Anda di halaman 1dari 317

DAFTAR ISI

CARA MEMAKAI BUKU INI


KETERANGAN UMUM 1
Buku Pedoman Reparasi ini menguraikan prosedur servis RANGKA / BODY PANELS
untuk skuter HONDA BEAT. / SISTEM PEMBUANGAN GAS 2
Ikuti petunjuk pada Jadwal Perawatan (Bab 3) untuk mem-
pertahankan skuter pada kondisi operasional puncak. PERAWATAN 3
Adalah sangat penting untuk menjalankan perawatan
berkala 1 dan 2 pada waktunya. Servis ini mengadakan MESIN & PERALATAN PENGGERAK
SISTEM PELUMASAN 4
penyesuaian terhadap keausan awal yang terjadi dalam
masa pemakaian mula. SISTEM BAHAN BAKAR 5
Bab 1 dan 3 berlaku untuk skuter secara keseluruhan.
Bab 2 menggambarkan prosedur untuk pelepasan/pema- PENURUNAN / PEMASANGAN MESIN 6
sangan komponen yang mungkin diperlukan untuk men-
jalankan servis yang diuraikan pada bab-bab berikutnya.
CYLINDER HEAD/VALVES/CYLINDER/PISTON 7
Bab 4 sampai dengan 17 menguraikan bagian-bagian
skuter yang dikelompokkan menurut lokasi.
KICKSTARTER / DRIVE PULLEY /
Carilah bab yang Anda inginkan pada halaman ini, kemu- DRIVEN PULLEY / CLUTCH 8
dian bacalah daftar isi pada halaman pertama dari bab
itu.
FINAL REDUCTION 9
Kebanyakan bab dimulai dengan gambar susunan atau
gambar sistem, keterangan servis dan cara mencari
penyebab kesukaran untuk bab itu. Halaman-halaman
CRANKCASE / CRANKSHAFT 10
berikutnya memberikan prosedur servis secara mendetil.
RODA DEPAN / SUSPENSI / KEMUDI 11
Jika Anda tidak mengetahui sumber penyebab kesukaran,
RANGKA

bacalah bab 19, TROUBLESHOOTING.


RODA BELAKANG / SUSPENSI 12
SISTEM REM 13
Semua keterangan, gambar, petunjuk dan spesifi- BATERAI / SISTEM PENGISIAN / ALTERNATOR 14
kasi di dalam publikasi ini berdasarkan data-data
produk terakhir yang tersedia pada waktu persi-
SISTEM PENGAPIAN 15
KELISTRIKAN

apan untuk pencetakan.

PT Astra Honda Motor berhak membuat perubahan


pada setiap waktu tanpa pemberitahuan dan tanpa
SISTEM STARTER LISTRIK 16
ikatan apapun.

Dilarang mengutip atau mencetak ulang bagian dari


LAMPU / METER / SAKLAR-SAKLAR 17
penerbitan ini tanpa ijin tertulis penerbit.
DIAGRAM LISTRIK 18
Buku Pedoman ini ditulis untuk orang yang te-
lah memiliki pengetahuan dasar perawatan skuter
Honda. TROUBLE SHOOTING 19
PT ASTRA HONDA MOTOR
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. 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 bahwa peringatan-peringatan ini tidak dapat meliputi semua cara-cara pelak-
sanaan servis, baik yang dianjurkan oleh Honda maupun yang tidak, ataupun akibat-akibat yang
mungkin berbahaya yang timbul dari setiap cara pelaksanaan servis, juga bahwa Honda tidak
dapat menyelidiki semua cara - cara tersebut.

Setiap orang yang menggunakan prosedur kerja ataupun tool, balk yang dianjurkan oleh Honda
maupun tidak, harus meyakinkan dirinya sendiri dengan pasti bahwa keamanan pribadi maupun
keamanan kendaraan tidak terancam oleh cara pelaksanaan servis ataupun tool yang dipilih.
1. KETERANGAN UMUM

SPESIFIKASI RODA BELAKANG/


PERATURAN SERVIS
SERVICE RULES ...................................
?????????????????????? 1-21-2 SUSPENSI
REAR .................................................. 1-7
WHEEL/SUSPENSION
SPECIFICATIONS ????????????????????? 1-7
IDENTIFIKASI MODEL ..................................
MODEL IDENTIFICATION ????????????? 1-21-2 SPESIFIKASI SISTEM REM ....................... 1-7
BRAKE SYSTEM SPECIFICATIONS ????? 1-7
SPESIFIKASI UMUM .....................................
GENERAL SPECIFICATIONS??????????? 1-41-4 SPESIFIKASI BATERAI/SISTEM
PENGISIAN/ALTERNATOR
BATTERY/CHARGING ....................... 1-8
SYSTEM/
SPESIFIKASI SISTEM
LUBRICATION PELUMASAN ........... 1-5
SYSTEM ALTERNATOR SPECIFICATIONS ?????? 1-8
SPECIFICATIONS ????????????????????? 1-5 SPESIFIKASI SISTEM PENGAPIAN.......... 1-8
SPESIFIKASI SISTEM BAHAN BAKAR ....... 1-5 IGNITION SYSTEM SPECIFICATIONS ?? 1-8
FUEL SYSTEM SPECIFICATIONS??????? 1-5 SPESIFIKASI SISTEM STARTER
SPESIFIKASI CYLINDER HEAD/VALVES.... 1-5 LISTRIK.......................................................
ELECTRIC STARTER SYSTEM 1-8
CYLINDER HEAD/VALVES SPECIFICATION ?????????????????????? 1-8
SPECIFICATIONS
SPESIFIKASI ????????????????????? 1-51-6
CYLINDER/PISTON................ SPESIFIKASI LAMPU/METER/
LIGHTS/METERS/SWITCHES
SAKLAR...................................................... 1-8
SPESIFIKASI KICKSTARTER/DRIVE
CYLINDER/PISTON SPECIFICATIONS ?? 1-6 SPECIFICATION ?????????????????????? 1-8
PULLEY/DRIVEN PULLEY/CLUTCH ............ 1-6 NILAI TORSI STANDARD .......................... 1-9
KICKSTARTER/DRIVE PULLEY/DRIVEN STANDARD TORQUE VALUES ????????? 1-9
PULLEY/CLUTCH
SPESIFIKASI FINAL SPECIFICATIONS ??? 1-61-6
REDUCTION................ NILAI TORSI MESIN & RANGKA............... 1-9
ENGINE & FRAME TORQUE VALUES ?? 1-9
FINAL REDUCTION
SPESIFIKASI CRANKCASE/SPECIFICATIONS?? 1-6 TITIK-TITIK PELUMASAN &
CRANKSHAFT............................................... 1-6 LUBRICATION & SEAL POINTS ??????? 1-121-12
PERAPATAN ............................................
CRANKCASE/CRANKSHAFT
SPECIFICATIONS
SPESIFIKASI RODA?????????????????????
DEPAN/ 1-6 CABLE & HARNESS
PERLETAKAN ROUTING
KABEL ???????? 1-141-14
& HARNESS.......
SUSPENSI/ KEMUDI ..................................... 1-7
FRONT WHEEL/SUSPENSION/STEERING SISTEM-SISTEM
EMISSION PENGATURAN
CONTROL EMISI..
SYSTEMS??????? 1-241-24
SPECIFICATIONS ????????????????????? 1-7

1-1
KETERANGAN UMUM
SERVICE RULES
PERATURAN SERVIS
GENERAL INFORMATION

1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that don’t meet Honda’s design specifications
1. Pakailah
may parts dan
cause damage pelumas
to the scooter.asli Honda atau yang direkomendasikan oleh Honda atau sejenisnya. Parts yang tidak memenuhi
2. spesifikasi
Use the specialrancangan Honda
tools designed for dapat mengakibatkan
this product kerusakan
to avoid damage pada skuter.
and incorrect assembly.
2.
3. Pakailah
Use special
only metric tools
tools when yang telah the
servicing dirancang
scooter. untuk
Metricproduk ini untuk
bolts, nuts menghindari
and screws kerusakan dan
are not interchangeable kesalahan
with pada pemasangan.
English fasteners.
4.
3. Install
Hanya new gaskets, O-rings,
pergunakan metriccotter
toolspins, and lock
ketika plates when
menservis reassembling.
skuter. Baut, mur dan sekrup metric tidak dapat dipertukarkan dengan
5. When tighteningsistem
pengencang bolts or nuts, begin with the larger diameter or inner bolt first. Then tighten to the specified torque diagonally in incremental
Inggris.
4. steps unless agasket,
Pasanglah particular sequence
O-ring, is specified.
cotter pin, dan lock plates baru ketika perakitan kembali.
6.
5. Clean
Ketika parts in cleaning solvent
mengencangkan bautupon
ataudisassembly. Lubricate
mur, mulailah any sliding
dengan surfacesdiameter
baut dengan before reassembly.
yang lebih besar atau baut di sebelah dalam
7. After
dulu.reassembly,
Kemudiancheck all parts for
kencangkan proper installation
dengan and operation.
torsi pengencangan yang telah ditentukan secara bersilang dalam langkah-langkah
8. Route all electrical
peningkatan wiresbila
kecuali as shown from page 1-14,
telah ditentukan urutanCable and Harness Routing.
tertentu.
6. Bersihkan parts yang telah dilepaskan dalam larutan pembersih. Lumasi semua permukaan luncur sebelum perakitan kembali.
7. Setelah perakitan kembali, periksalah semua bagian terhadap pemasangan dan pengoperasian yang benar.
MODEL IDENTIFICATION
8. Alurkan semua kawat listrik seperti diperlihatkan mulai halaman 1-14, Perletakan Kabel dan Harness.

IDENTIFIKASI MODEL

1-2
KETERANGAN UMUM
The frame
Nomor serial
seri numberdicetak
rangka is stamped on the
pada seatstay
seat stay as(penahan
shown. sadel) seperti
NOMOR SERI RANGKA
diperlihatkan.

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

NOMOR SERI MESIN

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

1-3
KETERANGAN UMUM
GENERAL SPECIFICATIONS
SPESIFIKASI UMUM
BAGIAN SPESIFIKASI
ITEM SPECIFICATIONS
DIMENSI Panjang menyeluruh 1.859 mm
DIMENSIONS Overall length 1,850 mm (72.8 in)
Lebar menyeluruh 676 mm
Overall width 676 mm (26.6 in)
Tinggi menyeluruh 1.053 mm
Overall
Jarak heightroda
sumbu 1.240 mm 1,040 mm (40.9 in)
Wheelbase
Tinggi tempat duduk 737 mm 1,240 mm (48.8 in)
Seat height
Tinggi pijakan kaki 260 mm 737 mm (29.0 in)
Footpeg
Jarak height ke tanah
terendah 135 mm 260 mm (10.2 in)
Ground
Berat clearance
motor siap pakai 89,2 kg 135 mm (5.3 in)
RANGKA Curb weight
Jenis rangka 89.2 (tulang
Jenis under bone kg (196.7 lbs)
bawah)
FRAME Frame typedepan
Suspensi Under bone type
Garpu teleskopik
Jarak
Front pergerakan
suspension poros depan 80,5 mm Telescopic fork
Suspensi
Front axlebelakang
travel Unit swing (unit berayun)
80.5 mm (3.17 in)
Jarak pergerakan poros belakang
Rear suspension 75,0 mm Unit swing
Ukuran
Rear axleban depan
travel 80/90-14M/C 4075.0 mm (2.95 in)
Ukuran ban
Front tire size belakang 90/90-14M/C 46P
80/90 - 14M/C40P
Merek ban
Rear tire size (Depan/Belakang) SRI FT235 90/90 - 14M/C46P
Rem depan
Tire brand SRI Rem cakram hidraulik
(Front/Rear) FT235
Rem belakang Mekanis, mendahului-mengikuti
Front brake Hydraulic disc brake
Sudut caster 26° 30′
Rear brake Mechanical leading trailing
Panjang trail 79,0 mm
Caster angle 26°30’
Kapasitas tangki bahan bakar 3,3 liter
Trail length 79.0 mm (3.11 in)
MESIN Diameter dan langkah 50,0 x 55,0 mm
Fuel tank capacity
Volume langkah 108,0 cm
3 3.3 liter (0.87 US gal, 0.73 lmp gal)
ENGINE Bore and strokekompressi
Perbandingan 9,2 : 1 50.0 x 55.0 mm (1.97 x 2.17 in)
Displacement
Peralatan penggerak klep 2 klep, SOHC108.0 cm3 (6.59
digerakkan cu-in)
rantai tunggal
Compression ratio
Klep masuk membuka ] pada peng- 9.5 : 1
10° BTDC (sebelum TMA)
Valve train menutup ] angkatan 2 valve,
35° ABDC (setelah single chain driven SOHC
TMB)
Intake
Klep valve membukaopens
buang ] 1 mm at 1 mm (0.04 in)
25°lift 10° BTDC
BBDC (sebelum TMB)
menutup closes
] at 1 mm (0.04 in)
0° lift 35° ABDC
ATDC (setelah TMA)
Sistem
Exhaustpelumasan
valve opens at 1 mm (0.04 in)
Di bawah tekananBBDC
lift 25° paksaan dgn bak oli basah
Jenis pompa oli closes at 1 mm (0.04 in) lift
Trochoid 0° ATDC
Sistem pendinginan
Lubrication system Forceddengan
Pendinginan udara pressurepaksaan
and wet sump
Saringan
Oil pump udara
type Trochoid
Saringan kertas
Berat
Coolingkosong
systemmesin 24,9 kg Forced air cooled
KARBURATOR Jenis karburator
Air filtration CV (constant velocity)
Viscous paper element
Diameter
Engine drythrottle
weight 22 mm atau ekuivalennya
24.9 kg (54.9 lbs)
PERALATAN
CARBURETOR Sistem kopeling
Carburetor type Kopeling kering,
CVjenis sentrifugal
(constant velocity)otomatis
PENGGERAK Throttle bore 2,68 : 1 - 0,85
22: mm
1 (0.9 in) or equivalent
DRIVE TRAIN Perbandingan
Clutch system drive belt (sabuk penggerak) Dry, automatic centrifugal clutch
Reduksi
Drive beltakhir
ratio 10,625 (51/182.68
x 45/12)
: 1 - 0.85 : 1
KELISTRIKAN Sistem pengapian
Final reduction DC – CDI 10.625 (51/18 x 45/12)
ELECTRICAL Sistem
Ignitionstarter
system Kickstarter dan motor starter listrik
DC-CDI
Sistem pengisian Alternator dengan output fase tunggal
Starting system Kickstarter with electric starter motor
Regulator/rectifier Fase tunggal/dibuka oleh SCR, pembetulan setengah
Charging system Single phase output alternator
gelombang
Regulator/rectifier
Sistem penerangan Alternator SCR shorted/single phase, half wave rectification
Lighting system Alternator

1-4
KETERANGAN UMUM
LUBRICATION SYSTEM
SPESIFIKASI SISTEM SPECIFICATIONS
PELUMASAN Satuan: mm
BAGIAN STANDARD BATAS SERVIS Unit: mm (in)
Kapasitas oli Pada penggantian oli 0,7 liter - SERVICE
mesin ITEM
Pada pembongkaran mesin 0,8 liter STANDARD - LIMIT
Oli mesin
Engine oil yang dianjurkan
capacity After drainingFederal Oil0.7
Supreme
liter (0.7Flick atau
US qt, 0.6oli
lmp qt) –
mesin 4 tak0.8
After disassembly sejenis dengan
liter (0.8 US qt,klasifikasi
0.7 lmp qt) - –
Recommended engine oil API serviceHonda
SG, "4-stroke motorcycle oil" or equivalent
Viskositas: motor
SAE 10W-30
oil JASO MB
Rotor pompa Jarak renggang pada ujung 0,15 API service classification: SG or0,20
higher
oli rotor (except oils labeled as energy conserving on –
Jarak renggang antara rotor 0,15 – 0,21the circular API service label) 0,35
dan rumah JASO T 903 standard: MB
Jarak renggang ke samping 0,05 – 0,10Viscosity: SAE 10W-30 0,12
Oil pump rotor rotor pompa Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014)
Side clearance 0.05 – 0.10 (0.002 – 0.004) 0.12 (0.005)

SPESIFIKASI SISTEM BAHAN BAKAR


FUEL SYSTEMBAGIAN
SPECIFICATIONS SPESIFIKASI
Nomor identifikasi karburator AVK2CH
Main jet ITEM # 100
SPECIFICATIONS
Slow jet identification number
Carburetor # 35
AVK2CH
Tahanan
Main jet listrik SE thermal valve Ω (20°C)
3,2 – 5,6 #100
Float level (tinggi permukaan pelampung)
Slow jet 13,0 #35
mm
Pembukaan
SE thermal valveawalresistance
pilot screw Lihat
3.2 – halaman 5-20
5.6 Ω (25°C/77°F)
–1
Putaran stasioner
Float level 1.700 ±13.0
100mmmenit (rpm)
(0.51 in)
Vakuum yang
Pilot screw ditentukan
initial opening untuk PAIR control valve 60 kPa (450 mmHg)
See page 5-20
Jarak
Engine idle speed putaran gas tangan
main bebas 1,7002 ±
–6 mm
100 min-1 (rpm)
PAIR control valve specified vacuum 60 kPa (450 mmHg)
Throttle grip free play 2 – 6 mm (0.1 – 0.2 in)

SPESIFIKASI CYLINDER HEAD/VALVES Satuan: mm


CYLINDER HEAD/VALVES
BAGIAN SPECIFICATIONS
STANDARD BAGIAN
Kompressi cylinder 1314 kPa (13,4 kgf/cm2, 191 -
Unit: mm (in)
psi) pada 520 min-1(rpm)
Perubahan bentuk melengkung SERVICE
ITEMpada cylinder head -
STANDARD 0,05
LIMIT
Rocker arm D.D. rocker arm IN/EX 10,000 – 10,015 2 10,04
Cylinder compression 1314 kPa (13.4 kgf/cm , 191 psi) at 520 min-1
(masuk/ –
(rpm)
buang)
Cylinder head warpage – 0.05 (0.002)
D.L. rocker arm shaft IN/EX 9,972 – 9,987 9,91
Rocker arm Rocker arm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.04 (0.395)
Jarak renggang arm ke shaft IN/EX 0,013 – 0,043 0,08
Camshaft Rocker
Tinggi arm shaft
cam lobe O.D.
(bubungan) IN/EX
IN 9.972 – 9.987
32,4006 – (0.3926
32,6406– 0.3932) 32,37 9.91 (0.390)
Arm to shaft clearance IN/EX
EX 0.013 – 0.043
32,0064 – (0.0005
32,2464– 0.0017) 31,97 0.08 (0.003)
Camshaft ValveCam lobe height IN IN 32.4006 – 32.6406 (1.27561 – 1.28506) 32.37 (1.274)
Valve, clearance (jarak renggang 0,14 ± 0,02 -
valve guide klep) EXEX 32.0064 – 32.2464 (1.26009 – 1.26954) 31.97 (1.259)
0,14 ± 0,02 -
Valve, valve Valve clearance IN 0.14 ± 0.02 (0.006 ± 0.001) –
D.L. valve stem IN 4,975 – 4,990 4,90
guide EX 0.14 ± 0.02 (0.006 ± 0.001) –
EX 4,955 – 4,970 4,90
Valve stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1965) 4.90 (0.193)
D.D. valve guide IN/EX 5,000 – 5,012 5,03
EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193)
Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.03 (0.198)
Jarak renggang stem-ke-guide IN 0,010 – 0,037 0,08
Stem-to-guide clearance IN 0.010 – 0.037 (0.0004 – 0.0015) 0.08 (0.003)
EX 0,030 – 0,057 0,10
EX 0.030 – 0.057 (0.0012 – 0.0022) 0.10 (0.004)
Proyeksi valve guide di atas IN/EX 9,1 – 9,3 -
Valve guide projection above IN/EX 9.1 – 9.3 (0.36 – 0.37) –
cylinder head
cylinder head
Lebar valve seat IN/EX 1,0 1,5
Valve seat width IN/EX 1.0 (0.04) 1.5 (0.06)
Panjang bebas valve spring IN/EX 29,78 29,11
Valve spring free length IN/EX 29.78 (1.172) 29.11 (1.146)

1-5
KETERANGAN UMUM
CYLINDER/PISTON SPECIFICATIONS
SPESIFIKASI CYLINDER/PISTON Satuan: mm
BAGIAN STANDARD BATAS SERVISUnit: mm (in)
Cylinder D.D. 50,000 – 50,015 50,10 SERVICE
ITEM STANDARD
Kelonjongan - 0,05 LIMIT
Cylinder I.D.
Ketirusan 50.005 – 50.015
- (1.9687 – 1.9691)
0,05 50.10 (1.972)
Out-of-round
Perubahan bentuk melengkung - – 0,05 0.05 (0.002)
Piston, piston Taper
D.L. piston 49,970 – 49,990 – 49,90 0.05 (0.002)
rings, piston Warpage – 0.05 (0.002)
pin
Piston, piston Piston
Titik O.D.
pengukuran D.L. piston 49.970
6,0 mm– dari
49.990 (1.9673 – 1.9681)
bagian - 49.95 (1.967)
rings, piston pin Piston O.D. measurement point 6.0 (0.24)
bawah from bottom of skirt
piston –
Piston
D.D. pin bore
lubang I.D.pin
piston 13.002
13,002––13.008
13,008 (0.5119 – 0.5121)
13,04 13.04 (0.513)
Piston
D.L. pistonpin pin
O.D. 12.994
12,994––13.000
13,000 (0.5116 – 0.5118)
12,96 12.96 (0.510)
Piston-to-piston
Jarak pin clearance
renggang antara 0.002
0,002––0.014
0,014(0.0001 – 0.0006)
0,02 0.02 (0.001)
Piston ring-to-ring
piston-ke-piston pin Top 0.015 – 0.050 (0.0006 – 0.0020) 0.08 (0.003)
groove
Jarak clearance
renggang Second
Ring paling atas 0.015
0,015––0.050
0,050(0.0006 – 0.0020)
0,08 0.08 (0.003)
piston
Piston ring-ke-alurnya
ring end gap Ring
Top kedua 0,015
0.10 – 0,050
– 0.25 (0.004 – 0.0020) 0,08 0.45 (0.018)
Celah pada ujung Ring paling atas
Second 0,10––0.25
0.10 0,25(0.004 – 0.0020) 0,45 0.45 (0.018)
piston ring Ring kedua
Oil (side rail) 0,10––0.70
0.20 0,25(0.008 – 0.028) 0,45 –
Cylinder-to-piston clearance Ring oli (side 0,20 –– 0,70
0.015 0.045 (0.0006 – 0.0018) - 0.09 (0.004)
Connecting rod small end I.D. rail) 13.010 – 13.028 (0.5122 – 0.5129) 13.05 (0.514)
Jarak renggang
Connecting antara cylinder-ke-piston
rod-to-piston pin clearance 0,015––0.034
0.010 0,045(0.0004 – 0.0013)
0,09 0.05 (0.002)
D.D. kepala kecil connecting rod 13,010 – 13,028 13,05
Jarak renggang antara connecting rod-ke-piston pin 0,010 – 0,034 0,05
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
SPECIFICATIONS
SPESIFIKASI KICKSTARTER/DRIVE PULLEY/ Unit: mm (in)
SERVICE
DRIVEN PULLEY/CLUTCH
ITEM STANDARD Satuan:
LIMIT mm
Drive belt width BAGIAN STANDARD
18.5 (0.73) BATAS SERVIS
17.5 (0.69)
Lebar drive
Movable belt
drive face Bushing I.D. 18,5
22.035 – 22.085 (0.8675 17,5
– 0.8695) 22.11 (0.871)
Movable drive face D.D.O.D.
Boss bushing 22,035
22.010– –22,085
22.025 (0.8665 22,11
– 0.8671) 21.98 (0.865)
D.L. boss
Weight roller O.D. 22,010
15.92 –– 22,025 21,98
16.08 (0.627 – 0.633) 15.3 (0.60)
Clutch D.L. weight
Lining thicknessroller 15,92 – 16,08 – 15,3 2.0 (0.08)
Clutch Ketebalan
Clutch lapisan kanvas
outer I.D. -
112.0 – 112.2 2,0
(4.41 – 4.42) 112.5 (4.43)
Driven pulley D.D.spring
Face clutch outer
free length 112,0
124.2– (4.89)
112,2 112,5 121.4 (4.78)
Driven pulley Driven face O.D. face spring
Panjang bebas 124,2
33.965 – 33.985 (1.3372 121,4
– 1.3380) 33.94 (1.336)
D.L. driven
Movable face
driven face I.D. 33,965
34.000– –33,985
34.025 (1.3386 33,94
– 1.3396) 34.06 (1.341)
D.D. movable driven face 34,000 – 34,025 34,06

FINAL REDUCTION SPECIFICATIONS


SPESIFIKASI FINAL
ITEM
REDUCTION SPECIFICATIONS
Unit: mm (in)
BAGIAN SPESIFIKASI
Final reduction oil capacity After draining 0.10 liter (0.11 US qt, 0.09 lmp qt)
Kapasitas oli final Pada penggantian periodik 0,10 liter
reduction After disassembly 0.12 liter (0.13 US qt, 0.11 lmp qt)
Setelah pembongkaran 0,12 liter
Recommended final reduction oil
Oli final reduction yang dianjurkan Honda Oil
Federal "4-stroke
Suprememotorcycle oil"oli
Flick atau or mesin
equivalent motor
4 tak oil dengan
sejenis
API service classification: SG or higher (except oils labeled as energy
klasifikasi API service SG, Viskositas: SAE 10W-30 JASO MB
conserving on the circular API service label)
JASO T 903 standard: MB
Viscosity: SAE 10W-30

SPESIFIKASI CRANKCASE/CRANKSHAFT Satuan: mm


CRANKCASE/CRANKSHAFT
BAGIAN SPECIFICATIONS
STANDARD BATAS SERVIS
Crankshaft Jarak renggang ke samping connecting 0,10 - 0,35 0,55
rod Unit: mm (in)
Jarak renggang SERVICE
ITEMradial connecting rod 0 – 0,012 STANDARD 0,05
Keolengan - 0,10 LIMIT
Crankshaft Connecting rod side clearance 0.10 – 0.35 (0.004 – 0.014) 0.55 (0.022)
Connecting rod radial clearance 0 – 0.012 (0 – 0.0005) 0.05 (0.022)
Runout – 0.10 (0.004)

1-6
KETERANGAN UMUM
FRONT WHEEL/SUSPENSION/STEERING
SPESIFIKASI SPECIFICATIONS
RODA DEPAN/SUSPENSI/KEMUDI Satuan: mm
BAGIAN STANDARD BATAS SERVIS Unit: mm (in)
Kedalaman minimum alur telapak ban - Sampai ke indikator SERVICE
ITEM 2 STANDARD
Tekanan udara Pengendara saja 200 kPa (2,00 kgf/cm , 29 psi) - LIMIT
2
ban (dingin)
Minimum Pengendara dan
tire tread depth 200 kPa (2,00 kgf/cm , 29 psi) – - To the indicator
Cold tire pressure pembonceng
Driver only 200 kPa (2.00 kgf/cm2, 29 psi) –
Keolengan axle (poros roda) Driver and passenger - kPa (2.00 kgf/cm2, 290,20
200 psi) –
Keolengan
Axle runout pelek Radial - – 2,0 0.2 (0.01)
roda
Wheel rim runout AksialRadial - – 2,0 2.0 (0.08)
Fork (garpu) Panjang
Axialbebas pegas 311,3 – 305,1 2.0 (0.08)
Fork Keolengan
Spring tabung
free length - (12.26)
311.3 0,20 305.1 (12.01)
Minyak
Pipegarpu
runoutyang Minyak sokbreker – - 0.2 (0.01)
dianjurkan
Recommended fluid Fork fluid –
Tinggi permukaan
Fluid level 50 50 (2.0) - –
minyak
Fluid capacity 75 ± 1 cm3
Kapasitas minyak 75 ± 1 cm
3
- –
(2.5 ± 0.03 US oz, 2.6 ± 0.04 Imp oz)

REAR WHEEL/SUSPENSION SPECIFICATIONS


SPESIFIKASI RODA BELAKANG/SUSPENSI Satuan: mmmm (in)
Unit:
BAGIAN STANDARD BATAS SERVIS SERVICE
Kedalaman minimum alur ITEM telapak ban - STANDARD Sampai ke indikator LIMIT
2
Tekanan
Minimumudara Pengendara saja
tire tread depth 225 kPa (2,25 kg/cm , 33 psi) – - To the indicator
2
ban
Colddingin
tire pressure Pengendara dan
Driver only 225 kPa (2,25 kg/cm
225 kPa, 33 psi)kgf/cm2, 33 psi)
(2.25 - –
pembonceng
Driver and passenger 225 kPa (2.25 kgf/cm2, 33 psi) –
Keolengan pelek
Wheel rim runout Radial
Radial - – 2,0 2.0 (0.08)
roda AksialAxial - – 2,0 2.0 (0.08)

BRAKE SYSTEM SPECIFICATIONS


SPESIFIKASI SISTEM REM Satuan:Unit:
mm mm (in)
SERVICE
BAGIAN
ITEM STANDARDSTANDARD BATAS SERVIS
LIMIT
Jarak main bebas rear brake lever (handel rem blk.) 10 - 20 -
Rear brake lever free play 10 – 20 (0.4 – 0.8) –
D.D. rear brake drum (tromol rem belakang) 130,0 131,0
Rear brake drum I.D. 130.0 (5.12) 131.0 (5.16)
Minyak rem yang dianjurkan DOT 3 atau 4 -
Specified brake fluid DOT 3 or 4 –
Brake disc Ketebalan 3,3 – 3,7 3,0
Brake disc
(cakram rem) Thickness 3.3 – 3.7 (0.13 – 0.15) 3.0 (0.12)
Perubahan bentuk melengkung - 0,10
Warpage – 0.10 (0.004)
Master cylinder D.D. Cylinder 11,000 – 11,043 11,055
Master cylinder Cylinder I.D.
D.L. Piston 11.000 – 11.043
10,957 – 10,984 (0.4331 – 0.4348)
10,945 11.055 (0.4352)
Piston O.D. 10.957 – 10.984 (0.4314 – 0.4324) 10.945 (0.4309)
Caliper D.D. Cylinder 32,030 – 32,080 32,090
Caliper Cylinder I.D. 32.030 – 32.080 (1.2610 – 1.2630) 32.090 (1.2634)
D.L. Piston 31,948 – 31,998 31,94
Piston O.D. 31.948 – 31.998 (1.2578 – 1.2598) 31.94 (1.257)

1-7
KETERANGAN UMUM
BATTERY/CHARGING SYSTEM/ALTERNATOR
SPESIFIKASI BATERAI/SISTEM SPECIFICATIONS
PENGISIAN/ALTERNATOR
ITEMBAGIAN SPESIFIKASI
SPECIFICATIONS
Baterai
Battery Kapasitas
Capacity 12 V12– V3.5
– Ah
3,5 Ah
Kebocoran arus listrik maksimum 0,5 mA
Current leakage 0.5 mA max.
Voltase Bermuatan penuh Di atas 12,8 V
Voltage Fully charged Above 12.8 V
Perlu diisi listrik kembali Di bawah 12,3 V
Needs charging Below 12.3 V
Arus pengisian Normal 0,4 A / 5-10 jam
Charging current Normal 0.4 A/5 – 10 h
Cepat 3,0 A / 0,5 jam
Quick 3.0 A/0.5 h -1
Alternator Kapasitas 0,140 kW / 5.000 menit (rpm)
Alternator Capacity 0.140 kW/5,000 min-1 (rpm)

SPESIFIKASI
IGNITION SISTEM
SYSTEM PENGAPIAN
SPECIFICATIONS
BAGIAN SPESIFIKASI
Busi StandardITEM CPR 8EA - 9 (NGK), U24EPR9 (DENSO)
SPECIFICATIONS
Spark plug Untuk pengendaraan
Standard lama pada CPR CPR
9EA 8EA
– 9 (NGK)
– 9 (NGK)
kecepatan tinggi
For extended high speed riding CPR 9EA – 9 (NGK)
Jarak renggang busi 0,80 – 0,90 mm
Spark plug gap 0.80 – 0.90 mm (0.031 – 0.035 in)
Voltase puncak ignition coil minimum 100 V
Ignition coil peak voltage 100 V minimum
Voltase puncak ignition pulse generator minimum 0,7 V
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing (pengaturan waktu pengapian) 14° sebelum TMA pada putaran stasioner
Ignition timing 14° BTDC at idle speed

ELECTRIC STARTER
SPESIFIKASI SYSTEM
STARTER SPECIFICATION
LISTRIK Satuan: mm
BAGIAN STANDARD BATAS SERVIS Unit: mm (in)
Panjang sikat starter motor 7,0 3,5 SERVICE
ITEM STANDARD
LIMIT
Starter motor brush length 7.0 (0.28) 3.5 (0.14)

SPESIFIKASI LAMPU2 / METER2 / SAKELAR2


LIGHTS/METERS/SWITCHES
BAGIAN SPECIFICATION
SPESIFIKASI
Bola lampu Lampu besar 12 V – 32/32 W
Lampu senja
ITEM 12SPECIFICATIONS
V – 3,4 W
Bulbs Lampu belakang/rem
Headlight 12 V12
–V 5/18 W W
– 32/32
Lampu seinlight
Position depan 12 V –1210VW– 3.4
x 2W
Lampu sein belakang
Tail/brake light 12 V –1210
VW x2 W
– 5/18
Lampu
Frontpenerangan instrumen
turn signal light 12 V 12
– 1,7
V –W10xW 2 x2
Indikator lampu
Rear turn jauh
signal light 12 V12–V1,7 WW x 2
– 10
Indikator lampu
Instrument sein
light 12 12
V –V3,4 WW x 2
– 1.7
Sekring Sekring utama
High beam indicator 15 12
AX 1
V – 1.7 W
Sekring
Turn tambahan
signal indicator 10 12
AX V 1– 3.4 W
Fuse Main fuse 15 A x 1
Sub fuse 10 A x 1

1-8
KETERANGAN UMUM
STANDARD
NILAI TORSITORQUE VALUES
STANDARD
JENIS TORSI JENIS TORSI
TORQUE TORQUE
PENGIKAT TYPE
FASTENER N.m (kgf.m; lbf.ft) PENGIKATFASTENER TYPE N.m (kgf.m; lbf.ft)
N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)
Baut dan mur hex 5 mm 5,2 (0,5; 3,8) Sekrup 5 mm 4,2 (0,4; 3,1)
5 mmdan
Baut hex mur
bolt and
hexnut
6 mm 10 (1,0; 5.2
7) (0.5, 3.8)
Sekrup 6 mm 5 mm screw 9,0 (0,9; 6,6)4.2 (0.4, 3.1)
6 mm hex bolt
(termasuk bautand nut SH)
flens 10 (1.0, Baut
7) flens 66mm
mm screw 12 (1,2; 9) 9.0 (0.9, 6.6)
(Include
Baut danSH flange
mur hex bolt)
8 mm 22 (2,2; 16) 6 mm flange
(termasuk NSHF) bolt
dan mur 12 (1.2, 9)
8 mmdan
Baut hex mur
bolt and
hexnut
10 mm Baut flens 8(Include
22 (2.2, 16)
34 (3,5; 25) mm danNSHF)
mur and nut 27 (2,8; 20)
10 mm
Baut hexmur
dan bolthex
and12nutmm 34 (3.5, 25)
54 (5,5; 40) 8 mm
Baut flens 10 mmflange bolt and nut
dan mur 39 (4,0; 29) 27 (2.8, 20)
12 mm hex bolt and nut 54 (5.5, 40) 10 mm flange bolt and nut 39 (4.0, 29)

TORSI PENGENCANGAN MESIN & RANGKA


ENGINE
• & FRAME
Spesifikasi torsi yang terdaftar diTORQUE VALUES
bawah adalah untuk pengikat tertentu.
•• Torque
Pengikat lain harus
specifications dikencangkan
listed dengan
below are for torsi
specified pengencangan standard yang terdaftar di atas.
fasteners.
•RANGKA/BODY
Others should bePANELS/SISTEM
tightened to standardPEMBUANGAN
torque values listed
GASabove.
FRAME/BODY PANELS/EXHAUST SYSTEMJUM- DIAMETER TORSI
BAGIAN LAH ULIR (mm) N.m (kgf.m; lbf.ft) CATATAN
THREAD TORQUE
Cooling fan cover ITEM
screw 2 Q'TY 5 0,8 (0,1; 0,6) REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Cooling fan cover bolt 2 6 9 (0,9; 6,6)
Cooling fan cover screw 2 5 0.8 (0.1, 0.6)
Muffler mouting bolt 2 10 59 (6,0; 44)
Cooling fan cover bolt 2 6 9 (0.9, 6.6)
Muffler
PERAWATANmounting bolt 2 10 59 (6.0, 44)

MAINTENANCE JUM- DIAMETER TORSI


BAGIAN LAH ULIR (mm) N.m (kgf.m; lbf.ft) CATATAN
Spark plug (busi) ITEM 1 Q'TY 10THREAD 16 (1,6;TORQUE
12) REMARKS
Valve adjusting screw lock nut 2 DIA. (mm)
5 10N·m
(1,0;(kgf·m,
7) lbf·ft)
Oleskan oli pd. ulir
Spark plug
Engine oil drain bolt 1 1 12 10 24 (2,4;1618)
(1.6, 12)
Valve adjusting
Engine screw
oil strainer lock nut
screen cap 1 2 30 5 20 (2,0;10 (1.0, 7)
15) Apply oil to the threads
Engine
Final oil drain oil
reduction boltcheck bolt 1 1 8 12 13 (1,3;2410)
(2.4, 18)
Engine
Final oil strainer
reduction oilscreen
drain cap
bolt 1 1 8 30 13 (1,3;2010)
(2.0, 15)
Final
Air reduction
cleaner oil check
housing boltscrew
cover 4 1 5 8 1,1 (0,1;130,8)
(1.3, 10)
Final reduction oil drain bolt 1 8 13 (1.3, 10)
SISTEM PELUMASAN
Air cleaner housing cover screw 4 5 1.1 (0.1, 0.8)
JUM- DIAMETER TORSI
LUBRICATION SYSTEMBAGIAN LAH ULIR (mm) N.m (kgf.m; lbf.ft) CATATAN
Oil pump plate screw 1 4THREAD 3 (0,3; TORQUE
2,2)
Oil pump mountingITEMbolt 2 Q'TY 6
DIA. (mm) 10N·m
(1,0;(kgf·m,
7) lbf·ft)
REMARKS
Oil pump plate screw 1 4 3 (0.3, 2.2)
Oil pump
SISTEM mounting
BAHAN bolt
BAKAR 2 6 10 (1.0, 7)

FUEL SYSTEM JUM- DIAMETER TORSI


BAGIAN LAH ULIR (mm) N.m (kgf.m; lbf.ft) CATATAN
Inlet pipe band screw ITEM 2 Q'TY 5THREAD 2 (0,2; TORQUE
1,5) REMARKS
SE thermal valve body screw 2 DIA. (mm) 3,4 N·m
5 (0,4; (kgf·m,
2,5) lbf·ft)
Inletthermal
SE pipe band screw
valve setting plate screw 1 2 4 5 2,1 (0,2;2 1,5)
(0.2, 1.5)
SE thermal
Vacuum valve body
chamber screw
cover screw 2 2 4 5 3.41,5)
2,1 (0,2; (0.4, 2.5)
SE thermal
Slow jet valve setting plate screw 1 1 - 4 2.11,1)
1,5 (0,2; (0.2, 1.5)
Main
Vacuum jet chamber cover screw 1 2 - 4 2,1 (0,2;
2.11,5)
(0.2, 1.5)
Needle
Slow jetjet holder 1 1 - – 2,5 (0,3;
1.51,8)
(0.2, 1.1)
Float
Main chamber
jet screw 3 1 4 – 2,1 (0,2;
2.11,5)
(0.2, 1.5)
Float
Needlechamber
jet holderdrain screw 1 1 - – 1,5 (0,2;
2.51,1)
(0.3, 1.8)
PAIR check valve
Float chamber screwcover screw 2 3 4 4 2,1 (0,2;
2.11,5)
(0.2, 1.5)
Fuel
Floatauto
chambervalve lockscrew
drain nut 1 1 16 – 22,5 (2,3;
1.5 17)
(0.2, 1.1)
PAIR check valve cover screw 2 4 2.1 (0.2, 1.5)
Fuel auto valve lock nut
PELEPASAN/PEMASANGAN MESIN 1 16 22.5 (2.3, 17)
JUM- DIAMETER TORSI
ENGINE REMOVAL/INSTALLATION
BAGIAN LAH ULIR (mm) N.m (kgf.m; lbf.ft) CATATAN
Engine hanger link nut (sisi mesin) 1 10THREAD 49 (5,0;TORQUE
36)
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Engine hanger link nut (Engine side) 1 10 49 (5.0, 36)

1-9
KETERANGAN UMUM
CYLINDER
CYLINDER HEAD/VALVES/CYLINDER/PISTON
HEAD/VALVES/CYLINDER/PISTON
JUM- DIAMETER
THREAD TORSI TORQUE
ITEM
BAGIAN LAH Q'TY ULIR (mm) CATATANREMARKS
DIA. (mm)N.m (kgf.m; lbf.ft) lbf·ft)
N·m (kgf·m,
Intake shroud mounting screw
Intake shroud mounting screw 3 3 5 5 0,8 (0,1; 0,6)
0.8 (0.1, 0.6)
Exhaust shroudmounting
Exhaust shroud mounting bolt
bolt 1 1 6 6 7 (0,7; 75,1)
(0.7, 5.1)
Cylinder headnut
Cylinder head nut 4 4 7 7 (1.8, 13) Oleskan oliApply
18 (1,8;1813) pd. uliroil to the threads
Cylinder head bolt 2 6 12 (1,2; 9) Oleskan oli pd. ulir
Cylinder head bolt 2 6 12 (1.2, 9) Apply oil to the threads
Cam sprocket bolt 2 5 8 (0,8; 5,9) Oleskan oli pd. ulir
Cam sprocket bolt 2 5 8 (0.8, 5.9) Apply oil to the threads
Cam chain tensioner lifter screw 1 6 4 (0,4; 3,0)
Cam chain tensioner lifter screw 1 6 4 (0.4, 3.0)
Cylinder head cover special bolt 2 6 12 (1,2; 9)
Cylinder
Cam head
chain cover special
tensioner sliderbolt
pivot pin bolt 1 2 6 6 10 (1,0;127)(1.2, 9)
Cam chain tensioner slider pivot pin bolt 1 6 10 (1.0, 7)

KICKSTARTER/DRIVE PULLEY/DRIVENPULLEY/CLUTCH
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
JUM- DIAMETER
THREAD TORSI TORQUE
ITEM
BAGIAN LAH Q'TY ULIR (mm) CATATANREMARKS
DIA. (mm)N.m (kgf.m; lbf.ft) lbf·ft)
N·m (kgf·m,
Left crankcase cover plate screw
Left crankcase cover plate screw 5 5 4 4 3 (0,3; 2,2)
3 (0.3, 2.2)
Drive
Drive pulley facenut
pulley face nut 1 1 14 14 108 (11,0; 80) 80) Oleskan oliApply
108 (11.0, pd. uliroil to the threads
Clutch/driven pulleynut
Clutch/driven pulley nut 1 1 28 28 54 (5,5;5440)
(5.5, 40)
Clutch outer nut 1 12 49 (5,0; 36)
Clutch outer nut 1 12 49 (5.0, 36)

FRONT WHEEL/SUSPENSION/STEERING
RODA DEPAN/SUSPENSI/KEMUDI
JUM- THREAD
DIAMETER TORSI TORQUE
ITEM
BAGIAN Q'TY REMARKS
CATATAN
LAH ULIRDIA.
(mm)(mm)N.m (kgf.m; lbf.ft) lbf·ft)
N·m (kgf·m,
Front axlenut
Front axle nut 1 1 12 12 59 (6,0;5944)
(6.0, 44) U-nut U-nut
Front brakedisc
Front brake discsocket
socket bolt
bolt 4 4 8 8 42 (4,3;4231)
(4.3, 31) ALOC bolt: ALOC bolt:
Handlebar post nut 1 10 59 (6,0; 44) ganti dgn. replace
yg. baru with new ones
Rear brakepost
Handlebar lever
nutpivot bolt 1 1 5 10 1 (0,1;590,7)
(6.0, 44)
Rear brakelever
Rear brake leverpivot
pivotbolt
nut 1 1 5 5 4,5 (0,5;1 3,3)
(0.1, 0.7)
Bottom bridge
Rear brake leverpinch
pivot bolt
nut 4 1 10 5 64 (6,5;
4.547)(0.5, 3.3)
Fork socket
Bottom bridgebolt
pinch bolt 2 4 8 10 20 (2,0;6415)
(6.5, 47)
Steering stem
Fork socket bolttop thread 1 2 26 8 (2.0, 15) Oleskan cairan
Lihat hal.2011-22 Applypengunci
locking agent
Steering stem lock nut 1 26 Lihat hal. 11-22
Steering stem top thread 1 26 See page 11-22
Steering stem lock nut 1 26 See page 11-22
RODA BELAKANG/SUSPENSI
REAR WHEEL/SUSPENSION JUM- DIAMETER TORSI
BAGIAN LAH ULIR THREAD
(mm) N.m (kgf.m; lbf.ft)
TORQUE CATATAN
ITEM Q'TY REMARKS
Rear axle nut 1 DIA. (mm) 118 N·m
16 (12,0;(kgf·m,
87) lbf·ft)U-nut, Oleskan oli pd. ulir
Engine hanger
Rear axle nut link nut (sisi rangka) 1 1 10 16 69 (7,0;
11851)
(12.0, 87) U-nut, Apply oil to the
threads
Engine hanger link nut (Frame side) 1 10 69 (7.0, 51)
SISTEM REM
BRAKE SYSTEM JUM- DIAMETER TORSI
BAGIAN LAH ULIR (mm) N.m (kgf.m; lbf.ft) CATATAN
THREAD TORQUE
Rear brake arm bolt ITEM 1Q'TY 6 10 (1,0; 7) ALOC bolt: ganti dengan
REMARKSyang baru
DIA. (mm) N·m (kgf·m, lbf·ft)
Brake caliper bleed valve 1 8 6 (0,6; 4,4)
Rear brake
Brake armcylinder
master bolt reservoir cap 2 1 4 6 2 (0,2; 10 (1.0, 7)
1,5) ALOC bolt: replace with a
screw new one
Brake caliper
Brake pad pinbleed valve 1 1 10 8 18 (1,8;6 13)
(0.6, 4.4)
Brake master cylinder
Front brake lever reservoir
pivot bolt cap screw 1 2 6 4 1 (0,1; 20,7)
(0.2, 1.5)
Brake brake
Front pad pinlever pivot nut 1 1 6 10 6 (0,6;18 (1.8, 13)
4,4)
Front brake
Front brakelever
light pivot
switchboltscrew 1 1 4 6 1 (0,1; 10,7)
(0.1, 0.7)
Front brake
Brake hoselever pivot nut
oil bolt 2 1 10 6 34 (3,5;6 25)
(0.6, 4.4)
Front brake
Brake light
caliper switch screw
mounting bolt 2 1 8 4 (0.1, 0.7) ALOC bolt: ganti dengan yang baru
30 (3,1;1 22)
Brake caliper
Brake hose oil pin
bolt 1 2 8 10 18 (1,8;3413)
(3.5, 25)
Brake caliper mounting bolt 2 8 30 (3.1, 22) ALOC bolt: replace with new
ones
Brake caliper pin 1 8 18 (1.8, 13)

1-10
KETERANGAN UMUM
BATTERY/CHARGING SYSTEM/ALTERNATOR
BATTERY/SISTEM PENGISIAN/ALTERNATOR
JUM- DIAMETER
THREAD TORSITORQUE
ITEM
BAGIAN LAH Q'TY ULIR (mm) N.m (kgf.m; lbf.ft) lbf·ft) REMARKS
CATATAN
DIA. (mm) N·m (kgf·m,
Cooling fan mounting
Cooling fan mountingboltbolt 3 3 6 6 10 (1,0;107)(1.0, 7)
Flywheel nut
Flywheel nut 1 1 10 10 39 (4,0;3929)
(4.0, 29)
Ignition pulse generator
lgnition pulse generator 2 2 5 5 6 (0,6; 64,4)
(0.6, 4.4)
IGNITION SYSTEM
SISTEM PENGAPIAN
JUM- THREAD TORQUE
ITEM Q'TY DIAMETER TORSI REMARKS
BAGIAN LAH ULIRDIA.
(mm)(mm)N.m (kgf.m;
N·m (kgf·m,
lbf.ft) lbf·ft) CATATAN
Key shutter
Key shutter socket
socketbolt
bolt 1 1 6 6 10 (1,0;107)(1.0, 7)
ELECTRIC STARTER SYSTEM
SISTEM STARTER LISTRIK THREAD TORQUE
ITEM JUM-Q'TY DIAMETER TORSI REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
BAGIAN LAH ULIR (mm) N.m (kgf.m; lbf.ft) CATATAN
Starter motor case screw 3 4 2 (0.2, 1.5)
Starter motor case screw 3 4 2 (0,2; 1,5)
OTHERS
LAIN-LAIN THREAD TORQUE
ITEM Q'TY REMARKS
JUM- DIA. (mm)
DIAMETER N·m (kgf·m, lbf·ft)
TORSI
BAGIAN
Carburetor throttle cable holder mounting LAH 2 ULIR (mm) 5 3.4 lbf.ft)
N.m (kgf.m; (0.4, 2.5) CATATAN
screw
Carburetor throttle cable holder 2 5 3,4 (0,4; 2,5)
Brake shoescrew
mounting anchor pin nut 1 8
Brake
(when shoe
using anchor
the stakepin
nut)nut 1 8 20 (2.0, 15)
(sewaktu memakai
(when using stake
the normal nut)nut) 20 (2,0;1815)
(1.8, 13)
(sewaktu memakai
Muffler protector normalbolt
mounting nut) 2 6 18 (1,8;1013)
(1.0, 7)
Muffler protector
Sidestand pivot nutmounting bolt 2 1 6 10 10 (1,0;
297)
(3.0, 21)
Sidestand pivotbolt
Sidestand pivot nut 1 1 10 10 29 (3,0;
1021)
(1.0, 0.7)
Sidestand pivot bolt 1 10 10 (1,0; 0,7)

1-11
KETERANGAN UMUM
LUBRICATION & SEAL POINTS
TITIK-TITIK PELUMASAN & PERAPATAN
ENGINE
MESIN
MATERIAL
BAHAN LOCATION
LOKASI REMARKS
CATATAN
Liquid sealant(recommended:
Liquid sealant (dianjurkan: Right crankcase mating surface
Permukaan penyatuan right crankcase See page
Lihat hal. 10-9 10-9
Three Bond 1207B or Three
Three Bond 1207B atau Three
Bond 1215 or equivalent)
Bond 1215 atau sejenisnya)
Liquid sealant (recommended: Cylinder head mating surface (semicircular area) See page 7-8
Liquid sealant (dianjurkan: Permukaan penyatuan cylinder head (daerah Lihat hal. 7-8
Three Bond 5211C or SHI-
Three Bond 5211C atau setengah lingkaran)
NETSU-SILICONE KE45T or
SHINETSU-SILICONE
Three Bond 1215 or equiva- KE45T
atau
lent) Three Bond 1215 atau
sejenisnya)
Adhesive (recommended: Cylinder head cover and seal rubber mating surface (hatched See page 7-7
Adhesive
CEMEDINE (dianjurkan:
575 or Three Cylinder head cover dan permukaan penyatuan
area) Lihat hal. 7-7
CEMEDINE
Bond 1194 or575 atau Three
equivalent) seal rubber (daerah penutupan)
Bond 1194 atau sejenisnya)
Locking agent (recommended: Driveshaft bearing set plate bolt threads See page 9-16
Locking
Three Bondagent
2415(dianjurkan:
or 1322N or Ulir supply
Air driveshaft
pipe bearing
mountingset
boltplate bolt
threads Lihat hal.See
9-16
page 5-25
Three
LOCKTITE 200 or atau
Bond 2415 1322N
equivalent) Ulir air supply pipe mounting bolt Lihat hal. 5-25
atau LOCKTITE 200 atau
Molybdenum oil solution (a Camshaft cam lobes
sejenisnya)
mixture of 1/2 engine oil and 1/
Molybdenum
2 molybdenumoil solution
disulfide Camshaft cam lobes (bubungan camshaft)
(campuran
grease) dari ½ oli mesin
dan ½ molybdenum
Molybdenum disulfidedisulfide
paste Kickstarter spindle sliding surface 0.1 – 0.3 g
grease) Kickstarter driven gear shaft 0.2 – 0.3 g
Molybdenum disulfide paste Permukaandriven
Kickstarter luncur kickstarter
gear spindle
friction spring sliding area 0,1 –0,3 g
Multi-purpose grease Kickstarter driven gear
Kickstarter spindle dust seal lip shaft 0,2 – 0,3 g
Daerah luncur kickstarter driven gear friction spring
Grease Driven face inner surface 7.0 – 8.0 g
Multi-purpose
(Shell ALVANIAgrease
R3 or Bibir kickstarter spindle dust seal
Movable driven face cam groove 2.0 – 2.5 g
Grease (gemuk)
IDEMITSU AUTOREX B or Permukaan
Starter piniondalam driven
gear shaft (bothface
end) 7,0 – 8,00.1
g – 0.3 g
(Shell ALVANIA R3 atau
equivalent) Alur movable driven face cam 2,0 – 2,5 g
Driven face ball bearing and needle bearing
IDEMITSU AUTOREX B atau Starter pinion gear shaft (kedua ujungnya) 0,1 – 0,3 g
Engine oil Oil pump drive gear teeth
sejenisnya) Driven face ball bearing dan needle bearing
(Without molybdenum addi- Oil pump rotor whole surface
tives) Oil pump oil shaft and pump cover sliding area
Oli mesin Gigi-gigi pump drive gear
(Tanpa molybdenum additives) Oil pump driven gear teeth
Seluruh permukaan oil pump rotor
Rocker
Daeraharm shaftoilsliding
luncur pumpsurface
shaft dan pump cover
Rocker
Gigi-gigiarmoilroller
pumpsliding
drivenareagear
Camshaft
Permukaan decompressor
luncur rocker rotating
arm surface
shaft 0.5 – 1.0 cc
Camshaft
Daerah luncurbearing rocker arm roller
Cam sprocketberputar
Permukaan teeth camshaft decompressor 0,5 – 1,0 cc
Camshaft
Cam bearing
chain whole surface
Gigi-gigi
Timing cam sprocket
sprocket teeth
Seluruh
Piston andpermukaan
cylinder slidingcam surfaces
chain
Gigi-gigi
Piston pintiming sprocket
hole sliding area
Permukaan
Piston ring wholeluncur piston
surface anddanringcylinder
grooves
Daerah
Piston pinluncur lubang piston pin
outer surface
Seluruh permukaan
Connecting rod small end piston ring
inner dan alur ring
surface
Permukaan luar piston pin
Crankshaft bearings Fill up 2 cc minimum
Permukaan dalam connecting rod small end
Connecting rod big end bearing Fill up 3 cc minimum
(kepala kecil connecting rod)
Valve stem (valve
Crankshaft bearingsguide sliding area) Isi dengan minimum 2 cc
Valve stem seal inner
Connecting rod big end surfacebearing (bantalan kepala Isi dengan minimum 3 cc
Bearing area of drive,
besar connecting rod)counter and final shaft
Drive,
Valve counter
stem (daerahand final gear teeth
luncur valve guide)
Cam set plunger
Permukaan whole
dalam surface
valve stem seal
Ball/needle
Daerah bearing bearing darisliding
drive,area
counter dan final shaft
Gigi-gigi
Each O-ringdrive,
wholecounter
surfacedan final gear
Seluruh
Oil permukaan
seal lips and outer cam surfacesset plunger
Degrease Daerah
Right luncur ball/needle
crankshaft tapered areabearing
Seluruh permukaan
Drive/driven pulley face masing-masing
and drive belt O-ring
Bibircrankcase
Left dan permukaan luar oil
cover bearing seal inner surface
bushing
Bersihkan dari gemuk Daerah meruncing dari right crankshaft
Muka drive/driven pulley dan drive belt
Permukaan dalam left crankcase cover bearing
bushing

1-12
KETERANGAN UMUM
FRAME
RANGKA
BAHAN LOKASI CATATAN
MATERIAL LOCATION REMARKS
Multi-purpose grease dengan Steering bearing race Isi dengan minimum 3 g
Multi-purpose
tekanan grease
sangat with
tinggi Steering
Bibir bearingstem
steering race dust seal Fill up 3 g minimum
extreme pressure (recom-
(dianjurkan: EXCELIGHT EP2 Steering stem dust seal lip
mended: EXCELIGHT EP2
buatan KYODO YUSHI,
manufactured by KYODO
Japan, atau Shell ALVANIA
YUSHI, japan. or Shell ALVA-
EP2 atau sejenisnya)
NIA EP2 or equivalent)
Grease (Shell BEARING Bagian dalam speedometer gear box
Grease Speedometer gear box inside
GREASE HD atau
(Shell BEARING sejenisnya)
GREASE
Multi-purpose grease
HD or equivalent) Bibir front wheel dust seal
Multi-purpose grease Permukaan
Front wheel dustluncursealfront
lip wheel axle
Seluruh permukaan front wheel distance collar
Front wheel axle sliding surface
Daerah luncur front wheel bearing
Front wheel distance collar whole surface
Bibir speedometer gear box seal
Front wheel
Rear brake bearing
cam dan sliding
shaftarea Oleskan masing-masing
Speedometer gear box seal lip 0,2 – 0,3 g
Rear brake
Rear brakecam and shaft
anchor pin shaft Oleskan Apply eachg0.2 - 0.3 g
0,2 – 0,3
Rear brake
Bibir anchordust
rear brake pin shaft
seal Apply 0.2 - 0.3 g
Rear brake dust
Permukaan seal lip
luncur rear brake lever pivot bolt
Rear brake
Daerah leverthrottle
luncur pivot bolt sliding surface drum
cable-ke-throttle Oleskan 0,1 – 0,2 g
Throttle cable-to-throttle
Daerah kontak seat catch drum sliding area
(penahan tempat duduk) Apply 0.1 - 0.2 g
Daerah centerstand
Seat catch contact areapivot
Daerah sidestand
Centerstand pivot areapivot
Sidestand pivot area
Silicone grease
Silicone grease Bagian dalam
Rear brake cablerearcap brake cable cap boot
boot inside
Daerah kontak
Front brake front brakepiston
lever-to-master lever-ke-master piston
contacting area Oleskan Apply
0,1 g 0.1 g
Daerah luncur front brake
Front brake lever pivot sliding arealever pivot
Daerah luncur
Brake caliper pinbrake
sliding caliper
area pin Oleskan Apply
minimum
0.4 g0,4 g
minimum
Seluruh permukaan brake
Brake caliper dust seal whole surfacecaliper dust seal
Speedometer cable
Speedometer cable
Bagian dalam throttle cable boot Oleskan 0,1 g
Throttle cable boot inside Apply 0.1 g
Bagian dalam throttle cable Oleskan minimum 0,2 g
Throttle cable inside Apply 0.2 g minimum
Brake fluid (minyak rem) Bagian dalam dan daerah luncur master cylinder
Brake 3fluid
(DOT atau DOT 4) Master cylinder
Seluruh permukaan insidebrake
and sliding
caliperarea
piston seal
(DOT 3 or DOT 4) Brake caliper piston seal whole
Seluruh permukaan brake caliper piston surface
Brake caliper
Master cylinderpiston whole
piston cupsurface
Fork fluid (minyak sokbreker) Master
Bibir cylinder
fork dust sealpistondancupoil seal
Fork fluid Fork dustpermukaan
Seluruh seal and oil sealfork lips
spring seat O-ring
Adhesive (Honda bond A atau Fork spring
Bagian dalamseathandlebar
O-ring whole gripsurface
rubber
Adhesive
sejenisnya) Handlebar
Daerah grip rubberPAIR
penyatuan insidecontrol valve rubber
(Honda bond A or equivalent) PAIR control
-ke-air cleaner valve rubber-to-air cleaner housing mating area
housing
Daerah penyatuan
Air cleaner connecting airhose-to-housing
cleaner connecting matinghose-ke-
area
Locking agent (recommended: housing
Centerstand shaft bolt threads See page 10-11
Locking agent
Three Bond (dianjurkan:
2415 or 1322 N or Ulir centerstand shaft bolt Lihat hal. 10-11
LOCKTITE
Three Bond 200
2415or atau
equivalent)
1322 N
atau LOCKTITE 200 atau
sejenisnya)

1-13
KETERANGAN UMUM
CABLE & HARNESS
PERLETAKAN KABELROUTING
& HARNESS

STARTER SWITCH
WIRE DIMMER SWITCH WIRE
LIGHTING SWITCH WIRE
TURN SIGNAL
SWITCH WIRE

RIGHT HANDLEBAR
SWITCH WIRE

FRONT BRAKE HOSE

FRONT BRAKE
LIGHT SWITCH LEFT HANDLEBAR HORN SWITCH
WIRE SWITCH WIRE WIRE

REAR BRAKE CABLE

REAR BRAKE LIGHT


SWITCH WIRE

THROTTLE REAR BRAKE


CABLE
HANDLEBAR SWITCH/
SPEEDOMETER WIRE

FRONT BRAKE
HOSE SPEEDOMETER
CABLE
HANDLEBAR SWITCH/ HANDLEBAR
SPEEDOMETER WIRE SWITCH/ FRONT BRAKE
SPEEDOMETE HOSE
R WIRE
THROTTLE CABLE
SPEEDOMETER
CABLE

REAR BRAKE CABLE

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

1-14
KETERANGAN UMUM

HORN WIRE

SPEEDOMETER CABLE

MAIN WIRE
HARNESS

THROTTLE CABLE

REAR BRAKE CABLE

FRONT BRAKE HOSE

MAIN WIRE
HARNESS

SPEEDOMETER CABLE

FRONT BRAKE HOSE

1-15
KETERANGAN UMUM

MAIN WIRE
HARNESS

Jepit daerah dengan pita putih:

REAR BRAKE CABLE


SIDESTAND SWITCH WIRE

THROTTLE CABLE

BATTERY NEGATIVE BATTERY POSITIVE


(–) CABLE (+) CABLE

FUSE BOX WIRE STARTER RELAY WIRE

1-16
KETERANGAN UMUM
PULSE SECONDARY CRANKCASE
AIR INJECTION (PAIR) BREATHER HOSE
STARTER ENRICHMENT CONTROL VALVE
(SE) THERMAL VALVE WIRE VACUUM HOSE CARBURETOR
AIR VENT HOSE

FUEL VALVE
VACUUM HOSE

THROTTLE CABLE
ALTERNATOR/IGNITION
PULSE GENERATOR WIRE

STARTER MOTOR/
GROUND CABLE

CARBURETOR
SIDESTAND DRAIN HOSE
SWITCH WIRE
AIR SUPPLY PIPE

STARTER ENRICHMENT
(SE) THERMAL VALVE WIRE

CRANKCASE
BREATHER HOSE

ALTERNATOR/
IGNITION PULSE
GENERATOR WIRE
STARTER MOTOR/
GROUND CABLE

1-17
KETERANGAN UMUM

° SISI ATAS CARBURETOR VACUUM


75 PISTON HOSE

AIR CLEANER
CONNECTING HOSE BAND

CRANKCASE BREATHER HOSE


SISI ATAS

CARBURETOR VACUUM
PISTON HOSE CLIP

FUEL HOSE

FUEL VALVE
VACUUM HOSE

CARBURETOR AIR
VENT HOSE

THROTTLE CABLE

SISI ATAS

INLET PIPE BAND

PULSE SECONDARY
AIR INJECTION (PAIR)
CONTROL VALVE
VACUUM HOSE

1-18
KETERANGAN UMUM

FUEL LEVEL
SENSOR WIRE GROUND CABLE
REGULATOR/ (KECIL)
SPARK PLUG WIRE RECTIFIER WIRE

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

TANDA

AIR SUPPLY PIPE

PULSE SECONDARY STARTING ENRICHMENT (SE)


AIR INJECTION (PAIR) AIR SUPPLY HOSE THERMAL VALVE WIRE
CONTROL VALVE
VACUUM HOSE
AIR SUPPLY HOSE

Terpasang

SISI AIR SUPPLY HOSE SPARK PLUG WIRE


ATAS
ALTERNATOR/
STARTER MOTOR/
IGNITION PULSE
GROUND CABLE
HOSE BAND GENERATOR WIRE

1-19
KETERANGAN UMUM

CARBURETOR VACUUM
PISTON HOSE

THROTTLE CABLE
FUEL HOSE

FUEL VALVE
VACUUM HOSE

FUEL HOSE

FUEL VALVE
PULSE SECONDARY VACUUM HOSE
AIR INJECTION (PAIR)
CONTROL VALVE FUEL VALVE
VACUUM HOSE VACUUM HOSE

THROTTLE CABLE

CRANKCASE
BREATHER HOSE

CARBURETOR
DRAIN HOSE

CARBURETOR
AIR VENT HOSE

1-20
KETERANGAN UMUM

GROUND CABLE

STARTER MOTOR CABLE GROUND CABLE

ALTERNATOR/IGNITION PULSE
GENERATOR WIRE

IGNITION PULSE GENERATOR WIRE

1-21
KETERANGAN UMUM

CRANKCASE BREATHER FINAL REDUCTION CASE


DRAIN HOSE BREATHER HOSE

Sewaktu memasang pedal kikstarter


pada posisi standard:

SEJAJAR

REAR BRAKE CABLE


CARBURETOR DRAIN
Waktu memasang Waktu memasang
standard samping pada standard utama pada
posisi standard: posisi standard:

1-22
KETERANGAN UMUM

POSITION LIGHT WIRE

LEFT FRONT TURN RIGHT FRONT TURN


SIGNAL LIGHT WIRE SIGNAL LIGHT WIRE

HEAD LIGHT WIRE

RIGHT REAR TURN


SIGNAL LIGHT WIRE

TAIL/BRAKE LIGHT WIRE

TAIL/BRAKE LIGHT/REAR LEFT REAR TURN SIGNAL


TURN SIGNAL LIGHT WIRE LIGHT WIRE

Tepatkan daerah yang


berpita putih dengan tab

TAIL/BRAKE LIGHT/REAR
TURN SIGNAL LIGHT WIRE

1-23
KETERANGAN UMUM
EMISSION CONTROL
SISTEM-SISTEM SYSTEMSEMISSI
PENGATURAN
SOURCEEMISSI
SUMBER OF EMISSIONS
The combustion process produces carbon monoxide and hydrocarbons. Controlling hydrocarbon emission is very important because, under
Proses pembakaran
certain conditions, theymenghasilkan karbon monoksida
react to form photochemical dan hidrokarbon.
smog when Pengaturan
subjected to sunlight. Carbonemissi hidrokarbon
monoxide adalah
does not react sangat
in the same penting
way, butoleh
it is
karena,
toxic. pada kondisi tertentu, mereka bereaksi membentuk photochemical smog ketika terkena cahaya matahari. Karbon
monoksida tidak bereaksi dengan cara yang sama, tetapi ia beracun.
Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide, oxides of nitrogen and
hydrocarbons.
Honda Motor Co., Ltd. menggunakan penyetelan karburator yang miskin maupun sistem lain, untuk mengurangi karbon monoksida,
oksida dari nitrogen dan hidrokarbon.
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned
to the combustion chamber through the air cleaner and carburetor.
SISTEM PENGATURAN EMISSI CRANKCASE
Mesin dilengkapi dengan sistem crankcase (bak mesin) tertutup untuk mencegah pengeluaran emissi bak mesin ke dalam atmosfir.
Blow-by gas (gas hasil pembakaran yang masuk ke dalam bak mesin melalui piston ring) dikembalikan ke dalam ruang
pembakaran melalui air cleaner (saringan udara) dan karburator.

CARBURETOR

AIR CLEANER

UDARA

BLOW-BY GAS

1-24
KETERANGAN UMUM
EXHAUST
SISTEM EMISSION CONTROL
PENGATURAN EMISSI GAS SYSTEM (PULSE SECONDARY AIR INJECTION SYSTEM)
PEMBUANGAN
(PULSE SECONDARY
The exhaust emission AIR
control system INJECTION
consists of a secondarySYSTEM)
air supply system which introduces filtered air into the exhaust gas in the exhaust
port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system. This charge of fresh air promotes
burning of
Sistem the unburned
pengaturan exhaust
emissi gasgaspembuangan
and changes aterdiri
considerable amount secondary
dari sebuah of hydrocarbons and carbon
air supply monoxide
system [sistemintopenyaluran
relatively harmless carbon
udara kedua]
dioxide
yang and water vapor.
memasukkan udara yang telah disaring ke dalam gas pembuangan pada lubang pembuangan. Udara segar ditarik ke dalam
lubang pembuangan
This model setiap
has the pulse kali ada
secondary airpulsa tekanan
injection (PAIR)negatif
controlpada sistem
valve gas pembuangan.
and PAIR Suntikan
check valve. PAIR checkudara
valve segar inireverse
prevents meningkatkan
air flow
pembakaran gas pembuangan
through the system. yangvalve
The PAIR control belum terbakar
reacts dan
to high mengubah
intake manifoldsejumlah besar
vacuum and willhidrokarbon dan karbon
cut off the supply monoksida
of the fresh ke dalam
air during engine
karbon dioksida
deceleration, danpreventing
thereby uap air yang relatifintidak
afterburn berbahaya.
the exhaust system.
No adjustment to the pulse secondary air injection system should be made, although periodic inspection of the components is recommended.
Model ini mempunyai pulse secondary air injection (PAIR) control valve dan PAIR check valve. PAIR check valve [klep penahan
PAIR] mencegah terjadinya arus udara terbalik melalui sistem. PAIR control valve [klep pengatur PAIR] bereaksi terhadap vakuum
intake manifold [manipol pemasukan] yang tinggi dan akan menutup penyaluran udara segar selama deselerasi mesin, dengan
demikian mencegah terjadinya afterburn [pembakaran susulan] dalam sistem gas pembuangan.

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

PAIR CONTROL VALVE CHECK VALVE PAIR AIR CLEANER

UDARA SEGAR

UDARA VAKUM

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

1-25
CATATAN
2. RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS

LOKASI BODY PANEL..........................


BODY PANEL LOCATIONS????????????? 2-22-2 TEMPAT DUDUK ........................................2-8
SEAT ????????????????????????????????? 2-8

PETA PELEPASAN
BODY BODY CHART
PANEL REMOVAL PANEL.......
?????? 2-22-2 GRAB RAIL.................................................
GRAB RAIL ??????????????????????????? 2-8 2-8

KETERANGAN SERVIS ........................


SERVICE INFORMATION ?????????????? 2-32-3 BODY COVER.............................................
BODY COVER????????????????????????? 2-9 2-9

TROUBLESHOOTING
TROUBLESHOOTING...........................
????????????????? 2-32-3 UNDER COVER
UNDER COVER........................................
?????????????????????? 2-10 2-10

FRONT UPPER
FRONT UPPERCOVER
COVER........................
???????????????? 2-42-4 FLOOR PANEL/FRONT
FLOOR PANEL/FRONTINNER
INNER COVER.. 2-11
COVER 2-11

FRONT HANDLEBAR
FRONT HANDLEBARCOVER..............
COVER ?????????? 2-52-5 REAR FENDER.........................................
REAR FENDER ??????????????????????? 2-11 2-11

REAR HANDLEBAR
REAR HANDLEBARCOVER
COVER ................
??????????? 2-52-5 LEFT CRANKCASE
LEFT CRANKCASECOVER
COVER DUCT .........2-12
DUCT ????? 2-12

FRONT LOWER
FRONT LOWERCOVER
COVER.......................
??????????????? 2-62-6 COOLING FAN
COOLING FANCOVER............................
COVER ??????????????? 2-12 2-12

FRONT INNER
FRONT INNERUPPER
UPPERCOVER
COVER ............
????????? 2-62-6 TRIM CLIPS
TRIM ..............................................
CLIPS ????????????????????????? 2-13 2-13

FRONT FENDER....................................
FRONT FENDER ?????????????????????? 2-72-7 BATTERY COVER
BATTERY ....................................
COVER ???????????????????? 2-13 2-13

LUGGAGE BOX.....................................
LUGGAGE BOX ??????????????????????? 2-72-7 EXHAUST PIPE/MUFFLER
EXHAUST PIPE/MUFFLER......................
???????????? 2-14 2-14

CENTER BODY
CENTER BODYCOVER........................
COVER ???????????????? 2-82-8

2-1
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
LOKASI BODYLOCATIONS
BODY PANEL PANEL
FRAME/BODY PANELS/EXHAUST SYSTEM

(8)
(1)

(9) (10)
(2)
(11)
(3)
(6)

(14)

(5) (17)

(13)

(15)
(12)
(7)
(16)
(4)
(1) Front handlebar cover (hal. 2-5) (9) Luggage box (hal. 2-7)
(1) Front handlebar cover (page 2-5) (9) Luggage box (page 2-7)
(2) Rear handlebar cover (hal. 2-5) (10) Grab rail (hal. 2-8)
(2) Front
(3) Rear handlebar cover(hal.
upper cover (page 2-5)
2-4) (10) Grab
(11) Body railcover
(page(hal.
2-8) 2-9)
(3) Front upper cover (page
(4) Front lower cover (hal. 2-6) 2-4) (11) Body cover (page
(12) Under cover (hal. 2-9)2-10)
(4) Front
(5) Front lower
fendercover
(hal.(page
2-7) 2-6) (12) Under
(13) Floorcover (page 2-10)
panel/Front inner cover (hal. 2-11)
(5) Front fender (page 2-7)
(6) Front inner upper cover (hal. 2-6) (13) Floor
(14) Rearpanel/Front
fender (hal.inner cover (page 2-11)
2-11)
(6) Center
(7) Front inner
bodyupper
covercover (page
(hal. 2-8)2-6) (14) Rear
(15) Leftfender (page cover
crankcase 2-11) duct (hal. 2-12)
(7) Seat
(8) Center(hal.
body2-8)
cover (page 2-8) (15) Left
(16) crankcase
Cooling cover duct
fan cover (hal.(page
2-12)2-12)
(8) Seat (page 2-8) (16) Cooling
(17) Batteryfan cover(hal.
cover (page 2-12)
2-13)
(17) Battery cover (page 2-13)

BODY PANEL REMOVAL CHART


PETA PELEPASAN BODY PANEL
• This chart shows removal order of frame covers by means of arrow.
• Peta ini memperlihatkan urutan pelepasan dari penutup rangka dengan perantaraan anak panah.
(5) Front fender (3) Front upper cover (1) Front handlebar cover

(9) Luggage box (4) Front lower cover (2) Rear handlebar cover

(15) Left crankcase cover duct (6) Front inner upper cover (7) Center body cover (10) Grab rail

(16) Cooling fan cover (12) Under cover (8) Seat (11) Body cover

(17) Battery cover (13) Floor panel/Front inner cover (14) Rear fender

2-2
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
SERVICE INFORMATION
KETERANGAN SERVIS
UMUM
GENERAL
•• This
Babsection coverspelepasan
ini meliputi removal anddan installation of the body
pemasangan bodypanels
panelsand danexhaust
sistem system.
pembuangan gas.
•• Always
Selalureplace the exhaust
ganti exhaust pipepipe gasketsetelah
gasket after removing the exhaust
melepaskan exhaustpipepipe
from(pipa
the engine.
pembuangan gas) dari mesin.
•• When installing
Ketika memasangthe exhaust
sistemsystem, loosely install
pembuangan gas, all of the exhaust
pasanglah semuapipepengikat
fasteners.exhaust
Always pipe
tighten the exhaust
dengan joint Selalu
longgar. first, then tighten the
kencangkan
mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly.
exhaust joint (penyambung pipa pembuangan gas) dulu, kemudian kencangkan mounting fasteners (pengikat pemasangan).
• Always inspect the
Jika mounting exhaust system
fasteners for leaks dulu,
dikencangkan after installation.
exhaust pipe mungkin tidak akan duduk dengan benar.
• Setelah pemasangan, selalu periksa sistem pembuangan gas terhadap kebocoran.
TORQUE
NILAI VALUES
TORSI
Cooling
Cooling fan
fancover
coverscrew
screw 0.8 N·m
0,8 N.m (0,1 (0.1 kgf·m,
kgf.m; 0.6 lbf·ft)
0,6 lbf.ft)
Cooling
Cooling fan
fancover
coverbolt
bolt 9 N.m9 (0,9
N·m kgf.m;
(0.9 kgf·m, 6.6 lbf·ft)
6,6 lbf.ft)
Muffler mounting
mountingbolt
bolt 5.9 N·m
5,9 N.m (0,6 (0.6 kgf·m,
kgf.m; 4.4 lbf·ft)
4,4 lbf.ft)

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

2-3
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
FRONT UPPER COVER
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Remove thesebagai
Lepaskan following:
berikut:
-– Headlight
Two boltsbulband license
socket plate
(hal. holder
17-6) from the front side LICENSE PLATE HOLDER
-– Position
Two screws
light from
bulb the lower(hal.
socket front17-6)
side
-– Front
Six screws from the
turn signal lightrear side
bulb sockets (hal. 17-8) FRONT UPPER COVER
-Remove
Enam the screws
front upper cover by releasing the following:
Be careful
Hati-hati agarnot to
tidak - Front turn signal units kanan/kiri 6P CONNECTOR
damage
merusak tabs,the tabs,
stoppers
danslots.
stoppers and slots. -– Headlight
Tabs on the lower front
adjusting boltside of the front upper cover from
the slots on
- Headlight the front lower cover
retainers
-– Headlight
Stoppers unit
around the rear side of the front upper cover BOLTS
from the front inner upper cover and front inner cover
Perakitan adalah dalam urutan terbalik dari
Disconnect the headlight/front turn signal light 6P connector.
pembongkaran.
Remove the two cushion rubbers.
Setel arah sinar headlight (hal. 3-18) setelah
Installation is in
pemasangan the reverse
front order of removal.
upper cover.

TABS

STOPPERS

CUSHION RUBBERS SCREW

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

Lepaskan headlight/front turn signal light 6P connector


(connector 6P lampu besar/lampu sein).

Lepaskan kedua cushion rubbers.


Pemasangan adalah dalam urutan terbalik dari
pelepasan.

BOLT
RETAINERS
HEADLIGHT UNIT

2-4
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
FRONT HANDLEBAR
FRONT HANDLEBAR COVER
COVER
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Longgarkan rear view
Loosen the rearview mirror
mirror lock nuts (mur pengunci
lock nuts.
kaca
Removespion).
the rearview mirrors by turning them counterclock- REAR VIEW MIRRORS
Lepaskan
wise. rear view mirrors (kaca spion) dengan
memutar mereka berlawanan arah jarum jam. FRONT HANDLEBAR COVER
Remove the following:
– Two screws
Lepaskan fromberikut:
sebagai the front side STOPPER
– Two screws from the rear side
- Dua screws dari sisi depan
Hati-hati agarnot
Be careful to -Remove
tidak the front
Dua screws handlebar
dari cover by releasing the following:
sisi belakang BOSSES
merusak
damagebosses, tabs,
the bosses,
– Four bosses on the upper side of the front handlebar cover
stoppers
tabs, and Lepaskan front handlebar cover dengan melepaskan
dan slots.
stoppers
from berikut:
sebagai the hole on the rear handlebar cover
slots.
– Two slots on the upper side of the front handlebar cover
from thebosses
- Empat tabs on the
padarearsisi
handlebar coverfront handlebar
atas dari
– cover
Two dari
stoppers on the
lubang padafront handlebar
rear cover
handlebar from the slots
cover. HOLES
- Duaon the combination
slots pada sisimeter
atas dari front handlebar cover
– dari
Hole
tabson pada
the front
rearhandlebar
handlebarcover from the front brake
cover.
master cylinder
- Dua stoppers pada front handlebar cover dari slots SLOT
pada combination
Installation meter.order of removal.
is in the reverse
- Lubang pada front handlebar cover dari front brake
master cylinder
TAB
Pemasangan adalah dalam urutan terbalik dari
pelepasan.

SCREW

REAR HANDLEBAR
HANDLEBAR COVER
COVER
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan
Remove thesebagai berikut:
following:
-– Front FRONT BRAKE REAR HANDLEBAR COVER
Frontupper
uppercover
cover (hal.
(page2-4)
2-4)
-– Front
Fronthandlebar
handlebar cover (hal. 2-5)
cover (page 2-5) LIGHT SWITCH
REAR BRAKE
CONNECTORS
Lepaskan/keluarkan
Disconnect/release theconnectors/kawat-kawat berikut ini:
following connectors/wires: LIGHT SWITCH
CONNECTORS
-? Speedometer
Speedometer cable dari the
cable from combination
combinationmeter.
meter SPEEDOMETER
-– Horn
Hornconnectors
connectors CABLE
-– Brake
Front/rear brake light
light switch switch connectors
connectors depan/belakang
-– Handlebar
Handlebar switch/speedometer
switch/speedometer wire 4P and 4P
wire 6P connectors
dan 6P
– connectors
Handlebar switch/speedometer wire boss from the han-
dlebar
- Handlebar switch/speedometer wire boss dari
– handlebar
Handlebar switch/speedometer wire from the wire guide
-Remove
Handlebar switch/speedometer wire dari wire guide WIRE
the following:
BOSS
Lepaskan sebagai
– Three screws berikut:
from the front side
– Rear handlebar cover
- Tiga screws dari sisi depan
Route
Alurkan wirethe wire -Installation
harness Rear handlebar
is in thecover
reverse order of removal.
dengan benar
harness (hal. Pemasangan adalah dalam urutan terbalik dari
properly
1-14).
(page 1-14). pelepasan.

HORN
WIRE GUIDE CONNECTORS

SCREWS 4P/6P CONNECTORS

2-5
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
FRONT
FRONT LOWER
LOWER COVER
COVER
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan
Remove thesebagai berikut:
following:
-– Front
Frontupper
uppercover
cover (hal.
(page2-4)
2-4)
-– Empat
Two screws
screwsfrom
dariboth
sisi sides
depan
-– Bolt
Two screws
dan fromhook
luggage the lower
dari front side
sisi belakang
Remove thewire
Lepaskan frontboss
lowerdari
cover by releasing
lubang the inner
dari front hooks upper
on its
lower side from the under cover.
cover.
Tarik frontis inner
Installation cover order
in the reverse sedikit ke belakang untuk
of removal.
Be careful not to
Hati-hati agar
damage the tidak
hooks.
membuat ruangan bagi pelepasan front inner upper
merusak hooks. cover.
Lepaskan bagian atas dari front inner upper cover dari
rear handlebar cover, kemudian tarik ke atas dan
keluarkan.

Pemasangan adalah dalam urutan terbalik dari


pelepasan.

SCREWS

FRONT LOWER COVER


HOOKS

FRONT
FRONT INNER
INNER UPPER
UPPER COVER
COVER
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan
Remove thesebagai berikut:
following:
-– Front
Frontupper
uppercover
cover (hal.
(page2-4)
2-4) FRONT INNER UPPER COVER
-– Dua screws
Four screwsdari
fromkedua sisiside
the front
-– Dua
Boltscrews dari sisi
and luggage hookdepan
from bawah
the rear side HOLE

Lepaskan
Release thefront
wire lower cover
boss from thedengan melepaskan
hole of the front inner hooks
upper BOLT
cover.sisinya yang bawah dari under cover.
pada WIRE BOSS
Slightly pull the front inner cover backward to make space
Hati-hati agarnot
Be careful tidak
to for front inner upper
Pemasangan cover removal.
adalah dalam urutan terbalik dari
merusak
damagefront
the inner
front Release the
pelepasan. upper side of the front inner upper cover from the
covercover
inner dan front
and inner
front rear handlebar cover, then pull it upward and remove it.
upper cover.
inner upper cover.
Installation is in the reverse order of removal.

LUGGAGE
HOOK

SCREWS

2-6
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS

FRONT FENDER (SPAKBOR DEPAN)


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

BOLTS

LUGGAGE BOX (KOTAK BAGASI)


PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan
Remove thesebagai berikut:
following:
WIRE HARNESS COVER BOLTS
-– Baterai
Battery(hal.
(page14-12)
14-12)
-– ICM
ICM(hal. 15-11)
(page 15-11)
-– Screw
Screwdari
fromsisi
thedepan atas side
front upper
-– Dua
Twoscrews
screwsdari
fromkedua sisi
both sides
-– Dua
Twobolts
boltsdan
andcollars
collars dari
fromsisi
the belakang
upper rear atas
side
-– Dua
Twobolts
boltsdari
from thedepan
sisi inner front
dalam side
COLLARS
-– Wire
Wireharness
harness cover
cover
Remove the luggage box upward while pulling the wire har-
Alurkan wire harness Lepaskan luggage box ke atas sementara menarik wire
ness out of
dengan benar (hal. harness its hole.
keluar dari lubangnya.
1-14)
Route the wire Installation is in the reverse order of removal.
harness properly Pemasangan adalah dalam urutan terbalik dari
(page 1-14) pelepasan. LUGGAGE
SCREWS BOX

WIRE
HARNESS

2-7
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
CENTER
CENTER BODY
BODY COVER
COVER
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan kunci
Unlock the seat withtempat duduk
the ignition key. dengan anak kunci
kontak.
Open the seat.
Buka tempat duduk. HOOK SCREWS
Remove the following:
Lepaskan sebagai
? Screw from frontberikut:
upper side
-– Screw
Two screws from
dari sisi frontatas.
depan lower side
-– Dua
Two screwsdari
screws fromsisi
both sides bawah
depan
-Push
Duathescrews
upperdarifrontkedua
side ofsisithe center body cover upward
and release
Dorong ke itatas
fromsisi
the depan
floor panel.
atas dari center body cover
Hati-hati agarnot
Be careful tidak
to dan lepaskan dari panel lantai.
Remove the center body cover while releasing its hooks from
merusak hooks dan the slots on the body cover by sliding it forward.
damage the hooks
slots. Lepaskan center body cover sementara melepaskan
and slots.
Installation isdari
hooks-nya in the reverse order of body
slots pada removal.cover dengan
menggesernya ke depan.

Pemasangan adalah dalam urutan terbalik dari


pelepasan.
SLOT CENTER BODY COVER

TEMPAT
SEAT DUDUK
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan
Remove thecenter
centerbody
body cover (hal. 2-8).
cover (page 2-8)
LUGGAGE BOX LID
Lepaskan
Unhook the kaitan
luggage dari luggage
box lid boxit. lid (tutup kotak
and remove
bagasi)
Slide thedan
pin lepaskan.
out and remove the seat.
Geser pin keluar dan lepaskan tempat duduk.
Installation is in the reverse order of removal.
Pemasangan adalah dalam urutan terbalik dari
pelepasan.

TEMPAT
DUDUK

PIN

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

2-8
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
BODY COVER
BODY COVER
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan
Remove thesebagai berikut:
following:
-– Center
Centerbody
bodycover
cover (hal.
(page2-8)
2-8)
-– Grab
Grabrail
rail(hal.
(page2-8)
2-8)
-– Dua
Two screwsdari
screws fromsisi
thebawah
lower side
-– Special
Specialbolt
boltdari
fromsisi
thekiri
lower left side
bawah
-– Dua
Two boltsdari
bolts from theatas
sisi upper side
Hati-hati agarnot
Be careful tidak Remove the body
to Lepaskan body covercover
by releasing
denganthe following tabs/
melepaskan
merusak
damage hooks dan tabs/bosses/hooks
the hooks bosses/hooks: berikut ini:
tabs.
and tabs. - Rear shock absorber cover tab dengan agak
– Rear shock absorber cover tab by slightly bending it
– membengkokkannya
Grab rail mounting bosses by slightly pulling the body
- Grab
coverrail mounting bosses dengan sedikit menarik
upward
body cover
– Hooks on the ke atas
front side of the body cover by pulling it
- Hooks pada sisi depan dari body cover dengan
backward
menariknya ke belakang
Disconnect the tail/brake light/rear turn signal light 6P con-
nector.
Lepaskan tail/brake light/rear turn signal light 6P
AlurkanRoute
wire the wire connector.
harness Installation is in the reverse order of removal.
dengan benar
harness (hal. Pemasangan adalah dalam urutan terbalik
properly dari
1-14). pelepasan.
(page 1-14).

BOLTS
BODY COVER
SCREWS

HOOKS/TABS

REAR SHOCK
ABSORBER
COVER TAB
SPECIAL BOLT
GRAB RAIL MOUNTING TAIL/BRAKE LIGHT/REAR TURN
BOSSES SIGNAL LIGHT 6P CONNECTOR

2-9
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
PEMBONGKARAN/PERAKITAN
DISASSEMBLY/ASSEMBLY
Lepaskan
Remove the sebagai berikut:
following:
- –Empat screws
Four screws
- – Tail/brake
Tail/brake light/rear turnsignal
light/rear turn signal unit unit (unit lampu
lightlight
– belakang/lampu rem/lampu sein belakang)
Right/left body covers
- –Body
Twocovers
screwskanan/kiri
- –Dua screws
Rear shock absorber cover
- Rear shock absorber cover
Assembly is in the reverse order of disassembly.
Perakitan adalah dalam urutan terbalik dari
pembongkaran. TAIL/BRAKE LIGHT/REAR TURN
SIGNAL LIGHT UNIT
SCREWS

SCREWS

BODY COVER

REAR SHOCK
ABSORBER COVER

UNDER
UNDER COVER
COVER
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan sebagai
Remove the berikut:
following:
- –Dua
Twoscrews
screwsdari
fromsisi
thedepan
front side HOOKS
- –Empat screwsfrom
Four screws dari both
kedua sisi
sides SCREWS
- –Dua
Twoscrews
screwsdari
fromsisi belakang
rear side
Lepaskan
Remove theunder coverbydengan
under cover releasing melepaskan
the following: sebagai
berikut:
– Hooks on the front side from the slots on front lower
- Hooks pada sisi depan dari slots pada front lower
cover
cover
– Tabs on both sides from the floor step
- Tabs pada kedua sisi dari floor step
Installation is in the reverse order of removal.
Pemasangan adalah dalam urutan terbalik dari
pelepasan.

TABS

UNDER COVER SCREWS

2-10
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
FLOOR PANEL/FRONT
FLOOR PANEL/FRONT INNER
INNERCOVER
COVER
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Lepaskan sebagai
Remove the berikut:
following:
- –Front
Frontlower
lowercover
cover(hal.
(page2-6)
2-6) FLOOR PANEL/FRONT INNER COVER
- –Front
Frontinner
innerupper
uppercover (hal. 2-6)
cover (page 2-6)
- –Body
Bodycover
cover(hal.
(page2-9)
2-9)
- –Under
Undercover
cover(hal.
(page2-10)
2-10)
Remove the
Lepaskan floorpanel/front
floor panel/frontinner
inner cover
cover assembly
assemblybydengan
pulling
it upward while
menariknya ke releasing the screwmelepaskan
atas sementara tabs from thescrew
frame. tabs
dari rangka.is in the reverse order of removal.
Installation
Pemasangan adalah dalam urutan terbalik dari
pelepasan.

SCREW
TABS

REAR FENDER
REAR FENDER (SPAKBOR BELAKANG)
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan sebagai
Remove the berikut:
following:
BOSSES HOOKS
- –Body
Body cover
cover(hal.
(page2-9)
2-9)
- –Fuel
Fueltank
tank(hal.
(page5-26)
5-26) BOLTS
Lepaskan ketiga
Remove the three bolts.
bolts.
Lepaskan
Remove therearrear fender sementara
fender while releasingmelepaskan
the bosses andbosses
hooks
by pulling
dan hooksitdengan
straight back and remove
menariknya it. ke belakang dan
lurus
melepaskannya.
Installation is in the reverse order of removal.
Pemasangan adalah dalam urutan terbalik dari
pelepasan.

REAR FENDER

2-11
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
LEFT CRANKCASE
LEFT CRANKCASE COVER
COVER DUCT
DUCT
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Lepaskan
Remove thesebagai berikut:
following:
-– Dua
Twobolts
bolts
-– Left crankcase
Left crankcase cover duct
cover duct LEFT CRANKCASE COVER DUCT
– Packing
Packing is in the reverse order of removal.
-Installation
Pastikan
Make sure bahwa
the
packing berada Pemasangan adalah dalam urutan terbalik dari
packing is indalam
good
kondisi baik dan ganti pelepasan.
condition and replace
bila perlu.
it if necessary.

PACKING

BOLTS

COOLING
COOLING FAN
FAN COVER
COVER
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan kedua screws dan kedua bolts.
Remove the two screws and two bolts.
Lepaskan starting enrichment (SE) thermal valve wire
Release
dan the starting
starter enrichment
motor wire (SE)guide
dari wire thermal valve
dari wire and
cooling fan SE THERMAL VALVE/STARTER MOTOR WIRE
starter motor wire from the wire guide of the cooling fan
cover.
cover.
Lepaskan
Remove thecooling
coolingfan
fancover.
cover.
Alurkan
Route wire
the wire Pemasangan adalah
Installation is in the reversedalam
order of urutan
removal. terbalik dari
harness dengan baik
harness properly pelepasan.
(hal.1-14).
1-14) TORQUE:
(page SCREW
Cooling fan cover screw:
TORSI:
Cooling fan (0.1
0.8 N·m cover screw:
kgf·m, 0.6 lbf·ft)
Cooling0,8fan
N.m (0,1bolt:
cover kgf.m; 0,6 lbf.ft)
Cooling
9 N·mfan cover
(0.9 kgf·m,bolt:
6.6 lbf·ft)
9 N.m (0,9 kgf.m; 6,6 lbf.ft) JOINT NUTS

COOLING FAN COVER

BOLTS

2-12
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
TRIM CLIPS
REMOVAL
PELEPASAN
Push the
Tekan centerpin
center pindari
of the trim
trim clip.
clip.
Remove thetrim
Lepaskan trimclip.
clip. CENTER PIN TRIM CLIP

INSTALLATION
PEMASANGAN
Naikkan centerpinpin
Raise the center denganthe
by pushing menekan retaining
retaining tabs back. tabs
kembali. RETAINING TABS
Install the trim clip.
Push the trim
center pin until the pin is flush with the outer casing. CENTER PIN
Pasang clip.
Tekan center pin sampai pin rata dengan outer casing.

TRIM CLIP

CENTER PIN
TRIM CLIP

BATTERY COVER
BATTERY COVER
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Unlock the ignition key.
Buka
Open penguncian
the seat. dengan anak kunci kontak.
Naikkan tempat duduk. BATTERY COVER
Remove the trim clip (see page 2-13).
Remove thetrim
Lepaskan battery
clip cover.
(lihat hal. 2-13).
Lepaskan battery cover.
Installation is in the reverse order of removal.
Pemasangan adalah dalam urutan terbalik dari
pelepasan.

TRIM CLIP

2-13
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
EXHAUST PIPE/MUFFLER
PIPE/MUFFLER (KNALPOT)
PELEPASAN
REMOVAL
Remove thesebagai
Lepaskan following:
berikut:
-– Dua
Two jointnuts
joint nuts
-– Dua
Two mufflermounting
muffler mountingbolts
bolts
JOINT
GASKET
-– Exhaust
Exhaustpipe/muffler
pipe/muffler
NUTS
-– Gasket
Gasket

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

BOLTS

EXHAUST PIPE/MUFFLER

2-14
3. PERAWATAN

KETERANGAN SERVIS ...........................3-2


SERVICE INFORMATION ?????????????? 3-2 OLI FINAL
FINAL DRIVE
DRIVE .....................................
OIL ???????????????????? 3-13 3-13

JADWAL PERAWATAN
MAINTENANCE ...........................3-4
SCHEDULE ??????????? 3-4 MINYAK
BRAKEREM............................................
FLUID ??????????????????????? 3-14 3-14

SALURAN BAHAN
FUEL LINE BAKAR .....................3-5
??????????????????????????? 3-5 KEAUSAN BRAKE SHOES/PADS...........
BRAKE SHOES/PADS 3-15
WEAR ?????????? 3-15

CARA KERJA OPERATION


THROTTLE THROTTLE .......................3-5
?????????????? 3-5 SISTEM
BRAKEREM ............................................
SYSTEM ????????????????????? 3-15 3-15

AIRAIR
CLEANER ..........................................3-6
CLEANER ???????????????????????? 3-6 BRAKE
BRAKELIGHT
LIGHTSWITCH
SWITCH...........................
?????????????? 3-17 3-17

CRANKCASE BREATHER.......................3-6
CRANKCASE BREATHER?????????????? 3-6 CARA KERJA
BRAKE LOCKBRAKE LOCK???????????
OPERATION ..................3-17
3-17

SPARK PLUG
SPARK PLUG(BUSI) ...............................3-7
????????????????????????? 3-7 PENYETELAN ARAH
HEADLIGHT AIM LAMPU BESAR ....3-18
???????????????????? 3-18

JARAK RENGGANG
VALVE KLEP......................3-8
CLEARANCE ?????????????????? 3-8 KEAUSAN CLUTCH
CLUTCH SHOES SHOES....................3-18
WEAR??????????????? 3-18

OLIENGINE
MESIN OIL
................................................3-9
?????????????????????????? 3-9 SIDESTAND ..............................................3-18
SIDESTAND?????????????????????????? 3-18

ENGINE OIL
ENGINE STRAINER
OIL STRAINERSCREEN.........3-11
SCREEN?????? 3-11 SUSPENSI ................................................3-19
SUSPENSION????????????????????????? 3-19

PUTARAN
ENGINE STASIONER MESIN .............3-11
IDLE SPEED ????????????????? 3-11 MUR, BAUT,
NUTS, PENGIKAT
BOLTS, ..........................
FASTENERS ??????????? 3-20 3-20

SECONDARY AIR
SECONDARY AIRSUPPLY
SUPPLY SYSTEM....3-12
SYSTEM ??? 3-12 RODA/BAN ...............................................
WHEELS/TIRES ?????????????????????? 3-20 3-20

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


DRIVE BELT ????????????????????????? 3-13
STEERING HEAD BEARINGS ................. 3-21
STEERING HEAD BEARINGS?????????? 3-21

3-1
PERAWATAN
SERVICE INFORMATION
KETERANGAN SERVIS
MAINTENANCE

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

SPESIFIKASI ITEM SPECIFICATIONS


Throttle grip freeplay 2 – 6 mm (0.1 – 0.2 in)
BAGIAN
Spark plug Standard SPESIFIKASI
CPR8EA-9 (NGK)
Jarak main bebas throttle Forgripextended high speed riding 2 – 6 mm(NGK)
CPR9EA-9
Busi
Spark plug gap Standard CPR8EA-9
0.80 – 0.90 mm(NGK), (0.031 U24EPR9
– 0.035 in) (DENSO)
Valve clearance Untuk
IN pengendaraan lama pada 0.14
CPR9EA-9
± 0.02 mm(NGK) (0.006 ± 0.001 in)
kecepatan
EX tinggi 0.14 ± 0.02 mm (0.006 ± 0.001 in)
Jarak renggangengine
Recommended busi oil 0,80 "4-stroke
Honda – 0,90 mm motorcycle oil" or an equivalent motor oil API service
Jarak renggang klep IN (Masuk) 0,14 ± 0,02SG
classification: mm or higher (except oils labeled as energy conserving on
EX (Buang) the0,14 ± 0,02
circular APImm service label)
Oli mesin yang dianjurkan JASO
FederalT 903Oil standard:
Supreme MB Flick atau oli mesin 4 tak sejenis
Viscosity:
dengan SAE 10W-30
klasifikasi API service SG,
Engine oil capacity After draining 0.7Viskositas:
liter (0.7 US qt, 0.6
SAE Imp qt)
10W-30 JASO MB
Kapasitas oli mesin After penggantian
Pada disassembly periodik 0.80,7
liter (0.8 US qt, 0.7 Imp qt)
liter
Engine idle speed Pada pembongkaran mesin 0,8 ±
1,700 100 min-1 (rpm)
liter
Drive belt
Putaran width mesin
stasioner 1.700 ± 10017.5
Service limit: mm-1 (0.69
menit (rpm)in)
Recommended
Lebar drive beltfinal reduction oil Honda
Batas "4-stroke
servis: motorcycle
17,5 mm oil" or an equivalent motor oil API service
Oli final reduction yang dianjurkan classification:
Federal OilSGSupreme or higher (except oils labeled
Flick atau as energy
oli mesin conserving
4 tak sejenison
thedengan
circularklasifikasi
API serviceAPI label)
service SG,
JASO T 903 standard:
Viskositas: SAE 10W-30 MB JASO MB
Kapasitas oli final Pada penggantian periodik Viscosity:
0,10 literSAE 10W-30
Final reduction oil
reduction After pembongkaran
Pada draining 0.10
0,12liter (0.11 US qt, 0.09 Imp qt)
liter
capacity
Jarak main bebas handel After disassembly
rem belakang 0.12
10 liter
– 20(0.13
mm US qt, 0.11 Imp qt)
Rear brakeclutch
Ketebalan lever free play(kanvas kopeling)
lining 10Batas
– 20 mm (0.4 2,0
servis: – 0.8mm in)
Clutch lining thickness
Tekanan udara ban Pengendara Depan Service limit: 2.0 mm
200 kPa (2,00 kgf/cm , 29 (0.082 in)
psi)
2
Cold tire pressure
dingin Driver only
saja Front
Belakang 200225kPakPa (2.00 kgf/cm
(2,25 kgf/cm, 292,psi)
33 psi)
2
Pengendara dan Depan Rear 225200kPakPa (2.25 kgf/cm
(2,00 kgf/cm, 332,psi)
29 psi)
2
Driver and
pembonceng passenger Front
Belakang 200 kPa (2.00 kgf/cm
225 kPa (2,25 kgf/cm , 292,psi)
33 psi)
Ukuran ban Depan Rear 225 kPa (2.25
80/90 kgf/cm2, 33 psi)
– 14M/C40P
Tire size Front
Belakang 80/90
90/90 – 14M/C40P
– 14M/C46P
Merek ban SRI Depan Rear 90/90
FT235 – 14M/C46P
Tire brand SRI Front
Belakang FT235
FT235
Kedalaman minimum alur telapak ban Depan Rear FT235
Sampai ke indikator
Minimum tire tread depth Front
Belakang ToSampai
the indicator
ke indikator
Rear To the indicator

3-2
PERAWATAN
TORQUE
NILAI VALUES
TORSI
Spark plug
Spark plug(busi) 16 N.m
16 N·m (1,6 kgf.m;
(1.6 kgf·m, 12 lbf.ft)
12 lbf·ft)
AirAir
cleaner
cleanerhousing
housingcover
cover screw
screw 1,1 N.m
1.1 N·m (0,1 kgf.m;
(0.1 kgf·m, 0,8 lbf.ft)
0.8 lbf·ft)
Valve
Valve adjusting screw lock
adjusting screw lock nut
nut 10 N·m (1.0 kgf·m, 7 lbf·ft) lbf.ft) ApplySemprotkan
10 N.m (1,0 kgf.m; 7 engine oil to oli
themesin
threadspada
and ulir dan
seatingpermukaan
surface. duduk
Engine
Engineoiloil
drain
drainbolt
bolt 24 N.m
24 N·m (2,4 kgf.m;
(2.4 kgf·m, 18 lbf.ft)
18 lbf·ft)
Engine
Engine oil strainerscreen
oil strainer screen cap
cap 20 N·m (2.0 kgf·m, 15 lbf·ft) lbf.ft)
20 N.m (2,0 kgf.m; 15
Final reduction
Final reductionoiloilcheck
checkbolt
bolt 13 N.m
13 N·m (1,3 kgf.m;
(1.3 kgf·m, 10 lbf.ft)
10 lbf·ft)
Final reduction oil drain bolt 13 N.m (1,3 kgf.m; 10 lbf.ft)
Final reduction oil drain bolt 13 N·m (1.3 kgf·m, 10 lbf·ft)

TOOLS
TOOLS
Valve adjusting wrench
07908-KE90000

3-3
PERAWATAN
MAINTENANCE SCHEDULE
JADWAL PERAWATAN
Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.
Jalankan Pemeriksaan Sebelum Jalan di dalam Buku Pedoman Pemilik pada masing-masing periode perawatan yang
I:dijadwalkan.
Inspect and Clean, Adjust,dan
P: Periksa Lubricate or Replace
Bersihkan, if Lumasi
Setel, necessary. C: Clean.
atau R: Replace.
Ganti bila A:Bersihkan.
perlu. B: Adjust. L: Lubricate.
G: Ganti. L: Lumasi. PB: Perawatan
Berkala. Bagian-bagian berikut memerlukan pengetahuan mekanis tertentu. Beberapa
The following items require some mechanical knowledge. Certain items (particularly those marked bagian
* and(terutama yang ditandai
**) may require * dan infor-
more technical **)
mation
dapat and tools. Consult
memerlukan lebihanbanyak
authorized Honda dealer.
informasi teknis dan perkakas khusus. Hubungi AHASS Anda.
FREQUENCY WHICHEVER
JADWAL PERAWATAN BERKALA, MANA YANG TERCAPAI TERLEBIH DAHULU
COMES FIRST ODOMETER READING (NOTE 1)
FREKUENSI → PEMBACAAN ODOMETER (km) - Catatan 1 LIHAT
REFER TO
X1,000 km 1 4 8 12 HALAMAN
↓ PB 1 PB 2 X1,000
PB mi3 PAGE
BAGIAN YANG DISERVIS 0.6 2.5 5 7.5
ITEMS 500 2.000 Months
4.000 8.000 6 12.000
12 18
** FUEL
SALURAN
LINEBAHAN BAKAR P P P P I PI I 3-5
3-5
** THROTTLE
CARA KERJAOPERATION
GAS TANGAN P P P P I PI I 3-5
3-5
** AIR
AIR CLEANER
CLEANER Catatan 2 NOTE2 SETIAPEVERY
16.000 km: G km (10,000 mi) R
16,000 3-6
3-6
CRANKCASE BREATHER
CRANKCASE BREATHER Catatan 4 NOTE4
B B B B C B
C C 3-6
3-6
BUSI
SPARK PLUG P P P G I P
R I 3-7
3-7
** VALVE
JARAK RENGGANG
CLEARANCE KLEP P P P PI I PI I 3-8
3-8
OLI MESINOIL
ENGINE G G SETIAP
R 4.000
R km: GR R 3-9
3-9
** ENGINE
ENGINE OIL
OILSTRAINER
STRAINERSCREEN
SCREEN - - - B - C 3-11
3-11
** ENGINE
PUTARANIDLE
STASIONER
SPEEDMESIN P P P PI I PI I 3-11
3-11
** SECONDARY
SECONDARY AIR SUPPLY
AIR SYSTEM
SUPPLY SYSTEM P - - - P I 3-12
3-12
* DRIVE BELT SETIAP 8.000 km: P 3-13
* DRIVE BELT EVERY 8,000 km (5,000 mi) I,
SETIAP 24.000 km: Gkm (15,000 mi) R 3-13
EVERY 24,000
* OLI FINAL DRIVE Catatan 3 3-13
* FINAL DRIVE OIL NOTE3 3-13
MINYAK REM Catatan 3 P P P P P 3-14
BRAKE FLUID NOTE3 I I I 3-14
KEAUSAN BRAKE SHOES/PADS P P P P P 3-15
BRAKE SHOES /PADS WEAR I I I 3-15
SISTEM REM P P P P P 3-15
BRAKE SYSTEM I I I I 3-15
* SAKELAR LAMPU REM P P P P P 3-17
* BRAKE LIGHT SWITCH I I I 3-17
* CARA KERJA BRAKE LOCK P P P P P 3-17
* BRAKE LOCK OPERATION I I I I 3-17
* ARAH SINAR LAMPU BESAR P P P P P 3-18
* HEADLIGHT AIM I I I 3-18
** KEAUSAN CLUTCH SHOES - - - P - 3-18
** CLUTCH SHOES WEAR I 3-18
STANDARD SAMPING P P P P P 3-18
SIDESTAND I I I 3-18
* SUSPENSI P P P P P 3-19
* SUSPENSION I I I 3-19
* MUR, BAUT, PENGENCANG P P P P P 3-20
*** NUTS, BOLTS, FASTENERS
RODA/BAN Catatan 3 P P P P
I P
I 3-20
3-20
**** WHEELS/TIRES
BANTALAN KEPALA KEMUDI P - - PI I -I I 3-20
3-21
** STEERING HEAD BEARINGS I I 3-21
* HARUS DISERVIS OLEH AHASS, KECUALI BILA PEMILIK MEMPUNYAI TOOLS YANG TEPAT DAN DATA
* SERVIS
SHOULD
YANGBE SERVICEDDAN
DIPERLUKAN, BY AN AUTHORIZED
MEMPUNYAI Honda MEKANIS
KETRAMPILAN DEALER,UNTUK
UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE
MENGERJAKANNYA.
DATA AND IS MECHANICALLY QUALIFIED.
** DEMI KEAMANAN, KAMI MENGANJURKAN AGAR PEKERJAAN-PEKERJAAN INI HANYA DILAKUKAN OLEH
** AHASS.
IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED Honda
DEALER.
CATATAN:
NOTES:
1. Pada pembacaan odometer lebih tinggi, ulangilah pada interval frekuensi yang ditentukan di atas.
1.2. AtServis
higher lebih
odometer readings,
sering repeat at the
jika dikendarai di frequency interval
daerah yang luarestablished
biasa basahhere.
atau berdebu.
2.3. Service more frequently when riding in unusually wet or dusty areas.
Ganti setiap 2 tahun. Penggantian memerlukan ketrampilan mekanis.
3. Replace every 2 years. Replacement requires mechanical skill.
4. Servis lebih sering jika dikendarai dalam hujan atau dengan gas penuh.
4. Service more frequently when riding in rain or at full throttle.

3-4
PERAWATAN
FUEL LINEBAHAN BAKAR
SALURAN
Lepaskan
Remove thebody
bodycover
cover(hal. 2-9)
(page 2-9)
Periksa fuel hose (slang bahan
Check the fuel hose for deterioration, bakar)
damage terhadap
or leakage.
pemburukan kondisi, kerusakan atau kebocoran.
Replace the fuel hose if necessary.
Ganti
Also,fuel hose
check bila hose
the fuel perlu.fittings for leakage.
Juga,
Installperiksa
the bodyfuel hose
cover fittings
(page 2-9). (peralatan pemasangan
fuel hose) terhadap kebocoran.

Pasang body cover (hal. 2-9)

FUEL HOSE

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

Sementara mesin berputar stasioner, putar handlebar


(stang stir) sama sekali ke kanan dan kiri untuk
memastikan bahwa putaran stasioner tidak berubah.
Jika putaran stasioner naik, periksa jarak main bebas
throttle grip dan alur perletakan throttle cable.

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

3-5
PERAWATAN
Throttle
Jarak grip free
main bebasplaythrottle
can be adjusted by turning
grip dapat the adjuster.
disetel dengan
memutar adjuster (penyetel).
Remove the body cover (page 2-9). ADJUSTER
Loosen thebody
Lepaskan lock nut and(hal.
cover turn 2-9).
the adjusting nut as required.
Tighten the lock
Longgarkan locknut.
nut (mur pengunci) dan putar adjusting
nut
Recheck the throttlesebanyak
(mur penyetel) operation. diperlukan.
Install the body
Kencangkan cover
lock nut.(page 2-9).
Periksa kembali cara kerja throttle.
Pasang body cover (hal. 2-9).

LOCK NUT

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

CRANKCASE BREATHER
? Service more frequently when ridden in rain, at full throt-
CATATAN:
tle, or after the scooter is washed or overturned. Service if
• Servis lebih sering jika dikendarai dalam hujan, HOSE CLAMP
the deposit level can be seen in the transparent section of
atau pada gas penuh, atau setelah skuter dicuci
the drain hose.
atau telah terbalik. Lakukan servis bila tinggi
Release the crankcase
permukaan breather
endapan drain
dapat hose dalam
terlihat from the hose
bagian
clamp.
tembus pandang dari drain hose (slang
pembuangan).
Remove the crankcase breather drain hose plug from the hose
end and drain deposits into a suitable container.
Lepaskan crankcase breather drain hose (slang
Install the crankcase
pembuangan breather
pernapasan bakdrain hosedari
mesin) plughose
and set the
clamp
crankcase
(klem breather hose to the hose clamp.
slang).
Remove the body cover (page 2-9).
Lepaskan crankcase breather drain hose plug
(penyumbat slang pembuangan pernapasan bak mesin) DRAIN HOSE HOSE PLUG
dari ujung hose dan keluarkan endapan ke dalam
penampung yang sesuai.

Pasang crankcase breather drain hose plug dan


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

3-6
PERAWATAN
SPARK PLUG
Lepaskan body cover (hal. 2-9).
Periksa crankcase breather hose terhadap pemburukan
kondisi, kerusakan atau kebocoran.
? Clean around the spark plug base with compressed air ore
removing
Ganti the plug,
crankcase and make
breather hose sure
bila that no debris is
perlu.
Juga periksa crankcase breather hose fittings terhadap
?
kebocoran.

Pasang body cover (hal. 2-9).


?

?
BREATHER HOSE
SPARK PLUG (BUSI)
? allowed to enter the combustion chamber.
CATATAN:
Remove the center body cover (page 2-8).
• Bersihkan disekitar dasar busi dengan udara dari
Disconnect the spark plug cap and clean around the spark
kompressor sebelum melepaskan busi, dan
plug base.
pastikan bahwa kotoran tidak memasuki ruang
Remove the spark plug.
pembakaran.

Lepaskan center body cover (hal. 2-8).


Lepaskan spark plug cap (topi busi) dan bersihkan
daerah di sekitar dasar busi.

Lepaskan spark plug.

SPARK PLUG CAP SPARK PLUG

Periksa atau
Inspect or ganti
replace seperti diuraikan
as described di dalamschedule
in the maintenance jadwal
(page 3-4). (hal. 3-4).
perawatan CENTER ELECTRODE
Periksa sebagai
Check the berikutnya
following danifganti
and replace bila perlu.
necessary.
•? Insulatorfor
Insulator terhadap
damage kerusakan
•? Electrodesfor(kutub-kutub
Electrodes wear busi) terhadap keausan
•? Kondisi condition,
Burning terbakar, coloration;
perubahan warna;
-? Coklat
Dark totua sampai
light browncoklat muda
indicates goodmenunjukkan
condition. kondisii
– baik.
Excessive lightness indicates malfunctioning ignition
- Warnaormuda
system yang berlebihan menunjukkan sistem
lean mixture.
? Wet or blackyang
pengapian sootytidak
deposit indicates
bekerja over-rich mixture.
dengan
baik
If the atau campuran
electrode bahan with
is contaminated bakarcarbon
yang deposits,
miskin. clean
- theEndapan yang basah atau hitam
electrode using a spark plug cleaner. arang menunjukkan
campuran bahan bakar yang terlalu INSULATOR SIDE ELECTRODE
Always
kaya.use the specified spark plug on this scooter.
SPECIFIED SPARK PLUG:
Jika elektroda terkontaminasi dengan endapan karbon,
Standard:
bersihkan electrode dengan menggunakan spark plug
cleaner.

Selalu pakai spark plug yang ditentukan pada skuter ini.


CPR8EA-9 (NGK)
For extended high
BUSI YANG DITENTUKAN:speed riding: CPR9EA-9 (NGK)
Standard:
CPR8EA-9 (NGK), U24EPR9 (DENSO)
Untuk pengendaraan lama pada kecepatan tinggi:
CPR9EA-9 (NGK)

3-7
PERAWATAN
Ukur jarak
Measure therenggang
spark plugbusi antara center
gap between electrodes
the center dan
and side elec-
side electrodes
trodes (elektrode
with a feeler gauge oftengah dan samping) dengan
a wire type.
If necessary,
feeler adjustvoeler)
gauge (alat the gap by kawat.
jenis bending the side electrode
carefully.
Bila perlu, setel jarak renggang busi dengan menekuk
electrode samping dengan hati-hati.
SPARK PLUG GAP: 0.80 – 0.90 mm (0.031 – 0.035 in)
0.80 – 0.90 mm
JARAK RENGGANG BUSI: 0,80 – 0,90 mm
(0.031 – 0.035 in)

Jangan not overtighten Pasang


Domengencangkan spark
Install and handplug (busi)
tighten the dengan tangan
spark plug to thepada cylinder
cylinder head,
theberlebihan.
busi secara then tighten
spark plug. head, the spark
kemudian plug to the specified
kencangkan torque.torsi yang
busi dengan
ditentukan.
TORQUE:16 N·m (1.6 kgf·m, 12 lbf·ft)
TORSI:
Connect 16the N.m
spark(1,6
plugkgf.m;
cap. 12 lbf.ft)
Pasang spark
Install the plug
center cap
body (topi(page
cover busi).
2-8).
Pasang center body cover (hal. 2-8).

SPARK PLUG CAP SPARK PLUG

JARAK
VALVE RENGGANG
CLEARANCEKLEP
PEMERIKSAAN
INSPECTION
CATATAN:
• ? Inspect
Periksaanddan setel
adjust thejarak
valve renggang klep the
clearance while sementara
engine is
mesin
cold dalam
(below keadaan dingin (di bawah 35° C).
35°C/95°F).
Remove the
Lepaskan following:
sebagai berikut:
PENUNJUK
? Cylinder
- Cylinder head headcover
cover (hal.
(page7-7)
7-7)
? Cooling fan cover (page 2-12)
- Cooling fan cover (hal. 2-12)
Rotate the crankshaft clockwise by rotating the cooling fan
Putar crankshaft (poros engkol) searah jarum jam
slowly and align the "T mark" on the flywheel with the index
dengan memutar cooling fan dengan pelan dan
notch on the right crankcase.
mentepatkan "tanda T" pada flywheel dengan index
Make (takik
notch sure the piston ispada
penunjuk) at TDC (Top
right Dead Center)
crankcase on the
(bak mesin
compression stroke.
kanan).
This position can be confirmed by checking that there is slack
in the rocker
Pastikan arm. piston berada pada TDC (Top Dead
bahwa
If there [TMA
Center) is no slack,
(TitikitMati
is because
Atas)] the piston
pada is moving
langkah through
kompressi.
the exhaust
Posisi stroke dipastikan
ini dapat to TDC. dengan memeriksa bahwa
Rotate
ada the crankshaftpada
kerenggangan one full turnarm.
rocker by rotating the cooling fan TANDA "T"
slowly
Jika and match
tidak up the "T" mark again.
ada kerenggangan, berarti bahwa piston
sedang bergerak melalui langkah pembuangan ke TDC.
Putar crankshaft satu putaran penuh dengan memutar
cooling fan dengan pelan dan mentepatkan "tanda T"
sekali lagi.

3-8
PERAWATAN
Check jarak
Periksa the valve clearance
renggang by inserting
klep dengan a feeler feeler
memasukkan gauge
between(lidah
gauge the valve adjustingantara
pengukur) screw and valveadjusting
valve stem. screw FEELER GAUGE
(sekrup penyetelan klep) dan valve stem (tangkai klep).
VALVE CLEARANCE:
IN: 0.14
JARAK ± 0.02 mm (0.006
RENGGANG KLEP:± 0.001 in)
EX: 0.14
IN: 0,14± 0.02 mm
± 0,02 mm(0.006 ± 0.001 in)
EX: 0,14 ± 0,02 mm

Jika
If thejarak
valverenggang
clearance klep tidak sesuai,
is incorrect, loosen longgarkan valve
the valve adjusting
adjusting
screw lockscrewnut andlock nut the
adjust danvalve
setelclearance
jarak renggang
by turningklep
the ADJUSTING SCREW LOCK NUT
dengan
adjustingmemutar
screw until adjusting
there is a screw sampai
slight drag on theada tahanan
feeler gauge.
sedikit
Apply padaenginefeeler gauge.
oil to the valve adjusting screw lock nut threads
and seating surface.
Semprotkan oli mesin pada ulir valve adjusting screw
Holdnut
lock thedan
adjusting screw and
permukaan tighten the lock nut.
duduk.
Tahan adjusting screw dan kencangkan lock nut.
TOOL:
Valve adjusting wrench
TOOL: 07908-KE90000
Valve adjusting wrench 07908-KE90000
TORQUE:10 N·m (1.0 kgf·m, 7 lbf·ft)
TORSI:
Recheck 10
theN.m
valve(1,0 kgf.m; 7 lbf.ft)
clearance.
Install the
Periksa following:
kembali jarak renggang klep.
Pasang
? Cylinder headberikut:
sebagai cover (page 7-7) VALVE ADJUSTING WRENCH
- ? Cylinder
Coolinghead
fan cover
cover(page
(hal.2-12)
7-7)
- Cooling fan cover (hal. 2-12)

OLI MESIN
ENGINE OIL
PEMERIKSAAN TINGGI PERMUKAAN OLI
OIL LEVEL CHECK
Letakkan
Support theskuter
scooterdiwithatas standard on
its centerstand utamanya di atas
a level surface.
tanah mendatar. FILLER CAP/DIPSTICK
Start the engine
Hidupkan mesinand danletbiarkan
it idle forberputar
3 - 5 minutes.
stasioner selama
Stop the
3-5 menit. engine and wait for 2 - 3 minutes.
Matikan
Removemesinthe oildan
fillertunggu selama
cap/dipstick 2-3
and menit.
wipe off the oil from
the dipstick with a clean cloth.
Lepaskan oil filler cap/dipstick (tutup pengisian
Insert the oil
oli/tangkai filler cap/dipstick
pengukur) dan sekalah without
oli screwing it in,
dari dipstick
remove kain
dengan it andbersih.
check the oil level. UPPER
The level should be between the "UPPER" and "LOWER"
Masukkan oil filler cap/dipstick tanpa menyekrupkannya
level lines of the oil filler cap/dipstick.
ke dalam, lepaskan dan periksa tinggi permukaan oli.
LOWER
Tinggi permukaan harus antara garis tinggi permukaan
"UPPER" (TERATAS) dan "LOWER" (TERBAWAH) dari
oil filler cap/dipstick.
Viskositas lain yang Jika
Other viscosities If thetinggi permukaan
oil level is below oroli
nearberada di bawah
the lower level lineatau dekat
on the dip-
diperlihatkan pada peta
shown
dapat dipakai in the
jikachart
suhu
garis tinggi
stick, add permukaanoil terbawah
the recommended dari dipstick,
to the upper level.
may be used di
rata-rata when the
daerah tambahkan oli yang dianjurkan sampai ke tinggi
average temperature RECOMMENDED
permukaan teratas. ENGINE OIL:
pengendaraan anda
in your
berada riding daerah
di dalam area is Honda "4-stroke motorcycle oil" or equivalent motor oil
within the indicated
jangkauan yang OLIAPI classification:
MESIN SG or higher
YANG DIANJURKAN:
diperlihatkan.
range. (exceptOil
Federal oils Supreme
labeled as energy
Flick conserving
atau oli on the circular
mesin 4 tak
API service
sejenis dengan label)
klasifikasi API service SG,
JASO T 903
Viskositas: SAE standard:
10W-30MB JASO MB
Viscosity: SAE 10W-30

3-9
PERAWATAN
Pastikan
Make surebahwa O-ring
the O-ring is inberada dalam kondisi
good condition baik it
and replace danif
ganti bila perlu.
necessary.
O-RING
Coat the O-ring with engine oil and install the oil filler cap/
Lapisi O-ring dengan oli mesin dan pasang oil filler
dipstick.
cap/dipstick.
For engine oil change, see page 3-10.
Untuk penggantian oli mesin, lihat hal. 3-10.

FILLER CAP/DIPSTICK
PENGGANTIAN
OIL CHANGE OLI
CATATAN:
•? Change
Ganti oli
the mesin
engine sewaktu mesin
oil with the dalam
engine warmkeadaan
and the
panas ondan
scooter levelskuter
grounddito atas
assuretanah mendatar
complete draining.untuk
memastikan pengeluaran secara menyeluruh.
Support the scooter with its centerstand.
Letakkan skuterwarm
Start the engine, padaitstandard utamanya.
up and stop it.
Hidupkan mesin,
Remove the panaskan
oil filler dan matikan.
cap/dipstick.
Lepaskan oil filler cap/dipstick.

FILLER CAP/DIPSTICK
Place an oilloyang
Letakkan drain pan under the engine
pembuangan oli di to collectmesin
bawah the oil,untuk
then
remove the oil drain
mengumpulkan oli,bolt
danandlepaskan
sealing washer.
oil drain bolt dan
sealing washer.
Slowly apply kickstarter and drain the engine oil.
After draining
Jalankan the oil dengan
kickstarter completely, install
pelan danthekeluarkan
new sealing
oli
washer and oil drain bolt.
mesin.
Tighten the drain bolt to the specified torque.
Setelah mengeluarkan oli secara menyeluruh, pasang
TORQUE:24 N·m (2.4 kgf·m, 18 lbf·ft)
sealing washer baru dan oil drain bolt.
Kencangkan drain
Fill the crankcase boltthe
with dengan torsi yang
recommended ditentukan.
engine oil.
TORSI:
ENGINE24 OILN.m (2,4 kgf.m; 18 lbf.ft)
CAPACITY:
0.7 liter (0.7
Isi crankcase denganUS qt, 0.6
oli lmp qt)yang
mesin afterdianjurkan.
draining
0.8 liter (0.8 US qt, 0.7 lmp qt) after disassembly
KAPASITAS OLI MESIN: WASHER/DRAIN BOLT
Check the oilpada
0,7 liter level penggantian
(page 3-9). periodik
Make sure that there are no oil leaks. mesin
0,8 liter setelah pembongkaran
Periksa tinggi permukaan oli (hal. 3-9).
Pastikan bahwa tidak ada kebocoran oli.

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

Pastikan bahwa tidak ada kebocoran oli.

PUTARAN STASIONER
ENGINE IDLE SPEED MESIN
CATATAN:
• ? Inspect
Periksaanddanadjust
setelthe
putaran stasioner
idle speed setelah
after all other semua
engine
bagian perawatan
maintenance mesin
items have beenyang lain telah
performed and dijalankan
are within ADJUSTING HOLE CAP
dan adalah sesuai dengan spesifikasi.
specifications.
• ? The engineharus
Mesin must bedalam
warm forkeadaan
accurate idle speed inspec-
panas untuk
tion and adjustment.
pemeriksaan danTen minutes of stop-and-go
penyetelan riding is
putaran stasioner
sufficient.
yang akurat. Sepuluh menit pengendaraan jalan-
dan-berhenti
Support the scooteradalah
with itscukup.
centerstand.
Warm up the engine about ten minutes.
Letakkan skuter pada standard utamanya.
Connect a tachometer
Panaskan and check
mesin selama the sepuluh
kira-kira idle speed.
menit.
IDLE SPEED:
Hubungkan 1,700 ± 100
tachometer danmin -1
(rpm)
periksa putaran stasioner.
-1
PUTARAN
If the engineSTASIONER:
idle speed is out1.700 ± 100 menit
of specification, (rpm)
adjust as fol-
lows: THROTTLE STOP SCREW
Jika putaran stasioner mesin tidak sesuai dengan
Unlock the seat with ignition key.
spesifikasi,
Open the seat. setel sebagai berikut:
Buka penguncian
Remove the adjusting tempat duduk
hole cap and dengan
turn the anak
throttlekunci
stop
kontak.
screw as required to obtain the specified idle speed.
Naikkan tempat duduk.
Lightly open
Lepaskan the throttle
adjusting holeforcap2 –dan
3 times,
putarthen checkstop
throttle the
enginesebanyak
screw idle speed again.
diperlukan untuk mendapatkan putaran
stasioner
Install the yang ditentukan.
removed parts in the reverse order of removal.
Bukalah throttle 2 - 3 kali dengan ringan, kemudian
periksa putaran stasioner mesin sekali lagi.

Pasang parts yang telah dilepaskan dalam urutan


terbalik dari pelepasan.

3-11
PERAWATAN
SECONDARY AIR SUPPLY SYSTEM
SYSTEM
INSPECTION
PEMERIKSAAN
Remove theairaircleaner
Lepaskan cleanerhousing
housing cover
cover(page
(hal. 3-6).
3-6).
Remove the PAIR air cleaner element.
Lepaskan PAIR air cleaner element. ELEMENT

CATATAN:
• ? Never
Janganuse sekali-kali memakai
gasoline or low bensin
flash point atauforpelarut
solvents clean-
dengan
ing titik Aapi
the element. rendah
fire or untuk
explosion couldmembersihkan
result. Peras larutan Penuhi
element. Dapat mengakibatkan kebakaran atau
Thoroughly wash the element in clean non flammable or high pembersih element
ledakan.
flash point cleaning solvent. sepenuhnya dengan oli
Allow theelement
Cucilah element todalam larutan pembersih yang tidak
dry thoroughly.
dapat terbakar atau mempunyai titik api tinggi.
After drying, apply 1.0 – 1.5 g of clean engine oil to the entire
surface of the element and rub it with hand to saturate the ele-
Biarkan element mengering secara menyeluruh.
ment with oil.
Setelah mengering, oleskan 1,0 – 1,5 g oli mesin bersih
pada seluruh permukaan
RECOMMENDED ENGINE element
OIL: dan gosok dengan
tangan untuk memenuhi element Cucilah dalam Oleskan 1,0 - 1,5 g
Honda "4-stroke motorcycle oil"dengan oli. motor oil
or equivalent
larutan oli mesin bersih
API classification: SG or higher
OLI(except
MESIN YANG DIANJURKAN: pembersih
oils labeled as energy conserving on the circular
Federal Oil Supreme
API service label) Flick atau oli mesin 4 tak
sejenis
JASOdengan klasifikasi
T 903 standard: MBAPI service SG,
Viskositas:
Viscosity: SAE 10W-30
10W-30 JASO MB
Install the
Pasang element.
element.
Install the
Pasang airair cleanerhousing
cleaner housing cover
cover (page 3-6).
(hal. 3-6).

Remove thebody
Lepaskan bodycover
cover(hal.
(page2-9).
2-9).
VACUUM HOSE AIR SUCTION JOINT
Check theairairsuction
Periksa suction joint
joint between
antara the
air air cleaner housing
cleaner housing
and PAIRsaringan
(rumah control valve for cracks,
udara) dan deterioration,
PAIR control damage or
valve
loose connections.
terhadap retak-retak, pemburukan kondisi, kerusakan
Jika joint
If thememperlihatkan
joint show any atau
Checksambungan longgar.
the air supply hose between the PAIR control valve
tanda-tanda
signs of heat damage, and air supply pipe for cracks, deterioration, damage or loose
kerusakan
inspect theakibat
PAIR
Periksa air supply hose antara PAIR control valve dan
connections.
checkpanas,
valveperiksalah
(page 5- air supply pipe terhadap retak-retak, pemburukan
PAIR check valve. Check the
kondisi, air supplyatau
kerusakan pipesambungan
between thelonggar.
air supply hose and
24).
cylinder head for damage or loose fasteners.
Check theair
Periksa supply
vacuum pipe
hose antara
between air supply
the intake hose
manifold dan
vacuum
cylinder head terhadap kerusakan atau
joint and PAIR control valve for deterioration, damage orpengikat
longgar.
loose connections.
Also check
Periksa that hose
vacuum is notantara
hose kinkedintake
or pinched.
manifold vacuum
joint control valve
Install the removed parts in the reverse order of pemburukan
dan PAIR terhadap removal.
kondisi, kerusakan atau sambungan longgar.

Juga periksa bahwa hose (slang) tidak tertekuk atau


terjepit. AIR SUPPLY HOSE/PIPE
Pasang parts yang telah dilepaskan dalam urutan
terbalik dari pelepasan.

3-12
PERAWATAN
DRIVE BELT
DRIVE BELT
Lepaskan
Remove theleft
leftcrankcase
crankcase cover (hal. 8-5).
cover (page 8-5).
Check the
Periksa drive
drive beltbelt for cracks,
terhadap separationpemisahan
retak-retak, or abnormal or
atau
excessive wear
keausan tidak and replaceatau
normal it if necessary
berlebihan(page
dan8-12).
ganti bila
perlu (hal. 8-11).

DRIVE BELT

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

SERVICE
BATAS LIMIT:17,5
SERVIS: 17.5 mmmm (0.69 in)
Replace
Ganti the drive
drive belt iflebarnya
belt jika it is less kurang
than the service limit servis
dari batas (page
8-12).8-11).
(hal.

DRIVE BELT

FINAL
FINAL DRIVE
DRIVEOIL
OIL
PEMERIKSAAN TINGGI PERMUKAAN OLI
OIL LEVEL CHECK
Pastikan
Make sure bahwa tidakreduction
that the final ada kebocoran
case has no oli pada final
oil leaks.
reduction case. SEALING WASHER
Support the scooter with its centerstand.
Remove the
Letakkan oil check
skuter padabolt.
standard utamanya.
Check whether
Lepaskan the oilbolt.
oil check flows out from the check bolt hole.
If the level
Periksa is lowoli(oil
apakah does notkeluar
mengalir flow out),
dari add the recom-
lubang check
mended oil as described below.
bolt.
Jika tinggi permukaan
RECOMMENDED rendah
FINAL (oli tidak mengalir
REDUCTION OIL: keluar),
tambahkan oli yang
Honda "4-stroke dianjurkan
motorcycle oil" orseperti diuraikan
equivalent di
motor oil
bawah.
API classification: SG or higher
(except oils labeled as energy conserving on the circular
FINAL REDUCTION
API service label) OIL YANG DIANJURKAN:
Federal
JASO TOil 903Supreme
standard: MBFlick atau oli mesin 4 tak CHECK BOLT LOWER LEVEL
sejenis dengan
Viscosity: SAE klasifikasi
10W-30 API service SG,
Viskositas: SAE 10W-30 JASO MB
Install the oil check bolt with a new sealing washer and
Pasang
tighten it oil check
to the specified dengan sebuah sealing washer
bolt torque.
baru dan kencangkan 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)

3-13
PERAWATAN
OIL CHANGE OLI
PENGGANTIAN
Place an oilsebuah
Letakkan drain pan underpembuangan
loyang the final reduction
oli dicase to collect
bawah final
the oil, thencase
remove the menerima
oil check bolt, DRAIN BOLT SEALING WASHER
reduction untuk oli,oil drain boltlepaskan
kemudian and seal-
ingcheck
oil washers.
bolt, oil drain bolt dan sealing washers.
Putar
Slowly turnbelakang
roda dengan
the rear wheel pelanthe
and drain danoil.keluarkan oli.
Setelah mengeluarkan oli secara menyeluruh, pasang
After
oil draining
drain the oil completely,
bolt dengan sebuah sealinginstallwasher
the oil drain
baru bolt
dan
with a new sealing
kencangkan washer
drain bolt and tighten
dengan the drain
torsi yang bolt to the
ditentukan.
specified torque.
TORSI: 13 N.m (1,3 kgf.m; 10 lbf.ft)
TORQUE:13 N·m (1.3 kgf·m, 10 lbf·ft)
Isilah
Fill thefinal
finalreduction casewith
reduction case dengan oli yangoil
recommended dianjurkan
up to the
sampai ke tinggi
correct level permukaan
(see page 3-13). yang tepat (lihat hal. 3-13).
KAPASITAS FINAL REDUCTION OIL:
FINAL REDUCTION
0,10 liter padaOIL CAPACITY:
penggantian periodik
0.10 liter
0,12 liter (0.11 US qt, 0.09 lmp qt) after draining
setelah pembongkaran CHECK BOLT SEALING WASHER
0.12 liter (0.13 US qt, 0.11 lmp qt) after disassembly
Pasang oil check bolt dengan sealing washer baru dan
Install the oil check bolt with a new sealing washer and
kencangkan dengan torsi yang ditentukan.
tighten it to the specified torque.
TORSI: 13 N.m
TORQUE:13 (1,3
N·m (1.3kgf.m;
kgf·m,10
10 lbf.ft)
lbf·ft)

FLUID (MINYAK REM)


BRAKE FLUID
CATATAN:
• ? Spilling
Minyakfluidremcan yang tertumpah
damage painted,dapat
plasticmerusak parts
or rubber parts.
yanga dicat,
Place rag over atautheseterbuat dari plastik
parts whenever atau is
the system karet.
ser-
Tutupilah parts ini dengan kain lap setiap kali
viced.
sistem diservis.
? Do not mix different types of fluid, as they are not com-
patible with each other.
• ? Do Jangan
not allowmencampurkan
foreign materialbermacam-macam
to enter the system when jenis
minyak
filling therem, oleh karena mereka tidak cocok satu
reservoir.
samathe
? When lain.
fluid level is low, check the brake pads for wear
• (see Jangan sampai
page 3-15). A low benda-benda
fluid level mayasingbe duememasuki
to wear of
sistem
the brakeketika
pads. mengisi reservoir.
• IfJika the tinggi permukaan
brake pads are worn,minyak rem piston
the caliper terlaluisrendah,
pushed
periksalah
out, and thisbrake
accountspads forterhadap keausan
a low reservoir (lihatIf hal.
level. the
brake
3-15).pads are not
Tinggi worn and the
permukaan fluid level
minyak rem is low,terlalu
yang check
entire
rendah system
dapatfor diakibatkan
leaks (page 3-15).
oleh keausan dari brake
pads.
Support
Jikathe scooter
brake padswithtelah
its centerstand.
aus, caliper piston didorong
Turnkeluar, dan ini
the handlebar menyebabkan
to the tinggi permukaan
left so the reservoir is level and
check yang rendah
the front brakedi reservoir
dalam reservoir.
fluid levelJika brake
through the pads
sight
glass.tidak aus dan tinggi permukaan minyak rem
If therendah, periksalah
level is near the lowerkeseluruhan
level mark, checksistem terhadap
the brake pads
kebocoran
for wear (see page(hal. 3-15).
3-15).
Letakkan skuter pada standard utamanya.
Putar handlebar (stang stir) ke kiri sehingga reservoir
mendatar dan periksa tinggi permukaan minyak rem di
dalam front brake reservoir melalui kaca pengintaian.

Jika tinggi permukaan dekat tanda batas permukaan


terendah, periksa brake pads terhadap keausan. (lihat TANDA TINGGI PERMUKAAN TERENDAH
hal. 3-15).

3-14
PERAWATAN
BRAKE SHOES/PADS
KEAUSAN WEAR
BRAKE SHOES/PADS
FRONT
FRONT DISCDISCBRAKE PADS PADS
BRAKE
(BRAKE PADS CAKRAM DEPAN)
Check the brake pads for wear.
Periksa brake pads terhadap keausan.
Replace the brake pads if either pad is worn to the wear limit
Ganti brake pads jika salah satu pad telah aus sampai
groove.
ke alur batas keausan.
To replace the brake pad, see page 13-8.
Untuk mengganti brake pad, lihat hal. 13-8.

ALUR-ALUR
REAR DRUM BRAKE SHOES BATAS KEAUSAN
(SEPATU REM TEROMOL
REAR DRUM BELAKANG)
BRAKE SHOES
Periksa
Check theposisi
wear indikator keausan
indicator position ketika
when handel
the brake rem
lever is
ditekan.
applied. BELAKANG: TANDA " "

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

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

3-15
PERAWATAN
Inspect the
Periksa brakehose
brake hose (slang
and fittings
rem)fordan
deterioration, cracks,
fittings (alat-alat
or signs of leakage.
pemasangan) terhadap pemburukan kondisi, retak- BRAKE HOSE
Tighten
retak, anytanda-tanda
atau loose fittings.kebocoran.
Replace the hose
Kencangkan and yang
fittings fittingslonggar.
as required.
Ganti hose dan fittings seperti diperlukan.

REAR DRUM BRAKE


(REM
REARTEROMOL BELAKANG)
DRUM BRAKE
Periksa brake
Check the brakecable
cable(kabel rem)lever
and brake danfor
brake
looselever (handel
connections,
excessive
rem) play orsambungan
terhadap other damage.longgar, jarak main bebas
Replace
yang or repair atau
berlebihan if necessary.
kerusakan lain.
Ganti atau 10 – 20 mm (0.4 – 0.8 in)
Measure theperbaiki bilalever
rear brake perlu.
free play at the end of the lever.
Ukur jarak main bebas rear brake lever (handel rem
FREE PLAY: 10 – 20 mm (0.4 – 0.8 in)
belakang) pada ujung lever.

JARAK MAIN BEBAS: 10 – 20 mm

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

ADJUSTING NUT

3-16
PERAWATAN
BRAKE LIGHT
BRAKE LIGHTSWITCH
SWITCH
(SAKLAR LAMPU REM)
? The brake light switch on the brake lever cannot be
CATATAN:
• adjusted. If theswitch
Brake light brake pada
light switch
brake actuation
lever tidak and dapat
brake
engagement
disetel. Jikaarepenjalanan
not synchronized,
brake either replace dan
light switch the
switch or malfunction parts of the system.
pengenaan rem tidak sinkron, gantilah switch atau
Checkparts
thatyang tidak light
the brake bekerja dengan
comes baik
on just daritosistem.
prior the brake
actually being engaged.
Periksa bahwa brake light (lampu rem) hidup tepat
For brakerem
sebelum lightsebenarnya
switch inspection
mulai(page 16-14).
bekerja.

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

REAR BRAKE FRONT BRAKE


LIGHT SWITCH LIGHT SWITCH

BRAKE LOCK OPERATION


BRAKE
(CARA LOCK
KERJA OPERATION
KUNCI REM)
CATATAN:
• ? Check
Periksathe cara
brakekerja brake lock
lock operation aftersetelah
the rear jarak
brake main
lever
bebas
free playrear brake and
is checked lever telah (page
adjusted diperiksa
3-16).dan disetel LOCK LEVER
(hal. 3-16).
Squeeze the rear brake lever and set the lock lever.
Tekan rearthe brake
Check that lever
rear wheel dan completely.
is locked tempatkan lock lever
(handel kunci).

Periksa bahwa roda belakang telah dikunci sama sekali.

BRAKE LEVER

3-17
PERAWATAN
HEADLIGHT AIM
PENYETELAN ARAH SINAR LAMPU
BESAR
CATATAN:
? Adjust the headlight beam as specified by local laws and
• regulations.
Setel arah sinar lampu besar seperti telah
ditentukan oleh undang-undang dan peraturan
Place the scooter on a level ground.
lokal.
Adjust the headlight beam vertically by loosening the head-
Letakkan skuter dibolt.
light aim adjusting atas tanah mendatar.
Hold the headlight aim adjusting bolt and tighten it.
Setel arah sinar lampu besar dalam arah vertikal
dengan melonggarkan headlight aim adjusting bolt baut
penyetelan arah sinar lampu besar).
Tahan headlight aim adjusting bolt dan kencangkan.

HEADLIGHT AIM
ADJUSTING BOLT

KEAUSAN CLUTCH
CLUTCH SHOES SHOES
WEAR
Lepaskan
Remove theclutch
clutchassembly
assembly (hal.
(page8-15).
8-16).
Periksa clutch shoes terhadap keausan
Check the clutch shoes for abnormal wear. tidak normal.
Ukur
Measure the thickness of each shoe. shoe.
ketebalan dari masing-masing
BATAS
SERVICE SERVIS: 2,0 mm
LIMIT:
Ganti clutch shoes 2.0jika
mm ketebalan
(0.08 in) mereka kurang dari
batas servis (hal. 8-17).
Replace the clutch shoes if they are less than the service limit
(page 8-18).
Pasang clutch assembly (hal. 8-16).
Install the clutch assembly (page 8-17).

CLUTCH SHOE

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

Jika ada persoalan dengan sistem, periksa sidestand


switch (saklar standard samping) (hal. 15-9).

3-18
PERAWATAN
SUSPENSI
SUSPENSION
DEPAN
FRONT
Bagian suspensi yang
Loose, aus
longgar, worn or
atau Periksa
Check thecara kerja
action forks
of the forks(garpu) dengan
by operating menjalankan
the front brake and
damaged suspension
rusak mempengarui compressing
rem depan dan the front
menekansuspension several
suspensi times.beberapa kali
depan
parts impair scooter
kestabilan dan Check
ke the entire assembly for signs of leaks, damage or loose
bawah.
stability and control.
pengendalian skuter. fasteners. keseluruhan susunan terhadap tanda-tanda
Periksa
kebocoran, kerusakan
Replace damaged atau pengikat
components longgar.
which cannot be repaired.
Tightenkomponen-komponen
Ganti all nuts and bolts. rusak yang tidak dapat
diperbaiki.
For fork service (page 11-11).
Kencangkan semua baut dan mur.
Untuk service fork (hal. 11-11).

FRONT FORK

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

Kencangkan semua baut dan mur.


Untuk servis shock absorber belakang (hal. 12-5).
REAR SHOCK
ABSORBER

Dukung skuter
Support the scooterdengan kokoh
securely and raise dan naikkan
the rear wheel offroda
the
belakang
ground. lepas tanah. ENGINE MOUNTING BUSHINGS
Check for worn engine mounting bushings by grabbing the
Periksa terhadap engine mounting bushings (bos-bos
engine and attempting to move the wheel side to side.
pemasangan mesin) yang aus dengan memegang
For engine
mesin dan bushing
mencoba service
untuk(page 12-6).
menggerakkan roda dari sisi
ke sisi.

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

3-19
PERAWATAN
NUTS,BAUT,
MUR, BOLTS, FASTENERS
PENGIKAT
Check thatbahwa
Periksa all chassis nuts and
semua boltsdan
baut are tightened to theirtelah
mur rangka cor-
rect torque values
dikencangkan (page 1-9).
dengan nilai torsi mereka yang benar
Check
(hal. that all cotter pins, safety clips, hose clamps and cable
1-9).
stays are bahwa
Periksa in place and
semuaproperly secured.
cotter pins, safety clips, hose
clamps dan cable stays berada pada tempatnya dan
telah dipasang dengan erat.
WHEELS/TIRES
RODA/BAN
Support the
Letakkan scooter
skuter di with
atas its centerstand.
standard utamanya.
WHEEL BEARINGS
Making sure
Pastikan bahwathat fork
the fork
tidakisdapat
not allowed to move,
bergerak, raiseroda
naikkan the
front wheel
depan and check
dan periksa for play.kelonggaran.
terhadap
Check forterhadap
Periksa worn front wheel
front bearings
wheel by grabbing
bearings (bantalanthe front
roda
wheel and
depan) attempting
yang aus denganto movememegang
the wheel side to side.
roda depan dan
Replace the
mencoba frontmenggerakkan
untuk wheel bearings ifrodaany dari
looseness
sisi keis sisi.
noted.
Turn the wheel and check that it rotates smoothly withada
Ganti front wheel bearings jika diketahui no
kelonggaran.
unusual noises.
If anyroda
Putar abnormal conditions
dan periksa are suspected,
bahwa inspect
ia berputar denganthe halus
front
wheel bearings (page 11-10).
tanpa adanya suara-suara tidak normal.

Jika ada dugaan adaya kondisi-kondisi tidak normal,


periksa front wheel bearings (hal. 11-10).
Dukung
Support theskuter
scooter dengan kokoh
securely and danrearnaikkan
raise the wheel. roda
FINAL GEAR SHAFT BEARINGS
belakang.
Check for worn final gear shaft bearings by grabbing the rear
Periksa terhadap final gear shaft bearings (bantalan
wheel and attempting to move the wheel side to side.
poros final gear) yang aus dengan memegang roda
Replace the
belakang danfinal gear shaft
mencoba untukbearings if anyroda
menggerak looseness is
dari sisi
noted.
ke sisi.
Turn the wheel and check that it rotates smoothly with no
Ganti
unusualfinal gear shaft bearings bila diketahui ada
noises.
kelonggaran.
If anyroda
Putar abnormal conditions
dan periksa are ia
bahwa suspected,
berputarcheck
denganthe halus
final
reduction
tanpa (pagesuara-suara
adanya 9-8). tidak normal.
Jika ada dugaan adanya kondisi-kondisi tidak normal,
periksa final reduction (hal. 9-8).

Periksa
Check the tekanan udarawith
tire pressure banthedengan air pressure
air pressure gauge whengauge
the
(meter
tires are pengukur
cold. tekanan udara ban) sewaktu ban
dalam keadaan dingin.
RECOMMENDED TIRE PRESSURE:
Driver only:UDARA BAN YANG DIANJURKAN:
TEKANAN
FRONT: 200
Pengendara kPa (2.00 kgf/cm2, 29 psi)
saja:
REAR: 225 kPa200
DEPAN: (2.25 kgf/cm
kPa 33 psi) 2; 29 psi)
(2,002, kgf/cm
2
BELAKANG:
Driver 225 kPa (2,25 kgf/cm ; 33 psi)
and passenger:
Pengendara
FRONT: 200 dankPa
pembonceng: 2
(2.00 kgf/cm , 29 psi)
2
DEPAN:
REAR: 225 kPa200 kPa
(2.25 (2,002, kgf/cm
kgf/cm 33 psi) ; 29 psi)
2
BELAKANG: 225 kPa (2,25 kgf/cm ; 33 psi)

PRESSURE GAUGE

3-20
PERAWATAN
Check the ban
Periksa tires for cuts, embedded
terhadap sayatan,nails,
pakuor yang
other damage.
tertancap,
INDICATOR
Check the front wheel
atau kerusakan lain.and rear wheel for trueness.
Periksa apakah TIRE
RECOMMENDED roda SIZEdepanANDdanTIREroda belakang
BRAND:
berjalan lurus dalam satu bidang.
UKURAN BAN DAN FRONTMEREK BAN REARYANG
DIANJURKAN:
Tire size 80/90-14M/C40P 90/90-14M/C46P
Tire brand SRI FT235 FT235
DEPAN BELAKANG
Measure
Ukuran theban
tread depth at the center of the tires.
80/90- 90/90-
Replace the tires when the tread depth reaches
14M/C40P the following
14M/C46P
limits.
Merek SRI FT235 FT235
ban
MINIMUM TIRE TREAD DEPTH:
Ukur kedalaman alur
FRONT/REAR: telapak
To the ban pada tengah-tengah
indicator
ban.
Ganti ban jika kedalaman telapak ban mencapai
batas sebagai berikut.
KEDALAMAN ALUR TELAPAK BAN MINIMUM:
DEPAN/BELAKANG: Sampai ke indikator

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

Hold the scooter


Peganglah skuterand
dancheck the steering
periksa steeringhead
headbearings for
bearings
wear by moving
terhadap keausanthedengan
fork forward and backward.
menggerakkan fork ke depan
STEM BEARINGS
dan belakang.
If the steering stem has vertical movement, inspect the steer-
ing head bearing (page 11-21).
Jika steering stem ada pergerakan vertikal, periksalah
steering head bearing (hal. 11-21).

3-21
CATATAN
4. SISTEM PELUMASAN

DIAGRAM SISTEM
LUBRICATION PELUMASAN.........
SYSTEM DIAGRAM????? 4-24-2 TROUBLESHOOTING ........................... 4-3
TROUBLESHOOTING ????????????????? 4-3

KETERANGAN SERVIS ........................


SERVICE INFORMATION ?????????????? 4-3 4-3 OIL PUMP .............................................. 4-4
PUMP ???????????????????????????? 4-4

4-1
SISTEM PELUMASAN
LUBRICATION
DIAGRAM SYSTEM
SISTEM DIAGRAM
PELUMASAN
LUBRICATION SYSTEM

ROCKER ARM SHAFT

CAM SHAFT

PISTON

CRANKSHAFT

OIL PUMP

OIL STRAINER SCREEN

4-2
SISTEM PELUMASAN
SERVICE INFORMATION
KETERANGAN SERVIS
UMUM
GENERAL
! PERINGATAN
Oli mesin bekas dapat menyebabkan kanker kulit jika berulangkali mengenai kulit untuk jangka waktu lama. Walaupun ini kecil
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely
kemungkinannya terjadi
unless you handle usedkecuali
oil on ajika anda
daily menangani
basis, oli bekas
it is still advisable to setiap hari,wash
thoroughly tetapyour
dianjurkan untuk
hands with secara
soap menyeluruh
and water as soon mencuci
as
tangan dengan
possible aftersabun danused
handling air sesegera
oil. mungkin setelah menangani oli bekas.

•• Oil oil
The pump (pompa
pump can beoli) dapat diservis
serviced with the dengan mesin terpasang
engine installed pada rangka.
in the frame.
•• The service procedures
Prosedur-prosedur in this
servis sectionbab
di dalam mustini be performed
harus withdengan
dijalankan the engine oil drained.
oli mesin dikeluarkan.
•• When
Ketikaremoving and installing
melepaskan dan memasangthe oil pump, use berhati-hatilah
oil pump, care not to allow dustdebu
agar or dirt to enter
atau thetidak
kotoran engine.
memasuki mesin.
• If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
•• Jika ada bagian dari oil pump yang aus melampui batas servis
After the oil pump has been installed, check that there are no oil leaks. yang ditentukan, gantilah oil pump sebagai sebuah susunan.
• Setelah oil pump telah dipasang, periksa bahwa tidak ada kebocoran oli.
SPECIFICATIONS
SPESIFIKASI
Unit: mmmm
Satuan: (in)
BAGIAN STANDARD SERVICE
BATAS SERVIS
ITEM STANDARD
LIMIT
Kapasitas oli Pada penggantian 0,7 liter -
Engine
mesin oil capacity periodik After draining 0.7 liter (0.7 US qt, 0.6 lmp qt) –
Pada After disassembly
pembongkaran 0,8 liter 0.8 liter (0.8 US qt, 0.7 lmp qt) - –
Recommended engine oil
mesin Honda "4-stroke motorcycle oil" or equiva-
lent motor oil
Oli mesin yang dianjurkan Federal Oil Supreme Flick atau
API classification: SGoli mesin 4 tak
or higher
sejenis dengan(except
klasifikasi API service
oils labeled SG, conserving-
as energy –
Viskositas: SAE
on10W-30 JASO
the circular APIMB service label)
Oil pump rotor Jarak renggang pada 0,15 JASO T 903 standard: MB 0,20
ujung rotor Viscosity: SAE 10W-30
Oil pump rotor Tip clearance
Jarak renggang antara 0,15 – 0,21 0.15 (0.006) 0,35 0.20 (0.008)
rotor dan rumah Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014)
Jarak renggang Sidekeclearance
0,05 – 0,10 0.05 – 0.10 (0.002 – 0.004) 0,12 0.12 (0.005)
samping rotor pompa
TORQUE VALUES
NILAI TORSI
Oil pump plate screw 3 N·m (0.3 kgf·m, 2.2 lbf·ft)
Oil pump mounting bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)
Oil pump plate screw 3 N.m (0,3 kgf.m; 2,2 lbf.ft)
Oil pump mounting bolt 10 N.m (1,0 kgf.m; 7 lbf.ft)

TROUBLESHOOTING
TROUBLESHOOTING
Engine oil level too low, high oil consumption
• External oil leak
• Worn
Tinggi piston ringsoli
permukaan or mesin
incorrect pistonrendah,
terlalu ring installation
pemakaian (pageoli7-35)
tinggi
• Worn cylinder (page 7-33)
• Ada kebocoran oli di luar
• Worn valve guide or seal (page 7-24)
• Piston rings aus atau pemasangan piston ring tidak benar (hal. 7-34)
•Oil contamination
Cylinder aus (hal. 7-32)
•• Oil not changed
Valve guide atauoften
sealenough
aus (hal. 7-14)
• Clogged oil strainer
• Worn piston rings (page 7-36)
Kontaminasi oli
• Oli jarang diganti
• Oil strainer tersumbat
• Piston rings aus (hal. 7-34)

4-3
SISTEM PELUMASAN
OIL PUMP
POMPA OLI
REMOVAL
PELEPASAN
• • When
Ketikaremoving the oiloil
melepaskan pump, do not
pump, allow dust
jagalah atar or dirt
debu
to enter the engine.
atau kotoran tidak memasuki mesin.
Drain the engine oil (page 3-10).
Keluarkan
Remove theollialternator
mesin (hal. 3-10).
(page 14-7).
Lepaskan
Remove the alternator (hal. 14-8).
following:
– Oil pump
Lepaskan coverberikut:
sebagai bolts
– Oil pump cover
- –OilO-ring
pump cover bolts
- –OilOil
pump
pumpcover
driven gear
- –O-ring
Oil pump bolts
- –OilOil pump
pump assembly
driven gear
- Oil pump bolts
- Oil pump assembly

OIL PUMP ASSEMBLY O-RING

OIL PUMP
DRIVEN GEAR

OIL PUMP COVER

Lepaskan oil pump cover dengan


menggunakan baut-baut 5 mm.
OIL PUMP BOLTS
5 mm BOLTS

OIL PUMP
COVER BOLTS

4-4
SISTEM PELUMASAN
INSTALLATION
PEMASANGAN
• • When
Ketikainstalling
memasangthe oiloilpump, do berhati-hatilah
pump, not allow dust oragar
dirt
OIL PUMP
to enter the engine.
debu atau kotoran tidak memasuki mesin.
Install the oil pump to the right crankcase.
Pasang oil pump
Install and pada
tighten theright crankcase.
oil pump mounting bolts to the
specified torque.
Pasang dan kencangkan oil pump mounting bolts
TORQUE:10
dengan N·m ditentukan.
torsi yang (1.0 kgf·m, 7 lbf·ft)

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

BOLTS

Semprotkan
Apply engineolioilmesin
to the pada oil pump
oil pump drivendriven gearoildan
gear and oil
pump
pump
shaft. shaft. DRIVEN GEAR
Tepatkan
Install the oil pump driven gear to the oil pump by align-
Pasang oil pump
ing the driven gear driven
cut-out gear pada
with oil oilcut-out.
pump pump dengan
mentepatkan potongan pada driven gear dengan
potongan pada oil pump.

Oleskan oli mesin


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

OIL PUMP COVER


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

BOLTS

4-5
SISTEM PELUMASAN
PEMBONGKARAN/PERAKITAN
DISASSEMBLY/ASSEMBLY
Remove the
Lepaskan following:
sebagai berikut:
– Dowel
- Dowel pins pins
– Screw
-– Screw
Pump plate
-– Pump
Outerplate
rotor
-– Outer
Innerrotor
rotor
- •Inner rotor
Apply engine oil to the inner rotor and outer rotor.
•Assembly is in theolireverse
Semprotkan mesinorder
padaofinner
disassembly.
rotor dan outer
rotor.
TORQUE:OIL PUMP PLATE SCREW
3 N·m (0.3 kgf·m, 2.2 lbf·ft)
Perakitan adalah dalam urutan terbalik dari
pembongkaran.

TORSI: OIL PUMP PLATE SCREW


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

OUTER ROTOR

PUMP BODY

SCREW
INNER ROTOR
3 N·m (0.3 kgf·m, 2.2 lbf·t)

4-6
SISTEM PELUMASAN
INSPECTION
PEMERIKSAAN
? Measure at several points and use the largest reading
• Ukur
to pada the
compare beberapa
service titik
limit.dan pakailah pembacaan
? Ifterbesar untukofmembandingkannya
any portion the oil pump is worn dengan
beyondbatas
the
specified
servis. service limits, replace the oil pump and oil
• pump cover
Jika ada as andari
bagian assembly.
oil pump yang aus melampaui
Tip batas servis yang ditentukan, gantilah oil pump dan
clearance
oil pump install
Temporarily cover sebagai
the outer,sebuah
inner susunan.
rotors and oil pump
driven gear into the oil pump body. Kerenggangan pada ujung
Jarak renggang pada ujung inner rotor inner rotor :
Measure the clearance between the outer rotor and the
inner rotor
Untuk with a feeler
sementara gauge.outer, inner rotors dan oil
pasanglah
pump
SERVICEdriven gear ke dalam oil pump body.
LIMIT: 0.20 mm (0.008 in)
Ukur kerenggangan antara outer rotor dan inner rotor
dengan feeler gauge.

BATAS SERVIS: 0,20 mm

Jarak renggang antara outer rotor dan badan


Body clearance
Ukur jarakthe
Measure renggang
clearanceantara oil pump
between the oil body
pump dan
bodyouter
and
the outer
rotor denganrotor with gauge.
feeler a feeler gauge. Kerenggangan antara
outer dan badan :
SERVICE
BATAS
LIMIT: SERVIS: 0.35
0,35 mm
mm(0.014 in)

Jarak renggang ke samping rotor pompa


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

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

4-7
CATATAN
5. SISTEM BAHAN BAKAR

LOKASI KOMPONEN
COMPONENT ..............................
LOCATION ?????????????5-2 5-2 PEMBERSIHAN KARBURATOR.............5-17
CARBURETOR CLEANING???????????? 5-17

DIAGRAM SISTEM ..................................


SYSTEM DIAGRAM ???????????????????5-3 5-3 PEMERIKSAAN KARBURATOR.............
CARBURETOR INSPECTION 5-18
?????????? 5-18

KETERANGAN SERVIS ..........................


SERVICE INFORMATION ??????????????5-4 5-4 PENYETELAN
PILOT SCREWPILOT SCREW................
ADJUSTMENT ????????? 5-20 5-20

TROUBLESHOOTING
TROUBLESHOOTING.............................
?????????????????5-5 5-5 INLET
INLETPIPE
PIPE..............................................
?????????????????????????? 5-22 5-22

AIR CLEANER
AIR CLEANERHOUSING
HOUSING.......................
??????????????5-6 5-6 SECONDARY AIR SUPPLY
SECONDARY AIR SUPPLYSYSTEM
SYSTEM..... 5-23
??? 5-23

PELEPASAN KARBURATOR
CARBURETOR ................. 5-8
REMOVAL ????????????? 5-8 TANGKI BAHAN
FUEL TANK BAKAR ........................5-26
????????????????????????? 5-26

PEMASANGAN
CARBURETORKARBURATOR
INSTALLATION.............
??????? 5-10 5-10 FUEL
FUELAUTO
AUTO VALVE
VALVE ................................
?????????????????? 5-27 5-27

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

5-1
SISTEM BAHAN BAKAR
COMPONENT
LOKASI LOCATION
KOMPONEN
FUEL SYSTEM

5-2
SISTEM BAHAN BAKAR
SYSTEM DIAGRAM
DIAGRAM SISTEM

MAIN FUSE SUB FUSE


15A 10A
R/Bl

G/O
R/Bl

R/Bl

Bl
R

R
2P 4P 6P Br 3P Bl

R/Bl

G/O

Bl
G

G
R

BATTERY IGNITION CONTROL


MODULE (ICM)

IGNITION STARTER
SWITCH ENRICHMENT (SE)
THERMAL VALVE

5-3
SISTEM BAHAN BAKAR
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
•? Bending
Menekuk or atau
twisting the control
memilin cable will impair
kabel pengontrol smooth operation
akan mengganggu and could
kelancaran causedan
kerjanya the dapat
cable to stick or bind,bahwa
menyebabkan resulting in loss
kabel of
macet
vehicle control.
? atau in
Work mengikat, sehingga
a well ventilated mengakibatkan
area. hilangnya
Smoking or allowing pengaturan
flames atas
or sparks in kendaraan.
the work area or where gasoline is stored can cause a fire
• orBekerjalah
explosion.di ruangan dengan ventilasi baik. Merokok atau membiarkan lidah api atau percikan bunga api di tempat kerja atau
? When disassembling
di tempat fuel system
di mana bensin parts,
disimpan notemengakibatkan
dapat the locations of kebakaran
the O-rings.atau
Replace them with new ones on reassembly.
ledakan.
•? Before
Sewaktudisassembling
membongkar the parts
carburetor,
sistemplace a suitable
bahan bakar, container
catatlah under
lokasi the carburetor
O-rings. Gantidrain hose.yang
dengan Loosen thepada
baru drain waktu
screw and drain
perakitan
the carburetor.
kembali.
? After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with pieces of tape to prevent any for-
• eign
Sebelum
materialmembongkar
from droppingkarburator, letakkan penampung yang sesuai di bawah carburetor drain hose (slang pembuangan
into the engine.
karburator). Longgarkan drain screw (sekrup pembuangan) dan kosongkan karburator.
• Setelah melepaskan karburator, bungkuslah lubang pemasukan mesin dengan kain lap atau tutuplah dengan pita perekat
SPECIFICATIONS
untuk mencegah masuknya benda asing ke dalam mesin.
ITEM SPECIFICATIONS
SPESIFIKASI
Carburetor identification number AVK2CH
Main jet #100
BAGIAN
Slow jet SPESIFIKASI #35
Nomor identifikasi
SE thermal karburator
valve resistance AVK2CH 3.2 – 5.6 Ω (25°C/77°F)
Main jet
Float level # 100 13.0 mm (0.51 in)
Slow
Pilot jet
screw initial opening # 35 See page 5-20
Tahanan
Engine idlelistrik SE thermal valve
speed 3,2 – 5,6 Ω (20° C) 1,700 ± 100 min-1 (rpm)
Tinggi pelampung
PAIR control valve specified vacuum 13,0 mm 60 kPa (450 mmHg)
Throttle grip awal
Pembukaan free play
pilot screw Lihat halaman 5-20 2 – 6 mm (0.1 – 0.2 in)
-1
Putaran stasioner mesin 1.700 ± 100 menit (rpm)
Vakuum PAIR control valve yang ditentukan 60 kPa (450 mmHg)
TORQUE
Jarak main bebasVALUES throttle grip 2 – 6 mm
Inlet pipe band screw 2 N·m (0.2 kgf·m, 1.5 lbf·ft)
NILAI TORSI
SE thermal valve body screw 3.4 N·m (0.4 kgf·m, 2.5 lbf·ft)
SE thermal valve setting plate screw 2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
Inlet pipe band screw 2 N.m (0-,2 kgf.m; 1,5 lbf.ft)
SEVacuum
thermal chamber cover
valve body screw
screw 3,4 N.m (0,4 N
2.1 ·m (0.2
kgf.m; ·m, 1.5 lbf·ft)
kgflbf.ft)
2,5
Slow jet
SE thermal valve setting plate screw 1.5 N ·m (0.2 kgf ·m, 1.1 lbf·ft
2,1 N.m (0,2 kgf.m; 1,5 lbf.ft)
Main jet
Vacuum chamber cover screw 2.1 N
2,1 N.m (0,2 ·m (0.2
kgf.m; 1,5 ·m, 1.5 lbf·ft)
kgflbf.ft)
Needle
Slow jet jet holder 2.5 N
1,5 N.m (0,2 ·m (0.3
kgf.m; ·m, 1.8 lbf·ft)
kgflbf.ft)
1,1
Float
Main jet chamber screw 2.1 N
2,1 N.m (0,2 ·m (0.2
kgf.m; ·m, 1.5 lbf·ft)
kgflbf.ft)
1,5
Floatjet
Needle chamber
holder drain screw 1.5 N
2,5 N.m (0,3 ·m (0.2
kgf.m; ·m, 1.1 lbf·ft)
kgflbf.ft)
1,8
Float
PAIRchamber screwcover screw
check valve 2,1 N.m (0,2
2.1kgf.m; 1,5 kgf
N·m (0.2 lbf.ft)
·m, 1.5 lbf·ft)
Float
Fuelchamber drain
auto valve screw
lock nut 1,5 N.m (0,2
22.5kgf.m; 1,1kgf
N·m (2.3 lbf.ft)
·m, 17 lbf·ft)
PAIR check valve cover screw 2,1 N.m (0,2 kgf.m; 1,5 lbf.ft)
Fuel auto valve lock nut 22,5 N.m (2,3 kgf.m; 17 lbf.ft)
TOOLS
TOOLS
Pin driver Carburetor float level gauge
07744-0010100 07401-0010000

5-4
SISTEM BAHAN BAKAR
TROUBLESHOOTING
TROUBLESHOOTING
Mesin
Enginetidak
won’tmau starthidup
•? No fuel inbahan
Tangki tank bakar kosong
•? No fuel to
Bahan carburetor
bakar tidak sampai ke karburator
? Fuel strainer clogged
- Fuel strainer
? Fuel hose clogged tersumbat
?- Fuel
Fueltank
hosebreather
tersumbat hole clogged
?- Faulty
Lubang fuelpernapasan
auto valve tangki bahan bakar tersumbat
? Float
- Fuellevel
autoincorrect
valve tidak bekerja dengan baik
•? Too
Floatmuch
levelfuel getting
(tinggi to the engine
pelampung) tidak sesuai
? Air cleaner clogged
• ?Terlalu
Flooded carburetor bakar yang masuk ke dalam mesin
banyak bahan
- Air cleaner
? Intake air leak tersumbat
- Karburator
? Fuel banjir
contaminated/deteriorated
•? Faulty starting enrichment
Ada kebocoran udara masuk (SE) thermal valve
•? Clogged
Bahan bakarstarting enrichment (SE) circuit kondisinya
terkontaminasi/memburuk
? Clogged carburetor slow circuit
•? Improper
Starting enrichment
throttle operation(SE) thermal valve tidak bekerja dengan baik
•? NoRangkaian
spark at plug starting enrichment
(faulty (SE) tersumbat
ignition system – page 15-3)
• Rangkaian stasioner karburator tersumbat
Engine stall, hard to start, rough idling
•? Fuel
Caralinekerja throttle tidak benar
restricted
•? Fuel
Tidak ada percikan
mixture bunga api pada busi (sistem pengapian tidak bekerja dengan baik – hal. 15-3)
too lean/rich
? Fuel contaminated/deteriorated
? Intake
Mesin air leakmendadak, sulit dihidupkan, putaran stasioner kasar
berhenti
? Idle speed misadjusted
•? Pilot
Saluran
screw bahan bakar terbatasi
misadjusted
•? Fuel
Campuran bahan hole
tank breather bakar terlalu miskin/kaya
clogged
•? Air
Bahan
cleanerbakar terkontaminasi/memburuk kondisinya
clogged
•? Slow
Ada circuit
kebocorancloggedudara masuk
•? Faulty startingputaran
Penyetelan enrichment (SE) salah
stasioner thermal valve
? Ignition system malfunction (page 15-3)
• Penyetelan pilot screw salah
•LeanLubang
mixturepernapasan tangki bahan bakar tersumbat
•? Fuel jets clogged
Air cleaner tersumbat
? Float valve faulty
•? Float
Rangkaian stasioner
level too low tersumbat
•? Fuel
Starting enrichment (SE) thermal valve tidak bekerja dengan baik
line restricted
•? Carburetor air vent hose
Sistem pengapian tidakclogged
bekerja dengan baik (hal. 15-3)
? Fuel tank breather hole clogged
? Intake airbahan
Campuran leak bakar terlalu miskin
? Vacuum piston faulty
• Fuel jets tersumbat
•RichFloat
mixture
valve tidak bekerja dengan baik
•? Air jet clogged
Float level terlalu rendah
? Float valve faulty
•? Float
Saluran
levelbahan
too high bakar terbatasi
•? Starting
Carburetorenrichment
air vent(SE)hosethermal
tersumbatvalve stuck open
•? Air cleaner
Lubang element contaminated
pernapasan tangki bahan bakar tersumbat
? Vacuum piston faulty
• Ada kebocoran udara masuk
•Backfiring
Vacuum or piston
misfiringtidakduring
bekerjaacceleration
dengan baik
? Fuel mixture too lean
? Ignition system malfunction (page 15-3)
Campuran bahan bakar terlalu kaya
•Afterburn
Air jet when
tersumbatengine braking is used
•? Lean
Floatmixture
valve tidakin slow circuitdengan baik
bekerja
•? Faulty
Float pulse secondary
level terlalu tinggiair injection (PAIR) system
? Faulty PAIR control valve
• ?Starting enrichment
Faulty PAIR (SE) thermal valve macet terbuka
check valve
• ?Air cleanerhose
Clogged element
of theterkontaminasi
PAIR system
•? Ignition
Vacuum system
pistonmalfunction
tidak bekerja (page 15-3) baik
dengan

Backfiring atau misfiring selama akselerasi


• Campuran bahan bakar terlalu miskin
• Sistem pengapian tidak bekerja dengan baik (hal. 15-3)

Afterburn ketika engine braking dipakai


• Campuran bahan bakar terlalu miskin pada rangkaian stasioner
• Pulse secondary air injection (PAIR) system tidak bekerja dengan baik
- PAIR control valve tidak bekerja dengan baik
- PAIR check valve tidak bekerja dengan baik
- Slang dari PAIR system tersumbat
• Sistem pengapian tidak bekerja dengan baik (hal. 15-3)

5-5
SISTEM BAHAN BAKAR
AIR CLEANER
AIR CLEANER HOUSING
HOUSING
REMOVAL
PELEPASAN
Remove the
Lepaskan following:
sebagai berikut:
PAIR CONTROL VALVE BOLTS
-? Luggage
Luggagebox (page
box(hal. 2-7)
2-7)
-? Body
Bodycover (page
cover(hal. 2-9)
2-9)
-? Left
Leftcrankcase
crankcasecover
coverduct (page2-12)
duct(hal. 2-12)
Remove the
Lepaskan two PAIR
kedua PAIRcontrol valve
control mounting
valve bolts bolts
mounting and
disconnect the valve from the air cleaner housing.
(baut pemasangan PAIR control valve) dan lepaskan
Disconnect the crankcase breather hose from the air
valve dari
cleaner air cleaner housing.
housing.
Lepaskan crankcase breather hose (slang pernapasan
bak mesin) dari air cleaner housing.

CRANKCASE BREATHER HOSE


Loosen the connecting
Longgarkan connectinghose
hoseband screw.
band screw (sekrup pita
Disconnect the vacuum piston hose from the air cleaner BAND SCREW
slang penyambung).
housing.
Lepaskan vacuum piston hose dari air cleaner housing.

VACUUM PISTON HOSE


Tarik
Pull outkeluar finalreduction
the final reductionbreather
breather
hosehose
from dari air
the air
cleaner housing.
housing. BOLTS BREATHER HOSE
cleaner
Release the
Lepaskan crankcase
crankcase breather
breather draindrain
hose hose from the
dari clamp.
clamp.
Lepaskan kedua air cleaner housing mounting bolts dari
Remove the two air cleaner housing mounting bolts from
sisi
the kiri.
left side.

BREATHER DRAIN HOSE CLAMP


Remove the
Lepaskan boltbolt
darifrom
sisithe right side.
kanan.
Be Hati-hati
careful not to Disconnect the connecting hose from the carburetor by
agar Lepaskan
holding the connecting
carburetor and hose dari
pulling thekarburator dengan
air cleaner housing
damage
tidak the air
merusak air memegang karburator dan menarik air cleaner housing
cleaner backward.
cleanerconnecting
connecting ke belakang.
hose.
hose. Remove the air cleaner housing from the right side of the
frame.
Lepaskan air cleaner housing dari sisi kanan dari
rangka.

AIR CLEANER
HOUSING

BOLT

5-6
SISTEM BAHAN BAKAR
INSTALLATION
PEMASANGAN
Install the
Pasang air air cleaner
cleaner housing
housing darifrom the right
sisi kanan dariside of the
rangka.
frame. BAND SCREW CONNECTING HOSE
Sambungkan connectinghose
Connect the connecting hoseto ke
the karburator
carburetor by dengan
hold-
Be careful not to
Hati-hati memegang karburator
and dan dengan hati-hati
the mendorong
damage theagar
ing the carburetor
air carefully pushing air cleaner
air
tidak merusak air cleaner
housing housing ke depan.
forward.
cleaner connecting
cleaner connecting
hose. Set the connecting hose band as shown.
Tempatkan
Tighten the connecting
hose. band screwhoseuntil band seperti
the band diperlihatkan.
seats on the collar
Kencangkan
as shown. band screw sampai band duduk pada
collar seperti diperlihatkan. 75°

VACUUM PISTON HOSE


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

CRANKCASE BREATHER HOSE


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

AIR CLEANER
HOUSING

BOLT

Install and
Pasang dantighten the two
kencangkan boltsbolts
kedua to the left sisi
pada sidekiriofdari
air
cleaner housing. BOLTS BREATHER HOSE
air cleaner housing.
Set the crankcase breather drain hose to the clamp on
Tempatkan crankcase breather drain hose pada clamp
the air cleaner housing.
pada
Insertairthe
cleaner
final housing.
reduction breather hose into the air
Masukkan final reduction breather hose ke dalam air
cleaner housing.
cleaner housing.
Install the following:
? Left crankcase
Pasang cover duct (page 2-12)
sebagai berikut:
? Body cover (page 2-9)
-? Left
Luggage box (page
crankcase cover2-7)
duct (hal. 2-12)
- Body cover (hal. 2-9)
- Luggage box (hal. 2-7)

BREATHER DRAIN HOSE CLAMP

5-7
SISTEM BAHAN BAKAR
CARBURETOR
PELEPASAN REMOVAL
KARBURATOR
Lepaskan sebagai
Remove the berikut:
following:
-? Left
Leftcrankcase
crankcasecover
coverduct (page2-12)
duct(hal. 2-12)
-? Luggage
Luggagebox (page
box(hal. 2-7)
2-7)
Place a suitable
Letakkan container
penampung yang under
sesuai the carburetor
di bawah drain
carburetor
hose and
drain hosedrain
danfuel from thebahan
keluarkan carburetor
bakarbydari
loosening the
karburator
drain screw.
dengan melonggarkan drain screw (sekrup
Tighten the float chamber drain screw to the specified
pembuangan).
torque.
Kencangkan
TORQUE:1.5 float chamber
N·m (0.2 kgf·m, drain screw dengan torsi
1.1 lbf·ft)
yang ditentukan.

TORSI: 1,5 N.m (0,2 kgf.m; 1,1 lbf.ft) FLOAT CHAMBER


DRAIN SCREW

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

CARBURETOR DRAIN HOSE


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

SE THERMAL VALVE 3P CONNECTOR


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

WIRE CLAMPS

5-8
SISTEM BAHAN BAKAR
Release the
Lepaskan crankcase
crankcase breather
breather draindrain
hose hose from the
dari clamp.
clamp. Kiri: Kanan
Lepaskan kedua air cleaner housing mounting bolts dari
Remove the two air cleaner housing mounting bolts from
sisi
the kiri.
left side of air cleaner housing. BOLTS
Lepaskan
Remove the boltbolt
darifrom
sisi the
kanan dari
right air of
side cleaner housing.
air cleaner hous-
ing.

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

AIR VENT HOSE

Disconnect the vacuum piston hose and fuel hose from


Lepaskan vacuum piston hose dan fuel hose dari
the carburetor. BAND SCREWS
karburator.
Loosen the air cleaner connecting hose band screw.
Disconnect the connecting hose from the carburetor
Longgarkan
while holdingairthe
cleaner connecting
carburetor hose band
and pulling screw.
the air cleaner
Lepaskan connecting hose dari karburator sementara
housing backward.
memegang karburator
Loosen the inlet danscrew
pipe band menarik
andair cleaner housing
disconnect the car-
ke belakang.
buretor from the inlet pipe.

Longgarkan inlet pipe band screw dan lepaskan


karburator dari inlet pipe.

FUEL HOSE VACUUM PISTON HOSE

5-9
SISTEM BAHAN BAKAR
CARBURETOR
PEMASANGAN INSTALLATION
KARBURATOR
Connect the carburetor to the inlet pipe while aligning the
Sambungkan karburator pada inlet pipe sementara
BeHati-hati to tab of the carburetor with the groove of the inlet pipe.
agar
careful not
mentepatkan tab dari karburator dengan alur dari inlet Tepatkan
tidak merusak inlet
damage the inlet pipe.
pipe. pipe.

Be careful
Hati-hati agarnot to
tidak Connect the airair
Sambungkan cleaner connecting
cleaner hose to hose
connecting the carbure-
pada
tor while holding the carburetor CARBURETOR CONNECTING HOSE
damage
merusak the air
air cleaner karburator sementara menahanand carefullydan
karburator pushing the
dengan
connecting hose. air cleaner housing forward.
cleaner connecting hati-hati mendorong air cleaner housing ke depan.
hose. Tighten the inlet pipe band screw to the specified torque.
TORQUE:2 N·m
Kencangkan inlet (0.2
pipekgf·m,
band1.5screw
lbf·ft)dengan torsi yang
ditentukan.
Set the air cleaner connecting hose band by the speci-
fied angle.
Tighten 2
TORSI: the connecting
N.m hose
(0,2 kgf.m; 1,5band
lbf.ft)screw until the band
seats on the collar as shown.

Tempatkan air cleaner connecting hose band dengan


sudut yang ditentukan.
Kencangkan connecting hose band screw sampai band
BAND SCREWS
duduk pada collar seperti diperlihatkan.
INLET PIPE BAND SCREW
ATAS

75°

CONNECTING HOSE BAND SCREW

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

AIR VENT VACUUM


HOSE FUEL HOSE PISTON HOSE

5-10
SISTEM BAHAN BAKAR
Tempatkan air housing
Set the air cleaner cleanerin position.
housing pada posisi Kanan Kiri:
Install and tighten the three air cleaner housing mounting
pemasangannya.
bolts. dan kencangkan ketiga air cleaner housing BOLTS
Pasang
Secure the
mounting crankcase breather drain hose to the clamp.
bolts.
Kokohkan pemasangan crankcase breather drain hose
pada clamp.

BOLT BREATHER
DRAIN HOSE CLAMP

Route the wire Secure thekedua


Kokohkan two SE
SE thermal
thermal valve
valvewire
wireclamps
clampstopada
the
Alurkan
harness wire
properly frame.
rangka. WIRE GUIDE
harness
(pagedengan
1-14). Set the SE thermal
Tempatkan valve
SE thermal wirewire
valve to the wirewire
pada guide.
guide.
benar (hal. 1-14).

WIRE CLAMPS

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

SE THERMAL VALVE 3P CONNECTOR


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

CARBURETOR DRAIN HOSE

5-11
SISTEM BAHAN BAKAR
CARBURETOR DISASSEMBLY/
PEMBONGKARAN/PERAKITAN
ASSEMBLY
KARBURATOR
• ? BeHati-hati
carefulketika melepaskan
when removing the vacuum
vacuum chamber cover
as it iskarena
oleh under ia
spring
beradapressure.
di bawah tekanan pegas.
• ? Before
Sebelum removing the pilotpilot
melepaskan screw, record
screw, the number
catatlah of
jumlah
turns until it seats lightly, then remove the pilot screw,
putaranwasher
spring, sampai andia O-ring.
duduk dengan ringan, kemudian
lepaskantopilot
? Damage the screw, spring,
pilot screw seatwasher danifO-ring.
will occur the screw
• isDudukan
tightenedpilot screw
against akan mengalami kerusakan
the seat.
Holdjika
thescrew dikencangkan
carburetor and lightlyterhadap
drive thedudukannya.
float pin from the
throttle drum side. PIN DRIVER
Pegang karburator dan dengan ringan dorong masuk
TOOL:
float pin dari sisi throttle drum.
Pin driver 07744-0010100
TOOL:
Pin driver 07744-0010100

FLOAT PIN

2.1 N·m (0.2 kgf·m, DIAPHRAGM/


1.5 lbf·ft) VACUUM PISTON
FLOAT VALVE
VACUUM
CHAMBER COVER FLOAT

FLOAT PIN

SE THERMAL
VALVE COVER
O-RING

DRAIN SCREW SE THERMAL


FLOAT VALVE
1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) CHAMBER

O-RING

COMPRESSION
SPRING O-RING

WASHER
2.1 N·m 2.1 N·m
SPRING SPRING (0.2 kgf·m, (0.2 kgf·m,
NEEDLE
1.5 lbf·ft) 1.5 lbf·ft)
HOLDER

NEEDLE
PILOT SETTING
JET
SCREW PLATE

O-RING
SLOW JET
JET NEEDLE 1.5 N·m (0.2 kgf·m, NEEDLE JET HOLDER SE THERMAL
1.1 lbf·ft) 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft) VALVE BODY
MAIN JET
O-RING 3.4 N·m (0.4 kgf·m, 2.5 lbf·ft)
2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)

5-12
SISTEM BAHAN BAKAR
FLOATCHAMBER
FLOAT CHAMBER(RUANG PELAMPUNG)
CATATAN:
• ? Handle
Tangani thejets
jetsdengan hati-hati.
with care. They Mereka mudah
can easily sekali
be scored
or scratched.
tergerus atau tergores.
NEEDLE JET
Pasang sebagai
Install the berikut:
following:
-? Slow
Slowjetjet
-? Needle
Needlejetjet NEEDLE JET
? Needle jet holder HOLDER
-? Needle
Main jetjet holder O-RING
- Main jet
Tighten them to the specified torque.
Kencangkan dengan torsi yang ditentukan.
TORQUE:
TORSI:
Slow jet: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
Slow
Mainjet: 1,5(0.2
jet: 2.1 N·m N.mkgf·m,
(0,2 kgf.m; 1,1 lbf.ft)
1.5 lbf·ft) WASHER
Main jet:jet holder:
Needle 2,12.5
N.m (0,2
N·m kgf.m;
(0.3 kgf·m,1,5
1.8lbf.ft)
lbf·ft)
Needle jet holder: 2,5 N.m (0,3 kgf.m; 1,8 lbf.ft) MAIN JET
PILOT SCREW SPRING SLOW JET

Kerusakan
Damageakan to theterjadi
pilot Pasang O-ring,
Install the O-ring,washer,
washer,spring
springdanand pilot
pilot screw
screw anddan
padaseatdudukan pilot kembalikan keoriginal
return it to its tempatnya semula
position seperti
as noted telahremoval.
during dicatat FLOAT PIN FLOAT VALVE
screw will occur
screw jika
if the pilot
pilot screw
screw is pada
Performwaktu
the pelepasan.
pilot screw Jalan prosedur
adjustment penyetelan
procedure pilot
if a new
dikencangkan terhadap
tightened against the pilot screw
screw is installed
seperti (page 5-20)
bila sebuah .
pilot screw baru telah
kedudukannya. dipasang
seat. Install the(hal.
float5-20).
and float valve in the carburetor body,
then install the float pin through the body and float.
Pasang float dan float valve di dalam badan karburator,
kemudian pasang float pin melalui badan dan float.

FLOAT
Drive the masuk
Dorong float pin lightly
float until
pin the height from
dengan the float
ringan pin
sampai
holder (SE dari
ketinggian thermal
floatvalve side) is(sisi
pin holder – 0.55
0.15SE mm (0.006
thermal valve)
– 0.0220,15
adalah in). – 0,55 mm. PIN DRIVER
TOOL:
TOOL:
Pin driver
Pin driver 07744-0010100
07744-0010100

0.15 – 0.55 mm
(0.006 – 0.022 in)

FLOAT PIN

Install a new O-ring into the float chamber.


Pasang
Install thesebuah O-ring baru ke dalam float chamber
float chamber.
(ruang pelampung). FLOAT CHAMBER
O-RING
Pasang float chamber.

5-13
SISTEM BAHAN BAKAR
Install and
Pasang dantighten the floatfloat
kencangkan chamber screws
chamber to thedengan
screws speci-
fied torque. SCREWS
torsi yang ditentukan.
TORQUE:2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
TORSI: 2,1 N.m (0,2 kgf.m; 1,5 lbf.ft)

VACUUM
VACUUM CHAMBER
CHAMBER
Pasang jetjet
Install the needle, spring
needle, springdan
andneedle
needleholder
holderkeinto
dalam
the
vacuum
vacuum piston.
piston. VACUUM PISTON

JET NEEDLE

SPRING

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

Be careful not to Install thediaphragm/vacuum


Pasang diaphragm/vacuum piston
piston into
ke the carburetor
dalam badan
body aligning the diaphragm tab with the groove on the Tempatkan VACUUM CHAMBER COVER
damage theagar
Hati-hati jet karburator dengan mentepatkan diaphragm tab dengan
needle. carburetor body.
tidak merusak jet alur pada badan karburator. SPRING
needle. Hold the vacuum piston almost full open to prevent the
diaphragm from being pinched by the chamber cover.
Tahan vacuum piston hampir terbuka penuh untuk
Install the compression spring into the Tepatkan
menghindari dijepitnya diaphragm olehvacuum
chamberpiston.
cover.
Set the boss of the vacuum chamber cover to the com-
pressioncompression
Pasang spring and install
springthe
kechamber cover. piston.
dalam vacuum
Tempatkan boss dari vacuum chamber cover pada
compression spring dan pasang chamber cover.

DIAPHRAGM/
VACUUM PISTON

5-14
SISTEM BAHAN BAKAR
Install and
Pasang tighten
dan the vacuumvacuum
kencangkan chamber chamber
cover screws to
cover
the specified
screws torque.
(sekrup-sekrup tutup ruang vakuum) dengan SCREWS
torsi yang ditentukan.
TORQUE:2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
TORSI: 2,1 N.m (0,2 kgf.m; 1,5 lbf.ft)

Periksa bahwa
Check that springis installed
the spring telah dipasang
correctly dengan benar
by pushing the
bottom of
dengan the piston with
mendorong bagian yourbawah
finger piston
and make sure that
dengan jari- SPRING PISTON
the piston
jari returns back bahwa
dan memastikan in place piston
smoothly.
kembali dengan
lancar ke tempatnya semula.

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

SE THERMAL VALVE BODY


Install the SE thermal valve body.
Pasang SE thermal valve body. SE THERMAL
Install and tighten the SE thermal valve body screws to VALVE BODY
Pasang dan kencangkan
the specified torque. SE thermal valve body screws
dengan torsi yang ditentukan.
TORQUE:3.4 N·m (0.4 kgf·m, 2.5 lbf·ft)
TORSI: 3,4 N.m (0,4 kgf.m; 2,5 lbf.ft)

SCREW

5-15
SISTEM BAHAN BAKAR
Pasang
Install a sebuah O-ring
new O-ring baru
to the SEpada SE thermal
thermal valve. valve.
SE THERMAL
Install the SE thermal valve into the carburetor
Pasang SE thermal valve ke dalam karburator sampai until it is
ia VALVE
fully seated.
telah duduk sepenuhnya.

O-RING

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

Install the setting Pasang setting


Install the plate
setting pada
plate ontoalur
the SE
SE thermal
thermal valve.
valve groove.
Pasangplate
setting
withplate
the
SETTING PLATE
Install and tighten the setting plate screw
Pasang dan kencangkan setting plate screw to the specified
dengan
dengan ujung yang edge
chamfered telah torque.
dipotong menghadap ke torsi yang ditentukan.
facing up.
atas. TORQUE:2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
TORSI: 2,1 N.m (0,2 kgf.m; 1,5 lbf.ft)

Atur SCREW

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

SE THERMAL
VALVE COVER

5-16
SISTEM BAHAN BAKAR
HOSES(SLANG-SLANG)
HOSES
Sambungkan airvent
Connect the air venthose
hoseand
dancarburetor
carburetordrain
drainhose.
hose.
AIR VENT HOSE

CARBURETOR DRAIN HOSE

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

5-17
SISTEM BAHAN BAKAR
CARBURETOR INSPECTION
PEMERIKSAAN KARBURATOR
SE
SE THERMAL
THERMAL VALVE
VALVE
PEMERIKSAAN VALVE/NEEDLE
VALVE/NEEDLE INSPECTION
Lepaskan SESE
Remove the thermal valve
thermal (hal.
valve 5-12).
(page 5-12).
VALVE
Periksa
Inspect valve danand
the valve needle terhadap
needle keausan
for stepped wearbertingkat
or dam-
age. kerusakan.
atau

SE THERMAL
VALVE

NEEDLE
PEMERIKSAAN VALVE THERMOWAX
VALVE
Measure THERMOWAX
the resistance atINSPECTION
the connector terminals of the
Ukur tahanan pada connector terminals dari sisi SE
Pemeriksaan tahanan
The SE thermal SE
valve SE thermal
thermal valve.valve side.
thermal valve
resistance dapat
inspection CONNECTION: Black – Green/Orange
candilakukan dengan
be done with the HUBUNGAN: Hitam
karburator terpasang STANDARD: 3.2 – 5.6–ΩHijau/Jingga
(at 25°C/77°F)
carburetor installed STANDARD: 3,2 – 5,6 Ω (pada 25° C)
pada mesin.
to the engine. If the resistance is abnormal, replace the SE thermal
Jika tahanan tidak normal, gantilah SE thermal valve.
valve.
PEMERIKSAAN CARA KERJA VALVE Bl G/O

Jika mesin telah dijalankan, biarkan mendingin (di


bawah 35° C) selama 30 menit atau lebih.

Lepaskan SE thermal valve body (hal. 5-12).


SE THERMAL VALVE 3P
Masukkan slang vinyl ke dalam fuel enrichment circuit CONNECTOR
(rangkaian
VALVE pengkayaan
OPERATION bahan bakar) dan tiuplah ke
INSPECTION
dalam hose.
If the engine has been running, let it cool down (below
°C (95°F)) for ke SE THERMAL VALVE
Udara 35
harus mengalir 30 dalam
minutes or more.
rangkaian.
Remove
Hubungkan the SE12thermal
baterai V pada valve
SEbody (page valve
thermal 5-12). 3P
connector terminals
Insert a vinyl dan
hosetunggu 5 menit.
into the fuel enrichment circuit and
Masukkan
blow slang vinyl
into the ke dalam fuel enrichment circuit
hose.
dan tiuplah ke dalam slang.
Air should flow into the circuit.
Connect the 12 V battery to the SE thermal valve 3P con-
Udara nector
tidak boleh mengalir
terminals ke dalam
and wait rangkaian.
5 minutes.
Insert a vinyl hose into the fuel
Jika cara kerja tidak normal, ganti SE thermal enrichment
valve.circuit and
blow into the hose.
Pasang AirSE thermal
should not valve (hal.the
flow into 5-15).
circuit.
If operation is abnormal, replace the SE thermal valve. FUEL ENRICHMENT SE THERMAL VALVE
CIRCUIT 3P CONNECTOR
Install the SE thermal valve (page 5-15).

5-18
SISTEM BAHAN BAKAR
PEMERIKSAAN SISTEM
SYSTEM INSPECTION
• ? Before
Sebelumperforming the systempemeriksaan
menjalankan inspection, make sure
sistem,
that the following is normal.
?pastikan
Battery bahwa yang berikut adalah normal.
condition
?- Fuse
Kondisi baterai
- Sekring
Remove the center body cover (page 2-8).
Lepaskan center
Disconnect body
the SE covervalve
thermal (hal.3P
2-8).
connector.
If the engine has been
Jika mesin Turn
telah Lepaskan SE thermal valve 3P connector.
running, letbiarkan
dijalankan, it cool
mendingin
down dulu
(below(di Putar kunci kontak ke "ON".
bawah C °(95
35°35 C)°F))
selama 30 Ukur voltase pada sisi wire harness dari SE thermal
for 30
menit atau
minutes lebih. valve connector.
or more.

HUBUNGAN: Hitam ( + ) - Hijau/Jingga ( - )


SE THERMAL VALVE 3P CONNECTOR
STANDARD:
the ignition switch "ON". ada voltase baterai
Tidak
Measure the
Hidupkan voltage at the wire harness side of SE ther-
mesin.
mal valve
Ukur connector.
voltase pada sisi wire harness dari SE thermal
CONNECTION:
valve connector Black (+) – Green/Orange
sementara mesin dalam (–) keadaan
panas.
STANDARD: No voltage
Start the engine. Hitam ( + ) - Hijau/Jingga ( - )
HUBUNGAN:
Measure the voltage at the wire harness side of SE ther- TO MAIN
STANDARD: Ada
mal valve connector voltase
while bateraiis hot.
the engine FUSE
R/Bl
•CONNECTION:
Jika ada voltase Black (+) – Green/Orange
baterai (–) periksa
pada setiap waktu,
STANDARD:
sebagai berikut: Battery voltage
- Hubungan singkat pada kawat Hijau/Jingga dari Bl
? If there is battery voltage at all time, check the follow-
ing:SE thermal valve R R/Bl R/Bl G/O
• ?Jika tidak
Short ada involtase
circuit baterai valve
SE thermal pada Green/Orange
setiap waktu,
wire sebagai berikut:
periksa
? If- there is no voltage
Rangkaian terbukaatpada
all time, check
kawat the following:
Hitam
?- Open circuit in
Rangkaian Black wire
terbuka pada kawat Hitam dari SE ICM
? Open circuit in SE thermal valve Black wire and/or
thermal valve dan/atau
Green/Orange wires kawat-kawat Hijau/Jingga.
R R/Bl
• ? IfJika kawat-kawat
the wires adalah
are normal, normal,
replace the ICMgantilah ICM
with a new
one,
denganand yang
recheck.
baru, dan periksa kembali.
SE THERMAL VALVE
3P CONNECTOR
VACUUM CHAMBER (RUANGAN VAKUUM)
Lepaskan vacuum chamber (hal. 5-12). IGNITION
SWITCH
Periksa sebagai berikut:
-VACUUM CHAMBER
Jet needle terhadap keausan bertingkat
- Vacuum piston terhadap keausan atau kerusakan
-Remove the vacuum
Diaphragm chamber
terhadap (page 5-12)
lubang kecil,. pemburukan VACUUM PISTON
kondisi
Check theatau kerusakan
following:
? Jet needle for stepped wear
? Vacuum piston for wear or damage
? Diaphragm for pin holes, deterioration or damage
JET NEEDLE

DIAPHRAGM

5-19
SISTEM BAHAN BAKAR
FLOATCHAMBER
FLOAT CHAMBER
Remove the
Lepaskan float
float (page 5-12).(hal. 5-12).
(pelampung) PIN FLOAT
Check the float for
Periksa float terhadap damage.
kerusakan.
Replace the float if there is fuel in the float.
Ganti float jika ada bahan bakar di dalam float.
Inspect the float valve seat for scores, scratches, clogs
and damage.
Periksa float valve seat (dudukan katub pelampung)
Check the tip of the float valve where it contacts the
terhadap
valve seatgerusan,
for steppedgoresan, sumbatan
wear or dan kerusakan.
contamination.
Periksa ujung dari float valve di tempat di mana ia
Replace the valve if the tip is worn or contaminated.
mengadakan kontak dengan valve seat terhadap
Check the operation of the float valve.
keausan bertingkat atau kontaminasi.
Push valve
Ganti the pinbilaon the floataus
ujungnya valve
atauand make sure that it
terkontaminasi. FLOAT VALVE
returns smoothly.
Periksa cara kerja dari float valve. VALVE SEAT
Dorong pin pada float valve dan pastikan bahwa ia
kembali dengan lancar.
Install the
Pasang float
float valve
valve and
dan float
float (page
(hal. 5-13).
5-13).
Set the float level With the float valve seated and the float arm just touch-
Letakkan float level Dengan float measure
ing the valve, valve pada posisi
the float duduk
level danspecial
with the float arm
tool
gauge so that it is tepat menyentuh valve, ukur float level (tinggi
gauge sedemikian as shown.
perpendicular to the
sehingga ia tegaklurus pelampung) dengan special tool seperti diperlihatkan.
float permukaan
pada chamber face at
float FLOAT LEVEL: 13.0 mm (0.51 in)
the highestpada
chamber pointtitik
of
FLOAT LEVEL: 13,0 mm
the float.
tertinggi dari float. TOOL:
Carburetor float level gauge
TOOL: 07401-0010000
Carburetor floatbe
The float cannot level gauge
adjusted. 07401-0010000
Replace the float assembly if the float level is out of
Float tidak dapat disetel.
specification.
Ganti float assembly (susunan pelampung) bila float
level tidak sesuai dengan spesifikasi.
FLOAT LEVEL GAUGE
PILOT
PILOTSCREW/JETS
SCREW/JETS
Remove pilot
Lepaskan pilotscrew
screwand
daneach jet (page 5-12)
masing-masing jet. (hal. 5-12).
Check the
Periksa following:
sebagai berikut: NEEDLE JET
? Pilot screw needle for wear or damage
-? Pilot
Pilot screw springterhadap
screw needle keausan atau kerusakan
for deterioration
-? Pilot screw spring terhadap
Each jet for clogging pemburukan kondisi NEEDLE JET
-? Masing-masing
Each passage jetforterhadap
clogging penyumbatan HOLDER
- Masing-masing jalan lintasan terhadap penyumbatan

MAIN JET

SPRING

PILOT SCREW SLOW JET

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

5-20
SISTEM BAHAN BAKAR
IDLEDROP
IDLE DROP PROCEDURE
PROCEDURE (PROSEDUR
Damage to the pilot PENURUNAN PUTARAN
1. Remove the luggage STASIONER)
box (page 2-7).
Kerusakan akan
screw seat pada
terjadi will occur
pilot Turn the pilot screw clockwise until it seats lightly, and
if the seat
screw pilotjika
screw is 1. then
pilot
Lepaskan
back itluggage box
out to the (hal. 2-7). given.
specification
tightened against the This
Putarispilot
an initial
screwsetting
searahprior
jarumto jam
the sampai
final pilot screw
ia duduk
screw dikencangkan adjustment.
terhadap dudukannya. seat. dengan ringan, dan kemudian putar keluar sampai
ke spesifikasi
INITIAL yang telah
OPENING: @@@ diberikan.
turns out
Ini merupakan penyetelan awal sebelum
2. Warm the engine
penyetelan akhir up to screw.
pilot operating temperature.
7
PEMBUKAAN
Stop-and-go AWAL:
riding for 101minutes
– /8 putaran keluar
is sufficient.
3. Stop
2. the engine.
Panaskan mesin sampai suhu operasionil.
Connect a tachometer according to the tachometer
Pengendaraaninstructions.
manufacturer’s jalan-dan-berhenti selama 10 menit
adalah cukup.
PILOT SCREW
3. Matikan mesin.
4. Disconnect
Hubungkanthetachometer
vacuum hose from PAIR
sesuai control
dengan valve
petunjuk
and connect the vacuum pump to the PAIR control
pemakaian pabrik pembuatnya.
valve vacuum hose joint. Plug the vacuum hose. VACUUM PUMP PAIR CONTROL VALVE
5. Apply the specified
4. Lepaskan vacuum vacuum toPAIR
hose dari the PAIR control
control valvevalve
dan
vacuum hose more than 60 kPa (450 mm Hg).
hubungkan vacuum pump (pompa vakuum) ke
PAIR control valve vacuum hose joint. Sumbat PLUG
vacuum hose.

5. Terapkan vakuum yang ditentukan pada PAIR


control valve vacuum hose lebih dari 60 kPa (450
mm Hg).

6. Hidupkan mesin dan setel putaran stasioner


dengan throttle stop screw.
-1
PUTARAN STASIONER: 1.700 ± 100 menit
(rpm)

7. Putar pilot screw masuk atau keluar dengan pelan


untuk mendapatkan putaran mesin tertinggi.
6. Start the engine and adjust the idle speed with the
8. throttle
Buka throttle 2 atau 3 kali dengan ringan, kemudian
stop screw. THROTTLE STOP SCREW
setel putaran stasioner dengan throttle screw.
IDLE SPEED: 1,700 ± 100 min-1 (rpm)
-1
PUTARAN STASIONER: 1.700 ± 100 menit
7. Turn the pilot screw in or out slowly to obtain the high-
(rpm)
est engine speed.
8. Lightly
9. Putar open
pilot the throttle
screw 2 or 3berangsur
secara times then ke
adjust the
dalam
idle speed with the throttle stop screw -1
sampai putaran mesin turun -1dengan 100 menit
IDLE
(rpm). SPEED: 1,700 ± 100 min (rpm)
9. Turn the pilot screw in gradually until the engine
10. speed
Putar drops
pilot by
screw
@@@ keluar
min-1 sampai
(rpm) ke pembukaan
akhir.
10.Turn the pilot screw
PEMBUKAAN outward½to putaran
AKHIR: the final opening.
keluar dari
FINAL OPENING:
posisi yang @@@
diperoleh turns
pada out from
langkah 9 the posi- PILOT SCREW
tion obtained in step 9
11. Lepaskan plug (sumbat) dari vacuum hose,
11.Disconnect the plug vacuum
kemudian lepaskan from thepump
vacuum hose, then
dan hubungkan
remove the vacuum pump and connect the vacuum
vacuum
hose hose
to the kecontrol
PAIR PAIR valve
control valve hose
vacuum vacuum hose
joint.
joint.
12.Readjust the idle speed with the throttle stop screw.
12. IDLE
Setel SPEED:
kembali 1,700 ± 100stasioner
putaran min-1 (rpm)
dengan throttle
stop screw.
Install the luggage box (page 2-7).
-1
PUTARAN STASIONER: 1.700 ± 100 menit
(rpm)

Pasang luggage box (hal. 2-7).

5-21
SISTEM BAHAN BAKAR
INLETPIPE
INLET PIPE(PIPA MASUK)
REMOVAL
PELEPASAN
Lepaskan sebagai
Remove the berikut:
following:
Kiri: Kanan
-? Left
Leftcrankcase
crankcasecover
coverduct
duct(hal.
(page2-12)
2-12)
-? Luggage
Luggagebox (page
box(hal. 2-7)
2-7) BOLTS
Release the crankcase breather drain hose from the
Lepaskan
clamp. crankcase breather drain hose dari clamp.
Lepaskan ketiga
Remove the airaircleaner
three cleanerhousing
housingmounting
mountingbolts.
bolts.

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

FUEL AUTO
VALVE
VACUUM
HOSE BAND SCREW
Remove the
Tutuplah lubang Lepaskan gasket
gasket danand clean any
bersikan sisagasket
bahanmaterial
gasketfrom
dari
pemasukan
Seal cylinder
the cylinder the inlet pipe
head permukaan mating surface
penyatuan of the
inlet pipe cylinder
dari head.
cylinder head.
headintake
dengan GASKET
portkain lap
with a
atau tutup dengan pita
shop towel or cover it PEMASANGAN
perekat untuk INSTALLATION
with a piece masuknya
menghindari of tape to
dalam Pasang
benda asing keforeign
prevent any gasket
Install a new baru
gasket to pada cylinder
the cylinder head.
head.
materialmesin.
from
dropping into the
engine.

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

5-22
SISTEM BAHAN BAKAR
Set the air cleaner
Letakkan air housing in housing
cleaner position. pada tempat
Install and tighten the three bolts. Kanan: Kiri:
pemasangannya. BOLTS
Pasang
Secure danthe kencangkan ketiga bolts.
crankcase breather drain hose with the
clamp.
Kokohkan pemasangan crankcase breather drain hose
Install the
dengan following:
clamp.
? Left crankcase cover duct (page 2-12)
? Luggage
Pasang (page 2-7)
box berikut:
sebagai
- Left crankcase cover duct (hal. 2-12)
- Luggage box (hal. 2-7)

BOLT BREATHER
DRAIN HOSE CLAMP

SECONDARY AIR
SECONDARY AIR SUPPLY
SUPPLY SYSTEM
PEMERIKSAAN SISTEM
SYSTEM INSPECTION
Hidupkan mesin and
Start the engine dan warm
panaskan sampai
it up to keoperating
normal suhu operasi
tem-
normal
peraturedan matikan
and mesin.
stop the engine. AIR INTAKE PORT
Remove the PAIR air cleaner element (page 3-12).
Lepaskan PAIR air cleaner element (hal. 3-12).
Check that the PAIR air intake port is clean and free of
Periksa bahwa PAIR air intake port (lubang pemasukan
carbon deposits.
PAIR) adalah bersihfouled,
If the port is carbon dan bebas dari
check theendapan karbon.
PAIR check valve.
Jika port kotor dengan karbon, periksa PAIR check
valve.

Remove the
Keluarkan two bolts
kedua bolts dan
and lepaskan
disconnectPAIR
the PAIR
controlcontrol
valve
valve
dari airfrom the air
cleaner cleaner
housing housing
(lihat (see page 5-24).
hal. 5-24).
Disconnect the PAIR control valve vacuum hose and VACUUM PUMP
Lepaskan PAIR control valve vacuum hose dan sumbat PAIR CONTROL VALVE
plug the hose.
hose.
Connect the vacuum pump to the PAIR control valve
vacuum hose joint.
Hubungkan vacuum pump pada PAIR control valve
Start the engine and open the throttle slightly to be cer- PLUG
vacuum
tain thathose
air isjoint.
sucked in through the joint of the PAIR
control valve.
Hidupkan mesin
If the air is not drawndan buka the
in, check throttle sedikit
joint and supply untuk
hose
for clogs.
memastikan bahwa udara dihisap masuk melalui joint
dari
WithPAIR control running,
the engine valve. gradually apply vacuum to the
Jika
PAIRudara
controltidak ditarik masuk, periksa joint dan slang
valve.
Check that
saluran the joint
terhadap of the PAIR control valve stops draw-
sumbatan.
ing air, and that the vacuum does not bleed.
Sementara mesin dalam
SPECIFIED VACUUM: 60 kPakeadaan
(450 mm Hg)hidup, secara
berangsur terapkan vakuum pada PAIR control valve.
If air is drawn
Periksa bahwain,joint
or if dari
the specified vacuum
PAIR control is notterhenti
valve main-
tained, replace
menarik the PAIR
udara, dan bahwa control
vakuum valve withbocor.
tidak a new one.

VAKUUM YANG DITENTUKAN: 60 kPa (450 mm Hg)


Jika udara dihisap masuk, atau jika vakuum yang
ditentukan tidak dapat dipertahankan, gantilah PAIR
control valve dengan yang baru.

5-23
SISTEM BAHAN BAKAR
PAIR CONTROL VALVE REMOVAL/
PELEPASAN/PEMASANGAN
INSTALLATION
PAIR CONTROL VALVE
Remove the
Lepaskan body
body cover
cover (page
(hal. 2-9).
2-9).
PAIR CONTROL BOLTS
Disconnect
Lepaskan the following:
sebagai berikut: VALVE
? Air supply
-? AirPAIR
supply hose
hose
control valve vacuum hose
- PAIR control valve vacuum hose
Remove the two PAIR control valve mounting bolts and VACUUM
pull out thekedua
Lepaskan PAIR PAIR
controlcontrol
valve from
valveair cleaner housing.
mounting bolts dan HOSE
Installation is in the reverse order of removal.
Route the hoses tarik keluar PAIR control valve dari air cleaner housing.
properly (page 1-14)
Alurkan hoses dengan Pemasangan adalah dalam urutan terbalik dari
benar (hal. 1-14) pelepasan.

AIR SUPPLY HOSE


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

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

Ganti
ReplacePAIR
the control valvevalve
PAIR control jika reed (buluh)
if the reed rusak atau
is damaged or
deteriorated,kondisinya,
rubber seat is cracked, deteriorated or RUBBER SEAT
memburuk rubber seat (dudukan karet)
damaged, ormemburuk
retak-retak, if there is kondisinya
clearance between the reed
atau rusak, atau and
jika
seat.
ada kerenggangan antara reed dan seat.
Installation is in the reverse order of removal.
Pemasangan
TORQUE: adalah dalam urutan terbalik dari
pelepasan.
Pair check valve cover screw:
2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
TORSI:
Pair check valve cover screw:
2,1 N.m (0,2 kgf.m; 1,5 lbf.ft)

REED

5-24
SISTEM BAHAN BAKAR
PAIR AIR SUPPLY
PELEPASAN PIPE
PAIR AIR REMOVAL
SUPPLY PIPE
Lepaskan PAIR
Disconnect air supply
the PAIR hose hose
air supply dari pipe.
from the pipe.
PAIR AIR SUPPLY
HOSE

Lepaskan ketiga
Remove the bolts
three boltsdan
andPAIR
PAIRairairsupply
supplypipe.
pipe.

BOLTS

PAIR AIR SUPPLY PIPE

Remove the gasket.


Lepaskan gasket.

PAIR AIR SUPPLY PIPE


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

GASKET

Letakkan
Set the PAIRPAIR air pipe
air supply supply pipe pada posisi
in position.
pemasangannya. 6.5 ± 1.0 mm
Apply locking agent to the PAIR air supply pipe mounting
bolts as shown, then install and tighten them. BOLTS (0.26 ± 0.04 in)
Oleskan cairan pengunci pada PAIR air supply pipe
mounting bolts seperti diperlihatkan, kemudian pasang
dan kencangkan.

PAIR AIR SUPPLY PIPE

5-25
SISTEM BAHAN BAKAR
Sambungkan PAIRairairsupply
Connect the PAIR supply hose
hose pada
to the pipe
pipe dengan
so that the
marked
sisi yangside of the dari
bertanda hosehose
is facing out as shown.
menghadap ke luar seperti PAIR AIR
diperlihatkan. SUPPLY HOSE

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

PAIR AIR
SUPPLY PIPE

FUEL TANK
TANK (TANGKI BAHAN BAKAR)
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan body
Remove the cover
body (hal.
cover 2-9).
(page 2-9).
FUEL HOSE
Wipe off spilled out Letakkan
Place an tempat
approvedpenampung
container yang
undersesuai di bawah
the fuel fuel
auto valve
Sekalah bahan bakar
fuel. and clamp
auto the fuel
valve dan jepithose.
fuel hose dengan clamp.
yang tertumpah. Disconnectfuel
Lepaskan the fuel
hosehose
danand vacuum
vacuum hosedari
hose fromfuel
the auto
fuel
auto valve,
valve, then tarik
kemudian pull them
merekaout keluar
of the dari
holelubang
on the pada
rear
fender.
rear fender (spakbor belakang).

VACUUM HOSE CLAMP

5-26
SISTEM BAHAN BAKAR
Disconnectfuel
Lepaskan the unit
fuel unit 3P connector
3P connector danand release wire
lepaskan the
wire clamp
clamp fromtank.
dari fuel the fuel tank. BOLTS FUEL TANK BOLTS/COLLARS
Remove the following:
Lepaskan
? Two bolts sebagai berikut:
? Two bolts/collars
- Dua bolts
-Slightly lift up the rear side of the luggage box and
Dua bolts/collars
remove the is
Installation fuel tank.
in the reverse order of removal.
Route the hoses and Angkat sisi belakang dari luggage box sedikit dan
wire harness properly lepaskan fuel tank.
(page 1-14).
Alurkan hoses dan wire Pemasangan adalah dalam urutan terbalik dari
harness dengan benar pelepasan.
(hal. 1-14)

3P CONNECTOR CLAMP

FUEL
FUEL AUTO
AUTO VALVE
VALVE
PEMERIKSAAN
INSPECTION
Lepaskan body
Remove the cover
body (hal.
cover 2-9).
(page 2-9).
Sekalah bahan bakar FUEL HOSE FUEL AUTO VALVE
Wipe spilled out Letakkan
off tertumpah.
yang
penampung
Place an approved fuelbahan bakar
container yang
under the sesuai di
fuel auto
valve and
fuel. bawah fuelclamp the fuel
auto valve hose.
dan jepit fuel hose dengan clamp.
Disconnectfuel
Lepaskan thehose.
fuel hose.
Check that the fuel does not come out from the joint of
Periksa bahwa
the fuel auto bahan bakar tidak mengalir keluar dari
valve.
joint dari fuel auto valve.

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

Bahan bakar harus mengalir keluar dari fuel hose ketika


vakuum diterapkan. VACUUM PUMP
Jika aliran bahan bakar terbatasi atau tidak mengalir,
gantilah fuel auto valve.

5-27
SISTEM BAHAN BAKAR
REMOVAL
PELEPASAN
Remove the
Lepaskan fuelfuel tank
tank (page
(hal. 5-26).
5-26).
FUEL AUTO VALVE
Place an approved
Wipe off spilled out Letakkan penampung fuel container
bahan bakarand drain
yangfuel.
sesuai dan
Seka bahan bakar fuel.
yang
keluarkan
Loosen thebahan bakar.
lock nut and remove the fuel auto valve. LOCK NUT
tertumpah.
Longgarkan lock nut dan keluarkan fuel auto valve.

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

FUEL AUTO VALVE

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

O-RING

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

STRAINER SCREEN

5-28
SISTEM BAHAN BAKAR
Install the
Pasang fuelfuel auto
auto valve
valve danand set it in the
tempatkan padacorrect
sudutangle
yang
as shown.
benar seperti diperlihatkan.

45 ± 3°

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

5-29
CATATAN
6. PENURUNAN / PEMASANGAN MESIN

LOKASI KOMPONEN
COMPONENT ............................6-2
LOCATION ????????????? 6-2 PENURUNAN MESIN
ENGINE REMOVAL ............................6-4
??????????????????? 6-4

KETERANGAN SERVIS ........................6-3


SERVICE INFORMATION ?????????????? 6-3 PEMASANGAN MESIN .........................6-6
ENGINE INSTALLATION ?????????????? 6-6

6-1
PENURUNAN / PEMASANGAN MESIN
COMPONENT
LOKASI LOCATION
KOMPONEN
ENGINE REMOVAL/INSTALLATION

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

6-2
PENURUNAN / PEMASANGAN MESIN
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
•• Support
Topangthe engine
mesin using menggunakan
dengan a jack or other dongkrak
adjustableatau
support
alattopenopang
ease of engine mounting
lain yang dapatbolt removal.
disetel untuk mempermudah pelepasan
• When
engine removing/installing
mounting bolt (bautthepemasangan
engine, tape the frame around the engine beforehand for frame protection.
mesin).
• The following components require engine removal for service.
• –Ketika menurunkan/memasang
Cylinder mesin, sebelumnya
head/camshaft/cylinder/piston (page 7-10) bungkuslah rangka di sekitar mesin dengan pita untuk melindunginya.
• –Komponen-komponen
Crankcase/crankshaft berikut ini memerlukan
(page 10-5) ) penurunan mesin agar dapat menservisnya.
- Cylinder head/camshaft/cylinder/piston (hal. 7-10)
• The following components(hal.
- Crankcase/crankshaft can be serviced with the engine installed in the frame.
8-15)
– Drive pulley (page 8-12)
– Driven pulley/clutch (page 8-16)
• –Komponen-komponen berikutnya dapat diservis dengan mesin terpasang pada rangka.
Final reduction (page 9-6)
- Drive pulley (hal. 8-11)
– Stator/ignition pulse generator (page 14-7)
–- Carburetor
Driven pulley/clutch
(page 5-8) (hal. 8-15)
–- Oil
Final reduction
pump (hal. 9-6)
(page 4-4)
- Stator/ignition pulse generator (hal. 14-7)
- Karburator (hal. 5-8)
SPECIFICATIONS
- Oil pump (hal. 4-4)

ITEM SPECIFICATIONS
SPESIFIKASI
Engine dry weight 24.9 kg (54.9 lbs)
Engine oil capacity
BAGIAN After draining 0.7 liter (0.7 US qt, 0.6 lmp qt)
SPESIFIKASI
Berat kosong mesin After disassembly 0.8 liter (0.8 US qt,24,9
0.7 kg
lmp qt)
Kapasitas oli mesin Pada penggantian periodik 0,7 liter
Setelah pembongkaran mesin 0,8 liter
TORQUE VALUES
Engine hanger link nut (Engine side) 49 N·m (5.0 kgf·m, 36 lbf·ft)
NILAI TORSI
Engine hanger link nut (sisi Mesin) 49 N.m (5,0 kgf.m; 36 lbf.ft)

6-3
PENURUNAN / PEMASANGAN MESIN
ENGINE REMOVAL
PENURUNAN MESIN
Remove the
Lepaskan following:
sebagai berikut:
SPRING
– Under cover (page 2-10)
- Under cover (hal. 2-10) ADJUSTING NUT
– Center body cover
- Center body cover (hal.(page 2-8)
2-8)
-– Luggage
Luggagebox (page
box(hal. 2-7)
2-7)
Remove the rear brake adjusting nut and joint pin from
Lepaskan rear cable.
the rear brake brake adjusting nut dan joint pin dari rear
brake cable.
Remove the return spring from the brake arm.
Lepaskan return spring dari brake arm.

BRAKE CABLE JOINT PIN

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

CABLE CLAMP/ BOLT CABLE HOLDER


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

WIRE CLAMP
SPARK PLUG CAP

Remove the bolt and ground cables.


Disconnect
Lepaskan thedan
bolt following
groundconnectors:
cables. BOLT/GROUND CABLES ALTERNATOR 3P
– Alternator 3P connector
Lepaskan connectors berikut ini: CONNECTOR
– Starter motor 2P connector
- –Alternator
SE thermal
3P valve 3P connector
connector
- Starter motor 2P connector
- SE thermal valve 3P connector

SE THERMAL VALVE
3P CONNECTOR

STARTER
MOTOR 2P
CONNECTOR

6-4
PENURUNAN / PEMASANGAN MESIN
Release the
Lepaskan following
wire clamps wire clamps
berikut from
ini dari the frame:
rangka:
SE THERMAL VALVE
– SE thermal valve wire clamp
- SE thermal valve wire clamp WIRE CLAMP
– Alternator wire clamp
-–Alternator wire clamp
Starter motor wire clamp
- Starter motor wire clamp

ALTERNATOR
WIRE CLAMP
STARTER MOTOR
WIRE CLAMP

Disconnect
Lepaskan the following:
sebagai berikut: THROTTLE CABLE FUEL HOSE
– Fuel hose
-–Fuel hose
Fuel auto valve vacuum hose
- Fuel auto valve vacuum hose
Loosen the lock nut and disconnect the throttle cable.
Longgarkan lock nut dan lepaskan throttle cable.

LOCK NUT

VACUUM HOSE

Untuk
To avoid damage to Lepaskan
menghindari Remove therearrear
shock absorber
shock lower
absorber mounting
lower bolt dan
mounting bolt
kerusakan the pada and release
rear lepaskan
ulirshock
rear rearthe rear absorber
shock shock absorber from the engine.
dari mesin. SHOCK ABSORBER
shockmounting
absorber absorber
mounting bolt,slightly
bolt threads, angkat
rodaliftbelakang
the rear sedikit.
wheel.

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

NUT/BOLT

6-5
PENURUNAN / PEMASANGAN MESIN
PEMASANGAN MESIN
ENGINE INSTALLATION
Maneuver mesin
Gerakkan the engine into therangka
ke dalam frame from
dari the
sisi right
kanansidedari
of
the vehicle.
kendaraan.
Set the engine
Tempatkan mesinstraight
lurus with
denganthe frame
rangkaand danpush the
dorong
engine forward so that the bolt holes are aligned.
mesin ke depan sehingga lubang-lubang bolt telah
Install the engine hanger link bolt from the left side of the
disejajarkan.
scooter.
Install and
Pasang tightenhanger
engine the nut to thebolt
link specified
(bauttorque.
penyambung
penggantung mesin) dari sisi kiri
TORQUE:49 N·m (5.0 kgf·m, 36 lbf·ft) dari skuter.

Pasang dan kencangkan nut dengan torsi yang


ditentukan.

TORSI: 49 N.m (5,0 kgf.m; 36 lbf.ft) NUT/BOLT

Tempatkan
Set the rearshock
shockabsorber
absorberbelakang sedemikian
so that the bolt holesrupa
are
sehingga
aligned. lubang-lubang bolt telah disejajarkan. SHOCK ABSORBER
To ease installation of Install and tighten the rear shock absorber lower mount-
Untuk mempermudah
the rear shock Pasang
ing bolt. dan kencangkan rear shock absorber lower
pemasangan
absorberrear shock
mounting mounting bolt (baut pemasangan bawah sokbreker
absorber mounting bolt, belakang.
bolt, slightly lift the
angkat roda belakang
rear sedikit.
wheel.

MOUNTING BOLT
Sambungkan throttlecable
Connect the throttle cable ke throttle
to the drum (teromol
throttledrum.
the throttle grip free play (page 3-5).
Adjustgas). THROTTLE CABLE FUEL HOSE
kabel
Setel
Connectjarak main bebas throttle grip (putaran gas
the following:
tangan) (hal. 3-5).
– Fuel auto valve vacuum hose
– Fuel hose
Sambungkan sebagai berikut:
- Fuel auto valve vacuum hose
- Fuel hose

VACUUM HOSE

Kokohkan
Secure the pemasangan wire clamps
following wire clamps berikut ini pada
to the frame:
rangka: SE THERMAL VALVE
– SE thermal valve wire clamp WIRE CLAMP
– Alternator wire clamp
-– SE thermal
Starter valve
motor wire
wire clamp
clamp
- Alternator wire clamp
- Starter motor wire clamp

ALTERNATOR
WIRE CLAMP
STARTER MOTOR
WIRE CLAMP

6-6
PENURUNAN / PEMASANGAN MESIN
Sambungkan connectors
Connect the following berikut ini:
connectors:
BOLT/GROUND CABLES ALTERNATOR 3P
– Alternator 3P connector
- Alternator 3P connector CONNECTOR
-– Starter
Starter motorwire
motor wire2P
2Pconnector
connector
– SE thermal valve 3P connector
- SE thermal valve 3P connector
Route the wire Set the ground cables in position, then install and tighten
Alurkan sire Tempatkan
the bolt. kabel-kabel massa pada tempatnya,
harness
harnessproperly
dengan kemudian pasang dan kencangkan bolt.
benar(page
(hal. 1-14).
1-14).
SE THERMAL VALVE
3P CONNECTOR

STARTER MOTOR WIRE


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

WIRE CLAMP
SPARK PLUG CAP

Set theand
Tempatkan
Install brake cablethe
brake
tighten through
cable the cable
cable (kabel holder.
rem)
clamp/bolt. melalui cable
BRAKE CABLE
Route the rear brake holder.
Alurkan rear brake
cable properly
cable dengan Pasang dan kencangkan cable clamp bolt.
benar(page
(hal. 1-14).
1-14).

CABLE CLAMP/ BOLT CABLE HOLDER


Pasang joint
Install the jointpinpindan
andadjusting
adjusting nut
nut to the rear
pada rear brake
cable.
cable. SPRING
Set the return spring ends intoreturn
the hole on the left(pegas
crank- ADJUSTING NUT
Tempatkan ujung-ujung spring
case and pin onke
pengembalian) thedalam
brake arm.
lubang pada left crankcase
dan pinthe
Adjust pada brake
rear brake arm (lengan
lever rem).
free play (page 3-16).
Install the following:
Setel jarak main bebas rear brake lever (hal. 3-16).
– Under cover (page 2-10)
Pasang
– Center sebagai berikut:
body cover (page 2-8)
-– Under
Luggagecoverbox (page
(hal. 2-7)
2-10)
- Center body cover (hal. 2-8)
- Luggage box (hal. 2-7)

BRAKE CABLE JOINT PIN

6-7
CATATAN
7. CYLINDER HEAD/VALVES/CYLINDER/PISTON

COMPONENT
LOKASI LOCATION ···························· 7-2
KOMPONEN-KOMPONEN......7-2 CYLINDER HEAD
CYLINDER HEAD··········································7-14
..................................7-14 7

SERVICE INFORMATION
KETERANGAN ····························· 7-3
SERVIS ........................7-3 CAMCHAIN
CAM CHAIN GUIDE...............................7-29
GUIDE······································7-29

TROUBLESHOOTING ...........................7-6
TROUBLESHOOTING ···································· 7-6 CAM
CAMCHAIN
CHAIN TENSIONER SLIDER···········7-30
TENSIONER SLIDER .......7-30

TEST KOMPRESSI
CYLINDER CYLINDER.............7-7
COMPRESSION TEST ·············· 7-7 CAM
CAMCHAIN
CHAIN TENSIONER LIFTER........7-31
TENSIONER LIFTER ···········7-31

CYLINDER
CYLINDER HEAD COVER····························
HEAD COVER ....................7-7 7-7 CYLINDER
CYLINDER .............................................7-32
······················································7-32

INTAKE/EXHAUST SHROUDS
INTAKE/EXHAUST SHROUDS .............7-9
····················· 7-9 PISTON ..................................................7-34
PISTON·····························································7-34

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

7-1
CYLINDER HEAD/VALVES/CYLINDER/PISTON
COMPONENT
LOKASI LOCATION
KOMPONEN-KOMPONEN
CYLINDER HEAD/VALVES/CYLINDER/PISTON

0.8 N·m (0.1 kgf·m, 0.6 lbf·ft)

10 N·m (1.0 kgf·m, 7 lbf·ft)

4 N·m (0.4 kgf·m, 3.0 lbf·ft)

18 N·m (1.8 kgf·m, 13 lbf·ft)

12 N·m (1.2 kgf·m,


9 lbf·ft)

8 N·m (0.8 kgf·m, 5.9 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)


7 N·m (0.7 kgf·m, 5.1 lbf·ft)

7-2
CYLINDER HEAD/VALVES/CYLINDER/PISTON
KETERANGAN SERVIS
SERVICE INFORMATION
GENERAL
UMUM
• This section covers service of the cylinder head, valves, rocker arms, camshaft, cylinder and piston.
•• Babengine
The ini meliputi
must beservis
removeddarifrom
cylinder head,tovalves,
the frame rocker
service the arms,
cylinder camshaft,
head, cylinder dan
valves, camshaft, piston.
cylinder and piston.
•• Mesindisassembling,
When harus dilepaskan
mark anddaristore
rangka untuk dapat menservis
the disassembled cylinder
parts to ensure head,
that they valves, camshaft,
are reinstalled cylinder
in their original dan piston.
locations.
•• Sewaktu
Clean pembongkaran,
all disassembled parts withtandai dan solvent
cleaning simpanlah parts
and dry yang
them dibongkar
by blowing themuntuk
off withmemastikan
compressed bahwa
air beforemereka dipasang kembali
inspection.
• pada lokasi
Camshaft and semula mereka.
rocker arm lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling cylinder
• head.
Bersihkan semua parts yang dibongkar dengan larutan pembersih dan keringkan dengan meniup dengan udara dari
• Be careful not to
kompressor damagepemeriksaan.
sebelum the mating surfaces when removing the cylinder head cover and cylinder head. Do not tap the cylinder head cover
• and cylinder
Minyak head too hard
pelumasan during removal.
camshaft dan rocker arm disalurkan melalui jalan lintasan oli di dalam cylinder head. Bersihkan jalan
• Take care not
lintasan to damagemerakit
oli sebelum the cylinder wallcylinder
kembali and piston.head.
•• When removing the piston, clean carbon
Hati-hati agar tidak merusak permukaan-permukaanand sludge from the penyatuan
top of the cylinder.
ketika melepaskan cylinder head cover dan cylinder head.
Jangan mengetuk cylinder head cover dan cylinder head terlalu keras pada waktu pelepasan.
• Hati-hati agar tidak merusak dinding cylinder dan piston.
CYLINDER

HEAD/VALVES SPECIFICATIONS
Ketika piston dilepaskan, bersihkan karbon dan kotoran dari bagian atas cylinder.
Unit: mm (in)
SPESIFIKASI CYLINDER HEAD/VALVES Satuan: mm
SERVICE
ITEM
BAGIAN STANDARD
STANDARD BATAS LIMIT
SERVIS
2
Tekanan kompressi cylinder
Cylinder compression 1341
1314 kPakPa(13.4(13,4 kgf/cm
kgf/cm 2
, 191 ,psi)
191 psi) -
pada -1 menit-1 (rpm)
520 –
at 520 min (rpm)
Perubahan
Cylinder head bentuk
warpagemelengkung cylinder head -– 0,05 0.05 (0.002)
Rocker
Rocker armarm D.D. rocker
Rocker armarmI.D. IN/EX
IN/EX 10,000
10.000 – 10,015
– 10.015 (0.3937 – 0.3943) 10,04 10.04 (0.395)
Rocker arm shaft O.D. (MASUK/ 9.972 – 9.987 (0.3926 – 0.3932)
IN/EX 9.91 (0.390)
Arm to shaft clearance BUANG) 0.013 – 0.043 (0.0005 – 0.0017)
IN/EX 0.08 (0.003)
Camshaft D.L.
Camrocker arm shaft
lobe height IN/EX
IN 9,972––32.6406
32.4006 9,987 (1.27561 – 1.28506) 9,91 32.37 (1.274)
Jarak renggang antara IN/EX
EX 0,013––32.2464
32.0064 0,043 (1.26009 – 1.26954) 0,08 31.97 (1.259)
Valve, valve arm ke shaft
Valve clearance IN 0.14 ± 0.02 (0.006 ± 0.001) –
Camshaft
guide Ketinggian cam lobe IN
EX 32,4006
0.14 – 32,6406
± 0.02 (0.006 ± 0.001) 32,37 –
(bubungan) EX 32,0064
Valve stem O.D. IN 4.975 – 4.990– (0.1959
32,2464– 0.1965) 31,97 4.90 (0.193)
Valve, valve Jarak renggang klep IN
EX 0,14 ± 0,02
4.955 – 4.970 (0.1951 – 0.1957) 4.90 -(0.193)
guide EX ±
Valve guide I.D. IN/EX 0,14 0,02
5.000 – 5.012 (0.1969 – 0.1973) 5.03 -(0.198)
D.L. valve stem
Stem-to-guide clearance IN
IN 4,975 – 4,990
0.010 – 0.037 (0.0004 – 0.0015) 4,90 0.08 (0.003)
EX
EX 4,955
0.030 – 4,970
– 0.057 (0.0012 – 0.0022) 4,90 0.10 (0.004)
D.D. valve
Valve guideguide
projection above IN/EX
IN/EX 9.15,000 – 5,012
– 9.3 (0.36 – 0.37) 5,03 –
Jarak renggang
cylinder head stem IN 0,010 – 0,037 0,08
keValve
guideseat width EX
IN/EX 1.00,030
(0.04)– 0,057 0,10 1.5 (0.06)
Valve spring Proyeksi
IN/EX valve guide IN/EX 9,1(1.172)
29.78 – 9,3 29.11- (1.146)
free length di atas cylinder head
Lebar valve seat IN/EX 1,0 1,5
Panjang bebas IN/EX 29,78 29,11
valve spring
CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
SPESIFIKASI CYLINDER/PISTON Satuan: mm
SERVICE
ITEM
BAGIAN STANDARD
STANDARD BATAS LIMIT
SERVIS
Cylinder D.D. 50,005 – 50,015 50,10
Cylinder I.D. 50.005 – 50.015 (1.9687 – 1.9691) 50.10 (1.972)
Kelonjongan - 0,05
Out-of-round – 0.05 (0.002)
Ketirusan - 0,05
Taper – 0.05 (0.002)
Perubahan bentuk melengkung - 0,05
Warpage – 0.05 (0.002)
Piston, piston D.L. piston 49,970 – 49,990 49,95
Piston, piston Piston O.D. 49.970 – 49.990 (1.9673 – 1.9681) 49.95 (1.967)
rings, piston
rings, piston pin Titik pengukuran D.L. piston
Piston O.D. measurement point
6 mm dari bagian bawah piston
6.0 (0.24) from bottom of skirt
-

pin D.D. lubang piston pin 13,002 – 13,008 13,04
Piston pin bore I.D. 13.002 – 13.008 (0.5119 – 0.5121) 13.04 (0.513)
D.L. piston pin 12,994 – 13,000 12,96
Piston pin O.D. 12.994 – 13.000 (0.5116 – 0.5118) 12.96 (0.510)
Jarak renggang antara piston-ke- piston pin 0,002 – 0,014 0,02
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.02 (0.001)
Jarak renggang Ring paling atas 0,015 – 0,050 0,08
Pistonpiston
antara ring-to-ring Top 0.015 – 0.050 (0.0006 – 0.0020) 0.08 (0.003)
Ring kedua 0,015 – 0,050 0,08
groove clearance Second 0.015 – 0.050 (0.0006 – 0.0020) 0.08 (0.003)
ring-ke-alurnya
Piston
Celah padaring end gap Top atas
Ring paling 0.10 – 0.25
0,10 (0.004 – 0.010)
– 0,25 0,45 0.45 (0.018)
ujung piston ring Second
Ring kedua 0.10
0,10 – 0,25 – 0.010)
– 0.25 (0.004 0,45 0.45 (0.018)
Oil(side
Ring oli (side rail)
rail) 0.20 – 0.70
0,20 (0.008 – 0.028)
– 0,70 - –
Cylinder-to-piston clearance
Jarak renggang antara cylinder-ke-piston 0.015 – 0.045
0,015 – 0,045 (0.0006 – 0.0018) 0,09 0.09 (0.004)
Connecting
D.D. kepalarod small
kecil end I.D. rod
connecting 13.010 – 13.028
13,010 – 13,028 (0.5122 – 0.5129) 13,05 13.05 (0.514)
Connecting
Jarak rod-to-piston
renggang pin clearancerod-ke-piston pin
antara connecting 0.010 – 0.034
0,010 (0.0004 – 0.0013)
– 0,034 0,05 0.05 (0.002)

7-3
CYLINDER HEAD/VALVES/CYLINDER/PISTON
TORQUE
NILAI VALUES
TORSI
Cylinder head
Cylinder headcover
coverspecial
special bolt
bolt 12 N.m (1,2(1.2
12 N·m kgf.m; 9 lbf.ft)
kgf·m, 9 lbf·ft)
CamCamsprocket
sprocketbolt
bolt 8 N.m (0,8(0.8
8 N·m kgf.m; 5,95.9
kgf·m, lbf.ft)
lbf·ft) Oleskan oli mesin
Apply pada
engine oilulir dan
to the permukaan
threads duduk.
and seating surface.
Cylinder head
Cylinder headnut
nut 18 N.m (1,8(1.8
18 N·m kgf.m; 13 13
kgf·m, lbf.ft)
lbf·ft) Oleskan oli mesin
Apply pada
engine oil ulir dan
to the permukaan
threads duduk.
and seating surface.
Cylinder
Cylinder headbolt
head bolt 12 N.m (1,2(1.2
12 N·m kgf.m; 9 lbf.ft)
kgf·m, 9 lbf·ft) Oleskan Apply
oli mesin pada
engine oil ulir dan
to the permukaan
threads duduk.
and seating surface.
Exhaust shroud mounting bolt 7 N.m (0,7 kgf.m; 5,1 lbf.ft)
Exhaust shroud mounting bolt 7 N·m (0.7 kgf·m, 5.1 lbf·ft)
Intake shroud mounting screw 0,8 N.m (0,1 kgf.m, 0,6 lbf.ft)
Intake shroud mounting screw 0.8 N·m (0.1 kgf·m, 0.6 lbf·ft)
Cam chain tensioner lifter screw 4 N.m (0,4 kgf.m; 3,0 lbf.ft)
CamCam chaintensioner
chain tensionerslider
lifter screw
pivot pin bolt 4
10 N.mN·m (0.4
(1,0 kgf·m,7 3.0
kgf.m; lbf·ft)
lbf.ft)
Cam chain tensioner slider pivot pin bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)

TOOLS
TOOLS

Valve spring compressor Valve spring compressor attachment Valve guide reamer, 5.0 mm
07757-0010000 07959-KM30101 07984-MA60001

Valve guide driver, 5.0 mm Valve guide adjusting driver Cam chain tensioner lifter stopper
07942-MA60000 07743-0020000 070MG-0010100

Seat cutter, 27.5 mm (IN, 45°) Seat cutter, 24 mm (EX, 45°) Flat cutter, 27 mm (IN, 32°)
07780-0010200 07780-0010600 07780-0013300

7-4
CYLINDER HEAD/VALVES/CYLINDER/PISTON
Flat cutter, 22 mm (EX, 32°) Interior cutter, 26 mm (IN, 60°) Interior cutter, 22 mm (EX, 60°)
07780-0012601 07780-0014500 07780-0014202

Cutter holder 5.0 mm


07781-0010400

7-5
CYLINDER HEAD/VALVES/CYLINDER/PISTON
TROUBLESHOOTING
TROUBLESHOOTING
? Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test or by trac-
• Persoalan pada bagian atasnoises
ing engine mesin biasanya
to the top-end mempengaruhi unjuk
with a sounding rod kerja mesin. Persoalan-persoalan ini dapat didiagnosa
or stethoscope.
dengan test kompressi
• If theatau dengan is
performance menelusuri
poor at lowsuara-suara mesin
speeds, check padasmoke
for white bagian atascrankcase
in the dengan breather
tangkai hose.
suaraIfatau stethoscope.
the hose is smoky,
• Jika unjuk kerja mesin buruk pada kecepatan
check for a seized piston ring. rendah, periksalah terhadap asap putih pada crankcase breather hose (slang
pernapasan bak mesin). Jika hose berasap, periksa terhadap piston ring yang macet.
Compression too low, hard starting or poor performance at low speed
• Valves:
Kompressi terlalu rendah, mesin sulit dihidupkan atau unjuk kerja buruk pada kecepatan rendah
– Incorrect valve adjustment
• Valves (klep-klep):
– Burned or bent valves
- Penyetelan valve–tidak benar
Incorrect valve timing
- Valves terbakar atau bengkok
– Broken valve spring
- Tertib waktu klep–tidak benar
Uneven valve seating
- Valve spring patah– Valve stuck open
- Valve seating (dudukan
– Weak klep)
valve tidak
springmerata
- Valve macet terbuka
• Cylinder head:
- Valve spring lemah– Leaking or damaged cylinder head gasket
• Cylinder head: – Warped or cracked cylinder head
- Cylinder head gasket bocor
– Loose atau
spark rusak
plug
- Ada perubahan ? bentuk melengkung atau retak-retak pada cylinder head
Worn cylinder
- Spark plug (busi) longgar
? Worn piston or piston rings
• Cylinder aus ? Bent connecting rod
• Piston atau piston rings aus too high, overheating or knocking
Compression
• Connecting rod bengkok
• Excessive carbon build-up on piston head or on combustion chamber
Excessive
Kompressi terlalu tinggi, smoke
overheating atau knocking
• Ada pembentukan • Worn
karbon valve stemberlebihan
secara or valve guide
pada piston head (kepala piston) atau di ruang pembakaran
? Damaged stem seal
? Worn cylinder
Asap berlebihan
? Worn piston or piston rings
• Valve stem atau?valve guideinstallation
Improper aus of piston rings
• Stem seal rusak? Scored or scratched piston or cylinder wall
• Cylinder aus
• Excessive
Piston atau piston rings ausnoise
• Incorrect valve adjustment
• Pemasangan piston rings tidak benar
? Sticking valve or broken valve spring
• Piston atau dinding cylinder tergerus atau tergores
? Excessively worn valve seat
? Worn or damaged camshaft
Mesin berisik ? Worn or damaged cam chain
• Penyetelan klep?tidak
Worn tepat
cam sprocket teeth
• Valve macet atau? valve
Worn spring patah
rocker arm and/or shaft
• Valve seat (dudukan
? Worn klep)
or aus berlebihan
damaged cam chain tensioner
• Camshaft aus atau rusakcylinder
? Worn
• ? Worn
Cam chain aus atau rusakpiston or piston rings
• Gigi-gigi cam sprocket aus
Rough idle
• Rocker arm dan/atau
• Lowshaft aus compression
cylinder
• Cam chain tensioner aus atau rusak
Abnormal noise
• Cylinder aus
• Worn piston pin or piston pin hole
• Piston atau piston
• rings
Worn ausconnecting rod small end
• Worn cylinder, piston or piston rings
Putaran stasioner kasar
• Piston
Tekanan kompressi ring sticking/scuffing,
cylinder rendah bearing damage
• Clogged oil gallery or oil strainer screen
Suara tidak normal • Internal oil leak
• • Not using
Piston pin atau lubang pistonrecommended
pin aus engine oil
• Kepala kecil connecting rod aus
• Cylinder, piston atau piston rings aus

Piston ring macet/menggeser, kerusakan bearing (bantalan)


• Saluran oli atau oil strainer screen tersumbat
• Ada kebocoran oli di dalam
• Tidak menggunakan oli mesin yang dianjurkan

7-6
CYLINDER HEAD/VALVES/CYLINDER/PISTON
CYLINDER
TEST COMPRESSION
KOMPRESSI TEST
CYLINDER
Warm the engine
Panaskan mesin to normalsuhu
sampai operating temperature.
operasi normal.
Stop the mesin
Matikan enginedanand lepaskan
remove thespark
sparkplug
plugcap
cap(topi
and spark
busi)
plugspark
dan (page plug
3-7). (busi) (hal. 3-7).
Install a compression gauge into the spark plug hole.
Untuk mencegah Pasang compression gauge (meter pengukur
To avoid discharging
menghabiskan muatan Open the throttle
kompressi) all the
ke dalam way and
lubang busi.crank the engine with the
thebaterai,
listrik battery,jangan
do not starterthrottle
Buka until the gauge reading
seluruhnya danstops
putarrising.
mesin dengan starter
operate the starter
menjalankan starter The maximum
sampai pembacaanreading is usually
gauge reached
berhenti naik.within 4 – 7 sec-
motor
motor fordari
lebih more7 than
detik.7 onds.
Pembacaan maksimum biasanya dicapai dalam 4 – 7
seconds. detik.
COMPRESSION PRESSURE:
TEKANAN
1,314 kPaKOMPRESSI:
(13.4 kgf/cm2, 191 psi) at 520 min-1(rpm)
2 -1
1.314 kPa (13,4 kgf/cm ; 191 psi) pada 520 menit
(rpm)
If compression is high, it indicates that carbon deposits have
Jika kompressi
accumulated tinggi,
on the ini menunjukkan
combustion bahwa
chamber and/or telah
the piston COMPRESSION GAUGE
crown.
terkumpul endapan karbon pada ruang pembakaran
dan/atau mahkota piston.
If compression is low, pour 3 – 5 cc (0.1 – 0.2 oz) of engine
oil into the cylinder through the spark plug hole and recheck
Jika kompressi rendah, tuangkan 3 – 5 cc oli mesin ke
the compression.
dalam cylinder melalui lubang spark plug dan periksa
If the compression
kembali kompressi.increases from the previous value, check
the cylinder, piston and piston rings.
Jika kompressi
• Leaking naikhead
cylinder darigasket
nilai sebelumnya, periksalah
cylinder, piston
• Worn piston ring dan piston rings.
• • Worn
Kebocoran
cylinderpada cylinder head gasket
and piston
• Piston ring aus
If compression is the same as the previous value, check the
•valves
Cylinder dan piston aus
for leakage.
Jika kompressi sama dengan nilai sebelumnya,
periksalah valves (klep-klep) terhadap kebocoran.
CYLINDER HEAD COVER
CYLINDERREMOVAL
HEAD COVER
PELEPASAN
Remove the center body cover (page 2-8).
CRANKCASE
Disconnect the crankcase breather hose. RUBBER SEAL
Jangan sampai
Do not oliengine
let the Remove the
mesin Lepaskan special
center bodybolts, mounting
cover rubbers and cylinder
(hal. 2-8). BREATHER
menetes ke atas
oil drip downrangka
to the head cover. HOSE
dari frame
cylinder head.
from the
Lepaskan crankcase breather hose.
cylinder head. Lepaskan
Remove thespecial bolts,
rubber seal mounting
from rubbers
the cylinder dan cylinder
head cover.
head cover.

Lepaskan rubber seal dari cylinder head cover.

SPECIAL BOLTS/
MOUNTING RUBBERS

PEMASANGAN
INSTALLATION
Make surebahwa
Pastikan the sealseal
rubber is in good
rubber condition
berada pada and replace
kondisi it
baik
if necessary. 5 – 15 mm SEAL POINTS
dan ganti bila perlu.
(0.2 – 0.6 in)
Apply adhesive (CEMEDINE 575 or Three Bond 1194 or
Oleskan perekat
equivalent) (CEMEDINE
to the cylinder 575 mating
head cover atau area
Three Bond
as speci-
1194
fied. atau sejenisnya) pada daerah penyatuan cylinder
head cover seperti ditentukan.

CYLINDER HEAD COVER

7-7
CYLINDER HEAD/VALVES/CYLINDER/PISTON
Install the
Pasang seal
seal rubberkeinto
rubber the alur
dalam groove on cylinder
pada the cylinder
headhead
cover.
cover. SEAL RUBBER

CYLINDER HEAD COVER

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

SEAL POINTS

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

MOUNTING RUBBER

Tempatkan cylinder
Set the cylinder head head
cover cover pada
onto the cylinder
cylinder head.head.
CRANKCASE CYLINDER HEAD COVER
Pasang
Install thespecial
special bolts
bolts dan kencangkan
and tighten them todengan torsi
the specified BREATHER
yang ditentukan.
torque. HOSE
TORQUE:12
TORSI: 12 N.mN·m (1.2
(1,2 kgf·m,99lbf.ft)
kgf.m, lbf·ft)
Connect the crankcase
Hubungkan crankcase breather hose.
breather hose.
Install the
Pasang centerbody
center bodycover
cover (hal.
(page2-8).
2-8).

SPECIAL BOLTS

7-8
CYLINDER HEAD/VALVES/CYLINDER/PISTON
INTAKE/EXHAUST
INTAKE/EXHAUSTSHROUDS
SHROUDS
(SELUBUNGREMOVAL/INSTALLATION
PEMASUKAN/PENGELUARAN)
PELEPASAN/PEMASANGAN
Remove the following: STARTER MOTOR SE THERMAL VALVE
Lepaskan sebagai
– Center body berikut:
cover (page 2-8) WIRE CLAMP WIRE CLAMP
-– Center
Luggagebodyboxcover
(page(hal.
2-7) 2-8)
-– Luggage
Inlet pipebox
(page 5-22)
(hal. 2-7)
-– Inlet
Muffler
pipe (page 2-14)
(hal. 5-22)
-– Muffler
PAIR air supply
(hal. 2-14)pipe (page 5-25)
-Release
PAIR air
the supply pipe
following (hal.
wire 5-25)from intake shroud:
clamps
Lepaskan
– Spark plugwirewire
clampsclampberikut dari intake shroud:
– Alternator wire clamp
- Spark plug wire clamp (penjepit kabel busi)
– SE thermal valve wire clamp
- Alternator wire clamp
– Starter motor wire clamp
- SE thermal valve wire clamp
-Remove
Starterthe
motor
threewire clamp
screws and a bolt. ALTERNATOR
Remove the intake/exhaust shrouds by releasing the tabs of SPARK PLUG WIRE CLAMP WIRE CLAMP
Lepaskan ketiga
intake shroud fromscrews
the slotdan sebuah
of the exhaustbolt.
shroud.
Lepaskan
Remove theintake/exhaust
rubber seal. shrouds dengan melepaskan
tabs dari intake shroud dari slot pada exhaust shroud.
Installationrubber
Be sure to align the Lepaskan is in theseal.
reverse order of removal.
"IN" mark and "EX"
markPastikan
on the rubber
TORQUE:
untuk Pemasangan adalaha dalam urutan terbalik dari
mentepatkan tanda
seal with the inlet"IN" Intake shroud mounting screw:
side pelepasan.
danand
"EX" pada rubber
exhaust side of TORSI:0.8 N·m (0.1 kgf·m, 0.6 lbf·ft)
seal dengan sisi masuk Intake
Exhaustshroud
shroudmounting
mounting screw:
bolt:
cylinder head.
dan keluar dari cylinder
0,8
7 N.m(0.7
N·m (0,1kgf·m,
kgf.m; 0,6
5.1 lbf.ft)
lbf·ft)
head.
Exhaust shroud mounting bolt:
7 N.m (0,7 kgf.m; 5,1 lbf.ft)

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

RUBBER SEAL

EXHAUST SHROUD

BOLT
7 N·m (0.7 kgf·m, 5.1 lbf·ft)

7-9
CYLINDER HEAD/VALVES/CYLINDER/PISTON
CAMSHAFT
CAMSHAFT
PELEPASAN
REMOVAL
Lepaskan
Remove thesebagai berikut:
following:
-– Mesin
Engine (page
(hal. 6-4)
6-4)
INDEX NOTCH
-– Cylinder
Cylinderhead
head cover
cover (page 7-7)
(hal. 7-7)
-– Cooling
Coolingfan
fancover
cover (hal.
(page2-12)
2-12)
-– Intake/exhaust
Intake/exhaust shroud
shroud (page
(hal. 7-9)
7-9)
Rotatecrankshaft
Putar the crankshaft clockwise
searah by rotating
perputaran jarumthejam
cooling fan
dengan
slowly andcooling
memutar align thefan
"T" dengan
mark on the flywheel
pelan dan with the index
mentepatkan
notch on"T"
tanda the pada
right crankcase.
flywheel dengan index notch (takik
penunjuk) pada right crankcase.
Make sure the piston is at TDC (Top Dead Center) on the
compression stroke.
Pastikan
This position bahwa
can bepiston
confirmedberada pada TDC
by checking (Topis Dead
that there slack
Center) [TMA
in the rocker arm. = Titik Mati Atas] pada langkah
kompressi. TANDA "T"
If there is no slack, it is because the piston is moving through
Posisi ini dapat
the exhaust dipastikan
stroke to TDC. dengan memeriksa bahwa
ada kerenggangan
Rotate the crankshaftpada rocker
one full turn arm.
by rotating the cooling fan
Jika
slowlytidak
and ada
matchkerenggangan,
up the "T" mark disebabkan
again. oleh karena
piston sedang bergerak melalui langkah pembuangan
Make
ke TDC.sure that the index line on the cam sprocket is flush
TANDA " "
with the
Putar top surfacesatu
crankshaft of cylinder
putaranhead and dengan
penuh that the "memutar
" mark
on the cam
cooling fansprocket
denganis pelan
facing updanas mentepatkan
shown (TDC ontanda the com-"T"
pression
sekali stroke).
lagi.
If the cam sprocket " " mark is not facing up, turn the cool-
ing fan (crankshaft)
Pastikan bahwa index one revolution
line (garisand realign thepada
penunjuk) "T" mark
cam
with the index
sprocket adalahnotch on the right
segaris crankcase.
dengan permukaan atas dari
cylinder head dan bahwa tanda "O" pada cam sprocket
menghadap ke atas seperti diperlihatkan (TDC pada
langkah kompressi).
Jika tanda "O" cam sprocket tidak menghadap ke atas,
putar cooling fan (crankshaft) satu putaran dan tepatkan
tanda "T" kembali dengan index notch pada right
crankcase. INDEX LINE

Longgarkan lock
Loosen the lock nutsnuts dan adjusting
and adjusting screws dengan
screws fully.
penuh. SCREWS
LOCK NUTS

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

7-10
CYLINDER HEAD/VALVES/CYLINDER/PISTON
Install the
Pasang specialtool
special toolkeinto the tensioner
dalam tensionerbody
bodyand
danturn the
putar
tool clockwise
tool until it stopsjarum
searah perputaran turning.
jam sampai ia berhenti LIFTER STOPPER
Hold the tensioner lifter by pushing the tool while aligning
berputar.
the tabs oftensioner
Tahan the tool withlifter
the grooves
denganof themendorong
tensioner lifter.tool
sementara
TOOL: mentepatkan tabs dari tool dengan alur-alur
dari
Camtensioner lifter.
chain tensioner 070MG-0010100
lifter stopper
TOOL:
Cam chain tensioner lifter stopper 070MG-
0010100

Tepatkan

Putar cooling
Turn the fanfan
cooling (crankshaft)
(crankshaft)satu
oneputaran dan
revolution tepatkan
and realign
kembali tanda
the "T" mark with"T" dengan
the index notchindex
on the notch pada right
right crankcase. TANDA" "
BOLTS
crankcase.
Make sure that the cam sprocket " " mark is not facing up.
Remove the
Pastikan bolts, cam
bahwa tandasprocket from the
"O" pada camcamshaft
sprocketandtidak
cam
Letakkan
Place akain
shoplap pada
towelchain off the ke
at camatas.
sprocket.
bagianthe
cranakcase menghadap
yang
opening of Attach a piece of wire to the cam chain to prevent it from fall-
the
terbuka untuktomenjaga
crankcase ing into thebolts,
prevent crankcase.
agar Lepaskan cam sprocket dari camshaft dan cam
the cam
cam sprocket
sprocket bolts
bolts
tidak jatuh ke dalam chain lepas dari cam sprocket.
from falling into the Ikatkan seutas kawat pada cam chain agar ia tidak jatuh
crankcase.
crankcase.
ke dalam crankcase.

CAM CHAIN

CAM SPROCKET

Remove thebolt
Lepaskan boltdari
from the cylinder
cylinder head.head.
BOLT

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

7-11
CYLINDER HEAD/VALVES/CYLINDER/PISTON
INSTALLATION
PEMASANGAN
Apply engine
Oleskan oil to the
oli mesin camshaft
pada bearings
camshaft and decompressor
bearings dan daerah
cam rotatingdecompressor
perputaran area. cam.
Apply molybdenum
Oleskan larusan oil solution to theoilcam
molybdenum lobes.cam lobes
pada
(bubungan cam).

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

TAB

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

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

TANDA"T"

7-12
CYLINDER HEAD/VALVES/CYLINDER/PISTON
Apply engine
Oleskan oli oil to the pada
mesin cam chain
camandchain
cam sprocket teeth.cam
dan gigi
sprocket. TANDA" "
Install the cam chain on the cam sprocket. CAM CHAIN
Install the cam sprocket to the camshaft then make sure that
Pasang
the indexcam
linechain
on thepada cam sprocket.
cam sprocket is flush with the cylinder
Pasang camthesprocket
head and that " " mark pada camshaft
on the cam sprocketkemudian
is facing
pastikan bahwa index lines (garis penunjuk)
down as shown (TDC on the exhaust stroke). pada cam
sprocket rata dengan cylinder head dan bahwa tanda
"O" pada cam sprocket sedang menghadap ke bawah
seperti diperlihatkan (TDC pada langkah pembuangan).

CAM SPROCKET
INDEX LINES

Oleskan oli mesin


Apply engine pada
oil to the permukaan
seating duduk
surface and dan
thread of ulir dari
the cam
cam sprocket
sprocket bolts. bolts.
BOLTS 2
Install and tighten the cam sprocket bolts to specified torque
Letakkan
Place a kain
shoplap Pasang
pada dan kencangkan
in the sequence
towel at shown. cam sprocket bolts dengan
lubang dari crankcase
torsi yang ditentukan pada urutan yang diperlihatkan.
the opening of the
untuk mencegah
crankcase to prevent TORQUE:8 N·m (0.8 kgf·m, 5.9 lbf·ft)
jatuhnya cam sprocket TORSI: 8 N.m (0,8 kgf.m; 5,9 lbf.ft)
boltthe
ke cam sprocket
dalam bolt
crankcase.
from falling into the
crankcase.

Lepaskan
Remove the camcamchain
chaintensioner
tensioner lifter
lifterstopper
stopper dan pasang
and install a
STOPPER SCREW
new O-ring
sebuah to thebaru
O-ring cam chain
padatensioner
cam chain lifter. tensioner lifter.
Install anddan
Pasang tighten the screw to screw
kencangkan the specified
dengan torque.
torsi yang
ditentukan.
TORQUE:4 N·m (0.4 kgf·m, 3.0 lbf·ft)
TORSI:
Install the4following:
N.m (0,4 kgf.m; 3,0 lbf.ft)
Pasang sebagai berikut:
– Intake/exhaust shroud (page 7-9)
– Cooling fan cover
- Intake/exhaust shroud (page(hal.
2-12)
7-9)
-– Cooling
Cylinderfanhead cover
cover (page
(hal. 7-7)
2-12)
-– Cylinder
Engine (page
head 6-6)
cover (hal. 7-7)
-Adjust
Mesinthe
(hal. 6-6)
valve clearance (page 3-8).

Setel jarak renggang klep (hal. 3-8). O-RING


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

Jika decompressor cam tidak bekerja dengan baik, ganti


camshaft sebagai sebuah kesatuan.

7-13
CYLINDER HEAD/VALVES/CYLINDER/PISTON
CAMSHAFT
CAMSHAFT
Turn the
Putar outerrace
outer race (lingkaran
of each camshaft
luar) bearing with your fin-
dari masing-masing
ger. The bearing
camshaft bearing should turn smoothly
(bantalan camshaft)and quietly.
dengan jari-jari. BEARING
Also check
Bearing thatberputar
harus the bearing inner race
dengan fitsdan
halus tightly on the
tanpa cam-
suara.
shaft.periksa bahwa bearing inner race (lingkaran dalam
Juga
Replace the
bantalan) camshaft
duduk denganassembly if thecamshaft.
erat pada bearing does not turn
smoothly,
Ganti quietly, assembly
camshaft or if they fitjika
loosely on thetidak
bearing camshaft.
berputar
dengan halus, tanpa suara, atau jika mereka duduk
dengan longgar pada camshaft.

Periksa
Check thecam lobes
cam lobes (bubungan)
for excessive wearterhadap
and damage.keausan
berlebihan dan kerusakan.
Measure
Ukur the height
ketinggian of masing-masing
dari each cam lobe. cam lobe.

BATAS
SERVICE SERVIS:
LIMIT:
IN: 32,37 mm
IN: 32.37mm(1.274 in)
EX: 31,97 mm
EX: 31.97mm(1.259 in)

CYLINDER
CYLINDERHEAD
HEAD
PELEPASAN
REMOVAL
• • When
Ketikaremoving
melepaskan cylinderhead
the cylinder headnuts,
nutsalways
(mur replace
kepala
silinder),
the cylinderselalu ganti and
head gasket cylinder head
cylinder gasket
gasket dan
with new
cylinder gasket dengan yang baru.
ones. INDEX NOTCH
Remove the
Lepaskan following:
sebagai berikut:
– Engine (page 6-4)
-– Mesin (hal.head
Cylinder 6-4)cover (page 7-7)
-– Cylinder
Coolinghead cover
fan cover (hal.2-12)
(page 7-7)
-– Cooling fan cover
Intake/exhaust (hal.(page
shroud 2-12)7-9)
- Intake/exhaust shroud (hal. 7-9)
Rotate the crankshaft clockwise by rotating the cooling fan
slowly and align the "T" mark on the flywheel with the index
Putar crankshaft searah dengan perputaran jarum jam
notch on the right crankcase.
dengan memutar cooling fan dengan pelan dan
Make sure the tanda
mentepatkan piston is
"T"at pada
TDC (Top Dead dengan
flywheel Center) on the
index TANDA"T"
compression
notch stroke.
pada right crankcase.

This position
Pastikan can be
bahwa confirmed
piston by checking
berada pada TDC that there
(TopisDead
slack
in the rocker
Center) arm. = Titik Mati Atas] pada langkah
[TMA
If there is no slack, it is because the piston is moving through
kompressi.
the exhaust stroke to TDC.
Rotate the
Posisi ini crankshaft one full turn
dapat dipastikan by rotating
dengan the cooling
memeriksa fan
bahwa
slowly
ada and match uppada
kerenggangan the "T" mark arm.
rocker again.
Jika tidak ada kerenganggan, disebabkan oleh karena
piston sedang bergerak melalui langkah pembuangan
ke TDC.
Putar crankshaft satu putaran penuh dengan memutar
cooling fan dengan pelan dan mentepatkan tanda "T"
sekali lagi.

7-14
CYLINDER HEAD/VALVES/CYLINDER/PISTON
Pastikan
Make surebahwa
that theindex
indexline
line pada
on thecam
cam sprocket adalah
sprocket is flush
rata TANDA" "
with dengan permukaan
the top surface atashead
of cylinder dariand
cylinder
that the head dan
" " mark
bahwa tanda
on the cam "O" pada
sprocket cam
is facing up assprocket menghadap
shown (TDC ke
on the com-
pressionseperti
atas stroke). diperlihatkan (TDC pada langkah
kompressi).
If the cam sprocket " " mark is not facing up, turn the cool-
ing fan
Jika (crankshaft)
tanda "O" pada one revolution
cam sprocketandtidak
realign the "T" mark
menghadap ke
with the index notch on the right crankcase.
atas, putar cooling fan (crankshaft) satu putaran dan
tepatkan kembali tanda "T" dengan index notch pada
right crankcase.

INDEX LINE

Lepaskan
Remove thescrew
screw dan O-ringfrom
and O-ring dari the
camcamchain
chaintensioner
tensioner
lifter. SCREW O-RING
lifter.

Pasang special
Install the specialtool
toolkeinto
dalam tensionerbody
the tensioner bodyand
dan putar
turn the
tool
tool searah
clockwisejarum
untiljam sampai
it stops ia berhenti berputar.
turning.
LIFTER
Tahan
Hold the tensioner
tensioner lifterlifter denganthe mendorong
by pushing tool
tool while aligning
the tabs of the
sementara tool with thetabs
mentepatkan grooves
darioftool
the tensioner lifter.
dengan alur-alur
dari tensioner lifter.
TOOL:
Cam chain tensioner
TOOL: 070MG-0010100
lifter stopper
Cam chain tensioner 070MG-0010100
lifter stopper

Tepatkan

Letakkan kain lap pada Lepaskan


Remove thebolts,
bolts,cam sprocketfrom
cam sprocket darithe
camshaft
camshaftdan
and cam
cam
chain CAM CHAIN
lubang
Place adari crankcase
shop towel at chain lepas
off thedari
camcam sprocket.
sprocket.
untuk menghindari
the opening of the
jatuhnya camtosprocket Attach a piece of wire to the cam chain to prevent it from fall-
crankcase prevent Ikat seutas kawat pada cam chain untuk mencegahnya
boltthe
ke cam
dalam crankcase. ing into the crankcase.
sprocket bolt jatuh ke dalam crankcase.
from falling into the
crankcase.

BOLTS

CAM SPROCKET

7-15
CYLINDER HEAD/VALVES/CYLINDER/PISTON
Remove thecylinder
Lepaskan cylinderhead
head bolts.
NUTS BOLTS
Loosen the cylinder
Longgarkan head
cylinder nutsnuts
head in a crisscross
dalam polapattern in two or
bersilangan
three steps.
dalam dua atau tiga langkah.
Remove the nuts and plates.
Lepaskan nuts dan plates.

PLATES

Lepaskan
Remove thespring
springdan
and plunger.
plunger.
PLUNGER

SPRING

Remove thecylinder
Lepaskan cylinderhead.
head.

CYLINDER HEAD

Remove the gasket and dowel pins.

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

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

GASKET

7-16
CYLINDER HEAD/VALVES/CYLINDER/PISTON
Alurkan
Route thecam
cam chain melaluithecylinder
chain through cylinderhead daninstall
head and pasangthe
cylinder
cylinder head padathecylinder.
head onto cylinder.
CAM CHAIN

CYLINDER HEAD

Apply engine oil to the plunger whole surface.


Oleskan
Install theoliplunger
mesinand
pada seluruh permukaan plunger.
spring.
Pasang plunger dan spring.
PLUNGER

SPRING

Semprotkan
Apply engineolioil mesin ke permukaan
to the seating surface andduduk dan
threads of ulir dari
the cyl-
cylinder
inder headhead
nuts.nuts.
InstallPasang
the platesplates dan kencangkan
and tighten the cylinder NUTS
cylinder
head nutshead nuts dalam
in a crisscross polatobersilangan
pattern the specified dengan
torque. torsi BOLTS
yang ditentukan.
TORQUE:18 N?m (1.8 kgf?m, 13 lbf?ft)
TORSI: 18 N.m (1,8 kgf.m; 13 lbf.ft)
Apply engine oil to the seating surface and threads of the cyl-
inder head mounting
Semprotkan oli mesin bolts,
padathen install and duduk
permukaan tighten dan
themulir
to
the specified
dari cylindertorque.
head mounting bolts, kemudian pasang
dan kencangkan dengan torsi yang ditentukan.
TORQUE:12 N?m (1.2 kgf?m, 9 lbf?ft)
TORSI: 12 N.m (1,2 kgf.m; 9 lbf.ft)

PLATES

Putar
Rotatecrankshaft searah
the crankshaft jarumand
clockwise jamalign
danthe
tepatkan tanda
"T" mark on
the flywheel
"T" with the index
pada flywheel notchindex
dengan on the right
notchcrankcase.
pada right
crankcase. INDEX NOTCH

TANDA"T"

7-17
CYLINDER HEAD/VALVES/CYLINDER/PISTON
Semprotkan
Apply engine oli mesin
oil to the cam pada
chaingigi
andcam chain dan
cam sprocket cam
teeth.
sprocket. CAM CHAIN
Install the cam chain on the cam sprocket.
Install the cam sprocket to the camshaft then make sure that
Pasang
the indexcam
linechain
on thepada
cam cam sprocket.
sprocket is flush with the cylinder
Pasang TANDA" "
head and "cam sprocket
" mark pada
is facing up camshaft
as shown (TDC onkemudian
the com-
pastikan bahwa
pression stroke). index line pada cam sprocket adalah
rata dengan cylinder head dan tanda "O" menghadap ke
atas seperti diperlihatkan (TDC pada langkah
kompressi).

INDEX LINES
CAM SPROCKET

Letakkan kain lap Semprotkan


Apply engineoli
oil mesin pada permukaan
to the seating dudukof dan
surface and thread ulir
the cam
menutupi lubang
Place a shop dari
towel at dari cam bolts.
sprocket sprocket bolts.
BOLTS
crankcase
the opening untuk
of the
mencegah to agar cam Install and tighten the cam sprocket bolts to specified torque
crankcase prevent Pasang dan kencangkan cam sprocket bolts dengan
sprocket boltsprocket
tidak jatuh in the sequence of the cam sprocket numbers.
the cam bolt torsi yang ditentukan dalam urutan dari nomor cam
ke dalam
from crankcase.
falling into the sprocket.
crankcase. TORQUE:8 N?m (0.8 kgf?m, 5.9 lbf?ft)
TORSI: 8 N.m (0,8 kgf.m; 5,9 lbf.ft)

NOMOR CAM SPROCKET

Lepaskan
Remove the camcamchain
chaintensioner
tensionerlifter
lifterstopper
stopper dan pasanga
and install
sebuah O-ring baru STOPPER SCREW
new O-ring to the campada
chaincam chainlifter.
tensioner tensioner lifter.
Pasang
Install anddan kencangkan
tighten the screw to screw dengan
the specified torsi yang
torque.
ditentukan.
TORQUE:4 N?m (0.4 kgf?m, 3.0 lbf?ft)
TORSI:
Install the4 following:
N.m (0,4 kgf/m, 3,0 lbf.ft)
Pasang sebagai berikut:
– Intake/exhaust shroud (page 7-9)
– Engine (page 6-6)
- Intake/exhaust shroud (hal. 7–9)
-Adjust
Mesinthe(hal. 6-6)
valve clearance (page 3-8).
Setel jarak renggang klep (hal.3-8).

O-RING

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

BOLT

ROCKER ARM SHAFT

7-18
CYLINDER HEAD/VALVES/CYLINDER/PISTON
CAMSHAFT
CAMSHAFT
Lepaskan boltanddan
Remove the bolt camshaft
camshaft with its tabdengan tab-nya
facing down.
menghadap ke bawah. CAMSHAFT
BOLT

TAB

VALVE
VALVE
To prevent
Untuk mencegah Remove thevalve
loss of Lepaskan valve cotters
cottersusing the valve
dengan spring compressor.
menggunakan valve
tension,
hilangnya do not spring compressor.
tegangan, VALVE SPRING COMPRESSOR
jangan tekan
compress valve
the valve
springs lebihmore
dari pada TOOLS:
springs than TOOLS:
yang diperlukan
necessary untuk
to remove Valve spring compressor 07757-0010000
Valve spring compressor 07757-0010000
melepaskan cotters.
the cotters. Valve spring compressor attachment 07959-KM30101
Valve spring compressor attachment 07959-M30101

Mark all parts


Tandai semuaduring
parts Lepaskan
Remove the valve spring
valve spring compressor
compressor dan the
and remove lepaskan
follow-
selama pembongkaran
disassembly so they sebagai
ing: berikut:
sehingga merekaback
can be placed dapat
in - Valve spring retainers VALVE
diletakkan their
kembali pada – Valve spring retainers
original - Valve springs
lokasi mereka semula. – Valve springs
locations. - Valve spring seats
– Valve spring seats
-– Valves
Valves VALVE STEM SEAL
-– Valve
Valvestem
stemseals
seals

VALVE SPRING SEAT


VALVE SPRING
VALVE SPRING RETAINER

Avoiduntuk
Hindari damaging
merusak Remove the
the Lepaskan carbon deposits
endapan form ruang
karbon dari the combustion
pembakaranchamber
dan
permukaan penyatuan
cylinder and clean off
mating bersihkan thepermukaan
dari cylinder head gasket head
cylinder surface.
gasket. COMBUSTION CHAMBER
cylinder
surfacedan
andpermukaan
valve seat
valve seat .
surfaces.

7-19
CYLINDER HEAD/VALVES/CYLINDER/PISTON
ASSEMBLY
PERAKITAN
COTTERS
VALVE SPRING
SPRING RETAINER

SPRING SEAT

VALVE STEM SEAL


EXHAUST ROCKER ARME

VALVE GUIDE

EXHAUST ROCKER CLIP


ARM SHAFT

INLET ROCKER
ARM SHAFT

BOLT
INLET ROCKER ARM

CAMSHAFT

INLET VALVE EXHAUST VALVE

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

STEM SEAL

7-20
CYLINDER HEAD/VALVES/CYLINDER/PISTON
Install thevalve
Pasang valve springs
springswithdengan
the tightlylilitan
woundyang
coils facing
rapat
the combustion
menghadap ke chamber.
ruang pembakaran.

Ke ruang
pembakaran

Install the
Pasang valvespring
valve springretainer.
retainer.
VALVE SPRING COMPRESSOR
Untuk
To mencegah
prevent loss of Install thevalve
Pasang valve cotters
cottersusing the valvemenggunakan
dengan spring compressor.
valve
hilangnya tegangan,
tension, do not spring compressor.
jangan
compresstekan
the valve
valve TOOLS:
springspring
lebih dari TOOLS:
morepada
than Valve
Valve spring compressor
spring compressor 07757-
07757-0010000
yang diperlukan untuk
necessary to install 0010000
memasang cotters. Valve spring compressor
the cotters. Valve spring compressor attachment 07959-
attachment 07959-KM30101
KM30101

Topang cylinder
Support head di Letakkan
the cylinder Place a suitable tool onto
tool yang thepada
sesuai valve valve
stem. stem.
atas
headpermukaan meja
above the work TOOL YANG SESUAI
kerja bench
untuk mencegah Tap the tool gently to seat the cotters firmly using a plastic
surface to Ketuk tool dengan ringan untuk mendudukkan cotters
kerusakan pada valve. hammer.
prevent valve dengan erat dengan menggunakan palu plastik.
damage.

VALVE STEM

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

TAB
TAB

7-21
CYLINDER HEAD/VALVES/CYLINDER/PISTON
Install and
Pasang tighten
dan the bolt. bolt.
kencangkan
BOLT

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

ROCKER ARM SHAFTS

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

Tepatkan

7-22
CYLINDER HEAD/VALVES/CYLINDER/PISTON
INSPECTION
PEMERIKSAAN
CYLINDERHEAD
CYLINDER HEAD
Check the
Periksa spark plug
lubang busihole
danand valve areas
daerah valvefor cracks. retak-
terhadap
Check the cylinder head for warpage with a straight edge and
retak.
a feeler gauge.
Periksa cylinder head terhadap perubahan bentuk
melengkung dengan sebuah mistar lurus dan feeler
gauge.
SERVICE
LIMIT: 0.05 mm (0.002 in)
BATAS SERVIS: 0,05 mm

ROCKERARM/SHAFT
ROCKER ARM/SHAFT
Disassemble
Bongkar the cylinder
cylinder head7-18).
head (hal. (page 7-18).
Check the
Periksa rockerarm
rocker armshafts
shafts dan
and rocker
rockerarms
armsforterhadap
wear or
damage. atau kerusakan.
keausan
Turn the rocker arm roller with your finger.
Putar rocker
The roller arm
should turn roller (penggelinding
smoothly and quietly. rocker arm)
dengan jari-jari.
Measure
Roller the I.D.
harus of each
berputar rocker halus
dengan arm. dan tanpa suara.
SERVICE
Ukur D.D. dari masing-masing
LIMIT: IN/EX: 10.04rocker arm. in)
mm (0.395
BATAS SERVIS: IN/EX: 10,04 mm
Measure the O.D. of each rocker arm shaft.
Ukur D.L. dari masing-masing rocker arm shaft.
SERVICE
BATAS
LIMIT: SERVIS: IN/EX:
IN/EX: 9.91
9,91mmmm(0.390 in)
Hitung jarak
Calculate therenggang rocker arm-ke-shaft.
rocker arm-to-shaft clearance.
BATAS
SERVICE SERVIS: IN/EX: 0,08 mm
LIMIT: IN/EX: 0.08 mm (0.003 in)
VALVESPRING
VALVE SPRING
Disassemble
Bongkar the cylinder
cylinder head7-18).
head (hal. (page 7-18).
Measure
Ukur the free
panjang length
bebas of the
dari valve
valve springs.
springs.
SERVICE
BATAS SERVIS: IN/EX: 29,11 mm
LIMIT: IN/EX: 29.11 mm (1.146 in)
Ganti springs jika mereka lebih pendek dari batas servis.
Replace the springs if they are shorter than the service limit.

7-23
CYLINDER HEAD/VALVES/CYLINDER/PISTON
VALVE/VALVE
VALVE/VALVE GUIDE
GUIDE
Disassemble the cylinder head7-18).
Bongkar cylinder head (hal. (page 7-18).
Check that
Periksa the valve
bahwa valvemoves smoothly
bergerak in the halus
dengan guide. di dalam
Check
guide. each valve for bend, burn, scratch or abnormal wear.
Periksa
Measuremasing-masing valve
each valve stem O.D. andterhadap
record it. kebengkokan,
keadaan terbakar, goresan atau keausan tidak normal.
SERVICE
LIMIT:
Ukur IN/EX: valve
D.L. masing-masing 4.90 mm
stem(0.193
dan in)
catat.
BATAS SERVIS: IN/EX: 4,90 mm

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

Periksa
Inspect anddan reface
reface the Ukur D.D.each
Measure masing-masing valve
valve guide I.D. andguide
recorddan
it. catat.
valve
valveseats
seatssetiap kali
whenever
valve guides diganti BATAS SERVIS: IN/EX: 5,03 mm
the valve guides are SERVICE
(hal. 7-26). LIMIT: IN/EX: 5.03 mm (0.198 in)
replaced (page 7-26).
Kurangi D.L. masing-masing valve stem dari D.D. guide
Subtract
yang each valve stem
bersangkutan untukO.D. from the corresponding
mendapatkan guide
jarak renggang
I.D. to obtain the stem-to-guide clearance.
stem-ke-guide
SERVICE
BATAS
LIMIT:SERVIS: IN: 0,08mm
IN: 0.08 mm(0.003 in)
EX: 0,10 mm
EX: 0.10 mm (0.004 in)
Jika
If thejarak renggang clearance
stem-to-guide exceedsmelampaui
stem-ke-guide the service batas
limit,
servis,
determine tentukan
if a newapakah sebuah
guide with guide
standard baru dengan
dimensions would
ukuran
bring thestandard
clearance akan
within membawa
tolerance. jarak renggang ke
If so, replace
dalam any guides as necessary and ream to fit (page 7-
toleransi.
25). demikian, ganti guides yang diperlukan dan ream
Jika
If thepas
agar stem-to-guide
(hal. 7-25).clearance exceeds the service limit with
new jarak
Jika guide, also replace stem-ke-guide
renggang the valve. melampaui batas
servis dengan sebuah guide baru, ganti valve juga.

7-24
CYLINDER HEAD/VALVES/CYLINDER/PISTON
VALVE GUIDEVALVE
PENGGANTIAN REPLACEMENT
GUIDE
Disassemble
Bongkar the cylinder
cylinder head 7-18).
head (hal. (page 7-18).
VALVE GUIDE DRIVER
Chill new valve
Dinginkan valveguides in abaru
guides freezer for about
dalam 1 hour.
bagian freezer dari
lemari es selama kira-kira 1 jam.
CATATAN:
• Be sure to wear heavy gloves to avoid burns when han-
• dling
Pastikan untukcylinder
the heated memakai sarung tangan berat untuk
head.
• Using a torch to heat the cylindersewaktu
menghindari luka-luka bakar head maymenangani
cause war-
cylinder head yang telah dipanaskan.
page.
• • Drive
Jangannew menggunakan obor untuk
guides from the camshaft memanaskan
side while the cylin-
cylinder
der head
head is still karena dapat mengakibatkan
heated.
perubahan bentuk melengkung.
Heat the cylinder head to 130 – 140°C (275 – 290°F) with a
• Dorong masuk guides baru dari sisi camshaft
hot plate or oven. Do not heat the cylinder head beyond
150°C (300°F). cylinder
sementara head masih
Use temperature dipanaskan.
indicator sticks, available
from welding supply stores, to be sure the cylinder head is VALVE GUIDE
Panaskan cylinder
heated to the head sampai 130 - 140° C dengan
proper temperature.
kompor listrik atau oven. Jangan memanaskan cylinder
Support
head the cylinder150
melampaui head and Pakailah
° C. drive the valve guides
tongkat out of
indikator
the cylinder
suhu, yangheaddapat
from the dibeli
combustion
darichamber
toko side.
pemasok
perlengkapan pengelasan, untuk memastikan bahwa
TOOL: head telah dipanaskan sampai ke suhu yang
cylinder
Valve guide driver, 5.0 mm
tepat. 07942-MA60000
Take outcylinder
Topang new valvehead
guides from
dan the freezer.
dorong keluar valve guides VALVE GUIDE ADJUSTING DRIVER
dari cylinder head dari sisi ruang pembakaran.
Drive new valve guides into the cylinder head to the specified
TOOL:
height from the cylinder head.
Valve guide driver, 5,0 mm 07942-MA60000
TOOL:
Keluarkan
Valve guidevalve guides
adjusting baru dari freezer.
driver 07743-0020000
Dorong masuk valve guides baru ke dalam cylinder
VALVE
head GUIDE
sampai PROJECTION:
ke ketinggian yang ditentukan dari cylinder
IN/EX: 9.1 – 9.3 mm (0.36 – 0.37 in) 9.1 – 9.3 mm
head. (0.36 – 0.37 in)
Let the cylinder head cool to room temperature.
TOOL:
Valve guide adjusting driver 07743-0020000

PROJEKSI VALVE GUIDE: VALVE GUIDE


IN/EX: 9,1 – 9,3 mm
Ream new valve guides after installation.
Biarkan cylinder head menjadi dingin kembali sampai ke VALVE GUIDE REAMER
suhu ruangan.
• Take care not to tilt or lean the reamer in the guide while
reaming.
Lakukan pekerjaan reaming pada valve guides baru.
• Use cutting oil on the reamer during this operation.
•Insert the reamer agar
Hati-hati from the tidak
combustionmemiringkan
chamber side ofatau
the
mencondongkan
cylinder head and alwaysreamer
rotate di
thedalam
reamerguide sementara
clockwise.
meng-reaming.
•TOOL:Gunakan cutting oil pada reamer selama
Valve guide reamer,
pengerjaan ini. 5.0 mm 07984-MA60001
Clean the cylinder
Masukkan reamerhead thoroughly
dari to remove
sisi ruang any metal dari
pembakaran par-
ticles after
cylinder reaming
head dan and reface
selalu the valve
putar reamerseatsearah
(page 7-26).
dengan
arah perputaran jarum jam.

TOOL;
Valve guide reamer, 5.0 mm 07984-MA60001

Bersihkan cylinder head secara menyeluruh untuk


membuang partikel-partikel logam setelah pekerjaan
reaming dan reface (bentuk kembali permukaan) valve
seat (hal. 7-26).

7-25
CYLINDER HEAD/VALVES/CYLINDER/PISTON
VALVE SEAT INSPECTION/REFACING
PEMERIKSAAN/REFACING VALVE SEAT
Disassemble
Bongkar the cylinder
cylinder head7-18).
head (hal. (page 7-18).
Clean the intake and exhaust
Bersihkan intake (masuk) dan valves thoroughly
exhaust to remove
(buang) valves
carbon deposits.
(klep) secara menyeluruh untuk menghilangkan
endapan karbon.
Apply a light coat of Prussian Blue to the valve seats.
Tap the valve against the valve seat several times using a
Oleskan lapisan
hand-lapping tool,ringan
withoutPrussian Blue
rotating the pada
valve valveaseats
to make clear
(dudukan
pattern. klep).
Ketuk valve terhadap valve seat beberapa kali dengan
menggunakan hand-lapping tool (alat skir klep dengan
tangan), tanpa memutar valve agar mendapatkan pola
jelas.

TheValves
valvestidak dapat
cannot be Remove thevalve
Lepaskan valvedan
andperiksa
inspect the valve
valve seat
seat face.
face.
digerinda.
ground. IfJika
the muka
valve
valve The valve
Kontak seatseat
valve contact should
harus be within
di dalam lebartheyang
specified width
ditentukan
face terbakar,
is burned,sangat
badly
and merata
even all sepanjang
around the circumference.
worn aus
or ifatau jika ia
it contacts dan kelilingnya.
engkontak seat secara
the seat unevenly, STANDARD: 1.0 mm (0.04 in)
tidak merata, gantilah STANDARD: 1,0 mm
replace the valve.
valve. SERVICE
BATAS
LIMIT: SERVIS: 1,5
1.5 mm
mm (0.06 in)
Jika lebar valve seat di luar spesifikasi, reface valve
If the valve seat width is not within specification, reface the
seat (bentuk kembali permukaan dudukan klep) (lihat
valve seat (see page 7-26).
hal. 7-26).
LEBAR SEAT

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

MUKA RUSAK LEBAR SEAT TIDAK MERATA

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

TERLALU RENDAH TERLALU TINGGI

7-26
CYLINDER HEAD/VALVES/CYLINDER/PISTON
• • Follow the refacer
Ikuti petunjuk manufacturer’s
pemakaian pabrikoperating
pembuat instructions.
refacer.
• • Be careful not
Hati-hati to grind
agar the seat
tidak more than necessary.
menggerinda seat lebih
daripada yang diperlukan.

45°

60°

32°

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

60°

Reface
Reface theseat
seatdengan
with a Pakailah seat° cutter,
Use a 45° 45 seat remove
cutter, any
hilangkan kekasaran
roughness atau
or irregularities
sebuah 45° cutter
45° cutter setiap
whenever a ketidak-teraturan
from the seat. dari seat.
kali sebuah valve guide KEKASARAN
valve guide is
diganti.
replaced. TOOLS:
TOOLS:
Seat cutter, 27.5 mm (45° IN) 07780-0010200
Seat cutter, 27.5 mm (45° IN)
Seat cutter, 24 mm (45° EX)
07780-0010200
07780-0010600
Seat cutter,
Cutter 24 mm
holder, 5.0 (45°
mm EX) 07780-0010600
07781-0010400
Cutter holder, 5.0 mm 07781-0010400

Pakailah flat° flat


Use a 32°32 cutter,
cutter, hilangkan
remove ¼ bagian
the top 1/4 teratasvalve
of the existing dari
bahan valve seat yang ada sekarang.
seat material.
TOOLS:
TOOLS: LEBAR SEAT LAMA
Flat
Flat cutter, 27mm
cutter, 27 (32°IN)
mm(32° IN) 07780-0013300
07780-0013300
Flat
Flat cutter, 22mm
cutter, 22 (32°EX)
mm(32° EX) 07780-0012601
07780-0012601
Cutter
Cutter holder, 5.0mm
holder, 5.0 mm 07781-0010400
07781-0010400

32°

7-27
CYLINDER HEAD/VALVES/CYLINDER/PISTON
Use a 60° interior
Pakailah cutter, remove
60° interior cutter,thehilangkan
bottom 1/4 of
¼ thebagian
exist-
ing valve seat
terbawah darimaterial.
bahan valve seat yang ada sekarang. LEBAR DUDUKAN
LAMA
TOOLS:
TOOLS:
Interior
Interior cutter, 26mm
cutter, 26 mm(60°
(60°IN)
IN) 07780-0014500
07780-0014500
Interior
Interior cutter, 22mm
cutter, 22 mm(60°
(60°EX)
EX) 07780-0014202
07780-0014202
Cutter holder, 5.0
Cutter holder, 5.0 mmmm 07781-0010400
07781-0010400

60°

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

45°
CATATAN:
• Tekanan skir klep yang berlebihan dapat merubah
bentuk atau merusak seat.
• ? Excessive
Ubah sudutlapping
daripressure
lappingmay
tooldeform or damage
sering-sering the
untuk
seat.
mencegah keausan seat yang tidak merata.
• • Change
Jagalahtheagar
angle lapping
of lapping tool frequently
compound to prevent
(ambril) tidak
uneven seat wear.
memasuki guides.
• Do not allow lapping compound to enter the guides.
Setelah memotong
After cutting the seat, seat, oleskancompound
apply lapping lapping tocompound
the valve
pada muka
face, and lap valve, dan
the valve skirlight
using kleppressure.
dengan menggunakan HAND-LAPPING TOOL
tekanan ringan.
After lapping, wash any residual compound off the cylinder
head and valve and recheck the seat contact.
Setelah menskir klep, cucilah compound yang tersisa
Assemble
dari the head
cylinder cylinder
danhead (page
valve dan7-20).
periksa kembali kontak
seat.

7-28
CYLINDER HEAD/VALVES/CYLINDER/PISTON
CAM
CAM CHAIN
CHAINGUIDE
GUIDE
PELEPASAN
REMOVAL
Remove the
Lepaskan cylinderhead
cylinder head(hal.
(page7-14).
7-14).
Lepaskan cam
Remove the camchain
chainguide.
guide.

CAM CHAIN GUIDE


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

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

Tepatkan

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

7-29
CYLINDER HEAD/VALVES/CYLINDER/PISTON
CAM CHAIN
CAM CHAINTENSIONER
TENSIONERSLIDER
SLIDER
REMOVAL
PELEPASAN
Remove thesebagai
Lepaskan following:
berikut:
PIVOT PIN BOLT
– Drive pulley (page 8-12)
- Drive pulley (hal. 8-11)
-– Cylinder
Cylinderhead
head(hal.
(page7-14).
7-14)
Remove thepivot
Lepaskan pivotpin
pinbolt.
bolt.

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

TENSIONER SLIDER

PEMASANGAN
INSTALLATION
Install thecam
Pasang cam chain
chain tensioner
tensionerslider to the
slider left crankcase.
pada sisi kiri dari
crankcase.
Coat a new O-ring with engine oil and install it into the pivot O-RING
pin bolt groove.
Lapisi sebuah O-ring baru dengan oli mesin dan pasang
ke dalam alur pivot pin bolt.

TENSIONER SLIDER

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

7-30
CYLINDER HEAD/VALVES/CYLINDER/PISTON
INSPECTION
PEMERIKSAAN
Check the
Periksa slidingluncur
daerah area ofdari
the cam
camchain
chaintensioner slider
tensioner for
slider
excessive keausan
terhadap wear or damage.
berlebihan atau kerusakan.
TENSIONER SLIDER

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

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

GASKET

7-31
CYLINDER HEAD/VALVES/CYLINDER/PISTON
Install a new
Pasang O-ring
sebuah to thebaru
O-ring cam chain
padatensioner
cam chain lifter.
tensioner
Install and tighten the screw to the specified torque.
lifter. SCREW
Pasang dan kencangkan screw dengan torsi yang
TORQUE:4 N·m (0.4 kgf·m, 3.0 lbf·ft)
ditentukan.
Install the luggage box (page 2-7).
TORSI: 4 N.m (0,4 kgf.m; 3.0 lbf.ft)
Pasang luggage box (hal. 2-7).

O-RING
PEMERIKSAAN
INSPECTION
Periksa cara
Check the camkerja
chaincam chainlifter
tensioner tensioner lifter:
operation:
TENSIONER SHAFT
-– Tensioner
The tensioner shaft
shafttidak boleh
should not gomasuk
into thekebody
dalam
whenbody
it is
pushed.
ketika ia didorong.
-– Jika
When ia itdiputar
is turned clockwise
searah jarumwithjam
the dengan
cam chain tensioner
cam chain
lifter stopper,
tensioner lifterthe tensionertensioner
stopper, shaft should be pulled
shaft harusinto the
ditarik
kebody.
dalamThebody.
shaft Shaft
shouldharus
protrude from thekeluar
menonjol body as soon
dari bodyas
the camsetelah
segera chain tensioner
cam chainlifter stopper islifter
tensioner released.
stopper
dilepaskan.

TENSIONER LIFTER LIFTER STOPPER

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

7-32
CYLINDER HEAD/VALVES/CYLINDER/PISTON
INSTALLATION
Lepaskan gasket dan dowel pins.
PEMASANGAN
Clean the cylinder mating surface.
Install dowel
Bersihkan pins and a penyatuan
permukaan new gasket. cylinder. GASKET
Pasang dowel pins dan sebuah gasket baru.

DOWEL PINS

Ikatlah
Attach seutasofkawat
a piece wire Semprotkan
Apply engineolioilmesin
to thepada permukaan
cylinder dalam
inner surface andcylinder
piston
pada camcam
chain untuk PISTON RINGS CAM CHAIN
to the chain to dan piston rings.
rings.
mencegahnya agarfalling
prevent it from tidak
jatuh ke dalam Route the cam chain through the cylinder and install the cyl-
into the crankcase.
crankcase.
Alurkan
inder overcam
thechain
pistonmelalui cylinder dan
while compressing thepasang cylinder
piston ring with
dari atas piston
your finger. sementara menekan piston ring dengan
jari-jari.
Install the cylinder head (page 7-16).
Pasang cylinder head (hal. 7-16).

CYLINDER

PEMERIKSAAN
INSPECTION
Lepaskan
Remove thecylinder
cylinder(hal.
(page7-32).
7-32).
Periksa
Inspect thediameter cylinder
cylinder bore for wearterhadap
or damage.keausan atau
kerusakan.
Measure the cylinder I.D. in the X and Y axis at three levels.
Ukur D.D.
Take the cylinder
maximum padato poros
reading determineX dan Y pada
the cylinder tiga
wear.
tingkat.
SERVICE
Ambil pembacaan maksimum untuk menentukan
LIMIT: 50.10 mm (1.972 in)
keausan cylinder.
Calculate the taper and out-of-round at three levels in the X
BATAS SERVIS:
and Y axis. Take the50,10 mm reading to determine both
maximum
measurements.
Hitung ketirusan dan kelonjongan pada tiga tingkat pada
poros X dan Y. Ambil pembacaan maksimum untuk
SERVICE LIMIT:
menentukan kedua pengukuran.
Taper: 0.05 mm (0.002 in)
Out ofSERVIS:
BATAS round: 0.05 mm (0.002 in)
Ketirusan: 0,05 mm
The cylinder must be rebored and an oversize piston/piston
Kelonjongan: 0,05 mm
rings fitted if the service limits are exceeded.
Cylinder harusoversize
The following dikorterpistons/piston
dan oversize piston/piston
rings are available:rings
dipasang jika batas servis dilampaui.
0.25 mm
Oversize (0.0098 in) rings berikut tersedia:
pistons/piston
0.50 mm (0.0197 in)
0,25 mm (0.0295 in)
0.75 mm
0,50 mm (0.0394 in)
1.00 mm
0,75 mm
The piston
1,00 mmto cylinder clearance for the oversize piston must
be: 0.015 – 0.045 mm (0.0006 – 0.0018 in).
Jarak renggang antara piston-ke-cylinder untuk oversize
Check the cylinder for warpage with a straight edge and
piston harus sebesar: 0,015 – 0,045mm.
feeler gauge in the directions as shown.
Periksa cylinder terhadap perubahan melengkung
dengan mistar lurus dan feeler gauge dalam arah-arah
SERVICE
seperti diperlihatkan.
LIMIT: 0.05 mm (0.002 in)
BATAS SERVIS: 0,05 mm

7-33
CYLINDER HEAD/VALVES/CYLINDER/PISTON
STUD BOLT REPLACEMENT
PENGGANTIAN STUD BOLT
Remove thecylinder
Lepaskan cylinder(hal.
(page 7-32).
7-32).
Thread dua
two nuts STUD BOLTS A
Putar nutsonto the stud
(mur) and tighten
pada them kencangkan
stud dan together, and
use wrench
mereka on sama
satu them tolain,
turn dan
the stud bolt out.kunci pas pada
pakailah 177.5 – 178.5 mm (6.99 – 7.03 in)
mereka untuk
Install new memutar
stud bolts A,stud boltthe
B into keluar.
crankcase and tighten
them.
Pasang stud bolts A, B baru ke dalam crankcase dan
After crankcase stud bolts installation, check that the length
kencangkan.
from the bolt head to the crankcase surface is within specifi-
cation. pemasangan crankcase stud bolts, periksa
Setelah
bahwa
SPECIFIEDpanjang dari kepala
LENGTH 177.5 bolt sampai
– 178.5 ke permukaan
mm (6.99 – 7.03 in)
crankcase adalah sesuai dengan spesifikasi.
Install the cylinder (page 7-33).
PANJANG YANG DITENTUKAN: 177,5 – 178,5 mm

Pasang cylinder (hal. 7-33).

STUD BOLTS B

177.5 – 178.5 mm (6.99 – 7.03 in)

PISTON
PELEPASAN
REMOVAL
Remove the
Lepaskan cylinder(hal.
cylinder (page 7-32).
7-32). PISTON
PISTON PIN
Hati-hati agar piston pin Lepaskan piston pin clips dengan tang.
Beclips
careful
tidaknot to let
jatuh ke Remove the piston pin clips with the pliers.
Dorong piston pin keluar dari piston dan connecting rod,
the piston
dalam pin clips
lubang dari Push the piston pin out of the piston and connecting rod, then
kemudian lepaskan piston.
fall into the opening
crankcase. remove the piston.
of the crankcase.

PISTON PIN CLIP

Jangan merusak
Do not piston
damage Spread each piston
the Renggangkan ring and remove
masing-masing it byring
piston lifting
danupkeluarkan
at a point
ring dengan
piston opposite mengangkatnya
ring by dengan the gap. ke atas pada sebuah titik di
merenggangkan
spreading theujung-
ends seberang celah.
ujungnya terlalu
toojauh.
far.

PISTON RING

7-34
CYLINDER HEAD/VALVES/CYLINDER/PISTON
use a wire Bersihkan
Never sekali-kali
Jangan Clean carbon endapan
deposits karbon
from the dari alur-alurwith
ring grooves ringa ring
dengan
that
memakai
brush, sikat
it willkawat,
damage will be discarded.
ia sebuah ring yang tidak dipakai lagi.
akan merusak alur.
the groove.

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

RING TANDA
TANDA
TERATAS

120°

120° RING TERATAS


RING KEDUA 120°

RING KEDUA

RING OLI

SIDE RAIL
SPACER
20 mm
atau lebih

20 mm
atau lebih

7-35
CYLINDER HEAD/VALVES/CYLINDER/PISTON
Apply engine oil
Semprotkan olito the connecting
mesin pada rod small end
lubang hole. kecil
kepala
connecting rod.

CONNECTING ROD

Pasang
Install thepiston
piston dengan tanda
with the "IN" "IN"
mark menghadap
facing the intake ke
side.sisi
pemasukan. TANDA"IN"
Apply engine oil to the piston pin and install it. PISTON PIN
Semprotkan oli mesin pada piston pin dan pasang.

Hati-hati agar piston


Be careful not to pin
let Pasang piston
Install new pinpin
piston clips baru.
clips.
clips tidak jatuh ke
the piston pin clips • Pastikan
dalam lubang dari ? Make sure bahwa piston
the piston pin clips
pin clips telahsecurely.
are seated duduk dengan
fall into the opening
crankcase. erat.
? Do not align the piston pin clip end gap with the piston
of the crankcase.
• Jangan mentepatkan celah pada ujung piston pin
cut-out.
clip dengan potongan pada piston.
Install the cylinder (page 7-33).
Pasang cylinder (hal.7-33).

CLIP
PEMERIKSAAN
INSPECTION
Lepaskan
Remove thepiston
piston(hal.
(page7-34).
7-34).
Periksa
Inspect thepiston
piston rings terhadap
rings for movementpergerakan
by rotating thedengan
rings.
memutar
The rings rings.
shouldRings
be ableharus dapatinbergerak
to move dalam
their grooves alur-
without
alur mereka tanpa menyangkut.
catching.
Dorong
Push thering
ring sampai
until thepermukaan
outer surfaceluar daripiston
of the piston
ringring
is
hampir rata with
nearly flush dengan piston
the piston anddan ukur the
measure jarak renggang
ring-to-groove
ring-ke-alur.
clearance.

BATAS
SERVICESERVIS:
LIMIT:
Atas/Kedua: 0,08 mm
Top/Second: 0.08 mm (0.003 in)

7-36
CYLINDER HEAD/VALVES/CYLINDER/PISTON
Insert eachmasing-masing
Masukkan piston ring intopiston
the bottom of the
ring secara cylinder
tegaklurus
squarely
ke usingbagian
dalam the piston.bawah dari cylinder dengan
Measure the ringpiston.
menggunakan end gap.
Ukur celah pada
SERVICE LIMIT: ujung ring.
Top/Second
BATAS 0.45 mm (0.018 in)
SERVIS:
Atas/Kedua: 0,45 mm

Periksa
Check thepermukaan
piston outerluar piston
surface terhadap
for scratches or goresan
damage. atau
kerusakan.
Measure the piston pin hole. Take the maximum reading to
determine
Ukur I.D. piston pin. Ambil pembacaan maksimum
lubang
untuk
SERVICEmenentukan D.D.
LIMIT: 13.04 mm (0.513 in)
BATAS SERVIS: 13,04 mm
Measure the piston pin O.D. at piston and connecting rod
Ukur
slidingD.L.
areas.piston pin pada piston dan daerah luncur
connecting rod.
SERVICE
LIMIT: SERVIS: 12.96
BATAS 12,96mmmm(0.510 in)
Calculate
Hitung the renggang
jarak piston-to-piston pin clearance.pin.
piston-ke-piston
BATAS SERVIS: 0,02 mm
SERVICE
LIMIT: 0.02 mm (0.001 in)
Ukur D.L.the
Measure piston
pistonpada
O.D. titik
at thesejauh 6,0mm
point 6.0 mm(0.24
dari in)
bagian
from
the bottom dan
bawahnya and 90°
90°todari
thelubang
piston pin hole.pin.
piston
SERVICE
BATAS SERVIS: 49,95 mm
LIMIT: 49.95 mm (1.967 in)
Hitung jarak renggang cylinder-ke-piston (D.D. cylinder:
Calculate
Lihat the cylinder-to-piston clearance (cylinder I.D.: See
hal. 7-33).
page 7-33).
BATAS SERVIS: 0,09 mm
SERVICE
LIMIT: 0.09 mm (0.004 in)

Measure
Ukur thekepala
D.D. connecting
kecilrod small endrod.
connecting I.D.
BATAS
SERVICE SERVIS: 13,05 mm
LIMIT: 13.05connecting
Hitung jarak renggang mm (0.514 in)
rod-ke-piston pin.
CalculateSERVIS:
BATAS the connecting
0,05rod-to-piston
mm pin clearance.

SERVICE
LIMIT: 0.05 mm (0.002 in)

7-37
CATATAN
CYLINDER HEAD/VALVES/CYLINDER/PISTON

7-39
8. KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH

LOKASI KOMPONEN-KOMPONEN......8-2 DRIVE BELT ..........................................8-11


COMPONENT LOCATION ···························· 8-2 DRIVE BELT ···················································8-12
KETERANGAN SERVIS ........................8-3 DRIVE PULLEY......................................8-11 8
SERVICE INFORMATION ····························· 8-3 DRIVE PULLEY··············································8-12
TROUBLESHOOTING ...........................8-4 CLUTCH/DRIVEN PULLEY ...................8-15
TROUBLESHOOTING ···································· 8-4 CLUTCH/DRIVEN PULLEY ························8-16
LEFT CRANKCASE COVER .................8-5
LEFT CRANKCASE COVER ························· 8-5

8-1
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
COMPONENT
LOKASI LOCATION
KOMPONEN-KOMPONEN
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH

108 N·m (11.0 kgf·m, 80 lbf·ft)

49 N·m (5.0 kgf·m, 36 lbf·ft)

8-2
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
• This section covers maintenance of the kickstarter, drive pulley, driven pulley and clutch.
?• Babservices
These ini meliputi perawatan
can be done with dari kickstarter,
the engine drive
installed pulley,
in the driven pulley dan clutch.
frame.
?• Avoid getting servis
Pekerjaan grease and oil on dilakukan
ini dapat the drive belt and drive/driven
dengan pulley faces
mesin terpasang padainrangka.
order to prevent belt slippage.
?• DoJagalah
not applyagar
grease to thedan
gemuk weight rollers.
oli tidak mengenai drive belt dan drive/driven pulley faces supaya belt tidak slip.
• Jangan mengoleskan gemuk pada weight rollers.
SPECIFICATIONS
SPESIFIKASI Satuan: mm
BAGIAN STANDARD BATAS SERVIS Unit: mm (in)
Lebar drive belt 18,5 17,5 SERVICE
ITEM STANDARD
Movable drive face D.D. bushing 22,035 – 22,085 22,11 LIMIT
Drive belt width D.L. boss 18.5 (0.73)
22,010 – 22,025 21,98 17.5 (0.69)
Movable drive face D.L. Bushing I.D.
weight roller 22.035
15,92 – 22.085 (0.8675 –15,3
– 16,08 0.8695) 22.11 (0.871)
Clutch TebalBoss O.D.
lining - 22.010 – 22.025 (0.8665 –2,0
0.8671) 21.98 (0.865)
D.D.Weight
clutch roller
outer O.D. 15.92––112,2
112,0 16.08 (0.627 – 0.633)
112,5 15.3 (0.60)
Clutch pulley
Driven Lining
Panjang thickness
bebas face spring 124,2 – 121,4 2.0 (0.08)
D.L. Clutch
driven outer
face I.D. 112.0 – 112.2
33,965 (4.41 – 4.42)
33,985 33,94 112.5 (4.43)
Driven pulley D.D.Face springdriven
movable free length
face 124.2 –
34,000 (4.89)
34,025 34,06 121.4 (4.78)
Driven face O.D. 33.965 – 33.985 (1.3372 – 1.3380) 33.94 (1.336)
Movable driven face I.D. 34.000 – 34.025 (1.3386 – 1.3396) 34.06 (1.341)
NILAI TORSI
TORQUE VALUES
Left crankcase cover plate screw 3 N.m (0,3 kgf.m; 2,2 lbf.t)
Drive pulley face nut 108 N.m (11,0 kgf.m; 80 lbf.ft) Oleskan oli mesin pada ulir dan
Left crankcase cover plate screw 3 N·m (0.3 kgf·m, 2.2 lbf·ft)permukaan duduk
Clutch/driven pulley
Drive pulley face nutnut 54 N.m (5,5108
kgf.m;
N·m40 lbf.ft)
(11.0 kgf·m, 80 lbf·ft) Apply engine oil to the threads and seating sur-
Clutch outer nut 49 N.m (5,0 kgf.m; 36 lbf.ft) face
Clutch/driven pulley nut 54 N·m (5.5 kgf·m, 40 lbt·ft)
Clutch outer nut 49 N·m (5.0 kgf·m, 36 lbt·ft)

TOOLS
TOOLS
Clutch center holder Socket wrench, 39 x 41 mm Clutch spring compressor
07724-0050002 07GMA-KS40100 07LME-GZ40201

Driver Pilot, 28 mm Pilot, 20 mm


07749-0010000 07746-0041100 07746-0040500

8-3
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Flywheel holder Bearing remover, 20 mm Fork seal driver attachment, 35.2 mm
07725-0040001 07931-MA70000 07947-KA20200

Attachment, 28 x 30 mm
07946-1870100

TROUBLESHOOTING
TROUBLESHOOTING
Mesin
Enginehidup tapiscooter
starts but skuterwon’t
tidakmove
mau bergerak
•? Worn
Drivedrive
belt belt
aus
•? Damaged
Ramp plate
ramprusak
plate
•? Worn or shoe
Clutch damagedausclutch shoe
atau rusak
•? Broken
Drivendriven face spring
face spring patah
Engine stalls or scooter creeps
Mesin maticlutch
• Broken tiba-tiba atau skuter merangkak
shoe spring
• Clutch shoe spring patah
Poor performance at high speed or lack of power
? Wornkerja
Unjuk drive belt
buruk pada kecepatan tinggi atau
? Weak driven
kekurangan face spring
tenaga
? Worn weight rollers
• Drive belt aus
? Contaminated pulley faces
• Driven face spring lemah
• Weight rollers aus
• Pulley faces terkontaminasi

8-4
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
LEFT
LEFT CRANKCASE
CRANKCASE COVER
COVER
PELEPASAN
REMOVAL
Remove the
Lepaskan leftleft crankcasecover
crankcase cover duct
duct (page 2-12)
(hal. 2-12) CARBURETOR DRAIN
Remove the
Lepaskan following:
sebagai berikut: BOLTS
HOSE CLAMP
- ?Cover
Coverbolts
bolts
- ?Carburetor
Carburetordrain
drainhose
hose clamp
clamp
- ?Rear
Rearbrake
brakecable
cable clamp
clamp
- ?Vent
Vent holecover
hole cover
Remove the
Lepaskan leftleft crankcasecover.
crankcase cover.

REAR BRAKE
CABLE CLAMP VENT HOLE COVER

Lepaskan
Remove thekedua dowel
two dowel pins,pins, cover from
cover gasket gasket
the left left
daricrank-
crankcase.
case. GASKET
Clean the gasket mating surface.
Bersihkan permukaan penyatuan gasket.

PEMASANGAN
Bersihkan oli dan gemuk dari bearing bushing pada left
crankcase cover.

Pasang kedua dowel pins.


Pasang cover gasket baru.

DOWEL PINS

INSTALLATION
Pasang
Clean anyleft crankcase
oil and cover
grease from pada bushing
the bearing left crankcase
on the left CARBURETOR DRAIN
crankcase
dengan cover.
mentepatkan dowel pins dengan lubang-lubang. BOLTS
HOSE CLAMP
Pasang carburetor
Install the two doweldrain hose clamp, rear brake cable
clamp, vent hole cover dan kencangkan left crankcase
left crankcase
cover bolts dalamcover onto
pola the left crankcase
bersilangan dalam by
duaaligning the
atau tiga
dowel pins with the holes.
langkah.
Install the carburetor drain hose clamp, rear brake cable
Pasang left crankcase
clamp, vent hole cover cover duct (hal.
and tighten 2-12)
the left crankcase cover
bolts in a crisscross pattern in two or three steps.
Install the left crankcase cover duct (page 2-12)

REAR BRAKE
CABLE CLAMP VENT HOLE COVER
PEMBONGKARAN
DISASSEMBLY
Naikkan
Raise thelock
locktabs
tabs dari leftleft
of the crankcase
crankcasecover
coverplate
plate dan
and
lepaskan
remove thescrews.
screws.

LOCK TABS/SCREWS

8-5
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Lepaskan
Remove thekickstarter
kickstarter driven gear while
driven gear sementara
turning memutar
the kick-
kickstarter spindle.
starter spindle. KICKSTARTER DRIVEN GEAR
Remove the thrust washer.
Lepaskan thrust washer.

THRUST WASHER

Sebelum melepaskan
Before removing kickstarter
the kickstarter pedal,
pedal, mark tandai
the pedalpedal
and
dan spindle
spindle untukinstallation
for proper posisi pemasangan
position. yang benar. KICKSTARTER PEDAL TANDA

Remove thebolt
Lepaskan boltdan
andkickstarter
the kickstarter pedal.
pedal.

BOLT

Remove thedust
Lepaskan dustseal
seal dari
fromleft
thecrankcase
left crankcase cover.
cover.
DUST SEAL

Lepaskan snap
Remove the snapring
ringdan
andwasher
washer dari
fromkickstarter spindle.
the kickstarter spin-
dle. WASHER

SNAP RING

8-6
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Unhook thekaitan
Lepaskan returnreturn
springspring
from the
dari pin
pin on the crankcase
pada crankcase
KICKSTARTER SPINDLE RETURN SPRING
cover.
cover.
Remove the kickstarter spindle and return spring.
Lepaskan kickstarter spindle dan return spring.

PIN

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

COLLAR
PERAKITAN
KICKSTARTER SPINDLE
COLLAR

BUSHING *1 3 N·m (0.3 kgf·m, 2.2 lbf·ft)

RETURN SPRING

DRIVEN GEAR

*2
COVER PLATE

FRICTION SPRING

THRUST WASHER
LEFT CRANKCASE COVER

SNAP RING

WASHER

DUST SEAL
KICKSTARTER PEDAL

BOLT *1: Oleskan 0.1 – 0.3 g


*2: Oleskan 0.2 – 0.3 g

8-7
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Install thebushing
Pasang bushing and
dancollar intoke
collar thedalam
left crankcase cover.
left crankcase
cover. BUSHING

COLLAR

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

Kaitkan
Hook theujung pendek
short end dari spring
of the spring pada groove.
to the spindle alur spindle.
Install
Pasang spindle
the spindle dan spring
and return return into
spring
the ke dalam cover
crankcase crankcase
while RETURN SPRING Kaitkan
settingsementara
cover the return meletakkan
spring along return
the guide on the
spring crankcase
di sepanjang
cover.pada crankcase cover.
guide
Hold the kickstarter spindle in position.
Tahan kickstarter spindle pada posisinya.

KICKSTARTER SPINDLE UJUNG PENDEK

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

WASHER SNAP RING

8-8
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Hook theujung
Kaitkan long panjang
end of the
darireturn
returnspring to pada
spring the pin
pinonpada
the
crankcase cover.
crankcase cover. UJUNG PANJANG PIN

Apply grease
Oleskan gemukto apada
new dust
bibirseal
dust lip.seal baru.
Install the
Pasang dustseal
dust sealsampai
until it ia
is rata
flushdengan
with theleft
leftcrankcase
crankcase
cover.
cover.
DUST SEAL

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

BOLT

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

THRUST WASHER

8-9
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Apply 0.20,2– –0.30,3
Oleskan g gof molybdenum
molybdenum disulfide
disulfide paste
paste topada
the
driven gear
driven gear shaft.
shaft. DRIVEN GEAR
Apply molybdenum
Oleskan molybdenum disulfide paste to paste
disulfide the friction
padaspring slid-
daerah
ing area.
luncur friction spring. WELD BEAD
Depress the kickstarter pedal and hold it.
Tekan kickstarter pedal dan tahan.
Install the driven gear while aligning the friction spring hook
with the groove
Pasang driven ingear
the crankcase
sementara cover, and return thekaitan
mentepatkan kick-
starter spindle
friction spring to engagealur
dengan the pada
drivencrankcase
gear teeth and spindle
cover, dan
gear teeth before
kembalikan the weld spindle
kickstarter bead point.
untuk menghubungkan
gigi driven gear dan gigi spindle gear sebelum weld
bead point (titik manik pengelasan).
Tepatkan
FRICTION SPRING

Pasang
Install theleft
left crankcase cover
crankcase cover plateplate dan kencangkan
and tighten the screws to
screws dengan
the specified torsi yang ditentukan.
torque.

TORQUE:3
TORSI: N·m
3 N.m (0.3kgf.m;
(0,3 kgf·m,2,2
2.2lbf.ft)
lbf·ft)
Bend the lock tabs of the cover plate against the screw heads.
Tekuk lock tabs dari cover plate terhadap kepala screw.

LOCK TABS/SCREWS

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

SPINDLE

BUSHING

-? Driven
Drivengear
gearterhadap
for wear or damage atau kerusakan
keausan STARTER
-? Friction
Frictionspring
springterhadap
for weakness or damage
kelemahan atau kerusakan FRICTION SPRING
RATCHET TEETH
-? Gigi
Starter ratchet
starter teethterhadap
ratchet for wear or damage atau kerusakan
keausan

DRIVEN GEAR

8-10
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
-? Journals
Journals dari
of thecrankcase coverfor
crankcase cover terhadap
wear or keausan
damage atau
kerusakan.

JOURNALS

DRIVE
DRIVEBELT
BELT
PENGGANTIAN
REPLACEMENT
CATATAN:
• ? The
Drive belt
drive dapat
belt can bediservis
serviceddengan
with the mesin
engine terpasang
installed in
pada rangka.
the frame.
Remove the
Lepaskan drivepulley
drive pulleyface
face(hal.
(page8-11).
8-11).
Remove the
Lepaskan drivebelt
drive beltdan
andganti
replace it with yang
dengan a newbaru.
one.
Install the
Pasang drive
drive pulleyface
pulley face(hal.
(page8-12).
8-12).

BELT

DRIVE
DRIVEPULLEY
PULLEY
PELEPASAN
REMOVAL
CATATAN:
• Drive pulley dapat diservis dengan mesin terpasang
? The
padadrive pulley can be serviced with the engine installed
rangka.
in the frame.
Lepaskan left
Remove the leftcrankcase
crankcase cover (hal. 8-5).
cover (page 8-5).
NUT/WASHER/ DRIVE PULLEY FACE
Tahan
Hold themuka drive face
drive pulley pulley
withdengan special
special tool tool dan
and loosen the RATCHET PLATE
longgarkan
drive pulley drive pulley face nut.
face nut.
TOOL:
TOOL:
Clutch center
Clutch center holder
holder 07724-0050002
07724-0050002
Remove the following:
Lepaskan sebagai berikut:
? Nut
-? Nut
Washer
-? Washer
Starter ratchet plate DRIVE FACE FIN
-? Starter
Drive ratchet
face fin plate
- Drive face fin
CLUTCH CENTER HOLDER

8-11
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Geser lepas
Slide off drivebelt
the drive belt dari
from thedrive pulley boss
drive pulley bossbydengan
squeez-
memencet
ing the drivedrive
belt.belt. BOSS

BELT

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

BOSS

PEMASANGAN
INSTALLATION
Clean any oli
Bersihkan oil dan
and gemuk
grease from the drive
dari drive faceface
dan and thebelt.
drive drive
belt. MOVABLE DRIVE FACE ASSEMBLY
Hati-hati agar movable Pasang movable drive face assembly pada crankshaft
drive
Be facenot
careful assembly Install the movable
to get sementara menahan drive
rampface assembly onto the crankshaft
plate.
tidak
theterbongkar dan while holding the ramp plate.
movable drive
pastikan untuk
face assembly
memasang assembly
disassembled and be
sampai duduk dengan
sure to install the
penuh.
assembly until fully
seated.

Compress
Tekan the driven
driven face spring
face spring denganby squeezing
memencet thedrive
drive belt
until there
sampai adais enough
cukup slack to installuntuk
kekenduran the drive belt to the drive
memasang DRIVE BELT
pulley
belt padaboss.
drive pulley boss.

8-12
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Be careful
Hati-hati agarnot to Tempatkan
tidak Set the drive drive beltthepada
belt onto drive boss
drive pulley pulley
by boss dengan
squeezing it to
DRIVE PULLEY FACE
damage the spline. memencetnya
merusak untuk
obtain the clearance between mendapatkan kerenggangan
the belt and shaft.
antara
Install belt dan shaft.
the drive pulley face while aligning its splines with
crankshaftdrive
Pasang splines.pulley face sementara mentepatkan
splines-nya dengan crankshaft splines.

Tepatkan

Pastikan
Make surebahwa
that thedrive
drivepulley
pulley face
face isduduk sepenuhnya
fully seated on the
pada
drive drive
pulleypulley
boss. boss.

Duduk sepenuhnya (Drive pulley face and

Install the
Pasang drive
drive facefin
face findan
andratchet
ratchet plate.
plate. RATCHET PLATE DRIVE FACE FIN
Apply engine
Oleskan oil to the
oli mesin driveulir
pada pulley facepulley
drive nut threads
face and
nut seat-
dan
ing surface then
permukaan dudukinstall it with the
kemudian washer.
pasang dengan washer.
Hold the drive pulley face with the special tool and tighten CLUTCH
Tahan
the nut todrive pulley torque.
the specified face dengan special tool dan CENTER
kencangkan nut dengan torsi yang ditentukan. HOLDER
TOOL:
Clutch center holder
TOOL: 07724-0050002
Clutch center holder 07724-0050002
TORQUE:108 N·m (11.0 kgf·m, 80 lbf·ft)
TORSI: 108 N.m (11,0 kgf.m; 80 lbf.ft)
Install the left crankcase cover (page 8-5).
Pasang left crankcase cover (hal. 8-5).
NUT
WASHER
PEMERIKSAAN
INSPECTION
DRIVE
DRIVEPULLEY
PULLEYFACE
FACE
Check thedrive
Periksa drivepulley
pulley face
faceforterhadap
scratches,goresan,
scoring or gerusan
damage.
atau kerusakan. DRIVE PULLEY FACE

8-13
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
DISASSEMBLY/ASSEMBLY
PEMBONGKARAN/PERAKITAN
Remove the following:
Lepaskan sebagai berikut:
? Drive face boss
- Driven face boss
? Ramp plate
- ? Ramp
Slideplate
pieces
- ? Slide pieces
Weight rollers
- Weight rollers
Clean any oil and Assembly is in the reverse order of disassembly.
Bersihkan weight
grease from the Perakitan adalah dalam urutan terbalik dari
rollers
weightdan movable
rollers and pembongkaran.
drive face
movable dariface.
drive oli
dan gemuk.

MOVABLE DRIVE FACE DRIVE FACE BOSS

Sisi left
crankcase cover

RAMP PLATE
WEIGHT ROLLERS

SLIDE PIECES

PEMERIKSAAN
INSPECTION
WEIGHT
WEIGHTROLLER
ROLLER
Periksa masing-masing
Check each rollerwear.
roller for abnormal terhadap keausan tidak
Measure the weight roller O.D.
normal.
Ukur D.L. weight roller.
SERVICE
LIMIT:SERVIS: 15,3
BATAS 15.3 mm
mm(0.60 in)

MOVABLE
MOVABLEDRIVE
DRIVEFACE
FACEBOSS
BOSS
Periksa
Check thedrive facebossboss
drive face terhadap
for wear keausan atau
or damage.
Measure the drive face boss O.D.
kerusakan.
Ukur D.L. drive face boss.
SERVICE
BATAS
LIMIT:SERVIS: 21,98 mm(0.865 in)
21.98 mm

8-14
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
MOVABLEDRIVE
MOVABLE DRIVEFACEFACE
Check the movable drive
Periksa movable drive face face terhadap
for scratches, scoringgerusan
goresan, or dam-
age. MOVABLE DRIVE FACE
atau kerusakan.
Measure the drive face bushing
Ukur D.D. drive face bushing. I.D.

BATAS SERVIS: 22,11 mm


SERVICE
LIMIT: 22.11 mm (0.871 in)

CLUTCH/DRIVEN
CLUTCH/DRIVENPULLEY
PULLEY
PELEPASAN
REMOVAL
CATATAN:
• Clutch/driven pulley dapat diservis dengan mesin
? The clutch/driven pulley can be serviced with the engine
installed
terpasangin the frame.
pada rangka.
Remove the
Lepaskan leftcrankcase
left crankcase cover
cover (page 8-5).
(hal. 8-5).
CLUTCH OUTER NUT/WASHER
Pakailah special tool Tahan clutch outer dengan special tool
Hold the clutch outer with the special tool and
danremove the
lepaskan
Use the
ketika special tool
melonggarkan nut.
nut.
lock nut.
when loosening the
Menahan roda belakang
lock nut.
TOOL:
atau rem belakang TOOL:
Flywheel holder 07725-0040001
Holding theakan
rear
merusak Flywheel holder 07725-0040001
wheel orsistem final
rear brake Remove the washer and clutch outer.
reduction.
will damage the final
Lepaskan washer dan clutch outer.
reduction system.

FLYWHEEL HOLDER
Jangan
Do notoleskan gemuk
get grease on Tahan
Hold theclutch/driven
clutch/drivenpulley
pulleyassembly dan compress
assembly and tekan drive
the
pada CLUTCH/DRIVEN PULLEY ASSEMBLY
the drive
drive shaft
shaft splines
splines face
drive spring dengan
face spring memutar
by turning movable
movable driven
driven face face
clockwise
dari sebelah dalam searah jarum jam sampai ia berhenti.
from the driven face until it stops.
driven face.
inside.

8-15
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Untuk menghindari
To avoid injury luka-
to Lepaskan
Remove the clutch/driven
clutch/drivenpulley
pulleyassembly
assembly dari
from drive belt
the drive
luka
yourpada
finger,jari-jari,
do not belt by holding
dengan menahanthe movable
movable driven
drivenface.
face. BELT
jangan lepaskan
release the driven
driven
Remove the drive belt from the clutch/driven pulley assem-
pulleypulley
whilesementara
removing Lepaskan drive beltthedari clutch/driven pulley assembly
melepaskan drive belt. bly while removing clutch/driven pulley assembly from
the drive belt. If sementara melepaskan clutch/driven pulley assembly
Jika dilepaskan drive the drive shaft.
released drive face dari drive shaft.
face spring akan
memanjangspringdengan
will extend
tiba-
suddenly
tiba dan movable and
driven
movable
face akandriven face
berputar,
will turn,
sehingga resulting in
menimbulkan
luka-luka
injury topada
your jari-jari.
finger.

CLUTCH/DRIVEN PULLEY ASSEMBLY


PEMASANGAN
INSTALLATION
Bersihkan
Clean any oiloli and
dangrease
gemuk darithe
from driven
drivenface
facedan
anddrive
drive belt.
belt.
Tahan
Hold the clutch/driven
clutch/drivenpulley
pulleyassembly
assembly anddan compress
tekan drivethe CLUTCH/DRIVEN
face PULLEY ASSEMBLY
drive spring
face springdengan memutar
by turning movable movable driven
driven face face
clockwise
searah jarum jam sampai ia berhenti.
until it stops.

MOVABLE DRIVEN FACE

Untuk menghindari
To avoid injury luka-
to Tempatkan
Set the drive drive
belt ontobeltthepada
pulley alur
groovepulley sementara
while holding the
luka
your pada
finger,jari-jari, movable driven
do not menahan movableface.driven face.
jangan lepaskan driven
BELT
release the driven
pulley sementara
pulley while installing
memasang drive belt.
the drive belt. If
Jika dilepaskan drive
released drive akan
face spring face
springdengan
memanjang will extend
tiba-
suddenly
tiba dan movable and
driven
movable
face akan driven face
berputar,
will turn,menimbulkan
sehingga resulting in
luka-luka
injury topada
yourjari-jari.
finger.

MOVABLE DRIVEN FACE


Jangan oleskan gemuk Pasang clutch/driven pulley assembly pada driveshaft.
Do not get grease on Install the clutch/driven pulley assembly onto the driveshaft. CLUTCH/DRIVEN PULLEY ASSEMBLY
pada drive shaft splines
the drive shaft splines
dari sebelah dalam
from the driven
driven face.
face
inside.

8-16
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Clean any oil
Bersihkan oli and
dangrease
gemuk from
darithe clutchouter.
clutch outer.
Install theclutch
Pasang clutchouter
outer while aligning
sementara its splines with
mentepatkan drive-
splines-
shaftdengan
nya splines.driveshaft splines. Tepatkan

CLUTCH OUTER

Install the
Pasang washerdan
washer andclutch
clutch outer
outer nut.
nut. FLYWHEEL HOLDER
Hold the
Tahan clutch
clutch outer
outer with the
dengan special
special tool
tool danand tighten the
kencangkan
clutch outer
clutch outer nut
nutto the specified
dengan torque.
torsi yang ditentukan.
TOOL:
TOOL:
Flywheel holder 07725-0040001
Flywheel holder 07725-0040001
TORQUE:49
TORSI: N·m
49 N.m (5.0kgf.m;
(5,0 kgf·m,36
36lbf.ft)
lbf·ft)
Pasang leftleft
Install the crankcase
crankcasecover (hal. 8-5).
cover (page 8-5).

NUT/WASHER
PEMBONGKARAN
DISASSEMBLY
CLUTCH/DRIVEN
CLUTCH/DRIVENPULLEY
PULLEY
Set the clutch
Tempatkan spring
clutch compressor
spring onto the
compressor clutch/driven
pada pul-
clutch/driven
CLUTCH SPRING COMPRESSOR
ley by aligning
pulley denganthe bosses of the compressor
mentepatkan bosses dariwithcompressor
the holes of
the clutch.
dengan lubang-lubang dari clutch. CLUTCH/DRIVEN
PULLEY
TOOL:
TOOL:
Clutch spring
Clutch spring compressor
compressor 07LME-GZ40201
07LME-GZ40201

Untuk
To mencegah
prevent Hold theclutch/driven
loss of Tahan clutch/driven pulley by turning memutar
dengan the clutch clutch
spring
hilangnya tegangan,
tension, compressor
do not spring clockwise.
compressor searah jarum jam.
jangan tekan driven
compress face
the driven
spring lebih daripada
face spring more than
yang diperlukan untuk
necessary to remove
melepaskan
the clutch/
clutch/driven driven
pulley nut.
pulley nut.

CLUTCH/DRIVEN
PULLEY

8-17
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Hold the
Tahan clutch
clutch springcompressor
spring compressor in a vise.
pada sebuah catok.
SOCKET WRENCH CLUTCH/DRIVEN
Remove the clutch/driven
Lepaskan pulley nut
clutch/driven using the
pulley specialdengan
nut tool. PULLEY NUT
menggunakan special tool.
TOOL:
Socket wrench, 39 x 41 mm 07GMA-KS40100
TOOL:
Socket wrench, 39 x 41 mm 07GMA-KS40100

Longgarkan clutchspring
Loosen the clutch springcompressor
compressor secaraand
gradually berangsur
remove
dan lepaskan sebagai berikut: CLUTCH ASSEMBLY
the following:
- Clutch assembly
- ? Spring
Clutchseat
assembly
? Spring seat SPRING SEAT
- Driven face spring
? Driven face spring
- Driven pulley assembly
? Driven pulley assembly

DRIVEN
DRIVEN PULLEY ASSEMBLY FACE

CLUTCH
CLUTCH
Remove the
Lepaskan three E-clips
ketiga E-clips and
danwashers.
washers.
E-CLIPS/WASHERS
Remove the
Lepaskan clutchshoes
clutch shoes dari
fromdrive
the drive plate.
plate.
Remove the
Lepaskan clutchshoe
clutch shoesprings.
springs.
Remove the
Lepaskan damperrubbers
damper rubbers dari
fromdrive
the drive plate.
plate.

SPRINGS

DAMPER RUBBERS DRIVE PLATE

8-18
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
DRIVEN
DRIVENPULLEY
PULLEY
Remove the
Lepaskan sealcollar.
seal collar.
SEAL COLLAR
Remove the
Lepaskan guidepins
guide pinsdan
and guide
guiderollers
rollersfrom
darithe driven
driven face.
face.
Remove the
Lepaskan movabledriven
movable drivenface
face dari
fromdriven
the driven face.
face. O-RINGS
Remove theO-rings
Lepaskan O-rings dan
and oil
oil seals
sealsfrom
darithemovable
movable driven
driven
face.
face.

OIL SEALS

MOVABLE
DRIVEN FACE

GUIDE PINS

DRIVEN FACE
GUIDE
ROLLERS

ASSEMBLY
PERAKITAN
GUIDE PINS
GUIDE ROLLERS
OIL SEALS

O-RINGS

SEAL COLLAR

DRIVEN FACE SPRING DRIVEN FACE

MOVABLE DRIVEN FACE


SPRING SEAT

WASHERS

E-CLIPS

CLUTCH SHOES
SPRINGS
CLUTCH DRIVEN PULLEY NUT DAMPER RUBBERS
54 N·m (5.5 kgf·m, 40 lbf·ft) DRIVE PLATE

DRIVEN PULLEY
Apply engine
DRIVEN oil to new oil seal lips and install them into the
PULLEY
movable driven face. O-RINGS
Oleskan oli mesin pada bibir oil seal baru dan pasang
Coat
ke new movable
dalam O-rings with engine
driven face.oil and install them into the OIL SEALS
movable driven face grooves.
Lapisi O-rings baru dengan oli mesin dan pasang ke
dalam alur-alur movable driven face.

8-19
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Bersihkan oli and
Clean any oil dangrease
gemukfrom
darithe
pulley face.
pulley face.
PINS/ROLLERS
Pasang movable
Install the movabledriven
drivenface
face pada driven
onto the face.
driven face.
Install the
Pasang guiderollers
guide rollersdan
andguide
guide pins.
pins.
Apply 2.0 – 2.5 g of grease (Shell ALVANIA R3 or
Oleskan 2,0 – 2,5 g gemuk (Shell ALVANIA R3 atau
IDEMITSU AUTOREX B or equivalent) to each guide
IDEMITSU AUTOREX B atau sejenisnya) pada masing-
groove.
masing alur guide.

MOVABLE DRIVEN FACE

Pasang seal
Install the sealcollar
collarpada
to thedriven
drivenpulley.
pulley.
SEAL COLLAR

CLUTCH
CLUTCH
Pasang damper
Install the damperrubbers
rubbers pada drive
onto the plate.
drive plate.
DRIVE PLATE

DAMPER RUBBERS

Pasang
Install theshoe springsinto
shoe springs kethe
dalam
clutchclutch
shoes asshoes
shown.seperti
diperlihatkan. CLUTCH SHOES SPRINGS
Install the clutch shoes into the drive plate by aligning the
shoe grooves and damper rubbers.
Pasang clutch shoes ke dalam drive plate dengan
mentepatkan alur-alur shoe dan damper rubbers.

DRIVE PLATE

8-20
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Install the
Pasang washersdan
washers and E-clips.
E-clips.

WASHERS/E-CLIPS

CLUTCH/DRIVEN
CLUTCH/DRIVENPULLEY PULLEY
Rakit sebagai
Assemble berikut:
the following:
CLUTCH ASSEMBLY
-? Driven
Drivenpulley
pulleyassembly
assembly
-? Driven
Drivenface
facespring
spring
-? Spring
Springseat
seat SPRING SEAT
-? Clutch
Clutchassembly
assembly

DRIVEN
DRIVEN PULLEY ASSEMBLY FACE

Tempatkan clutch compressor


Set the clutch spring spring over
compressor di atas
the clutch/driven pul- Tepatkan
clutch/driven pulley the
ley assembly aligning assembly
bosses of dengan mentepatkan
the compressor with the (BOSSES/ HOLES
bosses dariclutch.
holes of the compressor dengan lubang-lubang dari
clutch.
TOOL:
TOOL:
Clutch spring compressor 07LME-GZ40201
Compress
Clutch the driven
spring face spring while07LME-GZ40201
compressor aligning the cutout of
To prevent loss of the pulley nut threads with the drive plate hole and install the
tension,
Untuk do not
mencegah clutch/driven
Tekan drivenpulley
facenut.spring sementara mentepatkan
hilangnya tegangan,
compress the potongan dari ulir pulley nut dengan lubang drive plate
jangan tekan driven face dan pasang clutch/driven pulley nut.
driven face spring
spring lebih daripada
more untuk
yang diperlukan than
merakitnecessary to
clutch/driven CLUTCH SPRING Tepatkan (CUTOUT/
assemble
pulley the
nut. Jangan COMPRESSOR PLATE HOLES
merusak clutch/driven
ulir pulley nut.
pulley nut.
Do not damage the
pulley nut threads.

Hold the
Tahan springcompressor
spring compressor pada
in a vice.
sebuah catok.
CLUTCH SPRING
Tighten the clutch/driven
Kencangkan pulley
clutch/driven nut using
pulley the socket
nut dengan wrench
memakai COMPRESSOR
to the specified
socket torque. torsi yang ditentukan.
wrench dengan
TOOL:
TOOL:
Socket wrench, 39 x 41 mm 07GMA-KS40100
Socket wrench, 39 x 41 mm 07GMA-KS40100
TORQUE:54
TORSI: N·m
54 N.m (5.5kgf.m;
(5,5 kgf·m,40
40lbf.ft)
lbf·ft)
Lepaskan
Remove thespring
spring compressor daritheclutch/driven
compressor from clutch/driven pulley
assembly.
assembly.

SOCKET WRENCH

8-21
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
INSPECTION
PEMERIKSAAN
CLUTCH OUTER
CLUTCH OUTER
Check the clutch outer for wear or damage.
Periksa clutch outer terhadap keausan atau kerusakan.
Measure
Ukur D.D.the clutchouter.
clutch outer I.D.

BATAS
SERVICESERVIS: 112,5 mm
LIMIT: 112.5 mm (4.43 in)

DRIVEN
DRIVENFACE
FACESPRING
SPRING
Ukur panjang bebas driven
Measure the driven face face
spring freespring.
length.
BATAS SERVIS: 121,4 mm
SERVICE
LIMIT: 121.4 mm (4.78 in)

DRIVEN FACE
DRIVEN FACE
Check the driven face for scratches, scoring or damage.
Periksa
Measure driven face
the driven faceterhadap
boss O.D. goresan, gerusan atau
kerusakan.
Ukur D.L. driven face boss.
SERVICE
LIMIT: SERVIS: 33.94
BATAS 33,94mm mm(1.336 in)

8-22
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
MOVABLE
MOVABLEDRIVEN
DRIVENFACE
FACE
Check the
Periksa movabledriven
movable drivenface
face terhadap
for scratches, scoringgerusan
goresan, or dam-
age. kerusakan.
atau
Check thealur-alur
Periksa guide grooves
guideforterhadap
stepped wear or damage.
keausan bertingkat
Measure
atau the movable driven face I.D.
kerusakan.
Ukur D.D. movable driven face.
SERVICE
LIMIT:SERVIS: 34,06
BATAS 34.06 mm
mm(1.341 in)

PEMERIKSAAN
DRIVEN FACEDRIVEN FACE
BEARING BEARING
INSPECTION
Juga
Also periksa bahwa
check that bearingouter
the bearing outerrace
racefitsduduk
tightlydengan
in the
erat pada
driven driven face.
face.
Install the driven face to the driveshaft.
Pasang driven face pada driveshaft.
Turn the driven face with your hand. The bearing should turn
Putar
smoothlydriven face dengan tangan. Bearing harus
and quietly.
berputar dengan
Replace the bearingshalus dando
if they tanpa suara.
not turn smoothly, quietly, or
Ganti
if theybearings
fit looselyjika
on mereka tidak
the driven faceberputar dengan halus,
(page 8-23).
tanpa suara, atau jika mereka duduk dengan longgar
pada driven face (hal. 8-23).

DRIVEN FACE

DRIVEN FACE BEARING


PENGGANTIAN
REPLACEMENTDRIVEN FACE BEARING
Lepaskan
Remove the driven faceneedle
driven face needle
bearingbearing
using thedengan
special
menggunakan
tools. special tools. BEARING REMOVER

TOOLS:
TOOLS:
Bearing remover, 20 mm 07931-MA70000
Bearing ATTACHMENT
Fork sealremover, 20 mm
driver attachment, 07931-MA70000
Forkmm
35.2 seal driver attachment, 35.2 07947-KA20200
mm 07947-KA20200

NEEDLE BEARING

Lepaskan
Remove the snap
snapring
ringdan
anddorong ball
drive the bearing
ball bearingkeluar
out ofdari
the
driven
drivenface.
face. BEARING

SNAP RING

8-23
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
Pack new
Isilah ball bearing
ball bearing baruwith greasegemuk
dengan (Shell ALVANIA R3 or
(Shell ALVANIA
IDEMITSU AUTOREX B or equivalent). DRIVER
R3 atau IDEMITSU AUTOREX B atau sejenisnya).

SisiThe sealeddari
tertutup sideball
of Pasang ball
Install the ballbearing
bearing secara
into the tegaklurus ke dalam
driven face squarely driven
until it is
ball bearing
bearing is facing
menghadap ke face sampai
fully seated, ia the
using telah duduk
special tools. sepenuhnya, dengan
driven face.
the driven menggunakan special tools.
face. TOOLS:
TOOLS:
Driver 07749-0010000
Pilot, 28 mm
Driver 07746-0041100
07749-0010000
Pilot, 28 mm 07746-0041100

PILOT
BALL BEARING

Pasang
Install thesnap
snapring
ring dengan kokoh
to the groove on pada alur face
the driven pada driven
securely.
face.
Apply 7.0 – 8.0 g of grease (Shell ALVANIA R3 or
IDEMITSU
Oleskan 7,0AUTOREX
– 8,0 g gemukB or equivalent) to the driven
(Shell ALVANIA face
R3 atau
inner surface.
IDEMITSU AUTOREX B atau sejenisnya) pada
permukaan dalam driven face.

SNAP RING

Apply grease
Oleskan gemuk (Shell
(Shell ALVANIA
ALVANIA R3 R3 atau
or IDEMITSU
AUTOREX B ATTACHMENT DRIVER
AUTOREX B oratau
equivalent) to a newpada
sejenisnya) needleneedle
bearing.bearing
baru.
The sealed side of Press the needle bearing into the driven face squarely as
Sisi tertutup
needledari needle
bearing is shown. needle bearing secara tegaklurus ke dalam
Dorong 1.0 mm (0.04 in)
bearing menghadap ke
facing the special
special tools.
driven face seperti diperlihatkan.
tools. TOOLS:
TOOLS:
Driver 07749-0010000
Driver
Attachment, 28 x 30 mm 07749-0010000
07946-1870100
Attachment,
Pilot, 20 mm 28 x 30 mm 07946-1870100
07746-0040500 PILOT
Pilot, 20 mm 07746-0040500

NEEDLE BEARING

8-24
9. FINAL REDUCTION

LOKASI KOMPONEN-KOMPONEN......9-2
COMPONENT LOCATION ···························· 9-2PERAKITAN FINAL REDUCTION
FINAL REDUCTION CASE .........9-7
CASE ASSEMBLY ·····9-7

KETERANGAN SERVIS ........................9-3


SERVICE INFORMATION ····························· 9-3PEMERIKSAAN FINAL REDUCTION
FINAL REDUCTION CASE
INSPECTION ...9-8
··············9-8
9
TROUBLESHOOTING
TROUBLESHOOTING ...........................9-5
···································· 9-5PENGGANTIAN FINAL REDUCTION
FINAL REDUCTION BEARING ..............
BEARING ..........................................................9-10
REPLACEMENT·············································9-10
PEMBELAHAN FINAL
FINAL REDUCTION CASE
REDUCTION CASE
SEPARATION ...............................9-6 9-6
···················································

9-1
FINAL REDUCTION
COMPONENT
LOKASI LOCATION
KOMPONEN-KOMPONEN
FINAL REDUCTION

9-2
FINAL REDUCTION
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
• The final reduction can be serviced with the engine installed in the frame.
•• When
Final reduction
installing the dapat diservis
driveshaft, dengan
be sure to usemesin terpasang
the special pada rangka.
tools; position the special tools on the bearing inner race
• andKetika
pull thememasang
driveshaft into the bearing
driveshaft, until it untuk
pastikan is fullymemakai
seated. special tools; tempatkan special tools pada bearing inner race dan
tarik driveshaft ke dalam bearing sampai ia telah duduk sepenuhnya.

SPECIFICATIONS
SPESIFIKASI Unit: mm (in)
ITEM STANDARD
SPESIFIKASI
Final reduction oil capacity BAGIANAfter draining 0.10 liter (0.11 US qt, 0.09 lmp qt)
Kapasitas oli final Pada penggantian periodik
After disassembly 0,10 liter
0.12 liter (0.13 US qt, 0.11 lmp qt)
reduction Setelah pembongkaran 0,12 liter motorcycle oil" or equivalent motor oil
Recommended final reduction oil Honda "4-stroke
Oli final reduction yang dianjurkan Federalclassification:
API service Oil Supreme SG
Flick
ordengan klasifikasi
higher (except oilsAPI Service
labeled as
SG., Viskositas: SAE 10W-30 JASO MB
energy conserving on the circular API service label)
JASO T 903 standard: MB
Viscosity: SAE 10W-30
NILAI TORSI
Final reduction oil check bolt 13 N.m (1,3 kgf.m; 10 lbf.ft)
TORQUE VALUE
Final reduction oil drain bolt 13 N.m (1,3 kgf.m; 10 lbf.ft)

Final reduction oil check bolt 13 N·m (1.3 kgf·m, 10 lbf·ft)


Final reduction oil drain bolt 13 N·m (1.3 kgf·m, 10 lbf·ft)

TOOLS
TOOLS

Case puller Remover weight Bearing remover shaft, 10 mm


07SMC-0010001 07741-0010201 07936-GE00100

Bearing remover head, 10 mm Bearing remover shaft, 12 mm Bearing remover head, 12 mm


07936-GE00200 07936-1660120 07936-1660110

9-3
FINAL REDUCTION
Bearing remover shaft, 15 mm Bearing remover head, 15 mm Driver
07936-KC10100 07936-KC10200 07749-0010000

Attachment, 32 x 35 mm Attachment, 37 x 40 mm Attachment, 40 x 42 mm


07746-0010100 07746-0010200 07746-0010900

Attachment, 42 x 47 mm Pilot, 10 mm Pilot, 12 mm


07746-0010300 07746-0040100 07746-0040200

Pilot, 15 mm Pilot, 20 mm Pilot, 22 mm


07746-0040300 07746-0040500 07746-0041000

9-4
FINAL REDUCTION
Assembly collar Assembly shaft Assembly collar attachment
07965-GM00100 07965-1660200 07965-GM00200

TROUBLESHOOTING
TROUBLESHOOTING
Mesin
Enginebisa
does hidup tetapi
start but skuter
scooter tidak
won’t movemau bergerak
•• Damaged
Final reduction rusak
final reduction
•• Seized
Final reduction macet
final reduction
•• Faulty
Drivedrive
pulley dan and
pulley driven pulley/clutch
driven rusak
pulley/clutch
Abnormal
Suara tidaknoise
normal
• Worn, seized or chipped gears
• Gears aus, macet atau sumbing
• Worn or damaged final reduction bearing
• Final reduction bearing aus atau rusak
Oil leak
• Oil level too
Kebocoran oli high
•• Worn or permukaan
Tinggi damaged oil oli
sealterlalu tinggi
•• Cracked
Oil seal aus atau rusakfinal reduction case
crankcase and/or
• Crankcase dan/atau final reduction case retak

9-5
FINAL REDUCTION
FINAL REDUCTION
PEMBELAHAN FINALCASE
REDUCTION CASE
SEPARATION
PELEPASAN
REMOVAL
•• The
Final reduction
final dapat
reduction candiservis dengan
be serviced mesin
with the ter -
engine
pasanginpada rangka. BREATHER HOSE
installed the frame.
Drain the final
Keluarkan reduction
oli final oil (page
reduction (hal.3-13).
3-13).
Remove the following:
Lepaskan sebagai berikut:
-– Clutch/driven
Clutch/drivenpulley
pulley (hal.
(page8-15)
8-16)
– Rear wheel (page 12-4)
- Roda belakang (hal. 12-4)
– Rear brake shoes (page 13-5)
- Rear brake shoes (hal. 13-5)
Disconnect the final reduction case breather hose from the
Lepaskan final reduction case breather hose dari final
final reduction case hose joint.
reduction case hose joint.

Remove thebolts
Lepaskan boltsdan
and final reduction
reductioncase.
case. FINAL
REDUCTION CASE

BOLTS

Lepaskan
Remove thedowel
dowelpins
pins dan gasket.
and gasket.
DOWEL PINS

GASKET

9-6
FINAL REDUCTION
Remove the
Lepaskan following:
sebagai berikut:
- –Counter
Countergear
gear COUNTER GEAR
- –Final
Final gearshaft
gear shaft
- –Countershaft
Countershaft

COUNTERSHAFT

FINAL GEAR SHAFT

FINAL REDUCTION CASE ASSEMBLY


FINAL REDUCTION CASE ASSEMBLY
Apply engineolioilmesin
Semprotkan to each gearmasing-masing
pada tooth and each bearing sliding
gigi gear
areamasing-masing
dan of shaft. daerah luncur bearing dari shaft.
COUNTERSHAFT
Install the final gear shaft.
Pasang final gear shaft.
Install the countershaft into the counter gear while aligning
the countershaft
Pasang splines
countershaft ke with
dalamthecounter
counter gear
gear sementara
splines and
mentepatkan
install them tocountershaft splines
the final reduction case.dengan counter gear
splines dan pasang mereka pada final reduction case.

SPLINES

FINAL GEAR COUNTER


SHAFT GEAR

9-7
FINAL REDUCTION
Install the
Pasang dowel
dowel pinsdan
pins andgasket
a new gasket.
baru.
DOWEL PINS

GASKET

Pasang final
Install the reduction
final reductioncase
case dan kencangkan
and tighten bolts.
the bolts. FINAL
REDUCTION CASE

BOLTS

Sambungkan breatherhose
Connect the breather hoseto pada finalreduction
the final reductioncase
casehose
BREATHER HOSE
hose
joint.joint.
Install the following:
Pasang sebagai berikut:
– Rear brake shoes (page 13-5)
- –Rear
Rearbrake
wheelshoes
(page (sepatu
12-4) rem belakang) (hal. 13-5)
- –Roda belakangpulley
Clutch/driven (hal. 12-4)
(page 8-17)
- Clutch/driven pulley (hal. 8-16)
Fill the final reduction case with the recommended oil (page
Isi final reduction case dengan oli yang dianjurkan (hal.
3-13).
3-13).

PEMERIKSAAN FINAL REDUCTION


BEARING
FINAL REDUCTION INSPECTION
LEFT CRANKCASE
BEARING
Periksa masing-masing bearing terhadap keausan atau
LEFT CRANKCASE
kerusakan.
Putar
Checkinner race dari
each bearing countershaft
for wear or damage.dan final gear shaft
bearings (lingkaran dalam dari bantalan countershaft FINAL GEAR DRIVESHAFT
Turnfinal
the inner SHAFT BEARING BEARING
dan gearrace of the
shaft) countershaft
dengan and Bearing
jari-jari. final gearharus
shaft
bearings with your finger. The bearing should
berputar dengan halus dan tanpa suara. Juga periksa turn smoothly
and quietly.
bahwa Also check
bearing outer that
racetheduduk
bearing dengan
outer raceerat
fits tightly
pada
in the crankcase.
crankcase.
Replace the bearings if they do not turn smoothly, quietly, or
Ganti bearings jika mereka tidak berputar dengan halus,
if they fit loosely on the crankcase.
tanpa suara, atau jika mereka duduk dengan longgar
Turn crankcase.
pada the driveshaft with your hand. The bearing should turn
smoothly and quietly. Also check that the bearing outer race
fits tightly
Putar in thedengan
driveshaft crankcase and the
tangan. bearingharus
Bearing inner berputar
race fits
tightly onhalus
dengan the driveshaft.
dan tanpa suara. Juga periksa bahwa
Replace the
bearing outerbearings
raceif they
dudukdo not turn smoothly,
dengan erat di quietly,
dalamor
if they fit loosely
crankcase dan on the crankcase
bearing and driveshaft.
inner race duduk dengan erat COUNTERSHAFT BEARING
pada driveshaft.
Ganti bearings jika mereka tidak berputar dengan halus,
tanpa suara, atau jika mereka duduk dengan longgar
pada crankcase dan driveshaft.

9-8
FINAL REDUCTION
FINAL
FINALREDUCTION
REDUCTIONCASE
CASE
Check the
Periksa finalreduction
final reduction case
case bearings
bearingsanddan
finalfinal
gear gear
shaft
COUNTERSHAFT BEARING FINAL GEAR
oil seal
shaft oil for
sealwear or damage.
terhadap keausan atau kerusakan.
SHAFT
Turn each bearing inner race with your finger. BEARING
Putar masing-masing
The bearing should turnbearing inner
smoothly racefriction.
without dengan jari-jari.
Bearing harus berputar dengan halus tanpa
Check that there is no clearance between the outer gesekan.
race and
Periksa
the final bahwa case. ada kerenggangan antara outer
reductiontidak
race dan final reduction case.

FINAL GEAR
SHAFT OIL SEAL

LEFT
LEFTCRANKCASE
CRANKCASECOVER COVER
Lepaskan leftleft
Remove the crankcase
crankcasecover
cover (hal.
(page8-5).
8-5).
DRIVESHAFT BEARING
Putar
Turn theinner race
inner racedari driveshaft
of the driveshaftbearing
bearingdengan jari-jari.
with your finger.
Bearing
The bearingharusshould
berputarturn dengan
smoothlyhalus dan tanpa
and quietly. Alsosuara.
check
Juga periksa
that the bearingbahwa bearing
outer race outerinrace
fits tightly duduk dengan
the crankcase cover.
Replace
erat padathe bearing ifcover.
crankcase it does not turn smoothly, quietly, or if
it fits bearing
Ganti loosely on theiacrankcase
jika cover. dengan halus, tanpa
tidak berputar
suara, atau jika ia duduk dengan longgar pada
crankcase cover.

GEAR/SHAFT
GEAR/SHAFT
DRIVESHAFT
DRIVESHAFT
Periksa
Check thedriveshaft terhadap
driveshaft for tekukan,
bend, wear keausan atau
or damage.
DRIVESHAFT
kerusakan.

9-9
FINAL REDUCTION
COUNTER GEAR/COUNTERSHAFT/FINALGEAR
COUNTER GEAR/COUNTERSHAFT/FINAL GEAR
SHAFT
SHAFT
Check the countershaft, counter gear and final gear shaft for
Periksa countershaft, counter gear dan final gear shaft FINAL GEAR SHAFT
wear or damage.
terhadap keausan atau kerusakan.

COUNTER GEAR COUNTERSHAFT

FINAL REDUCTION BEARING


PENGGANTIAN
REPLACEMENTFINAL REDUCTION
BEARING
DRIVESHAFT DRIVESHAFT
BEARING LEFT
DRIVESHAFT BEARING (6204) CRANKCASE
10 x 32
COUNTERSHAFT
BEARING (6201)

FINAL GEAR SHAFT


BEARING (6022 UU)

LEFT CRANKCASE
COVER

OIL SEAL
20 x 32 x 6

COUNTERSHAFT
BEARING (6301)

FINAL GEAR SHAFT


BEARING (6302) FINAL REDUCTION
OIL SEAL
CASE
29 x 44 x 7

9-10
FINAL REDUCTION
LEFTCRANKCASE
LEFT CRANKCASE COVER
COVER
Remove the
Lepaskan left
left crankcase cover
crankcase cover (page 8-5).
(hal. 8-5). SNAP RING
Lepaskan snap ring dari alur left crankcasecover
Remove the snap ring from the left crankcase groove.
cover.

Lepaskan driveshaftbearing/bushing
Remove the driveshaft bearing/bushing
using the dengan
special
menggunakan
tools. special tools.
TOOLS:
Bearing
TOOLS:remover head, 10 mm 07936-GE00200
Bearing removerhead,
Bearing remover shaft,1010
mmmm 07936-GE00100
07936-GE00200
Remover weight shaft, 10 mm
Bearing remover 07741-0010201
07936-GE00100
Remover weight 07741-0010201
- Jika bearing tertinggal pada left crankcase cover,
lepaskan denganremains
– If the bearing menggunakan
in the lefttools sebagai
crankcase berikut:
cover, remove
TOOLS:
it using the following tools:
Bearing remover head, 15 mm 07936-KC10200
TOOLS:remover shaft, 15 mm
Bearing 07936-KC10100
Bearing remover
Remover weight head, 15 mm 07936-KC10200
07741-0010201
Bearing remover shaft, 15 mm 07936-KC10100 DRIVESHAFT
Remover weight 07741-0010201 BEARING/BUSHING

Jika bearing tertinggal di


dalam left crankcase cover:

DRIVESHAFT BEARING

Apply engineoli
Semprotkan oilmesin
to the bearing cavity.bearing.
pada rongga
DRIVER
Drive a new
Dorong masukdriveshaft
sebuahbearing into the
driveshaft left crankcase
bearing cover
baru secara
squarely until
tegaklurus keit dalam
is fully seated, using the special
left crankcase cover tools.
sampai ia
telah duduk sepenuhnya, dengan menggunakan special
tools.
TOOLS:
Driver 07749-0010000 ATTACHMENT
TOOLS:
Attachment, 32 x 35 mm 07746-0010100
Driver
Pilot, 10 mm 07749-0010000
07746-0040100
Attachment, 32 x 35 mm 07746-0010100
Pilot, 10 mm 07746-0040100

DRIVESHAFT
BEARING PILOT

9-11
FINAL REDUCTION
Install
Pasang Install the
the snap ring Pasang snapring
snap ringpada
to thealur
left left
crankcase covercover.
crankcase groove.
dengan
with theujung yang
chamfered
SNAP RING
dipotong
edgemenghadap
facing the
ke bearing.
bearing.

LEFT
LEFTCRANKCASE
CRANKCASE
Separate
Belah thereduction
final final reduction
case case
(hal.(page
9-6). 9-6).
SET PLATE
Remove the
Lepaskan two bolts
kedua boltsand
dansetset
plate.
plate.

BOLTS

Hati-hati tidakto Lepaskan


agar not
Be careful Remove thecountershaft danfinal
countershaft and finalgear
gear
shaftshaft bearings
bearings using
merusak permukaan
damage the final dengan menggunakan
the special tools. special tools.
penyatuan
reduction final
case mating
reduction case. TOOLS:
surface. TOOLS:
Countershaft bearing:
Countershaft bearing:
Bearing remover
Bearing removerhead,
head,1212
mmmm 07936-1660110
07936-1660110
Bearing removershaft,
Bearing remover shaft,
1212
mmmm 07936-1660120
07936-1660120
Remover weight
Remover weight 07741-0010201
07741-0010201
Final
Finalgear
gear shaft bearing:
shaft bearing:
Bearing removerhead,
Bearing remover head,1515
mmmm 07936-KC10200
07936-KC10200
Bearing remover shaft, 15
Bearing remover shaft, 15 mmmm 07936-KC10100
07936-KC10100
Remover weight
Remover weight 07741-0010201
07741-0010201
FINAL GEAR COUNTERSHAFT
SHAFT BEARING BEARING

9-12
FINAL REDUCTION
Apply engine
Oleskan oil topada
oli mesin each bearing cavity. rongga bearing.
masing-masing
Drive each new bearing into
Dorong masuk masing-masing bearingthe left crankcase baru
squarely until
secara
Sisi yang bertandaside
The marked dariof it is fully seated, using the special tools.
masing-masing tegaklurus ke dalam left crankcase sampai ia duduk COUNTERSHAFT
each bearing bearing
is facing
menghadap ke special sepenuhnya,
TOOLS: dengan menggunakan special tools. BEARING
the special tools.
tools. Countershaft bearing:
TOOLS:
Driver 07749-0010000
Countershaft
Attachment,bearing:
37 x 40 mm 07746-0010200
Driver 07749-0010000
Pilot, 12 mm 07746-0040200
Attachment, 37 x 40 mm 07746-0010200
Final gear shaft bearing:
Pilot, 12 mm 07746-0040200
FinalDriver
gear shaft bearing: 07749-0010000
Attachment, 42 x 47 mm
Driver 07746-0010300
07749-0010000
Pilot, 15 mm 42 x 47 mm
Attachment, 07746-0040300
07746-0010300 FINAL GEAR
Pilot, 15 mm 07746-0040300 SHAFT BEARING

DRIVER

ATTACHMENT

BEARING PILOT

Bersihkan dan oleskan


Clean and apply cairanto pengunci
locking agent pada
the set plate bolt ulir set
threads
SET PLATE
from bolt
plate its tipdari
to 6.5 ± 1.0 mm
ujungnya (0.26 ±6,5
sampai ± 1,0
0.04 in) down.
mm ke bawah.
Install the set plate with its "OUT" mark facing out. TANDA"OUT"
Pasang set plate dengan tanda "OUT" padanya
Install and tighten
menghadap the set plate bolts.
ke luar.

Pasang dan kencangkan set plate bolts.

6.5 ± 0.1 mm
(0.26 ± 0.04 in)

BOLTS

DRIVESHAFT
DRIVESHAFT
Remove the two bolts and set plate.
SET PLATE
Lepaskan kedua bolts dan set plate.

BOLTS

9-13
FINAL REDUCTION
Remove the
Lepaskan driveshaftdengan
driveshaft using the special tool. special tool.
menggunakan
DRIVESHAFT
TOOL:
TOOL:
Case puller 07SMC-0010001
Case puller 07SMC-0010001

CASE PULLER

CASE PULLER

DRIVESHAFT

Remove the
Lepaskan snapring
snap ringdari
from thedriveshaft.
alur driveshaft groove.
SNAP RING

Remove thedriveshaft
Lepaskan driveshaft bearing
bearingusing a hydraulic
dengan