight assembly sementara mentepatkan splines (seplain-seplain) dari and crankshaft. clutch weight assembly dan crankshaft.

UNIVERSAL HOLDER

GEAR HOLDER

LOCK NUT WRENCH

EXTENSION BAR

CLUTCH CENTER LOCK NUT


Tepatkan

CLUTCH WEIGHT ASSEMBLY

10-24

CLUTCH/GEARSHIFT LINKAGE Pasang washer baru pada crankshaft Install a sebuah new lock lock washer onto the crankshaft aligning its inner tabmentepatkan with the groove the clutch weight assembly. dengan tabofdalamnya dengan alur dari clutch weight assembly.

LOCK WASHER

Pasang washer dengan menghadap Install the washer with itstanda "OUT"OUT SIDE"SIDE" mark facing out. keluar.

Tepatkan

"OUT SIDE"

WASHER

Semprotkan ulir-ulirclutch centrifugal clutch lock and nut Apply oil to oli thepada centrifugal lock nut threads seating surface. dan permukaan duduk. Install the clutch centerholder holderdengan using proper bolts or Pasang clutch center menggunakan screws. bolts atau screws yang benar. Install the centrifugal clutch lock nut. Pasang clutchclutch lock nut. Tightencentrifugal the centrifugal lock nut to the specified Kencangkan centrifugal clutch lock nut dengan torsi torque using the special tools. yang ditentukan dengan menggunakan special tools. TOOLS: Lock nut wrench, 20 x 24 mm 07716-0020100 TOOLS: Extension bar 07716-0020500 Lock nut wrench, 20 x 24 mm 07716-0020100 Clutch center holder 07HMB-HB70100 Extension bar 07716-0020500 Clutch center holder 07HMB-HB70100 TORQUE:54 N·m (5.5 kgf·m, 40 lbf·ft) TORSI: 54 N.m (5,5 kgf.m; 40 lbf.ft) If any of the clutch lock nutlock groove not Jika salah satucentrifugal alur centrifugal clutch nut istidak aligned with dengan the lock washer tab, further tighten the cenbertepatan lock washer tab, kencangkan trifugal clutch lock nut and align the centrifugal clutch centrifugal clutch lock nut lebih lanjut dan tepatkan alur lock nut groove with the lock washer tab. centrifugal clutch lock nut dengan lock washer tab. Bend the lock washer tab against the centrifugal clutch lock nut groove. Tekuk lock washer tab pada alur centrifugal clutch loc nut.

CENTRIFUGAL CLUTCH LOCK NUT

LOCK NUT WRENCH TAB

EXTENSION BAR

CLUTCH CENTER LOCK WASHER

10-25

CLUTCH/GEARSHIFT LINKAGE Pasang clutch lever pada spindle sementara Install the clutch lever ontogearshift the gearshift spindle while aligning the punch marks. titik. mentepatkan tanda-tanda Install the clutch clutch lifter Pasang clutch lifterlifter cam cam plate plate pada onto clutchthe lifter bearing. bearing. Install the following: Pasang sebagai berikut:

LIFTER CAM PLATE

Engine centrifugalfilter filtercover cover(hal. (page 4-10) - – Engine oiloil centrifugal 4-10) Right crankcase cover – (page 10-7) - Right crankcase cover (hal. 10-7)

CLUTCH LEVER

Tepatkan

GEARSHIFT GEARSHIFTLINKAGE LINKAGE PELEPASAN REMOVAL Remove the clutch (page 10-8). Lepaskan clutch (hal. 10-8). Remove the bolt and the gearshift pedal. Sewaktu melepaskan When removing the Lepaskan bolt dan gearshift pedal.

GEARSHIFT PEDAL

gearshift pedal, tandai gearshift pedal, mark posisi pedal untuk the pedal position to memastikan posisi ensure the semula. original position.

BOLT

Bersihkan gearshiftspindle spindlethoroughly secara menyeluruh untuk Clean the gearshift to prevent the dirt or dust from entering the engine. menghindari masuknya kotoran atau debu ke dalam mesin.

GEARSHIFT SPINDLE Remove the following: Lepaskan sebagai berikut: – Shift drum stopper arm/bolt - –Shift drum stopper arm/bolt Return spring - Return spring

STOPPER ARM/BOLT

RETURN SPRING

10-26

CLUTCH/GEARSHIFT LINKAGE Remove the gearshift spindledengan by holding down the gearLepaskan gearshift spindle menekan gearshift shift arm as shown. arm ke bawah seperti diperlihatkan.

GEARSHIFT SPINDLE

GEARSHIFT ARM Remove the the gearshift cam plate. Lepaskan boltbolt danand gearshift cam plate. BOLT

GEARSHIFT CAM PLATE

Lepaskan gearshift drum pins Remove the gearshift drum pinsdan andstopper stopper plate plate pins from the gearshift drum. dari gearshift drum.

GEARSHIFT DRUM PINS

GEARSHIFT DRUM

STOPPER PLATE PINS

PEMERIKSAAN INSPECTION Periksa gearshift tekukan, keausan Check the gearshiftspindle spindle terhadap for bend, wear or damage. Check the gearshift arm spring and return spring for atau kerusakan. damagegearshift or fatigue. Periksa arm spring dan return spring terhadap Check the gearshift arm for wear or damage. kerusakan atau keletihan. Periksa gearshift arm terhadap keausan atau kerusakan.

GEARSHIFT ARM

GEARSHIFT ARM SPRING

GEARSHIFT SPINDLE

RETURN SPRING

10-27

CLUTCH/GEARSHIFT LINKAGE Periksa spindle oil seal terhadap pemburukan Inspect gearshift the gearshift spindle oil seal for deterioration or damage, replace if necessary. kondisi atau kerusakan, ganti bila perlu. If replacing the oil seal, install it until it is fully seated. Jika oil seal diganti, pasang sampai ia telah duduk dengan penuh.

OIL SEAL

PEMASANGAN INSTALLATION Apply grease topada the gearshift spindlespindle oil sealoil lips . Oleskan gemuk bibir gearshift seal.

OIL SEAL

Pasang lima gearshift Install the five gearshiftdrum drumpins pinsdan anddua two stopper stopper plate plate pinspada to thelubang-lubang holes on the gearshift drum. drum. pins pada gearshift Install the gearshiftcam cam plate plate while aligningmentepatkan the holes on Pasang gearshift sementara the plate with the stopper plate pins. lubang-lubang pada plate dengan stopper plate pins.

Tepatkan

GEARSHIFT CAM PLATE

Oleskan cairan agent pengunci pada gearshift cam plate Apply locking to the gearshift cam plate boltbolt as specified, then install and tighten to the specified seperti ditentukan, kemudian pasangit dan kencangkan torque. torsi yang ditentukan. dengan

Lebar lapisan: 6.5 ± 1.0 mm dari ujung

TORQUE: 17 N·m (1.7 kgf·m, 13 lbf·ft) TORSI: 17 N.m (1,7 kgf.m; 13 lbf.ft)

BOLT

10-28

STOPPER PLATE PINS

GEARSHIFT DRUM PINS

CLUTCH/GEARSHIFT LINKAGE Pasang gearshift sedemikian sehingga shift Install the gearshiftspindle spindle so that the shift return spring pin is spring locatedpin between ends of theujung returndari spring as return terletakboth antara kedua return shown. spring seperti diperlihatkan. Insert the gearshift spindle completely while holding down the gearshift as shown. Masukkan gearshiftarm spindle sama sekali sementara menahan ke bawah gearshift arm seperti diperlihatkan.

GEARSHIFT ARM

SPRING PIN

Oleskan cairanagent pengunci shift stoppe drum stopper arm Apply locking to thepada shift drum r arm bolt as specified. bolt seperti ditentukan. Set the return spring end along the crankcase wall as shown. Tempatkan ujung return spring di sepanjang dinding crankcase Install the seperti stopperdiperlihatkan. arm/bolt, then tighten it to t he specified torque. Pasang stopper arm/bolt, kemudian kencangkan TORQUE: 10 N·m (1.0 kgf·m, 7 lbf·ft) dengan torsi yang ditentukan.

GEARSHIFT SPINDLE

SPRING ENDS

Lebar lapisan : 6.5 ± 1.0 mm ± dari ujung

BOLT


RETURN SPRING END

Pasang gearshift pedalpedal padatoposisinya semula seperti Install the gearshift its original position as marked during removal. telah ditandai pada waktu pelepasan. Install and tighten the bolt. Pasang dan kencangkan bolt. Install the clutch (page 10-23). Pasang clutch (hal. 10-23).

STOPPER ARM

GEARSHIFT PEDAL

BOLT

10-29

MEMO

11. ALTERNATOR/STARTER CLUTCH

COMPONENT LOCATION ························ 11-2 LOKASI KOMPONEN-KOMPONEN... 11-2

STATOR ···················································· STATOR .............................................. 11-6 11-6

KETERANGAN SERVIS························· ..................... 11-3 SERVICE INFORMATION 11-3

FLYWHEEL/STARTER CLUTCH ....... 11-7 FLYWHEEL/STARTER CLUTCH ············· 11-7

LEFTCRANKCASE CRANKCASE COVER .............. 11-4 LEFT COVER ···················· 11-4

11

11-1

ALTERNATOR/STARTER CLUTCH

COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN ALTERNATOR/STARTERCLUTCH

40 N·m (4.1 kgf ·m, 30 lbf ·ft)

11-2


KETERANGAN SERVIS SERVICE INFORMATION GENERAL UMUM • • • • • • •

•

This section covers service of the alternator and starter clutch. Bab ini meliputi dari alternator dan starterinclutch. These services canservis be done with the engine installed the frame. Pekerjaan-pekerjaan servis ini dapat dilakukan dengan mesin terpasang pada rangka. For alternator inspection (page 16-7). Untuk pemeriksaan alternator (hal. (page 16-7)17-7). For ignition pulse generator inspection Untuk pemeriksaan ignition pulse generator (hal. 16-6 ).

SPECIFICATIONS TORSI PENGENCANGAN Flywheel nut

40 N.m (4,1 kgf.m; 30 lbf.ft) ITEM

Starter driven gear boss O.D.

Flywheel nut Starter clutch mounting torx bolt TOOLS

Flywheel holder 07725-0040001

Unit: mm (in) Semprotkan oli pada ulir dan permukaan duduk SERVICE STANDARD LIMIT 45.660 – 45.673 (1.7976 – 1.7981) 45.2 (1.78)

40 N·m (4.1 kgf ·m, 30 lbf ·ft) 6 N·m (1.6 kgf ·m, 12 lbf ·ft)

Apply oil to the threads and seating surface Apply oil to the threads and seating surface: See page 11-11

Flywheel puller, 28 mm 07933-KG20000

11-3


LEFT CRANKCASE LEFT CRANKCASE COVER COVER PELEPASAN REMOVAL Keluarkan oli mesin Drain the engine oil (hal. (page4-10). 4-10). Lepaskan sebagai berikut: Remove the following: Body cover (page 3-8) - – Body cover (hal. 3-8) Left crankcase rear cover – (page 3-16) - Left crankcase rear cover (hal. 3-16) Footpeg bar (page 3-15) - – Foot peg bar (hal. Remove the bolt and3-15) gearshift pedal. When removing the Lepaskan bolt dan gearshift pedal. Sewaktu melepaskan gearshift pedal, gearshift pedal, mark tandai posisi pedalto the pedal position untuk ensurememastikan the original posisi position. semula.

BOLT Disconnect the following: Lepaskan sebagai berikut: – Alternator 2P connector - Alternator 2P connector – Alternator wire (Yellow) connector - –Alternator wire connector Ignition pulse generator wire (Blue/yellow) connector - Ignition pulse generator wire connector

GEARSHIFT PEDAL

2P CONNECTOR

WIRE CONNECTORS Longgarkan bolts Remove the bolts. Loosen the bolts in a Lepaskan bolts. dalam polain crisscross pattern bersilangan severaldalam steps. beberapa langkah.

LEFT CRANKCASE COVER

The left crankcase Remove the left crankcase cover. cover (stator) is magnetically attached Left crankcase cover Lepaskan left crankcase cover. to(stator) the flywheel, be tertarik secara magnetis pada careful during flywheel, berhatiremoval. hatilah pada waktu pelepasan.

BOLTS Remove the gasket dowel pins. Lepaskan danand gasket dowel pins.

GASKET

DOWEL PINS

11-4

ALTERNATOR/STARTER CLUTCH INSTALLATION PEMASANGAN Hati-hati agar tidak bahan-bahan gasket dari permukaan Be careful not to Bersihkan Clean any gasket material from the left crankcase cover merusak left crankcase cover. mating surface. damagepermukaan the mating penyatuan penyatuan. surface. Install the dowel pins and a new gasket.

GASKET

Pasang dowel pins dan gasket baru.

DOWEL PINS Left crankcase cover Pasang leftleft crankcase cover. The left crankcase Install the crankcase cover. tertarik secara Pasang bolt dan kencangkan dalam pola Install the bolt and tighten the boltsbolts in a crisscross patcovermagnetis is magnetically pada tern in several steps. attached to the bersilangan dalam beberapa langkah. flywheel, berhati flywheel, be waktu careful hatilah pada during pemasangan. installation.

LEFT CRANKCASE COVER

BOLTS Connect the following: Sambungkan sebagai berikut: – Alternator 2P connector - –Alternator 2Pwire connector Alternator (Yellow) connector - –Alternator wire connector Ignition pulse generator wire (Blue/yellow) connector - Ignition pulse generator wire connector

2P CONNECTOR

WIRE CONNECTORS

Pasang gearshift pedal padainposisinya semula seperti Install the gearshift pedal its original position as marked during removal. telah ditandai pada waktu pelepasan. Install and the bolt. Pasang dantighten kencangkan bolt. Install the following: Pasang sebagai bar berikut: – Footpeg (page 3-15) – Left crankcase rear cover (page 3-16) - – Foot pegcover bar (hal. Body (page3-15) 3-8) - Left crankcase rear cover (hal. 3-16) thecover engine(hal. with3-8) the recommended engine oil (page 4- Fill Body 10).

Isi mesin dengan oli mesin yang direkomendasikan (hal. 4-10). BOLT

GEARSHIFT PEDAL

11-5


STATOR STATOR PELEPASAN REMOVAL Lepaskan leftleft crankcase cover (hal. 11-4). Remove the crankcase cover (page 11-4). Lepaskan ignition pulse generator mounting dan Remove the ignition pulse generator mounting bolts bolts and lepaskan wire grommet dari leftthe crankcase cover. cover. release the wire grommet from left crankcase

WIRE GROMMET

IGNITION PULSE GENERATOR

BOLTS

Lepaskan stator kemudian Remove the statormounting mounting bolts, bolts, then removelepaskan the stator and ignition pulse generator fromdari the left crankcase crankcase stator dan ignition pulse generator cover. cover.

STATOR

BOLTS

INSTALLATION PEMASANGAN IGNITION PULSE GENERATOR MOUNTING BOLTS STATOR MOUNTING BOLTS

STATOR

LEFT CRANKCASE COVER WIRE GROMMET


11-6

ALTERNATOR/STARTER CLUTCH Letakkan pulse generator generatorinto ke the dalam Place thestator stator dan and ignition pulse left crankcase cover. left crankcase cover. Install and tighten the stator mounting bolts. Pasang dan kencangkan stator mounting bolts.

STATOR

BOLTS

Oleskan (cairan perapat) padaor permukaan liquidsealant sealant(THREE Apply liquid BOND 1215 1207B or duduk wire grommet dangrommet pasang seating grommet ke dalam equivalent) to the wire surface and alur cover. install the grommet into the cover groove. Set the ignition pulse generator in position. Route the wire Install and tighten the ignition pulse generator mounting Tempatkan ignition pulse generator pada posisinya. bolts. properly (page 1-14). Pasang dan kencangkan ignition pulse generator Install the left crankcase cover (page 11-5). mounting bolts.

WIRE GROMMET


Pasang left crankcase cover (hal. 11-5).

BOLTS

FLYWHEEL/STARTER FLYWHEEL/STARTERCLUTCH CLUTCH PELEPASAN REMOVAL Remove the crankcase cover (page 11-4). Lepaskan left left crankcase cover (hal. 11-4).

REDUCTION GEAR

Remove the shaft starter reduction gear. Lepaskan shaft danand starter reduction gear.

SHAFT

Lepaskan nutand dan Remove theflywheel flywheel nut washerwasher using the dengan special tool. menggunakan special tool. TOOL: TOOL: Flywheel holder holder Flywheel

FLYWHEEL NUT/WASHER

07725-0040001 07725-0040001

FLYWHEEL HOLDER

11-7

ALTERNATOR/STARTER CLUTCH Lepaskan flywheel/starter clutch dengan menggunakan Remove the flywheel/starter clutch using the special tool. special tool. TOOL: Flywheel puller, 28 mm 07933-KG20000 TOOL: Flywheel puller, 28 mm 07933-KG20000

FLYWHEEL/ STARTER CLUTCH

FLYWHEEL PULLER Remove the needle bearing. Lepaskan needle bearing.

NEEDLE BEARING

waktu When Pada woodruff key Lepaskan Remove the woodruff key. woodruff key. pelepasan woodruff removal, be careful key,toberhati-hatilah not damage the key agar tidak merusak groove and alur key atau crankshaft. crankshaft. Do not lose the aga agar woodruff woodruff key. key tidak hilang.

WOODRUFF KEY

PEMBONGKARAN STARTER CLUTCH STARTER CLUTCH DISASSEMBLY Remove the flywheel/starter clutch (page 11-7). Lepaskan flywheel/starter clutch (hal. 11-7). Check the operation of the oneclutch way clutch by turning the Periksa cara kerja one way dengan memutar driven gear. driven gear. You should be able to turn the driven gear counterclockDriven gear harus diputar berlawanan arah jarum wise smoothly, butdapat the gear should not turn clockwise. am dengan halus, tetapi gear tidak boleh berputar Remove the starter driven gear from the flywheel/starter searah jarum jam. clutch while turning the driven gear counterclockwise.

Lepaskan starter driven gear dari flywheel/starter clutch sementara memutar driven gear berlawanan arah jarum am.

11-8

DRIVEN GEAR

ALTERNATOR/STARTER CLUTCH Tahan flywheel dengan tool dan Hold the flywheel using menggunakan the special tool special and remove the starter clutch outer mounting torx bolts.bolts. lepaskan starter clutch outer mounting TOOL: TOOL: Flywheel holder Flywheel holder

BOLTS

07725-0040001 07725-0040001

FLYWHEEL HOLDER Remove the starter clutch assembly. Lepaskan starter clutch assembly.

STARTER CLUTCH ASSEMBLY

PEMERIKSAAN INSPECTION Periksa starter reduction keausan Check the starter reductiongear gearterhadap for wear or damage.atau kerusakan.

STARTER REDUCTION GEAR

Periksa starter terhadap keausan atau Check the starterdriven driven gear for wear or damage. kerusakan. Measure the driven gear boss O.D. SERVICE LIMIT:

45.2 mm (1.78 in)

DRIVEN GEAR

11-9

ALTERNATOR/STARTER CLUTCH Lepaskan rollers danand springs dari starter clutch Remove plate, the plate, rollers springs from the starter outer. clutch outer.

CLUTCH OUTER

SPRING

ROLLER Starter clutch clutch should harus Periksa rollers, springs, outerforterhadap Starter Check the rollers, springs,starter starter clutch clutch outer wear or sebagai damage.atau kerusakan. bediganti replaced as an keausan sebuah assembly jika assembly if any parts ada parts yang rusak are damaged or atau aus. worn.

PLATE

CLUTCH OUTER

SPRING

ROLLER

Pasang plate, springs Install the plate, springsdan androllers rollers pada to the starter starter clutch outer as shown. outer seperti diperlihatkan.

SPRING

ROLLER

11-10

PLATE

ALTERNATOR/STARTER CLUTCH STARTER CLUTCH PERAKITAN STARTERASSEMBLY CLUTCH STARTER DRIVEN GEAR

STARTER CLUTCH OUTER

PLATE

FLYWHEEL

SPRING ROLLER

TORX BOLT 16 N·m (1.6 kgf ·m, 12 lbf ·ft) Install the starter clutch assembly ontoflywheel. the flywheel. Pasang starter clutch a ssembly pada

STARTER CLUTCH ASSEMBLY

FLYWHEEL

Oleskan cairan agent pengunci pada clutch ulir starter clutch Apply a locking to the starter mounting torx bolt threads mounting bolt.as specified. Hold the flywheel using menggunakan the special toolspecial and tighten the Tahan flywheel dengan tool dan bolts to the specified torque. kencangkan bolts dengan torsi yang ditentukan. TOOL: TOOL: Flywheel holder 07725-0040001 Flywheel holder 07725-0040001 TORQUE: 16 N·m (1.6 kgf·m, 12 lbf·ft) TORSI: 29 N.m (3,0 kgf.m, 22 lbf.ft).

Lebar lapisan : 6.5 ± 1.0 mm dari ujung

BOLT

FLYWHEEL HOLDER

11-11

ALTERNATOR/STARTER CLUTCH Semprotkan permukaan gelinding Apply engineolioilmesin to thepada starter clutch rolling surfacestarter of the drivendari gear. clutch driven gear.

Pasang starter driven gear gear padatoflywheel/starter clutch Install the starter driven the flywheel/starter clutch whilememutarnya turning it counterclockwise. sementara searah jarum jam. Make sure that the starter driven gear turns counterPastikan bahwa starter gear berputar berlawanan clockwise smoothly anddriven does not turn clockwise. arah jarum jam dengan halus dan tidak dapat Install the flywheel/starter clutch (page 11-12). berputar searah jarum jam.

DRIVEN GEAR

DRIVEN GEAR

Pasang flywheel/starter clutch (hal. 11-12).

PEMASANGAN INSTALLATION woodruff key dalam crankshaft During woodruff key Pasang Install the woodruff key in thealur crankshaft keykey. groove. installation, be careful not to damage the key groove or crankshaft.

Apply engineolioilmesin to thepada needle bearing. Semprotkan needle bearing. Install the needle bearing. Pasang needle bearing.

11-12

WOODRUFF KEY

NEEDLE BEARING

ALTERNATOR/STARTER CLUTCH Sekalah olioilyang ada pada surface permukaan Wipe any off the mating of thepenyatuan crankshaftdari and flywheel. dan flywheel. crankshaft

WOODRUFF KEY

FLYWHEEL/ STARTER CLUTCH

Install the flywheel/starter clutch to the crankshaft, alignPasang flywheel/starterclutch pada crankshaft, dengan ing the key way with the woodruff key. mentepatkan alur key dengan woodruff key.

KEY WAY

Pasang washer. Install the washer. Semprotkan mesin pada ulir flywheeland nut dan Apply engineoli oil to t he flywheel nut threads seating surface, then installkemudian it. permukaan duduk, pasang. Hold the flywheel using menggunakan the special toolspecial and tighten the Tahan flywheel dengan tool dan flywheel nut to the specified torque. kencangkan flywheel nut dengan torsi yang ditentukan. TOOL: TOOL: Flywheel holder 07725-0040001 Flywheel holder 07725-0040001 TORQUE: 40 N·m (4.1 kgf·m, 30 lbf·ft) TORSI: 40 N.m (4,1 kgf.m; 30 lbf.ft)

FLYWHEEL NUT

WASHER

FLYWHEEL HOLDER

Semprotkan mesin padareduction starter gear reduction Apply engine oli oil to the starter journalsgear (left crankcase and cover) and gear teeth. ournals (left crankcase dan cover) dan gigi-gigi gear. Install the starterreduction reduction gear gear with aligning the starter Pasang starter dengan mentepatkan drive gear and starter driven gear. starter drive gear dan starter driven gear.

DRIVE GEAR

REDUCTION GEAR JOURNAL

DRIVEN GEAR

REDUCTION GEAR

Semprotkan starter reduction Apply engineolioilmesin to thepada starter reduction gear gear shaft.shaft. Install the shaft thereduction reductiongear. gear. Pasang shaft ke into dalam

SHAFT

Install the left crankcase cover (page 11-5). Pasang left crankcase cover (hal. 11-5).

11-13

MEMO

12. CRANKSHAFT/TRANSMISSION/KICKSTARTER

LOKASI KOMPONEN-KOMPONEN.......12-2 COMPONENT LOCATION ·························· 12-2

TRANSMISSI............................................12-9 TRANSMISSION·············································12-9

KETERANGAN SERVIS............................12-3 SERVICE INFORMATION ···························12-3

CAM CHAIN GUIDE SPROCKET.........12-18 CAM CHAIN GUIDE SPROCKET·············12-18

TROUBLESHOOTING...............................12-5

PERAKITAN CRANKCASE...................12-19

PEMISAHAN CRANKCASE.....................12-6

KICKSTARTER........................................12-20

TROUBLESHOOTING ··································12-5

CRANKCASE SEPARATION ·······················12-6

CR ANKSH AFT............................................12-7 CRANKSHAFT······················· ························ · 12-7

CRANKCASE ASSEMBLY ························· 12-19

KICKSTARTER ············································12-20

12

12-1

CRANKSHAF/TRANSMISSI/KICKSTARTER

COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN CRANKSHAFT/TRANSMISSION/KICKSTARTER

10 N·m (1.0 kgf ·m, 7 lbf ·ft)

12-2


SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM • The crankcase must be separated to service the crankshaft, transmission and kickstarter. Crankcase dipisahkan agarbefore dapatseparating menservis • The • followingharus parts must be removed thecrankshaft, crankcase. transmission dan kickstarter. berikut harus dilepaskan sebelum memisahkan crankcase. • – Parts Engine (page ini 7-4) – -Stator (page Mesin (hal.11-6) 7-4) – -Flywheel (page 11-7) Stator (hal. 11-6) – -Clutch (page(hal. 10-8) Flywheel 11-7) – -Gearshift linkage (page 10-26) Clutch (hal. 10-8) – -Cam chain tensioner (page10-26) 8-24) Gearshift linkage (hal. – -Cylinder head (page 8-12) Cam chain tensioner (hal. 8-23) – -Cylinder/piston Cylinder head(page (hal. 9-5) 8-12) – -Oil pump (page 5-4) Cylinder/piston (hal. 9-5) – -Gear position switch Oil pump (hal. 5-4)(page 18-12) • Be careful not to damage crankcase - Gear position switchthe (hal. 19-12)mating surfaces when servicing. • Prior to assembling the crankcase halves, applypenyatuan sealant to the mating surface. Wipe off excess sealant thoroughly. Hati-hati agar tidak merusak permukaan crankcase pada waktu melakukan pekerjaan servis. • • Clean all disassembled parts with clean solvent and dry them using compressed air before inspection. Sebelum merakit belahan crankcase, oleskan sealant pada permukaan penyatuan. Seka sealant yang berlebihan sama • sekali. Bersihkan semua parts yang dibongkar dengan larutan pembersih dan keringkan dengan menggunakan udara dari • SPECIFICATIONS kompressor sebelum menjalankan pemeriksaan. Unit: mm (in) SERVICE SPESIFIKASI ITEM STANDARD LIMIT Satuan: mm Crankshaft Connecting rod side clearance 0.10 – 0.35 (0.004 – 0.014) 0.60 (0.024) BAGIAN STANDARD BATAS SERVIS Connecting rod radial clearance 0 – 0.008 (0 – 0.0003) 0.05 (0.002) Runout 0.10 (0.004) Crankshaft Jarak renggang ke samping connecting rod 0,10 ––0,35 0,60 Transmission Gear I.D. M2,rod M3 17.000 – 17.0180(0.6693 17.04 (0.671) Jarak renggang radial connecting – 0,008– 0.6700) 0,05 C1 18.000 – 18.018- (0.7087 – 0.7094) 18.04 (0.710) Keolengan 0,10 C4 20.000 – 20.02117,000 (0.7874– –17,018 0.7882) 20.04 (0.789) Transmission D.D. gear M2, M3 17,04 Bushing O.D. C1 17.966 – 17.984 (0.7073 – 0.7080) 17.94 (0.706) C1 18,000 – 18,018 18,04 Bushing I.D. C1 15.000 – 15.01820,000 (0.5906– –20,021 0.5913) 15.04 (0.592) C4 20,04 Gear-to-bushing clearance C1 0.016 – 0.052 (0.0006 – 0.0020) 0.10 (0.004) D.L. bushing C1 17,966 – 17,984 17,94 Mainshaft O.D. M3 16.966 – 16.984 (0.6680 – 0.6687) 16.95 (0.667) D.D. bushing C1 15,000 – 15,018 15,04 Countershaft O.D. C1 14.966 – 14.984 (0.5892 – 0.5899) 14.95 (0.589) Jarak renggang gear-ke-bushing C1 0,016 – 0,052 0,10 Gear-to-shaft clearance M3 0.016 – 0.052 (0.0006 – 0.0020) 0.09 (0.004) D.L. mainshaft M3 16,966 – 16,984 16,95 Bushing-to-shaft clearance C1 0.016 – 0.052 (0.0006 – 0.0020) 0.09 (0.004) D.L. countershaft C1 14,966 – 14,984 14,95 Shift fork/ Shift fork I.D. 34.075 – 34.100 (1.3415 – 1.3425) 34.14 (1.344) Jarak renggang gear-ke-shaft M3 0,016 – 0,052 0,09 Shift drum Shift fork claw thickness 4.85 – 4.95 (0.191 – 0.195) 4.60 (0.181) Jarak renggang bushing-ke-shaft C1 0,016 – 0,052 0,09 Shift drum O.D. Right 33.950 – 33.975 (1.3366 – 1.3376) 33.93 (1.336) Shift fork/ D.D. shift fork 34,14 Left 23.940 – 23.98034,075 (0.9425– –34,100 0.9441) 23.92 (0.942) Shift drum Ketebalan – 4,95 4,60 Kickstarter Pinion I.D. shift fork claw 20.000 – 20.0214,85 (0.7874– 0.7882) 20.08 (0.791) D.L. shift drum Kanan 33,950 – 33,975 33,93 Spindle O.D. 19.959 – 19.980 (0.7858 – 0.7866) 19.94 (0.785) Kiri 23,940 – 23,980 23,92 TORQUE Kickstarter VALUE D.D. pinion 20,000 – 20,021 20,08 D.L. spindle 19,959 – 19,980 19,94 Cam chain guide sprocket spindle 10 N·m (1.0 kgf ·m, 7 lbf ·ft)

TORSI PENGENCANGAN Cam chain guide sprocket spindle 10 N.m (1,0 kgf.m; 7 lbf.ft)

12-3

CRANKSHAF/TRANSMISSI/KICKSTARTER TOOLS Bearing remover set, 12 mm 07936-1660101

Bearing remover shaft, 12 mm 07936-1660120

Bearing remover head, 12 mm 07936-1660110

Remover weight 07741-0010201

Driver 07749-0010000

Pilot, 12 mm 07746-0040200

Universal bearing puller 07631-0010000

Assembly set, 14 mm 07JMF-KW70100

Assembly collar 07LMF-KAB0110

Attachment, 32 x 35 mm 07746-0010100

Attachment, 37 x 40 mm 07746-0010200

or equivalent commercially available Attachment, 28 x 30 mm 07946-1870100

12-4

CRANKSHAF/TRANSMISSI/KICKSTARTER Attachment, 52 x 55 mm 07746-0010400

Pilot, 17 mm 07746-0040400

Pilot, 22 mm 07746-0041000

TROUBLESHOOTING TROUBLESHOOTING Hard to shift Transmissi clutchdioper adjustment (page 4-17) • Incorrect sulit • Bent shift forks Penyetelan clutch tidak benar (hal. 4-19) • spindle (page 10-27) • Bent Shiftgearshift forks bengkok • • Damaged shift drum cam grooves Gearshift spindle bengkok (hal. 10-27) • • Incorrect engine oil viscosity Alur-alur shift drum cam rusak • Transmission out of gearsesuai Viskositasjumps oli mesin tidak • • Worn gear dogs and dog holes • Broken shift drum stopper arm Transmissi melompat dari (page gigi 10-27) stopperkeluar arm spring • Broken drum Gear dogs dan lubang-lubang dog aus • gearshift spindle return spring • Broken (page 10-27) Shift drum stopper arm patah • • Worn or bent shift forks • Worn shifter groove Drumgear stopper arm spring patah (hal. 10-27) • Gearshift • Excessive noisespindle return spring patah (hal. 10-27) Shift forks aus atau • • Worn connecting rod bengkok big end bearing • Worn crankshaft bearing Alur gear shifter aus • • Worn transmission bearing • Worn or damaged transmission gears Suara berlebihan Connecting rod big end bearing aus • Crankshaft bearing aus • Transmission bearing aus • Transmission gears aus atau rusak •

12-5


PEMISAHAN CRANKCASECRANKCASE SEPARATION ReferKeterangan to Service Information for parts removal of 12-3) Lihat Servis (hal.(page 12-3) untuk yang necessary parts before separating the crankcase. perlu dilepaskan sebelum memisahkan crankcase.

CAM CHAIN

Remove the cam chain from the timing sprocket. Lepaskan cam chain dari timing sprocket.

Longgarkan lepaskan crankcase bolts pola Loosen and dan remove the crankcase bolts in adalam crisscross pattern in several bersilangan dalamsteps. beberapa langkah.

Place theleft leftcrankcase crankcase di up. Letakkan sebelah atas. Carefully separate the left crankcase from the right Dengan hati-hati pisahkan crankcase dari with right crankcase while tapping themleft at several locations a crankcase dengan mengetuknya pada beberapa tempat soft hammer. dengan palu lunak.

BOLTS

LEFT CRANKCASE

RIGHT CRANKCASE

Be careful not to Hati-hati agar tidak damage the mating merusak permukaan surfaces. permukaan penyatuan.

Remove the dowel pins. Lepaskan dowel pins. Clean off the sealant from the left and right crankcase mating surfaces. Bersihkan sealant dari permukaan penyatuan left dan right crankcase.

DOWEL PINS

12-6


CRANKSHAFT PELEPASAN REMOVAL Remove the transmission (page 12-9). Lepaskan transmissi (hal. 12-9).

RIGHT CRANKCASE

CRANKSHAFT

Remove thecrankshaft crankshaft dari from the right crankcase dengan using a Hati-hati agar right crankcase Be careful not totidak drop Lepaskan hydraulic press. menjatuhkan crankshaft. the crankshaft. menggunakan hydraulic press.

If the crankshaft bearing remainscrankshaft) on the crankshaft, Jika crankshaft bearing (bantalan tertinggal remove it using a special tool as shown. pada crankshaft, lepaskan dengan menggunakan special TOOL:tool seperti diperlihatkan. Universal bearing puller 07631-0010000 or TOOL: equivalent commerUniversal bearing puller 07631-0010000 cially available atau tools serupa yang dapat dibeli di pasaran

CRANKSHAFT BEARING

UNIVERSAL BEARING PULLER

Jika crankcase,drive dorong If thebearing bearingtertinggal remains inpada the crankcase, it outkeluar from the sebelah outside. luar. dari Do not reuse the Discard the crankshaft bearing. angan pakai kembali Buanglah crankshaft bearing. crankshaft bearing.

RIGHT CRANKCASE:

crankshaft bearing yang telah dilepaskan.

CRANKSHAFT BEARING

INSPECTION PEMERIKSAAN SIDE CLEARANCE MeasureRENGGANG the side clearance by inserting the feeler gauge JARAK KE SAMPING between the crankshaft and connecting rod big end. Ukur jarak renggang ke samping dengan memasukkan SERVICE feeler gauge (lidah voeler) antara crankshaft dan kepala LIMIT: 0.60 mm (0.024 in) besar connecting rod.

FEELER GAUGE


12-7

CRANKSHAF/TRANSMISSI/KICKSTARTER JARAK RENGGANG RADIAL RADIAL CLEARANCE Set the crankshaft V-blocks and measure the jarak conLetakkan crankshaftonpada V-blocks dan ukur necting rod big end radial clearance. renggang radial kepala besar connecting rod. SERVICE BATAS 0,05mm mm(0.002 in) LIMIT: SERVIS: 0.05

CRANKSHAFT CRANKSHAFT Check thetiming timing sprocket wear or damage. Periksa sprocketfor terhadap keausan atau kerusakan. If replacing the timing sprocket, align the center of the Sewaktu kembali timing sprocket, tepatkan sprocket memasang teeth with the center of the woodruff key groove as shown. bagian tengah gigi sprocket dengan bagian tengah dari alur woodruff key (spie) seperti diperlihatkan.

WOODRUFF KEY GROOVE

TIMING SPROCKET

Letakkan penopang) VPlace thecrankshaft crankshaftpada on astand stand(alat or V-blocks andatau measure the runout a dial gauge. blocks dan ukurusing keolengan dengan menggunakan dial gauge. The measuring locations are shown in the illustration. SERVICE Lokasi pengukuran diperlihatkan pada gambar. LIMIT: 0.10 mm (0.004 in)


30 mm (1.2 in) 46 mm (1.8 in) Turn the outer race of the left crankshaft with Putar outer race (lingkaran luar) dari leftbearing crankshaft your finger. bearing dengan jari-jari. The bearing turndengan smoothly anddan quietly. Bearing harusshould berputar halus tanpa suara. Also check that the bearing inner race fi ts tightly on the Juga periksa bahwa bearing inner race (lingkaran dalam crankshaft. bantalan) duduk dengan erat pada crankshaft. Replace the bearing if the outer race does not turn smoothly, quietly, or if inner race fits loosely on the Ganti bearing jika outer race tidak berputar dengan crankshaft. halus, tanpa suara, atau jika inner race duduk dengan longgar pada crankshaft.

12-8

120 mm (4.7 in)

CRANKSHAF/TRANSMISSI/KICKSTARTER CRANKSHAFT BEARING PENGGANTIAN CRANKSHAFT BEARING REPLACEMENT Be careful not to Hati-hatidamage agar tidak the merusak crankcase. crankcase.

Apply oil to a new bearing rolling surface. Semprotkan oli right padacrankshaft permukaan gelinding right crankshaft bearing baru. Drive in the right crankshaft bearing with its marked side Dorong masuk right bearing dengan facing up until it is fullycrankshaft seated, using the special tools.sisi yang ada tandanya menghadap ke atas sampai sampai TOOLS: ia telah duduk sepenuhnya, dengan menggunakan Driver 07749-0010000 special tools. Attachment, 52 x 55 mm 07746-0010400 Pilot, 22 mm 07746-0041000 TOOLS:

DRIVER

Driver 07749-0010000 For transmission bearing replacement (page 12-15). Attachment, 52 x 55 mm 07749-0010400 Pilot, 22 mm 07746-0041000 Untuk penggantian transmission bearing (hal. 12-15). CRANKSHAFT BEARING

INSTALLATION PEMASANGAN Be sure that the connecting rod is Pastikan bahwa located in the connecting rod berada ada posisinya crankcasediopening. lubang crankcase.

ATTACHMENT/ PILOT

3

Semprotkan 1,0cm3 – of 2,0 pada kepala Apply 1.0 – 2.0 oil cm to theoli connecting rod big besar end. connecting rod. Draw the crankshaft into the right crankcase bearing inner race using the special tool. Tarik crankshaft ke dalam right crankshaft bearing inner TOOLS: race dengan menggunakan special tool. Assembly set, 14 mm 07JMF-KW70100 Assembly collar 07LMF-KAB0110 TOOLS: Assembly set, 14 mm 07JMF-KW70100 Install the transmission (page 12-16). Assembly collar 07LMF-KAB0110 Assemble the crankcase (page 12-19).

CRANKSHAFT ASSEMBLY COLLAR

CONNECTING ROD

Pasang transmission (hal. 12-16). Rakit crankcase (hal. 12-10). ASSEMBLY SET

RIGHT CRANKCASE

TRANSMISSION (TRANSMISSI) PELEPASAN REMOVAL Separatebelahan-belahan the crankcase halves (page 12-6). Pisahkan (hal. 12-6). crankcase

COUNTERSHAFT

Remove the mainshaft,countershaft countershaft and drum as Lepaskan mainshaft, dan shift shift drum an assembly. sebagai sebuah assembly (susunan).

SHIFT DRUM

MAINSHAFT

12-9

CRANKSHAF/TRANSMISSI/KICKSTARTER Lepaskan countershaft oil oil seal dari leftthe crankcase. Remove the countershaft seal from left crankcase.

COUNTERSHAFT OIL SEAL

PEMBONGKARAN DISASSEMBLY Jangan mainshaft, countershaft dan shiftand drum. Domerenggangkan not expand the Bongkar Disassemble the mainshaft, countershaft shift drum. snap ring lebih daripada snap ring more than Clean all disassembled parts in solvent thoroughly. yang diperlukan untuk Bersihkan semua parts yang telah dibongkar dalam necessary for pelepasannya. larutan pembersih secara menyeluruh. removal.

SHIFT DRUM

Keep track of the disassembled parts (gears, bushings, CATATAN: drum lock plate, friction spring, washers and snap rings) by slidingjejak them parts onto a yang tool or telah slippingdibongkar them onto a piece Ikutilah (gears, of wire. drum lock plate, friction spring, washers dan bushings, snap rings) dengan menggeser mereka pada sebuah tool atau memasangnya pada seutas kawat.

COUNTERSHAFT

Lepaskan yang berikutfrom dari shift shift drum: drum: Remove the following – Guide pin clips - –Guide pin clips Guide pins - –Guide Shift pins forks - Shift forks

GUIDE PIN

PIN CLIP

INSPECTION PEMERIKSAAN SHIFT FORK/SHAFT CheckFORK/SHAFT the shift fork for deformation or abnormal wear. SHIFT Measure each shift fork claw thickness. Periksa shift fork terhadap perubahan bentuk atau SERVICE keausan tidak normal. LIMIT: 4.60 mm (0.181 in) Ukur ketebalan masing-masing shift fork claw. Measure each shift fork I.D. BATAS SERVIS: 4,60 mm SERVICE LIMIT: 34.14 mm (1.344 Ukur D.D. masing-masing shift fork.in)


12-10

MAINSHAFT SHIFT FORKS

SHIFT DRUM

CRANKSHAF/TRANSMISSI/KICKSTARTER SHIFT SHIFTDRUM DRUM Periksa alur-alur shift drum for terhadap keausan atau Check the shift drum grooves wear or damage. Measure the shift drum O.D. at each end. kerusakan. Ukur D.L. shift drum pada masing-masing ujungnya. SERVICE LIMITS: Left side: 23.92 mm (0.942 in) BATAS SERVIS: Right side: 33.93 mm (1.336 in) Sisi kiri: 23,92 mm Sisi kanan: 33,93 mm

LEFT SIDE

ALUR-ALUR SHIFT DRUM Inspect the drum journal for abnormal wear or drum) damPeriksa shiftshift drum journal (bantalan luncur shift age. terhadap keausan tidak normal atau kerusakan.

CRANKCASE KIRI:

CRANKCASE KANAN:

GEAR/BUSHING/SHAFT GEAR/BUSHING/SHAFT Check the shifter groove for abnormal damPeriksa alurgear gear shifter terhadap keausanwear tidakornormal age.kerusakan. atau Check the gear dogs and teeth for abnormal wear ortidak lack Periksa gear dogs dan gigi-gigi terhadap keausan of lubrication. normal atau kekurangan pelumasan.

GEAR DOGS

GEAR SHIFTER

Periksa holes for(lubang-lubang terhadap Check thedog dog holes abnormal wear ordog) lack of lubrication. keausan tidak normal atau kekurangan pelumasan. Ukur D.D. masing-masing gear. Measure the I.D. of each gear. BATAS SERVIS: SERVICE LIMITS: M2, M3: 17,04 mm M2, M3: 17.04 mm (0.671 in) C1: 18,04 mm C1: 18.04 mm (0.710 in) C4: 20,04 mm C4: 20.04 mm (0.789 in) Periksa C1 bushingforterhadap keausan atau Check the C1 gear gear bushing wear or damage. kerusakan. Measure the gear bushing O.D. and I.D. Ukur D.L. dan D.D. gear bushing. SERVICE LIMITS: BATAS O.D.: SERVIS: 17.94 mm (0.706 in) D.L.: 17,94 mm I.D.: 15.04 mm (0.592 in) D.D.: 15,04 mm Calculate the gear to bushing clearance. Hitung jarak renggang antara gear ke bushing. SERVICE LIMIT: C1: 0.10 mm (0.004 in) BATAS SERVIS: C1: 0,10 mm

DOG HOLES

12-11

CRANKSHAF/TRANSMISSI/KICKSTARTER Periksa mainshaft dan keausan Check the mainshaft andcountershaft countershaftterhadap for abnormal wear tidak normal atau kerusakan. or damage. Measure of the dan mainshaft and countershaft. Ukur D.L. the dariO.D. mainshaft countershaft. SERVICE LIMITS: BATAS SERVIS: At M3: 16.95 mm (0.667 in) Pada M3: 16,95 mm At C1: 14.95 mm (0.589 in) Pada C1: 14,95 mm Calculate the gear to shaft clearance. Hitung jarak renggang antara gear ke shaft. SERVICE LIMIT: BATAS SERVIS: M3: 0.09 mm (0.004 in) M3: 0,09 mm Calculate the bushing to shaft clearance. Hitung jarak renggang antara bushing ke shaft. SERVICE LIMIT: C1: 0.09 mm (0.004 in) BATAS SERVIS: C1: 0,09 mm TRANSMISSION BEARING

Turn the inner race of each bearing with your finger. TRANSMISSION BEARING The bearings should turn smoothly and quietly. Putar inner race (lingkaran dari fits masing-masing Also check that each bearingdalam) outer race tightly in the bearing (bantalan) dengan jari-jari. crankcase. Bearings berputarif dengan halus dandoes tanpa suara. Replace harus the bearing the inner race not turn Juga periksa bahwa outerinrace smoothly, quietly, or masing-masing if the outer racebearing fits loosely the (lingkaran crankcase. luar bantalan) duduk dengan erat pada crankcase.

Ganti bearing jika inner race tidak berputar dengan halus, tanpa suara, atau jika outer race duduk dengan longgar pada crankcase.

JALAN LINTASAN OLI OIL PASSAGES Tiuplah terbuka lintasan crankcase Blow open the oil jalan passages of thedari rightright crankcase with compressed dengan udaraair. dari kompressor. Check the oil passages for clog, wear or damage. Periksa jalan lintasan oli terhadap sumbatan, keausan atau kerusakan.

12-12

COUNTERSHAFT C1 BUSHING

M3 MAINSHAFT

CRANKSHAF/TRANSMISSI/KICKSTARTER PERAKITAN ASSEMBLY Clean all parts in solvent and drylarutan them thoroughly. Bersihkan semua parts dalam pembersih dan keringkan secara menyeluruh. Apply molybdenum disulfide oil to the each rotating gear inner surfaceoliand C1 bushingdisulfide whole surface to ensure Semprotkan molybdenum pada permukaan initial lubrication. dalam masing-masing gear yang berputar dan seluruh permukaan C1 bushing agar mendapatkan Assemble all parts into their original positions.pelumasan awal. Rakit semua parts pada posisi mereka semula. • Check the gears for freedom of movement or rotation on the shaft. CATATAN: • Install the washers and snap rings with the chamfered Periksa gears terhadap kebebasan pergerakan edges facing the thrust load side. • • Do not reuse a worn snap ring which could easily spin atau perputaran pada shaft. in the groove. Pasang washers dan snap rings dengan ujung • • Check that the snap rings are seated in the grooves yang dipotong ke sisi gaya dorong. and align theirmenghadap end gaps with the grooves of the Jangan memakai kembali snap ring yang aus yang • spline. • Check the special washers aredalam seated in the shaft dapat dengan mudah berputar alurnya. grooves. Periksa bahwa snap rings telah duduk pada alurnya • dan tepatkan celah pada ujung mereka dengan alur-alur dari spline. Periksa bahwa special washers telah duduk pada • alur-alur shaft. MAINSHAFT: MAINSHAFT:

SNAP RINGS M2/M3:permukaan dalam M4: alur shift fork

SPLINE WASHER SPECIAL WASHER M3 GEAR (22T) M2 GEAR (18T) MAINSHAFT M1 GEAR (13T)

SPLINE WASHER

M4 GEAR (24T)

Arah washer dan snap ring :

12-13

CRANKSHAF/TRANSMISSI/KICKSTARTER COUNTERSHAFT: COUNTERSHAFT:

Pasang ke dalam alur C2 segar. Masukkan ujung spring ke dalam l ubang pada drum lock plate

C1/C4: permukaan dalam C3: alur shifk fork C2 GEAR (28T) COUNTERSHAFT LOCK WASHER

COLLAR

DRUM LOCK PLATE

SPLINE WASHER

FRICTION SPRING THRUST WASHER

C3 GEAR (25T) C1 BUSHING C4 GEAR (22T)

Masukkan lock washer tabs ke dalam slots dari spline washer.

SPLINE WASHER SNAP RING THRUST WASHER SPECIAL WASHER C1 GEAR (34T) arah washer dan snap ring :

SHIFT DRUM: GUIDE PINS

SHIFT FORKS

SHIFT DRUM

GUIDE PIN CLIPS

12-14

CRANKSHAF/TRANSMISSI/KICKSTARTER TRANSMISSION BEARING PENGGANTIAN TRANSMISSION BEARING REPLACEMENT Lepaskan crankshaft (hal. 12-7). Remove the crankshaft (page 12-7). Lepaskan bolts danand mainshaft bearing setset plates. Remove the bolts mainshaft bearing plates.

CRANKCASE KANAN:

MAINSHAFT BEARING

Dorong mainshaft dan bearings countershaft Drive outkeluar the mainshaft andbearing countershaft from the rightdari crankcase. bearing right crankcase.

BOLTS/SET PLATES

Dorong keluar crankcase. Drive out the countershaft countershaft bearing bearing dari fromleft the left crankcase.

COUNTERSHAFT BEARING

CRANKCASE KIRI:

COUNTERSHAFT BEARING

Keluarkan mainshaft bearing darifrom left crankcase dengan Remove the mainshaft bearing the left crankcase using the special tools. menggunakan special tools. TOOLS: TOOLS: Bearing remover set, 12 mm 07936-1660101 Bearing remover set, 12 mm 07936-1660101 - Bearing remover shaft, 12 mm 07936-1660120 – Bearing remover shaft, 12 mm 07936-1660120 - Bearing remover head, 12 mm 07936-1660110 – Bearingweight remover head, 12 mm 07936-1660110 Remover 07741-0010201 Remover weight 07741-0010201

CRANKCASE KIRI:

MAINSHAFT BEARING

REMOVER WEIGHT

BEARING REMOVER SET

12-15

CRANKSHAF/TRANSMISSI/KICKSTARTER Drive new bearings into thebaru crankcase with their marked Dorong masuk bearing ke dalam crankcase side facing untilada theytandanya are fully seated, using the spedengan sisi up yang menghadap ke atas cial tools. sampai mereka telah duduk sepenuhnya, dengan menggunakan special tools. TOOLS: Right crankcase mainshaft bearing: TOOLS: Driver 07749-0010000 Right crankcase Attachment, 37mainshaft x 40 mm bearing: 07746-0010200 Driver 07749-0010000 Pilot, 17 mm 07746-0040400 Attachment, 37 x 40 mm 07746-0010200 Right crankcase countershaft bearing: Pilot, 17 mm 07746-0040400 Driver 07749-0010000 Right crankcase countershaft bearing: Attachment, 32 x 35 mm 07746-0010100 Driver 07749-0010000 Pilot, 12 mm 32 x 35 mm 07746-0040200 Attachment, 07746-0010100 Left crankcase mainshaft bearing: Pilot, 12 mm 07746-0040200 Driver Left crankcase mainshaft bearing:07749-0010000 Attachment, 28 x 30 mm 07946-1870100 Driver 07749-0010000 Pilot, 12 mm 07746-0040200 Attachment, 28 x 30 mm 07946-1870100 Left crankcase Pilot, 12 mm countershaft bearing:07746-0040200 Left crankcase countershaft bearing: Driver 07749-0010000 Driver 07749-0010000 Attachment, 37 x 40 mm 07746-0010200 Attachment, 07746-0010200 Pilot, 17 mm 37 x 40 mm 07746-0040400 Pilot, 17 mm 07746-0040400 Apply locking to the mainshaft bearing set plate Oleskan cairan agent pengunci pada ulir mainshaft bearing set bolt threads as specified. plate bolt seperti ditentukan. Install the mainshaft bearing set plates and bolts to the right crankcase andbearing tighten the Pasang mainshaft setbolts. plates dan bolts pada right crankcase dan kencangkan Install the crankshaft (page 12-9). bolts.

DRIVER

BEARING

ATTACHMENT/PILOT

Lebar pelapisan: 6.5 ± 1.0 mm ±dari ujung

Pasang crankshaft (hal. 12-9).

SET PLATES/BOLTS

PEMASANGAN TRANSMISSION TRANSMISSION INSTALLATION Oleskan gemuk bibir-bibir countershaft Apply grease to apada new countershaft oil seal lips. oil seal Install the oil seal until it is flush with the crankcase surbaru. face. Pasang oil seal sampai ia rata dengan permukaan crankcase.

CRANKCASE KIRI:

COUNTERSHAFT OIL SEAL

12-16

CRANKSHAF/TRANSMISSI/KICKSTARTER Semprotkan mesin pada transmission dan Apply engineoli oil to the transmission gears andgears shift drum whole surface. seluruh permukaan shift drum. Engage the mainshaft, countershaft gears andgears shift drum Saling kaitkan mainshaft gears, countershaft dan assembly. shift drum assembly.

SHIFT DRUM

COUNTERSHAFT

Pasang danshift ke mainshaft, shift drum Install the mainshaft, countershaft countershaft and drum into the dalam right crankcase. right crankcase.

COUNTERSHAFT

SHIFT DRUM

Putar drum memeriksa cara operakerja Rotate shift the shift drum untuk to check the transmission tion. transmission. Tepatkan darilock lockplate plateand danshift alurdrum shift groove. drum. Align the ujung tip of the

MAINSHAFT

MAINSHAFT

LOCK PLATE

Assemble the crankcase (page 12-19). Rakit crankcase (hal. 12-19).

SHIFT DRUM GROOVE

12-17


CAM CHAIN CAM CHAIN GUIDE GUIDESPROCKET SPROCKET PELEPASAN REMOVAL Separatecrankcase the crankcase 12-6). Pisahkan (hal.(page 12-6). Hold the cam chain guide sprocket, turn thechain cam guide chain Tahan cam chain guide sprocket, putar cam guide sprocket spindle counterclockwise and remove sprocket spindle berlawanan jarum jam dan lepaskan them from the left crankcase. dari left crankcase.

CAM CHAIN GUIDE SPROCKET

SPINDLE

PEMERIKSAAN INSPECTION Periksa berikut: Inspectsebagai the following: Camchain chain guide guide sprocket wear or damage - –Cam sprocketforterhadap keausan atau – kerusakan Cam chain guide sprocket spindle for wear or damage - Cam chain guide sprocket spindle terhadap keausan atau kerusakan


SPINDLE

journal - –Spindle keausan tidak normal atau Spindle journalterhadap for abnormal wear or damage kerusakan.

SPINDLE JOURNAL

PEMASANGAN INSTALLATION Apply engineoli oil to the cam ch ain guide sprocket Semprotkan mesin pada permukaan luncurspindle cam sliding surface. chain guide sprocket spindle. Install the spindle to the crankcase, holdsprocket the sprocket Pasang spindle pada leftleft crankcase, tahan dan and tighten the spindle to thetorsi specified torque. kencangkan spindle dengan yang ditentukan. TORQUE:10 N·m (1.0 kgf·m, 7 lbf·ft) TORSI: 10 N.m (1,0 kgf.m; 7 lbf.ft) Assemble the crankcase (page 12-19). Rakit crankcase (hal. 12-19).


12-18

SPINDLE


CRANKCASE ASSEMBLY Bersihkan darithe left permukaan-permukaan Clean off thesealant sealant from and right crankcase penyatuan left crankcase dan right crankcase. mating surfaces. Install the dowel pins onto the right crankcase. Pasang dowel pins pada right crankcase.

DOWEL PINS Apply light but tipis through of sealant to the (zat left Oleskan lapisan tetapicoating menyeluruh dari sealant crankcase mating surface except the oil passage area as perapat) pada permukaan penyatuan left crankcase shown.daerah jalan lintasan oli seperti diperlihatkan. kecuali

Pasang leftleft crankcase pada right Install the crankcase onto the crankcase. right crankcase.

CRANKCASE KIRI

CRANKCASE KANAN

Pasang dantighten kencangkan crankcase bolts dalam pola Install and the crankcase bolts in a crisscross pattern in several steps. bersilangan dalam beberapa langkah.

BOLTS

12-19

CRANKSHAF/TRANSMISSI/KICKSTARTER Semprotkan oli cam mesin pada seluruh permukaan cam Apply oil to the chain whole surface. Install the cam chain over the timing sprocket. chain. Pasang cam chain diparts atas (page timing12-3) in sprocket. Install the removed the reverse order of removal. Pasang parts yang telah dilepaskan (hal. 12-2) dalam urutan terbalik dari pelepasan.

CAM CHAIN

TIMING SPROCKET

KICKSTARTER KICKSTARTER PELEPASAN REMOVAL Remove the gearshift linkage (page 10-26). Lepaskan gearshift linkage (hal. 10-26).

SNAP RING

Remove the snap retainer the kickstarter Lepaskan snap ringring danand retainer dari from kickstarter spindle. spindle.

RETAINER

Pisahkan (hal.(page 12-6). Separatecrankcase the crankcase 12-6). Remove the kickstarter spindle from the right crankcase. Lepaskan kickstarter spindle dari right crankcase.

KICKSTARTER SPINDLE

PEMBONGKARAN/PEMERIKSAAN DISASSEMBLY/INSPECTION Lepaskan sebagai berikut: Remove the following: Special washer - –Special washer Collar - –Collar – Return spring - Return spring

RETURN SPRING COLLAR

SPECIAL WASHER

12-20

CRANKSHAF/TRANSMISSI/KICKSTARTER Snap ring - –Snap ring Starter ratchet - –Starter ratchet – Ratchet spring - Ratchet spring

STARTER RATCHET SNAP RING

RATCHET SPRING Snap ring - –Snap ring – Washer - Washer – Starter pinion gear - Starter pinion gear

STARTER PINION GEAR

SNAP RING

WASHER

KICKSTARTER SPINDLE/STARTER PINION GEAR KICKSTARTER SPINDLE/STARTER PINION GEAR Periksa kickstarter spindle keausan Check the kickstarter spindleterhadap for bend,tekukan, wear or damage. atau kerusakan. Measure the kickstarter spindle O.D.

KICKSTARTER SPINDLE

SERVICE Ukur D.L. kickstarter spindle. LIMIT: 19.94 mm (0.785 in) BATAS SERVIS: 19,94 mm Check the starter pinion gear for abnormal wear or damPeriksa starter pinion gear terhadap keausan tidak age. normal atau Measure thekerusakan. starter pinion gear I.D. SERVICE Ukur D.D. starter pinion gear. LIMIT: 20.08 mm (0.791 in) BATAS SERVIS: 20,08 mm

STARTER PINION GEAR

Periksa starter spindlespindle journals dari left crankcase dan Check the kickstarter journals of the left and right crankcase for excessive wearkeausan or damage. right crankcase terhadap berlebihan atau kerusakan.

CRANKCASE KIRI :

CRANKCASE KANAN :

KICKSTARTER SPINDLE JOURNALS

12-21

CRANKSHAF/TRANSMISSI/KICKSTARTER PERAKITAN ASSEMBLY Clean all parts in solvent and drylarutan them thoroughly. Bersihkan semua parts dalam pembersih dan keringkan secara menyeluruh. CATATAN: • Install the washers and snap rings with the chamfered Pasang washers danload snap rings dengan ujung• edges facing the thrust side. • Do not yang reuse dipotong a worn snap ring which could easily spin ujung menghadap ke sisi dengan in the groove. gaya dorong. • Check the kembali snap rings are ring seated in yang the grooves Janganthat pakai snap aus dapat • and align their end gaps with the grooves of the dengan mudah berputar di dalam alurnya. spline. Periksa that bahwa ringswasher telah duduk pada alurnya • • Check thesnap special is seated in the dan tepatkan celah pada ujungnya dengan alur-alur groove. pada spline. Periksa bahwa special washer telah duduk pada • alurnya.

RETURN SPRING

KICKSTARTER SPINDLE

COLLAR

SPECIAL WASHER

SNAP RINGS WASHER

Pandangan dari sebelah dalam: pasang ratchet spring dan friction spring seperti diperlihatkan.

STARTER RATCHET

STARTER PINION GEAR RATCHET SPRING Arah washer dan snapring:

12-22

CRANKSHAF/TRANSMISSI/KICKSTARTER Semprotkan larutanoilmolybdenum oil starter pada permukaan Apply m olybdenum solution to the pinion gear inner surface. dalam starter pinion gear. Install the starter pinion gear, washer and snap ring.

STARTER PINION GEAR

SNAP RING

Make sure that the Pastikan bahwa snap Pasang starter pinion gear, washer dan snap ring. snap ring is firmly ring telah duduk dengan seated in the groove. erat pada alurnya.

WASHER Install ratchet spring to the starter ratchet. Pasang ratchet spring pada starter ratchet. Install the the starter ratchet and snap ring to the kickstarter spindle. Make sure that the Pasang starter ratchet dan snap ring pada kickstarter Pastikan bahwa snap snapduduk ring isdengan firmly spindle. ring telah

STARTER RATCHET SNAP RING

seated erat pada in thealurnya. groove.

RATCHET SPRING

Pasang springto the padakickstarter kickstarter spindle Install thereturn return spring spindle while aligning thementepatkan spring end with the hole on the spindle. sementara ujung spring dengan lubang pada spindle.

Tepatkan

RETURN SPRING

Pasang kickstarter spindle spindlewhile sementara Install thecollar collar pada to the kickstarter aligning mentepatkan alurnya dengan ujung its groove with the return spring end.return spring.

Tepatkan

COLLAR

12-23

CRANKSHAF/TRANSMISSI/KICKSTARTER Pasang special washer pada kickstarter spindle. Install the special washer to the kickstarter spindle. SPECIAL WASHER

PEMASANGAN INSTALLATION Pasang kickstarter mentepatkan Install the kickstarterspindle spindle sementara while aligning its ratchet ratchet spring nya dengan alur pada right spring with the groove of the right crankcase ascrankcase shown. seperti Insert diperlihatkan. the return spring end into the hole on the right crankcase as shown. Pasang ujung return spring ke dalam lubang pada right Assemble the crankcase (page 12-19). crankcase seperti diperlihatkan.

KICKSTARTER SPINDLE

Rakit crankcase (hal. 12-19).

Tepatkan

Tempatkan retainer pada kickstarter spindle. Set the retainer to the kickstarter spindle. Temporarily install the kickstarter pedal and bolt. Untuk pasang kickstarter pedal daninstall bolt. the Turn sementara the kickstarter pedal and completely Putar kickstarter pedal dan pasang retainer seluruhnya retainer while aligning its wide tooth with the wide spline sementara mentepatkan giginya yang lebar dengan on the spindle. spline lebar pada spindle. Release the kickstarter pedal. Remove the bolt and kickstarter pedal. Lepaskan kickstarter pedal. Keluarkan bolt dan kickstarter pedal.

BOLT

KICKSTARTER PEDAL Pastikan bahwa snap Pasang snap ring pada alur kickstarter spindle. Make sure that the Install the snap ring to the kickstarter spindle groove. ring telah duduk dengan snap ring is firmly Pasang gearshift linkage (hal. 10-28). erat pada alurnya. Install the gearshift linkage (page 10-28). seated in the groove.

12-24

Masukkan

Tepatkan

SNAP RING

RETAINER

13. RODA DEPAN/SUSPENSI/KEMUDI

LOKASI KOMPONEN-KOMPONEN .......13-2 COMPONENT LOCATION ·························· 13-2

FORK······························································13-11 .........................................................13-11 FORK


HANDLEBAR················································ ...........................................13-19 HANDLEBAR 13-19

TROUBLESHOOTING...............................13-6 TROUBLESHOOTING ··································13-6

STEERINGSTEM································· STEM ....................................13-21 STEERING ········ 13-21

FRONT WHEEL ..........................................13-7 FRONT WHEEL····················· ························· 13-7

13

13-1


COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN FRONTWHEEL/SUSPENSION/STEERING

59 N·m (6.0 kgf ·m, 44 lbf ·ft)

64 N·m (6.5 kgf ·m, 47 lbf ·ft)

59 N·m (6.0 kgf ·m, 44 lbf ·ft)

13-2


KETERANGAN SERVIS SERVICE INFORMATION GENERAL UMUM ! PERINGATAN Frequentmenghirup inhalation of brake pad pad, dust,apapun regardless of material composition be hazardous to your health. Seringkali debu brake komposisi bahannya, dapatcould membahayakan 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 servicing ini meliputi front (roda forkstem, (garpu), handlebar (stang stir) danasteering stem support. (poros kemudi). •• When the frontwheel wheel, fork depan), or steering support the motorcycle using jack or other menservis frontorwheel, fork atau steering stem, topang sepedamotor dengan menggunakan dongkrak atauaalat •• A Sewaktu contaminated brake disc pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with high quality brakelain. degreasing agent. penopang •• After thedisc frontatau pad wheel installation, check the brake operation by applying the brake lever. Brake yang terkontaminasi mengurangi daya pengereman. Buanglah pads yang terkontaminasi dan bersihkan • For brake system service, refer to page 15-3. disc yang terkontaminasi dengan zat pembersih gemuk berkualitas tinggi untuk peralatan rem. Setelah pemasangan front wheel, periksa cara kerja rem dengan menarik brake lever (handel rem). • • Untuk servis sistem rem, lihat hal. 15-3. SPECIFICATIONS

SPESIFIKASI

ITEM

STANDARD

BAGIAN Minimum tire tread depth Kedalaman minimum alurDriver kembang Cold tire pressure only ban Tekanan udara ban Pengendara saja Driver and passenger (dingin) Pengendara dan pembonceng Axle runout Keolengan poros roda Wheel rim runout Radial Kolengan wheel rim Radial Axial (pelek Aksial Wheelroda) hub-to-rim distance Jarak wheel hub-ke-rim (pusat Fork Springroda-ke-pelek) free length Fork Panjang bebas spring (pegas) Spring direction Arah spring Pipe runout Recommended fork fluid Keolengan pipe (pipa) Fork fluid (minyak garpu) yang Fluid level (full bottom) dianjurkan Fluid capacity Permukaan fluid (ditekan penuh ke bawah) Kapasitas fluid

STANDARD – 200 kPa (2.00 kgf/cm2, 229 psi) 2 ; 29 psi) 200kPa kPa(2.00 (2,00kgf/cm kgf.cm 200 , 229 psi) 200 kPa (2,00 kgf.cm – ; 29 psi) – – - page 13-8 See 290.1(11.4) 306,8 With the tightly wound coil side facing down Dengan lilitan yang rapat menghadap ke bawah – Honda Ultra Cushion Oil 10W or equivalent Honda Ultra Cushion Oil 10W atau 73.0 (2.87) sejenisnya 3 63.5 73,0± 1 cm (2.15 ± 0.03 US oz, 2.24 ± 0.04 lmp oz) 3

63,5 ± 1 cm

Unit: mm (in) SERVICE Satuan: LIMIT mm BATAS ToSERVIS indicator Sampai ke – indikator – 0.20 (0.008) 0,20 2.0 (0.08) 2,0 2.0 (0.08) 2,0 – 284.3 (11.193) 297,6 – 0.20 (0.008) 0,20 – – –

-

TORQUE VALUES SteeringPENGENCANGAN stem lock nut TORSI Steering stem top thread Steering lock nutbolt Bottom stem bridge pinch Steering stem topmounting thread nut Handlebar post Bottom bridge Front axle nutpinch bolt Handlebar post mounting nut Front brake disc socket bolt Front axle nut Front spoke Front brake disc socket bolt Fork socket bolt Front socket bolt Brake hose guide bolt Brake hose guide bolt

For tightening sequence (page 13-24) – For tightening sequence (page 13-24) – Untuk urutan pengencangan (hal. 13-24) 64 -N·m (6.5 kgf ·m, 47 lbf ·ft) Untuk urutan pengencangan (hal. 13-24) U-nut 59 -N·m (6.0 kgf ·m, 44 lbf ·ft) 64 N.m (6,559 kgf.m; 47 lbf.ft) U-nut N·m (6.0 kgf ·m, 44 lbf ·ft) 59 N.m (6,042 kgf.m; 44 lbf.ft) U nut N·m (4.3 kgf ·m, 31 lbf ·ft) ALOC bolt; replace with new ones 59 N.m (6,03.2 kgf.m; lbf.ft) U·ft) nut N·m 44 (0.33 kgf ·m, 2.4 lbf 42 N.m (4,3 kgf.m; 31 lbf.ft) ALOC bolt; Apply ganti dengan yang baru locking agent to the threads 20 N·m (2.0 kgf ·m, 15 lbf ·ft) 20 N.m (2,0 kgf.m; 15 lbf.ft) Oleskan zat pengunci pada ulir ALOC bolt; replace with a new one 12 N·m (1.2 kgf ·m, 9 lbf ·ft) 12 N.m (1,2 kgf.m; 9 lbf.ft) ALOC bolt; ganti dengan yang baru

13-3

RODA DEPAN/SUSPENSI/KEMUDI TOOLS Bearing remover shaft 07746-0050100


Driver 07749-0010000

Attachment, 32 x 35 mm 07746-0010100

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

13-4

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

atau sejenis yang dapat dibeli di pasaran.

13-5


TROUBLESHOOTING TROUBLESHOOTING Hard steering Kemudi berat tire pressure • Insufficient Tekanan • • Faulty tire udara ban kurang or distorted spokes • • Loose Ban rusak tight kencang Steeringstem stemlock locknut nuttoo terlalu • • Steering • Faulty steering head bearing • Steering head head bearing rusakrace • Faulty steering bearing Steering head bearing race rusak • • Bent steering stem • Steering stem bengkok Steers to one side or does not track straight • Bent front axle Kemudi satu sisi atau tidak dapat berjalan lurus • Wheelmenarik installedke incorrectly • • Worn Frontor axle (poros front depan) bengkok damaged wheel bearings fork • • Bent Roda tidak terpasang dengan benar • Bent • Frontframe wheel bearings (bantalan roda depan) aus atau rusak • Faulty steering head bearing • Fork (garpu) bengkok wheel wobbles Rangka bengkok •Front • Loose front axlebearing fasteners • Steering head (bantalan kepala kemudi) rusak • Bent rim • Worn or damaged front wheel bearings Roda depan bergoyang Front wheel turns • Pengikat fronthard axle longgar • Front brake drag Rim (pelek) bengkok • • Bent front axle • • Faulty Front front wheelwheel bearings (bantalan roda depan) aus atau rusak bearings Soft suspension Roda depan berat perputarannya • Low tire pressure Rem depanfork menyangkut • • Deteriorated fluid • • Incorrect Front axle bengkok fork fluid weight fluid in fork rusak • • Insufficient Front wheel bearings • Weak fork spring

Suspensi lunak Hard suspension tire pressure • • High Tekanan udara ban rendah • Too much in fork kondisinya • Fork fluid fluid memburuk • Incorrect fork fluid weight • Berat fork fluid tidak benar • Bent fork pipes Tidak ada cukup • • Clogged fluid di dalam fork fork fluid passage

Fork spring Suspension noisy lemah • Bent fork slider • Insufficient fluid in fork Suspensi keras • Loose fork fasteners •

•

Tekanan udara ban tinggi

•

Terlalu banyak fluid di dalam fork Berat fork fluid tidak benar Fork pipes bengkok Jalan lintasan fork fluid tersumbat

• • •

Suspensi berisik Fork slider bengkok • • Fluid di dalam fork kurang Pengikat fork longgar •

13-6


FRONT FRONT WHEEL WHEEL(RODA DEPAN) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Topang the sepedamotor dongkrak Support motorcycledengan using a menggunakan jack or other adjustable support. atau alat penopang lain yang dapat disetel. Lepaskan/pasang berikut: Remove/install the sebagai following: Speedometer cable – Speedometer cable - O-ring – O-ring - Axle – Axlenut nut – Frontaxle axle - Front – Frontwheel wheel - Front – Side collar - Side collar – Speedometer gearbox - Speedometer gearbox TORQUE: AXLE NUT 59 N·m (6.0 kgf·m, 44 lbf·ft) TORSI: NUTthe speedometer 59 N.m kgf.m; 44albf.ft) • AXLE Replace cable(6,0 O-ring with new Ganti speedometer cable O-ring dengan yang baru. • one. • grease to the frontfront axle,axle, speedometer gear gear and • Apply Oleskan gemuk pada speedometer speedometer cable O-ring. dan speedometer cable O-ring. • Check the brake operation after installation. Periksa cara kerja rem setelah pemasangan. • *

FRONT WHEEL

: 3 g ke gigi gear : 0.5 – 1.0 g ke permukaan

FRONT AXLE

AXLE NUT 59 N·m (6.0 kgf ·m, 44 lbf ·ft)

SIDE COLLAR

*

Tepatkan alur speedometer gearbox dengan boss pada kaki fork.

Tepatkan speedometer gear tabs dengan alur-alur wheel hub.

SPEEDOMETER GEARBOX

Lepaskan tab sementara menekannya dan lepaskan speedometer cable. O-RING

13-7

RODA DEPAN/SUSPENSI/KEMUDI PEMBONGKARAN/PERAKITAN ISASSEMBLY/ASSEMBLY D

Remove/install thesebagai following: Lepaskan/pasang berikut: - – Dust seals Dust seals Socket bolts - – Socket bolts Brake disc - – Brake disc Wheel bearings - –Wheel bearings – Distance collar - Distance collar • Replace the socket bolts, bearings and dust seals with new ones. • Ganti grease socket bolts, dan dust seals dengan • Apply to thebearings dust seal lips, bearing cavities yang baru. and distance collar. Oleskan gemuk pada bibir-bibir dust seal, rongga • TORQUE: bearing dan distance collar. BRAKE DISC TORSI: SOCKET BOLT 42 N·m (4.3 kgf·m, 31 lbf·ft) BRAKE DISC SOCKET BOLT 42 N.m (4,3 kgf.m; 31 lbf.ft) For wheel bearing replacement (page 13-9). Untuk penggantian wheel bearing (hal. 13-9). SOCKET BOLTS 42 N·m (4.3 kgf ·m, 31 lbf ·ft)

kencangkan bolts dalam pola bersilangan dalam 2 atau 3 langkah.

DISTANCE COLLAR

DUST SEAL

BRAKE DISC

RIGHT WHEEL BEARING (6201U)

LEFT WHEEL BEARING (6201U)

PENYETELAN WHEEL CENTER (PUSAT RODA) WHEEL CENTER ADJUSTMENT Letakkan padabench. meja kerja. Place therim rim(pelek) on the work Letakkan (pusat roda) of di the tengah2 rimbegin dan Place the wheel wheel hub hub in the center rim and lacing with new spokes. mulailah menganyam dengan spokes (jari-jari) baru. Adjust the wheel hub position so that the distance from Setel posisi wheel hubsurface sehingga jarak permukaan the wheel hub left end to the sidedari of rim is 16.5 ± ujung kiri(0.65 wheel hub sampai bagian samping rim adalah 1.0 mm ± 0.04 in) as shown. 16,5 ± 1,0 mm seperti diperlihatkan. TOOL: Spoke wrench, 4.5 x 5.1 mm 07701-0020200 TOOL: Spoke wrench, 4.5 x 5.1 mm 07701-0020200 TORQUE:3.2 N·m (0.33 kgf·m, 2.4 lbf·ft) TORSI: 3,2rim N.m (0,33(page kgf.m; 2,4 lbf.ft) Check the runout 13-10). Periksa keolengan rim (hal. 13-10)

13-8

DUST SEAL

16.5 ± 1.0 mm (0.65 ± 0.04 in)

RODA DEPAN/SUSPENSI/KEMUDI BEARING REPLACEMENT PENGGANTIAN BEARING Install the bearing remover head the bearing. bearing. Pasang bearing remover head ke into dalam From the opposite side, installbearing the bearing remover Dari sisi berlawanan, pasang remover shaftshaft dan and drive the bearing out of the wheel hub. dorong bearing keluar dari hub. out the other bearRemove the distance collarwheel and drive Lepaskan distance collar dan dorong keluar bearing ing. yang lain. TOOLS: Bearing remover head, 12 mm 07746-0050300 TOOLS: Bearing remover remover shaft 07746-0050100 Bearing head, 12 mm 07746-0050300 Bearing remover shaft 07746-0050100

REMOVER SHAFT

REMOVER HEAD

REMOVER HEAD

BEARING

BEARINGS

REMOVER SHAFT

Isilah rongga bearing dengan Pack all cavities with grease.gemuk. Drivesemua in bearing a new left bearing squarely with its sealed side facing up until it is fully seated. Never install the old Dorong masuk sebuah bearing kiri baru secara Jangan sekali-kali bearings. Once the memasang kembali bearings lama. Sekali bearings have been bearings telah removed, the bearings dilepaskan, harus must be replaced with diganti dengan newyang ones. baru.

REMOVER HEAD

ATTACHMENT

DRIVER

TOOLS: dengan sisinya yang tertutup menghadap tegaklurus keatas Driversampai ia telah duduk sepenuhnya. 07749-0010000 Attachment, 32 x 35 mm 07746-0010100 TOOLS: Pilot, 12 mm 07746-0040200 Driver 07749-0010000 Attachment, 32 x 35 mm 07746-0010100 Pilot, 12 mm 07746-0040200

BEARING

Oleskan lapisan gemuk pada distance dan Apply thin coat oftipis grease to the distance collarcollar and install it. pasang. Drive in a new right bearing squarely with its sealed side facing up. Dorong masuk sebuah bearing kanan baru secara tegaklurus TOOLS: dengan sisinya yang tertutup menghadap ke atas. Driver 07749-0010000 Attachment, 32 x 35 mm TOOLS: Pilot, 12 mm Driver Attachment, 32 x 35 mm Pilot, 12 mm

DISTANCE COLLAR

PILOT BEARING

07746-0010100 07746-0040200 07749-0010000 07746-0010100 07746-0040200

13-9

RODA DEPAN/SUSPENSI/KEMUDI INSPECTION PEMERIKSAAN AXLE(POROS) AXLE Place the axle axle on V-blocks and measure the runout with Letakkan pada V-blocks dan ukur keolengan a dial indicator. dengan dial indicator. SERVICE BATAS mm(0.008 in) LIMIT:SERVIS: 0,20 0.20 mm Keolengan sebenarnya adalah ½ dari pembacaan total Actual runout is 1/2 of the total indicator reading. indicator.

Replace the bearings in pairs. Ganti bearings dalam pasangan.

WHEEL WHEELBEARING BEARING(BANTALAN RODA) Putar inner race dari masing-masing dengan Turn the inner race of each bearing withbearing your finger, the bearingbearing should turn smoothly and quietly. ari-jari, harus berputar dengan halus dan tanpa Also check that the bearing outer race fits tightly in the suara. hub. periksa bahwa bearing outer race duduk dengan Juga Remove erat pada and hub.discard the bearings if the races do not turn smoothly, quietly, or if they fit loosely in the hub. Lepaskan dan buanglah bearings jika races tidak berputar dengan halus, tanpa suara, atau jika mereka duduk dengan longgar pada hub.

WHEEL (PELEK RODA) WHEELRIM RIM Periksa keolengan wheel rim by dengan Check the wheel rim runout placingmeletakkan the wheel roda on a turning stand.turning stand (alat pegangan roda). pada sebuah Spin the wheel by hand and read runout using a dial Putar roda dengan tangan danthe bacalah keolengan indicator. dengan menggunakan dial indicator. Actual runout is 1/2 the total indicator reading. Keolengan sebenarnya adalah ½ dari pembacaan total SERVICE LIMIT: indicator. Axial: 2.0 mm (0.08 in) BATAS SERVIS: 2.0 mm (0.08 in) Radial: Aksial: 2,0 mm Radial: 2,0 mm

13-10


FORK FORK (GARPU) PELEPASAN REMOVAL Remove the following: Lepaskan sebagai berikut: Front fender (page 3-5) - – Front fender (spakbor depan) (hal. 3-5) Front wheel – (page 13-7) - Remove Front wheel (rodacaliper depan)mounting (hal. 13-7) the brake bolts and brake caliSupport the front per from the right fork leg (page 15-12). Gantungkan front brake brake caliper with a Lepaskan brake caliper mounting bolts (baut-baut Remove the bottom bridge upper pinch bolts. brake caliper) dan brake caliper dari for caliper dengan seutas piece of wire so that it pemasangan Loosen the bottom bridge lower pinch bolts and remove kawatdoes sehingga ia tidak leg (kaki garpu) kanan (hal. 15-12). not hang from the fork legs.

UPPER PINCH BOLTS

bergantung pada front the front brake hose. brake hose. Lepaskan bottom bridge upper pinch bolts (baut-baut Do not twist the brake angan memilin brake hose. penjepit atas bottom bridge). hose.

Longgarkan bottom bridge lower pinch bolts (baut-baut penjepit bawah bottom bridge) dan lepaskan fork legs.

LOWER PINCH BOLTS

DISASSEMBLY PEMBONGKARAN Hold the slider in a vice with soft jaws or a lunak shop Tahan forkfork slider di dalam catok dengan penjepit towel. atau dengan kain lap. Loosen the fork socket bolt but do not remove yet. Longgarkan fork socket bolt tetapi jangan lepaskan dulu.

Put the suitable tooltool on the spring seat. Letakkan suitable (perkakas yang sesuai) pada spring seat. Press the spring seat into the fork pipe using a suitable To prevent loss of Untuktension, menghindari Tekan spring seat ke dalam fork pipe dengan tool and hydraulic press, then remove the stopper ring do not hilangnya tegangan, menggunakan using a small screwdriver. sebuah suitable tool dan hydraulic press, compress the fork jangan tekan fork spring kemudian lepaskan stopper ring dengan menggunakan spring more than Remove the spring seat, O-ring and spring from the fork lebih daripada yang pipe. obeng kecil. necessary. The spring sebuah

FORK SLIDER

SOCKET BOLT

SUITABLE TOOL SPRING SEAT

diperlukan. Spring seat seat under berada diis bawah spring pressure. tekanan spring. Berhati- Lepaskan spring seat, O-ring dan spring dari fork pipe. Use care when hatilah sewaktu removing the fork melepaskan fork assembly dari hydraulic assembly from the hydraulic press. press.

STOPPER RING

SPRING

O-RING

Tuangkan forkfork fluid (minyak sokbreker) keluar Pour out the fluid by pumping the fork pipe dengan several times. mempompa fork pipe beberapa kali.

13-11

RODA DEPAN/SUSPENSI/KEMUDI Lepaskan dust seal. Remove the dust seal. DUST SEAL

Lepaskan oil seal stopper ring. Remove the oil seal stopper ring. STOPPER RING

Lepaskan socket boltbolt dan sealing washer. Remove the socket and sealing washer. SEALING WASHER

SOCKET BOLT

Lepaskan forkfork piston danand rebound spring dari forkthe pipe. Remove the piston rebound spring from fork pipe.

FORK PISTON

REBOUND SPRING

13-12

RODA DEPAN/SUSPENSI/KEMUDI Pull the out dari fromfork the slider. fork slider. Tarik forkfork pipepipe keluar FORK SLIDER

FORK PIPE

Keluarkan oil seal dengan Remove the oil seal using menggunakan the special tool.special tool. TOOL: TOOL: Oil 07748-0010001 Oilseal seal remover remover 07748-0010001 or equivalent comatau sejenisnya yangmercially dapat dibeli di pasaran. available.

OIL SEAL REMOVER

OIL SEAL

INSPECTION FORK SPRING PEMERIKSAAN Measure the fork spring free length. FORK SPRING SERVICE Ukur panjang bebas fork spring. LIMIT: 284.3 mm (11.193 in) BATAS SERVIS: 284,3 mm

SPRING

FORK FORKPIPE/SLIDER/PISTON PIPE/SLIDER/PISTON Periksa forkfork pipe, fork slider Check the pipe, fork sliderdan andfork forkpiston piston terhadap for score tanda dan keausan berlebihan mark,gerusan, and excessive or abnormal wear. atau abnormal.

FORK SLIDER

Check the fork piston ring for wear or damage. Periksa fork piston ringfor terhadap keausan atau Check the rebound spring fatigue or damage. kerusakan. Replace the components if necessary. Periksa rebound spring terhadap keletihan atau kerusakan.

Ganti komponen-komponen bila perlu.

FORK PIPE REBOUND SPRING

FORK PISTON

FORK PISTON RING

13-13

RODA DEPAN/SUSPENSI/KEMUDI Letakkan V-blocks ukur keolengan. Place thefork forkpipe pipepada on V-block anddan measure the runout. Actual runout is 1/2 the total indicator Keolengan sebenarnya adalah ½ darireading. pembacaan total indicator. SERVICE LIMIT: 0.20 mm (0.008 in) BATAS SERVIS: 0,20 mm

FORK FORKPIPE PIPEBUSHING BUSHING Periksalah guidethe bushing di dalam forkfork slider secara Visually inspect guide bushing in the slider. Replace the fork slider as an assembly if there is excesvisual. sive scoring scratching, if the teflon is worn so that Gantilah fork or slider sebagaior sebuah assembly (susunan) the copper surface appears on more than 3/4 of jika the ika ada gerusan atau goresan berlebihan, atau entire surface. teflon aus sehingga permukaan tembaga tampak pada lebih dari ¾ dari seluruh permukaan.

GUIDE BUSHING

ASSEMBLY PERAKITAN FORK PIPE

FORK PISTON

FORK PISTON RING

STOPPER RING

DUST SEAL STOPPER RING OIL SEAL SPRING SEAT

FORK SLIDER O-RING

SOCKET BOLT 20 N·m (2.0 kgf ·m, 15 lbf ·ft)

FORK SPRING

SEALING WASHER

13-14

REBOUND SPRING

RODA DEPAN/SUSPENSI/KEMUDI Sebelum perakitan,wash cucilah semua parts dengan larutan Before assembly, all parts with high flash point or non-flammable solvent wipe them pembersih dengan titik and api tinggi atau dry. yang tidak dapat terbakar dan seka Install the fork pipekering. into the fork slider.

FORK SLIDER

Pasang fork pipe ke dalam fork slider.

FORK PIPE Pastikan bahwa Make sure thatfork the Pasang Install the rebound spring and fork pistonkeinto the fork rebound spring dan fork piston dalam fork pipe. piston fork ringpiston telah duduk ring is pipe. seated pada in thealurnya. groove.

FORK PISTON

REBOUND SPRING Clean the socket bolt threads andoleskan apply locking agent to Bersihkan ulir socket bolt dan zat pengunci the bolt pada ulirthreads. bolt. Install and tighten the socket bolt with a new sealing washer to thekencangkan fork piston. socket bolt dengan sealing Pasang dan washer baru pada fork piston.

SEALING WASHER

SOCKET BOLT

Install thedengan oil seal Pasang oil seal sisinya yang bertanda with its marked side menghadap ke atas. facing up.

Apply fork fluid to pada the lipbibir of a oil new oil baru. seal. Oleskan fork fluid seal Drive the oil seal sliderfork using the dengan special Dorong masuk kefork dalam oil into sealthe slider tools until it is fully seated. menggunakan special tools sampai ia telah duduk TOOLS: seluruhnya. Fork seal driver body 07747-0010100 TOOLS: Fork seal driver attachment, 07747-0010300 27.2 mm Fork seal driver body 07747-0010100 Fork seal driver attachment, 07747-0010300 27.2 mm

FORK SEAL DRIVER

ATTACHMENT

OIL SEAL

13-15

RODA DEPAN/SUSPENSI/KEMUDI Pasang oil seal stopper ring ke stopper ring Install the oil seal stopper ringdalam into alur the stopper groove the fork slider. pada forkonslider. STOPPER RING

Apply fork fluid to pada a newbibir dustdust sealseal lip. baru. Oleskan fork fluid Install the dust seal until itiaistelah fully duduk seated.sepenuhnya. Do mengetuk not tap thebibir dust Pasang Jangan dust seal sampai sealterlalu lip tookeras. hard. dust seal

DUST SEAL

Tuangkan fluid yang dianjurkan dalam jumlah Pour the fork specified amount of recommended fork yang fluid ditentukan ke dalam fork pipe. into the fork pipe. 3 FORK FLUID CAPACITY: KAPASITAS FORK FLUID: 63,5 1 cm 3 63.5 ± 1 cm (2.15 ± 0.03 US oz, 2.24 ± 0.04 Imp oz) Pompa fork pipe beberapa kali untuk mengeluarkan Pumpyang the fork pipe severaldari times to remove trapped air udara terperangkap bagian bawah dari for from the lower portion of the fork pipe. pipe.

Pastikan bahwa tinggi Tekan fork leg sama sekali ke bawah dan ukur tinggi Be sure the oil level is Compress the fork leg fully and measure the fluid level permukaan fluid adalah darifork bagian same in the both permukaan from the topfluid of the pipe.atas fork pipe. sama di dalam kedua forks. fork.

FORK FLUID TINGGI PERMUKAAN FORK FLUID: 73,0 mm LEVEL: 73.0 mm (2.87 in)

73.0 mm (2.87 in)

13-16

RODA DEPAN/SUSPENSI/KEMUDI Tarik forkfork pipepipe ke atas daninstall pasang Pull the up and the fork fork spring spring dengan with its tapered side down. menghadap ke bawah. ujungnya yangfacing meruncing

FORK SPRING

FORK PIPE

Tapered side

Lapisi baru dengan dan pasang ke Coat aO-ring new O-ring with fork fork fluid fluid and install it into the dalam pada spring seat. groovealur in the spring seat.

To prevent loss of tension, do not Untuk menghindari compress the fork hilangnya tegangan, spring more than jangan tekan fork spring necessary. lebih daripada yang diperlukan.

Set the fork assembly, spring seat and stopper ring onto Letakkan fork press. assembly, spring seat dan stopper ring the hydraulic pada hydraulic Put the suitablepress. tool on the spring seat. Letakkan suitable tool pada spring seat. Press the spring seat into the fork pipe until the stopper ring groove is visible. Dorong spring seat ke dalam fork pipe sampai alur stopper ring tampak.

SUITABLE TOOL

STOPPER RING O-RING

SPRING SEAT

Pasang stopper ring dalam alur stopper ring on pada Install the stopper ringke into the s topper ring groove the fork pipe. fork pipe.

STOPPER RING Hold the slider in a catok vise with soft jaws or a lunak shop Tahan forkfork slider dalam dengan penjepit towel. atau dengan kain lap. Tighten the fork socket bolt to the specified torque. Kencangkan fork socket bolt dengan torsi yang TORQUE:20 N·m (2.0 kgf·m, 15 lbf·ft) ditentukan.

FORK SLIDER


SOCKET BOLT

13-17

RODA DEPAN/SUSPENSI/KEMUDI INSTALLATION PEMASANGAN Install the fork pipe the steering steering stem. stem. Pasang fork pipe keinto dalam Align the upper pinch bolt hole with the groove the for fork Tepatkan lubang upper pinch bolt dengan alur of pada pipe as shown. pipe seperti diperlihatkan.

UPPER PINCH BOLT HOLE

GROOVE

FORK PIPE Install the bottom bridge upper pinch bolts. Pasang bottom bridge upper pinch bolts. Tighten the bottom upper/lower pinchpinch bolts tobolts the Kencangkan bottombridge bridge upper/lower specified torque. dengan torsi yang ditentukan. TORQUE:64 N·m (6.5 kgf·m, 47 lbf·ft) TORSI: 64 N.m (6,5 kgf.m; 47 lbf.ft) Install the following: Pasang sebagai berikut: – Front wheel (page 13-7) - – Front wheel (hal. 13-7) Front fender (page 3-5) - – Front fender (hal. 3-5)15-12) Brake caliper (page - Brake caliper (hal. 15-12)

STEERING STEM UPPER PINCH BOLTS

LOWER PINCH BOLTS

13-18


HANDLEBAR HANDLEBAR (STANG STIR) PELEPASAN/PERAKITAN REMOVAL/INSTALLATION

Lepaskan handlebar rear cover (hal. 3-11). Remove the handlebar rear cover (page 3-11) Lepaskan sebagai berikut dari handlebar clamps. Release the following from the handlebar clamps: - Front brake hose Front brake - –Throttle cable hose – Throttle cable - Speedometer cable – Speedometer cable Lepaskan sebagai berikut: Remove the following: - Master cylinder/holder/bolts – Master cylinder/holder/bolts - –Screws/handlebar weights Screws/handlebar weights - –Throttle pipe Throttle pipe - –Left handlebar grip Left handlebar grip Nut/collars/bolt/handlebarpost post - –Nut/collars/bolt/handlebar TORQUE: TORSI: HANDLEBAR POST HANDLEBAR POST MOUNTING NUT 44 59 MOUNTING NUT 59 N·m (6.0 kgf·m, lbf·ft) N.m (6,0 kgf.m; 44 lbf.ft) handlebar post/handlebar installation (page • • For Untuk pemasangan handlebargrip post/handlebar grip 13-20). (hal. 13-20). the kawat-kawat/kabel-kabel wires/cables properly (page dengan 1-15). Alurkan benar • • Route (hal. 1-15).

FRONT BRAKE HOSE

THROTTLE CABLE

SPEEDOMETER CABLE

CLAMPS

Kencangkan baut atas dulu, kemudian baru baut bawah.

Tepatkan ujung master cylinder dengan tanda titik pada handlebar. HANDLEBAR WEIGHT SCREW

THROTTLE PIPE

HOLDER

BOLTS

Letakkan holder dengan tanda "UP" menghadap ke atas.

HANDLEBAR POST HANDLEBAR GRIP

MASTER CYLINDER

BOLT COLLAR COLLAR NUT 59 N·m (6.0 kgf ·m, 44 lbf ·ft)

13-19

RODA DEPAN/SUSPENSI/KEMUDI PEMASANGAN HANDLEBAR POST HANDLEBAR POST INSTALLATION Pasang handlebar post pada stem stem sementara Install the handlebar post ontosteering the steering while aligning the bolt holes. mentepatkan lubang-lubang bolt. Rear collar is taller Install the front/rear collars, bolt and nut. Rear collar lebih tinggi Pasang front/rear collars, bolt dan nut. than the front collar. Tighten the nut to the specified torque. dari front collar.

NUT

REAR COLLAR

Kencangkan nut dengan torsi yang ditentukan. TORQUE:59 N·m (6.0 kgf·m, 44 lbf·ft) TORSI: 59 N.m (6,0 kgf.m; 44 lbf.ft)

FRONT COLLAR

BOLT

PEMASANGAN HANDLEBAR GRIP HANDLEBAR GRIP INSTALLATION Jika dilepaskan, oleskan If thehandlebar handlebargrips grips telah were removed, apply HondaHonda Bond A or equivalent to the inside of the grip and to the Bond A atau sejenisnya pada bagian dalam dariclean grip surfaces the left handlebar. dan pada of permukaan bersih dari left handlebar.

HANDLEBAR GRIP

Wait 3 – 5 minutes and install the grip. Tunggu 3 – 5 menit dan pasang grip. Allow the adhesive to Rotate the grip for even application of the adhesive. Biarkan mengering dry forlem 1 hour before Putar grip agar lem terbagi merata. selama 1 jam sebelum using. memakainya.

LEFT HANDLEBAR

Apply lubricant spray Semprotkan lubricant through the spray melalui lubang handlebar hole to the handlebar pada rubber rubber for easy untuk memudahkan removal. pelepasan.

PENGGANTIAN HANDLEBAR INNER WEIGHT HANDLEBAR INNER WEIGHT REPLACEMENT Dorong masuk retainer tab melalui lubang hole handlebar Push the retainer tab through the handlebar with a screwdriver or atau punch. dengan obeng drib. Temporarily install the grip end and screw, then remove Untuk sementara pasang grip end dan kemudian the inner weight assembly by turning thescrew, grip end. lepaskan inner weight assembly dengan memutar grip end.

RETAINER TAB

RETAINER

RUBBER CUSHION

INNER WEIGHT HOLE

Lepaskan screw, grip cushions from dari Remove the screw, gripend enddan and rubber rubber cushions the inner weight. inner weight. Discard the retainer. Buanglah retainer. Check that the condition ofcushions, the rubberganti cushions, replace Periksa kondisi dari rubber bila perlu. them if necessary.

INNER WEIGHT RETAINER

Install the rubber cushions a new retainer ontopada the Pasang rubber cushions danand sebuah retainer baru inner weight. inner weight. Install the grip end onto the inner weight aligning its boss Pasang grip with groove eachend other.pada inner weight dengan mentepatkan boss-nya dengan alur pemasangannya. Install the grip end screw. Pasang grip end screw.

SCREW RUBBER CUSHIONS GRIP END

13-20

RODA DEPAN/SUSPENSI/KEMUDI Masukkan inner weight weight assembly assemblyinto ke dalam handlebar. Insert the inner the handlebar. Turn the inner weight hookretainer the retainer tab with the Putar inner weight danand kaitkan tab pada lubang hole handlebar. in the handlebar. pada Remove the grip end screw and grip end. Lepaskan grip end screw dan grip end.

RETAINER TAB

INNER WEIGHT HOLE

RETAINER

GRIP END

SCREW

STEERING STEERING STEM STEM (POROS KEMUDI) PELEPASAN REMOVAL Lepaskan sebagai berikut: Remove the following:

CABLE GUIDE

Fork (page 13-11) - – Fork (hal. 13-11) Handlebar (page 13-19) - – Handlebar (hal. 13-19)

HOSE CLAMP

Remove the bolts, speedometer cable guide and brake Lepaskan bolts, speedometer cable guide dan brake hose clamp. hose clamp.

BOLTS

Tahan top pinloosen spanner Hold the topthread 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: Socket wrench 07916-KM10000 TOOLS: Pin spanner 07702-0020001 Socket wrench 07916-KM10000 Pin spanner 07702-0020001 Remove the steering stem lock nut.

SOCKET WRENCH STEM LOCK NUT PIN SPANNER

Lepaskan steering stem lock nut.

Hati-hati agar Be careful not totidak drop Tahan Hold the steering stem loosen the thread using steering stem danand longgarkan toptop thread dengan menjatuhkan steering the steering stem. menggunakan the stem socket. stem socket. stem.

TOOL: TOOL: Steering stem Steering stemsocket socket

STEM SOCKET

07916-3710101 07916-3710101

TOP THREAD

13-21

RODA DEPAN/SUSPENSI/KEMUDI Hati-hati agar upper bearing inner race steel Remove the upper bearing inner racedan andupper the upper Be careful not totidak drop Lepaskan menjatuhkan steering balls) sementara the steering stem and balls steel(23 balls (23 balls) while menahan holding thesteering steeringstem. stem. stem dan upper steel the upper steel balls. balls.

UPPER INNER RACE STEEL BALLS (23)

STEERING STEM

Hati-hati agar steering stemstem dan lower steel balls balls). Be careful not totidak drop Lepaskan Remove the steering and lower steel(29 balls (29 menjatuhkan steering the steering stem and balls). stem dan lower steel the lower steel balls. balls.

STEERING STEM

STEEL BALLS (29)

STEERING STEM BEARINGS PENGGANTIAN STEERING STEM REPLACEMENT BEARINGS • •

Always the balls steel balls and races as a sebuah set. Selalu replace ganti steel dan races sebagai set. Remove the steering stem (page 13-21). Lepaskan steering (hal. 13-21). Remove the upperstem bearing outer race using the following Lepaskan upper bearing outer race dengan tool. 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 Remove the lower lower bearing outer outer race using the following Lepaskan bearing race dengan tools. menggunakan tools berikut ini. TOOLS: TOOLS: Ball race race remover, mm Ball remover,34.5 34.5 mm Ball race remover shaft Ball race remover shaft

BALL RACE REMOVER SHAFT

07948-4630100 07948-4630100 07GMD-KS40100 07GMD-KS40100

BALL RACE REMOVER

13-22

LOWER OUTER RACE

RODA DEPAN/SUSPENSI/KEMUDI Lepaskan dust seal stem lower bearing Remove the dust sealdari fromsteering the steering stem lower bearing inner inner race.race. Lepaskan lower bearing sebuah Remove the lower bearinginner innerrace race dengan with a chisel or pahat atau tool toolbeing sejenis dengan tidak equivalent careful not toberhati-hati damage theagar stem. merusak Remove stem. the washer from the steering stem.

LOWER INNER RACE STEERING STEM

DUST SEAL

Lepaskan washer dari steering stem.

WASHER

Install the washer to the steering stem. Pasang washer pada steering stem. Install a new lower bearing inner using the following Pasang lower bearing inner race race baru dengan tool and hydraulic press. menggunakan tool berikut ini dan hydraulic press. TOOL: TOOLS: Fork seal driver attachment, 07947-KA20200 35.2 mm Fork Seal driver 07947-KA20200 attachment, 35.2 mm

WASHER

LOWER INNER RACE

FORK SEAL DRIVER ATTACHMENT

Oleskan gemuk with dengan zat tahan tekanan sangat tinggi Apply grease extreme pressure agent (recommended: EXCELIGHT by KYODO KYODO (dianjurkan: EXCELIGHTEP2 EP2manufactured 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. pada lower bearing inner race.

DUST SEAL Drive a masuk new upper bearing outer race intobaru the head pipe Dorong upper bearing outer race ke dalam usingpipe the following tools. head dengan menggunakan tools sebagai berikut. TOOLS: TOOLS: Driver Driver Bearing driver attachment Bearing driver attachment

DRIVER/ATTACHMENT

07749-0010000 07749-0010000 07946-3710701 07946-3710701

UPPER OUTER RACE

13-23

RODA DEPAN/SUSPENSI/KEMUDI Dorong lower bearing outer race ke dalam Drive a masuk new lower bearing outer race intobaru the head pipe usingpipe the following tools. head dengan menggunakan tools sebagai berikut. TOOL: TOOL: Oilseal seal driver driver 53.5 Oil 53.5mm mm

LOWER OUTER RACE

07947-SB00200 07947-SB00200

Install the steering stem (page 13-24). Pasang steering stem (hal. 13-24).

OIL SEAL DRIVER

INSTALLATION PEMASANGAN For steering stem bearing (page 13-22). Untuk penggantian steeringreplacement stem bearing (hal. 13-22). Gemuk dengan zat tahan tekanan sangat tinggi (di anjurkan : EXCELIGHT EP2 yang di buat oleh KYODO YUSHI, japan atau shell ALVANIA EP2 atau sejenisnya.

LOCK NUT

TOP THREAD

UPPER BEARING (23) UPPER INNER RACE

FRONT BRAKE HOSE CLAMP

BOLT

UPPER OUTER RACE

SPEEDOMETER CABLE GUIDE

LOWER OUTER RACE

BOLT

LOWER BEARING (29)

STEERING STEM LOWER INNER RACE

DUST SEAL

Replace the bearing Ganti bearing dan races and races balls as a balls sebagai sebuah set. set. Be careful not to drop Hati-hati agar tidak the steering stem and menjatuhkan steering the lower stem dan lower steel steel balls. balls.

Apply 3g3g of grease extreme agent (recomOleskan gemuk with dengan zat pressure tahan tekanan sangat mended: EXCELIGHT EP2 manufactured KYODO tinggi (dianjurkan: EXCELIGHT EP2 yang by dibuat oleh YUSHI, japan or Japan Shell ALVANIA or equivalent) to KYODO YUSHI, atau ShellEP2 ALVANIA EP2 atau the lower bearing races. sejenisnya) pada lower bearing races. Attach the steel balls (29 balls) to the lower bearing outer race. steel balls (29 balls) pada lower bearing outer Pasang race. Insert the steering stem into the steering head pipe, being careful not to stem drop the balls. Masukkan ke steel dalam steering steering head pipe, dengan berhati-hati agar tidak menjatuhkan steel balls.

STEEL BALLS (29 balls)

STEERING STEM

13-24

RODA DEPAN/SUSPENSI/KEMUDI Oleskan gemuk with dengan zat pressure tahan tekanan sangat Apply 3g3g of grease extreme agent (recommended: EXCELIGHT EP2 manufactured by KYODO tinggi (dianjurkan: EXCELIGHT EP2 yang dibuat oleh YUSHI, YUSHI, japan orJapan Shell ALVANIA or equivalent) to KYODO atau ShellEP2 ALVANIA EP2 atau the upper bearing races. sejenisnya) pada upper bearing races. Replace the bearing Install the steel balls (23 balls) onto the upper bearing Ganti bearing dan outer race. races and races balls as a Pasang steel balls (23 balls) pada upper bearing outer balls sebagai sebuah set set. race. Be careful not to drop Install the upper bearing inner race onto the stem. Hati-hati agar tidak the steering stem and Pasang upper bearing inner race pada stem.

UPPER INNER RACE

STEEL BALLS (23 balls)

menjatuhkan steering the upper stem dan upper steel steel balls. balls.

Install the thread. Pasang toptop thread. Hold the steering stemdan andkencangkan tighten the stem thread to Tahan steering stem stemtop top thread the initial torque using the special tool. sampai ke torsi awal dengan menggunakan special tool. TOOL: TOOL: Steering stem socket 07916-3710101 Steering stem socket 07916-3710101 TORQUE:25 N·m (2.5 kgf·m, 18 lbf·ft) TORSI: 25 N.m (2,5 kgf.m; 18 lbf.ft)

STEM SOCKET

TOP THREAD

Turn the steering stembeberapa lock-to-lock several times to seat Putar steering stem kali sepenuhnya dari the bearing. ujung-ke-ujung untuk mendudukkan bearing.

Completely top loosen the sama top thread. Longgarkan thread sekali. TOP THREAD

13-25

RODA DEPAN/SUSPENSI/KEMUDI Hold the steering stemdan andkencangkan tighten the stem top thread to Tahan steering stem stem top thread the specified the special tool. menggunakan dengan torsi torque yang using ditentukan dengan special TOOL:tool. Steering stem socket 07916-3710101 TOOL: Steering stem 07916-3710101 TORQUE: 2.5 socket N·m (0.25 kgf·m, 1.8 lbf·ft)

STEM SOCKET

TOP THREAD

TORSI: 2,5 N.m (0,25 kgf.m; 1,8 lbf.ft)

Turn the thread counterclockwise about 45 degrees. Putar top top thread berlawanan jarum jam sebanyak kirakira 45 derajat. TOP THREAD

45°

Tahan top pin spanner Hold the topthread thread dengan using themenggunakan pin spanner and tighten the steering stem locksteering nut to thestem specified dan kencangkan lock torque. nut dengan torsi yang ditentukan. TOOLS: Socket wrench 07916-KM10000 TOOLS: Pin spanner 07702-0020001 Socket wrench 07916-KM10000

STEM LOCK NUT

Pin spanner 07702-0020001 TORQUE:83 N·m (8.5 kgf·m, 61 lbf·ft) TORSI: N.m (8,5 kgf.m; 61 lbf.ft) Turn the83 steering stem lock-to-lock several times. Make sure the steering stem moves smoothly without play or binding. Putar steering stem dari ujung-ke-ujung beberapa kali. Pastikan bahwa steering stem bergerak dengan halus tanpa kelonggaran atau mengikat.

SOCKET WRENCH PIN SPANNER

Install thebrake brake hose hose clamp tighten the bolt while Pasang clamp and dan kencangkan bolt aligning the mentepatkan stoppers of the stoppers clamp and dari steering stem. dan sementara clamp steering stem. Install the speedometer cable guide and tighten the bolt while aligning the stoppers of the guide and steering stem. speedometer cable guide dan kencangkan bolt Pasang Install the following: sementara mentepatkan stoppers dari guide dan steering stem. – Fork (page 13-18) – Front wheel (page 13-7) Pasang sebagai berikut: – Handlebar (page 13-19)

- Fork (hal. 13-18) - Front wheel (hal. 13-7) - Handlebar (hal. 13-19)

Tepatkan

Tepatkan

CABLE GUIDE

BOLTS

13-26

HOSE CLAMP

14. RODA BELAKANG/REM/SUSPENSI

LOKASI KOMPONEN-KOMPONEN.......14-2 COMPONENT LOCATION ·························· 14-2

REM ...............................14-14 14-14 REARBELAKANG BRAKE ···············································


SWINGARM ........................................ 14-17 SWINGARM ··················································14-17


SHOCK ABSORBER .......................... 14-22 SHOCK ABSORBER ····································14-21

RODA BELAKANG ....................................14-6 REAR WHEEL ················································14-6

BRAKE PEDAL................................... 14-23 BRAKE PEDAL·············································14-22

14

14-1


LOKASI-LOKASI KOMPONEN REAR WHEEL/BRAKE/SUSPENSION

24 N·m (2.4 kgf ·m, 18 lbf ·ft)

59 N·m (6.0 kgf ·m, 44 lbf ·ft)

24 N·m (2.4 kgf ·m, 18 lbf ·ft)

59 N·m (6.0 kgf ·m, 44 lbf ·ft)

22 N·m (2.2 kgf ·m, 16 lbf ·ft)

24 N·m (2.4 kgf ·m, 18 lbf ·ft)

14-2


SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM ! PERINGATAN Frequentmenghirup inhalation debu of brake shoe dust,apapun regardless of material composition be hazardous to your health. Seringkali brake shoe, komposisi bahannya, dapat could membahayakan 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 service of the rear wheel, rear brake, swingarm, shock absorber and brake pedal. ini meliputi pekerjaan servis wheel (roda belakang), rearcontaminated brake (rem belakang), (lengan ayun), shock • ABab • contaminated brake drum or shoe rear reduces stopping power. Discard shoes and swingarm clean a contaminated drum with a high quality(sokbreker) brake degreasing agent. absorber dan brake pedal (pedal rem). • thebrake rear wheel support the motorcycle with its centerstand. Brakeservicing drum atau shoe and yangsuspension, terkontaminasi mengurangi daya pengereman. Buanglah shoes yang terkontaminasi dan • When • Use only genuine Honda replacement bolts and nuts for all suspension pivots andtinggi mounting points. bersihkan drum yang terkontaminasi dengan zat pembersih gemuk berkualitas untuk peralatan rem. Sewaktu menservis rear wheel dan suspensi, letakkan sepedamotor pada standard utamanya. • SPECIFICATIONS Hanya pakai bolts dan nuts pengganti asli Honda untuk semua titik-titik engsel dan pemasangan suspensi. •

SPESIFIKASI

ITEM

STANDARD

BAGIAN Minimum tire tread depth Cold tire pressure Driver only Kedalaman minimum alur kembang ban Driver and passenger Tekanan udara ban Pengendara saja Axle runout (dingin) Pengendara dan pembonceng Wheel rim runout Radial Keolengan poros roda Axial Kolengan wheel rim Radial Drive chain DID Size – link (pelek roda) Aksial RK Jarak wheel hub-ke-rim (pusat roda-ke-pelek) Slack Drive chain (rantai Size - link DID Brake Brake drum I.D. roda) RK Brake pedal freeplay Kekenduran Rem D.D. brake drum TORQUE VALUESJarak main bebas brake pedal Rear axle nut Driven sprocket nut Driven PENGENCANGAN flange stud bolt TORSI Rear brake stopper arm nut Rear axle nut Rear brake arm nut Driven sprocket nut Shock absorber upper mounting bolt Driven flange stud bolt Shock absorber lower mounting cap nut/nut Rear brake stopper arm nut Swingarm Rear brakepivot arm nut nut

Shock absorber upper mounting bolt Shock absorber lower mounting cap nut Swingarm pivot nut

STANDARD – 225 kPa (2.25 kgf/cm2, 33 psi) 225 kPa (2.25 kgf/cm2,233 psi) 225 kPa (2,25 kgf.cm ; 33 psi) – 2 225 kPa (2,25 kgf.cm ; 33 psi) – – 420DX – 102 420SL – 102 30 – 40 (1.2 – 1.6) 420DX - 102 110.0 – 110.2 (4.33 – 4.34) 420SL 102 1.2) 20 – 30 -(0.8 – 30 - 40 110,0 – 110,2 20 - 30

59 N·m (6.0 kgf·m, 44 lbf·ft) 32 N·m (3.3 kgf·m, 24 lbf·ft) – 22 N·m (2.2 kgf·m, 16 lbf·ft) 59 N.m (6,0 kgf.m; 44 lbf.ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 32 N.m (3,3 kgf.m; 24 lbf.ft) 24 N·m (2.4 kgf·m, 18 lbf·ft) 24 N·m (2.4 kgf·m, 18 lbf·ft) 22 N.m (2,2 kgf.m; 16 lbf.ft) 59 N·m kgf·m, 44 lbf·ft) 10 N.m (1,0(6.0 kgf.m; 7 lbf.ft)

24 N.m (2,4 kgf.m; 18 lbf.ft) 24 N.m (2,4 kgf.m; 18 lbf.ft) 59 N.m (6,0 kgf.m; 44 lbf.ft)

Unit: mm (in) SERVICE Satuan: LIMIT mm BATASTo SERVIS indicator – Sampai ke indikator – 0.20 (0.008) 2.0 (0.08) 0,20 2.0 (0.08) 2,0 – 2,0 – – 111.0 (4.37) – 111,0

U-nut U-nut See page 14-11

U-nut U-nut U-nut Lihat hal. 14-11 U-nut U-nut

U-nut

14-3

RODA BELAKANG/REM/SUSPENSI TOOLS Driver 07749-0010000

Pilot, 12 mm 07746-0040200

Pilot, 17 mm 07746-0040400

Attachment, 32 x 35 mm 07746-0010100

Attachment, 37 x 40 mm 07746-0010200

Bearing remover shaft 07746-0050100


14-4


TROUBLESHOOTING TROUBLESHOOTING Rear wheel wobbles Roda belakang bergoyang • Bent rim Rim wheel (pelek)bearings bengkok • Worn • Wheel b earings (bantalan roda) aus • • Faulty tire • Improperly tightened Tire (ban) rusak axle fasteners • • Faulty swingarm pivot bushings Pengikat axle (poros) tida k dikencangkan dengan benar • • Insufficient tire pressure Swingarm pivo t b ushings (bos engsel lengan ayun) tidak beke rja dengan bai k • Soft suspension Tekanan udara ban kurang • • Weak shock absorber springs • Oil leakage from damper unit Suspensi lunak • Low tire pressure Shock absorber springs (pegas peredam kejut) lemah • Stiff suspension Ada kebocoran oli dari damper unit • • Bent shock absorber damper rod Tekananswingarm udara banpivot rendah • • Damaged bushings

• Bent swingarm pivot Suspensi • High tirekaku pressure • shock absorber Shock absorber damper bushings rod bengkok • Damaged Swingarm pivo t b ushings rusak • Steers to one side or does not track straight Swingarm pivot bengkok • Bent • rear axle • frame udara ban tinggi Tekanan • Bent • Damaged swingarm pivot bushing Shock abso rber bushings rusak • • Axle alignment/chain adjustment not equal on both sides Poor brake performance Kemudi menarik ke satu sisi atau tidak dapat berjalan lurus • Improper brake adjustment Rear axle (poros belakang) bengkok • • Worn brake linings Rang ka bengkok • • Contaminated brake linings Swingarm pivot bushing rusak • Worn • brake cam • brake drum Perletakan axle/ penyetelan chain tidak sama pada kedua sisi • Worn • Brake arm serrations improperly engaged • Worn brake shoeslemah at cam contact faces Daya pengereman Penyetelan rem tidak benar • Brake linings aus • Brake linings terkontaminasi • Brake cam aus • Brake drum aus • Gerigi b rake arm tidak berhubungan dengan baik • Brake shoes aus pada permukaan kontak cam •

14-5


REAR WHEEL WHEEL(RODA BELAKANG) REAR REMOVAL Letakkan sepedamotor standard utamanya. Support the motorcyclepada with its centerstand. Lepaskan brake adjusting nut,nut, spring dan joint pin. Remove the brake adjusting spring and joint pin.

JOINT PIN

SPRING

ADJUSTING NUT Remove the following: Lepaskan sebagai berikut: – Cotter pin - –Cotter Nut pin - –Nut Washer - –Washer Rubber washer - Remove Rubber washer the bolt and release the stopper arm from the brake panel. Lepaskan bolt dan lepaskan stopper arm dari brake panel.

NUT

RUBBER WASHER

Longgarkan Loosen the axle nut. Loosen bothkedua drive chain lock nutslock and adjusters. driveadjuster chain adjuster nuts dan Longgarkan Push the rear wheel forward and release the drive chain. adjusters. rear Dorong ke depan dan lepaskan drive chain. Remove thewheel following:

COTTER PIN

WASHER

BOLT

STOPPER ARM

COLLAR

ADJUSTER PLATE

DRIVE CHAIN

LOCK NUT

AXLE NUT/ REAR AXLE

– Axle nut Lepaskan se bagai berikut: – Rear axle – Adjuster plates - –Axle nutwheel Rear - –Rear axle Right side collar - Adjuster plates - Rear wheel - Right side collar

Lepaskan brake panel assembly wheelwheel hub Remove the brake panel assemblydari fromright the right hub. roda sebelah kanan). (pusat

14-6

BRAKE PANEL ASSEMBLY

ADJUSTER

RODA BELAKANG/REM/SUSPENSI Remove the side collar Lepaskan side collar darifrom sisi the kiri.left side.

SIDE COLLAR

INSPECTION PEMERIKSAAN AXLE AXLE (POROS) Set the rear axle in V-blocks. Turn the rear rear axle axle pada and measure Letakkan V-blocks.the runout using a dial indicator. Putar rear axle dan ukur keolengan dengan Actual runout is 1/2 the total indicator reading. menggunakan dial indicator. Keolengan SERVICE sebenarnya adalah ½ pembacaan total indicator. LIMIT: 0.20 mm (0.008 in) BATAS SERVIS: 0,20 mm

WHEEL DAN FLANGE BEARING WHEELBEARING BEARING ANDDRIVEN DRIVEN FLANGE BEARING Putar inner race (lingkaran dalam) with dari your masing-masing Turn the inner race of each bearing finger. The bearings should turn smoothly bearing (bantalan) dengan j ari-jari. and quietly. Also check thatberputar the bearing outer racedan fitstanpa tightlysuara. in the Bearings harus dengan halus wheel hub or driven flange. Juga periksa bahwa bearing outer race (lingkaran luar Replace the bearings if the does turn Replace the bearings bantalan) duduk dengan eratinner padarace wheel hubnot (pusat smoothly quietly, or if the outer race fit loosely in the in pairs. roda) atauand driven flange. wheel hub or driven flange. Ganti bearings dalam Ganti bearings jika inner race tidak berputar dengan pasangan. halus dan tanpa suara, atau jika outer race duduk

dengan longgar pada wheel hub atau driven flange.

WHEEL (PELEK RODA) WHEELRIM RIM Check the rim runout placingmeletakkan the wheel roda in a truing Periksa keolengan rim by dengan pada stand. truing stand (alat pegangan roda untuk setel sebuah Spin the wheel slowly, and read the runout using a dial pelek). indicator. Putar dan bacalah Actualroda runoutdengan is 1/2 thepelan, total indicator reading.keolengan dengan dial indicator. SERVICE sebenarnya LIMITS: Keolengan adalah ½ dari pembacaan total Radial: 2.0 mm (0.08 in) indicator. Axial: 2.0 mm (0.08 in) BATAS SERVIS: Radial: 2,0 mm Aksial: 2,0 mm

14-7

RODA BELAKANG/REM/SUSPENSI PEMBONGKARAN DISASSEMBLY Remove the dust seal. Lepaskan dust seal. Loosen the driven driven sprocket sprocket nuts. nuts if removing the driven Longgarkan sprocket. Lepaskan driven flange dari wheel kiri. hub. Remove the driven flange from the hub left wheel

NUTS

DUST SEAL

DRIVEN FLANGE Lepaskan dan Lepaskan damper rubbers dan O-ring. Replace thenuts damper Remove the damper rubbers and O-ring. driven sprocket. rubbers as a set.

DAMPER RUBBERS

O-RING Lepaskan nuts dan driven sprocket. Remove the nuts and driven sprocket.

NUTS

DRIVEN SPROCKET

14-8

RODA BELAKANG/REM/SUSPENSI PENGGANTIAN WHEEL BEARING WHEEL BEARING REPLACEMENT Install the bearing remover the wheel wheelbbearing. Replace thewheel wheel Pasang Gantilah bearing remover heahead d keinto earing. dalam From opposite side install the bearing remover and bearings in pairs. Do Dari bearings dalam remove sisi yang berlawanan pasanglah bearing shaft drive the bearingbearing out of the wheel hub. pasangan. not reuse the old shaft dan dorong keluar dari wheel hub. Remove the distance collar and drive out the other bearangan memakai bearings. Lepaskan distance collar dan dorong keluar bantalan ing. kembali bearings yang lain. lama. TOOLS: Bearing remover head, 12 mm TOOLS: Bearingremover remover shaft Bearing head, 12 mm Bearing remover shaft

REMOVER SHAFT

REMOVER HEAD

07746-0050300 07746-0050100 07746-0050300 07746-0050100

REMOVER HEAD

BEARING

BEARINGS

REMOVER SHAFT

Isilah bearing Packrongga-rongga all bearing cavities with dengan grease. gemuk. Drive in masuk a new right bearing squarely with its sealed side Dorong sebuah bearing kanan baru secara facing up until it is fully seated. tegaklurus dengan sisinya yang tertutup menghadap ke atas sampai ia du duk sepenuhnya. TOOLS: Driver 07749-0010000 TOOLS: Attachment, 37 x 40 mm 07746-0010200 Driver 07749-0010000 Pilot, 12 mm 07746-0040200 Attachment, 37 x 40 mm 07746-0010200 Pilot, 12 mm 07746-0040200

REMOVER HEAD

ATTACHMENT

BEARING

Oleskan lapisan gemuk pada distance dan Apply thin coat oftipis grease to the distance collarcollar and install it. pasang. Drive in a new leftsebuah bearing bearing squarely with sealed side Dorong masuk kiri its baru secara facing up. 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 07746-0040200 Attachment, 32 x 35 mm 07746-0010100 Pilot, 12 mm 07746-0040200

DRIVER

PILOT

BEARING DISTANCE COLLAR

14-9

RODA BELAKANG/REM/SUSPENSI PENGGANTIAN DRIVEN FLANGE BEARING DRIVEN FLANGE BEARING REPLACEMENT Drive out the driven flange collar. Lepaskan driven flange collar. Dorong keluar driven flange bearing. TOOLS: Driver 07749-0010000 Pilot, 17 mm 07746-0040400

DRIVER

PILOT

DRIVEN FLANGE COLLAR Dorong keluar drivenflange flangebearing. bearing. Drive out the driven

DRIVEN FLANGE BEARING

Drive indriven the driven into dalam the a new Pasang flangeflange collarcollar dari sisi dari driven flange bearing with its sealed side facing down. flange. TOOLS: Driver 07749-0010000 Attachment, 37 x 40 mm 07746-0010200 Pilot, 12 mm 07746-0040200

DRIVER

ATTACHMENT/ PILOT

DRIVEN FLANGE BEARING

Isilah rongga bearing Packsemua all bearing cavities withdengan grease.gemuk.

DRIVER

Install the driven flange collar squarely with Pasang sebuah driven bearing flange and bearing baru secara its sealed side facing up. yang tertutup menghadap ke tegaklurus dengan sisinya atas. TOOLS: Driver 07749-0010000 TOOLS: Attachment, 37 x 40 mm 07746-0010200 Driver 007746-0040200 7749-0010000 Pilot, 12 mm Attachment, 37 x 40 mm 07746-0010200 Pilot, 17 mm 07746-0040400 DRIVEN FLANGE BEARING/ COLLAR

14-10

DRIVEN FLANGE COLLAR

ATTACHMENT/ PILOT

RODA BELAKANG/REM/SUSPENSI ASSEMBLY PERAKITAN RIGHT WHEEL BEARING (6301U)

O-RING

DAMPER RUBBER

DISTANCE COLLAR

DUST SEAL DRIVEN FLANGE

DRIVEN SPROCKET (37 T)

DRIVEN FLANGE COLLAR LEFT WHEEL BEARING (6201U)

DRIVEN FLANGE BEARING (6203U)

32 N·m (3.3 kgf ·m, 24 lbf ·ft)

DRIVEN FLANGE STUD BOLT DRIVEN FLANGE STUD BOLT Oleskan cairanagent pengunci driven stud Apply locking to the pada drivenulir flange stud flange bolt threads if the stud bolts are removed. bolt jika stud bolts dilepaskan. Install and tighten the driven flange stud bolt. Pasang dan ing kencangkan drivencheck flange stud bolt. After install the stud bolts, t hat the height from the bolt head to the driven flange surface is within speciSetelah fication. memasang stud bolts, periksa bahwa ketinggian kepala bolt sampai permukaan driven flange adalah sesuai dengan spesifikasi.

12.7 ± 0.5 mm (0.50 ± 0.02 in)

STUD BOLT

PERAKITAN ASSEMBLY Pasang damper rubbers ke into dalam Install the damper rubbers thewheel wheel hub. hub. Apply grease topa a new O-ringbaru and install it into the groove Oleskan gemuk da O-ring dan pasang pada alur of the wheel hub. dari wheel hub.

DAMPER RUBBERS

O-RING

14-11

RODA BELAKANG/REM/SUSPENSI Install the driven flange to the wheel Pasang driven flange pada wheel hubhub. . Install the driven sprocket and nuts. Pasang driven sprocket dan nuts. Tighten the nuts the specified torque. Kencangkan nutsto dengan torsi yang ditentukan. TORQUE:32 N·m (3.3 kgf·m, 24 lbf·ft) TORSI: 32 N.m (3,3 kgf.m; 24 lbf.ft) Apply grease to a new dust s eal lips and ins tall it to the driven flange untilpada it is flush with the end Oleskan gemuk bibir-bibir dustdriven seal flange baru dan surface. pasang pada driven flange.

NUTS

DRIVEN SPROCKET

DUST SEAL DRIVEN FLANGE

PEMASANGAN INSTALLATION Pasang side collar ke into dalam Install the side collar thedriven driven flange. flange.

SIDE COLLAR

DRIVEN FLANGE aga get agar gemuk b rake panel assembly keinto dalam Do not grease on Pasang Install the brake panel assembly the wheel wheel hub. tidak mengenai brake the brake drum or drum a tau daya stopping power will pengereman akan be reduced. berkurang.

Letakkan roda antara lengan-lengan Place the rear wheelbelakang between the swingarm. swingarm. Install the drive chain over the driven sprocket.

BRAKE PANEL ASSEMBLY

COLLAR

ADJUSTER PLATE

Apply grease to the di rear axle surface. Pasang drive chain atas driven spro cket. Install the following: Oleskan gemuk pada permukaan rear axle. – Left adjuster plate – Rearsebagai axle Pasang berikut: – Right side collar - –Left adjuster plate Right adjuster plate - –Rear Axleaxle nut - Right side collar - Right adjuster plate - Axle nut DRIVE CHAIN

14-12

AXLE NUT/ REAR AXLE

RODA BELAKANG/REM/SUSPENSI Pasang stopper dengan Install the stopperarm armpada to thebrake brake panel panel with bolt, bolt, rubber washer, washer anddan nut.nut. rubber washer, washer Tighten the nut to the specified torque. Kencangkan nut dengan torsi yang ditentukan. TORQUE:22 N·m (2.2 kgf·m, 16 lbf·ft) TORSI: 22 N.m (2,2 kgf.m; 16 lbf.ft) Install a new cotter pin. Pasang s ebuah cotter pin baru.

NUT

RUBBER WASHER Install the joint into the brake arm, then install the Pasang joint pin pin ke dalam brake arm, kemudian pasang spring,brake brakerod rod dan and adjusting adjusting nut. spring,

COTTER PIN

WASHER

BOLT

STOPPER ARM

JOINT PIN

SPRING

Adjust the drive chain slack (page 4-14). Setel kekenduran drive chain (hal. 4-13). Adjust the brake pedal freeplay (page 4-17). Setel jarak main bebas brake pedal (hal. 4-17).

BRAKE ROD

ADJUSTING NUT

BRAKE ARM

14-13


REM REARBELAKANG BRAKE Lepaskan rear wheel (hal. 14-6). INSPECTION Remove the rear wheel (page 14-6). PEMERIKSAAN Measure brake drum I.D. Ukur D.D. the rearrear brake drum. SERVICE BATAS SERVIS: 111,0 mm LIMIT: 111.0 mm (4.37 in) Pasang rear wheel (hal. 14-12). Install the rear wheel (page 14-12).

PEMBONGKARAN DISASSEMBLY Always replace the brake shoes as a set. When the brake shoes are reused, mark all parts before disassembly so they can be installed in their original locations.

Remove the rearshoes wheeldan (page 14-6). Lepaskan b rake springs. Remove the brake shoes and springs. • Selalu ganti brake shoes sebagai satu set. • Jika brake shoes akan dipakai kembali, tandailah semua parts sebelum membongkarnya sehingga mereka dapat dipasang pada lokasinya semula.

SPRINGS

BRAKE SHOES

Lepaskan nut,nut, boltbolt danand brake arm. Remove the brake arm. Remove the indicator plate. Lepaskan indicator plate.

NUT

BRAKE ARM

INDICATOR PLATE

Lepaskan felt seal dan band rake brake cam dari b rake Remove the felt seal cam frompanel. the brake panel. Periksa kondisi dari felt seal, ganti bila perlu. Check the condition of the felt seal, replace it if necessary.

BRAKE CAM

FELT SEAL

14-14

BOLT

RODA BELAKANG/REM/SUSPENSI ASSEMBLY PERAKITAN *: Oleskan 0.2 – 0.3 g gemuk

BRAKE ARM BOLT INDICATOR PLATE

FELT SEAL

*

BRAKE CAM NUT 10 N·m (1.0 kgf ·m, 7 lbf ·ft) *

ANCHOR PIN

BRAKE SHOES BRAKE PANEL

SPRINGS

Oleskan 0,2 0.3 – 0,3 gemuk pada brake panel anchor Apply 0.2 – g of g grease to the brake panel anchor pin. pin. Apply 0.2 – 0.3 g of grease to the brake cam sliding surOleskan – shoes 0,3 g contact gemuk area. pada permukaan luncur face and 0,2 brake bInstall rake cam dan daerah kontak b rakepanel. shoes. the brake cam into the brake Pasang b rake cam ke dalam b rake panel.

ANCHOR PIN

BRAKE CAM

Semprotkan pada dan pasang pada Apply gear oilolitogear the felt sealfelt andseal install it onto the brake bpanel. rake p anel.

FELT SEAL

14-15

RODA BELAKANG/REM/SUSPENSI Pasang pada brake cam camaligning dengan Install theindicator indicator plate plate on the brake its wide tooth with the wide groove the brake cam. pada mentepatkan giginya yang lebar on dengan alur lebar b rake cam.

INDICATOR PLATE

Tepatkan

Pasang brake arm dengan mentepatkan tanda-tanda Install the brake arm aligning the punch marks of the titik pada b rake b rake cam. brake arm and arm brakedan cam. Install the brake arm bolt and nut. Pasang rake arm b oltspecified dan nut. torque. Tightenbthe nut to the Kencangkan nut dengan torsi yang ditentukan. TORQUE:10 N·m (1.0 kgf·m, 7 lbf·ft)

NUT

Tepatkan


BRAKE ARM

BOLT

b rake shoes dan springs. If the brake shoes are Pasang Install the brake shoes and springs. reused, the shoes and Install the rear wheel (page 14-12). Pasang rear wheel (hal. 14-12). springs must be placed back in their original locations.

SPRINGS

BRAKE SHOES

14-16


SWINGARM SWINGARM PELEPASAN REMOVAL Letakkan sepedamotor standard utamanya. Support the motorcyclepada with its centerstand. Remove the following: Lepaskan sebagai berikut:

BRAKE LIGHT SWITCH SPRING

Exhaust pipe/muffler (page 3-16) - – Exhaust pipe/muffler (hal. 3-16) Rear wheel – (page 14-6) - Rear wheel (hal. 14-6) Unhook the brake light switch spring from the brake Lepaskan brake pedal light switch spring dari brake pedal. pedal.

BRAKE PEDAL

Lepaskan brake pedal return spring dari swingarm. Remove the brake pedal return spring from the s wingarm and brake rod.

RETURN SPRING Remove thebolt bolt and chain cover cover by releasing its Lepaskan dan drive drive chain dengan tab from thetab-nya slot on the melepaskan dariswingarm. slot pada swingarm.

TAB

SLOT

Lepaskan rearrear shock absorber lowerlower mounting cap nuts Remove the shock absorber mounting cap nut,washers. nut and washers. dan

DRIVE CHAIN COVER

BOLT

SHOCK ABSORBERS

Release both shock absorber lower mounts from the Lepaskan kedua shock absorber lower mounts dari swingarm studs. swingarm studs.

CAP NUT/ WASHER NUT/WASHER

14-17

RODA BELAKANG/REM/SUSPENSI Lepaskan se bagai baga i be rikut: Remove the following: - – Pivot Pivotnut/washer nut/was her - Bolt Bolt – - Plate Plate –

PIVOT NUT/WASHER

PLATE BOLT

Lepaskan se bagai baga i be rikut: Remove the following: - – Collar Collar - Pivot Pivotbolt bolt – - – Swingarm Swingarm

COLLAR

PIVOT BOLT SWINGARM

DISASSEMBLY/INSPECTION PEMBONGKARAN/PEMERIKSAAN Check the drive chain slider for wear or damage. Release drive the drive chainslider slider terhadap bosses from the holes on Periksa chain keausan atau the swingarm. kerusakan. Remove the drive chain slider by releasing its slots from the hooks on the swingarm. Lepaskan drive chain slider bosses dari lubang-lubang pada swingarm. Lepaskan drive chain slider dengan melepaskan slotsnya dari hooks pada swingarm.

SLOTS/HOOKS BOSSES

DRIVE CHAIN SLIDER Remove the following: Lepaskan sebagai berikut: Cotter - –Cotter pinpin – Nut - Nut – Washer - –Washer Spring washer - –Spring Bolt washer Stopper arm - –Bolt - Stopper arm

STOPPER ARM

NUT/WASHER/ SPRING WASHER/ BOLT

COTTER PIN

14-18

RODA BELAKANG/REM/SUSPENSI Periksa pivot bushingsfor terhadap keausan atau Check the pivot bushings wear or damage. kerusakan. Check the swingarm for cracks or damage. Periksa swingarm terhadap retak-retak atau kerusakan.

BUSHINGS

SWINGARM

ASSEMBLY PERAKITAN Install the following: Pasang sebagai berikut: – Stopper arm - –Stopper Bolt arm - –Bolt Spring washer - –Spring washer Washer Nut - –Washer - Tighten Nut the nut to the specified torque.

WASHER

Kencangkan dengan torsi 16 yang ditentukan. TORQUE:22nut N·m (2.2 kgf·m, lbf·ft) TORSI: N.m (2,2pin. kgf.m; 16 lbf.ft) Install a 22 new cotter Pasang cotter pin baru.

SPRING WASHER STOPPER ARM

COTTER PIN Install the drivechain chainslider slider pada to the swingarm swingarm while alignPasang drive sementara ing its slots with thenya hooks and itshooks bosses withbosses-nya the holes. mentepatkan slots-nya slotsdengan dan bossesnya dengan lubang-lubang.

Tepatkan

NUT/WASHERS/BOLT DRIVE CHAIN SLIDER

Tepatkan

PEMASANGAN INSTALLATION Alurkan drive chain swingarm keinto dalam Route the drive chaindan andpasang install the swingarm the frame. rangka. Insert the pivot pivot bolt Masukkan pivot Masukkan boltfrom dari the sisileft kiriside. dan kencangkan pivot nut untuk sementara.

PIVOT BOLT

SWINGARM

DRIVE CHAIN

14-19

RODA BELAKANG/REM/SUSPENSI Pasang collar ke to pivot bolt Install the collar pivot bolt. COLLAR

Install the following: Pasang sebagai berikut: - –Plate Plate Pivot nut/washer - – Pivot Piv ot Nut/washer Bolt - – Bolt Sementara kencangkan nut dan and danbolt. bolt Temporarilykencangkan pivot tighten the pivot pivot nut

PIVOT NUT/WASHER

PLATE BOLT

Kaitkan rear shock pada pivots, padathe pivots, Hook the rear shockabsorber absorberlower lower mounts mounts onto pivots, then install the washers, cap nut and kemudian pasang washers lower dan mounting lower mounting cap nut. nuts. Temporarily tighten the rear shock absorber lower mounting nuts. Kencangkan rear shock absorber lower mounting nuts untuk sementara.

SHOCK ABSORBERS

CAP NUT/ WASHER NUT/WASHER

Pasang drive chain cover sementara mentepatkan drive Install the drive chain cover while aligning the drive chain covercover tab with slot ofslot thepada swingarm. dengan chain tabthe swingarm. Install and tighten the bolt. Pasang dan kencangkan bolt.

Tepatkan

DRIVE CHAIN COVER

BOLT

14-20

RODA BELAKANG/REM/SUSPENSI Kaitkan yang sempit Hook theujung narrow end of brake dari pedalbrake return pedal spring return to the hole on the lubang blake rod, then hook thekemudian wide endkaitkan to the spring pada pada brake rod, swingarm slot. lebar pada swingarm slot (lubang ujung yang pemasangan pada lengan ayun).

BRAKE ROD HOLE

BRAKE PEDAL RETURN SPRING

SWINGARM SLOT BRAKE ROD HOLE SIDE

SWINGARM SLOT SIDE Hook the brake light return switchspring spring pada to theswingarm. brake pedal. Kaitkan brake pedal


BRAKE PEDAL

Turunkan dari14-12). standard utamanya dengan Install thesepedamotor rear wheel (page . 14-12) hati-hati dan peganglah sepedamotor dengan erat, Retract the centerstand carefully and support the motorkemudian kencangkan swingarm pivot nutpivot dengan cycle securely, then tighten the swingarm nut totorsi the yang ditentukan. specified torque.

PIVOT NUT

TORQUE:59 N·m (6.0 kgf·m,44 44lbf.ft) lbf·ft) TORS TOR S I: 59 N.m (6,0 kgf.m;

Tighten the sepedamotor bolt. Letakkan utamanya.

kembali

atas

standard

BOLT

14-21

RODA BELAKANG/REM/SUSPENSI Tighten the rear shock absorber lower mounting cap nut Kencangkan rear shock absorber lower mouting cap LOWER and nut to thetorsi specified torque. nuts dengan yang ditentukan. MOUNTING TORQUE:24 N·m (2.4 kgf·m, 18 lbf·ft) CAP NUT TORSI: 24 N.m (2,4 kgf.m; 18 lbf.ft) Support the motorcycle with its centerstand. Install the exhaust pipe/muffler (page 3-17). 3-17).

LOWER MOUNTING NUT

SHOCK SHOCK ABSORBER ABSORBER PELEPASAN REMOVAL Letakkan sepedamotor standard utamanya. Support the motorcyclepada with its centerstand. Remove the following: Lepaskan sebagai berikut:

Sisi kanan di perlihatkan:

Body cover (page 3-8) - – Body cover (hal. 3-8) Exhaust pipe/muffler – (page 3-16) - Exhaust pipe/muffler (hal. 3-16). Remove the shock absorber upper mounting bolts. Lepaskan shock absorber upper mounting bolts. Remove the shock absorber lower mounting nut and Right side: Lepaskan shock absorber lowerabsorber. mounting cap nuts dan washer, then remove the shock washers, kemudian lepaskan shock absorbers. Left side: Remove the shock absorber lower mounting cap nut and washer, then remove the shock absorber.

UPPER MOUNTING BOLT

SHOCK ABSORBER

LOWER MOUNTING NUT/WASHER

PEMERIKSAAN INSPECTION Do not disassemble the shock absorber. Replace the shock absorbers as a set.

Periksalah shock secara visualor damage. terhadap Visually inspect the absorber shock absorber for wear keausan atau kerusakan. Check the following:

BUSHINGS

– Deformation or oil leakage Periksa sebagai berikut: – Bushings for wear or damage - Check Perubahan bentuk atau kebocoran keboc oran oli. the smooth damper operation. - Bushings terhadap keausan atau kerusakan. - Damper rod terhadap kebengkokan atau kerusakan

Periksa kelancaran cara kerja damper.

PEMASANGAN INSTALLATION Install the shock absorbers ontorangka. the frame. Pasang shock absorbers pada Tighten the upper mounting bolts to the specified torque. Kencangkan upper mounting bolts dengan torsi yang TORQUE:24 N·m (2.4 kgf·m, 18 lbf·ft) ditentukan.

SIsi kanan di perlihatkan:

UPPER MOUNTING BOLT

Install the lower mounting cap nut/nut and washers. TORSI: 24 N.m (2,4 kgf.m; 18 lbf.ft) Tighten the nuts to the specified torque. Pasang lower mounting cap nuts dan washers. TORQUE:24 N·m (2.4 kgf·m, 18 lbf·ft) Kencangkan lower mounting cap nuts dengan torsi yang Install the following: ditentukan. – Exhaust pipe/muffler (page 3-17) TORSI: N.m(page (2,4 3-8) kgf.m; 18 lbf.ft) cover – Body24 Pasang sebagai berikut:

- Exhaust pipe/muffler (hal. 3-16) - Body cover (hal. 3-8)

14-22

LOWER MOUNTING NUT/WASHER

SHOCK ABSORBER


BRAKE PEDAL (PEDAL REM) PELEPASAN REMOVAL Letakkan sepedamotor pada standard utamanya atau Remove the exhaust pipe/muffler . (page 3-16). 3-16) gantung pada katrol. Support the motorcycle using a safety stand or hoist. Remove the brake pedal adjustingnut, nut,brake brakerod, rod, spring spring Lepaskan brake pedal adjusting and joint pin from the brake arm. dan joint dan joint pin dari brake arm.

JOINT PIN

BRAKE ROD

SPRING

ADJUSTING NUT

Lepaskan kaitan dari light switch dan Unhook the brake lightbrake switch spring fromspring the brake pedal. centerstand spring.


BRAKE PEDAL

Lepaskan kaitan brake pedal return spring. Unhook the brake pedal return spring.

Remove the following: Lepaskan cotter pin, kemudian lepaskan centerstand pivot. – Pivot nut/washer Lepaskan – Bolt centerstand dan brake pedal. – Plate


PIVOT NUT/WASHER

BOLT

PLATE

14-23

RODA BELAKANG/REM/SUSPENSI Lepaskan collar Remove the collar.

COLLAR

Lepaskan centerstand spring Unhook the centerstand spring.

CENTERSTAND SPRING Remove the cotter then remove the centerstand centerstand Lepaskan cotter pin,pin, kemudian lepaskan pivot. pivot Remove the centerstand and brake pedal. Lepaskan centerstand dan pedal rem

CENTERSTAND PIVOT

COTTER PIN

CENTERSTAND

BRAKE PEDAL

Lepaskan centerstand spring plate. Remove the centerstand spring plate.

SPRING PLATE

14-24

RODA BELAKANG/REM/SUSPENSI Lepaskan cotter pin, washer, rod Remove the cotter pin, washer,dan andlepaskan separate brake the brake rod brake from the brake pedal. dari pedal.

WASHER

COTTER PIN

BRAKE ROD

BRAKE PEDAL

PEMASANGAN INSTALLATION Hubungkan rodtopada brake pedal, Connect the brake brake rod the brake pedal, then kemudian install the washerwasher and a new pin.cotter pin baru. pasang dancotter sebuah

COTTER PIN

BRAKE ROD

WASHER

BRAKE PEDAL

Pasang centerstand pada boss onpada Install the centerstandspring spring plate plate to the boss the frame. rangka.

BOSS

SPRING PLATE

Oleskan gemuk pada permukaan Apply grease to the centerstand pivotluncur sliding centerstand surface. Install the brake pedal, centerstand and centerstand pivot. pivot to brake the frame. Pasang pedal, centerstand dan centerstand pivot pada rangka.

CENTERSTAND PIVOT

BRAKE PEDAL

CENTERSTAND

14-25

RODA BELAKANG/REM/SUSPENSI Masukkan centerstandpivot pivot sementara mentepatkan Insert the centerstand while aligning its cut-out with the frame cut-out. potongannya dengan potongan pada rangka. Secure the centerstand pivot with a new cotter pin. Amankan centerstand pivot dengan cotter pin baru.

COTTER PIN CENTERSTAND PIVOT

Tepatkan

Kaitkan centerstand ke spring plateto kemudian Hook the narrow endspring of centerstand spring the spring kaitkan lagi ke centerstand. plate, then hook the other end to the centerstand.

SPRING PLATE

CENTERSTAND SPRING

CENTERSTAND SIDE

SPRING PLATE SIDE Install the collar. Pasang collar. COLLAR

14-26

RODA BELAKANG/REM/SUSPENSI Install the following: Pasang sebagai berikut: Plate - –Plate – Pivot nut/washer - –Pivot Boltnut/washer - Bolt Tighten the swingarm pivot nut to the specified torque while holding swingarm the pivot bolt. Kencangkan pivot nut dengan torsi yang ditentukan sementara menahan pivot TORQUE:59 N·m (6.0 kgf·m, 44 lbf·ft)bolt. TORSI: 59 N.m (6,0 kgf.m; 44 lbf.ft) Tighten the bolt. Kencangkan bolt.

PIVOT NUT/WASHER

PLATE Hook theujung narrow end of brake dari pedalbrake return pedal spring return to the Kaitkan yang sempit hole on the blake rod, then hook the wide end to the spring pada lubang pada brake rod, kemudian kaitkan swingarm slot. ujung yang lebar pada swingarm slot (lubang pemasangan pada lengan ayun).

BOLT


SWINGARM SLOT

BRAKE ROD HOLE

BRAKE ROD HOLE SIDE

SWINGARM SLOT SIDE Hook the brake light switch spring to the brake pedal. brake light switch spring brake pedal. Kaitkan pada


BRAKE PEDAL

14-27

RODA BELAKANG/REM/SUSPENSI Pasang joint pin pin ke dalam brake arm, kemudian pasang Install the joint into the brake arm, then install the spring,brake brake rod rod dan and adjusting adjusting nut. spring,

JOINT PIN

BRAKE ROD

Install the exhaust pipe/muffler (page 3-17). Pasang exchaust pipe/muffler (hal. 3-17) Adjust the brake pedal freeplay (page 4-17).

Setel jarak main bebas brake pedal (hal. 4-17).

SPRING

ADJUSTING NUT

14-28

15. HYDRAULIC BRAKE

LOKASI KOMPONEN-KOMPONEN......15-2

COMPONENT LOCATION ··························15-7 15-2 BRAKE PAD/DISC..............................

KETERANGAN SERVIS ........................15-3

MASTER INFORMATION CYLINDER .......................... 15-9 SERVICE ···························15-3

TROUBLESHOOTING ...........................15-4

BRAKE CALIPER ............................... TROUBLESHOOTING ··································15-12 15-4

PENGGANTIAN BRAKE FLUID/

BRAKE FLUID REPLACEMENT/

AIR BLEEDING......................................15-5

AIR BLEEDING ··············································15-5

BRAKE PAD/DISC·························· ················ 15-7

MASTER CYLINDER ····································15-9

BRAKE CALIPER ········································15-12

15

15-1

HYDRAULIC BRAKE

COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN HYDRAULICBRAKE

34 N·m (3.5 kgf ·m, 25 lbf ·ft)

30 N·m (3.1 kgf ·m, 22 lbf ·ft)

34 N·m (3.5 kgf ·m, 25 lbf ·ft)

15-2

HYDRAULIC BRAKE

SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM ! PERINGATAN Frequentmenghirup inhalation of brake padpad, dust,apapun regardless of material composition, be hazardous to your health. Seringkali debu brake komposisi bahannya, dapat could membahayakan 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. • •

Spilled brake fluid will severely damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be careful whenever CATATAN you remove the reservoir cap; make sure the front reservoir is horizontal first.

Minyak rem yang tertumpah kerusakan parah pada lensa instrumen dan permukaan yang dicat. Ia juga • A contaminated brake disc akan or padmenyebabkan reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality brake agent. berbahaya bagi degreasing beberapa parts dari karet. Berhati-hatilah setiap kali membuka reservoir cap; pastikan bahwa reservoir depan • Check thehorisontal brake system pada posisi dulu.by applying the brake lever after the air bleeding. • Never allow contaminants (dirt, water, etc.) to get into an open reservoir. • Once the hydraulic system has been opened, or if the brake feels spongy, the system must be bled. Brake use discfresh atau pad mengurangi daya pengereman. pads yang • Always DOT 3 oryang DOT terkontaminasi 4 brake fluid from a sealed container when servicingBuanglah the system. Do not mix terkontaminasi different types ofdan fluid, bersihkan disc yang terkontaminasi dengan bahan pembersih gemuk berkualitas tinggi untuk peralatan rem. they may not be compatible. • Always check therem brake operation before riding thelever motorcycle. Periksa sistem dengan menjalankan brake (handel rem) setelah proses air bleeding (pembuangan udara palsu). Jagalah agar bahan-bahan pengotor (kotoran, air, dsb.) tidak masuk ke dalam reservoir terbuka. Sekali sistem hidraulik telah dibuka, atau jika rem terasa seperti sepons, buanglah udara palsu dari sistem. SPECIFICATIONS Selalu pakai minyak rem baru DOT 3 atau DOT 4 dari kemasan yang belum pernah dibuka sewaktu menservis sistem. Unit: mm (in) Jangan mencampurkan bermacam-macam jenis minyak rem, mereka mungkin tidak cocok satu sama lain. SERVICE Selalu periksa cara kerja rem sebelum mengendarai sepedamotor. ITEM STANDARD LIMIT Recommended brake fluid DOT 3 or DOT 4 – SPESIFIKASI Brake pad wear indicator To the groove – Satuan: mm Brake disc thickness 3.0 (0.12) 3.3 – 3.7 (0.13 – 0.15) BAGIAN STANDARD BATAS SERVIS Brake disc runout 0.30 (0.012) – Brake fluid (minyak DOT 3 atau DOT4 - 11.055 (0.4352) Master cylinder I.D.rem) yang dianjurkan 11.000 – 11.043 (0.4331 – 0.4348) Master piston O.D.brake pad 10.945 10.957 – 10.984 (0.4314 – 0.4324) Indikator keausan Sampai ke(0.4309) alur Caliper cylinder I.D. 34.02 (1.340) 33.96 – 34.01 (1.337 – 1.339) Ketebalan brake disc 3,3 – 3,7 3,0 Caliper piston O.D. 33.878 – 33.928 (1.3338 – 1.3357) Keolengan brake disc 0,3033.87 (1.333) D.D. master cylinder 11,000 – 11,043 11,055 D.L. master VALUES piston 10,957 – 10,984 10,945 TORQUE D.D. caliper cylinder 33,96 – 34,01 34,02 Caliper bleed valve 5.4 N·m (0.55 kgf ·m,33,878 4.0 lbf ·ft) D.L. caliper piston – 33,928 33,87 Pad pin 17 N·m (1.7 kgf ·m, 13 lbf ·ft) Caliper bracket pin bolt 17 N·m (1.7 kgf ·m, 13 lbf ·ft) Caliper mounting bolt ALOC bolt; replace with new ones 30 N·m (3.1 kgf ·m, 22 lbf ·ft) TORSI PENGENCANGAN Brake hose oil bolt 34 N·m (3.5 kgf ·m, 25 lbf ·ft) Master cylinder reservoir cap screw (0.15 kgf ·m, lbf ·ft) Caliper bleed valve 5,4 1.5 N.mN·m (0,55 kgf.m; 4,01.1 lbf.ft) Front brake light switch screw · 1.2 N·m (0.12 kgf m, 0.9 Pad pin 17 N.m (1,7 kgf.m; 13 lbf.ft) lbf ·ft) Brake lever pivot bolt 1.0 N·m 0.7 lbf ·ft) Caliper bracket pin bolt 17 N.m (1,7 (0.10 kgf.m;kgf 13·m, lbf.ft) Brake lever pivot nut 5.9 N·m kgf 4.4 lbf ·ft) ·m, Caliper mounting bolt 30 N.m (3,1(0.60 kgf.m; 22 lbf.ft) ALOC bolt; ganti dengan yang baru Brake hose oil bolt 34 N.m (3,5 kgf.m; 25 lbf.ft) Master cylinder reservoir cap screw 1,5 N.m (0,15 kgf.m; 1,1 lbf.ft) Front brake light switch screw 1,2 N.m (0,12 kgf.m; 0,9 lbf.ft) Brake lever pivot bolt 1,0 N.m (0,10 kgf.m; 0,7 lbf.ft) Brake lever pivot nut 5,9 N.m (0,60 kgf.m; 4,4 lbf.ft) •

• • • •

•

15-3

HYDRAULIC BRAKE TOOL Snap ring pliers 07914-SA50001

TROUBLESHOOTING TROUBLESHOOTING Brake lever soft or spongy • Air in the hydraulic system Brake lever (handel rem) terasa lunak atau seperti sepons • Leaking hydraulic system Ada udara di dalam sistem hidraulik • Worn caliper piston seal Ada kebocoran pada sistem hidraulik • Worn brake pad/disc Caliper piston seal aus • Caliper not sliding properly • Worn master cylinder Brake pad/disc aus piston cups • Low brake fluidmeluncur level Caliper tidak dengan benar • Clogged brake fluid passage aus Master cylinder piston cups • Contaminated brake pad/disc Tinggi permukaan brake fluid (minyak rem) terlalu rendah • Contaminated caliper Jalan lintasanmaster brake fluid tersumbat • Contaminated cylinder • Warped/deformed brake disc Brake pad/disc terkontaminasi • Sticking/worn caliper piston Caliper terkontaminasi • Sticking/worn master piston Master cylinder • Bent brake lever terkontaminasi Brake disc berubah bentuk melengkung/berubah bentuk Brake lever hard Caliper piston macet/aus • Sticking/worn caliper piston Masternot piston macet/aus • Caliper sliding properly Brake lever bengkok • Clogged/restricted brake fluid passage • Sticking/worn master piston • Bent brake lever Brake lever keras Caliper Brake drag piston macet/aus • Contaminated brake disc/pad Caliper tidak meluncur dengan benar • Warped/deformed brake disc Jalan lintasan brake fluid tersumbat/terbatasi • Caliper not sliding properly Master piston macet/aus • Sticking caliper piston Brake lever bengkok • Sticking/worn master piston • Clogged/restricted Caliper piston sealbrake aus hose joint • • • • • • • • • • • • • • •

• • • • • •

Rem menyangkut Brake disc/pad terkontaminasi Brake disc berubah bentuk melengkung/berubah bentuk Caliper tidak meluncur dengan benar Caliper piston macet Master piston macet/aus Brake hose joint tersumbat/terbatasi • • • • • •

15-4

HYDRAULIC BRAKE

PENGGANTIAN BRAKE FLUID/ BRAKE FLUID REPLACEMENT/AIR BLEEDING AIR BLEEDING CATATAN Minyak rem yang tertumpah dapat merusak parts yang Spilled fluid can damage painted, plastic, or rubber parts. dicat, atau terbuat dari plastik atau karet. Letakkan kain Place a rag over these parts whenever the system is serviced. lap menutupi parts ini sewaktu sistem diservis. • Do not allow foreign material to enter the system when filling the reservoir. Jangan membiarkan benda asing memasuki sistem • When using a commercially available brake bleeder, ketika mengisi reservoir. follow the manufacturer’s operating instructions. Sewaktu memakai alat brake bleeder yang dapat BRAKE DRAINING dibeli diFLUID pasaran, ikutilah petunjuk pemakaian pabrik pembuatnya. Turn the handlebar to the left until the reservoir is level •

•

SCREWS

before removing the reservoir cap.

Remove the screws, reservoir cap, FLUID setting plate and diaPENGELUARAN BRAKE (MINYAK phragm. REM)

Putar handlebar ke kiri sampai reservoir pada posisi mendatar sebelum membuka reservoir cap. Lepaskan screws, reservoir cap, setting plate dan diaphragm.

RESERVOIR CAP SETTING PLATE DIAPHRAGM

Connect a bleed hosebleed to thehose bleed (slang valve. pembuangan) Hubungkan sebuah pada bleed Loosen thevalve. bleed valve and pump the brake lever until no more fluid flows out of the bleed valve. Longgarkan valve dan pompa brake lever sampai Tighten the bleed bleed valve. fluid tidak mengalir keluar lagi dari bleed valve.

BLEED VALVE

Kencangkan bleed valve.

PENGISIAN BRAKE FLUID/AIR BLEEDING BRAKE FLUID FILLING/AIR BLEEDING Isi reservoir sampai ke casting ledge (birai tuangan)

angan mencampurkan dengan DOT 3 atau DOT 4 brake fluid (minyak rem) dari Do not mix different Fill the reservoir to the casting ledge with DOT 3 or DOT bermacam-macam yangfrom belum pernah dibuka. 4 brake fluid a sealed container. types of fluid. They kemasan jenis fluid. Mereka arecocok not compatible. tidak satu sama lain.

BLEED HOSE

CASTING LEDGE

15-5

HYDRAULIC BRAKE Connect a commercially availableyang brakedapat bleeder to the Hubungkan alat brake bleeder dibeli di bleed valve. pasaran pada bleed valve. Jalankan brake bleeder danand longgarkan bleed valve. Operate the brake bleeder loosen the bleed valve. Jika tidak memakai automatic refill system (sistem • Check kembali the fluid level often when bleedingbrake to prevent pengisian otomatis), tambahkan fluid air from being pumped into the system. sewaktu tinggi permukaan fluid di dalam reservoir • When using a brake bleeding tool, follow the manuadalah rendah. facturer’s operating instruction. • IfPeriksa air is entering the bleederfluid from around the untuk bleed tinggi permukaan sering-sering valve threads, seal the threads with teflon tape. menghindari dipompanya masuk udara ke dalam Aftersistem. bleeding the air completely , tighten the bleed valve to the sp memakai brake bleeding tool, ikuti penunjuk Jika pemakaian ecified torque. pabrik pembuatnya. Jika udara memasuki bleeder dari daerah di sekitar TORQUE:5.4 N·m (0.55 kgf·m, 4.0 lbf·ft) ulir bleed valve, rapatkan ulir dengan teflon tape. Setelah membuang udara palsu sama sekali, kencangkan bleed valve dengan torsi yang ditentukan.

BRAKE BLEEDER

BLEED VALVE

•

•

•

TORSI: 5,4 N.m (0,55 kgf.m; 4,0 lbf.ft) If a tidak brakeada bleeder not available, use prosedur the following proJika alat is brake bleeder, ikuti sebagai cedure: berikut: sampai casting ledge Fillreservoir the reservoir to theke casting ledge with (birai DOT 3tuangan) or DOT Do not mix Jangan different Isi 4 brake DOT fluid from the sealed mencampurkan 3 atau DOT 4container. brake fluid dari kemasan types of fluid. They dengan bermacam-macam belum pernah dibuka sebelumnya. are not compatible. yang Pump up the system pressure with the brake lever until jenis fluid. Mereka lever resistance is felt. tidak cocok satu sama Pompa tekanan sistem dengan brake lever sampai lain. terasa ada tahanan pada lever.

Hubungkan bleed hose hose to pada Connect a bleed the bleed bleed valve valve dan and keluarkan bleed the system as follows: udara palsu dari sistem sebagai berikut: Tekan brake lever. Buka bleed valve ½ putaran dan Jangan Do not lepaskan release 1.1. Squeeze the brake lever. Open the bleed valve 1/2 brake lever sampai tutup. the brake lever turn and close it. bleed valve telah 2. Lepaskan brake lever perlahan-lahan dan tunggu until theditutup. bleed beberapa detik setelah ia mencapai akhir dari valve has been lintasannya. closed. 2. Release the brake lever slowly and wait several seconds after it reaches the end2ofsampai its travel. Ulangi langkah-langkah 1 dan tidak ada lagi gelembung-gelembung udara dalam bleed Repeat steps 1 and 2 until airdibubbles do nothose. appear in the bleed hose. Setelah mem-bleeding udara , tighten palsu the sama After bleeding the air completely bleedsekali, valve kencangkan bleed valve dengan torsi yang ditentukan. to the specified torque. TORQUE:5.4 N·m (0.55 kgf·m, 4.0 lbf·ft) TORSI: 5,4 N.m (0,55 kgf.m; 4,0 lbf.ft)

Fillreservoir the reservoir to thekecasting ledge withdengan DOT 3 or DOT3 Isi sampai casting ledge DOT 4 brake fluid4from a sealed atau DOT brake fluid container. dari kemasan yang belum pernah dibuka sebelumnya.

15-6

BLEED VALVE

BLEED HOSE CASTING LEDGE

HYDRAULIC BRAKE Pasang diaphragm, setting plate dan reservoir cap. Install the diaphragm, setting plate and reservoir cap. Tighten the screws the specified torque. Kencangkan screwsto dengan torsi yang ditentukan.

SCREWS

TORQUE:1.5 N·m (0.15 kgf·m, 1.1 lbf·ft) TORSI: 1,5 N.m (0,15 kgf.m; 1,1 lbf.ft)

RESERVOIR CAP SETTING PLATE DIAPHRAGM

BRAKE BRAKE PAD/DISC PAD/DISC PENGGANTIAN BRAKE PAD BRAKE PAD REPLACEMENT tinggi keallow dalam untuk Check Periksa the brake fluid Dorong Push thecaliper caliper pistons allseluruhnya the way in to installation permukaan brake memungkinkan pemasangan brake pads baru. level in the reservoir of new brake pads. dalam as luid this di operation reservoir oleh karena causes the level to operasi ini rise. menyebabkan naiknya tinggi permukaan brake fluid.

Remove the pad O-ring brake pads. Lepaskan pad pin,pin, O-ring danand brake pads.

PAD PIN/O-RING Selalu ganti brake brake pads brake so caliper Always replace the Pasang Install new brake padsbaru into ke the dalam brake caliper their pads dalam pasangan ends seatujung-ujung against the retainer bracket bolt A.dan retainer mereka and duduk padapin brake pads in pairs to sehingga untuk memastikan bracket pin bolt A. ensure even disc tekanan disc yang pressure. merata.

RETAINER

BRAKE PAD

BRAKE PADS PIN BOLT A

BRAKE PAD

15-7

HYDRAULIC BRAKE Oleskan silicon grease pada O-ring Apply silicon grease to (gemuk the new silikon) O-ring and install it tobaru the padpasang pin. dan pada pad pin. Install the pad pin while pushing the pads against pad Pasang spring. pad pin sementara mendorong pads terhadap pad spring.

PAD PIN

O-RING

Kencangkan pad pinto dengan torsi yang ditentukan. Tighten the pad pin the specified torque. TORSI: 17 N.m (1,7 kgf.m; TORQUE:17 N·m (1.7 kgf·m,13 13lbf.ft) lbf·ft) Jalankan brake lever mendudukkan caliper Operate the brake leveruntuk to seat the caliper pistons pistons againstterhadap pads. the pads.

PAD PIN

PEMERIKSAAN BRAKE DISC BRAKE DISC INSPECTION Periksa secaradisc visual terhadap kerusakan Visually brake inspectdisc the brake for damage or cracks. atau keretakan. Measure the brake disc thickness at several points. SERVICE Ukur ketebalan brake disc pada beberapa titik. LIMIT: 3.0 mm (0.12 in) BATAS SERVIS: 3,0 mm

Ukur keolengan brake disc dengan indicator. Measure the brake disc runout with dial a dial indicator. BATAS SERVIS: 0,30 mm SERVICE LIMIT: 0.30 mm (0.012 in) Periksa wheel bearings (bantalan roda) terhadap kelonggaran berlebihan, jikafor keolengan melampaui Check the wheel bearings excessive play, if the batas servis. runout exceeds the service limit. Replace thedisc jika brake disc if the bearingsnormal. are normal. Ganti brake bearings adalah For brake disc replacement (page 13-8). Untuk penggantian brake disc (hal. 13-8).

15-8

HYDRAULIC BRAKE

MASTER MASTER CYLINDER CYLINDER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Keluarkan brakefluid fluid(page (hal.15-5). 15-5). Drain the brake Lepaskan handlebar rear cover (hal. 3-11). Remove the handlebar rear cover (page 3-11). Remove the oil bolt, brake hose and sealing washers. brake light switch When removing the Lepaskan Remove the bolts, holder andconnectors. master cylinder. oil bolt, cover the end Sewaktu melepaskan of the hose to prevent oil bolt, tutupilah contamination. ujung dari hose untuk menghindari kontaminasi.

Install the removed partshose in thedan reverse order of removal. Lepaskan oil bolt, brake sealing washers. • Replace the sealing washer withcylinder. new ones. Lepaskan bolts, holder dan master TORQUE: Pasang parts yang telah dilepaskan dalam urutan OIL BOLT terbalik dari pelepasan. 34 N·m (3.5 kgf·m, 25 lbf·ft) and Ganti washer dengan yang baru. Fill air sealing bleed the hydraulic system (page 15-5). •

TORSI: OIL BOLT

34 N.m (3,5 kgf.m; 25 lbf.ft)

Isi dan air bleed (buang udara palsu) sistem hidraulik (hal. 15-5). BOLTS

Tepatkan ujung dari master cylinder dengan tanda titik pada handlebar. Kencangkan upper bolt dulu, kemudian baru lower bolt

HOLDER

Letakkan holder dengan tanda "UP" menghadap ke atas. SEALING WASHERS

Tempatkan brake hose eyelet terhadap stopper. BRAKE HOSE OIL BOLT 34 N·m (3.5 kgf ·m, 25 lbf ·ft) MASTER CYLINDER

15-9

HYDRAULIC BRAKE PEMBONGKARAN/PERAKITAN DISASSEMBLY/ASSEMBLY Remove/install thesebagai following: Lepaskan/pasang berikut: - –Brake lever pivot nut, bolt dan Brake lever pivot nut, bolt andbrake brakelever lever Screw and brake lightswitch switch - –Screw dan brake light Boot - –Boot Remove/install the snap ring using the special tool. Lepaskan/pasang snap ring dengan menggunakan TOOL:tool. special TOOL: Snap ring pliers 07914-SA50001 Snap ring pliers 07914-SA50001 Remove/install the washer, master piston and spring. Lepaskan/pasang washer, mastersnap piston dan spring. • Keep the piston, cups, spring, ring and boot as a set; Jauhkan piston, cups, spring, snap ring dan boot do not substitute individual parts. • When installing do notganti allow parts the lipssecara to turn sebagai satu the set;cups, jangan inside out. tersendiri. • Be sure memasang that snap ring is firmly the groove. Ketika cups, jagaseated agar in bibirnya tidak • Apply brake fluid to the spring, piston cups and masberputar terbalik dengan bagian dalam di sebelah ter piston. luar. silicone grease to the pivot bolt sliding surface • Apply and brakebahwa lever contact areaduduk with piston. Pastikan snap ring dengan erat pada alurnya. Fill the brake fluid and bleed the hydraulic system (page 15-5). Oleskan brake fluid pada spring, piston cups dan master piston. TORQUE: Oleskan silicone grease pada permukaan luncur PIVOT BOLT 1.0 N·m (0.10brake kgf·m,lever 0.7 lbf·ft) pivot bolt dan daerah kontak dengan PIVOT 5.9 N·m (0.60 kgf·m, 4.4 lbf·ft) piston.NUT BRAKE Isilah brakeLIGHT fluid dan buang udara palsu dari sistem SWITCH 1.2 N·m (0.12 kgf·m, 0.9 lbf·ft) hidraulik (hal.SCREW 15-5). TORSI: PIVOT BOLT 1,0 N.m (0,10 kgf.m; 0,7 lbf.ft) PIVOT NUT 5,9 N.m (0,60 kgf.m; 4,4 lbf.ft) BRAKE LIGHT SWITCH SCREW 1,2 N.m (0,12 kgf.m; 0,9 lbf.ft)

SNAP RING

SNAP RING PLIERS

•

•

•

•

•

MASTER CYLINDER BODY

SPRING

WASHER

PIVOT BOLT * 1.0 N·m (0.10 kgf ·m, 0.7 lbf ·ft) BRAKE LIGHT SWITCH

PISTON CUPS SCREW 1.2 N·m (0.12 kgf ·m, 0.9 lbf ·ft)

BOOT

MASTER PISTON SNAP RING

*: Oleskan 0.1 g silicone grease

BRAKE LEVER

PIVOT NUT 5.9 N·m (0.60 kgf ·m, 4.4 lbf ·ft) Tepatkan switch boss dengan lubang.

15-10

HYDRAULIC BRAKE INSPECTION PEMERIKSAAN Check the pistoncups cups terhadap for wear, deterioration or damage. Periksa piston keausan, pemburukan Check atau the spring for fatigue or damage. kondisi kerusakan. Check the master cylinder inner surface and piston outer Periksa spring terhadap keletihan atau kerusakan. surface for scratches or damage. Periksa permukaan dalam master cylinder dan permukaan luar piston terhadap goresan atau kerusakan.

MASTER CYLINDER

CUPS

MASTER PISTON

SPRING

Measure master cylinder I.D. Ukur D.D. the master cylinder. SERVICE BATAS SERVIS: 11,055 mm LIMIT: 11.055 mm (0.4352 in) Ukur D.L. master piston. Measure the master piston O.D. BATAS SERVIS: 10,945 mm SERVICE LIMIT: 10.945 mm (0.4309 in)

15-11

HYDRAULIC BRAKE

CALIPER BRAKE CALIPER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Avoid spilling fluid on painted, plastic, or agalah agarparts. fluid rubber tidak tertumpah ke Place a shop towel atas parts yang dicat, over these parts atau yang terbuat whenever the system dari plastik atau is serviced. karet.

Drain the brake Keluarkan brakefluid fluid(page (hal. 15-5). 15-5).

Remove/install thesebagai following: Lepaskan/pasang berikut: - OilOilbolt/sealing – bolt/sealingwashers washers – Mountingbolts bolts - Mounting – Brakecaliper caliper - Brake TORQUE: TORSI: BRAKECALIPER CALIPER Letakkan kain lap BRAKE MOUNTING BOLT 30 N·m (3.1 (3,1 kgf·m, 22 lbf·ft) menutupi parts ini MOUNTING BOLT 30 N.m kgf.m; 22 lbf.ft) setiap kali sistem OIL BOLT 34 N·m (3.5 kgf·m, 25 lbf·ft) OIL BOLT 34 N.m (3,5 kgf.m; 25 lbf.ft) diservis.

• Replace the brake caliper mounting bolts and sealing washers Gantilahwith brake newcaliper ones. mounting bolts dan sealing washers dengan yang baru. Fill the brake fluid and bleed the hydraulic system (page 15-5). Isilah brake fluid dan buanglah udara palsu dari sistem hidraulik (hal. 15-5). •

BRAKE CALIPER

BRAKE CALIPER MOUNTING BOLTS 30 N·m (3.1 kgf ·m, 22 lbf ·ft)

BRAKE HOSE

OIL BOLT 34 N·m (3.5 kgf ·m, 25 lbf ·ft) SEALING WASHERS

15-12

HYDRAULIC BRAKE PEMBONGKARAN/PERAKITAN DISASSEMBLY/ASSEMBLY Lepaskan sebagai berikut: Remove the following: - Brake pads (hal. 15-7) – Brake pads (page 15-7) - –Caliper bracket Caliper bracket - –Bracket pinpin boots Bracket boots - –Pad spring Pad spring Place a shop towel over the piston. Letakkan kain lap menutupi piston. Position the caliper body with the piston facing down and Do notmemakai use high Letakkan Jangan caliper body dengan piston menghadap ke pressure air or bring apply small squirts of air pressure to the fluid inlet to udara bertekanan bawah dan semprotkan tiupan-tiupan kecil udara remove the piston. the nozzle too tinggi atau bertekanan pada lubang masuk fluid untuk meletakkan nozzle close to the inlet. Remove the dust seal/piston seal. mengeluarkan piston. terlalu dekat pada Install the removed parts in the reverse order of removal. inlet. • Apply dust brake fluid to theseal. caliper piston and piston seal. Lepaskan seal/piston • Apply silicone grease to the bracket pin sliding surPasang parts yangseal. dilepaskan dalam urutan terbalik dari face and dust pelepasan. • Replace the piston seal and dust seal with new ones Oleskan as a set. brake fluid pada caliper piston dan piston seal. Oleskan silicone grease pada permukaan luncur bracket pin dan dust seal. Gantilah piston seal dan dust seal dengan yang • baru sebagai satu set. BRACKET PIN BOOT BLEED VALVE * 5.4 N·m (0.55 kgf ·m, 4.0 lbf ·ft)

CALIPER PISTON

•

•

*: Oleskan minimum 0.4 g silicone grease

DUST SEAL PISTON SEAL

CALIPER BRACKET

BRACKET PIN BOOT

CALIPER BODY

CALIPER PISTON Pasang kaliper piston dengan ujung yang terbuka menghadap ke brake pads.

PAD SPRING

ICTION PEMERIKSAAN

Check the caliper cylinders for scoring, scratches or damage.caliper cylinders terhadap gerusan, goresan Periksa Measure the caliper cylinder I.D. atau kerusakan. Ukur D.D. caliper cylinder. SERVICE LIMIT: 34.02 mm (1.340 in) BATAS SERVIS: 34,02 mm Check the pistons for scoring, scratches or damage. Measure pistons the caliper piston O.D. Periksa terhadap gerusan, goresan atau kerusakan. SERVICE Ukur D.L. caliper piston. LIMIT: 33.87 mm (1.333 in)


15-13

MEMO

16. BATERAI/SISTEM PENGISIAN

LOKASI ........................................16-2 SYSTEMSISTEM LOCATION ····································16-2

BATERAI......................................................16-5 BATTERY ························································ 16-5

DIAGRAM SISTEM ....................................16-2 SYSTEM DIAGRAM ······································16-2

PEMERIKSAAN SISTEM PENGISIAN ...16-6 CHARGING SYSTEM INSPECTION ··········16-6


KUMPARAN PENGISIAN ALTERNATOR INSPECTION······················ 16-7 ALTERNATOR ............................................16-7


REGULATOR/RECTIFIER ························ ··· 16-8

REGULATOR/RECTIFIER........................16-8

16

16-1


LOKASI SYSTEMSISTEM LOCATION BATTERY/CHARGINGSYSTEM

REGULATOR/RECTIFIER SEKRING UTAMA 10 A

ALTERNATOR BATTERY

DIAGRAM SISTEM SYSTEM DIAGRAM To LIGHTING SWITCH

Y

G W

Y

G W

Y

MAIN FUSE 10A

R

R Y G W

G BATTERY

16-2

REGULATOR/ RECTIFIER

ALTERNATOR

R G Y W

: : : :

Red Green Yellow White


KETERANGAN SERVIS SERVICE INFORMATION UMUM GENERAL ! PERINGATAN Baterai mengeluarkan gas-gas yang dapat meledak; jauhkan percikan bunga api, lidah api dan rokok. Sediakan • memadai sewaktu gases; mengisikeep muatan listrik. • Theventilasi battery gives off explosive sparks, flames and cigarettes away. Provide adequate ventilation when charging. • • TheBaterai battery mengandung contains sulfuric acidsulfat (electrolyte). Contact with skin or eyes burns. Wear protective clothing asam (electrolyte). Kontak dengan kulitmay ataucause mata severe dapat mengakibatkan luka bakar parah. andPakailah a face shield. pakaian pelindung dan pelindung muka. – If-electrolyte gets onmengenai your skin,kulit, flushbilaslah with water. Jika electrolyte dengan air. – If electrolyte gets in your eyes, flush with water for at least 15 minutes and call a physic ian immediately. Jika electrolyte masuk ke dalam mata, bilaslah dengan air selama sekurangnya 15 menit dan mintalah bantuan • Electrolyte is poisonous. dokter dengan segera. – If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a call a physi cian immedi• ately. Electrolyte beracun. - Jika tertelan, minumlah sejumlah besar air atau susu dan mintalah bantuan Gawat Darurat atau dokter dengan segera. .

CATATAN • Always turn OFF the ignition switch before disconnecting any electrical component.

Selalu putar kunci kontakmay ke OFF s ebelum melepaskan sebuah komponen listrik. Some electrical components be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON posi• tion Beberapa komponen and current is present. listrik dapat rusak jika terminal-terminal atau connectors disambungkan atau dilepaskan sambungannya sementara ignition switch (kunci kontak) pada posisi ON dan ada arus listrik yang mengalir. • For extended storage, remove the battery, give it a full charge, and store it in a cool, dry space. For maximum service life, charge • the Untuk penyimpanan waktu panjang, lepaskan baterai, berikan muatan listrik penuh, dan simpan di tempat kering stored battery everyjangka two weeks. • For a battery in a stored umur motorcycle, disconnect the negative batterysetiap cable dua fromminggu. the battery terminal. yang sejuk. remaining Untuk mendapatkan pemakaian maksimum, isilah baterai • The maintenance free (MF) battery must be replaced when it reaches the end of its service life. baterai dari terminal baterai. Untuk baterai yang tetap terpasang pada sepedamotor yang disimpan, lepaskan kabel negatif • • The battery can be damaged if overcharged or undercharged, or if left to discharge for long period. These same conditions contrib• Baterai maintenance free (MF) harus diganti jika ia mencapai akhir dari umur pemakaiannya. ute to shortening the "life span" of the battery. E ven under normal use, the performance of the battery deteriorates after 2 – 3 years. • Bateraivoltage dapat rusak jika di-overcharge muatan berlebihan) atau muatan listrik), • Battery may recover after battery(diisi charging, butlistrik under heavy load, thedi-undercharge battery voltage (kurang will droppengisian quickly and eventually die atau bila iareason, dibiarkan sendiriismuatannya untuk as jangka waktu lama. Kondisi-kondisi sama ini ikut berperan dalam out. For this theberkurang charging system often suspected the problem. Battery overcharge often results from problems in the memperpendek baterai. Bahkan pada pemakaian unjuk cells kerjaisbaterai akan setelah battery itself, whichumur maypemakaian appear to be an overcharging symptom. If one normal, of the battery shorted and memburuk battery voltage does2-3 not increase, tahun. the regulator/rectifier supplies excess voltage to the battery. Under these conditions, the electrolyte level goes down • quickly. Voltase baterai dapat membaik kembali setelah pengisian muatan listrik baterai, tetapi di bawah beban berat, voltase • Before troubleshooting the charging system, check for proper use and maintenance of the battery. Check if the battery is frequently baterai akan turun dengan cepat itu, pengisian seringkali diduga penyebab under heavy load, such as having thedan turn akhirnya signal andmati. brakeKarena lights on forsistem long periods of time without riding thesebagai motorcycle. persoalannya. Battery overcharge seringkali diakibatkan oleh persoalan di dalam baterai sendiri, yang mungkin tampak • The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every two weeks to prevent sebagaifrom gejala overcharging. Jika salah satu sel baterai ada hubungan singkat dan voltase baterai tidak bertambah, sulfation occurring. checking the memasok charging system, followkethe steps in troubleshooting • When (page 16-4). regulator/rectifier voltasealways berlebihan baterai. Di the bawah kondisi ini, tinggi permukaan electrolyte akan menurun alternator service (page 11-3). • For dengan cepat. • Sebelum men-troubleshooting sistem pengisian, periksalah apakah baterai dipergunakan dengan baik dan bagaimana perawatannya. Periksa apakah baterai seringkali di bawah beban berat, seperti jika lampu besar dan lampu belakang BATTERY CHARGING menyala terus untuk jangka waktu lama tanpa mengendarai sepedamotor. • Turn power ON/OFF at the charger, not at dengan the battery terminal. jika sepedamotor tidak dipakai. Oleh karena itu, isilah baterai Baterai akan berkurang muatan listrik sendirinya • • For battery charging, dosetiap not exceed the charging current andterjadinya time specified on the battery. Using excessive current or extending dengan muatan listrik dua minggu untuk mencegah sulfasi. the charging time may damage the battery. • Sewaktu memeriksa ikuti langkah-langkah aliran troubleshooting (hal. 16-4). • Quick charging should sistem only bepengisian, done in anselalu emergency; slow charging ispada preferred. Untuk servis alternator (hal. 11-3). • • •

BATTERY PENGISIANTESTING MUATAN LISTRIK BATERAI ReferHidup/matikan to the instruction the Operation Manualpada for the recommended battery muatan tester for details about dan battery testing. recom• dayaof listrik dengan saklar charger (alat pengisian listrik baterai), bukan padaThe terminal mended battery tester puts a "load" on the battery so that the actual battery condition during load can be measured. baterai. Pada waktu mengisi muatan listrik baterai, jangan MATE melampaui arus dan waktu pengisian seperti tertera pada baterai. • Recommended battery tester: BM-210 or BATTERY or equivalent Mengisi dengan arus listrik berlebihan atau memperpanjang w aktu pengisian dapat merusak baterai. SPECIFICATIONS • Quick charging (pengisian muatan listrik dengan cepat) hanya boleh dilakukan dalam keadaan darurat, lebih diutamakan pengisian muatan listrik dengan pelan). ITEM SPECIFICATIONS Battery Capacity 12 V – 3.5 Ah PENGETESAN BATERAI Current leakage TBD mA max. Bacalah petunjuk pemakaian di dalam Operation Manual untuk battery tester yang dianjurkan untuk detil-detil mengenai Fully charged Voltage (20°C/ 13.0 – kondisi 13.2 V baterai sebenarnya pada pengetesan baterai. Battery tester yang dianjurkan meletakkan "beban" pada baterai s ehingga 68diukur. °F) Needs charging Below 12.4 V waktu ada beban dapat Charging curNormal 0.4 A/5 – 10 h Battery tester yang dianjurkan: BM-210 atau BATTERY MATE atau sejenisnya. rent Quick 3.0 A/0.5 h SPESIFIKASI Alternator Capacity 0.120 kW/5,000 min-1 (rpm) BAGIAN SPESIFIKASI0.2 – 1.0 Ω Charging coil resistance (20°C/68°F) Baterai Kapasitas 12 V – 3,5 Ah

Alternator

Kebocoran arus listrik Bermuatan penuh Voltase (20° C) Perlu diisi listrik kembali Arus pengisian Normal Cepat Kapasitas Tahanan kumparan pengisian (20° C)

maksimum 20 mA 13,0 – 13,2 V Di bawah 12,4 V 0,4 A / 5 – 10 h 3,0 A / 0,5 h -1 0,120 kW / 5.000 menit (rpm) 0,2 – 1,0 Ω

16-3


TROUBLESHOOTING TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK BATERAI RUSAK ATAU LEMAH 1. BATTERY TEST 1. TEST BATERAI

Remove the battery (page 16-5). Lepaskan baterai (hal. 16-5). Check the battery condition using the recommended battery tester (page 16-6). Periksa kondisi baterai dengan menggunakan battery tester yang dianjurkan (hal. 16-6). RECOMMENDED BATTERY TESBATTERY TESTER YANG DIANJURKAN: BM-210 atau BATTERY MATE atau sejenisnya TER: BM-210 or BATTERY MATE or equivalent

Apakah baterai dalam kondisi baik? Is the battery in good condition? YA LANJUTKAN TO STEP 2. DENGAN LANGKAH 2. YES – - GO TIDAK – -Faulty Baterai rusak battery NO 2. TEST KEBOCORAN ARUS 2. CURRENT LEAKAGE TESTLISTRIK Pasang 16-5) Install thebaterai battery(hal. (page 16-5). Periksathe kebocoran arus listrik baterai 16-6). Check battery current leakage ( page(hal. 16-6). Apakah kebocoran arus listrik di bawah 9 mA? Is the current leakage below TBD mA? YES YA

TO STEP 4. DENGAN LANGKAH 4. – -GO LANJUTKAN

TO STEP 3. DENGAN LANGKAH 3. NO TIDAK – -GO LANJUTKAN 3. CURRENT LEAKAGEARUS TESTLISTRIK WITHOUT REGULATOR/RECTIFIER CONNECTED 3. TEST KEBOCORAN TANPA REGULATOR/RECTIFIER TERSAMBUNG

Disconnect the regulator/rectifier connector recheck the battery current leakage. Lepaskan regulator/rectifier connector danand periksa kembali kebocoran arus listrik baterai. Is the current leakage below TBD mA? Apakah kebocoran arus listrik di bawah 9 mA? regulator/rectifier YES – - Faulty YA Regulator/rectifier rusak NO – • Shorted wire harness TIDAK - • • Faulty Ada hubungan singkat pada wire harness ignition switch • Ignition switch (kunci kontak) rusak 4. ALTERNATOR CHARGING COIL INSPECTION 4. PEMERIKSAAN KUMPARAN PENGISIAN ALTERNATOR Check the alternator charging coil (page 16-7). Periksa kumparan pengisian alternatorwithin (hal. 16-7). Is the alternator charging coil resistance 0.2 – 1.0 Ω (20° C/68° F)?

Apakah kumparan pengisian alternator di antara 0,2 – 1,0 5. YES – tahanan GO TO STEP YA NO

(20 C)?

LANJUTKAN LANGKAH 5. charging DENGAN coil – -Faulty

TIDAK - Kumparan pengisian rusak 5. CHARGING VOLTAGE INSPECTION 5.

Measure and record the battery voltage using a digital multimeter (page 16-6). PEMERIKSAAN VOLTASE PENGISIAN Start Ukur the danengine. catat voltase baterai dengan menggunakan digital multimeter (hal. 16-6). Measure charging voltage (page 16-7). Hidupkanthe mesin. Compare the measurements to result of the following calculation. Ukur voltase pengisian (hal. 16-7). STANDARD: Measured BV < Measured CV < 15.5 V Bandingkan hasilVoltage pengukuran dengan hasil dari perhitungan berikut ini. • BV = Baterry (page 16-6) • CV = Charging Voltage STANDARD: Voltase baterai yang diukur Voltase pengisian yang diukur

voltase baterai (hal. Is the measuredUntuk charging voltage within the16-6) standard voltage? Apakah pengisian yang diukur sesuai dengan voltase standard? YES – voltase Faulty battery YA NO

Baterai rusak TO STEP 6. – -GO

TIDAK - LANJUTKAN DENGAN LANGKAH 6. 6. REGULATOR/RECTIFIER SYSTEM INSPECTION 6.

Check the voltageSISTEM and resistance at the regulator/rectifier connectors (page 16-8). PEMERIKSAAN REGULATOR/RECTIFIER Are the results of dan checked voltage andregulator/rectifier resistance correct?connectors (hal. 16-8). Periksa voltase tahanan pada

regulator/rectifier YES – hasil Faultydari Apakah voltase dan tahanan yang diperiksa benar? Open circuit in related NO – - • Regulator/rectifier YA rusakwire • Loose or poor contacts of related terminal wireterbuka harnesspada kawat yang bersangkutan TIDAK - • • Shorted Rangkaian • Kontak longgar atau buruk dari terminal yang bersangkutan • Ada hubungan singkat pada wire harness

16-4

15,5 V


BATERAI BATTERY PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION • • Selalu putar Always turn

ignition switch (kunci posisi the ignition switch OFFkontak) before ke removing battery. OFFthe sebelum melepaskan baterai. Unlock and open the seat. Buka kuncithe tempat duduk angkat tempat ke Remove trim clip anddan battery cover whileduduk releasing atas. the battery cover tabs from slots in the luggage box.

TRIM CLIP

BATTERY COVER TABS

Lepaskan trim clip dan battery cover sementara melepaskan battery cover tabs dari slots di dalam luggage box.

SLOTS Selalu lepaskan Always disconnect the Lepaskan Remove the disconnect negative boltbolt danand lepaskan kabelthe negatif ( - ).( – ) cable. terminal negatif dulu. Tarik Pull back the positive cover. negative terminal terminal coverterminal (penutup terminal) positif ke Remove the bolt and disconnect the positive (+) cable. first. belakang.

Lepaskan boltbattery dan lepaskan kabel positif ( + ). Remove the out of the luggage box. Installationbaterai is in the reverse order of removal. Keluarkan dari luggage box.

BOLTS

POSITIVE (+) CABLE

BATTERY

positive (+) cable urutan to the battery first, then • Connect theadalah Pemasangan dalam terbalik dari connect the negative ( – ) cable. pengeluaran. Hubungkan kabel positif ( + ) pada baterai dulu, • kemudian hubungkan kabel negatif ( - ).

NEGATIVE ( – ) CABLE

16-5

BATERAI/SISTEM PENGISIAN VOLTAGE INSPECTION PEMERIKSAAN VOLTASE Measure the battery usingmenggunakan a commerciallydigital availUkur voltase bateraivoltage dengan able digital multimeter. multimeter yang dapat dibeli di pasaran. VOLTASE VOLTAGE(20 (20° C): C/68°F): Bermuatan penuh: 13,0V– 13,2 V Fully charged: 13.0 – 13.2 Perlu diisi kembali: Di bawah 12,4 V Needs charging: Below 12.4 V

CATATAN: akan mengukur voltase baterai setelah • Jika • When measuring the battery voltage after charging, pengisian, sekurangnya 30 results menit, leave it forbiarkan least 30sampai minutes, or the accurate atau hasilbeyang akurat tidak the dapat diperoleh cannot obtained because battery voltage oleh fluckarena baterai berubah-ubah tepat tuatesvoltase just after charging. setelah pengisian.

(+)

( – )

BATTERY TESTING

Refer to the instructions that are appropriate to the batPENGETESAN BATERAI

tery testing equipment available to you. Bacalah TOOL: petunjuk pemakaian dari peralatan pengetesan baterai akan dipakai. Batteryyang tester BM-210, BATTERY TOOL: MATE or equivalent Battery tester BM-210, BATTERY MATE atau sejenisnya

CHARGING SYSTEM INSPECTION PEMERIKSAAN SISTEM PENGISIAN CURRENT LEAKAGE TEST TEST KEBOCORAN ARUS LISTRIK

Remove the battery cover (page 16-5). Lepaskan battery cover (hal. 16-5). Turn the ignition switch OFF and disconnect the negative ( – ) cable fromswitch the battery. Putar ignition ke OFF, dan lepaskan kabel negatif the ammeter (+) probe to the negative ( – ) cable ( Connect - ) dari baterai. and the ammeter ) probe to the( battery ( – ) terminal. ke Hubungkan jarum( – pengetesan + ) amperemeter With the ignition check for leakage. kabel negatif danswitch jarum OFF, pengetesan ( - current ) ke terminal (-) baterai. Dengan ignition switchcurrent pada OFF, terhadap • When measuring using periksalah a tester, set it to a high range, and then bring the range down to an kebocoran arus listrik. appropriate level. Current flow higher than the range selected may blow the fuse in the tester. CATATAN: • While measuring current, not turn the ignition • Sewaktu mengukur arus dolistrik dengan tester, switch ON, A sudden surge of current may blow the letakkan pada daerah jangkauan pengukuran tinggi fuse in the tester. dulu, dan kemudian turunkan ke daerah jangkauan SPECIFIED CURRENT LEAKyang sesuai. Arus listrik yang lebih tinggi dari pada AGE: max. daerah jangkauan yang dipilih TBD dapatmA memutuskan sekring di dalam tester. If current leakage exceeds the specified value, a shorted Sewaktu mengukur arus listrik, jangan putar ignition • circuit is the probable cause. switch ke ON. Lonjakan arus listrik yang tiba-tiba dapat memutuskan sekring di dalam tester.

KEBOCORAN ARUS LISTRIK DIPERBOLEHKAN: maksimum 9 mA.

YANG

Jika kebocoran arus listrik melampaui nilai yang ditentukan, kemungkinan ada hubungan singkat. Carilah Locate the short by disconnecting connections one by lokasi melepaskan one and hubungan measuring thesingkat current. dengan hubungan-hubungan satu demi satu dan mengukur arus listrik.

16-6

( – ) PROBE

(+) PROBE

( – ) CABLE

BATERAI/SISTEM PENGISIAN PEMERIKSAAN VOLTASE INSPECTION PENGISIAN CHARGING VOLTAGE Remove the battery cover (page 16-5). Lepaskan battery cover (hal. 16-5). CATATAN: Pastikan bahwa baterai dalam kondisi baik sebelum • Make sure the battery is in good condition before permenjalankan pemeriksaan forming this inspection.ini. Panaskan ke suhuthe operasi normal. • Do notmesin disconnect battery or any cable in the Matikan mesin danwithout hubungkan multimeter seperti charging system first switching OFF the ignition switch. Failure to follow this precaution can damdiperlihatkan. age the tester or electrical components. CATATAN: Warm up the engine to normal operating temperature. angan melepaskan Untuk menghindari hubungan singkat, pastikan dengan hubungan To preventdengan a short, mutlak manakah terminal atau kabel-kabel positif dan baterai atau setiap make absolutely negatif. kabel pada sistem certain which are the Hubungkan tachometer sesuai dengan petunjuk pengisian tanpa positive and negative pabrik pembuatnya. sebelumnya memutar pemakaian t Stop the engine and connect the multimeter as shown. ignition switch ke Hidupkan kembali mesin. Connect a tachometer according to its mesin manufacturer’s voltase pada multimeter sewaktu berputar OFF. Ukur -1 instructions. Kegagalan untuk pada 5.000 menit (rpm). melakukan tindakan Restart the engine. Voltase yang diukur pengamanan ini dapat STANDARD: Measure the voltage onbaterai the multimeter when theVoltase engine -1 pengisian yang diukur 15,5 V erminals or cables. merusak tester atau runs at 5,000 min (rpm).

(+)

( – )

komponen listrik

ALTERNATOR INSPECTION KUMPARAN PENGISIAN ALTERNATOR Remove the body covers (page 3-8).

PEMERIKSAAN

ALTERNATOR 2P Disconnect the following: CONNECTOR (Putih) Lepaskan left lower side cover (hal. 3-5). – Alternator 2P connector – Alternator wire (Yellow) connector Lepaskan alternator 2P connector (Putih). Check the resistance between the following terminals of the alternator side. STANDARD: Charging coil (White – Green): 0.3 – 1.0 Ω (at 20 °C/68°F) Lighting coil (Yellow – Green): 0.1 – 0.8 Ω (at 20 °C/68°F)

ALTERNATOR WIRE CONNECTOR

Replace the stator if the resistance is out of specification. For stator removal (page 11-6). Periksa tahanan antara terminal-terminal kawat Putih Install thedari body covers (page 3-8). dan Hijau sisi alternator. STANDARD: 0,2 – 1,0 (pada 20 C)

Ganti stator jika tahanan tidak sesuai spesifikasi. Untuk pelepasan stator (hal. 11-6). Pasang left lower side cover (hal. 3-5).

ALTERNATOR 2P CONNECTOR (Putih)

ALTERNATOR WIRE CONNECTOR

dengan

WG

Y

WG

Y

16-7


REGULATOR/RECTIFIER REGULATOR/RECTIFIER PEMERIKSAAN SISTEM SYSTEM INSPECTION Lepaskan body cover (hal. 3-8). Remove the right body cover (page 3-8). Turn ignition the ignition switch OFF. Puter switch ke OFF. Disconnect the regulator/rectifier 4P connector, and Lepaskan regulator/rectifier 4P connector (Putih), dan check it for loose contact or corroded terminals. periksa terhadap kontak longgar atau terminal-terminal yang If theberkarat. charging voltage reading (page 16-7) is out of the specification, inspect the regulator/rectifier 4P connector terminals (wire harness as follows: Jika pembacaan voltaseside) pengisian (hal. 16-7) di luar spesifikasi, periksalah regulator/rectifier 4P connector Terminal Specification terminalsItem (sisi wire harness) sebagai berikut: Battery charging Red (+) and Battery voltage line should appear Ground ( ) – Bagian Terminal Spesifikasi Charging coil line White and – 1.0 Ω ada Saluran Merah/kuning ( + ) 0.3 Harus Green (at 20°C/68°F) pengisian dan Massa ( - ) voltase Ground line Green and Ground Continuity baterai baterai should exist Saluran Putih dan Hijau 0,3 – 1,0 Ω kumparan 20 ° C)and If all components of the charging system(pada is normal pengisian there are no loose connections at the regulator/rectifier 4P connector, the regulator/rectifier unit. ada Saluran massareplace Hijau dan massa Harus kontinuitas

Jika semua komponen dari sistem pengisian adalah normal dan tidak ada sambungan longgar pada regulator/rectifier 4P connector, gantilah regulator/rectifier unit.

4P CONNECTOR Y

R

R Y G W

WG

Y

WG

Y

G

REGULATOR/RECTIFIER 4P CONNECTOR Y

R

R Y G W

WG

Y

WG

Y

G


R

R Y G W

WG

Y

WG

Y

G


16-8

BATERAI/SISTEM PENGISIAN Lepaskan front cover (hal 3-11) Lepaskan front toptop cover (hal. 3-4). Lepaskan kabel utama/combination meter harness Lepaskan main wire/combination meter sub sub harness 9P 9P connector, kemudian connector terminals connector, kemudian periksaperiksa connector terminals (pada (sisi wire harness ) sebagai berikut: sisi wire harness) sebagai berikut: Item Terminal Specification Bagiancoil line Yellow Terminal Spesifikasi Lighting and 0.1 – 0.8 Ω ground 20Ω °C/68 °F) Saluran Kuning dan 0,1 –(at 0,8 (pada kumparan massa Ground line Green and ground Continuity 20°C) should exist penerangan Saluran massa Hijau dan Harus ada If all components of the system are normal and there are massa kontinuitas connecno loose connections at the regulator/rectifier tors, replace the regulator/rectifier unit. Jika semua komponen dari sistem adalah normal dan tidak ada hubungan longgar pada regulator/rectifier connectors, gantilah regulator/rectifier unit.

MAIN WIRE/COMBINATION METER SUB HARNESS 9P CONNECTOR

Y

R

R Y G W

WG

Y

WG

Y

G


R

R Y G W

WG

Y

WG

Y

G


REMOVAL/INSTALLATION PELEPASAN/PEMASANGAN Remove the right body cover (page 3-8). Lepaskan body cover (hal. 3-8). Turn the ignition switch OFF. Putar ignition switch ke OFF.

REGULATOR/RECTIFIER

BOLT

Disconnect the regulator/rectifier 4P connector. Lepaskan regulator/rectifier 6P connector (putih). Remove the bolts and the ground terminal. Lepaskan bolts dan terminal massa. Remove the regulator/rectifier from the frame. Lepaskan regulator/rectifier dari rangka. Route the wire Installation is in the reverse order of removal. harness properly lurkan wire Pemasangan (page 1-14) harness dengan pelepasan. benar (hal. 1-15)

adalah

dalam

urutan

terbalik

dari

4P CONNECTOR

GROUND TERMINAL

16-9

MEMO

17. SISTEM PENGAPIAN

LOKASI SISTEM................................. 17-2

PEMERIKSAAN SISTEM PENGAPIAN... 17-5 SYSTEM DIAGRAM ······································17-2

DIAGRAM SISTEM ............................. 17-2

IGNITION ........................................ 17-7 SERVICECOIL INFORMATION ···························17-3

KETERANGAN SERVIS ..................... 17-3

IGNITION TIMING .................................... 17-8 TROUBLESHOOTING ·································· 17-4

TROUBLESHOOTING ........................ 17-4

IGNITION SYSTEM INSPECTION ·············17-5

IGNITION COIL ·············································17-7 SYSTEM LOCATION ····································17-2 IGNITION TIMING········································17-8

17

17-1

SISTEM PENGAPIAN

LOKASI SISTEM IGNITIONSYSTEM

IGNITION SWITCH

MAIN FUSE 10 A IGNITION COIL

IGNITION CONTROL MODULE (ICM)

SPARK PLUG

IGNITION PULSE GENERATOR BATTERY

DIAGRAM SISTEM MAIN FUSE 10A

IGNITION SWITCH

R

R

l B Y / / l R B

G

Y / u B

Y / u B

G


G

IGNITION COIL

G

BATTERY

17-2


SPARK PLUG

Bl : Black Y : Yellow Bu : Blue G : Green R : Red

SISTEM PENGAPIAN

SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM ! AWAS Jika mesin harus dalam keadaan hidup untuk melakukan sesuatu pekerjaan, pastikan bahwa tempat kerja berventilasi If the engine must be run ning to do some wor k, make sure the area is well ventilated. Never run the engine in an enclosed area. The exhaust baik. Jangan sekali-kali menjalankan mesin dalam tempat tertutup. Gas pembuangan mengandung gas karbon contains poisonous carbon monoxide gas that may cause loss of consciousness and may monokside beracun yang dapat menghilangkan kesadaran dan akhirnya dapat membawa kematian. lead to death.

CATATAN Beberapa komponen listrik dapat rusak jika terminaloratau connector dihubungkan atau dilepaskan sewaktu • Some electrical components may be damaged if terminals connectors are connected or disconnected while the ignition ignition switch isswitch ON and (kunci kontak) pada posisi ON dan arus listrik mengalir. current is present.

•

servicing the ignition always follow the steps in the troubleshooting on pagepada • When 17-4.hal. 17-4. Sewaktu menservis sistemsystem, pengapian, selalu ikuti langkah-langkah pada urutansequence troubleshooting • The ignition timing does not normally need to be adjusted since the Ignition Control Module (ICM) is factory preset. Ignition timing (waktu pengapian) tidak perlu disetel oleh karena Ignition Control Module (ICM) telah disetel awal di pabrik. • • The Ignition Control Module (ICM) may be damaged if dropped. Also if the connector is disconnected when current is flowing, the • Ignition Control (ICM)the dapat menjadi rusak dijatuhkan. Jugabefore jika connector excessive voltageModule may damage module. Always turn jika off the ignition switch servicing. dilepaskan sewaktu arus listrik voltase berlebihan yang terjadi merusak matikan sebelum melakukan module. ignition switch Make • Amengalir, faulty ignition system is often related to poordapat connections. Check those Selalu connections before proceeding. sure the battery is adequately charged. Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at pekerjaan servis. the sparkpengapian plug. • Sistem yang tidak bekerja dengan baik biasanya disebabkan oleh sambungan yang buruk. Periksalah connector • Use spark plug of the correct heat range. Using spark plug with an incorrect heat range can damage the engine. connector sebelum melanjutkan. Pastikan bahwa baterai bermuatan listrik cukup. Baterai yang lemah menghasilkan putaran starter motor yang lebih rendah serta percikan bunga api yang lemah (atau tidak ada) pada busi. •SPECIFICATIONS Pakailah busi dengan derajat panas yang benar. Pemakaian busi dengan derajat panas yang tidak benar dapat merusak mesin. ITEM SPECIFICATIONS Spark plug Standard CPR6EA-9S (NGK) U20EPR9S (DENSO) SPESIFIKASI Optional CPR7EA-9S (NGK) U22EPR9S (DENSO) BAGIAN Spark plug gap 0.80 – 0.90SPESIFIKASI mm (0.031 – 0.035 in) Ignition coil peak voltage 100 V minimum Busi Standard CPR6EA-9S (NGK) U20EPR9S (DENSO) Ignition pulse generator peak voltage 0.7 V minimum Pilihan CPR7EA-9S (NGK) U22EPR9S (DENSO) ° BTDC Ignition timing ("F" 10 at idle Jarak renggang busimark) 0,80 – 0,90 mm Peak voltage (voltase puncak) ignition coil minimum 100 V Peak voltage ignition pulse generator minimum 0,7 V TORQUE VALUE Ignition timing (pengaturan waktu pengapian) (tanda "F") 10° sebelum TMA pada putaran stasioner •

Timing hole cap

1.5 N·m (0.15 kgf·m, 1.1 lbf·ft.)

TORSI PENGENCANGAN Timing hole cap

1,5 N.m 90,15 kgf.m; 1,1 lbf.ft)

TOOLS Imrie diagnostic tester (model 625) or Peak voltage adaptor 07HGJ-0020100

Timing cap wrench 07709-0010001

dengan digital multimeter (impedansi minimum 10MΩ /DCV) yang dapat di beli di pasaran.

17-3

SISTEM PENGAPIAN

TROUBLESHOOTING TROUBLESHOOTING • Inspect the following before diagnosing the system. sebagai • – Periksa Faulty spark plugberikut ini sebelum mendiagnosa sistem Spark plug (busi) rusak – Loose spark plug cap or spark plug wire connection Sambungan plugplug capcap (topi busi) atau spark plugvo wire (kabel busi) yang longgar – -Water got into Spark the spark (Leaking the sambungan ignition coil secondary ltage) - Air telah 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. Kondisi luar biasa primary voltage

Probable cause (Check in numerical order) 1. The multimeter impedance is too low; below 10 MΩ/DCV. penyebab 2. Cranking speed isKemungkinan too slow. (Battery is undercharged or operat(periksa menurut urutan angka) ing force of the kickstarter is weak) Ignition coil primary Peak voltage (voltase puncak) rendah. 3. 1.The Impedansi terlalu rendah; di bawah 10 not sampling multimeter time of the tester and measured pulse were voltage Ω M /DCV. synchronized. (System is normal if measured voltage is over the (voltase primer coil 2.standard Kecepatan perputaran mesin terlalu rendah. (Baterai voltage at least once.) pengapian) terlalu lemah atau gaya pada kickstarter 4. Poorly connected connectorstendang or an open circuit in the ignition lemah). system. Sampling time (waktu pengambilan contoh) dari tester 5. 3.Faulty ignition coil. dan pulsa yang diukur tidak sinkron. 6. Faulty ignition control module (ICM) (in case when above No. 1 (Sistem adalah normal jika voltase yang diukur – 5 are normal). sekurangnya sekali di atas voltase standard.) No peak voltage. 1. Incorrect peak voltage adaptor connections. 4. Connectors terhubung dengan buruk atau ada 2. Faulty ignition switch. rangkaian terbuka padaICM sistem pengapian. 3. Loose or poorly connected connectors. 5. Ignition coil tidak bekerja dengan baik. 4. Open circuit or poor connection in the Red/Black wire of the 6.ICM. Ignition control module (ICM) tidak bekerja dengan baik (dalam halorbila No. 1-5 di atas adalah 5. Open circuit poor connection in the Greennormal. wire of the ICM.

Tidak ada peak vo ltage.

Ignition pulse generator

Ignition pulse generator

Peak voltage is normal, but no spark jumps at the plug. Low peak voltage.

No peak voltage. Peak voltage adalah normal, tetapi tidak ada percikan bunga api pada busi. Peak voltage rendah.

Tidak ada peak vo ltage

17-4

6. 1.Faulty peak voltage adaptor (page 17-5). Sambungan-sambungan peak vo ltage ad aptor tidak 7. Faulty ignition pulse generator. (Measure the peak voltage.) benar. 8. 2.Faulty ICMswitch (in case when above dengan No. 1 – 7baik. are normal). Ignition tidak bekerja 1. 3.Faulty spark plug or leaking ignition coil secondary current. ICM connectors longgar atau tersambung dengan buruk. 2. 4.Faulty ignition coil. Rangkaian terbuka atau sambungan buruk pada kawat 1. The multimeter impedance Merah/Hitam dari ICM. is too low; below 10 MΩ/DCV. 2. 5.Cranking speedterbuka is too slow. is undercharged or operatRangkaian atau(Battery sambungan buruk pada kawat ing forcedari of the kickstarter is weak) Hijau ICM. 3. 6.The sampling time of the tester measured pulse were not 17Peak voltage adaptor tidakand bekerja dengan baik (hal. synchronized. (System is normal if measured voltage is over the 5). standard voltage at least once.) 7. Ignition pulse generator tidak bekerja dengan baik. 4. Faulty ignition vo pulse generator (in case when above No. 1 – 3 are (Ukur peak ltage). normal). 8. ICM tidak bekerja dengan baik (dalam hal bila No. 1-7 di 1. Faulty voltage adapter (page 17-5). atas peak adalah normal). 2. 1.Faulty pulse generator. Busi ignition tidak bekerja dengan baik atau ada kebocoran arus sekunder pada ignition coil. 2. Ignition coil tidak bekerja dengan baik. 1. Impedansi multimeter terlalu rendah; di bawah 10 MΩ /DCV. 2. Putaran mesin terlalu pelan. (Baterai lemah atau gaya tendang pada kickstarter lemah). 3. Sampling time (waktu pengambilan contoh) dari tester dan pulsa yang diukur tidak sinkron. (Sistem adalah normal jika voltase yang diukur adalah sekurangnya sekali di atas voltase standard). 4. Ignition pulse generator tidak bekerja dengan baik (dalam hal jika No. 1-3 di atas adalah normal). 1. Peak voltage adaptor rusak (hal. 17-5). 2. Ignition pulse generator tidak bekerja dengan baik.

SISTEM PENGAPIAN

IGNITION SYSTEM INSPECTION PEMERIKSAAN SISTEM PENGAPIAN CATATAN: Jika bungaallapi pada busi, • • If theretidak is noada sparkpercikan at plug, check connections for periksalah terhadap kontak loose or poorsemua contact sambungan before measuring peak voltage. commercially available digital multimeter an • Use longgar atau buruk sebelum mengukurwith peak impedance voltage. of 10 MΩ/DCV minimum. display sebuah value differs depending upon the dengan internal • • The Pakailah digital multimeter impedance of the multimeter. Ω/DCV yang minimum 10 M • Ifimpedansi using Imriesebesar diagnostic tester (model 625), follow the dapat dibeli di pasaran. manufacturer’s instructions. • Nilai yang ditayangkan berbeda tergantung pada Connect the peak voltage adaptor to the digital multimeinternal dari multimeter. ter, impedansi or use the Imrie diagnostic tester. Jika Imrie diagnostic tester (model 625) yang • TOOLS: dipakai, ikutilah petunjuk pemakaian pabrik Imrie diagnostic tester (model 625) or pembuatnya. Peak voltage adaptor 07HGJ-0020100 with Commercially multimeter Sambungkan peak available voltage digital adaptor pada (impeddigital Ω ance 10 M /DCV minimum) multimeter, atau gunakan Imrie diagnostic tester.

DIGITAL MULTIMETER

PEAK VOLTAGE ADAPTOR

TOOLS: PEAK VOLTAGE ADAPTOR Imrie diagnostic tester (model 625) atau Peak voltage adaptor 07HGJ-0020100 dengan digital multimeter (impedansi minimum 10 M /DCV) yang dapat dibeli di pasaran

PEMERIKSAAN PEAK VOLTAGE ADAPTOR INSPECTION Sewaktu mengetest tegangan tinggi sisi sekunder When testing the high tension on the pada ignition coil seconddari ignition coil menggunakan peak ary side using thedengan peak voltage adaptor, the innervoltage diode may be mungkin damaged.diode As a didamaged adaptor cause adaptor, dalamnya dalamwill keadaan incorrect voltage readings, consider a rusak. Olehpeak karena sebuah adaptoralways yang rusak akan defective adaptor if the peak voltage readings are all menghasilkan pembacaan peak voltage yang tidak abnormal. benar, selalu diode pertimbangkan adanya kerusakan pada The adaptor can be easily checked by the followadaptor jika pembacaan peak voltage semuanya adalah ing procedure. Therefore, be sure to check the adaptor before replacing the parts that display an abnormal testtidak normal. ing value. Adaptor diode dapat diperiksa dengan mudah dengan Set the multimeter to the AC voltage range and measure the local line voltage. If you touch the prosedur sebagai berikut. Oleh karena itu, pastikan Then, connect the peak voltage adaptor to the multimeadaptor jack untuk memeriksa adaptor sebelum mengganti parts ter, measure the same AC voltage with DC voltage range immediately after yang menghasilkan nilai tayangan pengetesan yang and compare it to AC voltage measured previously. disconnecting the tidak normal. adaptor, you may get • The adaptor is normal if the DC voltage measured via the adaptor is 1.4 times of AC voltage. angan menyentuh electrical shock. Letakkan multimeter pada daerah jangkauan voltase AC • The is defective if the DC voltage measured jack adaptor segera dan ukur adaptor voltase PLN Be sure to disconnect via the adaptor is 0lokal. V. setelah melepaskan the adaptor after Kemudian, hubungkan peak voltage adaptor pada adaptor, karena anda allowing the voltage multimeter, ukur voltase AC yang sama dengan daerah akan terkena kejutan to decrease angkauan voltase DC dan bandingkan dengan listrik. sufficiently. Pastikan untuk pengukuran voltase AC sebelumnya. melepaskan adaptor setelah membiarkan • voltase menurun dengan cukup. •

PEAK VOLTAGE ADAPTOR

Adaptor adalah normal jika pengukuran voltase DC melalui adaptor adalah sebesar 1,4 kali voltase AC. Adaptor adalah rusak jika voltase DC yang diukur melalui adaptor adalah 0 V.

17-5

SISTEM PENGAPIAN IGNITION COIL PRIMARY PEAK VOLTAGE IGNITION COIL PRIMARY PEAK (VOLTASE PUNCAK PRIMER IGNITION COIL) VOLTAGE CATATAN: • Check all system connections before performing this Periksa semua sambungan sistem sebelum • inspection. Loose connectors can cause incorrect menjalankan pemeriksaan ini. Connectors yang readings. longgarcylinder dapatcompression mengakibatkan pembacaan yang • Check and check that the spark plug is installed correctly. salah. •Support Periksalah kompressi dan periksa bahwa the motorcycle withcylinder its centerstand. spark plug (busi) telah dipasang dengan benar. Disconnect the spark plug cap from the spark plug. Connect a known good spark plug to the spark plug cap Letakkan sepedamotor padatostandard u tamanya. and ground the spark plug the cylinder head as done in a spark test. Lepaskan spark plug cap (topi busi) dari spark plug. Sambungkan sebuah spark plug yang diketahui bagus keadaannya pada spark plug cap dan hubungkan spar plug ke massa pada cylinder head seperti dilakukan pada test percikan bunga api busi.

SPARK PLUG CAP

SPARK PLUG YANG BAGUS KEADAANNYA Remove the right body cover (page 3-8). Lepaskan right body cover (hal. 3-8).

Avoid touching the tester probes to prevent Jangan sentuh electric jarum shock. jarum pemeriksaan

With theignition ignition coil coil primary wire connect the Dengan wire connected, (kawat primer ignition peak voltage adaptor or tester probes to the ignition coil coil) tersambung, hubungkan peak voltage adaptor atau primary wire terminal and ground. arum pemeriksaan tester pada ignition coil primary TOOLS:(terminal primer ignition coil) dan massa. terminal Imrie diagnostic tester (model 625) or TOOLS: Peak voltage adaptor 07HGJ-0020100 Imrie diagnostic tester (model 625)multimeter atau with commercially available digital (impedPeak voltage 07HGF-0020100 ance 10 M Ωadaptor /DCV minimum) dengan digital multimeter (impedansi minimum10 MCONNECTION: /DCV) yang dapat dibeli di pasaran Black/Yellow (–) – Body ground (+) HUBUNGAN: Turn the ignition (switch "ON". badan ( + ) Hitam/Kuning - ) – Massa Crank the engine with the starter motor and measure the ignition coil primary voltage. Putar ignition switch peak ke ON. PEAKmesin VOLTPutar dengan starter motor dan ukurlah ignition AGE: 100 V minimum coil primary peak voltage (voltase puncak primer ignition

IGNITION COIL PRIMARY WIRE TERMINAL (Hitam/ Kuning)

JARUM PEMERIKSAAN( – )

IGNITION COIL

tester untuk coil). menghindari kejutan If the peak voltage is abnormal, check each item followlistrik. ing the troubleshooting chart (page 17-4).

PEAK VOLTAGE: minimum 100 V Connect the spark plug cap to the spark plug.

Jika peak voltage tidak normal, periksalah masingmasing bagian mengikuti urutan langkah-langkah troubleshooting (hal. 17-4). Pasang spark plug cap pada spark plug.

BI/Y

Dari ICM

G

SPARK PLUG YANG BAGUS KEADAANNYA JARUM PEMERIKSAAN (+)

17-6

SISTEM PENGAPIAN IGNITION PULSE GENERATOR PEAK IGNITION PULSE GENERATOR VOLTAGE PEAK VOLTAGE CATATAN: before inspection. If the • • Check Periksaall system semua connection sambungan sistem sebelum system is disconnected, incorrect peak voltage might pemeriksaan. Jika sistem terlepas sambungannya, be measured. peak diukur adalah tidak sure benar. • Checkvoltage cylinderyang compression and make the spark • Periksa kompressi cylinder dan pastikan bahwa plug is installed correctly. dipasang dengan Turnbusi the telah ignition switch to "OFF".benar. Remove the body cover (page 3-8). Putar ignition switch ke "OFF". Disconnect the cover ICM 3P connector. Lepaskan body (hal. 3-8).


Connect the peak voltage adaptor or tester probes to the Lepaskan ICM 3P connector. ICM 3P connector.

Hubungkan peak voltage adaptor atau jarum TOOLS: pengetesan dari tester ke ICM625) 3P connector. Imrie diagnostic tester (model or TOOLS: Peak voltage adaptor 07HGJ-0020100 Imrie diagnostic tester (model 625)multimeter atau with commercially available digital (impedPeak voltage adaptor 07HGJ-0020100 ance 10 MΩ/DCV minimum) dengan digital multimeter (impedansi minimum 10 M /DCV) yang dapat dibeli di pasaran CONNECTION:Blue/Yellow (+) – Body ground (–) Turn the ignition switch "ON".( + ) – Massa badan ( - ) HUBUNGAN: Biru/Kuning Crank the engine with the starter motor and measure the Avoid touching the Putar ignition switch ke "ON". ignition pulse generator peak voltage. tester probes to Jangan prevent sentuh electric jarum- Putar mesin dengan starter motor dan ukur ignition PEAK VOLT jarum pengetesan shock. tester pulse generator peak voltage. AGE: 0.7 V minimum untuk menghindari PEAK VOLTAGE: minimum 0,7 V kejutan listrik. If the peak voltage measured at the ICM connector is Jika peak measure voltage yang diukur pada ICM connector abnormal, the peak voltage at the ignition pulse generator wire connector. adalah tidak normal, ukurlah peak voltage pada ignition pulse generator wire connector.

3P CONNECTOR ICM 3P CONNECTOR

Bu/Y

Bu/Y


17-7

SISTEM PENGAPIAN Connect the peak peak voltage tester or adaptor to the Hubungkan voltage tester atau probes jarum-jarum wire connector (Blue/Yellow) terminal of the terminal ignition pengetesan adaptor pada wire connector pulse generator (Biru/Kuning) dariside. sisi ignition pulse generator. In the same manner as at the ICM connector, measure the peakcara voltage and compare it topada the voltage measured Dengan yang sama seperti ICM connector, at the ICM connector. ukurlah peak voltage dan bandingkan dengan voltase • If diukur the peak voltage measured at the ICM is abnormal yang pada ICM connector. and the one measured at the ignition pulse generator is normal, the wire harness has an open or short cirJika or peak yang diukur pada ICM tidak • cuit, loosevoltage connection. danvoltages yang measure diukur pada ignition check pulse both peak are abnormal, • Ifnormal generator adalah normal, maka wire harness each item in the troubleshooting chart (page 17-4). rangkaian terbuka atau adagenerator hubungan Ifmempunyai all items are normal, the ignition pulse is singkat,See atau ada hubungan longgar.pulse generator faulty. page 11-6 for ignition replacement. • Jika kedua peak voltages yang diukur adalah tidak normal, periksalah masing2 bagian peta Install the removed parts in the reverse order pada of removal. troubleshooting (hal. 17-4). Jika semua bagian adalah normal, maka ignition pulse generator tidak bekerja dengan baik. Lihat hal. 11-6 untuk penggantian ignition pulse generator.

IGNITION PULSE GENERATOR WIRE CONNECTOR (Biru/Kuning)

IGNITION PULSE GENERATOR WIRE CONNECTOR (Biru/Kuning)

Pasang parts yang telah dilepaskan dalam urutan terbalik dari pelepasan.

Bu/Y


IGNITION IGNITIONCOIL COIL(KUMPARAN PENGAPIAN) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan right body cover (hal. 3-8). Remove the right body cover (page 3-8). Lepaskan spark plug cap plugspark dan lepaskan Disconnect the spark plugdari capspark from the plug and release the spark plug wire from the clamp. spark plug wire (kabel busi) dari clamp.

CLAMP SPARK PLUG CAP Disconnect the ignition coilconnectors. wire connectors. Lepaskan ignition coil wire Remove the bolts and ignition coil. Lepaskan bolts dan ignition coil. Route the wire Installation is in the reverse order of removal. lurkan kabel busi Pemasangan adalah dalam urutan terbalik harness properly dengan(page benar1-14). (hal. pelepasan.

CONNECTORS

dari

1-15).

IGNITION COIL

17-8

BOLTS

SISTEM PENGAPIAN

IGNITIONCONTROL CONTROLMODULE MODULE(ICM) (ICM) IGNITION PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Remove the body covers (page 3-8). Lepaskan body covers (hal. 3-8).


Turn ignition the ignition switch "OFF". Putar switch ke "OFF". Disconnect the ICM 2P/3P connectors. Lepaskan ICM 2P/3P connectors. Remove the ICM. Lepaskan ICM. Installation is in the reverse order of removal.


adalah

dalam

urutan

terbalik

dari

2P/3P CONNECTORS

PEMERIKSAAN SALURAN DAYA/MASSA POWER/GROUND LINE INSPECTION Remove the body covers (page 3-8). Lepaskan body covers (hal. 3-8). Disconnect the2P ICM 2P connector. Lepaskan ICM connector. Turn ignition the ignition switch "ON". Putar switch ke "ON". Measure the battery voltage between the ICM 2P conUkur voltase antaraside ICM 2Pground. connector dari sisi nector of the baterai wire harness and wire harness dan massa. CONNECTION:Red/Black (+) – Body ground (–) HUBUNGAN: Merah/Hitam ( + ) - Massa badan ( - ) Thereada should be battery with the ignition Harus voltase bateraivoltage sewaktu ignition switchswitch pada "ON". posisi "ON". If there is no voltage withsewaktu the ignition switchswitch "ON", check Jika tidak ada voltase ignition pada the following: posisi "ON", periksalah sebagai berikut: Wire harness between the dan battery and ICM - –Wire harness antara baterai ICM – Ignition switch - Ignition switch Main fuse 10 A - –Main fuse (sekring utama) 10A Turn the ignition switch "OFF". Putar ignition switch ke posisi "OFF". Disconnect the ICM 3P connector. Lepaskan 3P connector. Check forICM continuity between the ICM 3P connector of the wire harness side and ground. Periksa terhadap kontinuitas antara ICM 3P connector


2P CONNECTOR

3P CONNECTOR

SALURAN DAYA: MAIN FUSE 10 A

dari sisi wire harness dan massa. CONNECTION:Green – Body ground HUBUNGAN: Hijau – Massa badan There should be continuity at all time. Harus ada kontinuitas pada setiap waktu. Route the wire If there is no continuity, check the open circuit in green wire.tidak ada kontinuitas, periksa terhadap rangkaian lurkan wireproperly harness Jika harness dengan benar(page (hal. 1-14). 1-14). terbuka pada kawat hijau.

IGNITION SWITCH

R

R

R/Bl

G

ICM 2P CONNECTOR SALURAN MASSA:

G

G

ICM 3P CONNECTOR

17-9

SISTEM PENGAPIAN

IGNITION TIMING(WAKTU PENGAPIAN) IGNITION TIMING Warm up the engine. Panaskan mesin. Stop the engine andlepaskan remove the timing hole cap using Matikan mesin dan timing hole cap dengan the special tool. menggunakan special tool. TOOL: TOOL: Timing cap wrench 07709-0010001 Timing cap wrench 07709-0010001

TIMING HOLE CAP

Connect a tachometer. Hubungkan tachometer. Connect the timing light to the spark plug wire. Hubungkan timing light pada spark plug wire (kabel Start the engine and let it idle. busi). -1 Hidupkan mesin dan ±biarkan IDLE SPEED:1,400 100 minberputar (rpm) stasioner.

INDEX NOTCH

acalah Read petunjuk the pemakaian timing light. manufacturer’s instructions for timing light -1 1.400 (rpm) operation. PUTARAN The ignitionSTASIONER: timing is correct if the100 "F" menit mark on the fly-

TANDA"F"

Ignition timingwith adalah tanda "F" left pada flywheel wheel aligns the tepat index jika notch on the crankcase cover. bertepatan dengan index notch (takik penunjuk) pada left crankcase cover.

TIMING LIGHT Apply engine oil topada a new O-ring. Oleskan oli mesin O-ring baru. Install and the timing hole capcap to the specified Pasang dantighten kencangkan timing hole dengan torsi torque. yang ditentukan. TORQUE:1.5 N·m (0.15 kgf·m, 1.1 lbf·ft) TORSI: 1,5 N.m (0,15 kgf.m; 1,1 lbf.ft)

TIMING HOLE CAP

O-RING

17-10

18. SISTEM STARTER LISTRIK

LOKASI LOCATION SISTEM .....................................18-2 SYSTEM ····································18-2

TROUBLESHOOTING............................18-4 TROUBLESHOOTING ·································· 18-4

DIAGRAM SISTEM······································18-2 .................................18-2 SYSTEM DIAGRAM

STARTER MOTOR..................................18-6 STARTER MOTOR ········································ 18-6

KETERANGAN SERVIS.........................18-3 SERVICE INFORMATION ···························18-3

STARTER RELAY...................................18-10 STARTER RELAY········································18-10

18

18-1


SYSTEM LOCATION LOKASI SISTEM ELECTRICSTARTERSYSTEM

STARTER SWITCH IGNITION SWITCH MAIN FUSE 10 A SUB FUSE 7.5 A STARTER RELAY


STARTER MOTOR

BATTERY

DIAGRAMDIAGRAM SISTEM SYSTEM IGNITION SWITCH

MAIN FUSE 10A R

R

SUB FUSE 7.5A R/Bl

STARTER RELAY

R

G BATTERY

Y/R

W / R

Bl

G STARTER SWITCH

STARTER MOTOR

18-2

Bl : Black Y : Yellow G : Green R : Red W : White


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. A Selalu weak battery may beswitch unable(kunci to turnkontak) the starter motor"OFF" quicklysebelum enough,menservis or supply adequate ignition current. putar ignition ke posisi starter motor. Motor dapat hidup dengan tibaThe starter motor can luka-luka be serviced with the engine in the frame. tiba, menyebabkan parah. When checking the starter system, always follow the steps in the troubleshooting (page 18-4). Baterai yang lemah mungkin tidak dapat memutar starter motor dengan cukup cepat, atau memasok arus listrik pengapian If the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be damyang mencukupi. aged. Starter motor dapatcomponent diservis dengan mesin terpasang pada rangka. • Refer to the following information. Ignition switch – Sewaktu (page 19-14) memeriksa sistem starter, selalu ikuti langkah-langkah pada troubleshooting (hal. 18-4). Starter switch – Jika 19-16) mengalir melalui starter motor untuk memutarnya sementara mesin tidak berputar, starter motor arus listrik(page dibiarkan mungkin akan rusak. Bacalah informasi komponen sebagai berikut: SPECIFICATION - Ignition switch (hal. 19-14) Unit: mm (in) SERVICE ITEM STANDARD LIMIT SPESIFIKASI Starter motor brush length 7.0 (0.28) 3.5 (0.14) Satuan: mm BAGIAN STANDARD BATAS SERVIS Panjang sikat starter motor 7,0 ( 0,28 ) 3,5 ( 0,14 ) TORQUE VALUE •

•

• • •

•

Starter motor cable screw

2.0 N·m (0.20 kgf ·m, 1.5 lbf ·ft)

TORSI PENGENCANGAN Starter motor cable screw

2 N.m (0,2 kgf.m; 1,5 lbf.ft)

18-3


TROUBLESHOOTING TROUBLESHOOTING Starter motor not turn Starter motordoes tidak berputar 1. Standard Inspection 1. Pemeriksaan Standard

Periksa Check forterhadap following:sebagai berikut: –- Kondisi Battery condition baterai –- Sekring Burned fuse(s) putus Are the above items in good condition? Apakah bagian-bagian di atas dalam 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. 2. Starter Relay Operation 2. Turn Carathe kerja Starter Relay ignition switch "ON". Putarthe ignition ke "ON". Push starterswitch switch. You should hear the relay "CLICK" when the starter switch is depressed. Tekan starter switch. terdengar suara "KLIK" ketika starter switch (tombol starter) ditekan. IsHarus the "CLICK" heard?

Apakah suara O TO "KLIK" STEP 3. terdengar? YES – G YA NO

- LANJUTKAN TO STEP 5. DENGAN LANGKAH 3. – GO

TIDAKMotor - LANJUTKAN DENGAN LANGKAH 5. 3. Starter Cable Inspection 3. Turn Pemeriksaan Motor Cable the ignitionStarter switch "OFF". Check openswitch circuit ke in starter Putar for ignition "OFF".motor cable. Periksa terhadap rangkaian terbuka pada starter motor cable. Is the above cable in good condition? Apakah kabel atas4.pada kondisi baik? O TO di STEP YES – G YA NO

DENGAN LANGKAH 4. cable and starter motor Loose or poorly connected starter motor – •- LANJUTKAN • Open circuit in battery negative terminal. TIDAK •- Open Starter motor cable dan starter motor cable longgar atau tersambung dengan circuit in starter motor Red/White between the starter relay andburuk. starter motor. Rangkaian terbuka pada terminal negatif baterai. 4. Starter Motor Inspection Rangkaian terbuka pada starter motor cable Merah/Putih antara starter relay Apply battery voltage to the starter motor directly and check the operation. dan starter motor. 4. Does Pemeriksaan Starter Motor the starter motor turn? Hubungkan voltase baterai langsung pada starter motor dan periksa cara kerjanya. YES – • Open circuit in Red wire between the starter relay and battery. Faulty starterberputar? relay. Apakah •starter motor • • •

starter motor. NO YA – Faulty Rangkaian terbuka pada kawat Merah antara starter relay dan baterai. Starter relay tidak bekerja dengan baik. 5. Starter Relay Coil Circuit Inspection •

•

Disconnect starter relay 5P connector. rusak. TIDAK - the Starter motor Turn the ignition switch "ON" and push the starter switch. 5. Measure Pemeriksaan Rangkaian Coil relay 5P connector terminal of the wire harness side. the battery voltage Starter betweenRelay the starter Lepaskan starter relay 5P connector. CONNECTION:Yellow/Red (+) – Green (–) Putar ignition switch ke posisi "ON". Does batterybaterai voltageantara exist? starter relay 5P connector t erminal dari sisi wire harness. Ukurthe voltase STEP 6. YES – GO TO Kuning/Merah HUBUNGAN: ( + ) – Hijau ( - ) Loose or poorly connected connector. NO – •ada Apakah voltase baterai? • Open circuit in battery cable between the battery and ignition switch. YA LANGKAH 6. wire between the ignition switch and starter switch. •- LANJUTKAN Open circuit inDENGAN Red/Black and/or Black • Open circuit in starter relay Yellow/Red wire between the starter switch and starter relay. TIDAK •- Open Connector longgar buruk. circuit in Greenatau wire tersambung between the dengan starter relay and ground. Rangkaian pada19-14). kawat baterai antara baterai dan ignition switch. ignition terbuka switch (page • Faulty starter switch • Faulty (page Rangkaian terbuka pada19-16). kawat Merah/Hitam dan/atau Hitam antara ignition switch danInspection starter switch. 6. Starter Relay Continuity Rangkaian terbuka pada kawat Kuning/Merah starter relay antara starter switch Check the starter relay for continuity (page 18-11). dan starter relay. Rangkaian terbuka pada kawat Hijau antara starter relay dan massa. Is there continuity? Ignition switch tidak bekerja dengan baik (hal. 19-14). YES – Intermittent failure. 6. NO Pemeriksaan starter relay. Starter Relay – Faulty Kontinuitas Periksa starter relay terhadap kontinuitas (hal. 18-11). •

• •

•

• •

Apakah ada kontinuitas? YA

- Ada kegagalan terputus-putus.

TIDAK - Starter relay tidak bekerja dengan baik.

18-4

SISTEM STARTER LISTRIK Starter motor turns engine slowly Starter motor memutar mesin dengan pelan • Low battery voltage. Voltaseconnected baterai rendah. • Poorly battery terminal cable. Kabel terminal baterai tersambung dengan buruk • Poorly connected starter motor cable. • Faulty Kabel starter starter motor. motor tersambung dengan buruk • Poorly battery ground cable. Starterconnected motor tidak bekerja dengan baik Starter motor turns, but engine does not turn buruk Kabel massa baterai tersambung dengan • Starter motor is running backwards. – Case assembled improperly. Starter motor berputar, tetapi mesin tidak berputar – Terminals connected improperly. Starter motor berputar terbalik. • Faulty starter clutch. - Case tidak dirakit dengan baik. Starter relay "CLICK", but engine does not turn - Terminals tidak dihubungkan dengan baik. • Crankshaft does not turn due to engine problems. Starter clutch tidak bekerja dengan baik. • Faulty starter clutch. • • • • •

•

•

Starter relay berbunyi "KLIK", tetapi mesin tidak berputar Crankshaft tidak berputar karena persoalan pada mesin. Starter clutch tidak bekerja dengan baik. • •

18-5


STARTER MOTOR MOTOR REMOVAL PELEPASAN Lepaskan right lower side cover (hal. 3-5). Remove the right lower side cover (page 3-5). Disconnect the starter 2P connector. Lepaskan starter motormotor 2P connector. Remove the bolts and starter motor from the engine. Lepaskan bolts dan starter motor dari mesin.

STARTER MOTOR 2P CONNECTOR

STARTER MOTOR

BOLTS

Lepaskan O-ring. Remove the O-ring.

O-RING Pull off the dust dust cover. cover. Tarik lepas Remove the screw starter motor cable. Lepaskan screw danand starter motor cable. Remove the screw and ground cable. Lepaskan screw dan kabel massa.

SCREW/GROUND CABLE

DUST COVER SCREW/STARTER MOTOR CABLE

INSTALLATION PEMASANGAN Pasang kabel massa danand kencangkan . Install the ground cable tighten thescrew screw. Install the startermotor motor cable the screw. Pasang starter cable and dantighten kencangkan screw dengan Put the torsi dust yang coverditentukan. back in the appropriate position.

SCREW/GROUND CABLE

TORSI: 2 N.m (0,2 kgf.m; 1,5 lbf.ft) Letakkan dust cover kembali pada tempatnya yang benar.

DUST COVER SCREW/STARTER MOTOR CABLE

18-6

SISTEM STARTER LISTRIK Lapisi baru with dengan oli oil mesin ke Coat aO-ring new O-ring engine and dan installpasang it into the starteralur motor groove. dalam starter motor.

STARTER MOTOR

O-RING Install the starter motor and bolts to the engine. Pasang starter motor dan bolts pada mesin. Tighten the bolts. Kencangkan bolts. Connect the starter motor 2P connector. Sambungkan starter motor 2P connector. Install the right lower side cover (page 3-5). Pasang right lower side cover (hal. 3-5).

STARTER MOTOR 2P CONNECTOR

STARTER MOTOR

BOLTS

PEMBONGKARAN DISASSEMBLY Lepaskan screws dan starter motor case. Remove the screws and starter motor case. Lepaskan sebagai berikut: Remove the following: Armature - – Armature – Bracket - Bracket – Springs - –Springs Gasket - Gasket SCREWS

MOTOR CASE

ARMATURE

SPRING

GASKET

BRACKET

18-7

SISTEM STARTER LISTRIK ASSEMBLY PERAKITAN Pasang springs di dalam brushholders. holders. Install the springs in the brush

BRUSH HOLDERS

SPRINGS

Pasang ke the dalam bracket sementara Install thearmature armature into bracket while holding the brushes. brushes. memegang

ARMATURE

BRUSHES Install the bracket and armature to the motor case while new gasket onto the bracket. Pasangagasket baru pada bracket. holding the bracket side armature tightly. The coil may be dam- Pasang bracket dan armatureshaft pada motor case aged if the magnet sementara memegang armature shaft pada sisi bracket pulls the armature dengan erat.

BRACKET

MOTOR CASE

against the case.

GASKET

Pasang motor dantighten kencangkan Install the motorcase case screws screws and them. dengan torsi yang ditentukan.

18-8

ARMATURE

SCREWS

SISTEM STARTER LISTRIK INSPECTION PEMERIKSAAN BRUSH BRUSH (SIKAT) Inspect the brushes for damage and measure the brush Periksa length. brushes terhadap kerusakan dan ukur panjang brush. SERVICE BATAS SERVIS: 3.5 mm LIMIT: 3.5 mm (0.14 in)

ARMATURE ARMATURE Do not use emery or sand paper on the commutator.

Periksa commutator bars (lempengan komutator) dari Inspect the commutator bars of the armature for discoloration. armature terhadap perubahan warna. Bars discolored in pairs indicate shorted coils. Bars yang berubah warna dalam pasangan menunjukkan kumparan-kumparan yang ada hubungan singkat.

Periksa terhadap antara Check for continuitykontinuitas between each pairmasing-masing of commutator bars. pasangan commutator bars. Harus kontinuitas. Thereada should be continuity.

Periksa terhadap antara masing-masing Check for continuitykontinuitas between each commutator bar and the armaturebar shaft. commutator dan armature shaft. Tidak ada Thereboleh should bekontinuitas. no continuity.

COMMUTATOR BARS

KONTINUITAS:

TIDAK ADA KONTINUITAS:

18-9


STARTER RELAY RELAY PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Remove the battery cover (page 16-5). Lepaskan battery cover (hal. 16-5). Remove the starter relay from the stay. Lepaskan starter relay dari stay. Disconnect the starter relay 5P connector. Lepaskan starter relay 5P connector. Installation is in the reverse order of removal. Pemasangan adalah dalam urutan terbalik pelepasan.

STARTER RELAY

dari

5P CONNECTOR

PEMERIKSAAN CARA KERJA OPERATION INSPECTION Remove the battery cover (page 16-5). Lepaskan battery cover (hal. 16-5). Turn ignition the ignition switch "ON". Putar switch ke "ON". Push the starter switch. Tekan starter switch. The system is normal normal jika if thestarter starterrelay relayberbunyi clicks. klik. Sistem adalah If you don’t hear the relay "CLICK", inspect the Jika tidak terdengar suara "KLIK"dari relay, periksalah following: sebagai berikut: – Starter relay coil circuit (page 18-11) - Rangkaian starter relay coil (hal. 18-11) – Battery testing (page 16-6) - Test baterai (hal. 16-6) If you hear the relay "CLICK", but starter does not turn, Jika terdengar suara "KLIK", tetapi starter tidak inspect the starter relay continuity (page 18-11). berputar, periksalah kontinuitas starter relay (hal. 1811).

18-10

STARTER RELAY

SISTEM STARTER LISTRIK PEMERIKSAAN RANGKAIAN STARTER STARTER RELAY COIL CIRCUIT INSPECTION RELAY COIL Remove the battery cover (page 16-5). Lepaskan battery cover (hal. 16-5). Remove the starter relay from the stay. Lepaskan starter relay dari Disconnect the starter relaystay. 5P connector. Lepaskan starter relay 5P connector. Turn the ignition switch "ON". Putar ignition kebetween "ON". the starter relay 5P conMeasure theswitch voltage nector of the wire harness pressing and Ukur voltase antara starter side relaywhile 5P connector dariholdsisi ing the starter switch. wire harness sementara menekan dan menahan starter CONNECTION:Yellow/Red (+) – Green (–) switch.

STARTER RELAY

If the battery voltage appears only when the ignition HUBUNGAN: Kuning/Merah ( + ) – Hijau ( - ) switch is "ON" and starter switch is pressed, the circuit is normal. Jika voltase baterai hanya ada sewaktu ignition switch pada "ON" dan starter switch ditekan, rangkaian adalah normal.

5P CONNECTOR MAIN FUSE 10 A R

IGNITION SWITCH

R

G

SUB FUSE 7.5 A G

Y/R

Bl

R/Bl

STARTER SWITCH

STARTER RELAY 5P CONNECTOR

PEMERIKSAAN KONTINUITAS STARTER STARTER RELAY CONTINUITY RELAY INSPECTION Remove the starter relay (page 18-10). Lepaskan starter relay (hal. 18-10). Connect a fully charged 12 sebuah V batterybaterai positive 12V wire to the Hubungkan kabel positif yang relay switch terminal A and negative wire to the terminal bermuatan penuh kepada relay switch terminal A dan B. kawat negatif pada terminal B. Check for continuity at the terminal C and terminal D. Periksa terhadap kontinuitas pada the terminal dan There should be continuity between C and DCterminals while terminal D. the battery is connected, and no continuity when the battery is disconnected. Harus ada kontinuitas antara terminals C dan D sewaktu baterai dihubungkan, dan tidak boleh ada kontinuitas sewaktu baterai d ilepaskan.

A

C

B

D

STARTER RELAY A

B

C

D

18-11

MEMO

19. LAMPU-LAMPU/METER-METER/SAKLAR

LOKASI SYSTEMSISTEM....................................19-2 LOCATION ····································18-2

FUEL SENSOR/FUEL METER..19-8 FUEL LEVEL LEVEL SENSOR/FUEL METER······ 18-8

KETERANGAN SERVIS ........................ 19-3 SERVICE INFORMATION ···························18-3

IGNITION IGNITIONSWITCH.................................19-9 SWITCH·······································18-9

HEADLIGHT...........................................19-4 HEADLIGHT ···················································18-4

HANDLEBAR SWITCHES .....................19-10 HANDLEBAR SWITCHES··························18-10

TURN LIGHT ...........................19-4 TURNSIGNAL SIGNAL LIGHT··································18-4

BRAKE SWITCH ........................19-11 BRAKE LIGHT LIGHT SWITCH····························18-11

BRAKE/TAIL BRAKE/TAIL LIGHT LIGHT..............................19-5 ···································· 18-5

GEAR SWITCH························ ....................19-12 GEAR POSITION POSITION SWITCH 18-12

PEMERIKSAAN RANGKAIAN LIGHTING CIRCUIT INSPECTION···········18-6

HORN .....................................................19-14 HORN····························· ·························· ······· 18-14

PENERANGAN ......................................19-6 COMBINATION METER······························ 18-6

TURN RELAY·······························18-15 ..........................19-15 TURN SIGNAL SIGNAL RELAY

COMBINATION METER ........................19-6

19

19-1


SYSTEM LOCATION LOKASI SISTEM LIGHTS/METERS/SWITCHES

FRONT BRAKE LIGHT SWITCH

TURN SIGNAL RELAY

LIGHTING SWITCH

STARTER SWITCH

COMBINATION METER

IGNITION SWITCH

HORN

MAIN FUSE 10 A/ SUB FUSE 7.5 A FUEL LEVEL SENSOR

DIMMER SWITCH TURN SIGNAL LIGHT SWITCH

HORN SWITCH

GEAR POSITION SWITCH

REAR BRAKE LIGHT SWITCH

19-2


SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM • •• •• •• •

Be sure to install the dust cover after replacing the bulb. Pastikan untuk memasang dust cover setelah mengganti lampu). Check the battery condition before performing any inspectionbulb that(bola requires proper battery voltage. Route the kondisi wires and cables properlymenjalankan after servicing each component (page 1-14). voltase baterai yang cukup. Periksa baterai sebelum pemeriksaan yang memerlukan The following color codes arekabel useddengan throughout this section. Alurkan kawat-kawat dan benar setelah menservis masing-masing komponen (hal. 1-14). Kode-kode warna sebagai berikut dipakai di sepanjang bab ini. Bu = Blue G = Green Lg = Light green R = Red Bl Bu = Black Gr = Gray O = Orange W White = Blue (Biru) Gr = Gray (Abu-abu) P= = Pink (Merah muda) Br Bl = Brown = Pink YR= Yellow = Black (Hitam) Lb = Light blue Lb = LightPblue (biru muda) = Red (Merah)

Br = Brown (Coklat) G = Green (Hijau)

SPECIFICATIONS SPESIFIKASI Bulbs

Bulbs (Bola lampu)

Fuse

Fuse (Sekring)

Lg = Light green (hijau muda) O = Orange (Jingga)

W = White (Putih) Y = Yellow (Kuning)

ITEM Headlight (High/Low) BAGIAN Position light Headlight (Lampu besar) Brake/tail light (High/Low = jauh/dekat) Front turn signal light Position light (Lampu senja) Rear turn signal light Brake/tail light (Lampu rem/belakang) Meter light Front turn signal light (Lampu sein depan) Turn signal indicator Rear turn signal light (Lampu sein belakang) High beam indicator Meter light (Lampu penerangan instrumen) Gear position indicator Turn signal indicator (Indikator lampu sein) Neutral indicator High beam indicator (Indikator lampu jauh) Main Gear position indicator (Indikator posisi gigi transmissi) Sub Indikator neutral Main (Sekring utama) Sub (Sekring tambahan)

SPECIFICATIONS 12 V – 32/32 W SPESIFIKASI 12 V – 3.4 W x 2 12 V – 32/32 W 12 V – 18/5 W 12 V – 10 W x 2 12 V – 3,4 W x 2 12 V – 10 W x 2 12 V – 18/5 W 12 V – 1.7 W x 2 12 V – 10 W x 2 12 V – 3.4 W x 2 12 V – 10 W x 2 12 V – 1.7 W 12 V – 1,7 W x 2 12 V – 1.7 W x 4 12 V – 3,4 W x 2 12 V – 1.7 W 12 V – 1,7 W 10 A 12 V – 1,7 W x 4 7.5 A 12 V - 1,7 W 10 A 7,5 A

19-3


PEMERIKSAAN SISTEM PENERANGAN HEADLIGHT TIDAK MENYALA ATAU

L I

GHTING SYSTEM INSPECTION LEMAH SINARNYA Pemeriksaan Standard:

HEADLIGHT DOES NOT COME ON OR

Periksa sebagai berikut: IS WEAK - Standard Bulb (bola lampu) terbakar atau dengan watt yang Inspection tidak sesuai dengan spesifikasi Check the following: - Connector longgar Burnedswitch out bulb or bulb with unspecified wattage - –Lighting (saklar lampu) – Loose connector - Dimmer switch (saklar dim) – Lighting switch – Dimmer switch di atas adalah normal, periksa Jika bagian-bagian sebagai berikut: If the above items are normal, check as follows: Pemeriksaan Rangkaian Penerangan: Lighting Circuit Inspection Lepaskan sebagai berikut: Remove the followings:

HEADLIGHT 4P CONNECTOR

- – Front toptop cover (hal. 3-4) Front cover (page 3-4) - – Right body cover (hal. 3-8) Right body cover (page 3-8)

Lepaskan alternator wire connector (Kuning). Disconnect the alternator wire (Yellow) connector. Turn the lighting to HL dimmer switch to Hi Pindahkan lightingswitch switch ke and posisi HL dan dimmer position. switch ke posisi Hi. Check the continuity between the Blue terminal of the Periksa kontinuitas antara Biru dariof headlight headlight 4P connector andterminal yellow terminal the alter4P connector dan terminal Kuning dari alternator wire nator wire connector. connector. If there is continuity, check the following: Jika ada kontinuitas, periksa sebagai berikut:

ALTERNATOR WIRE CONNECTOR (Kuning) HEADLIGHT 4P CONNECTOR

DIMMER Bu SWITCH

LIGHTING SWITCH

Bu/R

Y

ALTERNATOR WIRE CONNECTOR (Kuning)

19-4

LAMPU-LAMPU/METER-METER/SAKLAR-SAKLAR Disconnect the regulator/rectifier 4P connector. Lepaskan regulator/rectifier 4P connector. Check thekontinuitas continuity between Yellow terminals the Periksa antara the terminal Kuning ofdari regulator/rectifier 4P connector and alternator wire (Yelregulator/rectifier low) connector. 4P connector dan alternator wire connector (Kuning). If there is continuity, check the following: Jika ada kontinuitas, periksa sebagai berikut:



Y

ALTERNATOR WIRE CONNECTOR (Kuning)

Ground Inspection Pemeriksaan Massa Periksa kontinuitas antara terminal Hijau terminal dari headlight Check the continuity between the Green of the headlight 4P connector and ground. 4P connector dan massa. Jika adais kontinuitas, periksa lightingcoil coil (kumparan If there continuity, check the lighting (page 16-7). penerangan) (hal. 16-7). If the lighting normal, check the regulator/rectifier Jika lightingcoil is coil adalah normal, periksa (page 16-8). regulator/rectifier (hal. 16-8).

HEADLIGHT 4P CONNECTOR

G

19-5


HEADLIGHT(LAMPU BESAR) HEADLIGHT BULB REPLACEMENT PENGGANTIAN BULB (BOLA LAMPU) Remove the front cover (page 3-4). Lepaskan front toptop cover (hal. 3-4). Pull back the dust Tarik dust cover kecover. belakang. Turn the socket counterclockwise and remove the socket Putar socket berlawanan arah jarum jam dan lepaskan and headlight bulb. socket dan headlight bulb. If you touch the bulb with your bare hands, clean it with a Jika bulb telah disentuh dengan tangan telanjang, cloth moistened with alcohol to prevent early bulb failure. bersihkan dengan kain yang telah dibasahkan dengan Install untuk a newmenghindari headlight bulb aligning bulb its tab with the alkohol kegagalan yang terlalu groove on the headlight unit. dini. Turn the socket clockwise and install dust cover with Pasang sebuah headlight bulbthe baru dengan the "TOP" mark facing up. mentepatkan tab-nya dengan alur pada headlight unit. Install the front top cover (page 3-4). Putar socket searah jarum jam dan pasang dust cover For headlight unit removal/installation (page 3-4). dengan tanda "TOP" menghadap ke atas. Pasang front top cover (hal. 3-4).

Tepatkan

SOCKET

TANDA "TOP"

HEADLIGHT BULB

DUST COVER

Untuk pelepasan/pemasangan headlight unit (hal. 3-4).

POSITION LIGHT BULB REPLACEMENT Remove the front topPOSITION cover (page 3-4). PENGGANTIAN LIGHT BULB (BOLA SENJA) Turn theLAMPU socket counterclockwise and remove it, then pull out the position light bulb from the socket. Lepaskan front top cover (hal. 3-4). Install a new bulb in the reverse order of removal. Putar socket berlawanan arah jarum jam dan lepaskan, Install the front top cover (page 3-4). kemudian tarik keluar position light bulb dari socket.

Pasang sebuah bulb baru dalam urutan terbalik dari pelepasan. Pasang front top cover (hal. 3-4). SOCKET POSITION LIGHT BULB

TURN SIGNAL LIGHT TURN SIGNAL LIGHT (LAMPU SEIN) BULB REPLACEMENT PENGGANTIAN BULB FRONT TURN SIGNAL LIGHT RemoveTURN the front top cover (page 3-4). SEIN DEPAN) FRONT SIGNAL LIGHT (LAMPU Lepaskan topcounterclockwise cover (hal. 3-4). and remove it, then Turn the front socket pull out the bulb from the socket. Putar socket berlawanan arah jarum jam dan lepaskan, Install a new in the reverse order of removal. kemudian tarikbulb keluar bulb dari socket. Pasang dalambulbs. urutan terbalik dari pelepasan. • Usebulb only baru the amber • For front turn signal light unit removal/installation Hanya pakai bulb kuning tua. • (page 3-4). Untuk pelepasan/pemasangan front turn signal light • unit (hal. 3-4).

SOCKET

BULB

19-6

LAMPU-LAMPU/METER-METER/SAKLAR-SAKLAR REAR TURNSIGNAL SIGNAL LIGHT (LAMPU SEIN REAR TURN LIGHT BELAKANG) Remove the two screws and tail light lens. Lepaskan kedua screws dan tail light lens.

TAIL LIGHT LENS

SCREWS Pull out the bulb bulb dari fromsocket. the socket. Tarik keluar Install the new bulb in the reverse order dari of removal. Pasang bulb baru dalam urutan terbalik pelepasan. • Use only the amber bulbs. • • For Hanya bulb kuning tua. tail pakai light unit removal/installation (page 19-8). • Untuk pelepasan/pemasangan tail light unit (hal. 19-8).

BRAKE/TAIL LIGHT BRAKE/TAIL LIGHT (LAMPU REM/BELAKANG)

BULB

PENGGANTIAN BULB BULB REPLACEMENT Remove the (page 19-7). Lepaskan tail tail lightlight lenslens (hal. 19-7). While menekan pushing the bulb turn itputar counterclockwise and Sambil bulb ke in, dalam, berlawanan arah remove it. arum jam dan lepaskan. Install the new bulb in the reverse order dari of removal. Pasang bulb baru dalam urutan terbalik pelepasan.

BRAKE/TAIL LIGHT BULB

19-7

LAMPU-LAMPU/METER-METER/SAKLAR-SAKLAR PELEPASAN/PEMASANGAN BRAKE/TAIL BRAKE/TAIL LIGHT UNIT REMOVAL/ LIGHT UNIT INSTALLATION Lepaskan sebagai berikut: Remove the following: - Body covers (hal. 3-8) Body covers (page 3-8) - – Dua bolts/washers – Two bolts/washers Tarik brake/tail light unit ke atas dan lepaskan Pull the brake/tail lightbosses unit upward release its gromgrommets-nya dari padaandrear fender dan mets from the bosses on the rear fender and frame. rangka. Disconnect the brake/tail light 6P connector. Lepaskan brake/tail 6P connector. Installation is in the light reverse order of removal. Pemasangan adalah dalam urutan terbalik dari pelepasan.

BOLTS/WASHERS GROMMETS

6P CONNECTOR

BRAKE/TAIL LIGHT UNIT

BOSSES

COMBINATION METER COMBINATION METER PENGGANTIAN BULB BULB REPLACEMENT Lepaskan handlebar front cover (hal. 3-10). Remove the handlebar front cover (page 3-10). Tarik keluar bulb socket dari combination meter Pull out the bulb socket from the combination meter assembly. assembly.bulb dari socket dan ganti dengan yang baru. Keluarkan Remove the bulb from the socket and replace it with a Pemasangan adalah dalam urutan terbalik dari new one. pelepasan. Installation is in the reverse order of removal.

BULB

BULB SOCKET

PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan handlebar rear cover (hal. 3-11). Remove the handlebar rear cover (page 3-11).

CONNECTORS

Disconnect the following: Lepaskan sebagai berikut: Dust cover and starter switch 2P (black) connector - –Dust cover dan starter switch 2P connector (hitam) – Lighting switch 3P (Red) and 3P connectors - –Lighting switch 3P (Merah) dan 3P connectors Dimmer switch 3P connector - Dimmer switch 3P connector

DUST COVER

19-8

LAMPU-LAMPU/METER-METER/SAKLAR-SAKLAR Lepaskan screws danand combination meter assembly. Remove the screws combination meter assembly. Install the removed parts in thedalam reverse orderterbalik of removal. Pasang parts yang dilepaskan urutan dari pelepasan.

COMBINATION METER

SCREWS

19-9

LAMPU-LAMPU/METER-METER/SAKLAR-SAKLAR DISASSEMBLY/ASSEMBLY PEMBONGKARAN/PERAKITAN • Be careful not to put fingerprints on the meter panel. Hati-hati meninggalkan sidik tabs jari diwhen atas • Be carefulagar not tidak to damage the retainer panel meter. removing the lens. • Hati-hati agar tidak merusak retainer tabs sewaktu • Route the combination meter sub harness properly. melepaskan lens. Remove the following: Alurkan combination meter subharness dengan • – Wire band screw/wire band benar. – Turn signal relay – Three terminal screws – Bulb sockets/combination Lepaskan sebagai berikut: meter sub harness – Lens - Wire screw/wire band – Twoband screws/washers - Turn signal relay – Combination meter panel Tiga terminal screws Assembly is in the reverse order of disassembly. - Bulb sockets/combination meter sub harness - Lens - Dua screws/washers - Combination meter panel Perakitan adalah dalam urutan terbalik dari pembongkaran. •

LENS COMBINATION METER PANEL

RETAINER TABS LOWER CASE

SCREWS/WASHERS COMBINATION METER SUB HARNESS

BULB SOCKET

Br, G

WIRE BAND

O, G

Lb, G

Bl, P Bl, W/Bu

WIRE BAND SCREW

TURN SIGNAL RELAY

TERMINAL SCREWS Bu, G

Bl, Bl/Bu

Bl, Lg/R

Bl, Y/R Bl Y/W

19-10

Bu/W


FUEL LEVEL SENSOR

REMOVAL PELEPASAN Unlock and open the seat using the ignition key. Disconnect fuel duduk level sensor 3Pkunci (Black) connector Buka kunci the tempat dengan kontak dan and release the harness from the clamp. angkat tempat duduk ke atas.

FUEL LEVEL SENSOR 3P CONNECTOR (Hitam)

Lepaskan fuel level sensor 3P connector (Hitam) dan lepaskan harness dari clamp.

CLAMP Turn the holder plate counterclockwise with ajam pairdengan of neePutar holder plate berlawanan arah jarum dle nose pliers and remove the fuel unit holder tang lancip dan lepaskan fuel unit holder plate. plate. Remove the fuel level sensor and the O-ring.

O-RING

Be careful not to Hati-hati agar tidak damage the float arm. Lepaskan fuel level sensor dan O-ring. merusak float arm.

HOLDER PLATE

FUEL LEVEL SENSOR

INSTALLATION PEMASANGAN Pasang O-ring baru pada fuel level sensor. Install the fuel sensor tofuel the fuel tank. new level O-ring to the level sensor. Hati-hati agar tidak Be careful not to Pasang fuel level sensor pada fuel tank. merusak float arm. damage the float arm.

O-RING

FUEL LEVEL SENSOR Set the holder plate as shown. Tempatkan holder plate seperti diperlihatkan. Turn the holder plate clockwise until the arrow marks on Putar holder plate searah jarum sampai tanda the holder plate and the fuel tank arejam aligned. panah pada holder plate dan fuel tank saling bertepatan.

TANDA "ARROW"

HOLDER PLATE

19-11

LAMPU-LAMPU/METER-METER/SAKLAR-SAKLAR Sambungkan fuellevel levelsensor sensor3P3P connector (Hitam) ke Connect the fuel (Black) connector to the fuellevel levelsensor. sensor. fuel Kokohkan dengan clamp. Secure thepemasangan harness withharness the clamp.


Close thetempat seat. duduk. Turunkan

CLAMP


Measure the resistance between the connector terminals with the float atantara upper connector (full) and lower (empty) positions. Ukur tahanan terminals dengan float (pelampung) (20°C/68°F) pada posisi atas (penuh) dan bawah (kosong). CONNECTION FLOAT POSITION FULL EMPTY POSISI FLOAT Blue/White - Green 400 – 700 Ω 25 – 45 Ω HUBUNGAN PENUH KOSONG Yellow/White – Green 25 – 45 Ω 400 – 700 Ω Biru/Putih – Hijau Ω 400 – 700 25 Yellow/White – Blue/ 450 – 750 Ω 450–– 45 750ΩΩ Kuning/Putih – Hijau 25 – 45 Ω 400 – 700 Ω White Kuning/Putih – 450 – 750 Ω 450 – 750 Ω Replace the fuel level sensor if it is out of specification. Biru/Putih

Ganti fuel level sensor jika tidak sesuai dengan spesifikasi.

19-12

G

Bu/W Y/W Penuh

FUEL LEVEL SENSOR

Kosong


FUEL METER METER (METER BAHAN BAKAR) FUEL PEMERIKSAAN METER CIRCUITRANGKAIAN INSPECTION LISTRIK METER FUEL METER DOES NOT MOVE

FUEL METER TIDAK BERGERAK • Before performing the system inspection, make sure that the following items are normal. • Sebelum menjalankan pemeriksaan sistem, –periksalah Battery condition bahwa bagian2 sebagai berikut adalah – Fuses normal: – Meter indicators - Kondisi baterai Unlock and open the seat using the ignition key. - Sekring-sekring Disconnect the fuel level sensor 3P (Black) connector - Meter indicators and release thelevel harness fromconnector the clamp.terminals of the Short the fuel sensor angan biarkan Buka kunci tempat duduk dengan menggunakan kunci wire harness side with the jumper wire. Do not leave the kontak terminal-terminal dan angkat tempat duduk ke atas. terminals connected CONNECTION:Yellow/White – Green tersambung dengan Lepaskan fuel level sensor 3P connector (Hitam) dan with thepenghubung jumper wire kawat lepaskan harness dari clamp. for a long time, as it Turn the ignition switch "ON" and check the fuel meter. untuk waktu lama, Hubungkan singkat fuel level sensor connector oleh karena hal causes damage toini the If the fuel meter gauge moves to the "F", it is normal. terminals dari sisi wire harness dengan kawat mengakibatkan fuel meter. • If the above inspection is normal, check the fuel level kerusakan pada fuel penghubung. sensor (page 19-12). meter. HUBUNGAN: Kuning/Putih – Hijau If the wire harness is normal, replace the combination meter assembly with a new one, recheck. Putar ignition switch ke "ON" dan and periksa fuel meter. Jika fuel meter gauge bergerak ke "F", maka ia nor mal.


CLAMP

Jika pemeriksaan di atas adalah normal, periksa fuel level sensor (hal. 19-12). Jika wire harness adalah normal, gantilah combination meter assembly dengan yang baru, dan periksa kembali. •

FUEL METER FUEL LEVEL SENSOR 3P CONNECTOR (Hitam) Dari

IGNITION SWITCH

SEKRING UTAMA 10 A

BI

Bu/ W Y/ W G

KAWAT PENGHUBUNG FUEL METER AT "F" FUEL METERSTAYS TETAP PADA "F"

Turn the ignition switch "OFF". Putar ignition switch ke "OFF". Remove the handlebar rear cover (page 3-11) and conLepaskan handlebar meter rear sub cover (hal. 3-11) dan nect the combination harness 9P/6P connecsambungkan combination meter sub harness 9P/6P tors. connectors. Disconnect the fuel level sensor 3P (Black) connector (page 19-11). Lepaskan fuel level sensor 3P connector (Hitam) (hal. 19-11). Check for continuity between the fuel level sensor conPeriksa kontinuitas fuelterminal. level sensor nector ofterhadap the wire harness sideantara and meter connector dari sisi wire harness dan meter terminal. CONNECTION:Blue/White – Blue/White

HUBUNGAN: Biru/Putih – there Biru/Putih • If there is no continuity, is open circuit in Blue/ White wire. FUEL METER If there is continuity, check the fuel level sensor • (page • Jika tidak ada kontinuitas, ada rangkaian terbuka 19-12). pada kawat Biru/Putih. fuelreplace level sensor (hal. • IfJika theada fuel kontinuitas, level sensorperiksa is normal, the combi19-12).meter assembly with a new one (page 19-8) nation IGNITION and Jikarecheck. fuel level sensor adalah normal, gantilah SWITCH combination meter assembly dengan yang baru Dari (hal. 19-8) dan periksa kembali. SEKRING UTAMA 10 A

FUEL METER TERMINAL (Biru/Putih)

Bu/ W Y/W G


19-13


IGNITIONSWITCH SWITCH(KUNCI KONTAK) IGNITION INSPECTION PEMERIKSAAN Remove the front cover (page 3-4). Lepaskan front toptop cover (hal. 3-4). Turn the ignition switch "OFF". Putar ignition switch ke "OFF". Disconnect the ignition switch 2P connector. Lepaskan ignition switch 2P connector. Check for continuity between the switch side of the conPeriksa terhadapin each kontinuitas antara sisi switch dari nector terminals switch position. Continuityterminals should exist between the color coded as connector pada masing-masing posisi wires switch. shown. Harus ada kontinuitas antara kawat-kawat dengan kode warna seperti diperlihatkan.


BAT BAT1 ON OFF LOCK COLOR

R

R/Bl

PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Remove the steering stem (page 13-22). Lepaskan steering stem (hal. 13-22). Disconnect the ignition 2P connector. Lepaskan ignition switchswitch 2P connector. Remove the two screws and ignition Lepaskan kedua screws dan ignition switch. switch. Installation is in the reverse order of removal. Pemasangan adalah dalam urutan terbalik pelepasan.

IGNITION SWITCH

dari

2P CONNECTOR

19-14

SCREWS


SWITCHES HANDLEBAR SWITCHES (SAKLAR STANG STIR) LEFT HANDLEBAR SWITCH Remove the handlebar front cover (page 3-10). LEFT HANDLEBAR SWITCH

DIMMER SWITCH 3P CONNECTOR

Turn the ignition switch "OFF". Lepaskan handlebar front cover 3-10). Disconnect the handlebar switch(hal. connectors. Putar ignition switch ke "OFF". the connector terminals in Check for continuity between each switch position.switch connectors. Lepaskan handlebar Continuity should exist between the color coded wire terPeriksa terhadap antara connector terminals minals as shown kontinuitas in the charts. pada masing-masing posisi switch. Harus ada kontinuitas antara terminals kawat dengan kode warna seperti diperlihatkan pada diagramdiagram.

HORN SWITCH 3P CONNECTOR (Hitam)

TURN SIGNAL SWITCH 3P CONNECTOR (Hitam) DIMMER SWITCH

TURN SIGNAL SWITCH

TURN SIGNAL SWITCH

DIMMER SWITCH HL

Lo

HORN SWITCH

Hi

WR

W

HORN SWITCH WL

Lo

R

FREE

(N)

N

PUSH

Hi

L

COLOR

COLOR Bu/R

W

Bu

COLOR

Lb

Gr

Ho

BAT

Lg

Bl

O

19-15

LAMPU-LAMPU/METER-METER/SAKLAR-SAKLAR RIGHT HANDLEBAR SWITCH RIGHT HANDLEBAR SWITCH Remove the handlebar front cover (page 3-10). Lepaskan (hal. 3-10). handlebar front cover

LIGHTING SWITCH

Turn the ignition switch "OFF". Putar ignition switch ke "OFF". Disconnect the handlebar connectors. Lepaskan handlebar switchswitch connectors. Check for continuity between the connector terminals in Periksa terhadap kontinuitas antara connector terminals each switch position. pada masing-masing posisi switch. Continuity should exist between the color coded wire terminals ada as shown in the charts. Harus kontinuitas antara wire terminals dengan kode warna seperti diperlihatkan pada tabel-tabel.

STARTER SWITCH LIGHTING SWITCH 3P CONNECTORS

STARTER SWITCH 2P CONNECTOR (Hitam)

LIGHTING SWITCH

STARTER SWITCH

HL

ST

C1

TL

BAT

FREE (N)

PUSH COLOR Y/R

(N)

COLOR Bu/R

Y

Br

BRAKE BRAKE LIGHT LIGHTSWITCH SWITCH DEPAN FRONT Lepaskan handlebar front cover (hal. 3-10). Remove the handlebar front cover (page 3-10). Disconnectfront the brake front brake light switch wire connectors Lepaskan light switch wire connectors dan and check for continuity between theswitch switchterminals. terminals. periksa terhadap kontinuitas antara There should be continuity with the brake lever squeezed and noada continuity with sewaktu the lever brake released. Harus kontinuitas lever (handel rem) ditarik dan tidak ada kontinuitas sewaktu lever dilepaskan.


19-16

Bl

LAMPU-LAMPU/METER-METER/SAKLAR-SAKLAR REAR BELAKANG Remove the right body cover (page 3-8). Lepaskan right body cover (hal. 3-8). Disconnect the rear brake light switch wire connectors. Lepaskan rear brake light switch wire connectors. Check for continuity between the switch side connector Periksa terhadap kontinuitas antara connector terminals terminals. pada sisi switch. There should be continuity with the brake pedal applied Harus kontinuitas sewaktu pedal (pedal rem) and noada continuity with the pedal brake released. ditekan dan tidak ada kontinuitas sewaktu pedal dilepaskan.

WIRE CONNECTORS

GEAR POSITION SWITCH GEAR POSITION SWITCH PEMERIKSAAN INSPECTION Putar switch ke ON, dan masukkan Turn ignition the ignition switch ON, and shift the transmission transmission ke dalam into eachmasing-masing gear position. posisi gigi. Check the operation of gear position neutral indicaPeriksa cara kerja gear position danand neutral indicator tor lights at each gear position. lights pada masing-masing posisi gigi. If all the indicator bulbs are normal but the gear position indicator does not light,bulbs checkadalah as follows: Jika semua indicator normal tetapi gear position indicator tidak menyala, periksalah sebagai berikut: :

NEUTRAL INDICATOR GEAR POSITION INDICATORS Remove the lower side cover (page 3-5). Lepaskan leftleft lower side cover (hal. 3-5).


Disconnect theposition gear position 6P (Black) connecLepaskan gear switchswitch 6P connector (Hitam). tor. Periksa terhadap kontinuitas antara terminals pada Check for continuity between the terminals at each gear masing-masing gear position. position. The gear position switch is normal if the continuity exist Gear position switch adalah normal jika ada kontinuitas between the color coded wires as shown in the chart. antara kawat-kawat dengan kode warna seperti diperlihatkan pada diagram.

GEAR

GROUND Lg/R

Y/R

Bl/Bu W/Bu

P

N 1 2 3 4

19-17

LAMPU-LAMPU/METER-METER/SAKLAR-SAKLAR REMOVAL PELEPASAN Remove the following: Lepaskan sebagai berikut: – Left lower side cover (page 3-5) - Left lower side cover (hal. 3-5) – Left crankcase rear cover (page 3-16) - Left crankcase rear cover (hal. 3-16) Disconnect the gear position switch 6P (Black) connecLepaskan gear position switch 6P connector (Hitam). tor. Lepaskan boltbolt danand gear position switch. Remove the gear position switch.


BOLT GEAR POSITION SWITCH

Lepaskan O-ring, contact dari Remove the O-ring, contactswitch switchcap cap dan and spring from the drum. shift drum. shift

CAP/SPRING

O-RING

PEMASANGAN INSTALLATION Pasang spring danand contact switch cap keinto dalam Install the spring contact switch cap the shift drum. drum.

SPRING

CAP

Semprotkan pada O-ring baru dan pasang Apply engineoli oil mesin to a new O-ring and install it to the gear position pada gearswitch. position switch. Pasang gear position switch pada crankcase. Install the gear position switch to the crankcase.

SHIFT DRUM

O-RING

GEAR POSITION SWITCH

19-18

LAMPU-LAMPU/METER-METER/SAKLAR-SAKLAR the wire Pasang Install and the bolt. Alurkan Route wire harness dantighten kencangkan bolt. dengan benar (hal. harness properly Connect thegear gearposition positionswitch switch6P 6Pconnector (Black) connector. Hubungkan (Hitam). (page1-14). 1-14).

BOLT


Install the following: Pasang sebagai berikut: – Left crankcase rear cover (page 3-16) - – Left crankcase rear cover (hal. 3-16) Left lower side cover (page 3-5) - Left lower side cover (hal. 3-5)

HORN HORN (KLAKSON) PEMERIKSAAN INSPECTION Lepaskan handlebar front cover (hal. 3-10). Remove the handlebar front cover (page 3-10). Lepaskan horn Disconnect thewire hornconnectors. wire connectors. Connect thebaterai 12 V battery the horn terminals. Hubungkan 12V ketohorn terminals. The horn is normal if it sounds when the 12 V battery is connected the horn terminals. Horn adalahtonormal jika ia berbunyi ketika baterai 12V dihubungkan pada horn terminals.

WIRE CONNECTORS

PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan handlebar front cover (hal. 3-10). Remove the handlebar front cover (page 3-10). Disconnect thewire hornconnectors. wire connectors. Lepaskan horn Remove the bolt/collar/damper rubbers and horn. Lepaskan bolt/collar/damper rubbers dan horn. Installation is in the reverse order of removal. Pemasangan adalah dalam urutan terbalik pelepasan.

WIRE CONNECTORS

dari

HORN

BOLT/COLLAR/RUBBERS

19-19


TURN SIGNAL SIGNAL RELAY RELAY TURN INSPECTION PEMERIKSAAN Check the following: Periksa sebagai berikut: – Battery condition - –Kondisi baterai Ignition switch and turn signal switch function - –Ignition dan fungsi turn signal switch Looseswitch connectors Sub fuse (7.5 A) - –Connectors longgar - IfSub fuse (sekring tambahan) (7,5 A) above items are all normal, check the following:

TURN SIGNAL RELAY

Remove thehal-hal handlebar rearadalah cover from the periksalah handlebar Jika semua di atas normal, and disconnect sebagai berikut: the horn wire connectors (page 3-11). Lepaskan rearrelay cover dari handlebar dan Disconnecthandlebar the turn signal 2P connector. lepaskan horn wire connectors (hal. 3-11).

Lepaskan turn signal relay 2P connector.

2P CONNECTOR

Hubungkan singkat Hitamofdan dari Short the Black and terminals Gray terminals the Abu-abu harness side connector with the jumper connector pada sisi wire. harness dengan kawat penghubung. Turn the ignition switch ON. Check the turn signal light by moving the turn signal switchignition to the switch right and Putar keleft. posisi ON. Periksa turn signal light dengan menggerakkan turn • If the turn signal light does not come on, there is open circuit in wire harness. signal switch ke kanan dan kiri. • If the lights come on, the circuit is normal. Replace the turn signal relay. Jika turn signal light tidak menyala, ada rangkaian • Install the removed parts in the reverse order of removal. terbuka pada wire harness. •

TURN SIGNAL RELAY 2P CONNECTOR

Dari SEKRING UTAMA 10 A

IGNITION SWITCH

O Bl

Gr Lb

G

Jika lights menyala, rangkaian adalah normal. Gantilah turn signal relay.

Pasang parts yang dilepaskan dalam urutan terbalik dari pelepasan.

TURN SIGNAL SWITCH

REMOVAL/INSTALLATION

Remove the handlebar rear cover from PELEPASAN/PEMASANGAN

the handlebar and disconnect the horn wire connectors (page 3-11). Lepaskan handlebar rear cover dari handlebar dan Disconnect the turn signal relay 2P connector. Remove horn the wire turn connectors signal relay from the combination lepaskan (hal. 3-11). meter. Lepaskan turn signal relay 2P connector. Installation is in the reverse order of removal. Lepaskan turn signal relay dari combination meter.


adalah

dalam

urutan

terbalik

TURN SIGNAL RELAY

dari

2P CONNECTOR

19-20

20. DIAGRAM LISTRIK

DIAGRAM LISTRIK

20-2

WIRING DIAGRAM······························· ········ 20-2

20

20-1

DIAGRAM LISTRIK

DIAGRAM LISTRIK WIRINGDIAGRAM

T H G I L L R A A N E G R I S W T N 0 H R 1 G U V I 2 R T 1

Y r G / G B

b G L

T H G I L L A R N A G E I R S W 0 T N 1 F R V E U 2 L T 1

T H G I L L W I A 5 / T W / E 8 K 1 A V R 2 B 1 G O

Y r b G / L G B O I N I M P 6 r b G Y L / G B O

Y A L E R R E T R A T S

N E E U E E L R N G B G N T T K Y G W N H A I O A H N R K G I G I R R I B O L L P G R A M r b g r / B O L L P G D N U O R G : W N K O E B E E T C L I M D A L U E H L E L R E O B Y B G R W C R O l u L B Y B G R W O C

P 5

W / R R / Y G R I N P I 2 M

R R

H Y A R . E 5 T 3 T V A 2 B 1

R / Y G

R E R T O R T A T O S M

R / Y G P 2

W / R G

G

W / R G

R

E N I S A A U 0 M F 1 l B / R

I N P I 3 M

I N P I l 6 M B

R l B / R l B

R l B / R l B

E B S A U 5 U . S F 7

H C E T K I A W R S B T R H A E G I R L

l B Y / G

R / g L R / Y u B / l B u B / W P

R / g L R / Y u B / l B u B / W P

Y

Y

l B Y / G

R O T A N R E T L A

P 2

D E N U M O A R R F G

G

G W

G W

Y / u B

Y / u B

P 4

/ R O T R E I A F L I U T C G E E R R L O R T ) N M O C I C ( N E L O I U T I D N O G I M

G W Y R

R O T N A O R I E E T S I L N N E U G I P G

P 3

Y / u B I N P I l 3 M B

G l B / R Y / l B

L E V E R L O L S E N E U F S

G W / Y W / u B

P 2

G

N O I T L I I N O G I C

H C T T A I B W S T R S E T R A T S

Y / l B

u u R l r / R / B / B P B Y B G g / L Y l B W

P 2

N H T A B O I T C T A B T I I 1 N W G I S

R l B / R

I N I M P 9

R l B / R

W Y b R W / / / / u G L O Y Y B I N I M P 6

u u R l r / / R / B / B P B Y B G g Y L l B W

E H C K T A I R W B T S T N H O G R I F L

W Y R / W / / b / u G L O Y Y B

Y / G l B

N R O H

G g L

R E H T S T C A B T T R I A T W S S

P l 3 B

P l 3 B

R / Y l B

O b L r G

P 3

1 C L H

Y R / u B

1 C L T

Y r B

H

o H C N T T A B R I

g L l B

P 3 R

H C T I W S G N I T H G I L

N O H I C T T R I I A S E O W G P S

1 N 2 3 4

P 3 R

r u B B G W I N I M

L H i H o L

R E H C M T I M I W D S

R / Y E E R F

H S U P

R O L O C

l B g L E E R F

H S U P

R O L O C

L W

O W L W H S A N R G W L I H S A C N L W N T I G R R W I H U W S C T S W N T I R W U T S

P 3

R / u B u B W

H T A C B T I o W H S N R O H

l B

O r G b L R

N

L

i H

H C o T I L W S L R H E M M I D

R O L O C

u B W

o L

) N (

i H

R / u B R O L O C

P 4 G b L

O G

r u B B G W

I N I M P 2 r l G B

G b L

u u l R r r R / l u G b G G O / l / l / l B B B B B P B g B B B G B G Y l L L B W

l B

W W / / u Y B

r B G

u B G W

l B I N I M P 2 r G B

O G

W P 2 L

T H G I L T L A N N O G R F I S W 0 T N 1 H R V G I U 2 R T 1

20-2

T S 1

L A N G I S N Y A R L U E T R

2 x W R T 7 . E 1 T H V E G I 2 M L 1

D N 2

D R 3

4 R x N O T W O A I . T C 7 R I I 1 A S D E O N V 2 G P I 1

H T 4

R

L

L A 2 N R x M R R L O A O G O A T W E T W I W S T 4 R A 7 B 7 A . . . N A T C C C 3 1 1 I H I U D R I V V V D G E N 2 I N 2 U D 2 N N I 1 H I 1 T I 1

R E T E M L E U F

T H G I L N W O I 4 . T I 3 S V O 2 P 1

T W 2 3 H / G I L W 2 D 3 A E V 2 H 1

T H G I L N W O I 4 . T I 3 S V O 2 P 1

T H G I L L T A N N G O I R S F W 0 1 T N F R V E U 2 L T 1

r B

L

H T C T I 1 W C S L G H N I T H G I L H C 1 T T I A W B S T N A B O I T I N G I

Y

) N (

) N (

l B / R R N O

F F O

K C O L

R O L O C

R / u B R O L O C

21. TROUBLESHOOTING

ENGINE DOES NOT START MESIN TIDAK MAU HIDUP ATAU

POOR PERFORMANCE

UNJUK KERJA LEMAH PADA

OR IS HARD TO START ·······························21-2

AT HIGH SPEED ············································21-6

ENGINE LACKS POWER ·····························21-3

POOR HANDLING ········································· 21-7

SULIT DIHIDUPKAN................................ 21-2 MESIN KEKURANGAN TENAGA .......... 21-3

KECEPATAN TINGGI ............................21-6 PENGENDALIAN BURUK ..................... 21-7

POOR PERFORMANCE

UNJUK KERJA LEMAH PADA GIGI

AT LOW AND IDLE SPEED ························· 21-5

SATU DAN PUTARAN STATIONER ....... 21-5

21

21-1

TROUBLESHOOTING

ENGINE DOESMAU NOTHIDUP STARTATAU OR ISSULIT HARDDIHIDUPKAN TO START MESIN TIDAK TROUBLESHOOTING

1. Fuel Line Inspection 1. Pemeriksaan Saluran Bahan Bakar

Check fuel flow bahan to carburetor. Periksa aliran bakar ke karburator. Does fuel bahan reach the carburetor? Apakah bakar mencapai karburator?

TO STEP 2. DENGAN LANGKAH 2. YES – G-OLANJUTKAN YA NO – • Clogged fuel line or strainer TIDAK Saluran bahan bakar atau strainer tersumbat. • Clogged fuel tank cap Fuel tank tersumbat. • Sticking floatcap valve macet Float valve • Clogged fuel filter tertahan •

• •

•

Fuel filter tersumbat

2. Spark Plug Inspection 2. Remove Pemeriksaan Busi and inspect spark plug. Lepaskan Is the sparkdan plugperiksa wet? busi.

Apakah basah? • Flooded carburetor YES – busi • valvebanjir open YA - Throttle Karburator • Dirty air cleaner Throttle valve terbuka terus 3. kotor NO – GO TO AirSTEP cleaner •

• •

3. Spark TIDAKTest - LANJUTKAN DENGAN LANGKAH 3.

spark test. 3. Perform Test percikan bunga api Busi Is there weak no spark? Jalankan testorpercikan bunga api busi. YES – • Faulty spark plug Apakah • percikan api lemah atau tidak ada? Fouled bunga spark plug • disconnected ignitionbaik system wires YA - Loose Busi or tidak bekerja dengan • Faulty ignition pulse generator Busi kotor • Faulty ignition coil Kawat2 sistem pengapian • Faulty ignition control module longgar (ICM) atau terlepas Ignition pulse generator tidak bekerja dengan baik STEP coil 4. tidak bekerja dengan baik NO – GO TO Ignition Ignition control module (ICM) tidak bekerja dengan baik 4. Cylinder Compression •

• • • • •

TIDAK - LANJUTKAN Test cylinder compression. DENGAN LANGKAH 4. the compression low? 4. Is Kompressi Cylinder

open YES • Valve stuck Periksa– kompressi cylinder. • Worn cylinder and piston rings Apakah • kompressi Damaged rendah? cylinder head gasket • Seized valve YA Valve macet terbuka • Improper valve timing rings aus Cylinder dan piston • Valve clearance too small Cylinder head gasket rusak STEP 5. NO – GO TO Valve macet Valve timing 5. Engine Starting Condition tidak benar Jarak renggang klep terlalu kecil Start by following normal procedure. TIDAK - LANJUTKAN DENGAN LANGKAH 5. Does the engine start then stops? 5. Kondisi Menghidupkan Mesin YES – • Improper choke operation Hidupkan • dengan prosedur normal. Incorrectly adjusted carburetor • Leaking carburetor insulator or inlet pipe Apakah mesin hidup kemudian mati lagi? • Improper ignition timing (Faulty ICM or ignition pulse generator) •- Contaminated fuel tidak benar YA Cara kerja choke Penyetelan karburator tidak benar Carburetor insulator atau inlet pipe bocor Ignition timing (waktu pengapian) tidak benar (ICM atau ignition pulse generator tidak bekerja dengan baik) Bahan bakar terkontaminasi •

• • • • •

•

• • •

•

21-2

TROUBLESHOOTING

ENGINE LACKS POWER MESIN KEKURANGAN TENAGA 1. Train Inspection 1. Drive Pemeriksaan Drive Train

Raise wheel off the ground anddan spinputar it by dengan hand. tangan. Naikkan roda lepas tanah Apakah rodaspin berputar Does the wheel freely?dengan bebas?

YA YES

- LANJUTKAN O TO STEP 2. DENGAN LANGKAH 2. – G

TIDAK– •- Brake Remdragging menyangkut NO • Worn or damaged bearings Wheel bearingswheel aus atau rusak •

•

2. Pressure Inspection 2. Tire Pemeriksaan Tekanan Udara Ban

Check tiretekanan pressure.udara ban. Periksa Are the tiretekanan pressuresudara low? ban rendah? Apakah

tireban valve – • - Faulty Ventil tidak bekerja dengan baik • Punctured tire Ban bocor NO – GO TO STEP 3. TIDAK - LANJUTKAN DENGAN LANGKAH 3. 3. Clutch Inspection 3. Pemeriksaan Clutch Accelerate rapidly from low to second. Berakselerasilah dengan cepat, oper gigi dari satu ke dua. Does the engine speed change accordingly when the gearshift pedal is applied? pedal ditekan? Apakah putaran mesin berubah sesuai dengannya ketika gearshift YES YA

•

•

YES YA

STEP 4. – GO-TO LANJUTKAN DENGAN LANGKAH 7.

NO TIDAK– • • • • • • • •

Clutch slipping Clutch (kopling) slip Worn clutch discs/plates Clutch discs/plates aus Warped clutch discs/plates Clutch discs/plates berubah bentuk melengkung Weak clutch spring Clutchinspring Additive enginelemah oil Ada additive di dalam oli mesin Faulty clutch weight Clutch weight tidak bekerja dengan baik Faulty clutch lining Clutchclutch liningadjustment tidak bekerja dengan baik Incorrect Penyetelan clutch tidak benar 4. Engine Performance Inspection 4. Pemeriksaan Unjuk Kerja Mesin Accelerate lightly. Berakselerasilah dengan ringan. Does the engine speed increase? Apakah putaran mesin naik? YES – GO TO STEP 5. Cara kerja choke tidak benar YA chokekotor operation NO – • Improper Air cleaner • Dirty air cleaner Aliran bahan bakar terbatasi • Restricted fuel flow Sistem pembuangan • Clogged exhaust system gas tersumbat Fuel tank • Clogged fuel cap tank tersumbat. cap •

• • •

•

• • •

• • • • •

TIDAK LANJUTKAN DENGAN LANGKAH 5. 5. Spark Plug- Inspection 5. Remove Pemeriksaan Spark Plug and inspect spark plug.(Busi) dan periksalah spark plug . IsLepaskan the spark plug fouled or discolored? Apakah plug kotor atau berubah warna? O TO STEP 6. YES – Gspark notkurang servicedmendapatkan frequently enough – • - Plugs Plugs perawatan • Incorrect spark plug heattidak rangetepat Derajat panas busi • Incorrect spark plug busi gap tidak tepat Jarak renggang TIDAKOil -Inspection LANJUTKAN DENGAN LANGKAH 6. 6. Engine NO YA

• • •

6. Check Pemeriksaan Olicondition. Mesin oil level and tinggilevel permukaan dan kondisinya. IsPeriksa there correct and goodolicondition? Apakah permukaan oli mesin benar dan oli dalam kondisi baik? O TO STEP 7. YES – Gtinggi NO YA

level too highDENGAN LANGKAH 7. – • Oil - LANJUTKAN • Oil level too low TIDAK •- Contaminated Tinggi permukaan oli terlalu tinggi oil Tinggi permukaan oli terlalu rendah Oli terkontaminasi •

• •

21-3

TROUBLESHOOTING 7. Ignition TimingIgnition Inspection 7) Pemeriksaan Timing (Waktu Pengapian)

Check ignition timing. Periksalah ignition timing. Is the ignition timing correct? Apakah ignition timing sesuai dengan ketentuan? TO STEP 8. DENGAN LANGKAH 8. YES – G YA -O LANJUTKAN

ignition control module (ICM) NO TIDAK – • - Faulty Ignition control module (ICM) tidak bekerja dengan baik • Faulty ignition pulse generator Ignition pulse generator tidak bekerja dengan baik 8. Cylinder Compression Inspection 8) Pemeriksaan Kompressi Cylinder Test cylinder compression. Jalankan test kompressi cylinder . Is the compression low? Apakah kompressi rendah? YES – • Valve clearance too small YA - • Valve Jarakstuck renggang open klep terlalu kecil Valve macetand terbuka • Worn cylinder piston rings • Damaged headrings gasket Cylindercylinder dan piston aus • Improper Cylindervalve headtiming gasket rusak • Seized Valvevalve timing tidak benar Valve macet 9. NO – GO TO STEP •

•

•

• • • • •

TIDAK - LANJUTKAN 9. Carburetor Inspection DENGAN LANGKAH 9. 9)

Pemeriksaan Karburator Check carburetor for clogging. Is the carburetor forterhadap clogged? sumbatan. Periksa karburator

serviced frequently enough YES – karburator Carburetor not Apakah tersumbat? NO YA

TO STEP 10. – GO - Karburator kurang mendapatkan perawatan

10. Lubrication Inspection TIDAK - LANJUTKAN DENGAN LANGKAH 10.

cylinderPelumasan head cover and inspect lubrication. 10) Remove Pemeriksaan Is the valvecylinder train lubricated properly? Lepaskan head cover dan periksalah pelumasan.

STEP 11. YES – valve GO TOtrain Apakah (peralatan penggerak klep) mendapatkan pelumasan memadai? Clogged oil passage NO – • YA - LANJUTKAN DENGAN LANGKAH 11 • Clogged oil orifice TIDAK • - Oil Jalan lintasan tersumbat strainer screenolinot serviced frequently enough • Oil filter not serviced frequently enough Oilcentrifugal orifice (lubang lintas oli) tersumbat Oil strainer screen kurang mendapatkan perawatan 11. Overheating Inspection Oil centrifugal filter kurang mendapatkan perawatan. Check for engine overheating. 11) Pemeriksaan Over Heating Is the engine overheating? Periksa mesin terhadap over heating (panas berlebihan). YES – • Excessive carbon build-up in combustion chamber Apakah mesin heating? • Use over of poor quality fuel • Wrong type of fuel YA Ada pembentukan karbon secara berlebihan di ruang pembakaran •- Clutch slipping Pemakaian bahan bakar dengan kualitas buruk • Lean fuel mixture Pemilihan jenis bahan bakar salah STEP 12. NO – GO TO Clutch slip Campuran bahan bakar terlalu miskin 12. Engine Knocking Inspection •

• • •

•

• • • •

Accelerate run at high speed. TIDAK - or LANJUTKAN DENGAN LANGKAH 12. there knocking? 12) Is Pemeriksaan Engine Knocking (mesin mengelitik)

piston and cylinder YES – • Wornatau Berakselerasilah jalankan pada kecepatan tinggi. • Wrong type of fuel Apakah ada knocking? • Excessive carbon build-up in combustion chamber • Ignition timing too advance YA Piston dan cylinder aus (Faulty ICM or ignition pulse generator) • Lean fuel mixture. Pemilihan jenis bahan bakar salah Ada pembentukan karbon secara berlebihan di ruang pembakaran Ignition timing terlalu maju (ICM atau ignition pulse generator tidak bekerja dengan baik) Campuran bahan bakar terlalu miskin •

• • •

•

21-4

TROUBLESHOOTING

POOR PERFORMANCE AT LOW AND IDLE SPEED UNJUK KERJA BURUK PADA GIGI SATU 1. Idle Adjustment Inspection DAN PUTARAN STASIONER Check the idle speed. Pemeriksaan Penyetelan Putaran Stasioner Is the idle speed correct? Periksa putaran stasioner. YES – GO TO STEP 2. Apakah putaran stas ioner benar? NO – Adjust the idle speed YA - L ANJUTKAN DENGAN LANGKAH 2. 2. Intake Air Leak Inspection TIDAK Setel carburetor putaran stasioner Check for -leaking insulator and inlet pipe.

1.

2. Is Pemeriksaan there leaking?Kebocoran Udara Masuk Periksa kebocoran insulator pada carburetor insulator dan inlet pipe. YES – terhadap • Damaged O-ring Apakah • adaFaulty kebocoran? • Loose inlet pipe YA Insulator rusak NO – GO TO STEP 3. O-ring tidak bekerja dengan baik 3. Spark Test Inlet pipe longgar •

• •

Perform test. TIDAK spark - L ANJUTKAN DENGAN LANGKAH 3. there weak or intermittent spark? 3. Is Test Busi Faulty YES – •test Jalankan busi.spark plug • Fouled spark plug Apakah • percikan api lemah atau tidakwires teratur? Loose orbunga disconnected ignition system • Faulty ignition coil YA Busi tidak bekerja dengan baik • Faulty ignition control module (ICM) Busi kotor STEP 4. NO – GO TO Kawat-kawat ignition system longgar a tau terlepas Ignition coil tidak bekerja dengan baik 4. Ignition Timing Inspection Ign ition control module (ICM) tidak bekerja dengan baik Check ignition timing. TIDAK - L ANJUTKAN DENGAN LANGKAH 4. Is the ignition timing correct? 4. Pemeriksaan Ignition Timing YES – GO TO STEP 5. Periksa ignition timing. NO – • Faulty ignition control module (ICM) Faultytiming ignitionbenar? pulse generator Apakah •ignition •

• • • •

5. Air YAScrew- Inspection L ANJUTKAN DENGAN LANGKAH 5.

Check carburetor airition screw adjustment. TIDAK Ign control module (ICM) tidak bekerja dengan baik Ignition pulse generator tidak bekerja dengan baik Is the adjustment correct? • •

5. NO Pemeriksaan Air6-15 Screw – See page Periksa penyetelan carburetor air screw. Apakah penyetelan benar? TIDAK - Lihat hal. 6-15

21-5

TROUBLESHOOTING

POOR PERFORMANCE AT HIGH SPEED UNJUK KERJA BURUK PADA KECEPATAN TINGGI 1. Fuel Line Inspection 1. Pemeriksaan Saluran Bahan Bakar Disconnect fuel line at carburetor. Lepaskan saluran bahan bakar pada karburator. Does fuel flow freely? Apakah bahan bakar mengalir dengan bebas? YES – GO TO STEP 2. YA - LANJUTKAN DENGAN LANGKAH 2. NO – • Restricted fuel line and strainer TIDAK •- Restricted Saluran fuel bahan tankbakar cap dan strainer terbatasi Fuel tank cap terbatasi • Restricted fuel filter Fuel filter terbatasi 2. Spark Plug Inspection 2. Pemeriksaan Busi Remove and inspect the spark plug. Lepaskan dan periksa busi. In the spark plug in good condition? Apakah kondisi baik? O TOdalam STEP 3. YES – Gbusi •

• •

YA NO

– • TIDAK • • • •

LANJUTKAN DENGAN Plug not serviced frequentlyLANGKAH enough 3. Incorrect spark plug heat range perawatan Busi kurang mendapatkan Incorrect spark plug gap Derajat panas busi tidak benar Air cleaner dirty Jarak renggang busi tidak benar Improper choke operation Air cleaner kotor 3. Carburetor Inspection Cara kerja choke tidak benar •

• • • •

carburetor Karburator for clogging. 3. Check Pemeriksaan IsPeriksa the carburetor apakahclogged? karburator tersumbat. arburetor nottersumbat? serviced frequently enough YES – Ckarburator Apakah NO – GO TO STEP 4. YA - Karburator kurang mendapatkan perawatan 4. Ignition Timing Inspection TIDAK - LANJUTKAN DENGAN LANGKAH 4. Check ignition timing. 4. Pemeriksaan Ignition Timing Is the ignition timing correct? Periksa ignition timing. YES – GO TO STEP 5. Apakah ignition timing benar? NO – • Faulty ignition control module (ICM) YA LANJUTKAN DENGAN LANGKAH 5. • - Faulty ignition pulse generator

TIDAK - Inspection Ignition control module (ICM) tidak bekerja dengan baik 5. Valve Timing Ignition pulse generator tidak bekerja dengan baik Check valve timing. 5. Pemeriksaan Valve Timing Is the valve timing correct? Periksa valve timing. YES – GO TO STEP 6. Apakah valve timing benar? NO – Cam sprocket not installed properly YA Spring - LANJUTKAN DENGAN LANGKAH 6. 6. Valve Inspection •

•

TIDAK - springs. Cam sprocket tidak terpasang dengan baik Check valve 6. Is Pemeriksaan Valve Springwithin specification? the valve spring free length Periksa valve O TOsprings. STEP 7. YES – G Apakah panjang valvebebas springvalve spring sesuai dengan spesifikasi? NO – Faulty YA - LANJUTKAN DENGAN LANGKAH 7. 7. Camshaft Inspection TIDAKand - inspect Valve spring tidak bekerja dengan baik. Remove the camshaft. 7. IsPemeriksaan Camshaft the cam lobe height within specification? NO – Faulty Lepaskan dancamshaft periksa camshaft.

Apakah tinggi cam lobe sesuai dengan spesifikasi? TIDAK - Camshaft tidak bekerja dengan baik

21-6

TROUBLESHOOTING

POOR HANDLINGBURUK PENGENDALIAN Steering is heavyberat Kemudi terasa • Steering top thread too tight Steering top thread terlalu kencang • Damaged steering head bearings Steering head bearings rusak • Low tire pressure Tekanan udara ban kurang Either wheel is wobbling • Excessive wheel bearing play Salah satu roda bergoyang • Bent rim Ada kelonggaran berlebihan pada wheel bearing • Excessively worn swingarm pivot bushings Rim (pelek) bengkok • Bent frame Swingarm pivot bushings aus secara berlebihan Motorcycle to one side Rangkapulled bengkok • Front and rear wheels not aligned • Bent fork menarik ke satu sisi Sepedamotor • Bent swingarm Roda depan dan belakang tidak sebidang • Bent Forkaxle bengkok • Bent frame bengkok Swingarm • Axle alignment (chain adjustment not equal on both sides) Axle bengkok Rangka bengkok Penyetelan axle (penyetelan rantai tidak sama pada kedua sisi) • • •

• • • •

• • • • • •

21-7

Buku Pedoman Reparasi Blade

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