Anda di halaman 1dari 437

HOW TO USE

MEMAKAI BUKUTHIS
INI MANUAL DAFTAR ISI
You will find important safety information in a variety of forms including:
• Safety Labels – on the vehicle
This service
Buku manual describes
Pedoman Reparasitheini
service procedures for
menguraikan the ANF110.
prosedur servis
untuk sepedamotor New Revo.
KETERANGAN UMUM 1
Follow the Maintenance Schedule (Section 3) recommendations to
ensure that the vehicle is in peak operating condition. RANGKA/BODY PANELS/SISTEM PEMBUANGAN
Ikuti petunjuk pada Jadwal Perawatan (Bab 3) untuk GAS 2
Performing the first scheduled maintenance is very important. It
mempertahankan sepedamotor
compensates for the initial pada
wear that occurs duringkondisi operasional
the break-in period.
puncak. PERAWATAN 3
Sections 1 and 3 apply to the whole motorcycle. Section 2 illustrates
procedures for removal/installation of components that may be
Adalah
required to sangat penting
perform service untuk
described in themenjalankan perawatan
following sections. SISTEM PELUMASAN 4
berkala
Section 4 1through
dan 218pada waktunya.
describe Servis
parts of the ini mengadakan
motorcycle, grouped
according to location.
penyesuaian terhadap keausan awal yang terjadi dalam
masa
SISTEM BAHAN BAKAR 5
Find thepemakaian
section you mula.
want on this page, then turn to the table of
contents on the first page of the section.
Bab 1 dan 3 berlaku untuk seluruh sepedamotor.
PENURUNAN/PEMASANGAN MESIN 6
Most sections start with an assembly or system illustration, service
Bab
information 2and troubleshooting
menggambarkan prosedur
for the section. The subsequent untuk
CYLINDER HEAD/VALVES 7

MESIN
pelepasan/pemasangan
pages give detailed procedure. komponen-komponen yang
mungkin diperlukan untuk menjalankan pekerjaan servis
If you don't know the source of the trouble, go to section 20
yang diuraikan dalam bab-bab berikutnya.
Troubleshooting.
CYLINDER/PISTON 8
Bab 4 melalui 18 menguraikan bagian-bagian dari
sepedamotor, yang dikelompokkan menurut lokasi. CLUTCH/GEARSHIFT LINKAGE 9
Carilah bab yang Anda inginkan pada halaman ini,
kemudian bacalah daftar isi pada halaman pertama dari
ALTERNATOR/STARTER CLUTCH 10
bab yang bersangkutan.
CRANKSHAFT/TRANSMISSION/KICKSTARTER 11
Kebanyakan bab dimulai dengan gambar susunan atau
gambar sistem, keterangan servis dan troubleshooting RODA DEPAN/SUSPENSI/KEMUDI 12
RANGKA

untuk bab itu. Halaman-halaman berikutnya memberikan


prosedur servis secara mendetil. RODA BELAKANG/REM/SUSPENSI 13
Jika Anda tidak mengetahui sumber penyebab kesukaran, REM HIDRAULIK 14
bacalah bab 20, TROUBLESHOOTING.
BATERAI/SISTEM PENGISIAN 15
KELISTRIKAN

Semua keterangan, gambar, petunjuk dan SISTEM PENGAPIAN


spesifikasi di dalam publikasi ini berdasarkan data-
16
data produk terakhir yang tersedia pada waktu
persiapan untuk pencetakan. SISTEM STARTER LISTRIK 17
PT Astra Honda Motor berhak membuat perubahan LAMPU/INSTRUMENT/SAKLAR 18
pada setiap waktu tanpa pemberitahuan dan tanpa
ikatan apapun. DIAGRAM LISTRIK 19
Your safety, and the safety of others, is very important. To help
you makemengutip
Dilarang informed decisions we haveulang
atau mencetak provided safety
bagian dari TROUBLESHOOTING 20
penerbitan ini tanpa ijin tertulis penerbit.

Buku Pedoman ini ditulis untuk orang yang telah


memiliki pengetahuan dasar perawatan
sepedamotor Honda.

DAFTAR ISI PT ASTRA HONDA MOTOR

messages and other information throughout this manual. Of


course, it is not practical or possible to warn you about all the
hazards associated with servicing this vehicle.
You must use your own good judgement.
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 kunci perkakas, 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 kunci perka-
kas yang dipilih.
1. KETERANGAN UMUM

PERATURAN SERVIS ............................. 1-2


SERVICE RULES·············································· 1-2 SPESIFIKASI RODA BELAKANG/
REAR WHEEL/BRAKE/SUSPENSION
REM/SUSPENSI....................................... 1-8
SPECIFICATIONS············································1-8
IDENTIFIKASI MODEL ............................ 1-2
MODEL IDENTIFICATION ··························· 1-2
SPESIFIKASI
HYDRAULIC REM HIDRAULIK..............
BRAKE SPECIFICATIONS···1-8 1-8
SPESIFIKASI UMUM ............................... 1-4
GENERAL SPECIFICATIONS······················· 1-4
SPESIFIKASI BATERAI/SYSTEM
BATTERY/CHARGING
SPESIFIKASI SISTEM PELUMASAN ..... 1-5 SISTEM PENGISIAN................................ 1-8
SPECIFICATIONS············································1-8
LUBRICATION SYSTEM
SPECIFICATIONS············································ 1-5
SPESIFIKASI SISTEM BAHAN BAKAR . 1-5 SPESIFIKASI SISTEM
IGNITION SYSTEM PENGAPIAN....... 1-8
SPECIFICATIONS······1-8
FUEL SYSTEM SPECIFICATIONS··············· 1-5
SPESIFIKASI CYLINDER HEAD/ SPESIFIKASI SISTEMSYSTEM
ELECTRIC STARTER
VALVES ................................................... 1-5
CYLINDER HEAD/VALVES
STARTER LISTRIK.................................. 1-9
SPECIFICATIONS············································1-9
SPECIFICATIONS············································ 1-5
SPESIFIKASI CYLINDER/PISTON.......... 1-6 SPESIFIKASI LAMPU LAMPU/
LIGHTS/METERS/SWITCHES
CYLINDER/PISTON SPECIFICATIONS ····· 1-6 INSTRUMEN/SAKLAR ............................ 1-9
SPECIFICATIONS············································1-9
SPESIFIKASI CLUTCH/GEARSHIFT
LINKAGE .................................................
CLUTCH/GEARSHIFT LINKAGE 1-6 TORSI PENGENCANGAN
STANDARD STANDARD..
TORQUE VALUES 1-10
··················1-10
SPECIFICATIONS············································ 1-6
SPESIFIKASI ALTERNATOR/ TORSI PENGENCANGAN
ENGINE & FRAME TORQUE VALUES ····1-10
STARTER CLUTCH .................................
ALTERNATOR/STARTER CLUTCH 1-6 MESIN & RANGKA .................................. 1-10
SPECIFICATIONS············································ 1-7 LUBRICATION & SEAL POINTS ···············1-14
SPESIFIKASI CRANKSHAFT/ TITIK-TITIK PELUMASAN &
TRANSMISSION/KICKSTARTER............
CRANKSHAFT/TRANSMISSION/KICK- 1-7 PERAPATAN ...........................................
CABLE & HARNESS ROUTING··················1-16 1-14
STARTER SPECIFICATIONS························ 1-7
SPESIFIKASI RODA DEPAN/ PERLETAKAN KABELSYSTEMS···············1-24
EMISSION CONTROL & HARNESS...... 1-16
SUSPENSI/KEMUDI ................................ 1-7
FRONT WHEEL/SUSPENSION/
STEERING SPECIFICATIONS ······················ 1-7 SISTEM-SISTEM PENGATURAN EMISI. 1-24

1-1
KETERANGAN UMUM
PERATURAN SERVIS
SERVICE RULES
GENERAL INFORMATION

1.
1. Pakailah parts
Use genuine dan pelumas
Honda asli Honda atau
or Honda-recommended partsyang
and direkomendasikan oleh Honda
lubricants or their equivalents. atau
Parts thatsejenisnya.
do not meet Parts yang
Honda's tidak
design memenuhi
specifications
spesifikasi rancangan Honda
may cause damage to the motorcycle. dapat mengakibatkan kerusakan pada sepedamotor.
2.
2. Pakailah specialtools
Use the special tools yang telah
designed dirancang
for this untuk
product to avoidproduk
damageiniand
untuk menghindari
incorrect assembly.kerusakan dan pemasangan yang tidak benar.
3.
3. Hanya
Use onlypergunakan
metric toolsmetric tools ketika
when servicing menservis sepedamotor.
the motorcycle. Baut,
Metric bolts, nuts mur dan
and screws aresekrup metric tidakwith
not interchangeable dapat dipertukarkan
English fasteners. dengan
4. pengikat sistem
Install new Inggris.
gaskets, O-rings, cotter pins, and lock plates when reassembling.
4.
5. Pasanglah gasket,
When tightening O-ring,
bolts cotter
or nuts, beginpin, dan
with thelock plates
larger baruorpada
diameter inner waktu perakitan
bolt first. kembali.
Then tighten to the specified torque diagonally in incremental
5. Sewaktu mengencangkan
steps unless baut atau
a particular sequence mur, mulailah dengan baut dengan diameter yang lebih besar atau baut di sebelah dalam
is specified.
6. dulu.
CleanKemudian kencangkan
parts in cleaning solvent upondengan torsi pengencangan
disassembly. yangsurfaces
Lubricate any sliding telah ditentukan secara bersilang dalam langkah-langkah
before reassembly.
7. peningkatan kecuali
After reassembly, apabila
check urutan
all parts tertentu
for proper lain telahand
installation ditentukan.
operation.
6.
8. Bersihkan parts yang
Route all electrical wirestelah dilepaskan
as shown dalam
in the Cable and larutan pembersih.
Harness Routing (pageLumasi
1-16). semua permukaan peluncuran sebelum perakitan
kembali.
7. Setelah perakitan kembali, periksalah semua parts terhadap pemasangan dan pengoperasian yang benar.
IDENTIFIKASI MODEL
8. Alurkan semua kawat listrik seperti diperlihatkan dalam Perletakan Kabel dan Harness (hal. 1-15).

IDENTIFIKASI MODEL

1-2
KETERANGAN UMUM
NOMOR-NOMOR SERI
SERIAL NUMBERS
Nomor seri
The frame rangka
serial dicetak
number pada sisi
is stamped kirileft
on the dari kepala
side of thekemudi.
steering head.
NOMOR SERI RANGKA

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

NOMOR SERI MESIN

Nomor identifikasi
The carburetor karburator
identification dicetak
number pada sisi
is stamped onkanan dari
the right badan
side of thekarburator.
carburetor
body. NOMOR IDENTIFIKASI KARBURATOR

1-3
KETERANGAN UMUM
SPESIFIKASI UMUM
GENERAL SPECIFICATIONS
BAGIAN
ITEM SPESIFIKASI
SPECIFICATIONS
DIMENSI
DIMENSIONS Overall lengthmenyeluruh
Panjang 1.9251,925
mm mm (75.8 in)
Lebar
Overall menyeluruh
width 709 mm709 mm (27.9 in)
Tinggi
Overall menyeluruh
height 1.0841,084
mm mm (42.7 in)
Jarak
Wheelbase sumbu roda 1.2211,221
mm mm (48.1 in)
Tinggi
Seat heighttempat duduk 770 mm770 mm (30.3 in)
Tinggi pijakan kaki 268 mm
Footpeg height 268 mm (10.6 in)
Jarak terendah ke tanah 147 mm
Ground clearance 147 mm (5.8 in)
Berat motor siap pakai 97 kg (Tipe roda dengan jari-jari)
Curb weight 98 kg97(Tipe
kg (214rodalbs) (Spoke wheel type)
tuangan)
RANGKA Jenis rangka Jenis back bone (tulang wheel
98 kg (216 lbs) (Cast type)
belakang)
FRAME Frame type depan
Suspensi Garpu Back bone type
teleskopik
Front suspension
Jarak pergerakan poros depan 81 mm Telescopic fork
Front axle travel
Suspensi belakang Swing 81armmm (lengan
(3.2 in) ayun)
RearJarak pergerakan poros belakang
suspension 83 mm Swingarm
RearDamper (peredam kejut) belakang
axle travel Jenis83pipammpengoperasian
(3.3 in) satu sisi
RearUkuran
damperban depan 70/90-17
One sideM/Coperation
38P tube type
Ukuran
Front ban belakang
tire size 80/90-17
70/90-17M/CM/C 44P38P
RearMerek ban
tire size Depan NF63B (IRC)/D-FR
80/90-17 M/C 44P (SRI)
Tire brand Belakang
Front NR78Y NF63B (IRC)/FT(SRI)
(IRC)/D-RR 138 (SRI)
Rem depan Rear RemNR78Y
cakram(IRC)/FT
hidraulik138 (SRI)
Rem
Front belakang
brake Mekanis,
Hydraulicmendahului-mengikuti
disc brake
Rear brakecaster
Sudut 26°00'Mechanical leading trailing
Panjang trail 67 mm
Caster angle 26°00’
Kapasitas tangki bahan bakar 3,7 liter
Trail length 67 mm (2.6 in)
MESIN FuelDiameter dan langkah
tank capacity 50,0 3.7
x 55,6
liter mm
(0.98 US gal, 0.81 lmp gal)
ENGINE Volume
Bore and stroke langkah cmx3 55.6 mm (1.97 x 2.19 in)
109,150.0
Perbandingan kompressi 9,0 : 1
Displacement 109.1 cm3 (6.66 cu-in)
Peralatan penggerak klep 2 valve, SOHC digerakkan rantai tunggal
Compression ratio 9.0 : 1
Klep masuk membuka ] 5° BTDC (sebelum TMA)
Valve train menutup ] pada pengang- 2 valve, single chain driven SOHC
30° ABDC (setelah TMB)
Intake
Klep valve
buang opens ] katanat1 1mm
membuka mm (0.04 in) lift 5° BTDC
34° BBDC (sebelum TMB)
closes ]
menutup at 1 mm (0.04 in) lift 30° ABDC
0° ATDC (setelah TMA)
Exhaust
Sistem valve
pelumasanopens at 1 mm (0.04 in) lift 34° BBDC
Di bawah tekanan paksaan dgn bak oli basah
Jenis pompa oli closes at 1 mm (0.04 in) lift 0°
Trochoid ATDC
Sistem pendinginan
Lubrication system Pendinginanpressure
Forced udara and wet sump
Oil Saringan
pump typeudara ElemenTrochoid
kertas kental
Jenissystem
Cooling crankshaft JenisAir cooled
rakitan
AirBerat kosong mesin
filtration 22,6 Viscous
kg paper element
Susunan
Crankshaft cylinder
type SatuAssembled
cylinder miring type 80° dari vertikal
KARBURATOR Engine
Jenis drykarburator
weight Piston22.6 kg (49.8
valve type lbs)
Cylinder
Diameterarrangement
throttle 18 mm Single cylinder inclined 80° from vertical
CARBURETOR
PERALATAN Carburetor
Sistem Typekopeling Piston valve
Pelat-banyak, type
basah
PENGGERAK Throttle
Sistem borepengoperasian kopeling Jenis18sentrifugal
mm (0.7 in) otomatis
DRIVE TRAIN Transmission
Clutch system Bertautan tetap,wet
Multi-plate, 4-kecepatan
Primary
Clutch reduction
operation system 4,059Automatic
(69/17) centrifugal type
Final reduction
Transmission 2,642Constant
(37/14)mesh, 4-speed
Perbandingan
Primary reduction gigi gigi 1 2,6154.059
(34/13)
(69/17)
Final reduction gigi 2 1,5552.642
(28/18)
(37/14)
Gear ratio gigi 3 1st 1,1362.615
(25/22)
(34/13)
gigi 4 2nd 0,9161.555
(22/24)
(28/18)
Pola pengoperan gigi 3rd Sistem1.136pengembalian
(25/22) digerakkan kaki kiri (sistem
4th rotary; hanya
0.916 (22/24) sewaktu sepedamo-tor tidak
bergerak) N – 1 – 2 – 3 – 4 (- N)
Gearshift pattern Left foot operated return system
KELISTRIKAN Sistem pengapian DC-CDI(rotary system; only when the motorcycle is not
Sistem starter Kickstarter
running)dengan starter motor listrik
Sistem pengisian Single- Nphase
- 1 - 2output
- 3 - 4 (-alternator
N)
ELECTRICAL Regulator/rectifier
Ignition system SCRDC-CDI
opened/single phase, half wave rectification
Sistem
Starting penerangan
system Alternator
Kickstarter with electric starter motor
Charging system Single phase output alternator
Regulator/rectifier SCR opened/single phase, half wave rectification
Lighting system Alternator

1-4
KETERANGAN UMUM
SPESIFIKASI
LUBRICATION SISTEM PELUMASAN
SYSTEM SPECIFICATIONS
Satuan: mm(in)
Unit: mm
BAGIAN STANDARD BATAS SERVIS
SERVICE
Kapasitas oli mesin ITEM
Pada penggantian oli 0,8 liter STANDARD -
LIMIT
Engine oil capacity Pada pembongkaran mesin
At draining 1,00.8
liter
liter (0.8 US qt, 0.7 lmp qt) -–
Oli mesin yang dianjurkan At disassembly Oli1.0mesin 4 tak
liter (1.1 USdengan klasifikasi
qt, 0.9 lmp qt) API –
Recommended engine oil service SJ.
API classification: SE, SF or SG -
Viskositas:
(except oils SAE 10W-30
labeled JASO
as energy MA
conserving on
Oil pump rotor Jarak renggang pada ujung rotor -
the circular API service label) 0,15–
Jarak renggang antara rotor dan 0,15 – 0,21 SAE 10W-30
Viscosity: 0,26
rumah JASO T 903 standard: MA
Oil pump rotor Jarak renggang ke
Tipsamping
clearancerotor 0,03 – 0,09 – 0,15
0.15 (0.006)
pompa Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.26 (0.010)
Side clearance 0.03 – 0.09 (0.001 – 0.004) 0.15 (0.006)

SPESIFIKASI SISTEM BAHAN BAKAR


FUEL SYSTEM SPECIFICATIONS
BAGIAN SPESIFIKASI
Nomor identifikasi karburator PB7UB
ITEM SPECIFICATIONS -1
Putaran stasioner
Carburetor mesinnumber
identification 1.400 ± 100 menit (rpm)
PB7UB
Jarak
Enginemain
idlebebas
speed throttle grip (gas tangan) 1,4002±–100
6 mm
min-1 (rpm)
Main jet grip freeplay
Throttle 2 – 6 mm# 88
(0.1 – 0.2 in)
Mainjet
Slow jet #88
# 35
Slow jet #35
Float level (tinggi pelampung) 11,7 mm
Float level 11.7 mm (0.46 in)
Pembukaan awal air screw Lihat hal. 5-16
Air screw initial opening See page 5-16
Vakuum PAIRvalve
PAIR control control valve vacuum
specified yang ditentukan 6060kPa
kPa(450
(450mmHg)
mmHg)

SPESIFIKASI CYLINDER HEAD/VALVES


CYLINDER HEAD/VALVES SPECIFICATIONS
Satuan: mm
Unit: mm (in)
BAGIAN STANDARD BATAS SERVIS
SERVICE
Tekanan kompressi cylinderITEM 1.245 kPa (12,7 STANDARD
2
kgf/cm , 181 psi) -
LIMIT
-1
Cylinder compression pada 600 menit (rpm) 2, 181 psi)
1,245 kPa (12.7 kgf/cm
Perubahan bentuk melengkung pada cylinder head at 600 min-1 (rpm) - 0,05–
Valve,
Cylinder head warpageValve clearance IN/EX – 0.05 (0.002)
valve
Valve,guide (jarak renggang
Valve clearance klep) (masuk/
IN/EX 0.10± ±0,02
0,10 0.02 (0.004 ± 0.001) -–
valve guide Valve stem O.D. buang)
IN 4.975 – 4.990 (0.1959 – 0.1965) 4.965 (0.1955)
D.L. valve stem IN 4,975 – 4,990 4,965
EX 4.955 – 4.970 (0.1951 – 0.1957) 4.945 (0.1947)
EX 4,955 – 4,970 4,945
Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.03 (0.198)
D.D. valve guide IN/EX 5,000 – 5,012 5,03
Stem-to-guide clearance IN 0.010 – 0.037 (0.0004 – 0.0015) 0.065 (0.0026)
Jarak renggang stem- IN 0,010 – 0,037 0,065
EX 0.030 – 0.057 (0.0012 – 0.0022) 0.085 (0.0033)
ke-guide EX 0,030 – 0,057 0,085
Valve guide projection IN/EX 9.1 – 9.3 (0.36 – 0.37) –
Proyeksi valve guide di IN/EX 9,1 – 9,3 -
Valve seat width IN/EX 0.90 – 1.10 (0.035 – 0.043) 1.6 (0.06)
atas cylinder head
Valve spring free length IN/EX 30.67 (1.207) 29.70 (1.169)
Lebar valve seat IN/EX 0,90 – 1,10 1,6
Rocker arm/ Rocker
Panjang bebas valve spring arm I.D. IN/EX
IN/EX 10.000 – 10.015 (0.3937 – 0.3943)
30,67 10.10
29,70 (0.398)
shaft Rocker arm shaft
Rocker arm/ D.D. rocker armO.D. IN/EX
IN/EX 9.972 –
10,000 – 9.987
10,015(0.3926 – 0.3932) 9.91
10,10(0.390)
shaft Rocker arm-to-shaft
D.L. rocker arm shaft clear- IN/EX 9,972
IN/EX 0.013– –9,987
0.043 (0.0005 – 0.0017) 9,91
0.044 (0.0017)
ance
Jarak renggang rocker IN/EX 0,013 – 0,043 0,044
Camshaft Cam lobe height
arm-ke-shaft IN 32.194 – 32.434 (1.2675 – 1.2769) 32.16 (1.266)
Camshaft Tinggi cam lobe INEX 31.990––32,434
32,194 32.230 (1.2594 – 1.2689) 31.96
32,16 (1.258)
Cam chain ten- Push rod O.D.
(cuping bubungan) EX 31,990 – 32,230 (0.4718 – 0.4724)
11.985 – 12.000 11.94
31,96 (0.470)
sioner Spring free rod
length 111.3 (4.38) 109 (4.3)
Cam chain D.L. push 11,985 – 12,000 11,94
tensioner Panjang bebas spring 111,3 109

1-5
KETERANGAN UMUM
CYLINDER/PISTON SPECIFICATIONS
SPESIFIKASI CYLINDER/PISTON
Satuan:
Unit: mmmm
(in)
BAGIAN STANDARD BATAS SERVIS
SERVICE
Cylinder D.D. ITEM STANDARD
50,005 – 50,015 50,05
LIMIT
Cylinder Kelonjongan
I.D. -
50.005 – 50.015 (1.9687 – 1.9691) 0,10
50.05 (1.970)
Ketirusan
Out-of-round – - 0,10
0.10 (0.004)
Perubahan
Taper bentuk melengkung – - 0,05
0.10 (0.004)
Piston, Arah tanda piston
Warpage Tanda "IN" – menghadap ke 0.05-(0.002)
piston
Piston,pin,
piston Piston mark direction sisi pemasukan
"IN" mark facing toward the intake side –
piston
rings rings D.L. piston
Piston O.D. 49,980
49.980 – 49.995 – 49,995
(1.9677 – 1.9683) 49,91
49.91 (1.965)
Titik pengukuran
Piston D.L. piston
O.D. measurement point 10 mm (0.4 in)10from
mm bottom
dari bagian bawah
of skirt -–
Piston pin bore I.D. piston
13.002 – 13.008 (0.5119 – 0.5121) 13.03 (0.513)
D.D. lubang
Piston piston pin
pin O.D. 13,002
12.994 – 13.000 – 13,008
(0.5116 – 0.5118) 13,03
12.98 (0.511)
D.L. piston pin pin clearance
Piston-to-piston 0.002 – 0.01412,994
(0.0001– –13,000
0.0006) 12,98
0.075 (0.0030)
Jarak
Pistonrenggang antara piston-ke-piston
ring-to-ring Top pin 0.015 – 0.0500,002 – 0,014
(0.0006 – 0.0020) 0,075
0.09 (0.004)
Jarak
grooverenggang
clearancepiston ring- Ring paling atas 0,015 – 0,050 0,09
ke-alurnya Second 0.015 – 0.050 (0.0006 – 0.0020) 0.09 (0.004)
(Riken) Ring kedua 0,015 – 0,050 0,09
(Riken)
Piston ring-to-ring Top 0.015 – 0.045 (0.0006 – 0.0018) 0.09 (0.004)
Jarak
grooverenggang
clearance Ring paling atas 0,015 – 0,045 0,09
Second 0.015 – 0.045 (0.0006 – 0.0018) 0.09 (0.004)
piston ring-ke-alurnya
(Teikoku) Ring kedua 0,015 – 0,045 0,09
(Teikoku)
Piston ring end gap Top 0.10 – 0.25 (0.004 – 0.010) 0.5 (0.02)
Celah
(Riken)pada ujung SecondRing paling atas 0,10 –– 0,25
0.10 – 0.25 (0.004 0.010) 0.50,5
(0.02)
piston ring (Riken) Ring
Oil (side rail)kedua 0.20 – 0.70 (0.008
0,10 –– 0,25
0.028) 0,5
1.1 (0.04)
Piston ring end gap Top Ring oli (side0.10rail)– 0.25 (0.004
0,20 –– 0,70
0.010) 0.51,1
(0.02)
Celah pada ujung
(Teikoku) SecondRing paling atas 0,10 –– 0,25
0.10 – 0.25 (0.004 0.010) 0.50,5
(0.02)
piston ring (Teikoku) Ring
Oil (side rail)kedua 0.20 – 0.70 (0.008
0,10 –– 0,25
0.028) 0,5
1.1 (0.04)
Cylinder-to-piston clearance Ring oli (side0.010
rail) – 0.0350,20 – 0,70
(0.0004 – 0.0014) 0.101,1
(0.004)
Jarak renggang
Connecting antara
rod small endcylinder-ke-piston
I.D. 0,010
13.016 – 13.034 – 0,035
(0.5124 – 0.5131) 0,10
13.05 (0.514)
D.D. kepala rod-to-piston
Connecting kecil connecting rod
pin clearance 0.016 – 0.04013,016
(0.0006– –13,034
0.0016) 13,05
0.07 (0.003)
Jarak renggang antara connecting rod-ke-piston pin 0,016 – 0,040 0,07

CLUTCH/GEARSHIFT LINKAGE SPECIFICATIONS


SPESIFIKASI CLUTCH/GEARSHIFT LINKAGE Unit: mm (in)
Satuan: mm
SERVICE
ITEM
BAGIAN STANDARD
STANDARD BATAS SERVIS
LIMIT
Manual
Manual clutch
clutch Tebal disc
Disc thickness Four bolts 2,00 –– 2,20
2.00 – 2.20 (0.079 0.087) 1,82
1.82 (0.072)
type
Perubahan bentuk melengkung plate - 0,20
Six bolts 2.30 – 2.50 (0.091 – 0.098) 2.08 (0.082)
Tinggi bebas clutch springtype 5,01 4,63
Clutch outer
Plate guide
warpage D.D. 16,991 ––17,009 17,049
0.20 (0.008)
Clutch spring free Four bolts 5.01 (0.197) 22,959 – 22,980
D.L. 22,940
4.63 (0.182)
D.D.height
primary driven gear type 23,000 – 23,021 23,07
D.L. mainshaft pada clutchSix outer
boltsguide 4.89 (0.193) 16,966 – 16,984 16,87
4.52 (0.172)
Centrifugal clutch D.D. clutch drum type 104,0 – 104,2 104,3
Tebal clutch
Clutch weight lining I.D.
outer 1,5 (0.6689 – 0.6696)
16.991 – 17.009 1,0(0.6712)
17.049
D.D.guide
one-way clutch drumO.D. 42,000
22.959 – 22.980 – 42,020
(0.9039 – 0.9047) 42,04
22.940 (0.9031)
D.L. Primary
one-waydriven
clutch roller
gear I.D. 4,990
23.000 – 23.021 – 5,000
(0.9055 – 0.9063) 4,97
23.07 (0.908)
D.D.Mainshaft
primary drive
O.D. gear
at clutch outer guide 19,030
16.966 – 16.984 – 19,058
(0.6680 – 0.6687) 19,11
16.87 (0.664)
Centrifugal clutch D.L. Clutch
crankshaft
drum pada
I.D. primary drive gear 104.0 – 104.218,967
(4.09 ––4.10)
18,980 18,92
104.3 (4.11)
Clutch weight lining thickness 1.5 (0.06) 1.0 (0.04)
One-way clutch drum I.D. 42.000 – 42.020 (1.6535 – 1.6543) 42.04 (1.655)
One-way clutch roller O.D. 4.990 – 5.000 (0.1965 – 0.1969) 4.97 (0.196)
Primary drive gear I.D. 19.030 – 19.058 (0.7492 – 0.7503) 19.11 (0.752)
Crankshaft O.D. at primary drive
18.967 – 18.980 (0.7467 – 0.7472) 18.92 (0.745)
gear

1-6
KETERANGAN UMUM
ALTERNATOR/STARTER
SPESIFIKASI CLUTCH SPECIFICATIONS
ALTERNATOR/STARTER CLUTCH
Satuan:
Unit: mmmm
(in)
BAGIAN STANDARD BATAS SERVIS
SERVICE
ITEM STANDARD
LIMIT
D.L. starter driven gear boss 45,660 – 45,673 45,2
Starter driven gear boss O.D. 45.660 – 45.673 (1.7976 – 1.7981) 45.2 (1.78)

CRANKSHAFT/TRANSMISSION/KICKSTARTER SPECIFICATIONS
SPESIFIKASI CRANKSHAFT/TRANSMISSION/ Unit: mm (in)
KICKSTARTERITEM STANDARD
SERVICE
Satuan: mm
LIMIT
Crankshaft Connecting rod BAGIAN
side clearance STANDARD
0.10 – 0.35 (0.004 – 0.014) BATAS SERVIS
0.60 (0.024)
Connecting rod radial clearance 0 – 0.008 (0 – 0.0003) 0.05 (0.002)
Crankshaft Jarak renggang ke samping connecting rod 0,10 – 0,35 0,60
Runout – 0.10 (0.004)
Transmission Jarak renggang radial connecting
Gear I.D. M2,rod
M3 0 –(0.6693
17.000 – 17.018 0,008 – 0.6700) 17.040,05
(0.671)
Keolengan C1 -
18.000 – 18.018 (0.7087 – 0.7094) 18.040,10
(0.710)
Transmission D.D. gear C4 M2, M3 – 20.021
20.000 17,000 – 17,018
(0.7874 – 0.7882) 17,04
20.04 (0.789)
Bushing O.D. C1 C1 18,000
17.966 – 17.984 – 18,018
(0.7073 – 0.7080) 18,04
17.94 (0.706)
Bushing I.D. C1 C4 20,000
15.000 – 15.018 – 20,021
(0.5906 – 0.5913) 20,04
15.04 (0.592)
D.L. bushing clearance
Gear-to-bushing C1 C1
0.016 – 0.05217,966
(0.0006––17,984
0.0020) 17,94
0.10 (0.004)
Mainshaft
D.D. bushingO.D. M3 16.966 – 16.984
C1 (0.6680
15,000 – 0.6687)
– 15,018 16.95 (0.667)
15,04
Countershaft O.D.
Jarak renggang gear-ke-bushing C1 14.966
C1 – 14.984 (0.5892
0,016 – 0,052– 0.5899) 14.950,10
(0.589)
Gear-to-shaft clearance M3 0.016 – 0.052 (0.0006 – 0.0020) 0.09 (0.004)
D.L. mainshaft M3 16,966 – 16,984 16,95
Bushing-to-shaft clearance C1 0.016 – 0.052 (0.0006 – 0.0020) 0.09 (0.004)
D.L. countershaft C1 14,966 – 14,984 14,95
Shift fork/ Shift fork I.D. 34.075 – 34.100 (1.3415 – 1.3425) 34.14 (1.344)
Shift drum Jarak renggang gear-ke-shaft M3 0,016 – 0,052 0,09
Shift fork claw thickness 4.85 – 4.95 (0.191 – 0.195) 4.60 (0.181)
Jarak renggang
Shift drum O.D. bushing-ke-shaft
Right C1 0,016 – 0,052
33.950 – 33.975 (1.3366 – 1.3376) 0,09
33.93 (1.336)
Shift fork/ D.D. shift fork Left 34,075
23.940 – 23.980 (0.9425– 34,100
– 0.9441) 34,14
23.92 (0.942)
Shift drum
Kickstarter Pinionshift
I.D. fork claw 20.000 – 20.021 (0.7874–
Tebal 4,85 – 4,95 0.7882) 20.08 (0.791)
4,60
Spindle
D.L. shiftO.D.
drum 19.959 – 19.980
Kanan (0.7858
33,950 – 0.7866)
– 33,975 19.94 (0.785)
33,93
Kiri 23,940 – 23,980 23,92
Kickstarter D.D. pinion 20,000 – 20,021 20,08
FRONT WHEEL/SUSPENSION/STEERING
D.L. spindle
SPECIFICATIONS
19,959 – 19,980 19,94
Unit: mm (in)
SERVICE
ITEM STANDARD
LIMIT
SPESIFIKASI
Minimum tire tread depthRODA DEPAN/SUSPENSI/KEMUDI
– To indicator
Cold tire pressure Driver only 200 kPa (2.00 kgf/cm2, 29 psi) Satuan:
– mm
BAGIAN
Driver and passenger STANDARD
200 kPa (2.00 kgf/cm 2
, 29 psi) BATAS–SERVIS
Kedalaman
Axle runoutminimum alur telapak ban – - Sampai
0.20 ke
(0.008)
Wheel rim runout Radial – indikator
2.0 (0.08)
2
Tekanan udara ban Pengendara saja
Axial 200 kPa (2.00 kgf/cm
– , 29 psi) -
2.0 (0.08)
2
(dingin)
Wheel hub-to-rim distance Pengendara dan pembonceng 200 kPa
See page 12-9 (2.00 kgf/cm , 29 psi) –-
Keolengan
Fork axle (poros roda)
Spring free length 306.8 (12.08) - 297.60,20
(11.72)
Keolengan wheel rim Radialdirection
Spring With the tightly wound coil- side facing down 2,0

(pelek roda) Aksial
Pipe runout – - 0.20 2,0
(0.008)
Fork Panjang bebas
Recommended spring
fork fluid Fork306,8
fluid 297,6

Arahlevel
Fluid spring
(full bottom) 78.5Kumparan
(3.09) dengan lilitan yang rapat –-
Fluid capacity ± 1 cm3
64.5menghadap ke bawah

Keolengan pipe (2.18 ± 0.03 US oz, 2.27 -± 0.04 lmp oz) 0,20
Fork fluid yang dianjurkan Fork fluid -
Tinggi permukaan fluid (pipa masuk 73,0 -
penuh ke bawah)
3
Kapasitas fluid 66,0 ± 1 cm -

1-7
KETERANGAN UMUM
REAR WHEEL/BRAKE/SUSPENSION
SPESIFIKASI SPECIFICATIONS
RODA BELAKANG/REM/SUSPENSI
Satuan:
Unit: mmmm
(in)
BAGIAN STANDARD BATAS SERVIS
SERVICE
ITEM STANDARD
Kedalaman minimum alur telapak ban - SampaiLIMIT
ke
Minimum tire tread depth – indikator
To indicator
2
Tekanan
Cold tire udara ban
pressure Pengendara
Driver only saja 225 225 kPa (2.25
kPa (2.25 kgf/cm
kgf/cm 2
, 33 psi)
, 33 psi) -–
(dingin) 2
Pengendara
Driver dan pembonceng
and passenger 225 225 kPa (2.25
kPa (2.25 kgf/cm
kgf/cm 2
, 33 psi)
, 33 psi) -–
Keolengan
Axle runoutaxle (poros roda) –- 0,20
0.20 (0.008)
Keolengan wheel rim
Wheel rim runout Radial
Radial –- 2,0
2.0 (0.08)
(pelek roda) Axial
Aksial –- 2.0
2,0(0.08)
Wheelwheel
Jarak hub-to-rim distance
hub-ke-rim See Lihat
page 13-11
hal. 14-11 -–
Drivechain
Drive chain Size
Size– -link
link RK
RK 420SL – 102RJ
420SL – 102RJ -–
DID 420DX – 102RB –
DID 420DX – 102RB -
Slack
Kekenduran
30 –30
40–(1.2
40
– 1.6) -

Brake
Rem Brake
D.D. drum
brakeI.D.
drum 110.0 – 110.2 (4.33 – 4.34)
110,0 – 110,2 111.0
111,0 (4.37)
Brake pedal freeplay 20 – 30 (0.8 – 1.2) –
Jarak main bebas brake pedal 20 - 30 -

HYDRAULIC
SPESIFIKASI BRAKE SPECIFICATIONS
REM HIDRAULIK
Satuan: mm(in)
Unit: mm
BAGIAN STANDARD SERVICE
BATAS SERVIS
ITEM STANDARD
LIMIT
Brake fluid (minyak rem) yang dianjurkan DOT 3 atau DOT4 -
Recommended brake fluid DOT 3 or DOT 4 –
Indikator keausan brake pad - Sampai ke alur
Brake pad wear indicator – To the groove
Tebal brake disc 3,3 – 3,7 3,0
Brake disc thickness 3.3 – 3.7 (0.13 – 0.15) 3.0 (0.12)
Keolengan brake disc - 0,30
Brake disc runout – 0.30 (0.012)
D.D. master cylinder 11,000 – 11,043 11,055
Master cylinder I.D. 11.000 – 11.043 (0.4331 – 0.4348) 11.055 (0.4352)
D.L. master piston 10,957 – 10,984 10,945
Master piston O.D. 10.957 – 10.984 (0.4314 – 0.4324) 10.945 (0.4309)
D.D. caliper cylinder 33,96 – 34,01 34,02
Caliper cylinder I.D. 33.96 – 34.01 (1.337 – 1.339) 34.02 (1.340)
D.L. caliper piston 33,878 – 33,928 33,87
Caliper piston O.D. 33.878 – 33.928 (1.3338 – 1.3357) 33.87 (1.333)

SPESIFIKASI BATERAI/SISTEM
BATTERY/CHARGING SYSTEM PENGISIAN
SPECIFICATIONS
ITEM BAGIAN SPESIFIKASI
SPECIFICATIONS
Baterai
Battery Kapasitas
Capacity 12 V –123.0V Ah
– 3,0 Ah
Kebocoran
Current arus listrik
leakage 20 maksimum
mA max. 20 mA
Voltase(20°C/
Voltage (20° C) Bermuatan
Fully charged penuh 13.0 –13,0
13.2 –V13,2 V
68°F) Perlucharging
Needs diisi listrik kembali Below Di 12.4
bawah V 12,4 V
Arus pengisian
Charging current Normal
Normal 0,3–A10/ 5
0.3 A/5 h – 10 h
Cepat
Quick 3,0 Ah / 0,5 h
3.0 A/0.5
-1
Alternator
Alternator Kapasitas
Capacity 0,120
0.120 kW / 5.000
kW/5,000 menit (rpm)
min-1 (rpm)
Charging
Tahanancoil resistancepengisian
kumparan (20°C/68°F)
(20° C) 0,3Ω– 1,0 Ω
0.3– 1.0

IGNITION SYSTEM
SPESIFIKASI SPECIFICATIONS
SISTEM PENGAPIAN
ITEM SPECIFICATIONS
BAGIAN SPESIFIKASI
Spark plug Standard CPR6EA-9S (NGK) U20EPR9S (DENSO)
Busi Standard CPR6EA-9S (NGK) U20EPR9S (DENSO)
Optional CPR7EA-9S (NGK) U22EPR9S (DENSO)
Spark plug gap Pilihan CPR7EA-9S
0.80 –(NGK)
0.90 mm (0.031 U22EPR9S
– 0.035 in) (DENSO)
Jarak renggang
Ignition coil peakbusi
voltage 0,80 – 0,90
100 V minimum mm
Ignition coil peak
Ignition pulse voltage
generator peak voltage 0.7 V minimum V
minimum 100
Ignition
Ignition timing ("F" mark)peak voltage
pulse generator 10°minimum
BTDC at0,7
idleV
Ignition timing (pengaturan waktu pengapian) (tanda "F") 10° sebelum TMA pada putaran stasioner

1-8
KETERANGAN UMUM
ELECTRIC STARTER
SPESIFIKASI SYSTEM SPECIFICATIONS
SISTEM STARTER LISTRIK
Satuan:
Unit: mmmm
(in)
BAGIAN STANDARD BATAS SERVIS
SERVICE
ITEM STANDARD
Panjang sikat starter motor 7,0 3,5 LIMIT
Starter motor brush length 7.0 (0.28) 3.5 (0.14)

SPESIFIKASI LAMPU/INSTRUMEN/SAKELAR
LIGHTS/METERS/SWITCHES SPECIFICATIONS
BAGIAN SPESIFIKASI
Bola lampu Lampu ITEM
besar SPECIFICATIONS
12 V – 32/32 W
Bulbs Headlight (High/Low)
(High/Low = jauh/dekat) 12 V – 32/32 W
Position light 12 V – 3.4 W x 2
Lampu senja 12 V – 3,4 W x 2
Brake/tail light 12 V – 18/5 W
Lampu rem/belakang 12 V – 18/5 W
Front turn signal light 12 V – 10 W x 2
Lampu sein depan 12 V – 10 W x 2
Rear turn signal light 12 V – 10 W x 2
Lampu sein belakang 12 V – 10 W x 2
Meter light 12 V – 1.7 W x 2
Lampu penerangan instrumen 12 V – 1,7 W x 2
Turn signal
Indikator lampuindicator
sein 1212V –V3.4 W xW2 x 2
– 3,4
High beam indicator
Indikator lampu jauh 1212
V –V1.7 WW
– 1,7
Gear position
Indikator posisi indicator
gigi transmissi 12 12
V –V1.7 WW
- 1,7 x 4x 4
Neutral indicator
Indikator neutral 1212
V –V1.7 W
– 1,7 W
Fuse
Sekring Main utama
Sekring 10 10
A A
Sub 7.5 A
Sekring tambahan 7,5 A

1-9
KETERANGAN UMUM
TORSI PENGENCANGAN
STANDARD STANDARD
TORQUE VALUES
JENIS PENGIKAT TORSI JENIS PENGIKAT TORSI
TORQUE
N.m (kgf.m; lbf.ft) N.mTORQUE
(kgf.m; lbf.ft)
FASTENER TYPE FASTENER TYPE
5 mm bolt and nut (baut & mur) N·m
5,2(kgf·m, lbf·ft)
(0,5; 3,8) 5 mm screw (sekrup) N·m
4,2(kgf·m, lbf·ft)
(0,4; 3,1)
65 mm
mm bolt
bolt and
andnutnut 5.2 (0.5, 3.8) 6 5mm
mmscrew
screw 4.2 (0.4,
9,0 (0,9;3.1)
6,6)
6 mm bolt
(termasuk SHand nut bolt)
flange 10 (1,0; 7) 6 6mm
mmflange
screw bolt 9.0 (0.9, 6.6)
8(Include
mm boltSHand nut bolt)
flange 2210(2,2;
(1.0,16)
7) (kepala
6 mm8flange
mm, flange
bolt kecil) 10 (1,0; 7)
10 mmbolt
8 mm boltand
and nutnut 34
22(3,5;
(2.2, 25)
16) 6 (8
mmmm flange
head,bolt
small flange) 10 (1.0, 7)
12
10 mm
mm bolt and
andnutnut 55
34(5,6;
(3.5, 41)
25) (kepala
6 mm8flange
mm, flange
bolt besar) 12 (1,2; 9)
12 mm bolt and nut 55 (5.6, 41) 6 (8
mmmm flange large(kepala
head,bolt 10 mm) and nut
flange) 12 (1.2, 9)
8 6mm
mmflange
flangebolt
bolt and nut head)
(10 mm 12 (1,2; 9)
10and
mmnutflange bolt and nut 27
12 (2,8; 20)
(1.2, 9)
8 mm flange bolt and nut 39 (4,0;20)
27 (2.8, 29)
10 mm flange bolt and nut 39 (4.0, 29)

TORSI PENGENCANGAN MESIN & RANGKA


ENGINE & FRAME TORQUE VALUES
•• Torque
Spesifikasi torsi yang
specifications dicantumkan
listed below di bawah
are for specified adalah untuk pengikat tertentu.
fasteners.
•• Others
Pengikat
shouldlain harus dikencangkan
be tightened to standard torquedengan torsiabove.
values listed pengencangan standard yang dicantumkan di atas.
FRAME/BODY PANELS/EXHAUST SYSTEM
RANGKA/BODY PANELS/SISTEM PEMBUANGAN GAS
BAGIAN JUM- THREAD
DIAMETER TORQUE
TORSI CATATAN
ITEM Q'TY REMARKS
LAH DIA. (mm)
ULIR (mm) N·m
N.m(kgf·m,
(kgf.m;lbf·ft)
lbf.ft)
Throttle cable lock nut 1 8 – See page 2-17
Throttle
Exhaust cable locknut
pipe joint nut 2 1 8 8 27 (2.8, -20) Lihat hal. 2-17
Exhaust pipe joint nut 2 8 27 (2,8; 20)
Exhaust pipe stud bolt 2 8 – See page 2-21
Exhaust pipe stud bolt 2 8 - Lihat hal. 2-21
MAINTENANCE
PERAWATAN THREAD TORQUE
ITEM
BAGIAN Q'TY
JUM- DIAMETER TORSI REMARKS
CATATAN
DIA. (mm) N·m (kgf·m, lbf·ft)
LAH ULIR (mm) N.m (kgf.m; lbf.ft)
Oil drain bolt 1 12 24 (2.4, 18)
Oil drain
Valve bolt lock nut
adjusting 2 1 5 12 24 (2,4;
9 (0.92, 6.6)18) Apply oil to the threads and
Valve adjusting lock nut 2 5 9 (0,92; 6,6) Semprotkan
seating surface.oli pada ulir
dan permukaan duduk.
Oil centrifugal filter cover bolt 3 5 5 (0.51, 3.7) Apply locking agent to the
Oil centrifugal filter cover bolt 3 5 5 (0,51; 3,7) OleskanSee
threads: zatpage
pengunci
3-12
pada ulir: Lihat hal. 3-12
Clutch adjuster lock nut 1 8 12 (1.2, 9)
Clutch adjuster lock nut 1 8 12 (1,2; 9)
Spark plug 1 10 16 (1.6, 12)
Spark plug (busi) 1 10 16 (1,6; 12)
Throttle cable
Throttle cable adjuster
adjusterlock
locknut
nut 1 1 7 7 3.83,8
(0.39, 2.8)2,8)
(0,39;
Aircleaner
Air cleaner housing
housingcover
coverscrew
screw 5 5 5 5 1.11,1
(0.11, 0.8)0,8)
(0,11;
LUBRICATION SYSTEM
SISTEM PELUMASAN
BAGIAN JUM- THREAD
DIAMETER TORQUE
TORSI CATATAN
ITEM Q'TY REMARKS
LAH DIA. (mm)
ULIR (mm) N·m
N.m(kgf·m, lbf·ft)
(kgf.m; lbf.ft)
Oil pump cover screw 3 5 5 (0.51, 3.7)
Oil pump cover screw 3 5 5 (0,51; 3,7)
FUEL SYSTEM
SISTEM BAHAN BAKAR THREAD TORQUE
ITEM Q'TY REMARKS
BAGIAN JUM- DIAMETER
DIA. (mm) N·m (kgf·m,TORSI
lbf·ft) CATATAN
Inlet pipe band screw 1LAH ULIR
– (mm) N.m (kgf.m;
– lbf.ft) See page 5-14
Inlet
Fuel pipe
valveband
screwscrew 2 1 3 - -
0.88 (0.090, 0.65) Lihat hal. 5-14
Fuel valve valve
Air cut-off screwscrew 2 2 4 3 0,88
2.1 (0,090;
(0.21, 1.5) 0,65)
Air cut-off
Slow jet valve screw 1 2 – 4 1.5 2.1 (0,21;
(0.15, 1.1) 1,5)
Slow
Main jet
jet 1 1 – - 1.5 1,5 (0,15;
(0.15, 1.1) 1,1)
Main
Needlejetjet holder 1 1 – - 2.5 (0.25, 1.8) 1,1)
1,5 (0,15;
Needle jet holder 1 - 2,5 (0,25; 1,8)
Float chamber screw 2 4 2.1 (0.21, 1.5)
Float chamber screw 2 4 2,1 (0,21; 1,5)
Float chamber drain screw 1 – 1.5 (0.15, 1.1)
Float chamber drain screw 1 - 1,5 (0,15; 1,1)
Fuel strainer
Fuel strainer cup
cup 1 1 – - 5.9 5,9
(0.60, 4.4) 4,4)
(0,60;
Throttle cable holder
Throttle cable holderscrew
screw 1 1 5 5 3.4 3,4
(0.35, 2.5) 2,5)
(0,35;
Fuel valve
Fuel valve lever
leverscrew
screw 1 1 4 4 2.1 2,1
(0.21, 1.5) 1,5)
(0,21; Apply locking agent to the
Inlet pipe mounting bolt 2 6 12 (1,2; 9) threads.
Inlet pipe
PAIR checkmounting bolt screw
valve cover 2 2 6 4 122,1
(1.2, 9)
(0,21; 1,5)
PAIR check valve cover screw 2 4 2.1 (0.21, 1.5)

1-10
KETERANGAN UMUM
PELEPASAN/PEMASANGAN
ENGINE REMOVAL/INSTALLATION MESIN
BAGIAN JUM- DIAMETER
THREAD TORSI
TORQUE CATATAN
ITEM Q'TY
LAH ULIR (mm) N.m (kgf.m; lbf.ft) REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Drive sprocket fixing plate bolt 2 6 12 (1,2; 9)
Drive sprocket fixing plate bolt 2 6 12 (1.2, 9)
Engine hanger nut 3 10 59 (6,0; 44)
Engine hanger nut 3 10 59 (6.0, 44)

CYLINDER HEAD/VALVES
CYLINDER HEAD/VALVES THREAD TORQUE
ITEM
BAGIAN Q'TY
JUM- DIAMETER TORSI REMARKS
CATATAN
DIA. (mm) N·m (kgf·m, lbf·ft)
Cylinder head cover special bolt 2LAH ULIR
6 (mm) N.m
10(kgf.m;
(1.0, 7) lbf.ft)
Cylinder
Cylinderhead cover special bolt
head nut 42 7 6 1310 (1,0;
(1.3, 10)7) Apply oil to the threads and
Cylinder head nut 4 7 13 (1,3; 10) Semprotkan oli pada ulir
seating surface.
Cam sprocket bolt 2 5 8 (0.82, 5.9) dan permukaan
Apply locking agent duduk.
to the
Cam sprocket bolt 2 5 8 (0,82; 5,9) Oleskan zat pengunci
threads: See page 7-11
pada ulir: Lihat hal. 7-11
Cam chain tensioner sealing bolt 1 14 22 (2.2, 16)
Cam chain tensioner sealing bolt 1 14 22 (2,2; 16)
Cam chain tensioner arm pivot bolt 1 8 16 (1.6, 12)
Cam chain tensioner arm pivot bolt 1 8 16 (1,6; 12)
CYLINDER/PISTON
THREAD TORQUE
ITEM
CYLINDER/PISTON Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
BAGIAN
Cam chain guide roller pin bolt JUM-
1 DIAMETER
8 TORSI
10 (1.0, 7) CATATAN
LAH ULIR (mm) N.m (kgf.m; lbf.ft)
Cylinder stud bolt 4 7 – See page 8-8
Cam chain guide roller pin bolt 1 8 10 (1,0; 7)
Cylinder stud bolt
CLUTCH/GEARSHIFT LINKAGE 4 7 - Lihat hal. 8-8
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
CLUTCH/GEARSHIFT LINKAGE (KOPLING/PERALATAN
Shift drum stopper arm bolt 1 6 PENGGERAK GIGI)
10 (1.0, 7) Apply locking agent to the
BAGIAN JUM- DIAMETER TORSI CATATAN
threads: See page 9-31
Shift return spring pin 1LAH ULIR
8 (mm) N.m (kgf.m;
30 (3.1, 22) lbf.ft)
Shift drum stopper arm
Gearshift cam plate bolt bolt 1 1 6 6 17 (1.7, 13)7)
10 (1,0; Oleskan zat pengunci
Apply locking agent to the
pada ulir:
threads: SeeLihat
pagehal.
9-309-30
Shift return spring
Centrifugal pin nut
clutch lock 11 14 8 5430 (3,1;
(5.5, 40)22) Apply oil to the threads and
Gearshift cam plate bolt 1 6 17 (1,7; 13) Oleskan zat pengunci
seating surface.
Clutch center lock nut 1 14 54 (5.5, 40) pada
Applyulir:
oil toLihat hal. 9-29
the threads and
Centrifugal clutch lock nut 1 14 54 (5,5; 40) Semprotkan
seating surface. pada ulir
oli
dan permukaan duduk.
Clutch lifter plate bolt (Four bolts type) 4 6 12 (1.2, 9)
Clutch center lock nut 1 14 54 (5,5; 40) Semprotkan oli pada ulir
Clutch lifter plate bolt (Six bolts type) 6 5 7 (0.71, 5.2)
dan permukaan duduk.
Clutch lifter plate bolt
ALTERNATOR/STARTER CLUTCH 4 6 12 (1,2; 9)
THREAD TORQUE
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
ALTERNATOR/STARTER
Flywheel nut CLUTCH 1 10 40 (4.1, 30) Apply oil to the threads and
BAGIAN JUM- DIAMETER TORSI CATATAN
seating surface.
Starter clutch mounting torx bolt 6LAH ULIR
6 (mm) N.m
16 (kgf.m;
(1.6, 12) lbf.ft) Apply locking agent to the
Flywheel nut 1 10 40 (4,1; 30) Semprotkan oli pada
threads: See page 10-12ulir
dan permukaan duduk.
Starter clutch mounting torx bolt
CRANKSHAFT/TRANSMISSION/KICKSTARTER 6 6 16 (1,6; 12) Oleskan zat pengunci
THREAD TORQUE pada ulir. Lihat. hal. 10-12
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Cam chain guide sprocket spindle 1 6 10 (1.0, 7)
CRANKSHAFT/TRANSMISSION/KICKSTARTER
BAGIAN JUM- DIAMETER TORSI CATATAN
LAH ULIR (mm) N.m (kgf.m; lbf.ft)
Cam chain guide sprocket spindle 1 6 10 (1,0; 7)

1-11
KETERANGAN UMUM
FRONT WHEEL/SUSPENSION/STEERING
RODA DEPAN /SUSPENSI/KEMUDI
BAGIAN JUM- DIAMETER
THREAD TORSI
TORQUE CATATAN
ITEM Q'TY
LAH ULIR (mm) N.m (kgf.m; lbf.ft) REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Steering handle
Steering stem weight
lock nut screw 12 266 9 (0,92;
– 6,6) For tightening sequence; See
Steering stem lock nut 1 26 - Untuk urutan pengencang-
page 12-25
Steering stem top thread 1 26 – anFor
; Lihat hal. 12-25
tightening sequence; See
Steering stem top thread 1 26 - Untuk urutan pengencang-
page 12-25
Bottom bridge pinch bolt 4 10 64 (6.5, 47) an ; Lihat hal. 12-25
Bottom bridge
Handlebar pinch
weight bolt
screw 24 610 964 (6,5;6.6)
(0.92, 47) SL thread screw
Handlebar weight screw 2 6 9 (0,92; 6,6) SL thread screw
Handlebar post mounting nut 1 10 59 (6.0, 44) U-nut
Handlebar post mounting nut 1 10 59 (6,0; 44) U-nut
Front axle nut 1 12 59 (6.0, 44) U-nut
Front axle nut 1 12 59 (6,0; 44) U-nut
Front brake disc
Front brake discsocket
socketbolt
bolt 44 88 42
42 (4.3,
(4,3;31)
31) ALOC bolt;ganti
ALOC bolt; replace with new
dengan
ones.
yang baru.
Frontsocket
Fork spoke bolt 362 BC 2.9
8 25
20(0.25,
(2,0;1.8)
15) Oleskan zat pengunci pada
Fork socket bolt 2 8 20 (2.0, 15) Apply locking agent to the
ulir.
threads.
RODAWHEEL/BRAKE/SUSPENSION
REAR BELAKANG/REM/SUSPENSI
BAGIAN JUM- DIAMETER
THREAD TORSI
TORQUE CATATAN
ITEM Q'TY
LAH ULIR (mm) N.m (kgf.m; lbf.ft) REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Rear axle nut 1 12 59 (6,0; 44) U-nut
Rear axle nut 1 12 59 (6.0, 44) U-nut
Driven sprocket nut 4 8 32 (3,3; 24) U-nut
Rear spoke 36 BC 3.2 3.7 (0.38, 2.7)
Driven flange stud bolt 4 8 - Lihat hal. 13-11
Driven
Rear sprocket
brake nut arm nut
stopper 42 88 32
22 (3.3,
(2,2;24)
16) U-nut
Driven flange stud
Rear brake arm nut bolt 41 86 – 7)
10 (1,0; U-nutpage 13-11
See
Rear brake stopper
Shock absorber upperarm nut
mounting bolt 22 810 22
24 (2.2,
(2,4;16)
18)
Shock absorber
Rear brake lower mounting cap nut/nut
arm nut 1 6 10 (1.0, 7) U-nut
Swingarm pivotupper
Shock absorber nut mounting bolt 22 1010 24 (2.4,
24 (2,4;18)
18)
Shock absorber lower mounting cap nut/nut 21 1012 59 (2.4,
24 (6,0;18)
44) U-nut
Swingarm pivot nut 1 12 59 (6.0, 44) U-nut
REM HIDRAULIK
HYDRAULIC BRAKE
BAGIAN JUM- DIAMETER TORSI CATATAN
LAH THREAD
ULIR (mm) N.mTORQUE
(kgf.m; lbf.ft)
ITEM Q'TY REMARKS
Caliper bleed valve 1 DIA. (mm)
8 N·m
5,4(kgf·m,
(0,56; lbf·ft)
4,0)
Caliper
Pad pin bleed valve 11 810 5.4
17(0.55,
(1,7; 4.0)
13)
Caliper
Pad pin bracket pin bolt 11 108 17 (1.7,
17 (1,7;13)
13)
Caliper
Caliper mounting
bracket pinbolt
bolt 12 88 30 (1.7,
17 (3,1;13)
22) ALOC bolt, ganti dengan
Caliper mounting bolt 2 8 30 (3.1, 22) yang
ALOCbaru.
bolt; replace with new
Brake hose oil bolt 2 10 34 (3,5; 25) ones.
Master cylinder
Brake hose reservoir cap screw
oil bolt 22 104 1,5
34 (0,15; 1,1)
(3.5, 25)
Front brake
Master lightreservoir
cylinder switch screw
cap screw 21 44 1,2 (0.15,
1.5 (0,12;1.1)
0,9)
Brake lever light
Front brake pivotswitch
bolt screw 11 46 1,0 (0.12,
1.2 (0,10;0.9)
0,7)
Brake
Brake lever pivot bolt
lever pivot nut 11 66 5,9 (0.10,
1.0 (0,60;0.7)
4,4)
Brake
Brake hose clampnut
lever pivot bolt 11 66 5.912(0.60,
(1,2;4.4)
9) ALOC bolt, ganti dengan
Brake hose clamp bolt 1 6 12 (1.2, 9) yang
ALOCbaru.
bolt; replace with a
new one.
SISTEM PENGAPIAN
IGNITION SYSTEM
BAGIAN JUM- DIAMETER TORSI CATATAN
LAH THREAD
ULIR (mm) N.mTORQUE
(kgf.m; lbf.ft)
ITEM Q'TY REMARKS
Timing hole cap 1 DIA. (mm)
14 N·m
1,5(kgf·m,
(0,15; lbf·ft)
1,1)
Timing hole cap 1 14 1.5 (0.15, 1.1)
SISTEM STARTER LISTRIK
ELECTRIC STARTER SYSTEM
BAGIAN JUM- DIAMETER TORSI CATATAN
LAH THREAD
ULIR (mm) N.mTORQUE
(kgf.m; lbf.ft)
ITEM Q'TY REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Starter motor cable screw 1 4 2,0 (0,20; 1,5)
Starter motor
Starter motor cable
case screw
screw 13 45 2.0
4,2 (0.20,
(0,43;1.5)
3,1)
Starter motor case screw 3 5 4.2 (0.43, 3.1)
LAMPU/INSTRUMEN/SAKLAR
LIGHTS/METERS/SWITCHES
BAGIAN JUM- DIAMETER TORSI CATATAN
THREAD TORQUE
ITEM LAH
Q'TY ULIR (mm) N.m (kgf.m; lbf.ft) REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Ignition switch mounting bolt
Ignition switch mounting bolt 22 66 99 (0.92,
(0,92;6.6)
6,6) ALOC
ALOC bolt;ganti
bolt; dengan
replace with new
yang baru.
ones.
Key shutter assembly socket bolt 1 5 3.9 (0.40, 2.9) ALOC bolt; replace with new
one.

1-12
KETERANGAN UMUM
LAIN-LAIN
OTHERS
BAGIAN JUM- DIAMETER
THREAD TORSI
TORQUE CATATAN
ITEM Q'TY
LAH ULIR (mm) N.m (kgf.m; lbf.ft) REMARKS
DIA. (mm) N·m (kgf·m, lbf·ft)
Sidestand pivot bolt
Sidestand pivot bolt 1 1 10 10 1818 (1,8;
(1.8, 13)13)
Sidestand pivot nut 1 10 44 (4,5; 32)
Sidestand pivot nut 1 10 44 (4.5, 32)

1-13
KETERANGAN UMUM
LUBRICATION & SEAL POINTS
TITIK-TITIK PELUMASAN & PERAPATAN
ENGINE
MESIN
BAHAN
MATERIAL LOKASI
LOCATION CATATAN
REMARKS
Oli mesin
Engine oil Bagian dalam
Cylinder bore cylinder
Permukaan
Piston luar piston
outer surface dan alur2
and piston piston ring
ring grooves
Permukaan
Piston pin holedalam lubang piston pin
inner surface
Permukaan
Piston pin outerluar piston pin
surface
Pistonrings
Piston rings
Permukaan
Connecting dalam
rod smallkepala
end innerkecil connecting rod
surface 3
Kepala besar connecting
Connecting rod big end rod 1,0 – 2,0 cm
1.0 – 2.0 cm3
Permukaan luar IN/EX valve stem
IN/EX
Seluruh valve stem outercamshaft
permukaan surface
Camshaft whole surfacecam chain
Seluruh permukaan
Cam chaincam
Gigi-gigi whole surface
sprocket
Cam sprocket dalam
Permukaan teeth lubang rocker arm shaft
Seluruh
Rocker permukaan
arm rocker
shaft hole inner arm shaft
surface
Daeraharm
Rocker gelinding rocker
shaft whole arm roller
surface
Daeraharm
Rocker peluncuran oil area
roller rolling pump inner dan outer rotor
Seluruh
Oil pump permukaan
inner and outer cam chain
rotor guide
sliding areasprocket spindle
Permukaan
Cam luarsprocket
chain guide clutch outer
spindleguide
whole surface
Clutchouter
Clutch discsguide outer surface
Gearshift
Clutch discsspindle journal
Permukaan
Gearshift peluncuran
spindle journal shift fork inner
Shift fork inner sliding shift
Seluruh permukaan surfacedrum
Daerah
Shift drum perputaran
whole surface countershaft shift drum lock plate
Gigi-gigi gear (primary, transmission, kickstarter)
Countershaft shift drum lock plate rotating area
Bagian dalam cam chain tensioner push rod
Gear teeth (primary, transmission, kickstarter)
Permukaan gelinding starter clutch
Cam chain
Journal tensioner
dan gigi-gigipush rod inside
starter reduction gear 4.04,0
– 5.0 cc cc
– 5,0
Starter
Starterclutch rollinggear
reduction surface
shaft
Starter
Masing2 reduction gear both
permukaan journal bantalan
gelinding and gear teeth
Starter
Masing2 reduction
O-ringgear shaft
Each bearing rolling surface
Zat pengunci Ulir oil
Each stopper plate bolt
O-ring Lihat hal. 7-26
Locking agent Ulirstopper
Oil mainshaftplatebearing set plate bolt
bolt threads SeeLihat
pagehal.
7-2611-16
Liquid sealant (dianjurkan: Mainshaft bearing set platecylinder
Permukaan penyatuan head (daerah setengah
bolt threads Lihat hal.
See page 11-167-7
Three bond 5211C atau lingkaran)
Liquid sealant (recommended: Cylinder head mating surface (semicircular area) See page 7-7
SHINETSU-SILICONE
Three bond 5211C or SHI- KE45T
atau Three bond 1215
NETSU-SILICONE KE45T or atau
sejenisnya)
Three bond 1215 or equivalent)
Molybdenum
Molybdenum disulfide oil (a
disulfide oil Permukaan
Kickstarter dalam
pinion kickstarter
gear pinion gear
inner surface
(campuran dariengine
mixture of 1/2 ½ oli oil
mesin dan
and 1/ Permukaan dalam primary
Primary drive gear inner surfacedrive gear
½2 molybdenum disulfide
molybdenum disulfide Permukaan dalam masing2 gear berputar transmission
Each transmission rotating gear inner surface
grease)
grease) Seluruh permukaan C1 gear bushing
C1 gear bushing whole surface
Alur M4, C3 gear shift fork
M4, C3 gear shift fork groove
Sealant (Three
Sealant (Threebond
bond1215
1215or atau Left crankcasepenyatuan
Permukaan mating surface
left crankcase SeeLihat
pagehal.
11-19
11-19
1207B or LOCTITE or equiva-
1207B atau LOCTITE atau
lent)
sejenisnya)
Sealant (Three bond 1215 or Alternator wire grommet seating surface
Sealant (Three bond 1215 atau Permukaan duduk alternator wire grommet
1207B or equivalent)
1207B atau sejenisnya)
Multi-purpose grease Gearshift spindle oil seal lip
Countershaft oil seal lip
Multi-purpose grease Bibir gearshift spindle oil seal
Kickstarter spindle oil
Bibir countershaft oilseal
seallip
Degreasing Flywheel
Bibir kickstarter spindle oilcontact
and left crankshaft seal areas
Bersihkan dari gemuk Flywheel dan daerah kontak left crankshaft

1-14
KETERANGAN UMUM
RANGKA
FRAME
MATERIAL LOCATION REMARKS
Urea based BAHAN
multipurpose Steering stem dust seal lips LOKASI Apply 3 g CATATAN
minimum
Multipurpose greasepressure
grease with extreme ber- Bibir-bibir
Upper innersteering
and outerstem dust
bearing seal
races Berikan
Apply minimum 3 g
3 g minimum
dasarkan
(example:urea yang
Kyodo tahan
Yushi Upperinner
Lower innerand
danouter
outer bearing
bearing races
races Berikan
Apply minimum 3 g
3 g minimum
tekanan
EXCELITEsangat
EP2,tinggi
Shell (contoh:
ALVA- Lower inner dan outer bearing races Berikan minimum 3 g
Kyodo Yushi
NIA EP2 EXCELITE EP2,
or equivalent)
Shell ALVANIAgrease
Multi-purpose EP2 atau Brake panel anchor pin Apply 0.2 – 0.3 g
sejenisnya) Brake cam sliding surface Apply 0.2 – 0.3 g
Multi-purpose grease Brakecam
Brake panel anchor
(brake shoepin contact area) Berikan
Apply 0.2 –0,2
0.3–g 0,3 g
Permukaan peluncuran
Front/rear axle surface brake cam Berikan 0,2 – 0,3 g
Brake cam
Front/rear (daerah
wheel distancekontak brake shoe)
collar Berikan 0,2 – 0,3 g
Permukaan front/rear axle
Front wheel dust seal lips
Front/rear wheel distance collar
Throttle pipe surface, flange groove and slot
Bibir-bibir front wheel dust seal
Rear wheel driven
Permukaan flange
throttle pipe,dust seal
alur lips dan slot
flange
Rear wheel rear
Bibir-bibir hub O-ring
wheel driven flange dust seal
Speedometer
Rear wheel cable inside
hub O-ring
Speedometer cable
Bagian dalam speedometer O-ring cable
Speedometer
Kickstarter pedalcable
slidingO-ring
area
Daerah handle
Steering peluncuran kickstarter
lock sliding area pedal dan steel ball
Daerah
Seat lock peluncuran
sliding area steering handle lock
Daerah peluncuran
Sidestand pivot slidingseat lock
surface
Permukaan
Rear peluncuran sidestand
brake pedal/centerstand pivotsurface
pivot sliding
Permukaan
Each peluncuran rear brake pedal/center stand pivot
wheel bearing
Masing-masing
Speedometer gearwheel
teeth bearing Apply 3 g
Gigi-gigi speedometer
Speedometer gear
gear inner surface Berikan
Apply 0.5 –31.0
g g
Silicone grease Permukaan dalam speedometer
Front brake lever pivot bolt sliding surface gear Apply 0.1 g – 1,0 g
Berikan 0,5
Silicone grease Permukaan peluncuran front brake
Front brake lever-to-master piston contacting lever pivot bolt
surface Berikan 0,1 g
Permukaan kontak front brake lever-ke-master piston
Brake caliper bracket pin sliding surface Apply 0.4 g minimum
Permukaan peluncuran brake caliper bracket pin
Brake caliper dust seal
Brake caliper dust seal Berikan minimum0,4g
Pad
PadpinpinO-ring
O-ring
Brake fluid
Brake fluidDOT
DOT 33 atau
or DOT 4 4
DOT Brake
Brakemaster
master piston,
piston, spring
springanddan
piston cupscups
piston
Brake
Brakecaliper
caliperpiston
piston
Brake
Brakecaliper
caliperpiston
piston seal
seal
Honda Bond
Honda Bond A
A or equivalent
atau sejenisnya Handlebar
Bagian dalam grip rubber
handlebar insidegrip rubber
Front
Fronttoptopcover
coverrubbers
rubbers
Lowerside
Lower sidecover
cover rubbers
rubbers
Fork
Forkfluid
fluid Bibir-bibir
Fork oil sealfork
lipsoil seal
Bibir-bibir
Fork forklips
dust seal dust seal
Forkcap
Fork capO-ring
O-ring
SAE
SAE#80
#80 atau
or 90 90
geargear
oil oroildrive
atau Drive chain
Drive chain
drive
chainchain lubricant
lubricant
Gear
Gear oil
oil Rearbrake
Rear brake cam
cam feltfelt
sealseal

1-15
KETERANGAN UMUM
PERLETAKAN KABEL & HARNES

FRONT BRAKE LIGHT


SWITCH WIRE

FRONT BRAKE LIGHT SWITCH WIRE


CONNECTORS (Hitam,Hijau/Kuning)

LEFT HANDLEBAR
SWITCH WIRE

DIMMER SWITCH
LIGHTING SWITCH 3P CONNECTOR
4P CONNECTOR
HEADLIGHT ASSEMBLY
9P CONNECTOR

STARTER SWITCH 3P HORN SWITCH 3P


CONNECTOR (Hitam) CONNECTOR (Hitam)

TURN SIGNAL LIGHT


SWITCH 3P
CONNECTOR (Merah)

SPEEDOMETER CHOKE CABLE


CABLE COMBINATION
METER SUB
HARNESS

FRONT BRAKE COMBINATION


HOSE METER SUB
HARNESS

IGNITION SWITCH 2P
CONNECTOR

SPEEDOMETER
CABLE

FRONT BRAKE
HOSE
CONNECTORS:
– COMBINATION METER 9P CONNECTOR
– COMBINATION METER 6P CONNECTOR
HORN WIRE CONNECTORS (Hijau
muda, Hijau)

WIRE BAND

FRONT BRAKE
HOSE

1-16
KETERANGAN UMUM

THROTTLE CABLE

FRONT BRAKE HOSE


15⋅

HANDLEBAR

SPEEDOMETER CABLE

FRONT BRAKE THROTTLE CABLE


HOSE

CARBURETOR
AIR VENT HOSE

CHOKE CABLE

COMBINATION
METER SUB
HARNESS

CHOKE CABLE

CRANKCASE BREATHER
HOSE
SPEEDOMETER CABLE
CARBURETOR
AIR VENT HOSE
FUEL HOSE
CARBURETOR
DRAIN HOSE

1-17
KETERANGAN UMUM

THROTTLE CABLE

15°

HANDLEBAR

IGNITION SWITCH 2P
CONNECTOR

CONNECTORS:
– COMBINATION METER
9P CONNECTOR
– COMBINATION METER
6P CONNECTOR
CARBURETOR
AIR VENT HOSE

FRONT BRAKE HOSE

THROTTLE CABLE

CHOKE CABLE

CARBURETOR
SPARK PLUG WIRE AIR VENT HOSE

MAIN WIRE HARNESS

1-18
KETERANGAN UMUM

IGNITION CONTROL
MODULE (ICM)

IGNITION PULSE GENERATOR WIRE CONNECTOR (Biru/Kuning)


ALTERNATOR WIRE CONNECTOR (Kuning)
REGULATOR/RECTIFIER 4P CONNECTOR
IGNITION PULSE
GENERATOR/ MAIN WIRE
ALTERNATOR WIRE BAND HARNESS
WIRE

MAIN WIRE
HARNESS
GROUND
TERMINAL

VACUUM
MAIN WIRE HOSE
HARNESS

SPARK PLUG
WIRE

REAR BRAKE LIGHT


SWITCH WIRE
CONNECTORS
(Hitam, Hijau/Kuning)

REAR BRAKE LIGHT


SWITCH WIRE
AIR SUPPLY HOSE
CLAMPS
BATTERY WIRE
HARNESS
AIR SUPPLY PIPE
IGNITION COIL WIRE
CONNECTORS START MOTOR 2P
(Hitam/Kuning, Hijau) CONNECTOR

BATTERY WIRE HARNESS


2P/3P CONNECTORS

1-19
KETERANGAN UMUM

IGNITION PULSE
AIR SUPPLY GENERATOR/
HOSE ALTERNATOR WIRE
SEPARATE
CRANKCASE AIR FILTER
BREATHER HOSE
ICM
15 mm

MAIN WIRE
HARNESS

FUEL
HOSE

AIR SUPPLY
HOSE

IGNITION CONTROL
MODULE (ICM) 2P/3P
CONNECTORS

CRANKCASE
BREATHER HOSE ALTERNATOR 2P
CONNECTOR GEAR POSITION
SWITCH 6P
CONNECTOR (Hitam)
CARBURETOR AIR SUPPLY
DRAIN HOSE HOSE

1-20
KETERANGAN UMUM

AIR SUPPLY HOSE

ALTERNATOR 2P
CONNECTOR
FUEL HOSES
GEAR POSITION SWITCH
6P CONNECTOR (Hitam)

BRAKE/TAIL LIGHT UNIT


6P CONNECTOR
FUEL LEVEL SENSOR
3P CONNECTOR (Hitam)

FUEL HOSE

MAIN WIRE HARNESS

1-21
KETERANGAN UMUM

LEFT FRONT
TURN SIGNAL
LIGHT WIRE RIGHT REAR
LEFT FRONT
POSITION POSITION
LIGHT WIRE LIGHT WIRE

HEAD LIGHT WIRES


RIGHT REAR
TURN SIGNAL
LIGHT WIRE

HEAD LIGHT ASSEMBLY


9P CONNECTOR

BRAKE/TAIL LIGHT WIRE

RIGHT REAR LEFT REAR


TURN SIGNAL TURN SIGNAL
LIGHT WIRE LIGHT WIRE

BRAKE/TAIL LIGHT UNIT


6P CONNECTOR

1-22
KETERANGAN UMUM

BATTERY
BATTERY POSITIVE (+)
CABLE

BATTERY NEGATIVE (–)


CABLE

MAIN FUSE 10 A
SUB FUSE 7.5 A

STARTER RELAY

IGNITION PULSE GENERATOR

ALTERNATOR WIRE

1-23
KETERANGAN UMUM
EMISSION CONTROL
SISTEM-SISTEM SYSTEMS EMISSI
PENGATURAN
SOURCEEMISSI
SUMBER OF EMISSIONS
Proses pembakaran
The combustion processmenghasilkan
produces carbonkarbon
monoxidemonoksida dan hidrokarbon
and hydrocarbons (HC).hydrocarbon
(HC). Controlling Pengaturanemission
emissi ishidrokarbon
very importantadalah sangat
because, under
penting oleh karena, pada kondisi2 tertentu, mereka bereaksi membentuk photochemical smog ketika terkena cahaya matahari.
certain conditions, they react to form photochemical smog when subject to sunlight. Carbon monoxide does not react in the same way, but it is
Karbon
toxic. monoksida tidak bereaksi dengan cara yang sama, tetapi ia beracun.
Honda Motor
Honda Motor Co.,
Co., Ltd. utilizes lean carburetor
Ltd menggunakan settings
penyetelan as well yang
karburator as other systems,
miskin to reduce
maupun carbon monoxide,
sistem-sistem lain untukoxides of nitrogen
mengurangi and
karbon
hydrocarbons.oksida2 dari nitrogen dan hidrokarbon.
monoksida,
CRANKCASE
SISTEM EMISSION
PENGATURAN CONTROL
EMISSI SYSTEM
CRANKCASE
Mesin dilengkapi
The engine dengan
is equipped with a sistem crankcase
closed crankcase (baktomesin)
system tertutup untuk
prevent discharging mencegah
crankcase pengeluaran
emissions emissi Blow-by
into the atmosphere. gas ke
crankcase dalam
is returned
atmosfir. gas (gas
Blow-bychamber
to the combustion hasil the
through pembakaran yang
air cleaner and masuk ke dalam bak mesin melalui piston ring) dikembalikan ke dalam ruang
carburetor.
pembakaran melalui air cleaner (saringan udara) dan karburator.

AIR CLEANER HOUSING

CRANKCASE BREATHER HOSE

CARBURETOR

UDARA SEGAR

BLOW-BY GAS

1-24
EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDARY AIR INJECTION KETERANGAN SYSTEM)UMUM
EXHAUST EMISSION
The exhaust emission CONTROL
control system SYSTEM
consists of a secondary (PULSE
air supply system SECONDARY AIR
which introduces filtered air INJECTION SYSTEM)
into the exhaust gases in the exhaust
port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system. This change of fresh air promotes
SISTEM
burning ofPENGATURAN EMISI
the unburned exhaust GAS
gases andPEMBUANGAN (SISTEM
changes a considerable PULSA
amount INJEKSI UDARA
of hydrocarbons SEKUNDER)
and carbon monoxide into relatively harmless carbon
dioxide and water vapor.
Sistem pengaturan emisi gas pembuangan terdiri dari sistem penyaluran udara sekunder yang memasukkan udara yang telah
This model has the pulse secondary air injection (PAIR) control valve and PAIR check valve. PAIR check valve prevents reverse air flow
disaring ke dalam
through the system.gasThepembuangan
PAIR controldivalve
dalam lubang
reacts pembuangan.
to high Udara segar
inlet pipe vacuum tersedot
and will cut offkethe
dalam lubang
supply of thepembuangan setiap
fresh air during kali
engine
ada pulsa tekanan
deceleration, negatif diafterburn
thereby preventing dalam sistem pembuangan
in the exhaust system. gas. Pengisian udara segar ini memperlancar pembakaran gas-gas
pembuangan
No adjustment to yang belum
the pulse terbakar
secondary airhabis dansystem
injection mengubah sejumlah
should be besar periodic
made, although hidrokarbon dan of
inspection karbon monoksida
the components menjadi karbon
is recommended.
dioksida dan uap air yang relatif tidak berbahaya.

Model ini mempunyai pulse secondary air injection (PAIR) control valve (klep pengaturan) dan PAIR check valve (klep
pengendali). PAIR check valve mencegah aliran kembali udara di dalam sistem. PAIR control valve bereaksi terhadap vakuum
tinggi di dalam inlet pipe (salurah masuk ke ruang pembakaran) dan akan menghentikan aliran udara segar sewaktu mesin
berdeselerasi (pada waktu kecepatan sepedamotor diturunkan), dengan demikian mencegah terjadinya afterburn (pembakaran
susulan) di dalam sistem pembuangan gas.

Pulse secondary air injection system tidak memerlukan penyetelan, walaupun dianjurkan untuk melakukan pemeriksaan periodik
dari komponen-komponennya. PAIR CONTROL VALVE
SEPARATE AIR FILTER VACUUM HOSE
PAIR CONTROL VALVE

CARBURETOR

PAIR CHECK VALVE

UDARA SEGAR
VACUUM AIR

NOISE EMISSION CONTROL SYSTEM (SISTEM PENGATURAN EMISSI KEBISINGAN)


NOISE EMISSION CONTROL SYSTEM
DILARANG
TAMPERINGMENGUTAK-ATIK
WITH THE NOISE CONTROL SISTEM PENGATURAN EMISSI KEBISINGAN:
SYSTEM IS PROHIBITED: Local law mayUndang-undang melarang
prohibit the following acts or tindakan-tindakan
the causing thereof:
berikut atau penyebab
(1) The removal daripada:
or rendering (1)by
inoperative Pelepasan
any person,atau
otherdibuat
than fortidak bekerjanya
purposes oleh seseorang,
of maintenance, selain untuk
repair or replacement, tujuan
of any perawatan,
device or element
perbaikan atau penggantian,
of design incorporated dari setiap
into any vehicle for theperalatan
purpose ofatau
noiseelemen rancangan
control prior yang
to its sale telah dipasang
or delivery padacustomer
to the ultimate sebuahorkendaraan untuk
while it is in use;
tujuan pengaturan
(2) the use kebisingan
of the vehicle after suchsebelum
device orpenjualan
element ofatau penyerahannya
design has been removedkepada pelanggan
or rendered akhir by
inoperative atau
anysementara
person. ia dipergunakan;
(2) Pemakaian kendaraan setelah peralatan atau elemen rancangan sedemikian telah dilepaskan atau dibuat tidak dapat bekerja
AMONG
oleh THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
seseorang.
DI
1. ANTARA
Removal of, TINDAKAN2
or puncturingYANG
of the DIANGGAP MERUPAKAN
muffler, baffles, header pipes orPENGUTAK-ATIKAN ADALAH
any other component which TINDAKAN-TINDAKAN
conducts exhaust gases. SEPERTI DI
BAWAH
2. Removal INI:of, or puncturing of any part of the intake system.
1. Melepaskan
3. Lack atau melubangi knalpot, komponen pengaturan aliran, pipa pendahulu atau setiap komponen lain yang
of proper maintenance.
menyalurkan
4. Replacing gas pembuangan.
any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.
2. Melepaskan atau melubangi setiap bagian dari sistem pemasukan udara.
3. Tidak menjalankan perawatan yang layak.
4. Mengganti bagian bergerak dari kendaraan, atau bagian dari sistem pembuangan atau pemasukan, dengan part lain
daripada yang telah ditentukan oleh pabrik.

1-25
MEMO
2. RANGKA/BODY PANEL/SISTEM PEM-
BUANGAN GAS

LOKASI BODYLOCATIONS···························
BODY PANEL PANELS ............................ 2-22-2 GRAB
GRAB RAIL.........................................
RAIL 2-8
·······················································2-8

DIAGRAM PELEPASAN
BODY PANEL REMOVAL BODY
CHARTPANEL
··············....
2-22-2 BODY
BODY COVER..................................... 2-9
COVER···················································2-9

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


SERVICE INFORMATION ····························· 2-3
LUGGAGE BOX.................................. 2-10
LUGGAGE BOX··············································2-10
TROUBLESHOOTING ................................ 2-3 REAR FENDER................................... 2-11
TROUBLESHOOTING ···································· 2-3 REAR FENDER ···············································2-11
FRONT TOP COVER .................................. 2-4 HANDLEBAR COVER ........................ 2-12
FRONT TOP COVER ······································· 2-4 HANDLEBAR COVER···································2-12
FRONT FENDER......................................... 2-5 FOOTPEG BAR .................................. 2-18
FRONT FENDER ·············································· 2-5 FOOTPEG BAR···············································2-18
LOWER SIDE COVER ................................ 2-6 PASSENGER FOOTPEG HOLDER.... 2-18
LOWER SIDE COVER····································· 2-6 PASSENGER FOOTPEG HOLDER·············2-18
CENTER COVER ........................................ 2-6 LEFT CRANKCASE REAR COVER ... 2-19
CENTER COVER·············································· 2-6 LEFT CRANKCASE REAR COVER ···········2-19
MAIN PIPE COVER..................................... 2-7 DRIVE CHAIN COVER........................ 2-19
MAIN PIPE COVER ········································· 2-7 DRIVE CHAIN COVER ·································2-19
SEAT ........................................................... 2-8 EXHAUST PIPE/MUFFLER ................ 2-19
SEAT ··································································· 2-8 EXHAUST PIPE/MUFFLER ·························2-19

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

(11)

(13)
(12) (14) (15)
(1)
(3)
(5)
(10)

(8)

(7)
(4)
(2)

(6)
(17)
(16) (9)
(1) Front Top cover (hal. 2-4) 10. Grab rail (hal. 2-8)
(1) Front top cover (page 2-4) (10) Grab rail (page 2-8)
(2) Lower side cover (hal. 2-6) 11. Seat (hal. 2-8)
(2) Lower side cover (page 2-6) (11) Seat (page 2-8)
(3) Main pipe cover (hal. 2-7) 12. Luggage box (hal. 2-10)
(4)(3) Main pipecover
Center (page2-6)
cover(hal. 2-7) 13.(12) Handlebar
Luggage box top(page
cover2-10)
(hal. 2-12)
(5)(4) Center fender(page
Front cover (hal.2-6)
2-5) 14.(13) Handlebar
Handlebar front cover(page
top cover (hal.2-12)
2-12)
(6)(5) Front fender
Footpeg (page
bar (hal.2-5)
2-18) (14)
15. Handlebar front cover (page
Handlebar rear cover (hal. 2-14)2-12)
(7)(6) Footpeg
Body coverbar (page
(hal.2-18)
2-9) 16.(15) Left
Handlebar rear rear
crankcase (page(hal.
covercover 2-14)2-19)
(8)(7) Body
Rearcover (page
fender 2-9)
(hal. 2-11) 17.(16) Drive
Left crankcase
chain coverrear cover
(hal. (page 2-19)
2-19)
(9)(8) Rear fender (page
Passenger 2-11)
footpeg holder (hal. 2-18) (17) Drive chain cover (page 2-19)
(9) Passenger footpeg holder (page 2-18)

DIAGRAM PELEPASAN BODY PANEL


BODY PANEL REMOVAL CHART
• This chart shows removal order of frame covers.
• Diagram ini memperlihatkan urutan pelepasan dari frame covers (penutup rangka).
(1) FRONT TOP COVER (4) CENTER COVER

(5) FRONT FENDER (3) MAIN PIPE COVER

(2) LOWER SIDE COVER (6) FOOTPEG BAR (17) DRIVE CHAIN COVER

(10) GRAB RAIL (9) PASSENGER FOOTPEG HOLDER

(7) BODY COVER


(16) LEFT CRANKCASE REAR COVER

(11) SEAT (12) LUGGAGE BOX (8) REAR FENDER

(13) HANDLEBAR TOP COVER (14) HANDLEBAR FRON T COVER (15) HANDLEBAR REAR COVER

2-2
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
KETERANGAN SERVIS
SERVICE INFORMATION
GENERAL
UMUM
• This section covers removal and installation of the body panels and exhaust system.
•• Bab ini burns
Serious meliputi
maypelepasan danexhaust
result if the pemasangan
systemdari body
is not panels
allowed dan exhaust
to cool system (sistem
before components pembuangan
are removed gas).
or serviced.
•• Always
Sistemreplace the exhaust
pembuangan pipe gasket
gas yang after removing
tidak dibiarkan the dingin
menjadi exhaustdulu
pipesebelum
from the komponen-komponen
engine. dilepaskan atau diservis,
• When
dapatinstalling the exhaust
mengakibatkan lukarsystem, loosely install all of the muffler fasteners. Always tighten the exhaust joint first, then tighten the
bakar parah.
mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly.
• • Always
Selalu inspect
ganti exhaust pipe gasket
the exhaust systemsetelah
for leaksmelepaskan exhaust pipe (pipa knalpot) dari mesin.
after installation.
• Sewaktu memasang exhaust system, pasanglah semua pengikat muffler (knalpot) dengan longgar dulu. Selalu kencangkan
exhaust joint (penyambung pipa knalpot) dulu,kemudian baru mounting fasteners (pengikat pemasangan). Jika mounting
TORQUE
fasteners VALUES
dikencangkan dulu, exhaust pipe mungkin tidak dapat duduk dengan benar.
• Selalu periksa exhaust system terhadap kebocoran setelah selesai dipasang.
Shock absorber upper mounting bolt 24 N·m (2.4 kgf·m, 18 lbf·ft)
Throttle cable lock nut – See page 2-17
TORSI PENGENCANGAN
Exhaust pipe joint nut 27 N·m (2.8 kgf·m, 20 lbf·ft)
Exhaust
Shock pipe stud
absorber uipperbolt
mounting bolt 24 N.m (2,4 kgf.m; 18 – lbf.ft) See page 2-21
Throttle cable lock nut - Lihat hal. 2-17
Exhaust pipe joint nut 27 N.m (2,8 kgf.m; 20 lbf.ft)
TROUBLESHOOTING
Exhaust pipe stud bolt - Lihat hal. 2-21

Excessive exhaust noise


• Broken exhaust system
TROUBLESHOOTING
• Exhaust gas leak
Poor performance
Knalpot berisik secara berlebihan
• • Deformed exhaustpatah
Exhaust system system
• Exhaust gas leak
• • Clogged
Ada kebocoran
muffler gas pembuangan

Unjuk kerja sepedamotor lemah


• Exhaust system berubah bentuk
• Ada kebocoran gas pembuangan
• Muffler (knalpot) tersumbat

2-3
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
FRONT
FRONT TOP
TOP COVER
COVER
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Remove
Lepaskanthe following:
sebagai berikut:
-– Dua
Twoboltsbolts(baut) dan license
and licence plate holder
plate holder (pemegang
from the front side nomorplat)
– dari
Twosisi special
depan screws from the lower front side
– Eight
- Dua special
special screws(sekrup
screws from the rear side
khusus) dari sisi depan bawah
– Front topspecial
- Delapan cover screws dari sisi belakang
Installation
- Front top iscover
in the reverse order of removal.
Pemasangan rubbers
• If the two were dropped,
adalah dalam clean dari
urutan terbalik the pelepasan.
rubbers
and frame surfaces. Apply Honda Bond A or equiva-
• lentJikato kedua
the rubbers on the
rubbers framekaret)
(cincin side. telah terjatuh, bersihkan
Wait 3 - 5 dan
rubbers minutes and install
permukaan the rubbers.
rangka. Oleskan Honda Bond A atau
sejenisnya pada rubbers pada sisi rangka.
Tunggu 3 – 5 menit dan pasang rubbers.

SPECIAL SCREWS

RUBBERS

LICENCE PLATE HOLDER

BOLTS

SPECIAL SCREWS

FRONT TOP COVER

2-4
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
FRONT FENDER
FRONT
FRONT FENDER
FENDER A
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Remove the
Lepaskan following:
sebagai berikut:
-– Front
Front top cover(hal.
top cover (page2-4)
2-4)
-– Bolt,
Bolt,speedometer
speedometercablecableclamp
clampdan andcollar
collar
-– Bolt,
Bolt,brake
brakehose
hoseguide
guidedan
andcollar
collar
-– Bolt/collar
Bolt/collar
Lepaskanthe
Remove front
front fender
fender A Adengan
by releasing the twokedua
melepaskan hookshooks
from slots of the front fender B.
(kaitan) dari slots (lubang pemasangan) pada front fender B.
Installation is in the reverse order of removal.
Pemasangan adalah dalam urutan terbalik dari pelepasan.
BRAKE HOSE CLAMP
COLLARS
BOLTS

HOOKS

FRONT FENDER A SLOTS

BOLT/COLLAR SPEEDOMETER CABLE GUIDE

FRONT
FRONT FENDER B
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Remove the
Lepaskan following:
sebagai berikut:
-– Front
Frontwheel
wheel(roda
(pagedepan)
12-7) (hal. 12-7)
-– Front
Frontfender
fenderAA(hal.
(page2-5)
2-5)
-– Dua
Twobolts/collars
bolts/collars
-– Front
Frontfender
fenderBB
Installation
Pemasangan is in the reverse
adalah order of
dalam removal.
urutan terbalik dari
pelepasan.

FRONT FENDER B

BOLTS/COLLARS

2-5
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
LOWER SIDE COVER
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan
Remove the sebagai berikut:
following:
- Front top cover (hal. 2-4)
- –Screw/washer
Front top cover (page 2-4)
- –Screw
Screw/washer
– Screw
Sisi kiri: Lepaskan
Remove the leftleftlower
lowerside
side cover dengan
cover by melepaskan
releasing the two
Lefttidak
side:
Hati-hati agar kedua tabs
tabs from the (lidah
slots onpemasangan)
the body coverdari slots
and left lower (lubang
side
Bemerusak
careful not to
tabs. pemasangan)
cover. pada body cover dan left lower side cover.
damage the tabs.
Sisi kanan: Lepaskan
Remove the right
rightlower
lower side cover bydengan
side cover melepaskan
releasing the three
Right side:
Hati-hati agar tidak ketiga tabsthe
tabs from darislotslots pada
on the body body cover
cover dan lower
and right right lower
side
Bemerusak
careful not to
tabs. side cover.
cover.
damage the tabs.
Pemasangan adalah dalam urutan terbalik dari
Installation is in the reverse order of removal.
pelepasan.
• • IfJika
therubber
rubber pada on each side were dropped,
masing-masing sisi telahclean the
terjatuh,
rubbers and lower side cover stay surfaces. Apply
bersihkan rubbers dan permukaan lower side cover
Honda Bond A or equivalent to the rubbers on the
stay.side.
stay
Oleskan
Wait Honda and
3 - 5 minutes Bond A the
install atau sejenisnya pada
rubbers.
rubbers pada stay side.
Tunggu 3 – 5 menit dan pasang rubbers.
Sisi kiri : Sisi kanan :

TABS
TABS

SCREW SCREW
RUBBER
RUBBER
SCREW/WASHER SCREW/WASHER

CENTER COVER
CENTER COVER
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Buka
Openkunci seatusing
the seat (tempat duduk)key.
the ignition dengan menggunakan
anak kunci kontak.
Remove the following: SPECIAL SCREWS
– Two special screws SCREW
Hati-hati agar tidak Lepaskan
– Screwsebagai berikut:
merusak tabs. - Dua special screws
Be careful not to - Release
Screw the tabs of the center cover from the slots of the
damage the tabs. body cover and remove the center cover.
Lepaskan
Installationtabs
is indari center cover
the reverse dari
order of slots pada body
removal.
cover dan lepaskan center cover.

Pemasangan adalah dalam urutan terbalik dari


pelepasan.

CENTER COVER SLOTS


TABS

2-6
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
MAIN PIPE COVER
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan
Remove the sebagai berikut:
following:
- Center cover (hal. 2-6)
– Center cover (page 2-6)
-– Sembilan special screws
Nine special screws
-– Dua
Twoscrews
screws
Hati-hati agar not
Be careful tidak
to Lepaskan
Release the tabs
tabspada sisirear
on the belakang dari main
side of main pipe cover
pipe cover from
merusak
damage thetabs
tabsdan
and the slots pada
dari on thelower
lowerside
sidecover
coverdan
and remove main
lepaskan the main
pipe
slots.
slots. pipe cover.
cover.
Installation is in the reverse order of removal.
Pemasangan adalah dalam urutan terbalik dari
pelepasan.

MAIN PIPE COVER


SCREWS

SLOTS

SPECIAL SCREWS
TABS
PEMBONGKARAN/PERAKITAN
DISASSEMBLY/ASSEMBLY
Lepaskan
Remove the screw
screwdan
andwater
waterguard
guardcover.
cover.
Lepaskan
Remove the kelima screwsand
five screws dan pisahkan
separate the main
main pipe rear
rear
cover dari
cover frommain
the main
pipe pipe
frontfront cover.
cover.
Assembly is in the reverse order of disassembly.
Perakitan adalah dalam urutan terbalik dari
pembongkaran.
SCREW
WATER GUARD COVER

SCREWS

MAIN PIPE FRONT COVER


MAIN PIPE REAR COVER

2-7
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
SEAT (TEMPAT DUDUK)
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Buka
Open
Removekunci
thethetempat
seattwousingduduk
nutsthe dengan
andignition
the key.menggunakan anak
seat.
kunci kontak.
Support the seat while Installation is in the reverse order of removal.
SEAT
removing the seat
nuts.
Peganglah Lepaskan kedua nuts dan seat.
sementara
melepaskan nuts. Pemasangan adalah dalam urutan terbalik dari
pelepasan.

NUTS

GRAB RAIL
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Openkunci
Buka the seat usingduduk
tempat the ignition
dengankey.menggunakan anak
BOLTS GRAB RAIL
Support the grab rail kunci kontak.
Remove the four mounting bolts and the grab rail.
while removing the Installation is in the reverse order of removal.
rail Lepaskan keempat mounting bolts dan grab rail.
Peganglah grabbolts.
sementara
melepaskan bolts. Pemasangan adalah dalam urutan terbalik dari
pelepasan.

2-8
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
BODY
BODY COVER
COVER
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan sebagai berikut:
- Remove the following:
Center cover (hal. 2-6)
- –Lower
Center sidecover (page
covers 2-6)2-6)
(hal.
- –Grab
Lowerrail side 2-8) (page 2-6)
(hal.covers
- –Dua
Grab rail (page
special screws 2-8)
– Two special screws
Right dan left body Lepaskan kedua lubang pada bagian belakang dari
Rightcovers
and left body Release the two holes on rear side of the body cover
dapat body cover
from the dari ofbosses
bosses frame. (tonjolan pemasangan) pada
covers
dilepaskan can be
dengan rangka.
removed in the
cara yang same
sama.
Release the two bosses from the grommets on the frame
Lepaskan
and tab from kedua thebosses dari grommets
rear fender, padatherangka
then remove body
manner. cover.
dan tab dari rear fender, kemudian lepaskan body
cover.
Installation is in the reverse order of removal.
Pemasangan adalah dalam urutan terbalik dari
pelepasan.
Sisi kanan diperlihatkan:
GROMMETS
BOSSES

HOLES

TAB

SPECIAL
SCREWS
BOSSES
BODY COVER
PEMBONGKARAN/PERAKITAN
DISASSEMBLY/ASSEMBLY
Lepaskan
Remove theketiga
threescrews
screwsdan
andrear
rear lower
lower cover from
dari rear
bodycover
coverdengan
by releasing the tab. tab. Sisi kanan diperlihatkan:
body melepaskan
Remove the four screws and center body cover from rear
Hanya sisi kanan: Lepaskan keempat screws dan center body cover dari
body cover. CENTER BODY REAR BODY COVER
rear body cover. COVER
Right side only: Remove the two screws and right lower body cover from
Lepaskan
rear body kedua
cover. screws dan right lower body cover dari
rear body cover.
Assembly is in the reverse order of disassembly. TAB
SCREWS
Perakitan adalah dalam urutan terbalik dari
pembongkaran.

REAR
LOWER
COVER

SCREWS

RIGHT LOWER BODY COVER

2-9
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
LUGGAGE BOX (KOTAK BAGASI)
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan
Remove the sebagai berikut:
following:
-– Baterai (hal. 15-5)
Battery (page 15-5)
-– Seat
Seat(hal. 2-8)
(page 2-8)
-– Body
Body cover(hal.
cover 2-9)
(page 2-9)
Lepaskan wire band
Release the wire band danand
lepaskan battery
disconnect the wire harness
battery wire
connectors dan starter
harness connectors motor motor
and starter 2P connector dari from
2P connector main
the main
wire wire harness.
harness.
Remove the
Lepaskan bolt,
bolt, two special
kedua specialbolts
boltsand
danthree collars.
tiga collars.
Release the air supply hose from the guide on the left
Tempatkan wire side of luggage
Lepaskan box. hose dari guide pada sisi kiri dari
air supply
harness dengan benar Raise the
luggage luggage box while pulling out the battery wire
box.
(hal. 1-15). Hati-hati harness. luggage box sementara menarik keluar battery
Naikkan
agar Route
tidak menjepit
the wire Installation
wire harness.is in the reverse order of removal.
wire harness antara
harnesses properly
luggage box dan Pemasangan adalah dalam urutan terbalik dari
(pagerangka.
1-16). pelepasan.
Be careful not to
pinch the wire SPECIAL BOLTS/
harness between the
AIR SUPPLY HOSE COLLARS
luggage box and
frame.
BATTERY WIRE
HARNESS

BOLT/COLLAR

GUIDE

LUGGAGE BOX

CONNECTORS
WIRE BAND

2-10
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
REAR FENDER
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Remove the
Lepaskan following:
sebagai berikut:
-– Brake/tail
Brake/taillight
lightunit
unit (hal.
(page18-8)
18-8)
-– Fuel
Fueltank
tank (hal.
(page5-17)
5-17)
Remove the
Lepaskan shockshock absorber
absorber left left
sideside
upperupper mounting
mounting bolt,
bolt, then turn the shock absorber backward.
kemudian putar shock absorber ke belakang.
Release the main wire harness from the three wire
Lepaskan
guides. main wire harness dari ketiga wire guides.
Lepaskan
Remove theketiga bolts,special
three bolts, special bolt
bolt anddan
rearrear fender.
fender.
Remove the
Lepaskan screw
screw and
dan cover.
cover.
Remove the spring, retainer and key cylinder.
Lepaskan spring, retainer dan key cylinder.
Installation is in the reverse order of removal.
Pemasangan
TORQUE: adalah dalam urutan terbalik dari
pelepasan.
SHOCK ABSORBER
UPPER MOUNTING
TORSI:
BOLT 24 N·m (2.4 kgf·m, 18 lbf·ft)
SHOCK ABSORBER 24 N.m (2,4 kgf.m; 18 lbf.ft)
UPPER MOUNTING BOLT
WIRE GUIDES
MAIN WIRE HARNESS

BOLTS

REAR FENDER

SCREW
COVER

SPECIAL BOLT

SPRING

UPPER MOUNTING RETAINER


BOLT
SHOCK ABSORBER KEY CYLINDER

2-11
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
HANDLEBAR COVER
HANDLEBAR
HANDLEBARTOP
TOPCOVER
COVER
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Remove the
Lepaskan four screws.
keempat screws.
Remove
Lepaskan the handlebar
handlebar toptop cover
cover by releasing
dengan the boss and tabs from the grommet and slots on the handlebar
melepaskan
front cover.
boss dan tabs dari grommet dan slots pada handlebar
front cover.
HANDLEBAR TOP COVER
TABS

GROMMET

BOSS

SCREWS

SLOTS

HANDLEBAR
HANDLEBARFRONT
FRONTCOVER
COVER
Removal/Installation
Pelepasan/Pemasangan
Remove the
Lepaskan handlebar
handlebar toptop cover
cover (page
(hal. 2-12).
2-12). REARVIEW MIRRORS
Loosen the lock
Longgarkan locknuts
nutsand remove
dan the rearview
lepaskan mirrors
rearview by
mirrors
turning
(kaca themdengan
spion) counterclockwise.
memutar mereka berlawanan arah
jarum jam.

LOCK NUTS

2-12
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
Hati-hati not to Lepaskan
agar tidak
Be careful Remove thesebagai berikut:
following:
merusak damage the -– Special
handlebar bolt pada sisi
Bolt/collar/rubber on depan.
the front side
handlebar front -– Enam
front cover. screws/washers
Six screws/washers
cover.
Remove the
Lepaskan handlebarfront
handlebar frontcover
cover dengan
by releasing the two
melepaskan
bossesbosses
kedua from the holes
dari on the handlebar
lubang-lubang rear cover rear
pada handlebar and
disconnecting the headlight 9P connector.
cover dan melepaskan headlight 6P connector.
Installation is in the reverse order of removal.
Pemasangan adalah dalam urutan terbalik dari
pelepasan.
BOSSES
HANDLEBAR FRONT COVER

BOLT
HOLES
COLLAR

RUBBER

HEADLIGHT 9P CONNECTOR
SCREWS/WASHERS
Pembongkaran/Perakitan
Disassembly/Assembly
Lepaskan
Remove the sebagai berikut:
following:
- Special bolt
-– Dua
Special bolt
holders
– Two holders
Lepaskan headlight assembly dengan melepaskan
Remove
kedua tabsthe headlight
dari assembly
slots pada by front
handlebar releasing
cover.the two
tabs from the slots on the handlebar front cover.
Assembly is adalah
Perakitan in the reverse
dalamorder urutan
of disassembly.
terbalik dari
pembongkaran.
SLOTS
HOLDERS

TABS

HEADLIGHT ASSEMBLY
SPECIAL BOLT

2-13
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
PELEPASAN
HANDLEBARHANDLEBAR REAR
REAR COVER
REMOVAL
COVER
Lepaskan handlebar
Remove the following:front cover (hal. 2-12).
BRAKE LIGHT SWITCH
Lepaskan speedometer
– Front top cable dari combination meter
cover (page 2-4) WIRE CONNECTORS
assembly. SPEEDOMETER
– Handlebar front cover (page 2-12)
CABLE
Lepaskan connectors berikut ini:
Disconnect the speedometer cable from the combination
- meter
Frontassembly.
brake light switch wire connectors
- Combination meter sub harness 9P/6P connectors
Disconnect the following connectors:
Lepaskan
– Front wire
brakeband
lightboss dariwire
switch rangka.
(Black, Green/Yellow)
Lepaskan combination meter sub harness dari cable
connectors
guides.
– Horn wire (Light green, Green) connectors
– Combination meter sub harness 9P/6P connectors CABLE
Release the wire band boss from the frame. GUIDES
Release the combination meter sub harness from the
cable guides.

HORN WIRE
CONNECTORS

WIRE BAND BOSS

COMBINATION METER SUB


HARNESS CONNECTORS
Lepaskan choke
Disconnect cable cable
the choke dari choke lever.
from the choke lever.

CHOKE CABLE

Lepaskan
Remove thekedua screws
two front depan
screws dan
and the rearspecial screw
special screw.
HANDLEBAR REAR SPECIAL
belakang.
Release the handlebar rear cover from the handlebar. COVER SCREW
Lepaskan handlebar rear cover dari handlebar.

SCREWS

2-14
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
Lepaskan screw
Remove the danand
screw throttle upper upper
the throttle housing dengan
housing by
unhooking the lower housing tab. SCREW UPPER HOUSING
melepaskan kaitan dari lower housing tab.

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

THROTTLE
CABLE

LOCK NUT LOWER HOUSING


Lepaskan
Remove thehandlebar rearrear
handlebar cover dengan
cover menarik
by pulling the choke
choke
and throttle
cable cables
dan throttle out ofkeluar
cables its holes.
dari lubangnya. CHOKE CABLE

HANDLEBAR
REAR COVER

THROTTLE CABLE

2-15
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
HANDLEBARREAR
HANDLEBAR REARCOVER
COVER
INSTALLATION
PEMASANGAN
Set the handlebar rear cover in position.
Letakkan handlebar rear cover pada posisinya.
Route the choke and throttle cables through the holes on
the handlebar
Alurkan choke rear
cablecover.
dan throttle cable melalui lubang-
lubang pada handlebar rear cover.

HANDLEBAR THROTTLE CABLE


REAR COVER

CHOKE CABLE
Alurkan
Route thethrottle cable
throttle melalui
cable throttle
through lower housing
the throttle dan
lower hous-
ing and
untuk temporarily
sementara tighten thelock
kencangkan locknut.
nut. THROTTLE
Apply grease
Oleskan gemuk to the throttle
pada alurpipe flangepipe
throttle groove and throt-
flange dan PIPE
tle pipepipe
throttle slot.slot.
Connect the throttle cable to the throttle pipe.
Hubungkan throttle cable pada throttle pipe.
Install the throttle lower housing in position by aligning
the pin with
Pasang the hole
throttle loweronhousing
the handlebar.
pada posisinya dengan
mentepatkan pin dengan lubang pada handlebar.
Tepatkan THROTTLE
CABLE

LOCK NUT LOWER HOUSING


Pasang throttle
Install the throttleupper
upper housing
housing by dengan mentepatkan
aligning its slot with
the lowerdengan
slot-nya housinglower
tab, then installtab,
housing andkemudian
tighten thepasang
screw. SCREW UPPER HOUSING
dan kencangkan screw.

TAB

2-16
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
Tighten the throttle
Kencangkan throttlecable
cablelock
locknutnut
to the specified
dengan torsitorque
yang
while holding
ditentukan the throttlemenahan
sementara cable in the specified
throttle angle
cable as
pada
shown.
sudut yang ditentukan seperti diperlihatkan.
TORQUE:10 N·m (1.0 kgf·m, 7 lbf·ft)
TORSI: 10 N.m (1,0 kgf.m; 7 lbf.ft)

LOCK NUT

THROTTLE CABLE

15°

HANDLEBAR

AlurkanRoute the wire Tempatkan


wire harness handlebar
Set the handlebar rear incover
rear cover pada
position, then posisinya,
install and
dengan benar (hal. 1- kemudian
harness properly tighten the two front
pasang danscrews and thekedua
kencangkan rear special
screwsscrew.
depan HANDLEBAR REAR SPECIAL
6) COVER SCREW
(page 1-16). dan special screw belakang.

SCREWS
Hubungkan
Connect thechoke
chokecable
cablepada choke
to the chokelever.
lever.

CHOKE CABLE

2-17
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
Hubungkan
Connect the speedometer
speedometercable padatocombination
cable meter
the combination
meter assembly. BRAKE LIGHT SWITCH
assembly.
WIRE CONNECTORS SPEEDOMETER
Route the wire Set the combination meter sub harness to the cable
Alurkan wire harness
harness properly guides.
Tempatkan combination meter sub harness pada cable CABLE
dengan benar (hal. 1- guides.
(page 1-16).
6) Connect the following connectors:
Pasang wire band boss pada rangka.
– Front brake light switch wire (Black, Green/Yellow)
connectors
Hubungkan
– Horn wire connectors berikut:
(Light green, Green) connectors
– Combination meter sub harness 9P/6P connectors
- Install
Combination
the wire meter sub harness
band boss 9P/6P connectors
to the frame.
- Front brake light switch wire connectors CABLE
Install the following: GUIDES
– Front
Pasang (pagecover
top coverfront
handlebar 2-4) (hal. 2-12)
– Handlebar front cover (page 2-12)

HORN WIRE
CONNECTORS

WIRE BAND BOSS

COMBINATION METER SUB


HARNESS CONNECTORS

FOOTPEG BAR
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan
Remove the keempat boltsand
four bolts danfootpeg
footpeg
barbar sementara
while pushing
down thepedal
menekan rear brake pedal. ke bawah.
rem belakang BOLTS
Installation is in the reverse order of removal.
Pemasangan adalah dalam urutan terbalik dari
pelepasan.

FOOTPEG BAR

PASSENGER FOOTPEG HOLDER


PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan muffler
Remove the mounting
muffler bolt,bolt,
mounting nut, nut,
washer, collar,
washer, dan
collar,
mount rubber
and mount (sisi kanan
rubber saja)only)
(right side (hal.(page
2-19).
2-19). Sisi kanan di perlihatkan: SOCKET BOLTS

Remove the two socket bolts and passenger footpeg


holder. kedua socket bolts dan passenger footpeg
Lepaskan BOLT/NUT/
holder. WASHER/
Installation is in the reverse order of removal.
COLLAR/
Pemasangan adalah dalam urutan terbalik dari RUBBER
pelepasan.

FOOTPEG
HOLDER

2-18
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
LEFT CRANKCASE REAR COVER
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan
Remove the kedua
two bolts
bolts dan
and left
left crankcase cover.
crankcase rear cover.
BOLTS
Installation is inadalah
Pemasangan the reverse
dalamorder urutan
of removal.
terbalik dari
pelepasan.

LEFT CRANKCASE
REAR COVER

DRIVE CHAIN COVER


PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Remove thebolt
Lepaskan bolt and
dan drive chain
drive cover cover
chain by releasing its
dengan
tab from thetab-nya
slot on the DRIVE CHAIN COVER
melepaskan dariswingarm.
slot pada swingarm. TAB
Installation is in the reverse order of removal.
Pemasangan adalah dalam urutan terbalik dari
pelepasan.

SLOT
BOLT

EXHAUST PIPE/MUFFLER
(PIPA KNALPOT)
REMOVAL
PELEPASAN
Remove the exhaust pipe joint nuts.

Lepaskan exhaust pipe joint nuts.

JOINT NUTS

2-19
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
Remove the
Lepaskan muffler
muffler mounting
mounting bolt,
bolt, nut,
nut, and
dan washer.
washer.
NUT/WASHER
Remove the
Lepaskan bolt. bolt.
Remove the exhaust pipe/muffler while pushing down
Lepaskan exhaust
the rear brake pedal.pipe/muffler sementara menekan
pedal rem belakang ke bawah.

MOUNTING BOLT BOLT


Lepas kanthe gasket from
Remove dari exhaustportport
the exhaust (lubang
of the cylinder
head.
pem buangan gas) dari cylinder head.

GASKET

PEMASANGAN
NUT

WASHER

MOUNT RUBBER

COLLAR

GASKET
EXHAUST PIPE/
MUFFLER

BOLTS

27 N·m (2.8 kgf·m, 20 lbf·ft)

2-20
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
EXHAUST
EXHAUSTPIPE
PIPESTUD
STUDBOLT
BOLT
Thread dua
Pasang two nuts
nuts(mur)
to the
padastud bolt
stud boltand
dantighten them
kencangkan
together,
mereka thensama
satu use alain,
wrench on thempakailah
kemudian to turn the stud pas
kunci bolt
out. memutar stud b olt keluar.
untuk
Install and tighten new stud bolts into the cylinder head
to the specified
Pasang torque.
dan kencangkan stud b olts baru ke dalam
cylinder
TORQUE:11head dengan
N·m (1.1torsi yang
kgf·m, ditentukan.
8 lbf·ft)
TORSI: 11 N.m (1,1 kgf.m ; 8 lbf.ft)
After tightening the stud bolts, check that the length from
Setelah mengencangkan
the bolt head to the cylinderstud
headbolts,
surfaceperiksa
is withinbahwa
speci-
fication. jarak dari kepala b olt sampai ke permukaan
panjang
cylinder head adalah sesuai dengan spesifikasi.
29.5 ± 1.0 mm
(1.16 ± 0.04 in)

Selalu
Alwaysganti the Pasang
gasket
replace Install asebuah gasket
new gasket intobaru
the ke dalamport
exhaust exhaust
of theport dari
cylinder
dengan
gasketyang
with baru. head. head.
a new cylinder
one.

GASKET

Tekan pedaltherem
Push down brakekepedal
bawah dan pasang
and install exhaust
the exhaust pipe/
muffler, exhaust
pipe/muffler, pipe pipe
exhaust joint joint
nuts, nuts,
muffler mounting
muffler bolts,
mounting
washer
bolts, and nut.
washer dan nut.
Tighten
Kencangkan the exhaust
exhaust pipe
pipejoint
jointnuts
nutsdengan
to thetorsi
specified
yang
torque.
ditentukan.
TORQUE:27 N·m (2.8 kgf·m, 20 lbf·ft)
TORSI: 27 N.m (2,8 kgf.m; 20 lbf.ft)
Tighten the muffler mounting bolt.
Hold the mounting
Kencangkan mufflerbolt and tighten
mounting bolt. the nut.
Tahan mounting bolt dan kencangkan nut.

EXHAUST PIPE/ JOINT NUTS


MUFFLER

NUT/WASHER

BOLT MOUNTING BOLT

2-21
MEMO
3. PERAWATAN

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


SERVICE INFORMATION ····························· 3-2 SECONDARY AIRSUPPLY
SECONDARY AIR SUPPLY SYSTEM...3-13
SYSTEM ········3-13

JADWAL PERAWATAN
MAINTENANCE ........................3-4
SCHEDULE ························ 3-4 DRIVE CHAIN················································3-13
DRIVE CHAIN ........................................3-13

SALURAN BAHAN BAKAR ..................3-5


FUEL LINE ························································ 3-5
BRAKE FLUID .......................................3-16
BRAKE FLUID ················································3-16

CARA KERJA THROTTLE ....................3-5


THROTTLE OPERATION ······························ 3-5
KEAUSAN BRAKE SHOES/PADS........3-16
BRAKE SHOES/PADS WEAR ······················3-16
CARA KERJA CHOKE ..........................3-6 SISTEM REM .........................................3-17
CHOKE OPERATION······································ 3-6 BRAKE SYSTEM ············································3-17
AIR CLEANER .......................................3-6 BRAKE LIGHT SWITCH ........................3-18
AIR CLEANER·················································· 3-6 BRAKE LIGHT SWITCH ······························3-18
CRANKCASE BREATHER....................3-7 ARAH SINAR LAMPU BESAR ..............3-18
CRANKCASE BREATHER····························· 3-7 HEADLIGHT AIM··········································3-18
BUSI .......................................................3-7 SISTEM KOPLING .................................3-19
SPARK PLUG ···················································· 3-7 CLUTCH SYSTEM ·········································3-19
JARAK RENGGANG KLEP...................3-9 STANDARD SAMPING..........................3-19
VALVE CLEARANCE ····································· 3-9 SIDESTAND·····················································3-19
OLI MESIN .............................................3-10 SUSPENSI .............................................3-19
ENGINE OIL····················································3-10 SUSPENSION···················································3-19
ENGINE OIL STRAINER SCREEN........3-11 MUR, BAUT, PENGIKAT .......................3-20
ENGINE OIL STRAINER SCREEN·············3-11 NUTS, BOLTS, FASTENERS ························3-20
ENGINE OIL CENTRIFUGAL FILTER...3-11 RODA/BAN ............................................3-20
ENGINE OIL CENTRIFUGAL FILTER ·····3-11 WHEELS/TIRES ·············································3-20
PUTARAN STASIONER MESIN ............3-12 BANTALAN KEPALA KEMUDI .............3-22
ENGINE IDLE SPEED ··································· 3-12 STEERING HEAD BEARINGS·····················3-22

3-1
KETERANGAN
SERVICE SERVIS
INFORMATION
MAINTENANCE

GENERAL
UMUM
• Place the motorcycle on a level ground before starting any work.
•• Gasoline
Letakkan is sepedamotor
extremely flammable and is
pada tanah explosive
mendatar under certain
sebelum memulaiconditions.
sesuatu pekerjaan.
•• Work in asangat
Bensin well ventilated area. Smoking
mudah terbakar or allowing
dan dapat meledak flames
pada or sparks
kondisi in the work area or where the gasoline is stored can cause a
tertentu.
fire or explosion.
•• The
Bekerjalah di tempat dengan ventilasi baik. Merokok atau membiarkan
exhaust contains poisonous carbon monoxide gas that may cause loss apiofatau percikan bunga
consciousness and api
maydilead
tempat kerja atau
to death. di
Run the
tempatindi
engine mana
and openbensin disimpan
area or with an dapat
exhaustmenyebabkan kebakaran
evacuation system atau
in and ledakan.
enclosed area.
• Gas pembuangan mengandung gas karbon monoksida beracun yang dapat menghilangkan kesadaran dan dapat membawa
kematian. Jalankan mesin di tempat terbuka atau di tempat tertutup yang dilengkapi dengan sistem pengeluaran gas
SPECIFICATIONS
pembuangan.
ITEM SPECIFICATIONS
Throttle grip freeplay
SPESIFIKASI 2 – 6 mm (0.1 – 0.2 in)
Spark plug Standard CPR6EA-9S (NGK) U20EPR9S (DENSO)
BAGIAN Optional SPESIFIKASICPR7EA-9S (NGK) U22EPR9S (DENSO)
Sparkmain
Jarak plug bebas
gap throttle grip 2 – 6 mm 0.80 – 0.90 mm (0.031 – 0.035 in)
Engine oil capacity
Spark plug (busi) At draining
Standard CPR6EA-9S (NGK) 0.8 liter (0.8 US qt, 0.7 lmp
U20EPR9S qt)
(DENSO)
At disassembly 1.0 liter (1.1 US qt, 0.9 lmp qt)
Pilihan CPR7EA-9S (NGK) U22EPR9S (DENSO)
Recommended engine oil API classification: SE, SF or SG
Jarak renggang busi 0,80 – 0,90 mm
(except oils labeled as energy conserving on the circular API ser-
Kapasitas oli mesin Pada penggantian periodik 0,8vice
literlabel)
Pada pembongkaran mesin 1,0Viscosity:
liter SAE 10W-30
JASO T 903 standard: MA
Oli mesin yang dianjurkan Oli mesin 4 tak dengan klasifikasi API service SJ,
Engine idle speed
Viskositas: SAE 10W-301,400 JASO ± 100 -1
MA min (rpm)
Putaranclearance
Valve stasioner mesin IN/EX 0.10 ± 0.02 mm (0.004 ± 0.001 in)
-1
1.400 ± 100 menit (rpm)
Drive chain Size – link RK 420SL – 102RJ
Jarak renggang klep IN (Masuk) / EX (Buang)
DID 0,10 ± 0,02 mm 420DX – 102RB
Drive chain Size - link
Slack
RK 420SL – 102RJ
30 – 40 mm (1.2 – 1.6 in)
(rantai roda) DID 420DX – 102RB
Drive chain length at 41 pins (40 links) 508 mm (20.0 in)
Recommended brake fluid Kekenduran 30 – 40 mm DOT 3 or DOT 4
Panjang drivefreeplay
Brake pedal chain pada 41 pins (40 links) 508 mm 20 – 30 mm (0.8 – 1.2 in)
Brake
Tire size (Brand) rem) yang dianjurkan
fluid (minyak Front DOT 3 atau DOT 4 M/C 38P (IRC: NF63B/SRI: FT 138)
70/90-17
Jarak main bebas brake pedal (pedal rem) Rear 20 – 30 mm 80/90-17 M/C 44P (IRC: NR78Y/SRI: FT 138)
2
Ukuran ban
Cold tire (Merk)
pressure Driver only DepanFront 70/90-17 M/C 38P (IRC: NF63B/SRI:
200 kPa D-FR)
(2.00 kgf/cm , 29 psi)
2
Rear
Belakang 80/90-17 M/C 44P (IRC: 225 kPa (2.25 kgf/cm
NR78Y/SRI: D-RR) , 33 psi)
2
Tekanan udara ban PengendaraDriver and passenger
saja DepanFront 200 kPa (2,00 kgf/cm200 kPa
; 29 (2.00 kgf/cm2, 29 psi)
psi)
2
dingin Rear
Belakang 225 kPa (2,25 kgf/cm225 kPa
; 33 (2.25 kgf/cm2, 33 psi)
psi)
2
Minimum tire tread depth Pengendara & DepanFront 200 kPa (2,00 kgf/cm ; 29 psi)To indicator
2
pembonceng Rear
Belakang 225 kPa (2,25 kgf/cm ; 33 psi)To indicator
Kedalaman minimum alur telapak ban Depan Sampai ke indikator
Belakang Sampai ke indikator
TORQUE VALUES
Oil drain bolt 24 N·m (2.4 kgf·m, 18 lbf·ft)
TORSI PENGENCANGAN
Valve adjusting lock nut 9 N·m (0.92 kgf·m, 6.6 lbf·ft) Apply oil to the threads and seating surface
Oil centrifugal filter cover bolt 5 N·m (0.51 kgf·m, 3.7 lbf·ft) Apply locking agent to the threads: See page 3-12
OilClutch
drain bolt
adjuster lock nut 24 N.m (2,4
12kgf.m; 18 kgf
N·m (1.2 lbf.ft)
·m, 9 lbf·ft)
Valve
Sparkadjusting
plug lock nut 9 N.m (0,92
16kgf.m; 6,6kgf
N·m (1.6 lbf.ft) Semprotkan oli ke ulir dan permukaan duduk
·m, 12 lbf·ft)
OilRear
centrifugal filter cover bolt
axle nut 5 N.m (0,51
59kgf.m; 3,7kgf
N·m (6.0 lbf.ft) Oleskan cairan
·m, 44 lbf·ft) pengunci pada ulir: Lihat hal. 3-12
U-nut
Clutch adjuster lock nut 12 N.m (1,2 kgf.m; 9 lbf.ft)
Throttle cable adjuster lock nut 3.8 N·m (0.39 kgf·m, 2.8 lbf·ft)
Spark plug (busi) 16 N.m (1,6 kgf.m; 12 lbf.ft)
Air cleaner housing cover screw 1.1 N·m (0.11 kgf·m, 0.8 lbf·ft)
Rear axle nut 59 N.m (6,0 kgf.m; 44 lbf.ft) U-nut
Front spoke
Throttle cable adjuster lock nut 3,8 N.m (0,39 N·m (0.25
2.5 kgf.m; 2,8 kgf ·m, 1.8 lbf·ft)
lbf.ft)
AirRear spoke
cleaner housing cover screw 1,1 N.m (0,11 N·m (0.38
3.7 kgf.m; 0,8 kgf ·m, 2.7 lbf·ft)
lbv.ft)

3-2
TOOLS
Valve adjusting wrench Spoke wrench, 4.5 x 5.1 mm
07708-0030400 07701-0020200

3-3
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,
P: Periksa danLubricate or Setel,
Bersihkan, Replace if necessary.
Lumasi C: Clean.
atau Ganti R: Replace.
bila perlu. A: Adjust.
B: Bersihkan. L: Lubricate.
G: Ganti. S: Setel. L: Lumasi .
The following items require some mechanical knowledge. Certain items (particularly
Bagian-bagian berikut memerlukan pengetahuan mekanis tertentu. Beberapa bagian (terutama those marked * and
yang**)ditandai
may require more
* dan **) techni-
dapat
cal information and tools. Consult an authorized Honda dealer.
memerlukan lebih banyak informasi tehnis dan perkakas khusus. Hubungi AHASS Anda.
FREQUENCY WHICHEVER
YANGCOMES
LEBIH → FIRST PEMBACAAN ODOMETER
ODOMETERREADING (NOTE
(km) - CATATAN 1 1)
REFER TO
FREKUENSI DULU DI- X1,000 km 1 4 8 12 LIHAT
PAGE
CAPAI ↓ PB I X1,000
PB II mi 0.6
PB III 2.5 5 7.5 HALAMAN
ITEMS Km 500 Months
2.000 4.000 6 8.000 12 18
12.000
BAGIAN
* FUEL YANGLINEDISERVIS Bulan 6 I 12 I 18 I 3-5
** THROTTLE
SALURAN BAHAN OPERATION
BAKAR P IP I P I 3-5 3-5
** CHOKE
CARA KERJAOPERATION
THROTTLE P IP I P I 3-5 3-6
* AIR CLEANER
CARA KERJA CHOKE NOTE2 EVERY
P 16,000P km (10,000 P mi) R 3-6 3-6
CRANKCASE
AIR CLEANER BREATHER Catatan 2 NOTE3
SETIAP 16.000 km: G C C C 3-6 3-7
SPARK PLUG
CRANKCASE BREATHER Catatan 3 B I B R B I 3-7 3-7
** VALVE
BUSI CLEARANCE P P PI IG I P I 3-7 3-9
R R
** ENGINE OIL
JARAK RENGGANG KLEP P P PR P P R 3-93-10
* ENGINE OIL STRAINER SCREEN C 3-11
OLI MESIN G G G G G 3-10
* ENGINE OIL CENTRIFUGAL FILTER C 3-11
* ENGINE OIL STRAINER SCREEN B 3-11
** ENGINE IDLE SPEED I I I I 3-12
** SECONDARY
ENGINE OIL CENTRIFUGAL
AIR SUPPLY FILTER
SYSTEM B I 3-11
3-13
** DRIVE
PUTARAN STASIONER
CHAIN MESIN P P P P
EVERY 1,000 km (600 mi) I, L P 3-12
3-13
* SECONDARY
BRAKE FLUID AIR SUPPLY SYSTEM NOTE4 I I P I 3-13
3-16
RANTAI SHOES/PADS
BRAKE RODA WEAR SETIAP 500 km: L I I I 3-13
3-16
BRAKE FLUID
BRAKE SYSTEM (MINYAK REM) Catatan 4 PI IP I P I 3-16
3-17
KEAUSAN
* BRAKE BRAKE
LIGHT SHOES/ /PADS
SWITCH P IP I P I 3-16
3-18
SISTEM REM AIM
* HEADLIGHT P P P IP I P I 3-17
3-18
* SAKELARSYSTEM
CLUTCH LAMPU REM PI IP I P I 3-18
3-19
* ARAH SINAR LAMPU BESAR
SIDESTAND P P P IP I P I 3-18
3-19
SISTEM KOPLING
* SUSPENSION P P P IP I P I 3-19
3-19
STANDARD
* NUTS, BOLTS,SAMPING
FASTENERS PI P I P 3-19
3-20
*** WHEELS/TIRES
SUSPENSI PI IP I P I 3-19
3-20
*** STEERING
MUR, BAUT,HEADPENGIKAT
BEARINGS P P I P I 3-20
3-22
** RODA/BAN P P P P P 3-20
*** Should
BANTALAN KEPALA KEMUDI
be serviced by an authorized Honda dealer, P unless the owner has proper tools and service data P and is mechanically
3-22
qualified.
* ** Harus
In thediservis
interestoleh
of safety,
AHASS, we kecuali
recommend these items
bila pemilik be serviced
mempunyai tools only
yangbytepat
an authorized Honda dealer.
dan data servis
yang diperlukan, dan mempunyai ketrampilan mekanis untuk mengerjakannya.
Honda recommends that an authorized Honda dealer should road test your motorcycle after each periodic maintenance is carried out.
** Demi keamanan, kami menganjurkan agar pekerjaan-pekerjaan ini hanya dilakukan oleh
NOTES: AHASS.
1. At higher odometer readings, repeat at the frequency interval established here.
2. Service at every 16,000 km (10,000 mi) more frequently when riding in unusually wet or dusty areas (cleaning is prohibited).
CATATAN:
3. Service more frequently when riding in rain or at full throttle.
1.
4. Replace Pada pembacaan
every odometer lebih
2 years. Replacement tinggi,mechanical
requires ulangilah pada
skill. interval frekuensi yang ditentukan di atas.
2. Servis lebih sering jika dikendarai di daerah yang luar biasa basah atau berdebu.
3. Servis lebih sering jika dikendarai dalam hujan atau dengan gas penuh.
4. Ganti setiap 2 tahun. Penggantian memerlukan ketrampilan mekanis.

3-4
FUEL LINE
FUEL LINE (SALURAN BAHAN BAKAR)
Lepaskan left left
Remove the b ody cover
body (hal.
cover 2-9).2-9).
(page
FUEL LINE
Periksa
Check the saluran bahan
fuel line bakar terhadap
for deterioration, damagepemburukan
or leakage.
kondisi,
Replace kerusakan atau
the fuel line kebocoran.
if necessary.
Ganti saluran
Install the leftbahan bakar(page
body cover bila perlu.
2-9).
Pasang left b ody cover (hal. 2-9).

FUEL LINE

CARA KERJA THROTTLE


THROTTLE
(GAS OPERATION
TANGAN)
Periksa
Check terhadap pemburukanorkondisi
for any deterioration damage atau kerusakan
to the throttle
cable.throttle
pada Checkcable.
the throttle
Periksa grip for grip
throttle smooth operation.
(putaran gas
Check that
tangan) the throttle
terhadap opens cara
kelancaran and automatically
kerja. Periksaclosesbahwa in
all steering positions. 2 – 6 mm (0.1 – 0.2 in)
throttle membuka dan secara otomatis menutup kembali
If thesemua
pada throttleposisi
grip does not return properly, lubricate the
kemudi.
throttle cable, and overhaul and lubricate the throttle grip
housing.
Jika throttle grip tidak kembali dengan benar, lumasi
For cable
throttle lubrication:
cable, Disconnect
dan bongkar danthe throttlethrottle
lumasi cable at its
grip
upper end. Thoroughly lubricate the cable and its pivot
housing.
point
If the with a commercially
throttle grip still doesavailable
not returncable lubricant
properly, or a
replace
lightweight
the throttle oil.
cable.
Pemakaian kembali Untuk melumasi cable: Lepaskan throttle cable pada
throttle
Reusingcable yang
a damaged, With the
ujung engineLumasi
atasnya. idling, turn thedan
cable handlebar all the way to
titik perputarannya
rusak, tertekukbent
abnormally atauor the right
secara and left to dengan
menyeluruh ensure that the idle
pelumas speed
kabel yangdoes not
dapat
kusut secara
kinked throttletidak
cable change. If idle speed increases, check the throttle grip
dibeli di pasaran
freeplay ataucable
and throttle dengan oli dengan berat ringan.
connection.
can normal
preventdapat
proper
mengganggu cara Measure thegrip
throttle
throttle operation
kerja throttle yang
and Jika throttle tetapgrip freeplay
tidak dapatat kembali
the throttle grip
dengan
may lead to a loss of flange.
benar dan dapat benar, gantilah throttle cable.
throttle control while
mengakibatkan FREEPLAY: 2 – 6 mm (0.1 – 0.2 in)
riding.
kehilangan Sementara mesin berputar stasioner, putar handlebar
pengontrolan atas (stang stir) sama sekali ke kanan dan ke kiri untuk
throttle sewaktu
memastikan bahwa putaran stasioner tidak berubah.
mengendarai
sepedamotor. Jika putaran stasioner naik, periksa jarak main bebas
throttle grip dan perletakan throttle cable.

Ukur jarak main bebas throttle grip pada throttle grip


flange.

JARAK MAIN BEBAS: 2 – 6 mm

3-5
Jarak main
Throttle bebas
grip throttle
freeplay cangrip
be dapat disetel
adjusted pada throttle
at throttle cable
adjuster.
cab le adjuster. ADJUSTER
Lepaskan
Remove the dust cover
dust darifrom
cover adjuster.
the adjuster.
Longgarkan
Loosen the lock nut.
Adjust
Setel the main
jarak freeplay by turning
bebas denganthe adjuster.
memutar adjuster.
Tighten the lock
Kencangkan locknutnut
to the specified
dengan torque
torsi yangwhile holding
ditentukan
the adjuster.
sementara menahan adjuster.
TORQUE:3.8 N·m (0.39 kgf·m, 2.8 lbf·ft)
TORSI: 3,8 N.m (0,39 kgf.m ; 2,8 lbf.ft)
Install the dust cover to the adjuster.
Pasang
Recheck dust
thecover pada
throttle adjuster.
operation.
Replace any damaged parts, if necessary. LOCK NUT
Periksa kembali cara kerja throttle.
Ganti parts yang rusak, bila perlu.
DUST COVER

CHOKE
CARA OPERATION
KERJA CHOKE
Periksa
Check terhadap
for smooth kelancaran
choke levercaraoperation
kerja choke
andlever dan
lubricate
the choke
lumasi cable
choke if required.
cable bila perlu.
Inspect the cable for cracks which could allow moisture
Periksa
to enter.cable terhadap retak-retak yang memungkinkan
Replace theuntuk
kelembaban chokemasuk
cable ifke
necessary.
dalam.

Ganti choke cable bila perlu.

CHOKE LEVER

AIR CLEANER
CATATAN:
• • The
Viscous air cleaner
viscous paper element
paper element connect tidak dapat
be cleaned
dibersihkan
because the oleh karena
element element
contains mengandung
a dust adhesive. lem
• Ifyang
the mengikat
motorcycledebu.
is used in unusually wet or dusty
• areas,
Jika sepedamotor dipakai
more frequent di daerah
inspections yang luar biasa
are required.
Remove the screws, air cleaner housingpemeriksaan
basah atau berdebu, akan diperlukan cover and
yang lebih sering.
seals. SCREWS AIR CLEANER
ELEMENT
Remove and
Lepaskan discard
screws, the air housing
air cleaner cleaner cover
element
daninseals.
accor-
dance with the maintenance schedule (page 3-4).
Lepaskan dan buanglah air cleaner element mengikuti
Replace the element any time if it is excessively dirty or
jadwal perawatan (hal. 3-4).
damaged.
Make sure
Pastikan bahwathe seals
seals Install the removed parts in the reverse order of removal.
Gantilah element setiap kali ia sangat kotor atau dalam
are properly
telah ditempatkan TORQUE:
keadaan rusak.
positioned
dengan in the
benar pada AIR CLEANER
alur-alur
grooves dari
on air
air
cleaner
HOUSING
Pasanglah SCREW
parts 1.1 N·m (0.11
yang dilepaskan kgf·m,
dalam 0.8 lbf·ft)
urutan terbalik
cleanerhousing
housingdan and
cover. dari pelepasan.
cover.
TORSI:
AIR CLEANER 1,1 N.m (0,11 kgf.m; 0,8 lbf.ft)
HOUSING SCREW

AIR CLEANER
HOUSING COVER
SEALS

3-6
CRANKCASE BREATHER
CRANKCASE BREATHER
CATATAN:
Servis
Servicelebih
moresering bilamana
frequently whendikendarai dalam
ridden in rain hujan
or at full
throttle.
atau Service
dengan gasif penuh.
the deposit level
Servis bilacan be seen
tinggi in the
permukaan CLIP
drain cap.
endapan dapat terlihat pada drain cap.
Check the crankcase breather drain cap.
If deposits
Periksa has collected,
crankcase remove
b reather the clip and crankcase
drain cap.
breather
Bila drain cap.
endapan telah terkumpul, lepaskan clip dan
Drain deposits into the suitable container.
crankcase
Install the bcrankcase
reather drain cap. drain cap and clip.
breather
Keluarkan endapan dan buang ke dalam penampung
yang sesuai.
Pasang crankcase b reather drain cap dan clip.

DRAIN CAP
Remove the
Lepaskan leftleft body
b ody cover
cover (page
(hal. 2-9).
2-9).
BREATHER HOSE
Check crankcase
Periksa the crankcase breather
b reather hose hose for deterioration,
terhadap pemburukan
damagekerusakan
kondisi, or leakage.atau kebocoran.
Install the left body cover (page 2-9).
Pasang left b ody cover (hal. 2-9).

SPARK PLUG
SPARK PLUG (BUSI)
PELEPASAN
REMOVAL
Disconnect
Lepaskan the
spark
Remove the spark
plug
spark plug cap.
cap.
plug. SPARK PLUG
Clean around
Bersihkan daerah the
di Lepaskan
Inspect orbusi.
replace as described in the maintenance
spark plugdasar
sekitar base busi
with schedule (page 3-4).
dengan udara
compressed dari
air before Periksa atau ganti seperti diuraikan di dalam jadwal
kompressor the plug perawatan (hal. 3-4).
removingsebelum
melepaskan
and makebusisuredan
no
pastikan
debris bahwa tidak
is allowed to
adathe
enter kotoran yang
combustion
dapat memasuki
chamber.
ruang pembakaran.

SPARK PLUG CAP

3-7
INSPECTION
PEMERIKSAAN
Clean the spark
Bersihkan plug electrodes
kutub-kutub with a sikat
busi dengan wire brush
kawator atau
spe-
cial plugspecial
cleaner. CENTER ELECTRODE
dengan plug cleaner.
Check the insulator for cracks or damage, and the elec-
Periksa insulator
trodes for terhadap
wear, fouling retak-retak atau kerusakan,
or discoloration.
dan electrodes terhadap keausan, pengotoran atau
Replace the plug if necessary.
perubahan warna.
Always use the RECOMMENDED SPARK PLUG (OR EQUIVALENT):
Selalu pakai
specified sparkbusi
plug Standard:
Ganti NGK:
busi bila perlu. CPR6EA-9S
yang
ontelah ditentukan
this motorcycle. DENSO: U20EPR9S
untuk sepedamotor
BUSI YANG DIANJ
Optional: NGK: URKAN (ATAU SEJ ENISNYA):
CPR7EA-9S
ini.
Standard: DENSO: NGK: U22EPR9SCPR6 EA-9S
DENSO: U20EPR9S
Pilihan: NGK: CPR7 EA-9S
DENSO: U22EPR9S
INSULATOR SIDE ELECTRODE

Ukur jarak the


Measure renggang
spark busi
gap antara
between center
the electrode
center and(kutub
side
electrodes
tengah) danwith a feeler
side gauge.(kutub samping) dengan
electrode
feeler gauge (lidah pengukur).
SPARK PLUG GAP:
0.80 –RENGGANG
JARAK 0.90 mm (0.031 – 0.035 in)
BUSI:
If0,80 – 0,90 mm
necessary, adjust the gap by bending the side elec- 0.80 – 0.90 mm
trode carefully.
(0.031 – 0.035 in)
Bila perlu, setel jarak renggang dengan menekuk side
electrode dengan hati-hati.

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

Sambungkan spark plug cap (topi busi).

SPARK PLUG CAP

3-8
VALVE CLEARANCE
JARAK RENGGANG KLEP
CATATAN:
• Periksa dan setel jarak renggang klep sementara
• Inspect and adjust the valve clearance while the
mesin dalam
engine is cold keadaan
(below 35dingin
°C/95°(di
F).bawah 35° C).
INSPECTION
PEMERIKSAAN
Remove the
Lepaskan following:
sebagai berikut:
– Left lower side cover (page 2-6)
- –Left lowerplug
Spark side(page
cover (hal. 2-6)
3-7)
- –Spark plug head
Cylinder (busi)cover
(hal. (page
3-7) 7-6)
- Cylinder head cover (hal. 7-6)
Shift the transmission into 3rd or 4th gear. GARIS"I"
Masukkan transmissi ke dalam gigi 3 atau 4.
Turn the rear wheel counterclockwise little by little, in a
quickroda
Putar motion.
belakang berlawanan arah jarum jam sedikit
Position
demi the dengan
sedikit, cam sprocket
gerakan socepat.
that the cylinder head top
Tempatkan cam sprocket "ll"
surface comes between the and "l" lines
sedemikian on the
sehingga
sprocket.
permukaan atas cylinder head berada antara garis-garis GARIS"Il"
Make
"II" dansure the piston
"I" pada is at TDC (Top Dead Center) on the
sprocket.
compression stroke.
This position can be obtained by confirming that there is
Pastikan bahwa
slack in the rocker piston
arms.berada pada
If there is TDC turn
no slack, (ToptheDead
rear
Center)
wheel again[TMA until–theTitik
correct Mati Atas]
position pada langkah
is obtained.
kompressi.
Posisi ini dapat diperoleh dengan memastikan bahwa
ada kelonggaran pada rocker arms. Jika tidak ada
kelonggaran, putar roda belakang sekali lagi sampai
posisi yang benar telah diperoleh.

Periksa jarakvalve
Check each renggang masing-masing
clearance by inserting a valve (klep)
feeler gauge
betweenmemasukkan
dengan the valve adjusting
feelerscrew
gaugeand (lidah
valve stem.
pengukur)
antara valve adjusting screw dan valve stem.
VALVE CLEARANCE:
IN/EX:0.10 ± 0.02 mm (0.004 ± 0.001 in)
JARAK RENGGANG KLEP:
IN/EX: 0,10 mm ± 0,02 mm

FEELER GAUGE

PENYETELAN
ADJUSTMENT
Adjustdengan
Setel by loosening the lock nutlock
melonggarkan and turning
nut danthe memutar
adjusting
screw until
adjusting theresampai
screw is a slight
adadrag on a feeler
tahanan sedikitgauge.
pada feeler ADJUSTING SCREW LOCK NUT
gauge.
Apply engine oil to the lock nut.
Hold the adjusting screw and tighten the lock nut to the
specified torque.
Semprotkan oli mesin pada lock nut.
Tahan
TOOL: adjusting screw dan kencangkan lock nut dengan
torsi
Valveyang ditentukan.
adjusting wrench 07708-0030400
TOOL:
TORQUE:9 N·m (0.92 kgf·m, 6.6 lbf·ft)
Valve adjusting wrench 07708-0030400
Recheck the valve clearance.
TORSI: 9 N.m (0,92 kgf.m ; 6,6 lbf.ft)
Install the following:
Periksa kembali jarak renggang klep.
– Cylinder head cover (page 7-7) VALVE ADJUSTING
– Spark
Pasang plug (page
sebagai 3-8)
berikut: WRENCH
- –Cylinder
Left lower
headside cover
cover (page
(hal. 7-7)2-6)
- Spark plug (hal. 3-8)
- Left lower side cover (hal. 2-6)

3-9
OLI MESIN
ENGINE OIL
PEMERIKSAAN TINGGI PERMUKAAN
OIL LEVEL INSPECTION
OLI
Start the engine and let it idle for 3 – 5 minutes.
Hidupkan mesin dan biarkan berputar stasioner selama O-RING
Stop the engine and wait 2 – 3 minutes.
3 – 5 menit.
Hold the motorcycle in an upright position.
Matikan
Removemesin
the oildan tunggu
filler 2 – 3 menit.
cap/dipstick and wipe oil from the
Tahan sepedamotor
dipstick with a clean padacloth.posisi tegak. BATAS
Lepaskan
Insert theoil
oilfiller
fillercap/dipstick
cap/dipstick(tutup lubang
without pengisian
screwing it in, ATAS
remove it and
oli/tangkai check the
pengukur) danoilseka
level.oli dari dipstick dengan
kain bersih. BATAS
Pasang oil filler cap/dipstick tanpa menyekrupnya ke BAWAH
dalam, lepaskan dan periksa tinggi permukaan oli.

OIL FILLER CAP/


DIPSTICK
Jika
If thepermukaan
level is below di bawah
or near atau dekatlevel
the lower dengan
on thelower
dip-
stick, add
level- the recommended
(tinggi oil to the upper
permukaan terendah) padalevel.
dipstick,
tambahkan dengan oli yang dianjurkan sampai ke upper
RECOMMENDED ENGINE OIL:
level (tinggi permukaan teratas).
API classification: SE, SF or SG
OLI(except
MESINoils YANG DIANJURKAN:
labeled as energy conserving on the circular
Oli
APImesin
service4 label)
tak dengan klasifikasi API service SJ.
Viskositas:
Viscosity: SAE SAE10W-30
10W-30, JASO MA
JASO T 903 standard: MA
Periksa bahwa O-ring pada pada oil filler cap berada
dalam
Checkkondisi
that thebaik, dan
O-ring onganti bila
the oil perlu.
filler cap is in good condi-
Pasang
tion, and oilreplace
filler cap/dipstick.
it if necessary.
Install the oil filler cap/dipstick.

ENGINE OIL CHANGE


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

TORSI: 24 N.m (2,4 kgf.m ; 18 lbf.ft)

DRAIN BOLT/SEALING WASHER

Isi
Fillmesin dengan
the engine olirecommended
with mesin yang dianjurkan.
engine oil.
O-RING
ENGINE OILOLI
KAPASITAS CAPACITY:
MESIN:
0,8 liter padaUS
0.8 liter (0.8 qt, 0.7 lmp qt)
penggantian at draining
periodik
1,0 liter pada pembongkaranat
1.0 liter (1.1 US qt, 0.9 lmp qt) disassembly
mesin
Check that the O-ring on the oil filler cap is in good condi-
Periksa
tion, andbahwa
replaceO-ring pada oil filler cap berada dalam
it if necessary.
kondisi baik,
Install the oildan
fillerganti bila perlu.
cap/dipstick.
Pasang
Make sure oil filler
therecap/dipstick.
are no oil leaks.
Check the
Pastikan engine
bahwa oil level
tidak (page 3-10).oli.
ada kebocoran

Periksa tinggi permukaan oli mesin (hal. 3-10).


OIL FILLER CAP/DIPSTICK

3-10
ENGINE
ENGINE OIL
OIL STRAINER
STRAINER SCREEN
SCREEN
Lepaskan right
Remove the crankcase
right cover
crankcase (hal.
cover 9-5).
(page 9-5).
Lepaskan
Remove the oil oilstrainer
strainer screen and
danclean
bersihkan dalam
it in non-flam-
larutan
mable orpembersih
high flash point yangsolvent.
tidak dapat terbakar atau
mempunyai
Install the oil titik api tinggi.
strainer screen with its tapered side facing SISI
the crankcase side and thinner edge facing up as shown. CRANKCASE
Pasang
Install theoilrightstrainer
crankcase cover dengan
screen (page 9-8).sisinya yang
meruncing menghadap ke sisi crankcase dan ujung
yang lebih tipis di sebelah atas seperti diperlihatkan
pada gambar.

Pasang right crankcase cover (hal. 9-8).

OIL STRAINER SCREEN

ENGINE OIL
ENGINE OIL CENTRIFUGAL
CENTRIFUGAL FILTER
FILTER
PEMBERSIHAN
CLEANING
Remove the
Lepaskan right
right crankcase
crankcase cover
cover (page
(hal. 9-5).
9-5).
GASKET BOLTS
Remove the
Lepaskan bolts,
b olts, oil centrifugal
oil centrifugal filter
filter cover
cover danand gasket.
gasket.

OIL CENTRIFUGAL FILTER COVER


Bersihkan
Clean the oil
oil centrifugal
centrifugal cover dan bagian
filter cover dalamof dari
and inside the
drive
driveplate
platedengan
using a menggunakan kain bersih yang tidak
clean lint-free cloth.
mudah terurai.

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

3-11
Oleskan zat pengunci
Apply locking agent topada ulircentrifugal
the oil oil centrifugal
filterfilter
covercover
bolt
threads
bolt as diperlihatkan.
seperti shown. 4.5 ± 1.0 mm (0.18 ± 0.04 in)

Install the
Pasang oil oil centrifugal
centrifugal filter
filter cover
cover and
dan bolts.
b olts.
Tighten the bolts BOLTS
Kencangkan boltsto the specified
dengan torque.
torsi yang ditentukan.
TORQUE:5 N·m (0.51 kgf·m, 3.7 lbf·ft)
TORSI: 5 N.m (0,51 kgf.m ; 3,7 lbf.ft)
Install the right crankcase cover (page 9-8).
Pasang right crankcase cover (hal. 9-8).

OIL CENTRIFUGAL FILTER COVER

PUTARAN STASIONER
ENGINE IDLE SPEED MESIN
CATATAN:
• Periksa dan setel putaran stasioner mesin setelah
• Inspect
semua and adjust
bagian the engine
perawatan mesin idle yang
speedlain
after all
telah
other engine maintenance items have been per-
dijalankan dan adalah sesuai dengan
formed and are within specifications. spesifikasi.
• • The
Mesinengineharus
must dalam
be warmkeadaan
for accurate panas
engine untuk
idle
pemeriksaan
speed inspectiondan
andpenyetelan
adjustment. putaran stasioner
-1
• Use
yangaakurat.
tachometer with graduations of 50 min (rpm)
• or smaller tachometer
Pakailah that will accurately
denganindicate
skala 50 a 50 min-1-1 (rpm)
menit (rpm)
change.
atau lebih kecil yang dapat memperlihatkan
-1
perubahan
Warm sebesar
up the engine for 50 menit
about (rpm) dengan akurat.
10 minutes.
THROTTLE STOP SCREW
Connect a tachometer according to the tachometer man-
Panaskan
ufacturer’smesin selama
operating kira2 10 menit.
instructions.
Hubungkan tachometer
Check the engine idle speed. sesuai dengan petunjuk
pemakaian pabrik tachometer.
IDLE SPEED: 1,400 ± 100 min-1 (rpm)
Periksa
Turn theputaran stasioner
throttle mesin.
stop screw as required to obtain the
specified engine idle speed. -1
PUTARAN STASIONER: 1.400 ± 100 menit (rpm)
Putar throttle stop screw sebanyak yang diperlukan
untuk mendapatkan putaran stasioner mesin yang
ditentukan.

3-12
SECONDARY
SECONDARY AIR
AIR SUPPLY
SUPPLY SYSTEM
SYSTEM
Lepaskan
Remove the sebagai berikut:
following:
VACUUM HOSE
- –Right
Rightlower
lowerside
sidecover
cover(hal. 2-6)
(page 2-6)
- –Left b ody
Left bodycover
cover(hal. 2-9)
(page 2-9)
Periksa
Check theair air
supply hose
supply danand
hose pipe antara
pipe PAIR
between thecontrol
PAIR
valve
controldan
valveexhaust port port
and exhaust (lubang pembuangan
for cracks, gas)
deterioration,
damage or
terhadap loose connections.
retak-retak, pemburukan kondisi, kerusakan
atau hubungan
Check the vacuumlonggar.
hose between the PAIR control valve
and inlet pipe vacuum joint for cracks, deterioration,
damagevacuum
Periksa or loose hose
connections.
antara PAIR control valve dan
inlet pipe vacuum joint terhadap retak-retak,
pemburukan kondisi, kerusakan atau hubungan longgar.

AIR SUPPLY HOSE/PIPE


Check the
Periksa air supply
air supply hoses
hoses for deterioration,
terhadap pemburukan damage or
kondisi,
loose connections.
kerusakan atau hubungan longgar. AIR SUPPLY HOSES
Also check that hoses are not cracked, kinked or
pinched.
Juga periksa bahwa hoses tidak ada retak-retak, kusut
atau
Make terjepit.
sure that the hoses are not cracked.
Remove and check the air supply hoses.
Pastikan bahwa hoses tidak ada retak-retak.
If there are
Lepaskan dancarbon
periksadeposits
air supplyinhoses.
the air supply hoses,
checkada
Jika the PAIR valve (page
checkkarbon
endapan pada5-19)
air. supply hoses,
periksa PAIR
Install the check parts
removed valve in
(hal.
the5-19).
reverse order of removal.

Pasang parts yang telah dilepaskan dalam urutan


terbalik dari pelepasan.

DRIVE CHAIN
DRIVE CHAIN (RANTAI PENGGERAK)
CATATAN:
Jangan sekali-kali memeriksa dan setel drive chain
Never inspect and adjust the drive chain while the engine
sementara
is running.mesin dalam keadaan hidup.
DRIVE CHAIN SLACK
PEMERIKSAAN KEKENDURAN INSPECTION DRIVE
CHAIN
Support the motorcycle with its centerstand and shift the
transmission
Letakkan into neutral.pada standard utamanya dan
sepedamotor
masukkan transmissi
Measure the dalam
drive chain neutral.
slack, on the chain run midway
between the sprockets.
Ukur
CHAINkekenduran
SLACK: 30drive
– 40 mmchain,
(1.2pada rantai ditengah-
– 1.6 in)
tengah di antara sprockets.

KEKENDURAN RANTAI: 30 – 40 mm
Excessive chain slack, 50 mm (2.0 in) or more, may damage
CATATAN:
the frame.
Kekenduran rantai b erlebihan, seb anyak 50 mm atau
leb ih, dapat mengakibatkan kerusakan pada rangka.

30 – 40 mm (1.2 – 1.6 in)

3-13
ADJUSTMENT
PENYETELAN
Loosen the rear
Longgarkan rear axle
axle nut
nut and
dan both
kedualock
locknuts.
nuts.
Putar kedua drive chain adjusters sampai correct
Turn both drive chain adjusters until the drive
kekenduran
chain slack is obtained. ADJUSTER
drive chain yang benar telah diperoleh.

LOCK NUT AXLE NUT


Pastikan bahwa
Make sure the ujung
front depan
end ofdari
bothkedua adjuster
adjuster plates
plates are
aligned
telah with the
disetel same
pada indexlines
index lines (garis-garis
on the swingarm.
penunjuk) ADJUSTER PLATE
yang sam a pada swingarm .

INDEX LINES
Kencangkan rearaxle
Tighten the rear axlenut
nutto
dengan torsi yang
the specified ditentukan.
torque.
TORSI: 59 N.m
TORQUE:59 N·m(6,0 kgf.m
(6.0 ; 4444lbf.ft)
kgf·m, lbf·ft)
Kencangkan kedua drive chain lock
Tighten the both drive chain lock nuts nuts dengan erat.
securely.
Recheck the drive chain slack and free wheel rotation.
Periksa kekenduran drive chain dan kebebasan
Check theroda.
perputaran rear brake pedal freeplay (page 3-17) and
adjust itjarak
Periksa if necessary.
main bebas pedal rem belakang (hal. 3-
17) dan setel bila perlu.

LOCK NUT AXLE NUT


CLEANING, LUBRICATION
PEMBERSIHAN, PELUMASAN AND
DAN
INSPECTION
PEMERIKSAAN
Letakkan
Support thesepedamotor padaitsstandard
motorcycle with centerstandutamanya
and shiftdan
the
transmission
masukkan into neutral.
transmissi ke dalam neutral. RETAINING CLIP MASTER LINK
If the drive chain becomes extremely dirty, it should be
Jika driveandchain
removed menjadi
cleaned prior to sangat kotor, ia harus
lubrication.
dilepaskan dan dibersihkan sebelum dilumasi.
Remove the left crankcase rear cover (page 2-19).
Carefully left
Lepaskan remove the retaining
crankcase clip with
rear cover (hal.pliers.
2-19).
Remove the master link and link plate, and disconnect
Dengan
the drivehati-hati
chain. lepaskan retaining cllp dengan tang.
Remove the
Keluarkan drivelink
master chain.
dan link plate, dan lepaskan drive
chain.
Keluarkan drive chain.

LINK PLATE
RETAINING CLIP

3-14
Bersihkan
Clean the rantai
chain dengan larutan pembersih
with non-flammable or high yang
flash tidak
point
solvent
dapat and wipe
terbakar it dry.
atau mempunyai titik api tinggi dan seka LARUTAN YANG TIDAK DAPAT TERBAKAR
Be surekering.
sampai the chain has dried completely before lubricat- ATAU MEMPUNYAI TITIK API TINGGI
ing.
Pastikan bahwa rantai telah mengering sama sekali
Inspect the drive chain for possible damage or wear. BERSIKAN
sebelum melumasinya.
Replace any chain that has damaged rollers, loose fitting
Periksalah drive chain
links, or otherwise terhadap
appears kemungkinan adanya
unserviceable.
kerusakan
Installing aatau
newkeausan.
chain on badly worn sprockets will cause
the new chain
Gantilah rantaitoyang
wear mempunyai
quickly. rollers yang rusak,
Inspect
links yangandterpasang
replace thedengan
sprocket as necessary.
longgar, atau selain itu
tampaknya tidak dapat diperbaiki lagi.
Pemasangan sebuah rantai baru di atas sprockets yang SEKA DAN KERINGKAN
sudah sangat aus akan mengakibatkan keausan cepat
pada rantai baru.
Periksa dan ganti sprocket bila perlu.

Lubricate
Lumasi the drive
drive chainchain #80 ––9090gear
with #80
dengan oil or
gear oildrive
(oli
Lumasi
chain lubricant.
transmissi) Wipe chain
atau drive off anylubexcess oil or chain
ricant (pelumas lubri-
khusus
cant. rantai roda). Sekalah oli atau chain lub ricant yang
untuk
berlebihan pada rantai.

#80 – 90 GEAR OIL ATAU


DRIVE CHAIN LUBRICANT
Measurejarak
Ukurlah the antara
distancebentangan
between 41 a span
pins of
(4041links)
pins dari
(40
links) from pin center
tengah-tengah pin ke to pin center by holding
tengah-tengah pin sodengan
that all
links are straight.
memegangnya sedemikian sehingga semua links dalam
keadaan lurus. LENGTH (41 pins/40 links)
DRIVE CHAIN
STANDARD: 508 mm (20.0 in)
PANJ ANG DRIVE CHAIN (41 pins/40 links)
SERVICE BATAS SERVIS: 518 mm
STANDARD:
LIMIT: 518 mm508 mm
(20.4 in)
BATAS SERVIS: 518 mm

PEMERIKSAAN SPROCKET
SPROCKET INSPECTION
Periksa
Inspect gigi-gigi
the drive drive sprocket
and driven dan teeth
sprocket drivenforsprocket
wear or
terhadap
damage,keausan atau ifkerusakan,
replace them necessary.ganti bila perlu.
Never use a new drive chain on worn sprockets. AUS
Jangan sekali-kali
Both chain memakaimust
and sprockets sebuah
be indrive
goodchain baru di
condition, or
the new
atas replacement
sprockets chain will wear rapidly.
yang aus.
Baik chain maupun sprockets harus berada dalam
kondisi baik, atau chain pengganti yang baru akan
mengalami keausan dengan cepat.
RUSAK NORMAL

3-15
Pasang drive
Install the chain
drive chainpadaonto sprockets.
the sprockets.
Install the master RETAINING CLIP MASTER LINK
Pasang master linklink
danand linklink plate.
plate.
Install the
Pasang retaining
retaining clipclipdengan
with itsujungnya
open endyangopposite the
terbuka
direction of dengan
berlawanan chain travel.
arah perjalanan chain.
Adjust the drive chain slack (page 3-14).
Setel kekenduran
Install drive chain
the left crankcase rear (hal.
cover3-14).
(page 2-19).
Pasang left crankcase rear cover (hal. 2-19).

LINK PLATE
RETAINING CLIP
BRAKE
BRAKE FLUID
FLUID (M INYAK REM )
CATATAN
Brake fluid yang tertumpah dapat merusak parts yang
dicat, atau terbuat dari plastik atau karet. Letakkan kain
Spilled fluid can damage painted, plastic or rubber parts.
lap menutupi parts ini setiap kali sistem diservis.
Place a rag over these parts whenever the system is serviced.
CATATAN:
• Jangan mencampurkan bermacam-macam jenis
minyak
• Do rem,different
not mix oleh karena
typesmereka
of fluid, tidak cocok
as they aresatu
not
compatible
sama lain. with each other.
• • DoJangannot allow
sampai foreign material to asing
benda-benda enter the system
memasuki
when
sistemfilling
ketikathemengisi
reservoir.
reservoir.
Turn the handlebar so that the reservoir is level and
checkhandlebar
the front brake fluid level through KACA PENGINTAIAN
Putar sampai reservoir pada the sight
posisi glass.
mendatar
dan
When periksa
the fronttinggi
brakepermukaan
fluid level is minyak
low, check remthedepan
brake
melalui
pad wear (pagepengintaian.
jendela 3-16).
A low fluid level may be due to wear of the brake pads. If
the brake
Jika tinggipads are worn minyak
permukaan the caliper rempistons
depanare rendah,
pushed
out, and this
periksalah accounts
keausan b rakeforpada (hal.
low reservoir
3-16). level. If the
brake pads are
Permukaan not worn
minyak remand the
yang fluid rendah
level is low, check
mungkin
the entire system
diakibatkan oleh keausan (page 3-17)
for leaks brake pads. . Jika b rake pads
aus, caliper pistons terdorong keluar, dan ini
menyebabkan tinggi permukaan yang rendah di dalam
reservoir. Jika b rake pads tidak aus dan tinggi
permukaan minyak rem rendah, periksalah keseluruhan
sistem terhadap kebocoran (hal. 3-17). TANDA TINGGI PERMUKAAN TERENDAH

BRAKE SHOES/PADS
KEAUSAN WEAR
BRAKE SHOES/PADS
BRAKE
FRONTPADS DEPAN
BRAKE PADS
Check the
Periksa brake
b rake pads
pads for wear.
terhadap keausan.
Replace
Ganti the brake
b rake pads pads if either
apabila salahpad is worn
satu pad totelah
the wear
aus
limit groove.
sampai ke alur batas keausan.
Always replace the For brake pad replacement (page 14-7).
Kekenduran
brake pads as arantai
set to Untuk penggantian b rake pad (hal. 14-7).
berlebihan,
assure sebanyak
even disc
50 mm atau lebih,
pressure.
dapat mengakibatkan
kerusakan pada
rangka.

WEAR LIMIT GROOVES

3-16
REAR BRAKE
BRAKE SHOES
SHOES BELAKANG
Check the
Periksa wear wear
posisi indicator position when
indicator the brake
(indikator pedal
keausan)
is applied. TANDA " " INDICATOR PLATE
sewaktu b rake pedal ditekan.
If the indicator plate aligns with the " " mark on the
brake
Jika panel, inspect
indicator the brake drum
plate bertepatan dengan(pagetanda
13-14)"Δ. " pada
panel
If the rem,
brakeperiksa b rake
drum I.D. drum the
is within (teromol
servicerem)
limit,(hal. 13-
replace
14).
the brake shoes (page 13-14).
Jika D.D. b rake drum berada di bawah batas servis,
gantilah b rake shoes (hal. 13-14).

SISTEM REM
BRAKE SYSTEM
PEMERIKSAAN REM HIDRAULIK
HYDRAULIC BRAKE INSPECTION
Tekan
Firmly b rake the
apply lever (handel
brake rem)check
lever and dengan kuat
that no air dan
has
entered bahwa
periksa the system.
tidak ada udara yang telah memasuki
sistem.
If the lever feels soft or spongy when operated, bleed the
air from the system (page 14-5).
Jika handel terasa lunak atau seperti sepons ketika
Remove the
dijalankan, handlebar
buanglah frontpalsu
udara (page
coverdari 2-12)(hal.
sistem . 14-5).
Inspect the brake hose and fittings for deterioration,
Lepaskan
cracks and handleb arleakage.
signs of front cover (hal. 2-12).
Tighten any loose fittings.
Periksa
Replaceb hoses
rake hose (slang as
and fittings rem) dan fittings (peralatan
required.
pemasangan) terhadap pemburukan kondisi, retak-retak
Install the handlebar front cover (page 2-12).
dan tanda2 kebocoran.
Kencangkan fittings yang longgar.
Ganti hoses dan fittings bila perlu.
BRAKE HOSE
Pasang handlebar front cover (hal. 2-12).
BRAKE HOSE

JARAK
BRAKEMAIN BEBAS
PEDAL BRAKE PEDAL
FREEPLAY
Measure
Ukur themain
jarak rear brake
bebaspedal freeplay
b rake pedalat the tip ofrem)
(pedal the
brake pedal.
belakang pada ujung dari b rake pedal.
JARAK MAIN20
FREEPLAY: BEBAS:
– 30 mm20 – 30
(0.8 mm
– 1.2 in)

20 – 30 mm (0.8 – 1.2 in)

3-17
MakePastikan
sure the bahwa Adjustjarak
cut-out Setel the brake
main pedal
bebas freeplay by turning
brake pedal the memutar
dengan adjusting
of thepotongan
adjusting pada nut.
nut is adjusting nut.
adjusting nutthe
seated on duduk
joint Recheck the freeplay, then check and adjust the rear
pada joint pin.
pin. Periksa kembali
brake light switchjarak
(page main
3-18). bebas, kemudian periksa
dan setel rear b rake light switch (saklar belakang lampu
rem) (hal. 3-18).

ADJUSTING NUT JOINT PIN


BRAKE LIGHT SWITCH
BRAKE LIGHT
(SAKLAR LAMPUSWITCH
REM)
CATATAN:
• • The
Brakefront
lightbrake
switchlight switch
depan onmaster
pada the master
cylindercylinder
tidak
cannot be adjusted.
dapat disetel. If the front bbrake
Jika penjalanan light switch
rake light switch
actuation
depan dan and brake engagement
pengenaan rem tidak are not synchro-
sinkron, gantilah
nized, either replace the switch unit or the malfunc-
switch unit atau parts
tioning parts of the system.
yang tidak bekerja dengan
baik dari
• Adjust thesistem.
rear brake light switch after the brake pedal
• freeplay
Setel badjustment.
rake light switch belakang setelah
Check that the jarak
penyetelan brake main bebas on
light comes b rake
just pedal
prior totelah
the
brakedilakukan.
actually being engaged. BRAKE LIGHT SWITCH
If the light fails to come on, adjust the switch by turning
Hold
Tahanthe switch
badan body the adjusting nut so that the light comes on at the proper
switch Periksa
time. bahwa lampu rem menyala tepat sebelum rem
and
danturn theadjusting
putar adjusting
nut.
nut. Recheck themulai
sebenarnya brakebekerja.
light switch operation.
Do not turn the
Jangan switch
memutar
badan switch
Jika lampu rem tidak menyala, setel switch dengan
body whilesewaktu
turning
memutar adjusting
the adjusting nut.
memutar adjusting nut sehingga lampu menyala pada
nut. waktu yang tepat.

Periksa kembali cara kerja b rake light switch.

ADJUSTING NUT
PENYETELAN ARAH SINAR
HEADLIGHT
LAMPU AIM
BESAR
Letakkan
Place the sepedamotor
motorcycle onpada tanah
the level mendatar
ground di atas
using the cen-
terstand.utama.
standard
Adjust the headlight Adjust the headlight beam vertically by loosening the bolt
beamSetel arah sinar
as specified by Setel arah sinar
and moving lampu unit,
the headlight besar
thendalam
tighten arah vertikal
the bolt.
lampu besar seperti dengan melonggarkan b olt dan menggerakkan
local laws and
telah ditentukan oleh headlight unit, kemudian kencangkan b olt.
regulations.
undang-undang dan
peraturan lokal.

BOLT

3-18
CLUTCH SYSTEM
CLUTCH SYSTEM (SIST EM KOPLING)
Longgarkan clutch adjuster
Loosen the clutch adjuster locklocknutnutand
danturn
putar
the clutch
clutch
adjuster
adjuster searah
clockwisejarum
one jam satudo
full turn; putaran
not turnpenuh; jangan
excessively. LOCK NUT
Slowly turn
memutar the adjuster
secara counterclockwise until resistance
berlebihan.
is felt. pelan putar adjuster berlawanan arah jarum
Dengan
Hold the adjuster jam
Fromsampai terasa
this point, ada
turn tahanan.
the adjuster clockwise 1/8 turn, and ADJUSTER
while tightening the tighten the lock nut to the specified torque.
Tahan lock
adjuster
nut. Dari titik ini, putar
TORQUE:12 N·m adjuster
(1.2 kgf·m, searah jarum jam sebanyak
9 lbf·ft)
sementara 1/8 putaran, dan kencangkan lock nut dengan torsi yang
mengencangkan lock • Check for clutch operation after adjustment.
ditentukan.
nut.
TORSI: 12 N.m (1,2 kgf.m ; 9 lbf.ft)

• Periksa cara kerja clutch (kopling) setelah


penyetelan selesai.

SIDESTAND (STANDARD SAMPING)


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

SIDESTAND

SUSPENSION
SUSPENSI
FRONT SUSPENSION
PEMERIKSAAN INSPECTION
SUSPENSI DEPAN
Check the
Periksa caraaction
kerjaofforks
the forks by operating
(garpu) the fronthandel
dengan menarik brake
anddepan
rem compressing the frontsuspensi
dan menekan suspension several
depan times. kali
beberapa SUSPENSI DEPAN :
Check
ke the entire assembly for signs of leaks, damage or
bawah.
loose fasteners.
Periksa keseluruhan susunan terhadap tanda-tanda
Loose, worn or Replace damaged
kebocoran, kerusakan components whichlonggar.
atau pengikat yang cannot be
damaged suspension repaired.
parts impair
Parts suspensi yang Tighten allkomponen2
Gantilah nuts and bolts.
yang rusak yang tidak dapat
motorcycle stability
longgar, aus atau diperbaiki.
For fork service (page 12-11).
rusak mempengaruhi
and control.
stabilitas dan
Kencangkan semua nuts dan bolts.
pengendalian atas
sepedamotor. Untuk menservis fork (hal. 12-11).

3-19
REAR SUSPENSION
PEMERIKSAAN INSPECTION
SUSPENSI BELAKANG
Check the
Periksa action
cara kerjaof shock
the rear shock absorbers
absorbers (peredamby kejut)
com-
pressing dengan
belakang them several times. beberapa kali ke bawah.
menekannya SUSPENSION BELAKANG:
Check the
Periksa entire shock
keseluruhan absorber
susunan assembly
shock ab sorberforterhadap
signs of
leaks, damage or loose fasteners.
tanda2 kebocoran, kerusakan
Tighten all nuts and bolts. atau pengikat yang
longgar.
For rear shock
Kencangkan absorber
semua nuts service (page 13-21).
dan bolts.

Untuk menservis shock ab sorb er belakang (hal. 13-21).

Letakkan
Support thesepedamotor
motorcyclepada standard
with its utamanya.
centerstand.
SWINGARM BUSHINGS:
Check for
Periksa worn swingarm
terhadap swingarmbushings
bushingsby(bos
grabbing theayun)
lengan rear
ends aus
yang of thedengan
swingarm and attempting
memegang to move
ujung2 the swing-
belakang dari
arm side to side.
swingarm dan mencoba untuk menggerakkan swingarm
Replace
dari sisi kethe
sisi.swingarm bushings if any looseness is
noted (page 13-17).
Gantilah swingarm bushings jika ada kelonggaran (hal.
13-17).

NUTS, BOLTS, FASTENERS


(MUR,
NUTS,BAUT, PENGIKAT)
BOLTS, FASTENERS
Periksa bahwa semua nuts dan bolts dari rangka telah
Check that alldengan
dikencangkan chassistorsi
nuts and bolts aremereka
pengencangan tightened to
yang
their correct
benar torque values (page 1-10).
(hal. 1-9).
Check that
Periksa all cotter
bahwa semua pins, safety
cotter clips,safety
pins, hose clamps and
clips, hose
cable stays
clamps dan are
cablein place
stays and
ada properly secured. dan telah
pada tempatnya
dipasang dengan erat.

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

3-20
Periksa terhadap
Check for wheelbearings
worn wheel b earings
by (bantalan
holding theroda) yang
swingarm
and dengan
aus move themenahan
rear wheelswingarm
sideways. dan menggerakkan REAR WHEEL BEARINGS:
roda belakang
Replace ke samping.
the wheel bearings if any looseness is noted
(page 13-9).
Ganti wheel b earings jika ada kelonggaran (hal. 13-9).

Periks athetekanan
Check udara
tire pressure withban
a tiredengan
pressuretire pressure
gauge when
the tires(alat
gauge are cold.
pengukur tekanan udara ban) sewaktu ban
dalam keadaan dingin.
RECOMMENDED TIRE PRESSURE AND SIZE:
TEKANAN UDARA DAN UKURAN BAN YANG
DIANJ URKAN: Unit: kPa (kgf/cm2, psi)
FRONTkPa (kgf/cm
Satuan: REAR
2
; ps i)
Cold tire pressure DEPAN BELAK ANG
Driver
Tekanan only: udara 200 (2.00, 29) 225 (2.25, 33)
Driver and Passenger:200200
ban dingin (2.00,
(2,00; 29)29) 225
225 (2.25, 33)
(2,25;
Tire size
Pengendara 70/90-17 80/90-17
33)
s aja: M/C 38P M/C 44P
Tire brand
Pengendara dan 200IRC: NF63B
(2,00; 29) IRC: NR78Y
225 (2,25;
pem bonceng: SRI: FT 138 33) SRI: FT 138
Ukuran ban 70/90-17 80/90-17
M/C 38P M/C 44P
Merek ban IRC: NF63B IRC: NR78Y
Check the tires for cuts, embedded
SRI: D-FR nails,SRI:
or other
D-RRdam-
age.
Check the ban
Periksa front and rear wheels
terhadap for trueness.
sayatan, paku yang
Measure the tread
tertancap,atau depth at
kerusakan the center of the tires.
lain.
Replace the tires when the tread depth reaches the fol-
lowing limits.
Periksa roda depan dan belakang apakah lurus ke
depan.
MINIMUM TIRE TREAD
Ukur kedalaman alur ban pada bagian
DEPTH: tengah ban.
To indicator
Ganti ban jika kedalaman alur ban mencapai batas2
berikut ini:

KEDALAMAN ALUR BAN MINIMUM: Sampai ke


indikator

Periksa
Inspectpelek roda rims
the wheel dan and
jari-jari terhadap
spokes kerusakan.
for damage.
Tighten any loose spokes to the specified
Kencangkan spokes (jari-jari) yang longgar dengan torque using
torsi
the special
yang tool. dengan menggunakan special tool.
ditentukan
TOOL:
TOOL:
Spoke wrench, 4.5 x 5.1 mm 07701-0020200
Spoke wrench, 4.5 x 5.1 mm 07701-0020200
TORQUE:
TORSI:
FRONT 3,2 SPOKE
N.m (0,332.5 kgf.m
N·m ;(0.25
2.4 lbf.ft)
kgf·m, 1.8 lbf·ft)
REAR SPOKE 3.7 N·m (0.38 kgf·m, 2.7 lbf·ft)

3-21
STEERING HEAD
STEERING HEAD BEARINGS
BEARINGS
(BANTALANSupport
KEPALA KEMUDI)
the motorcycle securely and raise the front
wheel off the ground.
Dukunglah sepedamotor dengan kokoh dan angkat roda
Check that the handlebar moves freely from side to side.
depan
Make lepas tanah.
sure the control cables do not interfere with han-
dlebar rotation.
Periksa bahwa handlebar bergerak dengan bebas dari
ujung ke ujung. Pastikan bahwa control cables (kabel2
pengaturan) tidak mengganggu perputaran handlebar.

Check steering
Periksa for steering
stemstem bearings
bearings by grabbing
(bantalan the fork
poros kemudi)
legs andmemegang
dengan attempting tofork
movelegs
the front forkgarpu)
(kaki2 forward dan
and
backward.
mencoba untuk menggerakkan front fork (garpu depan) STEERING STEM
ke
If depan dan belakang.
the handlebar moves unevenly, binds, or has vertical
movement, inspect the steering head bearings (page 12-
22).handleb ar bergerak secara tidak merata, mengikat,
Jika
atau ada pergerakan vertikal, periksalah steering head
bearings (hal. 12-22).

3-22
4. SISTEM PELUMASAN

DIAGRAM SISTEM
LUBRICATION PELUMASAN.........4-2
SYSTEM DIAGRAM··········· 4-2 TROUBLESHOOTING ...........................4-3
TROUBLESHOOTING ····································4-3

KETERANGAN SERVIS ........................4-3


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

4-1
SISTEM PELUMASAN
DIAGRAM SISTEM PELUMASAN
LUBRICATION SYSTEM

CAMSHAFT

PISTON

OIL PUMP

CRANKSHAFT

MAINSHAFT
OIL CENTRIFUGAL
FILTER

COUNTERSHAFT

OIL STRAINER SCREEN

4-2
SISTEM PELUMASAN
KETERANGAN
SERVICE SERVIS
INFORMATION
GENERAL
UMUM
PERINGATAN !
OliUsed engine
mesin oil may
bekas dapatcause skin cancer ifkanker
menyebabkan repeatedly
kulitleft in contact
jika with the
berulangkali skin for prolonged
mengenai periods.
kulit untuk jangkaAlthough
waktu this is unlikely
lama. Walaupununless
iniyou
kecil
handle used oil onterjadi
kemungkinannya a dailykecuali
basis, itjika
is still
andaadvisable to thoroughly
menangani wash
oli bekas your hands
setiap with soap
hari, tetap and wateruntuk
dianjurkan as soon as possible
secara after handling
menyeluruh mencuci
used oil.
tangan dengan sabun dan air sesegera mungkin setelah menangani oli bekas.
•This section covers service of the oil pump.
••TheBaboilinipump
meliputi
can servis dari oilwith
be serviced pumpthe (pompa oli).
engine installed in the frame.
••TheOil service
pump dapat diservis
procedures in dengan mesin
this section terpasang
must pada rangka.
be performed with the engine oil drained.
••When removing and installing
Prosedur-prosedur servis di the oil pump,
dalam bab iniuse care
harus not to allow
dijalankan dust or
dengan olidirt to enter
mesin the engine.
dikeluarkan.
••If Sewaktu
any portion of the oil pump
melepaskan is worn beyond
dan memasang the specified
oil pump, service agar
berhati-hatilah limits,debu
replaceatauthe oil pump
kotoran as memasuki
tidak an assembly.
mesin.
•After the oil pump has been installed, check that there are no oil leaks.
• Jika ada bagian dari oil pump yang aus melampaui batas servis yang ditentukan, gantilah oil pump sebagai sebuah
susunan.
SPECIFICATIONS
• Setelah oil pump telah dipasang, periksa bahwa tidak ada kebocoran oli.
Unit: mm (in)
SERVICE
ITEM STANDARD
SPESIFIKASI LIMIT
Enginemm
Satuan: oil capacity At draining 0.8 liter (0.8 US qt, 0.7 lmp qt) –
BAGIAN At disassembly 1.0 liter (1.1 US qt, 0.9 lmp qt)
STANDARD –
BATAS SERVIS
Recommended
Kapasitas engine oil
oli mesin Pada penggantian periodik API classification: SE, SF or SG
0,8 liter -
(except oils labeled as energy conserving on
Pada pembongkaran mesin 1,0 liter -
the circular API service label) –
Oli mesin yang dianjurkan Oli mesin 4 tak dengan klasifikasi API
Viscosity: SAE 10W-30
service
JASOSJ,T 903 standard: MA
Viskositas: SAE 10W-30 JASO MA
Oil pump rotor Tip clearance – 0.15 (0.006)
Oil pump rotor Jarak renggang pada ujung - 0,15
Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.26 (0.010)
rotor
Side clearance 0.03 – 0.09 (0.001 – 0.004) 0.15 (0.006)
Jarak renggang antara rotor 0,15 – 0,21 0,26
dan rumah
TORQUE VALUE Jarak renggang ke samping 0,03 – 0,09 0,15
rotor pompa
Oil pump cover screw 5 N·m (0.51 kgf·m, 3.7 lbf·ft)
TORSI PENGENCANGAN
Oil pump cover screw 5 N.m (0,51 kgf.m; 3,7 lbf.ft)
TROUBLESHOOTING
Engine oil level too low
• Oil consumption
TROUBLESHOOTING
• External oil leak
• Worn piston rings (page 8-7)
• Improperly
Tinggi installed
permukaan oli piston
terlalurings (page 8-9)
rendah
• Worn valve guide or stem seal (page 7-14)
• Konsumsi oli
• Worn cylinder (page 8-6)
• Ada kebocoran oli di luar
Oil
• contamination
Piston rings aus (hal. 8-7)
•• Worn piston
Piston tidak(page
ringsrings 8-7) dengan benar (hal. 8-9)
dipasang
•• Improperly
Valve guide installed piston
atau stem aus(page
rings
seal (hal.8-9)
7-14)
• Worn valve guide or stem seal (page 7-14)
• Cylinder aus (hal. 8-6)
• Oil not changed frequently enough
• Clogged oil strainer screen (page 3-11)
Kontaminasi oli
• Piston rings aus (hal. 8-7)
• Piston rings tidak dipasang dengan benar (hal. 8-9)
• Valve guide atau stem seal aus (hal. 7-14)
• Oli jarang diganti
• Oil strainer screen tersumbat (hal. 3-11)

4-3
SISTEM PELUMASAN
OIL PUMP (POMPA OLI)
PELEPASAN
REMOVAL
Drain the engine
Keluarkan oli mesin (page3-10).
oil (hal. 3-10).
OIL PUMP
Remove the
Lepaskan following:
sebagai berikut:
– Right crankcase cover (page 9-5)
- Right crankcase cover (hal. 9-5)
– Three bolts
- –Tiga
Oil bolts
pump
- Oil pump

BOLTS

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

OIL PUMP

PELEPASAN/PEMASANGAN

OIL PUMP BODY

OIL PUMP SHAFT

SCREWS
5 N·m (0.51 kgf·m, 3.7 lbf·ft)

OUTER ROTOR

INNER ROTOR
OIL PUMP COVER

4-4
SISTEM PELUMASAN
Semprotkan
Apply engineolioilpada permukaan
to the inner rotorpeluncuran innersliding
and outer rotor rotor
dan outer rotor.
surfaces. INNER ROTOR

Install the inner and outer rotors to the oil pump body.
Pasang inner
Install the rotor shaft
oil pump dan aligning
outer rotor pada
the flat rumahofoil_
surfaces the
pump. OIL
oil pump shaft and the inner rotor.
Pasang oil pump shaft dengan mentepatkan PUMP
permukaan-permukaan mendatar dari oil pump shaft SHAFT
dan inner rotor.

Tepatkan OUTER ROTOR


Install the
Pasang oil pump
oil pump cover.
cover.
Install and
Pasang dan tighten the three
kencangkan screws
ketiga screws to dengan
the specified
torsi SCREWS
torque.
yang ditentukan.
TORQUE:
TORSI: 5 N·m
5 N.m (0.51
(0,51 kgf·m,
kgf.m; 3.7lbf.ft)
3,7 lbf·ft)
Install the
Pasang oil pump
oil pump (page
(hal. 4-6).
4-6).

OIL PUMP COVER

INSPECTION
PEMERIKSAAN
If any portion of the
Jika ada bagian dari
Disassemble the oil pump (page 4-4).
Bongkar oil pump (hal. 4-4). TIP CLEARANCE:
oiloil pump
pump is worn
yang aus Temporarily install the outer and inner rotors into the oil
beyond the service
melampaui batas Untuk
pumpsementara
body. pasang outer rotor dan inner rotor ke
limit, replace
servis, theoil
gantilah oil dalam
Installrumah
the oil oil pump.
pump shaft.
pump sebagai
as an assembly. Pasang oil the
pump
tip shaft.
pump sebuah
Measure clearance between the inner and outer
assembly.
rotors.
Ukur jarak renggang antara pada ujung rotor antara
SERVICE LIMIT: 0.15 mm (0.006 in)
inner rotor dan outer rotor.

BATAS SERVIS: 0,15 mm

Ukur jarak the


Measure renggang antaraclearance
pump body outer rotor dan rumah
between oil_
the outer
rotor and the oil pump body.
pump. BODY CLEARANCE:
SERVICE LIMIT: 0.26 mm (0.010 in)
BATAS SERVIS: 0,26 mm

4-5
SISTEM PELUMASAN
Ukur jarakthe
Measure renggang ke samping
side clearance usingdengan menggunakan
a straight edge and a SIDE CLEARANCE:
feeler lurus
mistar gauge.
dan sebuah feeler gauge.
SERVICE LIMIT: 0.15 mm (0.006 in)
BATAS SERVIS: 0,15 mm
Assemble the oil pump (page 4-4).
Rakit oil pump (hal. 4-4).

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

OIL PUMP

Install and
Pasang dantighten the three
kencangkan bolts.
ketiga bolts.
OIL PUMP
Clean the oil
Bersihkan oil strainer screen (page
strainer screen 3-11).
(hal. 3-11).
Install the
Pasang right
right crankcase
crankcase cover
cover (page
(hal. 9-8)
9-8).
After installation, fill the crankcase with recommended
engine oil (page 3-10).
Setelah pemasangan, isilah crankcase dengan oli mesin
yang
Startdianjurkan
the engine(hal. 3-10). that there are no oil leaks.
and check

Hidupkan mesin dan periksa bahwa tidak ada


kebocoran oli.

BOLTS

4-6
5. SISTEM BAHAN BAKAR

LOKASI KOMPONEN
COMPONENT ..............................
LOCATION 5-2
···························· 5-2 PENYETELAN AIR SCREW
AIR SCREW ADJUSTMENT ..................5-16
························5-16

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


SERVICE INFORMATION 5-3
····························· 5-3 FUEL TANK ····················································5-17
FUEL TANK ...........................................5-17

TROUBLESHOOTING .............................5-4
TROUBLESHOOTING ···································· 5-4 FUEL FILTER.........................................5-18
FUEL FILTER ·················································5-18

AIR
AIRCLEANER HOUSING .......................5-5
CLEANER HOUSING······························ 5-5 FUEL STRAINERSCREEN
FUEL STRAINER SCREEN ...................5-18
··························5-18

PELEPASAN KARBURATOR
CARBURETOR .................5-5
REMOVAL ··························· 5-5 SECONDARY AIRSUPPLY
SECONDARY AIR SUPPLY SYSTEM...5-19
SYSTEM ········5-19

PEMBONGKARAN/PEMERIKSAAN
CARBURETOR DISASSEMBLY/ SEPARATE AIRFILTER
SEPARATE AIR FILTER······························5-21
.......................5-21
KARBURATOR ........................................5-7
INSPECTION····················································· 5-7
AIR
AIR SUPPLY PIPE .................................5-21
SUPPLY PIPE··········································5-21
PERAKITAN KARBURATOR
CARBURETOR ..................
ASSEMBLY ························ 5-11
5-11
INLET
INLET PIPE ............................................5-22
PIPE ·····················································5-22
PEMASANGAN KARBURATOR ............. 5-14
CARBURETOR INSTALLATION················5-14

5-1
SISTEM BAHAN BAKAR
LOKASI KOMPONEN
FUEL SYSTEM

12 N·m (1.2 kgf·m, 9 lbf·ft)

5-2
SISTEM BAHAN BAKAR
KETERANGAN
SERVICE SERVIS
INFORMATION
GENERAL
UMUM
• Bending or twisting the throttle cable will impair smooth operation and could cause the cable to stick or bind, resulting in loss of
• Menekuk
vehicle atau memilin throttle cable (kabel gas) akan mengganggu kelancaran cara kerjanya dan dapat menimbulkan
control.
• kemacetan
Work in a wellatau pengikatan
ventilated area. pada cable,
Smoking or sehingga mengakibatkan
allowing flames or sparks in kehilangan pengendalian
the work area or where atas kendaraan.
gasoline is stored can cause a fire
• orBekerjalah
explosion. di tempat dengan ventilasi baik. Merokok atau memperbolehkan adanya api atau percikan bunga api di tempat
• If kerja
the vehicle
atau diistempat
to be stored
di mana forbensin
more than one month,
disimpan drain the float kebakaran
dapat menyebabkan chamber. Fuelatauleft in the float chamber may cause clogged
ledakan.
• jets,
Jikaresulting
kendaraan in hard
akanstarting
disimpanor poor driveability.
selama lebih dari satu bulan, kosongkan float chamber (ruang pelampung). Bahan bakar yang
• Before disassembling the carburetor, place an approved fuel container under the carburetor, loosen the drain screw and drain the
tertinggal di dalam float chamber dapat mengakibatkan tersumbatnya jets, sehingga mesin sulit dihidupkan atau
carburetor.
• Whensepedamotor sulit dikendalikan.
disassembling the fuel system parts, note the locations of the O-rings. Replace them with new ones on reassembly.
•• After
Sebelum
removingmembongkar karburator,
the carburetor, wrap theletakkan penampung
intake port yang with
of the engine sesuai di bawah
a shop karburator,
towel or cover it withlonggarkan
a piece ofdrain
tape screw (sekrup
to prevent any
foreign material from
pembuangan) dropping into
dan kosongkan the engine. Be sure to remove the cover when reinstalling the carburetor.
karburator.
• Sewaktu membongkar parts sistem bahan bakar, catatlah lokasi dari O-rings. Gantilah dengan yang baru pada waktu
perakitan kembali.
SPECIFICATIONS
• Setelah melepaskan karburator, bungkuslah intake port (lubang pemasukan) dari mesin dengan kain lap atau tutuplah
dengan pita perekat untuk ITEMmencegah masuknya benda asing ke dalam mesin. Jangan SPECIFICATIONS
lupa untuk melepaskan penutup pada
Carburetor identificationkembali
waktu pemasangan numberkarburator. PB7UB
Engine idle speed 1,400 ± 100 min-1 (rpm)
Throttle grip freeplay 2 – 6 mm (0.1 – 0.2 in)
SPESIFIKASI
Main jet #88
BAGIAN SPESIFIKASI
Slow jet #35
Nomor identifikasi karburator
Float level PB7UB 11.7 mm (0.46 in)
-1
Putaran
Air screw stasioner mesin
initial opening 1.400 ± 100 menit (rpm)See page 5-16
Jarak
PAIR main
controlbebas
valvethrottle gripvacuum
specified 2 – 6 mm 60 kPa (450 mmHg)
Main jet # 88
Slow jet # 35
TORQUE VALUE
Float level (tinggi pelampung) 11,7 mm
Pembukaan awal air screw Lihat halaman 5-16
Inlet pipe band screw – See page 5-14
Vakuum PAIR control valve yang ditentukan 60 kPa (450 mmHg)
Fuel valve screw 0.88 N·m (0.090 kgf·m, 0.65 lbf·ft)
Air cut-off valve screw 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
TORSI
Slow jetPENGENCANGAN 1.5 N·m (0.15 kgf·m, 1.1 lbf·ft)
Mainpipe
Inlet jet band screw 1.5 N·m (0.15
- kgf·m, 1.1 lbf·ft) Lihat hal. 5-14
Needle
Fuel jet screw
valve holder 0,88 ·m (0.25
2.5 NN.m (0,090 ·m, 1.80,65
kgfkgf.m; lbf·ft)
lbf.ft)
Air
Floatcut-off valvescrew
chamber screw 2,1
2.1N.m
N·m (0,21
(0.21 kgf.m;
kgf·m, 1,5
1.5 lbf.ft)
lbf·ft)
Slow
Float jet
chamber drain screw 1,5
1.5N.m
N·m (0,15
(0.15 kgf.m;
kgf·m, 1,1
1.1 lbf.ft)
lbf·ft)
Main jet
Fuel strainer cup 1,5
5.9N.m
N·m (0,15
(0.60 kgf.m;
kgf·m, 1,1
4.4 lbf.ft)
lbf·ft)
Needle
Throttlejet holder
cable holder screw 2,5
3.4N.m
N·m (0,25
(0.35 kgf.m;
kgf·m, 1,8
2.5 lbf.ft)
lbf·ft)
Float chamber
Fuel valve leverscrew
screw 2,1
2.1N.m
N·m (0,21
(0.21 kgf.m;
kgf·m, 1,5
1.5 lbf.ft)
lbf·ft) Apply locking agent to the threads
Float chamber
Inlet pipe drainbolt
mounting screw 1,5 N.m
12 N (0,15kgf
·m (1.2 kgf.m;
·m, 9 1,1 lbf.ft)
lbf·ft)
Fuel strainer cup
PAIR check valve cover screw
5,9 N.m (0,60 kgf.m; 4,4 lbf.ft)
2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
Throttle cable holder screw 3,4 N.m (0,35 kgf.m; 2,5 lbf.ft)
Fuel valve lever screw 2,1 N.m (0,21 kgf.m; 1,5 lbf.ft)
Inlet pipe mounting bolt 12 N.m (1,2 kgf.m; 9 lbf.ft)
PAIR check valve cover screw 2,1 N.m (0,21 kgf.m; 1,5 lbf.ft)

TOOL
Carburetor float level gauge
07401-0010000

5-3
SISTEM BAHAN BAKAR
TROUBLESHOOTING
TROUBLESHOOTING
Engine tidak
Mesin won’tmau start hidup
• Too much fuel getting to the engine
• –Terlalu banyak
Air cleaner bahan bakar yang masuk ke dalam mesin
clogged
–- Flooded
Air cleaner tersumbat
carburetor
- Karburator
• Intake air leak banjir
•• Fuel
Adacontaminated/deteriorated
kebocoran udara masuk
•• No fuel tobakar
Bahan carburetor
terkontaminasi/memburuk kondisinya
– Fuel filter clogged
• –Bahan bakar tidak
Fuel strainer clogged sampai ke karburator
–- Fuel
Fueltank
filtercap tersumbat
breather hole clogged
–- Fuel
Fuelline clogged/bent
strainer tersumbat
–- No fuel inpernapasan
Lubang tank fuel tank cap tersumbat
Lean- mixture
Saluran bahan bakar tersumbat/tertekuk
- Fuel
• Fuel jetstank
clogged kosong
• Float valve faulty
• Float level
Campuran too low
bahan bakar terlalu miskin
•• Fuel
Fuelline
jetsrestricted
tersumbat
• Carburetor air vent hose clogged
•• Intake
Float air
valveleaktidak bekerja dengan baik
•• Throttle
Float level
valveterlalufaultyrendah
•RichSaluran
mixture bahan bakar terbatasi
•• Carburetor
Carburetorchoke air vent hose tersumbat
stuck
•• Float
Ada valve
kebocoran faulty udara masuk
•• Float levelvalve
Throttle too high tidak bekerja dengan baik
• Air jets clogged
• Air cleaner element contaminated
Campuran
• Flooded bahancarburetor bakar terlalu kaya
• Carburetor choke macet
•Engine stall,
Float valvehard to start,
tidak rough
bekerja idlingbaik
dengan
• Fuel line restricted
•• Ignition
Float level
system terlalu tinggi
malfunction
•• Fuel
Air jets
mixturetersumbat
too lean/rich
•• Fuel contaminated/deteriorated
Air cleaner element terkontaminasi
•• Intake air leak
Karburator banjir
• Idle speed misadjusted
• Air screw misadjusted
Mesin
• Slowberhenti mendadak, sulit dihidupkan, putaran stasioner kasar
circuit clogged
•• Improper
Saluran chokebahanoperation
bakar terbatasi
•• Low cylinder
Sistem compression
pengapian tidak bekerja dengan baik
•• Air cleaner clogged
Campuran bahan bakar terlalu miskin/kaya
•Afterburn
Bahanwhen bakarengine braking is used
terkontaminasi/kondisinya memburuk
•• Lean
Ada mixture
kebocoran in slowudaracircuit
masuk
•• Faulty pulse secondary
Ada kesalahan air injection
penyetelan putaran(PAIR) system
stasioner
– Faulty PAIR control valve
• –Ada kesalahan penyetelan
Clogged hose of the PAIR system air screw
•• Ignition
Rangkaiansystem pelan tersumbat
malfunction
•• Faulty
Choke airtidak
cut-off valve dengan baik
bekerja
•Backfiring
Tekanan kompressi
or misfiring cylinder
during rendah
acceleration
•• Ignition
Air cleaner
system tersumbat
malfunction
• Fuel mixture too lean
Afterburn ketika engine
Poor performance braking
(driveability) anddipakai
poor fuel economy
•• Fuel
Campuran
system cloggedbahan bakar terlalu miskin pada slow circuit (rangkaian pelan)
•• Ignition system malfunction
Pulse secondary air injection (PAIR) system tidak bekerja dengan baik
• Air cleaner
- PAIR clogged
control valve tidak bekerja dengan baik
- Hose dari PAIR system tersumbat
• Sistem pengapian tidak bekerja dengan baik
• Air cut-off valve tidak bekerja dengan baik

Backfiring atau misfiring selama akselerasi


• Sistem pengapian tidak bekerja dengan baik
• Campuran bahan bakar terlalu miskin

Unjuk kerja (kemampuan berkendaraan) lemah dan pemakaian bahan bakar boros
• Sistem bahan bakar tersumbat
• Sistem pengapian tidak bekerja dengan baik
• Air cleaner tersumbat

5-4
SISTEM BAHAN BAKAR
AIR CLEANER HOUSING
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Remove the
Lepaskan following:
sebagai berikut: CRANKCASE
– Main pipe cover
- Main pipe cover (hal.(page 2-7).
2-7). BREATHER HOSE
– Air cleaner element (page
- Air cleaner element (hal. 3-6) 3-6)
Disconnect the crankcase breather hose.
Lepaskan crankcase
Loosen the breather
connecting hose.screw.
hose band
Longgarkan connecting hose band screw.

SCREW
Disconnect
Lepaskan airthe airhose.
vent vent hose.
Remove the bolts and air cleaner rear housing assembly. AIR VENT AIR CLEANER
Lepaskan bolts dan air cleaner rear housing assembly. HOSE REAR HOUSING

BOLT
Pemasangan
Installation is inadalah dalam
the reverse order urutan terbalik dari
of removal.
pelepasan.
• Tighten the connecting hose band screw so that the
• Kencangkan
gap between theconnecting hose
band ends is 5band (0.2 in).sehingga
mm screw
celah antara ujung-ujung band adalah 5 mm.

5 mm (0.2 in.)

PELEPASAN KARBURATOR
PEMBONGKARAN CARBURETOR
THROTTLE
THROTTLEVALVE
VALVE
Remove the
Lepaskan following:
sebagai berikut:
CARBURETOR TOP
– Lower side covers (page
- Lower side covers (hal. 2-6).
2-6).
– (page 2-7)
- Main pipe cover (hal. 2-7). .
Main pipe cover
Remove the
Lepaskan carburetortop
carburetor top and
dan throttle
throttlevalve fromdari
valve the
carburetor.
karburator.

5-5
SISTEM BAHAN BAKAR
Lepaskan throttle
Remove the cable
throttle cabledari throttle
from valve valve
the throttle sementara
while
compressing
menekan the valve
throttle throttle valve spring.
spring.

THROTTLE CABLE

SPRING

THROTTLE VALVE
Lepaskan
Remove the retainer,
retainer,spring
spring dan jetneedle
and jet needlewhile
sementara
pushing
mendorong
the retainerretainer
with a sedikit dengan
screwdriver obeng,
slightly and kemudian
turning it THROTTLE VALVE SCREWDRIVER
counterclockwise.
memutarnya berlawanan dengan arah jarum jam.
Check the throttle valve and jet needle for scratches,
Periksa
wear orthrottle
damage. valve dan jet needle terhadap goresan,
keausan
Replaceatau
themkerusakan.
if necessary.

Ganti mereka bila perlu.


JET NEEDLE

SPRING

RETAINER
CARBURETOR
BADAN BODY
KARBURATOR
Turn fuel
Putar the fuel
valvevalve "OFF".
ke 'OFF'.
Place a suitable container under the carburetor drain
Letakkan
hose andpenampung yang
drain fuel from thesesuai di bawah
carburetor carburetor
by loosening the
drain hose (slang pembuangan karburator) dan
drain screw.
keluarkan
Tighten the bahan bakardrain
float chamber dariscrew.
karburator dengan
melonggarkan drain screw (sekrup pembuangan).
TORQUE:1.5 N·m (0.15 kgf·m, 1.1 lbf·ft)
Kencangkan float chamber drain screw (sekrup
pembuangan ruang pelampung).

TORSI: 1,5 N.m (0,15 kgf.m; 1,1 lbf.ft)

DRAIN SCREW
SCREWDRIVER

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

DRAIN HOSE FUEL HOSE

5-6
SISTEM BAHAN BAKAR
Loosen the air cleaner connecting
Longgarkan connecting hose
hose band
band screw.
screw.
Remove the
Lepaskan carburetor
carburetor mountingbolts,
mounting bolts,insulator,
insulator, O-rings
O-rings CARBURETOR
andcarburetor
dan carburetordari
frominlet
the pipe.
inlet pipe. BOLTS

SCREW
INSULATOR/O-RINGS
Lepaskan choke
Release the chokecable dari
cable clamp
from dan lepaskan
the clamp choke
and disconnect
cable.
the choke cable. CHOKE CABLE CLAMP

PEMBONGKARAN/PEMERIKSAAN
KARBURATOR
FUELVALVE
FUEL VALVE
Removal
Pelepasan
Remove the screws, fuel valve and O-ring.
Lepaskan screws, fuel valve dan O-ring. SCREWS FUEL VALVE

O-RING

Disassembly
Remove the screw and fuel valve lever from the fuel
valve. FUEL VALVE LEVER

FUEL VALVE

SCREW

5-7
SISTEM BAHAN BAKAR
AIR CUT-OFF VALVE
Pembongkaran
Remove the
Lepaskan screws
screw dan and air cut-off
fuel valve levervalve
dari cover.
fuel valve.
SCREWS

AIR CUT-OFF VALVE COVER


AIR CUT-OFF
Remove VALVE
the spring, diaphragm and O-ring.
O-RING
Lepaskan screws dan air cut-off valve cover.

SPRING

DIAPHRAGM
Lepaskan
Check thespring, diaphragm dan O-ring.
following:
AIR PASSAGES
– Diaphragm for pin holes, deterioration or damage SPRING
– Spring for deterioration
– Needle of diaphragm for wear
– Air passages for clogging NEEDLE

AIR CUT-OFF VALVE


DIAPHRAGM

FLOAT CHAMBER
Remove
Periksa the screws
sebagai and float chamber.
berikut:
Remove the O-ring from the float chamber. FLOAT CHAMBER O-RING
- Diaphragm terhadap lubang-lubang kecil, pemburukan
kondisi atau kerusakan
- Spring terhadap pemburukan kondisi
- Needle dari diaphragm terhadap keausan
- Air passages (saluran lintasan udara) terhadap
penyumbatan

SCREWS

5-8
SISTEM BAHAN BAKAR
FLOAT
Check theCHAMBER
operation of the float valve.
FLOAT VALVE FLOAT PIN
Remove the float pin and float.
Lepaskan screws dan float chamber.
Inspect the
Lepaskan float dari
O-ring for deformation or damage.
float chamber.

FLOAT
Periksa
Remove cara
thekerja float valve.
float valve.
Inspect the
Lepaskan float
float pinvalve seat for scratches, clogging and
dan float. FLOAT VALVE
damage.
Periksa
Check the tip ofterhadap
float perubahan
the float valve where itbentuk
contactsatau
the
kerusakan.
valve seat for stepped wear or contamination.
Check the float valve operation by pushing its end pin.
The pin should return smoothly.
Replace the valve if the tip is worn or contaminated.

Lepaskan float valve.


Pemeriksaan ujung float tip:
Periksa float valve seat (dudukan klep pelampung)
terhadap goresan, penyumbatan dan kerusakan.

Periksa ujung dari float valve di mana ia menyentuh


valve seat (dudukan klep) terhadap keausan bertingkat
atau kontaminasi.

Periksa cara kerja float valve dengan mendorong ujung


pin-nya. Normal: Aus:
Pin harus kembali dengan lancar.
Pemeriksaan cara kerja float valve :
Ganti valve jika ujungnya aus atau terkontaminasi.

PIN

Kembali dengan lancar: Macet:

Handle all jets with


care. They can easily
be scored or
scratched.

5-9
SISTEM BAHAN BAKAR
Tangani semua jets Lepaskan sebagai
Remove the berikut:
following:
dengan hati-hati. NEEDLE JET MAIN JET
Mereka dapat mudah - Main jet HOLDER
tergerus atau - Needle jet holder SLOW JET
tergores. - Needle jet
- Slow jet
- Throttle stop screw/spring NEEDLE JET
Kerusakan akan – Main
Putar air jet
screw ke dalam dan catat jumlah putaran
terjadi pada dudukan – Needle jet holder
sampai
– Needleia duduk
jet dengan ringan.
air screw jika air Catatlah angka ini untuk dipakai sebagai referensi
screw dikencangkan – Slow jet
ketika memasang
– Throttle kembali air screw.
stop screw/spring
terhadap dudukannya.
Lepaskan
Turn the air screw inspring,
air screw, washer
and record the dan O-rings.
number of turns until THROTTLE STOP
Damage to the air
screw seat will occur it seats lightly. SCREW/SPRING
if the air screw is
Periksa
Make a notemasing-masing
of the number jettoterhadap keausan when
use as a reference atau
reinstallingdan
kerusakan the ganti
air screw.
mereka bila perlu. AIR SCREW/SPRING/WASHER/O-RINGS
tightened against the Remove the air screw, spring, washer and O-rings.
seat.
Inspect each jet for wear or damage and replace them if
necessary.
Tiuplah terbuka
Blow open eachsetiap saluran
air and lintasan udara
fuel passage in the dan bahan
carburetor
body with
bakar compressed
di dalam badanair.
karburator dengan udara dari
kompressor.

5-10
SISTEM BAHAN BAKAR
PERAKITAN KARBURATOR
DIAPHRAGM

FLOAT PIN
O-RING
0.88 N·m FLOAT VALVE WASHER
(0.090 kgf·m, 6.5 lbf·ft)
AIR SCREW
FLOAT SPRING

FUEL VALVE
LEVER O-RING
O-RINGS

THROTTLE
STOP RETAINER
RETAINER
SCREW
O-RING
JET
NEEDLE
2.1 N·m SLOW JET 2.1 N·m
(0.21 kgf·m, 1.5 N·m (0.21 kgf·m,
1.5 lbf·ft) (0.15 kgf·m, 1.5 lbf·ft)
1.1 lbf·ft)
FUEL VALVE AIR CUT-OFF
NEEDLE JET VALVE COVER

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

FLOAT CHAMBER MAIN JET


O-RINGS 1.5 N·m (0.15 kgf·m, 1.1 lbf·ft)
THROTTLE VALVE
FUEL STRAINER
SCREEN
DRAIN SCREW
FUEL STRAINER CUP 1.5 N·m (0.15 kgf·m, 1.1 lbf·ft)
5.9 N·m (0.60 kgf·m, 4.4 lbf·ft)

FLOATCHAMBER
FLOAT CHAMBER
Handle all
Tangani jets with
semua jets Install the
Pasang following:
sebagai berikut:
care. They can easily
WASHER
dengan hati-hati. - –Throttle
Throttle stop
stop screw/spring
screw/spring
be scored
Mereka dapat mudah or SLOW JET
- –Slow
Slow jetjet SPRING
tergerus atau
scratched. – Needle jet
tergores. - –Needle
Needle jetjet holder
- –Needle
Main jetjet holder AIR
- Main jet MAIN SCREW
Tighten them to the specified torque. JET
TORQUE: mereka dengan torsi yang ditentukan.
Kencangkan
Slow jet 1.5 N·m (0.15 kgf·m, 1.1 lbf·ft)
TORSI:
Needle jet holder 2.5 N·m (0.25 kgf·m, 1.8 lbf·ft) SPRING
Slow jet 1,5 N.m (0,20 kgf.m; 1,1 lbf.ft)
Main jet 1.5 N·m (0.15 kgf·m, 1.1 lbf·ft) NEEDLE JET O-RINGS
Needle jet holder 2,5 N.m (0,25 kgf.m; 1,8 lbf.ft)
Main
Installjet
the following: 1,5 N.m (0,15 kgf.m; 1,1 lbf.ft) NEEDLE JET THROTTLE STOP
– Spring HOLDER SCREW
Pasang
– Washer sebagai berikut:
- –Spring
New O-rings
- Install
Washer the air screw and return it to its original position as
- noted
O-rings baruremoval.
during
Pasang air screw dan kembalikan pada posisinya
semula seperti telah dicatat pada waktu pelepasan.

5-11
SISTEM BAHAN BAKAR
Pasang float
Install the valve
float pada
valve ontofloat.
the float.
Install the FLOAT VALVE FLOAT PIN
Pasang floatfloat
danand floatvalve
float valvepada
in the carburetor
badan body,
karburator,
then install
kemudian the float
pasang pinpin
float through
melaluithebadan
body and float. dan
karburator
float.

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

TOOL:
TOOL:
Carburetor
Carburetorfloat
float level gauge
level gauge 07401-0010000
07401-0010000
The float
Float level level
tidakcannot be adjusted.
dapat disetel.
Replace float
Gantilah the float assembly
assembly jika if float
the float
level level
tidakis sesuai
out of
specification.
dengan spesifikasi.

Pasang
Install asebuah O-ring
new O-ring barufloat
in the pada alur float
chamber chamber.
groove.
Pasang float
Install the chamber.
float chamber. FLOAT CHAMBER

O-RING
Pasang dantighten
Install and kencangkan
the floatfloat chamber
chamber screws
screws dengan
to the speci-
fied yang
torsi torque.
ditentukan.
TORQUE:2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
TORSI: 2,1 N.m (0,21 kgf.m; 1,5 lbf.ft)

SCREWS

5-12
SISTEM BAHAN BAKAR
AIRCUT-OFF
AIR CUT-OFFVALVE
VALVE
Install a new
Pasang O-ring
O-ring with dengan
baru its flat sidesisinya
facing the carburetor
yang datar
body. SISI
menghadap ke badan karburator.
Install the diaphragm to set the diaphragm rib in the YANG
Pasang
groove indiaphragm (membran)
the carburetor dengan menempatkan
body properly. DATAR
diaphragm rib (tulang membran) dengan benar pada
alur di dalam badan karburator.

O-RING

DIAPHRAGM

Hati-hati agar not


Be careful tidak
to Pasang spring
Install the danand
spring valve cover.
valve cover.
menjepit SCREWS
pinch the diaphragm
diaphragm Install and
Pasang dantighten the screws
kencangkan to the specified
screws dengan torque.
torsi yang
dan O-ring antara
and O-ring between ditentukan.
TORQUE:2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
badan karburator dan
the body and valve
valve cover sewaktu
cover when tightening
mengencangkan cover TORSI: 2,1 N.m (0,21 kgf.m; 1,5 lbf.ft)
the cover screws.
screws.

DIAPHRAGM/SPRING

AIR CUT-OFF VALVE COVER

FUEL VALVE
FUEL VALVE
Assembly
Apply locking agent to the screw threads.
Perakitan
Install the FUEL VALVE LEVER
Oleskan zatfuel valve lever
pengunci padaand
ulirscrew
screw.to the fuel valve.
Tighten the screw to the specified torque.
Pasang fuel valve
TORQUE:2.1 N·mlever
(0.21dan screw
kgf·m, 1.5 pada
lbf·ft)fuel valve.
Kencangkan screw dengan torsi yang ditentukan.
TORSI: 2,1 N.m (0,21 kgf.m; 1,5 lbf.ft)

FUEL VALVE

SCREW
Pemasangan
Installation
Pasang
Install asebuah O-ring
new O-ring baru
and fueldan fuel valve.
valve.
FUEL VALVE

O-RING

5-13
SISTEM BAHAN BAKAR
Pasang dantighten
Install and kencangkan screws
the screws dengan torque.
to the specified torsi yang
ditentukan. SCREWS
TORQUE:0.88 N·m (0.090 kgf·m, 0.65 lbf·ft)
TORSI: 0,88 N.m (0,090 kgf.m; 0,65 lbf.ft)

PEMASANGAN KARBURATOR
BADAN KARBURATOR
CARBURETOR BODY
Hubungkan
Connect thechoke cable topada
choke cable karburatorand
the carburetor dan clamp
clamp the
cable.
(jepit dengan klem) cable. CHOKE CABLE CLAMP

Pasang badan
Install the karburator
carburetor body pada
to theair
aircleaner
cleaner connecting
connecting
hose.
hose. CARBURETOR
BOSS
Install the insulator Install new O-rings into the insulator and carburetor body
Pasang insulator
with the boss facing
Pasang
grooves.O-rings baru ke dalam insulator dan alur-alur
dengan boss-nya badan karburator.
menghadap ke atas. up.

O-RINGS INSULATOR
Pasang badan
Install the karburator
carburetor bodydan
and insulator
insulator pada
to the inlet
inlet pipe
pipe
andkencangkan
dan tighten the bolts.
bolts dengan erat.
Tighten the connecting
Kencangkan connectinghose band
hose screw
band so that
screw the gap
sehingga
between theujung-ujung
band ends isband
5 mm (0.2 in). CARBURETOR
celah antara adalah 5 mm.

5 mm (0.2 in.)

SCREW
BOLTS INSULATOR

5-14
SISTEM BAHAN BAKAR
Sambungkan sebagai berikut:
Connect the following:
- –AirAir
vent hose AIR VENT HOSE
vent hose
- –Drain hose
Drain hose CLAMP
- –Fuel hose
Fuel hose
Remove the hose clamp.
Lepaskan hosevalve
Turn the fuel clamp.
"ON".
Putar fuel valve ke "ON".

DRAIN HOSE FUEL HOSE


THROTTLE
THROTTLE VALVE
VALVE
Install the jet needle into the throttle valve.
Pasang jet needle ke dalam throttle valve.
Secure the jet needle with retainer and spring while THROTTLE VALVE SCREWDRIVER
Kokohkan
pushing the pemasangan
retainer withjeta needle dengan
screwdriver retainer
slightly dan
and turn-
spring sementara mendorong retainer sedikit dengan
ing it clockwise.
sebuah obeng, dan memutarnya searah jarum jam.

JET NEEDLE

SPRING

RETAINER
Install the
Pasang throttle
throttle valve
valve spring
spring onto
pada the throttle
throttle cable.cable.
Connect the throttle
Sambungkan cablecable
throttle to the throttle
pada valve whilevalve
throttle com-
pressing the throttle valve spring.
sementara menekan throttle valve spring.

THROTTLE CABLE

SPRING

THROTTLE VALVE
Pasang throttle
Install the throttle valve ke the
valve into dalam badan
carburetor karburator
body by align-
ing its cut-out
dengan with thepotongan
mentepatkan throttle stop screw.dengan throttle
padanya THROTTLE VALVE
stop screw.

POTONGAN

THROTTLE STOP SCREW

5-15
SISTEM BAHAN BAKAR
Kencangkan carburetortop.
Tighten the carburetor top (tutup karburator).
CARBURETOR TOP
After installing the carburetor,
Setelah memasang karburator, checkperiksalah
for the following:
terhadap
berikut ini:
– Throttle grip free play (page 3-5)
- –Jarak
Enginemainidle
bebas throttle
speed (page grip
3-12)(hal. 3-5)
- –Putaran
Air screw stasioner mesin(page
adjustment (hal.5-16)
3-12)
- Penyetelan air screw (hal. 5-16)
Install the following:
– Mainsebagai
Pasang pipe cover (page 2-7).
berikut:
- –Main
Lower
pipeside (hal.(page
covers
cover 2-7). 2-6).
- Lower side covers (hal. 2-6).

AIR SCREW ADJUSTMENT


PENYETELAN AIR SCREW
IDLE DROP
PROSEDUR PROCEDURE
PENURUNAN PUTARAN
STASIONER
• The air screw is factory pre-set and no adjustment is
• necessary unless awal
Air screw disetel the carburetor is overhauled
di pabrik dan or the
tidak diperlukan
air screw is replaced.
penyetelan lagi kecuali jika karburator telah
• dibongkar atau air screw diganti baru.
-1
• • Pakailah tachometer dengan skala 50 menit (rpm)
• Use
atau a lebih
tachometer
kecil with graduations
yang of 50 min-1akurat
dapat dengan (rpm)
-1 -1
or smaller that will accurately
memperlihatkan perubahan sebesar indicate a 5050 (rpm)
minmenit
change.
(rpm).
Remove the right lower side cover (page 2-6).
Kerusakan akan Lepaskan right lower side cover (hal. 2-6). THROTTLE STOP SCREW
terjadi pada dudukan
Damage to the air 1. Turn the air screw clockwise until it seats lightly, then AIR SCREW
air seat
screw screw jika
will air 1. back
occur Putaritair
outscrew searah jarum
to specification jam sampai ia duduk
given.
screw dikencangkan
if the air screw is This is
dengan an initial
ringan, setting
kemudianprior to thekembali
putar final air keluar
screw
terhadap dudukannya. adjustment.
sampai ke spesifikasi yang diberikan.
tightened against the
seat. Ini merupakan
INITIAL OPEN- penyetelan awal sementara sebelum
penyetelan
ING: akhir air 1-3/4
screw. turns out
PEMBUKAAN AWAL: 1 – 7/8 putaran keluar
2.2. Warm up the
Panaskan mesin engine to operating
sampai temperature. Stop
suhu operasional.
and go riding forjalan-dan-berhenti
Pengendaraan 10 minutes is sufficient.
selama 10 menit
3. Stop thecukup.
adalah engine and connect the tachometer accord-
3. ing to its manufacturer’s
Matikan mesin dan hubungkaninstructions.
tachometer sesuai
dengan petunjuk
4. Disconnect pemakaian
the vacuum hosepabrik pembuatnya.
of PAIR control valve,
4. then connect
Lepaskan it to thehose
vacuum vacuum daripump
PAIRandcontrol
plug the vac-
valve, VACUUM HOSE
uum
dan port.
hubungkan ke vacuum pump (pompa
vakum) dan sumbat vacuum port (lubang vakum).

5-16
SISTEM BAHAN BAKAR
5.5. Terapkan
Apply the specified
vakum vacuum to the PAIR pada
yang ditentukan control PAIR
valve
vacuumvalve
control hose more
vacuumthanhose
60 kPa (450 mmHg).
sebanyak lebih dari 60
6. kPa
Start(450
the mmHg).
engine and adjust the idle speed with the
throttle stop mesin
6. Hidupkan screw. dan setel putaran stasioner
dengan throttle
IDLE SPEED:1300 stop±screw.
100 min-1 (rpm)
PUTARAN STASIONER: 1.300 ± 100 menit
-1 VACUUM PUMP
7. (rpm)
Turn the air screw in or out slowly to obtain the high- VACUUM HOSE
est engine
7. Putar speed.masuk atau keluar dengan pelan
air screw
8. untuk
Lightlymendapatkan
open the throttle 2 or mesin
putaran 3 times, then adjust the
tertinggi.
idle speed
8. Buka with
throttle 2 the
atauthrottle
3 kali stop
denganscrew.
ringan, kemudian
9. setel putaran
Turn the stasioner
air screw dengan
out until throttle
the engine stop drops
speed screw.by
9. Putar PLUG
50 minair-1 screw
(rpm). keluar sampai putaran mesin turun
-1
dengan 50 menit (rpm).
10.Turn the air screw clockwise to the final opening from
10. Putar air screw
the position obtained stepjarum
searah 9. jam ke pembukaan
akhir dari posisi yang diperoleh pada langkah 9.
FINAL OPEN- AKHIR: ¼ putaran ke dalam
PEMBUKAAN
ING:
11. Lepaskan plug 1/4 turns in dari vacuum port,
(sumbat)
kemudian lepaskan vacuum
11.Disconnect the plug from the pump dan hubungkan
vacuum port, then
vacuum
remove the hose dari PAIR
vacuum pumpcontrol
and valve.
connect the vacuum
12. Setel
hose ofkembali putaran
PAIR control stasioner dengan throttle
valve.
stop screw.
12.Readjust the idle speed with the throttle stop screw. -1
PUTARAN STASIONER: 1.400 ± 100 menit
IDLE SPEED:1,400 ± 100 min-1 (rpm)
(rpm)
Install the right lower side cover (page 2-6).
Pasang right lower side cover (hal. 2-6).

FUEL TANK (TANGKI BAHAN BAKAR)


PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan body
Remove the covers
body (hal.
covers 2-9).2-9).
(page
WIRE CLAMP
Lepaskan fuel
Disconnect thelevel
fuelsensor 3P connector
level sensor (Hitam).
3P (Black) connector.
Release the
Lepaskan wirewire from dari
(kawat) the clamp.
clamp.

3P CONNECTOR (Hitam)
Clamp
Jepit fuelthe fuel hose.
hose.
Disconnect
Lepaskan the
fuel fuel dan
hose hoselepaskan
and remove
fuel the fuel tank.
tank. CLAMP

FUEL HOSE

5-17
SISTEM BAHAN BAKAR
Remove the
Lepaskan mounting
mounting bolts.
bolts.
Installation is in the reverse order urutan
of removal. FUEL TANK
Pemasangan adalah dalam terbalik dari
pelepasan.

BOLTS

FUEL FILTER
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Remove the
Lepaskan left left
bodybody
covercover (page
(hal. 2-9).2-9). FUEL FILTER FUEL HOSES
Klem fuel hoses dari sisi fuel tanktank
Clamp the fuel hoses of the fuel dan side andvalve.
sisi fuel fuel valve
side.
Lepaskan fuel hoses dan lepaskan fuel filter.
Disconnect the fuel hoses and remove the fuel filter.
Wipe off spilled out Place an tempat
Sekalah bahan bakar Letakkan approved fuel container
penampung andbakar
bahan drain the
yangfuel.
sesuai
fuel. diCheck
yang tertumpah. bawahthe fuel
fuel filter
tank dan forkeluarkan
damage orbahancontamination.
bakar.
Replace the fuel filter if necessary.
Periksa fuel filter
Installation terhadap
is in the reversekerusakan atau kontaminasi.
order of removal.
Gantilah fuel filter bila perlu.

Pemasangan adalah dalam urutan terbalik dari


pelepasan.
CLAMPS

TO THE FUEL TANK SIDE

TO THE FUEL VALVE SIDE

FUEL FILTER
DIRECTION MARK

FUEL STRAINER SCREEN


Lepaskan rightright
Remove the lower sideside
lower cover (hal.
cover 2-6).
(page 2-6).
STRAINER SCREEN/O-RINGS
Turn fuel
Putar the fuel
valve valve "OFF".
ke "OFF".
Remove fuel
Lepaskan the strainer
fuel strainer cup, strainer
cup, strainer screenscreen and O-
dan O-rings.
rings.
Clean the strainer
Bersihkan strainer screen
screenand strainer
dan cup in
strainer cupnon-flam-
dalam
mable or
larutan high flash point
pembersih yangsolvent.
tidak dapat terbakar atau
Replace thetitik
mempunyai strainer screen if necessary.
api tinggi.
Gantilah strainer screen bila perlu.

STRAINER CUP

5-18
SISTEM BAHAN BAKAR
Pasang O-rings
Install new baru,strainer
O-rings, strainerscreen
screen dan
and strainer
strainer cup.
cup.
Tighten the strainer cup to the specified torque. O-RINGS
Kencangkan strainer cup dengan torsi yang ditentukan.
TORQUE:5.9
TORSI: 5,9 N.mN·m (0.60
(0,60 kgf·m,4,4
kgf.m; 4.4lbf.ft)
lbf·ft)
Turn fuel
Putar the fuel valve
valve ke "ON"
"ON" and
danmake surebahwa
pastikan that there areada
tidak no
fuel leakage.
kebocoran bahan bakar.
Install the right lower side cover (page 2-6).
Pasang right lower side cover (hal. 2-6).

STRAINER SCREEN STRAINER CUP

SECONDARY AIR SUPPLY SYSTEM


PEMERIKSAAN PAIR (PULSE AIR
PAIR (PULSE SECONDARY
INJECTION)AIR
SECONDARY CHECK VALVE
INJECTION) CHECK
INSPECTION
VALVE
Remove the
Lepaskan rightright lower
lower side
side cover
cover (page
(hal. 2-6).
2-6).
PAIR CONTROL
Remove the
Lepaskan screwsscrewsdanand check
check valvecover
valve coverdari
from the
PAIR SCREWS VALVE BODY
PAIR control
control valve body.
valve body.

CHECK VALVE COVER


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

PAIR CHECK VALVE

Periksa
Check thereedreed
terhadap kerusakan
for damage atau replace
or fatigue, keletihan, ganti
if neces-
bila perlu.
sary.
Replace
Ganti PAIRthecheck
PAIR valve
checkjika
valve if theseat
rubber rubber seat is
retak-retak,
cracked, deteriorated
memburuk kondisinyaor atau
damaged,
rusak,or ifatau
therejika
is clear-
ada
ance between antara
kerenggangan the reed anddan
reed seatseat.
Installation is in the reverse order of removal.
REED
Pemasangan
TORQUE: adalah dalam urutan terbalik dari
pelepasan.
PAIR check valve
cover screw 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
TORSI:
PAIR check valve cover screw 2,1 N.m (0,21
kgf.m; 1,5 lbf.ft)

RUBBER SEAT CHECK VALVE

5-19
SISTEM BAHAN BAKAR
PELEPASAN/PEMASANGAN PAIR
PAIR CONTROL VALVE REMOVAL/
INSTALLATION
CONTROL VALVE
Lepaskan right
Remove the lower
right side
lower cover
side (hal.
cover 2-6).
(page 2-6).
PAIR CONTROL VALVE BOLTS
Disconnect
Lepaskan the vacuum
vacuum hose hose andsupply
dan air air supply
hosehoses from
dari PAIR
the PAIR
control control valve.
valve.
Remove the bolts and PAIR control valve body.
Lepaskan bolts
Installation is indan
the PAIR control
reverse ordervalve body.
of removal.
Pemasangan adalah dalam urutan terbalik dari
pelepasan.
AIR SUPPLY
HOSES

VACUUM
HOSE

PEMERIKSAAN SISTEM
SYSTEM INSPECTION
Remove the
Lepaskan following:
sebagai berikut:
– Lower side covers (page
- Lower side covers (hal. 2-6).
2-6).
– Center cover (page 2-6)
- Center cover (hal. 2-6). .
VACUUM HOSE
Start the engine
Hidupkan and panaskan
mesin dan warm it up sampai
to normal keoperating tem-
suhu operasi
perature and stop the engine.
normal dan matikan mesin.
Disconnect the air supply hose from the separate air filter
Lepaskan
(page 5-21)air. supply hose dari separate air filter (hal. 5- AIR SUPPLY HOSE
21). VACUUM PUMP
Remove the PAIR check valve (page 5-19) and check the
inside
Lepaskan of PAIR
PAIRcontrol
checkvalve
valveis (hal.
clean 5-19)
and free
danof periksa
carbon
deposits.
bahwa bagian dalam dari PAIR control valve adalah
Checkdan
bersih the bebas
PAIR check valve if the
dari endapan inside of PAIR control
karbon.
valve is carbon fouled.
Periksa PAIR check valve jika bagian dalam dari PAIR PLUG
Disconnect
control valvethe PAIR
kotor control
dengan valve vacuum hose from the
karbon.
inlet pipe and plug the hose joint.
Connect the vacuum pump to the PAIR control valve
Lepaskan
vacuum hose. PAIR control valve vacuum hose dari inlet
pipe dan sumbat hose joint.
Start the engine and open the throttle slightly to be cer-
Hubungkan
tain that air isvacuum
sucked inpump
throughkethePAIR control
air supply hose.valve
vacuum
If the airhose.
is not drawn in, check the air supply hose for
clogging.
Hidupkan mesinrunning,
With the engine dan buka throttle
gradually sedikit to
apply vacuum untuk
the
memastikan
PAIR controlbahwa udara hose.
valve vacuum dihisap masuk melalui air
supply
Checkhose.that the air supply hose stops drawing air, and
thatudara
Jika the vacuum does notmasuk,
tidak dihisap bleed. periksa air supply hose
terhadap sumbatan.
SPECIFIED VACUUM:60 kPa (450 mmHg)
If the airmesin
Dengan is drawn
dalam in keadaan
or if the jalan,
specified vacuum
secara is not
berangsur
maintained,
terapkan install
vakum padaa new
PAIRPAIR control
control valve.
valve vacuum hose.
If afterburn
Periksa occurs
bahwa air on deceleration,
supply even when
hose berhenti the sec-
menghisap
ondary air supply system is normal, check the air cut-off
udara,
valve. dan bahwa tidak ada kebocoran vakum.
Install the removed parts in the reverse order of removal.
VAKUM YANG DITENTUKAN: 60 kPa (450 mmHg)

Jika udara ditarik masuk atau jika vakum yang


ditentukan tidak dapat dipertahankan, pasang sebuah
PAIR control valve baru.
Jika terjadi peristiwa afterburning pada deselerasi,
bahkan jika secondary air supply system adalah normal,
periksalah air cut-off valve.

Pasang parts yang dilepaskan dalam urutan terbalik dari


pelepasan.

5-20
SISTEM BAHAN BAKAR
SEPARATE AIR FILTER
Lepaskan center
Remove the cover
center (hal.
cover 2-7).
(page 2-6). GUIDES
Release the
Lepaskan air air supply
supply hoseshosesdarifrom the guides.
guides.
Disconnect
Lepaskan airthe air supply
supply hoses hoses
dari from the separate
separate air filterairdan
fil-
ter and remove
lepaskan separate theair
separate
filter. air filter.
Check the separate air filter and replace it if necessary.
Periksa separate
Installation air reverse
is in the filter danorder
gantiofbila perlu.
removal.
Pemasangan adalah dalam urutan terbalik dari
pelepasan.
AIR SUPPLY
HOSES

SEPARATE AIR FILTER

SEPARATE AIR FILTER

DIRECTION MARK

TO THE PAIR
CONTROL VALVE

AIR SUPPLY PIPE


PELEPASAN
REMOVAL
Remove the
Lepaskan right
right lower
lower side
side cover
cover (page
(hal. 2-6).
2-6). BOLTS
Remove the
Lepaskan bolts.
bolts.
Disconnect
Lepaskan airthe air supply
supply hoselepaskan
hose dan and air supply pipe.pipe.
air supply
Remove the gasket and clean the both mating surface.
Lepaskan gasket dan bersihkan kedua permukaan
penyatuan.

AIR
SUPPLY
HOSE

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

5-21
SISTEM BAHAN BAKAR
INSTALLATION
PEMASANGAN
Install asebuah
Pasang new gasket to baru
gasket the air supply
pada air pipe.
supply pipe.

GASKET
AIR SUPPLY PIPE
Hubungkan
Connect theairairsupply
supplyhose
hosedan
andair
airsupply
supplypipe.
pipe.
Install and
Pasang dantighten the bolts.
kencangkan bolts. BOLTS
Install the right lower side cover (page 2-6).
Pasang right lower side cover (hal. 2-6).

AIR
SUPPLY
HOSE

AIR SUPPLY
PIPE GASKET

INLET PIPE
PELEPASAN
REMOVAL
Lepaskan lower
Remove the sideside
lower covers (hal.
covers 2-6).2-6).
(page
BOLTS O-RINGS
Lepaskan
Disconnect vacuum hose. hose.
the vacuum
Remove the following:
Lepaskan sebagai berikut:
- –Bolts
Bolts
- –Insulator
Insulator
- –O-rings
O-rings
– Inlet pipe
- Inlet pipe
INSULATOR

VACUUM HOSE
PEMASANGAN
INSTALLATION
Pasang
Install asebuah gasket
new gasket to baru pada cylinder
the cylinder head. head.

GASKET

5-22
SISTEM BAHAN BAKAR
Pasang inlet
Install the pipe
inlet danand
pipe bolts pada
bolts cylinder
to the head.
cylinder head.
Tighten the bolts
Kencangkan bolts to the specified
dengan torque.
torsi yang ditentukan. INLET PIPE
TORQUE:12 N·m (1.2 kgf·m, 9 lbf·ft)
TORSI: 12 N.m (1,2 kgf.m; 9 lbf.ft)

BOLTS
Pasang
Install theinsulator
insulator Pasang O-rings
Install new baru
O-rings intokethedalam insulator
insulator dan alur-alur
and carburetor body
dengan boss-nya
with the boss grooves.
facing badan karburator. BOSS
menghadap ke atas.
up.

INSULATOR
O-RINGS
Pasang insulator
Install the dan
insulator bolts
and pada
bolts badan
to the karburator
carburetor body dan
and
tighten the bolts. BOLTS
kencangkan bolts.
Connect the vacuum hose to the inlet pipe.
Hubungkan vacuum hose pada inlet pipe.
Install the lower side covers (page 2-6).
Pasang lower side covers (hal. 2-6).

INSULATOR

VACUUM HOSE

5-23
MEMO
6. PENURUNAN/PEMASANGAN MESIN

LOKASI KOMPONEN-KOMPONEN......6-2
COMPONENT LOCATION ···························· 6-2 PENURUNAN MESIN ............................6-4

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


SERVICE INFORMATION ····························· 6-3 PEMASANGAN MESIN .........................6-6

ENGINE REMOVAL ········································ 6-4

ENGINE INSTALLATION ······························ 6-6

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

59 N·m (6.0 kgf·m, 44 lbf·ft)


59 N·m (6.0 kgf·m, 44 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

12 N·m (1.2 kgf·m, 9 lbf·ft)

6-2
PENURUNAN/PEMASANGAN MESIN
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
• During engine removal and installation, support the motorcycle with its centerstand.
•• Support
Sewaktu themenurunkan
engine usingdan a jack or other mesin,
memasang adjustable support
letakkan to ease of engine
sepedamotor hanger bolts
pada standard removal.
utamanya.
•• The following
Topang mesin components can be serviced
dengan menggunakan with theatau
dongkrak engine
alatinstalled
penopangin the frame.
lain yang dapat disetel untuk mempermudah pelepasan
–engine
Alternator (page 10-6)
hanger bolts (baut penggantung mesin).
– Manual clutch (page 9-9)
• Komponen-komponen berikut ini dapat diservis dengan mesin terpasang pada rangka.
– Centrifugal clutch (page 9-9)
–- Gearshift
Alternatorlinkage
(hal. 10-6)
(page 9-28)
- Manual clutch
– Cylinder head (page (kopling
7-12)manual) (hal. 9-9)
–- Cylinder/piston
Centrifugal clutch(page(kopling
8-5) sentrifugal) (hal. 9-9)
- Gearshift linkage
– Oil pump (page 4-4) (peralatan pemindah gigi) (hal. 9-27)
–- Starter
Cylinder head
motor (kepala
(page 17-6)silinder) (hal. 7-12)
- Cylinder/piston (hal. 8-5)
• The following
- Oil pump (hal.components
4-4) require engine removal for service.
–- Crankshaft/transmission/kickstarter
Starter motor (hal. 17-6) (page 11-6)
– Shift forks/shift drum (page 11-9)
– Cam chain guide sprocket (page 11-18)
• Komponen-komponen berikut ini memerlukan penurunan mesin agar dapat menservisnya.
- Crankshaft/transmission/kickstarter (hal. 11-6)
SPECIFICATIONS
- Shift fork/shift drum (hal. 11-9)
- Cam chain guide sprocket (hal. 11-18)
ITEM SPECIFICATIONS
Engine dry weight
SPESIFIKASI 22.6 kg (49.8 lbs)
Engine oil capacity
BAGIAN At draining SPESIFIKASI 0.8 liter (0.8 US qt, 0.7 lmp qt)
Berat kosong mesin At disassembly 22,6 kg 1.0 liter (1.1 US qt, 0.9 lmp qt)
Recommended
Kapasitas oli mesin engine oil Pada penggantian periodik API classification:
0,8 liter SE, SF or SG
(except oils labeled as energy conserving on the circular API service
Pada pembongkaran mesin 1,0 liter
label)
Oli mesin yang dianjurkan Oli mesin 4 tak dengan klasifikasi API service SJ,
Viscosity: SAE 10W-30
Viskositas:
JASO SAE 10W-30
T 903 standard: MA JASO MA

TORSI
TORQUEPENGENCANGAN
VALUES
Engine hanger
Engine hanger nut
nut 5959N.m
N·m(6,0
(6.0kgf.m;
kgf·m,4444 lbf.ft)
lbf·ft)
Drive sprocket fixing
Drive sprocket fixing plate
platebolt
bolt 12 N·m (1.2 kgf·m, 9 lbf·ft)
12 N.m (1,2 kgf.m; 9 lbf.ft)
Inletpipe
Inlet pipe mounting
mounting bolt
bolt 1212N.m
N·m(1,2
(1.2kgf.m;
kgf·m, 99 lbf.ft)
lbf·ft)
Swingarm pivot nut
Swingarm nut 5959N.m
N·m(6,0
(6.0kgf.m;
kgf·m,4444 lbf.ft)
lbf·ft) U-nut
U-nut

6-3
PENURUNAN/PEMASANGAN MESIN
PELEPASAN MESIN
PENURUNAN MESIN
Letakkan sepedamotor
Support the motorcyclepada standard
with its utamanya.
centerstand. GUIDE
Keluarkan
Drain the oli mesin
engine oil(hal.
(page3-10).
3-10).
Remove the
Lepaskan following:
sebagai berikut:
- –Body covers (hal.
Body covers (page 2-9)
2-9)
- –Left crankcase
Left crankcase rear cover
rear cover(hal. 2-19)
(page 2-19)
- –Exhaust pipe/muffler (hal. 2-19)
Exhaust pipe/muffler (page 2-19)
- –PAIR
PAIRcontrol valve
control (hal.
valve 5-20)
(page 5-20)
Lepaskan spark plug cap
Disconnect the spark plug cap dan lepaskan spark the
and release plugspark
wire
dari
plugguide.
wire from the guide.

SPARK PLUG CAP


Disconnect
Lepaskan the following:
sebagai berikut: WIRE BAND BOSS
– Starter motor 2P connector
- Starter motor 2P connector
– Alternator wire (Yellow) connector
- –Alternator
Ignition pulse generator (Kuning)
wire connector wire (Blue/yellow) connector
- Ignition pulse generator wire connector (Biru/Kuning)
Remove the wire band boss.
Lepaskan wire band boss.

CONNECTORS

Disconnect
Lepaskan the following:
sebagai berikut: 6P CONNECTOR
- Alternator 2P2P
– Alternator connector
connector (Hitam)
– Gear position switch 6P (Black) connector
- –Gear position breather
Crankcase switch 6P connector (Hitam)
hose
- Crankcase breather hose

CRANKCASE
BREATHER
HOSE 2P CONNECTOR
Lepaskan carburetor
Release the drain
carburetor hose
drain darifrom
hose lower
the side
lowercover
side
cover stay.
stay.

DRAIN HOSE

6-4
PENURUNAN/PEMASANGAN MESIN
Remove the
Lepaskan inletinlet
pipepipe mounting
mounting bolts
bolts danand gasket.
gasket. BOLTS

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

AXLE NUT
LOCK NUT
Remove the
Lepaskan drive
drive sprocket
sprocket fixing
fixing plate
plate bolts.
bolts.
Turn dan
and lepaskan
remove the fixing plate. BOLTS FIXING PLATE
Putar fixing plate.
Remove the drive sprocket from the countershaft and DRIVE CHAIN
drive chain.
Lepaskan drive sprocket dari countershaft dan drive
chain.

DRIVE SPROCKET

Remove the
Lepaskan following:
sebagai berikut: PIVOT NUT/WASHER
– Pivot nut/washer
- –Pivot
Boltnut/washer
- –Bolt
Plate
- Plate

BOLT PLATE

6-5
PENURUNAN/PEMASANGAN MESIN
Lepaskan collar
Remove the darifrom
collar pivot bolt.
the pivot bolt.
COLLAR

Topang
Support mesin dengan
the engine usingmenggunakan
a jack or other dongkrak
adjustable atau
sup-
port.penopang lain yang dapat disetel.
alat
Remove the front engine hanger nut.
Lepaskan front engine hanger nut (mur penggantung
Remove the rear upper engine hanger nut and rear lower
depan
enginemesin).
hanger nut.
Lepaskan rear upper engine hanger nut (mur
Remove
penggantung the engine hanger
belakang atasbolts and dan
mesin) engine from
rear the
lower
frame.
engine hanger nut (mur penggantung belakang bawah
• Wrap the inlet pipe port with a shop towel or cover it
mesin).
with a piece of tape to prevent any foreign material
Lepaskan engine into
from dropping hanger bolts (baut-baut penggantung
the engine.
mesin) dan engine dari rangka.
• Bungkuslah lubang intlet pipe dengan kain lap
bersih atau tutuplah dengan selembar pita untuk
ENGINE HANGER
mencegah jatuhnya benda-benda asing ke dalam BOLTS/NUTS
mesin.
PEMASANGAN MESIN
CATATAN:
• • Note
Perhatikan arah dari
the direction hanger
of the hanger bolts.
bolts.
• • Use a floordongkrak
Pakailah jack or other
atauadjustable support,lain
alat penopang carefully
yang
place
dapatthe engine
disetel, into the
dengan frame tempatkan
hati-hati and maneuver it into
mesin ke
place.
dalam rangka dan manuver ke posisi
• Route the wires and hoses properly (page 1-16).
pemasangannya.
• Alurkan wires (kawat listrik) dan hoses (slang-
slang) dengan benar (hal. 1-15)

Pada engine
During waktu Letakkan
Place the mesin
enginekeintodalam rangka
the frame and dan topang
support mesin
the engine
pemasanganhold
installation, mesin,
the using a jack
dengan or other adjustable
menggunakan dongkraksupport.
atau alat penopang
peganglah mesin lain yang
engine securely and
dengan erat dan Install thedapat disetel.
engine hanger bolts and nuts.
be careful not to
berhati-hatilah agar Tighten the rear upper engine hanger nut to the specified
tidakdamage
merusaktherangka
frame Pasang
torque. engine hanger bolts dan nuts.
and
dan engine.
mesin. Kencangkan
TORQUE:59rear N·mupper engine
(6.0 kgf·m, lbf·ft) nut dengan torsi
44hanger
yang ditentukan.
Tighten 59
TORSI: theN.m
rear (6,0
lowerkgf.m;
engine44hanger
lbf.ft) nut to the specified
torque.
Kencangkan rear lower engine hanger nut dengan torsi
TORQUE:59 N·m (6.0 kgf·m, 44 lbf·ft)
yang ditentukan.
TORSI:
Tighten 59
theN.m (6,0
front kgf.m;hanger
engine 44 lbf.ft)
nut to the specified
torque.
Kencangkan front engine hanger nut dengan torsi yang ENGINE HANGER
TORQUE:59 N·m (6.0 kgf·m, 44 lbf·ft)
ditentukan. BOLTS/NUTS
TORSI: 59 N.m (6,0 kgf.m; 44 lbf.ft)

6-6
PENURUNAN/PEMASANGAN MESIN
Pasang collar
Install the pada
collar pivot bolt.
to pivot bolt.
COLLAR

Install the
Pasang following:
sebagai berikut:
PIVOT NUT/WASHER
- –Plate
Plate
- –Pivot
Pivotnut/washer
nut/washer
- –Bolt
Bolt
Retract the centerstand carefully and support the motor-
Turunkan sepedamotor
cycle securely, then tightendari standard pivot
the swingarm utama
nut todan
the
peganglah sepedamotor dengan erat,
specified torque while holding the pivot bolt. kemudian
kencangkan swingarm pivot nut dengan torsi yang
TORQUE:59
ditentukan N·m (6.0menahan
sementara kgf·m, 44pivot
lbf·ft)bolt.
Tighten the bolt.
TORSI: 59 N.m (6,0 kgf.m; 44 lbf.ft)

Kencangkan bolt.
BOLT PLATE

Support the
Letakkan motorcyclepada
sepedamotor with its centerstand.
standard utamanya. FIXING PLATE
Install the drive chain onto the drive sprocket. DRIVE CHAIN
Pasang drive
Install the chain
drive pada drive
sprocket sprocket.
onto the countershaft.
Pasang drive sprocket pada countershaft.
Install the fixing plate to the countershaft while aligning
their teeth.
Rotate the
Pasang fixingplate
fixing plate and
padaaligncountershaft
their bolt holes.
sementara
mentepatkan gigi-giginya.
Install and tighten the drive sprocket fixing plate bolts
Putar fixingto plate
alternately dan tepatkan
the specified torque. lubang-lubang bolt
mereka.
TORQUE:12 N·m (1.2 kgf·m, 9 lbf·ft)
Pasang dan kencangkan drive sprocket fixing plate bolts
secara bergantian dengan torsi yang ditentukan.

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


DRIVE SPROCKET BOLTS

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

GASKET

6-7
PENURUNAN/PEMASANGAN MESIN
Alurkan carburetor
Route the drain
carburetor hose
drain melalui
hose lower
through the side
lowercover
side
cover stay.
stay.

DRAIN HOSE
Connect thesebagai
Hubungkan following:
berikut: 6P CONNECTOR
- –Crankcase breather
Crankcase breather hose.
hose. (Hitam)
- –Alternator 2P2P
Alternator connector
connector
- –Gear
Gear position
position switch
switch 6P6P (Black) connector
connector (Hitam)

CRANKCASE
BREATHER
HOSE 2P CONNECTOR
Connect thesebagai
Hubungkan following:
berikut: WIRE BAND BOSS
- –Starter
Startermotor
motor 2P2Pconnector
connector
- –Alternator
Alternator wire
wire (Yellow) (Kuning)
connector connector
- –Ignition
Ignition pulse
pulse generator
generator wireconnector
wire (Blue/yellow) connector
(Biru/kuning)
Install the wire band boss.
Pasang wire band boss.

CONNECTORS
Hubungkan
Connect thesparksparkplug
plugcap
cap dan
and spark plug wire
spark plug wire to
pada
the GUIDE
guide.
guide.
Install the following:
Pasang sebagai berikut:
- –PAIR
PAIR control
control valve
valve (page
(hal. 5-20)
5-20)
– Exhaust pipe/muffler (page
- Exhaust pipe/muffler (hal. 2-20) 2-20)
– Left crankcase rear cover (page 2-19)
- Left crankcase rear cover (hal. 2-19)
– Body covers (page 2-9)
- Body covers (hal. 2-9)
Fill the recommended engine oil up to the proper level
Isilah oli mesin yang dianjurkan sampai ke tinggi
(page 3-10).
permukaan yang chain
Adjust the drive benarslack
(hal. (page
3-10).3-14).
Setel kekenduran drive chain (hal. 3-14).

SPARK PLUG CAP

6-8
7. CYLINDER HEAD/VALVES

LOKASI KOMPONEN-KOMPONEN......7-2
COMPONENT LOCATION ···························· 7-2 CAMSHAFT ...........................................7-8
CAMSHAFT·······················································7-8 7

KETERANGAN
SERVICE SERVIS ........................7-3
INFORMATION ····························· 7-3 CYLINDER
CYLINDER HEAD ..................................7-12
HEAD··········································7-12

TROUBLESHOOTING
TROUBLESHOOTING ...........................7-5
···································· 7-5 CAM
CAMCHAIN
CHAIN TENSIONER .....................7-24
TENSIONER ···························7-24

TEST KOMPRESSI
CYLINDER CYLINDER.............7-6
COMPRESSION TEST ·············· 7-6 OIL
OILSTOPPER PLATE...........................7-26
STOPPER PLATE···································7-26

CYLINDERHEAD
CYLINDER HEADCOVER
COVER ....................7-6
···························· 7-6

7-1
CYLINDER HEAD/VALVE
LOKASI KOMPONEN
CYLINDER HEAD/VALVES

8 N·m (0.82 kgf·m, 5.9 lbf·ft)


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

16 N·m (1.6 kgf·m, 12 lbf·ft)


22 N·m (2.2 kgf·m, 16 lbf·ft)

7-2
CYLINDER HEAD/VALVE
KETERANGAN
SERVICE SERVIS
INFORMATION
GENERAL
UMUM
• This section covers service of the cylinder head, valves, camshaft and cam chain tensioner.
•• Bab
The ini meliputi
cylinder head,servis dari
valves, cylinderand
camshaft head,
camvalves, camshaft services
chain tensioner dan camcan chain
be tensioner.
done with the engine installed in the frame.
•• When disassembling,
Pekerjaan servis darimark and store
cylinder head,thevalves,
disassembled
camshaftparts
danto cam
ensure that tensioner
chain they are reinstalled in their original
dapat dilakukan denganlocations.
mesin terpasang
• Clean
padaall disassembled parts with cleaning solvent and dry them by blowing them off with compressed air before inspection.
rangka.
• Camshaft lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling cylinder head.
•• BeSewaktu pembongkaran,
careful not to damage thetandai
matingdan simpanlah
surfaces when parts yangthedibongkar
removing untuk memastikan bahwa mereka dipasang kembali
cylinder head.
pada lokasi mereka semula.
• Bersihkan semua parts yang dibongkar dengan larutan pembersih dan keringkan dengan meniup dengan udara dari
SPECIFICATIONS
kompressor sebelum memeriksanya.
• Minyak pelumasan camshaft disalurkan melalui jalan lintasan oli di dalam cylinder head. Bersihkan jalan lintasanUnit: oli sebelum
mm (in)
merakit kembali cylinder head. SERVICE
• ITEMpermukaan-permukaan penyatuan ketika melepaskan
Hati-hati agar tidak merusak STANDARD cylinder head. LIMIT
Cylinder compression 1,245 kPa (12.7 kgf/cm2, 181 psi)

SPESIFIKASI at 600 min-1 (rpm)
Cylinder
Satuan: mm head warpage – 0.05 (0.002)
Valve,
BAGIAN Valve clearance IN/EX 0.10 ± 0.02 (0.004
STANDARD ± 0.001) BATAS SERVIS–
valve guide Valve stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1965)2 4.965 (0.1955)
Tekanan kompressi cylinder 1.245 kPa (12,7 kgf/cm : 181 psi) -
EX 4.955 –pada
4.970 (0.1951
600 – 0.1957)
menit-1 (rpm) 4.945 (0.1947)
Valve guidecylinder
Perubahan bentuk melengkung I.D. head IN/EX 5.000 –- 5.012 (0.1969 – 0.1973) 0,05 5.03 (0.198)
Valve, Stem-to-guide
Jarak renggang clearance
klep IN
IN/EX 0.010 –0,10
0.037 (0.0004 – 0.0015)
± 0,02 - 0.065 (0.0026)
valve guide EX
(MASUK/BUANG) 0.030 – 0.057 (0.0012 – 0.0022) 0.085 (0.0033)
Valve guide
D.L. val projection
ve stem ININ/EX 9.1 – 9.3 (0.36
4,975 – 0.37)
– 4,990 4,965 –
Valve seat width EXIN/EX 0.90 – 4,955
1.10 (0.035 – 0.043)
– 4,970 4,9451.6 (0.06)
Valve spring free lengthD.D. val ve guide IN/EX
IN/EX 30.67 (1.207)
5,000 – 5,012 5,0329.70 (1.169)
Rocker arm/ Rocker
Jarak arm I.D.
renggang stem-ke- IN IN/EX – 10.015
10.0000,010 (0.3937 – 0.3943)
– 0,037 0,06510.10 (0.398)
shaft Rocker
guide arm shaft O.D. EXIN/EX 9.972 –0,030 0,057 – 0.3932)
9.987–(0.3926 0,085 9.91 (0.390)
Rocker
Proyeksiarm-to-shaft
valve guide clear- IN/EX 9,1 – 9,3 -
ance IN/EX 0.013 – 0.043 (0.0005 – 0.0017) 0.044 (0.0017)
Lebar valve seat IN/EX 0,90 – 1,10 1,6
Camshaft
Panjang bebas valve Cam lobe height
spring IN
IN/EX – 32.434 (1.2675 – 1.2769)
32.19430,67 29,7032.16 (1.266)
Rocker arm/ D.D. rocker arm EX
IN/EX – 32.230
31.99010,000 (1.2594 – 1.2689)
– 10,015 10,1031.96 (1.258)
Cam
shaft chain ten- Push rod O.D.
D.L. rocker arm shaft IN/EX 11.985 – 12.000 (0.4718
9,972 – 9,987 – 0.4724) 9,9111.94 (0.470)
sioner Spring free length 111.3 (4.38)
Jarak renggang rocker IN/EX 0,013 – 0,043 0,044 109 (4.3)
arm-ke-shaft
Camshaft Ketinggian cam lobe IN 32.194 – 32,434 32,16
TORQUE VALUES (cuping bubungan) EX 31,990 – 32,230 31,96
Cam chain D.L. push
Cylinder head cover special bolt rod 10 N·m (1.0 kgf·m, 7 lbf·ft) 11,985 – 12,000 11,94
tensioner
Cylinder head nut Panjang bebas spring 13 N·m (1.3 kgf·m, 10 lbf·ft)111,3 109
Apply oil to the threads and seating surface.
Cam sprocket bolt 8 N·m (0.82 kgf·m, 5.9 lbf·ft) Apply locking agent to the threads:
See page 7-11
Cam chain tensioner sealing bolt 22 N·m (2.2 kgf·m, 16 lbf·ft)
TORSI PENGENCANGAN
Cam chain tensioner arm pivot bolt 16 N·m (1.6 kgf·m, 12 lbf·ft)
C ylinder head cover special bolt 10 N.m (1,0 kgf.m; 7 lbf.ft)
C ylinder head nut 13 N.m (1,3 kgf.m; 10 lbf.ft) Semprotkan oli pada ulir dan permukaan duduk.
Cam sprocket bolt 8 N.m (0,82 kgf.m; 5,9 lbf.ft) Oleskan zat pengunci pada ulir: Lihat hal. 7-11
Cam chain tensioner sealing bolt 22 N.m (2,2 kgf.m; 16 lbf.ft)
Cam chain tensioner arm pivot bolt 16 N.m (1,6 kgf.m; 12 lbf.ft)

7-3
CYLINDER HEAD/VALVE
TOOLS
Valve spring compressor Valve spring compressor attachment Valve guide driver, 5.0 mm
07757-0010000 07959-KM30101 07942-MA60000

Valve guide reamer, 5.0 mm Seat cutter, 27.5 mm (45° IN) Seat cutter, 24 mm (45° EX)
07984-MA60001 07780-0010200 07780-0010600

Flat cutter, 27 mm (32° IN) Flat cutter, 22 mm (32° EX) Interior cutter, 26 mm (60° IN)
07780-0013300 07780-0012601 07780-0014500

Interior cutter, 22 mm (60° EX) Cutter holder, 5.0 mm


07780-0014202 07781-0010400

7-4
CYLINDER HEAD/VALVE
TROUBLESHOOTING
TROUBLESHOOTING
• Engine top-end problems usually affect engine performance. These problem can be diagnosed by a compression test or by tracing
• Persoalan
engine noisespada bagian
to the top-endataswith
mesin biasanya
a sounding rodmempengaruhi
stethoscope. unjuk kerja mesin. Persoalan ini dapat didiagnosa dengan test
• Ifkompressi atau dengan
the performance is poormenelusuri suara-suara
at low speeds, check formesin
white pada
smokebagian
in theatas denganbreather
crankcase sounding rod Ifstethoscope.
hose. the hose is smoky, check for a
• seized
Jika unjuk
pistonkerja
ring mesin buruk
(page 8-7) . pada kecepatan rendah, periksalah terhadap asap putih pada crankcase breather hose (slang
pernapasan bak mesin). Jika hose berasap, periksa terhadap piston ring yang macet (hal. 8-7).
Compression too low, hard starting or poor performance at low speed
• Valves:
Kompressi
– Incorrectterlalu
valverendah,
clearance mesin sulit dihidupkan atau
unjuk kerja buruk pada
– Burned or bent valves kecepatan rendah
• –Valves (klep-klep):
Incorrect valve timing
–- Broken valve spring
Jarak renggang klep tidak benar
–- Valve
Valvesstuck openatau bengkok
terbakar
• Cylinder head:
–- Uneven
Tertib waktu klep tidak benar
valve seating
–- Leaking
Valve spring patah cylinder head gasket
or damaged
–- Warped
Valve macet terbuka
or cracked cylinder head
• • Worn head:piston or piston rings (page 8-6)
cylinder,
Cylinder
- Valve seating
Compression (dudukan
too high, klep)ortidak
overheating merata
knocking
- Cylindercarbon
• Excessive head gasket
build-up bocor atau rusak
on piston head or combustion chamber
- Ada perubahan bentuk melengkung atau retak-retak pada cylinder head
Excessive smoke
• Cylinder, piston atau piston rings aus (hal. 8-6)
• Cylinder head:
– Worn valve stem or valve guide
Kompressi
– Damaged terlalu
stemtinggi,
seal overheating atau knocking
• • Worn cylinder, pistonkarbon
Ada pembentukan or piston (page 8-6) pada piston head (kepala piston) atau di ruang pembakaran
ringsberlebihan
secara
Excessive noise
Asap berlebihan
• Cylinder head:
• –Cylinder
Incorrecthead:
valve clearance
–- Sticking
Valve stem
valveatau valve guide
or broken valve aus
spring
–- Damaged or worn
Ada kerusakan camshaft
pada stem seal
• –Cylinder,
Loose orpiston
worn cam
atau chain
piston rings aus (hal. 8-6)
– Worn or damaged cam chain guide roller/sprocket
– Worn or damaged cam chain tensioner
Mesin berisik
– Worn cam sprocket teeth
• –Cylinder head:arm and/or shaft
Worn rocker
• Worn cylinder,
- Jarak piston
renggang or piston
klep rings (page 8-6)
tidak benar
- Valve
Rough idle macet atau valve spring patah
- Camshaft
• Low rusak atau aus
cylinder compression
- Camfuel
• Faulty chain longgar
system (pageatau
5-3)aus
- Cam chain guide roller/sprocket aus atau rusak
- Cam chain tensioner aus atau rusak
- Gigi-gigi cam sprocket aus
- Rocker arm dan/atau shaft aus
• Cylinder, piston atau piston rings aus (hal. 8-6)

Putaran stasioner kasar


• Tekanan kompressi cylinder rendah
• Sistem bahan bakar tidak bekerja dengan baik (hal. 5-3)

7-5
CYLINDER HEAD/VALVE
CYLINDER COMPRESSION
TEST KOMPRESSI TEST
CYLINDER
Panaskan
Warm up mesin sampai
the engine suhu operasi
to normal normal.
operating temperature.
COMPRESSION
Matikan
Stop themesin
enginedan lepaskan
and spark
disconnect theplug cap
spark (topi
plug busi).
cap. GAUGE
Remove the
Lepaskan spark
spark plugplug (page
(busi) 3-7)
(hal. .
3-7).
Install the compression
Pasang compression gauge in the (meter
gauge spark plugpengukur
hole.
kompressi) pada lubang
Turn the ignition switch ON. busi.
Putar
Shift ignition switch (kunci
the transmission kontak) ke ON.
into neutral.
To avoid discharging Masukkan
Open the transmissi
throttle all ke
thedalam
way andneutral.
crank the engine with
the battery,
Agar do not
tidak Buka throttle seluruhnya dan putar stops
the starter until the gauge reading mesinrising.
dengan starter
menghabiskan
operate the starter The maximum reading is usually reached within 4 – 7
sampai
seconds.
pembacaan gauge berhenti naik. Pembacaan
muatan listrik
motor for morebaterai,
than 7 maksimum biasanya dicapai dalam 4 - 7 detik.
jangan jalankan
seconds. STANDARD:
starter motor untuk
lebih dari 7 detik. STANDARD:
1,245 kPa (12.7 kgf/cm2, 181 psi) at 600 min-1(rpm)
2 -1
1.245 kPa (12,7 kgf/cm ; 181 psi) pada 600 menit
If
(rpm)compression is high, it indicates that carbon deposits
have accumulated on the combustion chamber and/or
Jika kompressi
the piston head. tinggi, ini menunjukkan bahwa telah
terkumpul endapan karbon pada ruang pembakaran
If compression
dan/atau low, pour 3 – 5 cc (0.1 – 0.2 oz) of
mahkotaispiston.
engine oil into the cylinder through the spark plug hole
andkompressi
Jika recheck therendah,
compression.
tuangkan 3 – 5 cc oli mesin ke
dalam
If the cylinder melalui
compression lubang busi
increases fromdan
the periksa kembali
previous value,
check the cylinder, piston and piston rings for the follow-
kompressi.
ing:
Jika kompressi
– Leaking naik head
cylinder dari gasket
nilai sebelumnya, periksalah
– Worn piston ring
cylinder, dan piston rings terhadap sebagai
– rn cylinder and piston
berikut:
- IfKebocoran
the compression is the same
pada cylinder headasgasket
the previous value,
- the
Keausan
valves piston ring
for leakage.
- Keausan cylinder dan piston

Jika kompressi sama dengan nilai sebelumnya,


periksalah valves (klep-klep) terhadap kebocoran.

CYLINDER HEAD COVER


PELEPASAN
REMOVAL
Lepaskan special
Remove the bolts,
special bolts,mounting
mountingrubbers
rubbers dan cylinder
and cylinder
head
headcover.
cover. SPECIAL BOLTS/
MOUNTING RUBBERS

CYLINDER HEAD COVER

7-6
CYLINDER HEAD/VALVE
Lepaskan rubber
Remove the sealseal
rubber danand
dowel pinpin
dowel dari cylinder
from head
the cylinder
head cover. DOWEL PIN
cover.
RUBBER SEAL

CYLINDER HEAD COVER


PEMASANGAN
INSTALLATION
Tiuplah terbuka
Blow open the jalan lintasan in
oil passage olithe
di dalam cylinder
cylinder head head
cover
cover dengan
with the udara dari
compressed air.kompressor. CYLINDER HEAD
COVER

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

CYLINDER HEAD COVER


Oleskan liquid
Apply liquid sealant
sealant (Three(Three bond or
bond 5211C 5211C atau
SHINETSU
SILICONE KE45T
SHINETSU SILICONEor Three
KE45T bond 1215
atau or equivalent)
Three bond 1215to
the semicircular
atau sejenisnya) area
padaofdaerah
rubber seal as shown.
setengah lingkaran dari SEAL POINTS
rubber seal seperti diperlihatkan.

7-7
CYLINDER HEAD/VALVE
Pasang mounting
Install the rubbers
mounting dengan
rubbers tanda
with their "UP"
"UP" markmereka
facing
up.
menghadap ke atas. TANDA"UP"

MOUNTING RUBBER

Letakkan cylinderhead
Set the cylinder headcover
coveronto
pada
thecylinder
cylinderhead.
head.
SPECIAL BOLTS/
Install the
Pasang specialbolts
special bolts dan
and tighten them todengan
kencangkan the specified
torsi MOUNTING RUBBERS
torque.
yang ditentukan.
TORQUE:10 N·m (1.0 kgf·m, 7 lbf·ft)
TORSI: 10 N.m (1,0 kgf.m; 7 lbf.ft)

CYLINDER HEAD COVER

CAMSHAFT
REMOVAL
PELEPASAN
CATATAN:
• • Camshaft
Camshaft candapat diservis with
be serviced dengan mesin installed
the engine terpasangon
the
padaframe.
rangka.
Remove the
Lepaskan following:
sebagai berikut:
- –Lower
Lowerside covers
side (page
(hal.
covers 2-6)
2-6)
- –Cylinder
Cylinder head
head cover
cover (page
(hal. 7-6)
7-6)
- –Left
Left crankcase
crankcase cover
cover (page
(hal. 10-4)
10-4)
- –Cam
Cam chain
chain tensioner
tensioner sealing
sealing washer/bolt
washer/bolt

SEALING WASHER/BOLT
Putar crankshaft
Turn the crankshaftberlawanan arah jarum
counterclockwise jam
until the sampai
index lines
on thelines
cam(garis
sprocket is aligned withcam
the top surfacesejajar
of the INDEX LINES
index penunjuk) pada sprocket
cylinderpermukaan
dengan head. atas dari cylinder head.
Pastikan
Make sure bahwa piston
the piston berada
is at TDC (Toppada TDC
Dead (Top on
Center) Deadthe
compression
Center) [TMAstroke.
= Titik Mati Atas] pada langkah
This position can be obtained by confirming that there is
kompressi.
slack in
Posisi ini the rocker
dapat arms. Ifdengan
diketahui there ismengkonfirmasikan
no slack, turn the
crankshaft again until the correct position is obtained. CAM
bahwa ada kerenggangan pada rocker arms. Jika tidak CHAIN
Remove
ada the bolts, cam
kerenggangan, putarsprocket fromsekali
crankshaft the camshaft and
lagi sampai
cam chain off the cam sprocket.
posisi yang benar telah diperoleh.
Attach a piece of wire to the cam chain to prevent it from
falling into bolts,
Lepaskan the crankcase.
cam sprocket dari camshaft dan
lepaskan cam chain dari cam sprocket.
Ikatlah cam chain dengan sepotong kawat agar tidak BOLTS
dapat terjatuh ke dalam crankcase. CAM SPROCKET

7-8
CYLINDER HEAD/VALVE
Remove the
Lepaskan bolt/washer
bolt/washer darifrom the cylinder
cylinder head. head.
BOLT/WASHER

Remove the
Lepaskan camshaft dari
camshaft from the cylinder
cylinder head sementara
head while hold-
ing the rockerrocker
arms to ease ROCKER ARMS CAMSHAFT
memegang armsremoval.
untuk mempermudah
pelepasan.

INSPECTION
PEMERIKSAAN
Turn outer
Putar the outer
racerace of eachluar)
(lingkaran camshaft bearing camshaft
dari masing2 with your
finger. The
bearing bearing
dengan should
jari-jari. turn smoothly
Bearing and quietly.
harus berputar dengan
Also check that the bearing inner race fits tightly on the
halus dan tanpa suara.
camshaft.
Juga periksa
Replace the bahwa
camshaftbearing inner ifrace
assembly the (lingkaran
bearing doesdalam
not
bantalan) duduk quietly,
turn smoothly, denganor erat padafitcamshaft.
if they loosely on the cam-
shaft. susunan camshaft jika bearing tidak berputar
Ganti
dengan halus, tanpa suara, atau jika mereka duduk
dengan longgar pada camshaft.

BEARINGS
Periksa cam
Check the cam lobes
lobes for(cuping bubungan)
excessive terhadap
wear and damage.
keausan
Measureberlebihan
the heightdan kerusakan.
of each cam lobe. CAM LOBES
SERVICE
Ukur LIMIT: cam lobe.
tinggi masing2
IN: 32.16 mm(1.266 in)
BATAS SERVIS:
EX: 31.96 mm(1.258 in)
IN: 32,16 mm
EX: 31,96 mm

7-9
CYLINDER HEAD/VALVE
INSTALLATION
PEMASANGAN
Apply engine oil
Semprotkan oli tomesin
the camshaft
pada whole surface.
seluruh permukaan
camshaft.
Install the camshaft into the cylinder head with its tab fac- ROCKER ARMS
ing up while holding the rocker arms to ease installation.
Pasang camshaft ke dalam cylinder head dengan tab-
nya menghadap ke atas sementara memegang rocker
arms untuk mempermudah pemasangan.

CAMSHAFT TAB
Install and
Pasang dantighten the bolt/washer.
kencangkan bolt/washer.
BOLT/WASHER

Rotatecrankshaft
Putar the crankshaft counterclockwise
berlawanan arah jarumuntil
jamthe index
sampai
line online
index the (garis
flywheel is alignedpada
penunjuk) with the index notch
flywheel on the
bertepatan INDEX NOTCH
left crankcase.
dengan index notch (takik penunjuk) pada left
crankcase.

INDEX LINE
Semprotkan
Apply engine oli oil
mesin pada
to the camchain
cam chainand
dancam
gigi-gigi cam
sprocket
sprocket.
teeth. CAM CHAIN
Install the cam chain on the cam sprocket with its stamp
Pasang cam up,
mark facing chain padasure
making camthat
sprocket dengan
the index tanda
lines on the
cam dicetak
yang sprocketmenghadap
are flush withke the topdengan
atas, surfacememastikan
of the cylin-
der head
bahwa as shown
index lines (TDC
padaoncamthe compression stroke).
sprocket adalah rata STAMP
Install the
dengan cam sprocket
permukaan to the
atas daricamshaft.
cylinder head seperti MARK
diperlihatkan (TDC pada langkah kompressi).
Pasang cam sprocket pada camshaft.

CAM SPROCKET INDEX LINES

7-10
CYLINDER HEAD/VALVE
Oleskan zat pengunci
Apply locking pada
agent to the camulir cam bolt
sprocket sprocket
threadsbolt
as
shown.diperlihatkan. Coating width: 6.5 ± 1.0 mm
seperti
(0.26 ± 0.04 in) from tip
Install and tighten the cam sprocket bolts to specified
torque. dan kencangkan cam sprocket bolts dengan
Pasang
torsi yang ditentukan.
TORQUE:8 N·m (0.82 kgf·m, 5.9 lbf·ft)
TORSI: 8 N.m (0,82 kgf.m; 5,9 lbf.ft)

BOLTS

Tuangkan
Pour 4.0 –4,0
5.0– cc
5,0ofcc oli mesin
engine ke the
oil into dalam
camcam
chainchain
ten-
SEALING
tensioner push
sioner push rodrod
asseperti
shown.diperlihatkan. WASHER/BOLT
Install a new sealing washer and the bolt, then tighten it.
Pasang sebuah sealing washer baru dan bolt, kemudian
Install the following:
kencangkan.
Pasang sebagai
– Cylinder headberikut:
cover (page 7-7)
- –Cylinder head cover
Left crankcase (hal.
cover 7-7).
(page 10-5)
- –Left crankcase
Lower cover(page
side covers (hal. 2-6)
10-5)
- Lower side covers (hal. 2-6)

4.0 – 5.0 cc

7-11
CYLINDER HEAD/VALVE
CYLINDER HEAD (KEPALA SILINDER)
CATATAN:
REMOVALylinder head can be serviced
• Cylinder head dapat diservis dengan mesin
with the engine
terpasang installed on the frame.
pada rangka.
Remove the
Lepaskan following:
sebagai berikut :
NUTS BOLTS
- –Cam sprocket
Cam sprocket (hal. 7-8)
(page 7-8)
- –Exhaust
Exhaust pipe/muffler
pipe/muffler(hal. 2-19)
(page 2-19)
- –Inlet pipe
Inlet mounting
pipe mounting bolts/gasket
bolts/gasket(hal. 5-22)
(page 5-22)
- –PAIR
PAIRairair
supply
supply pipe (hal.
pipe 5-21)
(page 5-21)
Lepaskan
Remove the cylinder head
cylinder bolts.
head bolts.
Longgarkan cylinder head nuts in
Loosen the cylinder head nuts a crisscross
dalam pattern in
pola bersilangan
two ordua
dalam three steps.
atau tiga langkah.
Remove the four nuts, two washers and a plate.
Lepaskan keempat nuts, dua washers dan sebuah
plate.
PLATE
NUTS/WASHERS
Lepaskan cylinder
Remove the head.
cylinder head.

CYLINDER HEAD

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

GASKET

7-12
CYLINDER HEAD/VALVE
DISASSEMBLY
PEMBONGKARAN
ROCKER ARM/SHAFT
ROCKER ARM/SHAFT
Remove the
Lepaskan rocker
rocker armarm shaft
shaft stopper
stopper bolt.
bolt. BOLT

Sekrupkan
Screw the 5 mm boltbolt into
ke dalam lubanghole
the threaded berulir di dalam
in the rocker
arm shaft ROCKER ARMS
rocker arm and
shaftpull
dan it out of the
tariklah cylinder
keluar darihead.
cylinder head.
Remove the
Keluarkan rocker
rocker arms.arms. 5 mm BOLT

ROCKER ARM SHAFT

CAMSHAFT
CAMSHAFT
Keluarkan bolt/washer
Remove the danand
bolt/washer camshaft.
camshaft.
BOLT/WASHER

CAMSHAFT
VALVE
VALVE
Untuk menghindari
To prevent loss of Lepaskan valve
Remove the cotters
valve cottersdengan menggunakan
using the valve spring valve
com-
hilangnya tegangan,
tension, do not pressor.
spring compressor. VALVE SPRING COMPRESSOR
jangan tekan
compress thevalve
valve
springs TOOLS:
springs lebih
moredari
than TOOLS:
yang diperlukan untuk Valve spring compressor 07757-0010000
necessary to remove
melepaskan cotters.
Valve spring compressor 07757-0010000
the cotters. Valve spring compressor
Valve spring compressor attachment 07959-KM30101
07959-KM30101
attachment

COTTERS
ATTACHMENT

7-13
CYLINDER HEAD/VALVE
Tandailah
Mark all partssemua
during Lepaskan
Remove the valve
valvespring
spring compressor danremove
compressor and lepaskan
the
parts pada waktu
disassembly so they following:
sebagai berikut: VALVE
can bepembongkaran
placed back in - –Valve spring
Valve retainers
spring retainers
sehingga mereka
their original - –Valve springs
Valve springs
dapat diletakkan VALVE STEM SEAL
locations.
kembali pada lokasi - –Valve
Valve spring
spring seats
seats
semula mereka. - –Valves
Valves
– Valve stem seals
- Valve stem seals

VALVE SPRING SEAT

VALVE SPRING
VALVE SPRING RETAINER
Hati-hati agar tidak
Avoid damaging the Buanglah endapan
Remove the carbonkarbon dari
deposits ruang
form pembakaran
the combustion dan
cham-
merusak
matingpermukaan
surface and bersihkan permukaan
ber and clean cylinderhead
off the cylinder headgasket
gasket.surface. COMBUSTION CHAMBER
penyatuan dan
valve seat surfaces.
permukaan valve seat.

INSPECTION
PEMERIKSAAN
CYLINDERHEAD
CYLINDER HEAD
Check the
Periksa spark plug
lubang busi hole
dananddaerah
valve areas for cracks.
di sekitar valve
Check the
terhadap cylinder head for warpage with a straight edge
retak-retak.
and a feeler
Periksa gauge.head terhadap perubahan bentuk
cylinder
melengkung
SERVICE dengan mistar lurus dan sebuah feeler
gauge (lidah pengukur).
LIMIT: 0.05 mm (0.002 in)

BATAS SERVIS: 0,05 mm

ROCKER
ROCKERARM/SHAFT
ARM/SHAFT
Disassemble
Bongkar thehead
cylinder cylinder head
(hal. (page 7-13).
7-13).
Check the rocker armshafts
shaftsdan
and rocker arms ROLLERS
Periksa rocker arm armsforterhadap
wear or
damage.atau kerusakan.
keausan
Turn the rocker arm rollers with your finger.
The rollers
Putar rockershould turn smoothly
arm rollers and quietly.
dengan jari-jari.
Rollers
Measureharus dapat
the I.D. berputar
of each dengan
rocker arm. halus dan tanpa
suara.
SERVICE
LIMIT: IN/EX: 10.10 mm (0.398 in)
Ukur D.D. masing-masing rocker arm.
Measure the O.D. of each rocker arm shaft.
BATAS SERVIS: IN/EX: 10,10 mm
SERVICE
Ukur D.L. masing-masing
LIMIT: IN/EX: rocker arm
9.91 mm shaft.
(0.390 in)
BATAS SERVIS: IN/EX: 9,91 mm ROCKER ARM SHAFTS
Calculate the rocker arm-to-shaft clearance.
Hitung jarak renggang antara rocker arm-ke-shaft.
SERVICE
LIMIT:SERVIS: IN/EX:
BATAS IN/EX: 0,044
0.044 mm
mm(0.0017 in)

7-14
CYLINDER HEAD/VALVE
VALVESPRING
VALVE SPRING
Disassemble
Bongkar thehead
cylinder cylinder
(hal.head (page 7-13).
7-13).
Measure
Ukur the bebas
panjang free length
valveofsprings.
the valve springs.
SERVICE
BATAS SERVIS: IN/EX: 29,70 mm
LIMIT: IN/EX: 29.70 mm (1.169 in)
Gantilah springs jika mereka lebih pendek dari batas
Replace the springs if they are shorter than the service
servis.
limit.

VALVE/VALVE
VALVE/VALVE GUIDE
GUIDE
Bongkar cylinder head (hal.head
Disassemble the cylinder (page 7-13).
7-13).
Check that
Periksa the valve
bahwa valve moves smoothly
bergerak denganin the
halusguide.
di dalam
Check each valve for bend, burn, scratch or abnormal
guide.
wear.
Periksa masing-masing valve terhadap keadaan
Measure each
melengkung, valve stem
keadaan O.D. and
terbakar, recordatau
goresan it. keausan
SERVICE
tidak normal.
LIMIT: IN: 4.965 mm (0.1955 in)
EX: 4.945
Ukur D.L. masing-masing mmstem
valve (0.1947
danin)
catat.

BATAS SERVIS: IN: 4,965 mm


EX: 4,945 mm

Selalu putarrotate
Always reamer Ream the
Lakukan
the valve guide
pekerjaan to remove
reaming pada any carbon
valve guidebuild up
untuk
searah
reamerjarum jam,
clockwise, before measuring
membuang the guide.karbon sebelum mengukur
pembentukan VALVE GUIDE REAMER
jangan sekali-kali
never Insert the reamer from the combustion chamber side of
guide.
putar berlawanan the cylinderreamer
head and
counterclockwise
jarumwhen
Masukkan
jam inserting,
sewaktu
dari always rotate pembakaran
sisi ruang the reamer clock-
dari
wise.
memasukkan, cylinder head dan selalu putar reamer searah jarum
removing and jam.
TOOL:
mengeluarkan dan
reaming.
melakukan pekerjaan Valve guide reamer, 5.0 mm 07984-MA60001
reaming. TOOL:
Valve guide reamer, 5.0 mm 07984-MA60001

Periksaand
Inspect danreface
lakukan
the Ukur D.D. each
Measure masing-masing
valve guidevalve guide
I.D. and dan catat.
record it.
pekerjaan
valve refacing
seats whenever
BATAS SERVIS: IN/EX: 5,03 mm
thepada
valvevalve seats
guides are SERVICE
setiap kali valve LIMIT:D.L. masing-masing
IN/EX: 5.03 mm stem
(0.198dari
in) D.D. guide
replaced (page 7-21).
guides diganti (hal. 7-
Kurangi valve
21). yang bersangkutan untuk mendapatkan jarak renggang
Subtract each valve stem O.D. from the corresponding
stem-ke-guide.
guide I.D. to obtain the stem-to-guide clearance.
SERVICE
BATAS SERVIS: IN: 0,065 mm
LIMIT: IN: 0.065
EX: 0,085mm
mm(0.0026 in)
EX: 0.085 mm (0.0033 in)
Jika
If thejarak renggang
stem-to-guide stem-ke-guide
clearance exceeds the melampaui
service limit,
batas servis,
determine if atentukan
new guideapakah
with sebuah
standard guide baru
dimensions
would bring
dengan the clearance
ukuran standardwithin tolerance.
akan membawa jarak
If so, replace any guides as necessary and ream to fit
renggang di dalam toleransi.
(page 7-20).
Jika demikian, gantilah guides yang diperlukan dan
If the stem-to-guide clearance exceeds the service limit
lakukan
with newpekerjaan reaming
guide, also agar
replace the pas (hal. 7-20).
valve.
Jika jarak renggang stem-ke-guide melampaui batas
servis dengan guide yang baru, gantilah valve juga.

7-15
CYLINDER HEAD/VALVE
PERAKITAN
COTTERS

VALVE SPRING
SPRING RETAINER EXHAUST ROCKER ARM

SPRING SEAT
INLET ROCKER ARM

VALVE STEM SEAL

VALVE GUIDE

EXHAUST ROCKER CLIP


ARM SHAFT

INLET ROCKER
ARM SHAFT

ROCKER ARM SHAFT


STOPPER BOLT

BOLT/WASHER

EXHAUST VALVE
CAMSHAFT

INLET VALVE
VALVE
VALVE
Tiuplah melaluithe
Blow through jalan
oil lintasan
passageoliindithe
dalam cylinder
cylinder headhead
with
compressed
dengan udaraair.
dari kompressor.
Install the
Pasang valve
valve spring
spring seatsseats
danand newstem
valve valveseals
stembaru.
seals. VALVE
Coat the valve stem sliding surface with engine oil.
Insert the
Lapisi valves into
permukaan the valve guides
peluncuran valve while
stem turning
dengan them
oli SPRING SEAT
slowly to avoid damage to the valve stem seals.
mesin.
Masukkan valves ke dalam valve guides sementara
memutar mereka dengan pelan untuk menghindari
kerusakan pada valve stem seals.

STEM SEAL

7-16
CYLINDER HEAD/VALVE
Pasang
Install thevalve
valve springs with
dengan lilitan
the tightly yang
wound coilsrapat
fac-
ing the combustion
menghadap ke ruangchamber.
pembakaran.

Ke ruang
pembakaran

Install the
Pasang valve
valve spring
spring retainer.
retainer.
VALVE SPRING COMPRESSOR
To prevent
Untuk loss of
menghindari Install the
Pasang valvecotters
valve cotters using
denganthe valve spring compres-
menggunakan valve
tension,
hilangnya do not
tegangan, sor.
spring compressor.
jangan
compresstekan
thevalve
valve TOOLS:
springspring
lebih more
daripada
than Valve spring compressor 07757-0010000
TOOLS:
yangnecessary
diperlukan to untuk
install
memasang Valve
Valvespring compressor
spring compressor 07757-0010000
thecotters.
cotters. attachment
Valve spring compressor 07959-KM30101
07959-KM30101
attachment

ATTACHMENT

Topang cylinder
Support head
the cylinder Letakkan sebuahtoolsuitable
Place a suitable onto thetool
valve(alat
stem.perkakas yang
di atas permukaan sesuai)
head above
meja
the work
kerja untukto Tap thepada valve stem.
tool gently to seat the cotters firmly using a ham- SUITABLE TOOL
bench surface mer.
menghindari
prevent valve
terjadinya kerusakan
Ketuk tool dengan ringan untuk mendudukkan cotters
damage. dengan erat dengan menggunakan palu plastik.
pada valve.

COTTERS

VALVE STEM
CAMSHAFT
CAMSHAFT
Semprotkan oli tomesin
Apply engine oil pada whole
the camshaft seluruh permukaan
surface.
camshaft. CAMSHAFT
Install the camshaft with its tab facing up.
Pasang camshaft dengan tab-nya menghadap ke atas.

TAB

7-17
CYLINDER HEAD/VALVE
Pasang dantighten
Install and kencangkan bolt-washer.
the bolt/washer.
BOLT/WASHER

ROCKER
ROCKERARM ARM
Semprotkan
Apply engineolioilmesin
to thepada permukaan
sliding peluncuran
surface and dan
roller surface
of the rocker
permukaan arm.dari rocker arm.
roller INLET
Apply engine ROCKER ARM
Semprotkan olioilmesin
to thepada
sliding surface ofpeluncuran
permukaan the rocker dari
arm
shaft. arm shaft.
rocker EXHAUST
ROCKER ARM

ROCKER ARM SHAFTS


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

ROCKER ARM SHAFTS

INLET ROCKER ARM SHAFT

Tepatkan (bolt holes)

7-18
CYLINDER HEAD/VALVE
Pasang dantighten
Install and kencangkan rocker
the rocker armarm shaft
shaft stopper
stopper bolt.
bolt.
BOLT

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

GASKET
Alurkan
Route thecamcamchain melalui
chain cylinder
through the head danhead
cylinder pasang
and
install the cylinder CAM CHAIN
cylinder head pada head onto the cylinder.
cylinder.

CYLINDER HEAD
Semprotkan
Apply engineolioilmesin
to the pada
seatingpermukaan
surface andduduk danof ulir
threads the
cylinder
dari head
cylinder nuts.nuts.
head Install the plate
Pasang anddan
plate twodua
washers and
washers NUTS BOLTS
tighten
dan the cylindercylinder
kencangkan head nutsheadin a crisscross
nuts dalampattern
polato
the specified
bersilangan torque.torsi yang ditentukan.
dengan
TORQUE:13 N·m (1.3 kgf·m, 10 lbf·ft)
TORSI: 13 N.m (1,3 kgf.m; 10 lbf.ft)
Install and tighten the cylinder head mounting bolts.
Pasang danfollowing:
Install the kencangkan cylinder head mounting bolts.
– Camsebagai
Pasang sprocket (page 7-10)
berikut:
– Exhaust pipe/muffler (page 2-20)
- –Cam sprocket (hal.
Gasket/inlet pipe 7-10)
mounting bolts (page 5-22)
- –Exhaust pipe/muffler
PAIR air supply pipe(hal. 2-20)
(page 5-22)
- Gasket/inlet pipe mounting bolts (hal. 5-22)
- PAIR air supply pipe (hal. 5-22) PLATE
NUTS/WASHERS

7-19
CYLINDER HEAD/VALVE
VALVE GUIDEVALVE
PENGGANTIAN REPLACEMENT
GUIDE
Disassemble
Bongkar thehead
cylinder cylinder
(hal.head (page 7-13).
7-13). VALVE GUIDE DRIVER
Chill new valve guides in a freezer
Dinginkan valves guides baru di dalam for about 1 hour.
bagian freezer
dari lemari es selama kira-kira 1 jam.
CATATAN:
• Be sure to wear heavy gloves to avoid burns when
• handling the
Pastikan untukheated
memakaicylinder head.tangan tebal untuk
sarung
• menghindari
Using a torchluka-luka
to heat the cylinder
bakar head menangani
sewaktu may cause
warpage.
cylinder head yang telah dipanaskan.
• Drive new guides from the camshaft side while the
• Jangan menggunakan
cylinder head is still heated.obor untuk memanaskan
cylinder head karena dapat mengakibatkan
Heat the cylinder head to 130 – 140°C (275 – 290°F) with
perubahan bentuk melengkung.
a hot plate or oven. Do not heat the cylinder head
• beyond
Dorong
150°masuk
C (300°F). guides
Use temperature sisi camshaft
baru dari indicator sticks,
sementara cylinder head masih panas.
available from welding supply stores, to be sure the cylin-
Panaskan
der head is cylinder
heated headto the sampai 130 – 140°C dengan
proper temperature. VALVE GUIDE
kompor listrik atau oven. Jangan memanaskan cylinder
Support
head the cylinder
melampaui head and
150°C. drive the
Pakailah valve guides
tongkat out
indikator
of the cylinder head from the combustion chamber side.
suhu, yang dapat dibeli dari toko pemasok
TOOL:
perlengkapan pengelasan, untuk memastikan bahwa
Valve guide
cylinder headdriver,
telah 5.0 mm
dipanaskan 07942-MA60000
sampai ke suhu yang
tepat.
Take out new valve guides from the freezer.
Topang cylinder head dan dorong keluar valve guides VALVE GUIDE DRIVER
Drive
dari new clips
cylinder headand darivalve guides
sisi ruang into the cylinder head
pembakaran.
to the specified height from the cylinder head.
TOOL: VALVE
Valve
TOOL: guide driver, 5.0 mm 07942-MA60000 GUIDE/
Valve guide driver, 5.0 mm 07942-MA60000 CLIP
Keluarkan valve guides baru dari freezer.
VALVEmasuk
Dorong GUIDEclips
PROJECTION:
baru dan valve guides ke dalam
cylinder head
IN/EX: 9.1sampai ke (0.36
– 9.3 mm ketinggian
– 0.37 yang
in) ditentukan dari
permukaan cylinder head.
Let the cylinder head cool to room temperature.
TOOL:
Valve guide driver, 5.0 mm 07942-MA60000
PROYEKSI VALVE GUIDE: 9.1 – 9.3 mm
IN/EX: 9,1 – 9,3 mm (0.36 – 0.37 in)
Biarkan cylinder head menjadi dingin kembali sampai ke
suhu ruangan.

Lakukan
Ream new pekerjaan reaming
valve guides pada valve guides baru
after installation.
setelah pemasangan. VALVE GUIDE REAMER
CATATAN:
• • Hati-hati
Take care not agarto tilt or lean the
tidak reamer in the guide
memiringkan atau
while reaming.
mencondongkan reamer di dalam
• Use cutting oil on the reamer during this guide sewaktu
operation.
meng-reaming.
Insert the reamer from the combustion chamber side of
• the Pakailah cutting
cylinder head oil pada
and always reamer
rotate the reamerselama
clock-
pengerjaan
wise. ini.
Masukkan reamer dari sisi ruang pembakaran dari
TOOL: head dan selalu putar reamer searah dengan
cylinder
Valve guidejarum
perputaran reamer,
jam. 5.0 mm 07984-MA60001
Clean the cylinder head thoroughly to remove any metal
TOOL:
particles after reaming and reface the valve seat (page 7-
Valve
21). guide reamer, 5.0 mm 07984-MA60001
Bersihkan cylinder head secara menyeluruh untuk
membuang partikel-partikel logam setelah pekerjaan
reaming dan jalankan pekerjaan refacing (pembentukan
kembali permukaan) pada valve seat (hal. 7-21).

7-20
CYLINDER HEAD/VALVE
VALVE SEAT INSPECTION/REFACING
PEMERIKSAAN/REFACING VALVE SEAT
Disassemble
Bongkar thehead
cylinder cylinder head
(hal. (page 7-13).
7-13). HAND-LAPPING TOOL
Clean the intake and exhaust
Bersihkan intake valves (klep pemasukan)valves thoroughly to
dan exhaust
remove carbon deposits.
valves (klep pembuangan) secara menyeluruh untuk
Apply a light
membuang coat of Prussian
endapan karbon. Blue to the valve seats.
Tap the valve against the valve seat several times using
a hand-lapping tool, without rotating the valve to make a
Oleskan lapisan tipis Prussian Blue pada valve seats
clear pattern.
(dudukan klep).
Ketuk valve terhadap valve seat beberapa kali dengan
menggunakan hand-lapping tool (alat skir klep dengan
tangan), tanpa memutar valve agar mendapatkan pola
yang jelas.

Valves
The valvestidak dapat
cannot be Remove the
Lepaskan valve
valve danand inspect
periksa the valve
muka valve seat.
seat face.
digerinda.
ground. Jika
If themuka
valve The valve seat contact should be within
Kontak valve seat harus di dalam lebar yang theditentukan
specified
valve
faceterbakar,
is burned, sangat
badly width and even all around the circumference.
wornausor atau jika ia
if it contacts dan merata sepanjang kelilingnya.
mengkontak seat STANDARD: 0.90 – 1.10 mm (0.035 – 0.043 in)
the seat unevenly,
secara tidak merata, SERVICE
STANDARD: 0,90 - 1,10 mm
replace the valve.
gantilah valve. LIMIT:SERVIS: 1.61,6
BATAS mmmm (0.06 in)
If the valve seat width is not within specification, reface
Jika lebar valve seat di luar spesifikasi, reface valve
the valve seat (page 7-21).
seat (bentuk kembali permukaan dudukan klep) (hal. 7-
21).
LEBAR SEAT

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

KERUSAKAN PADA MUKALEBAR SEAT TIDAK


MERATA

• • Contact area (too


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

TERLALU RENDAH TERLALU TINGGI

7-21
CYLINDER HEAD/VALVE
• • Follow
Ikuti petunjuk pemakaian
the refacer pabrik pembuat
manufacturer’s refacer.
operating instruc-
• tions.
Hati-hati agar tidak menggerinda seat lebih
• Be carefulyang
daripada not todiperlukan.
grind the seat more than necessary.

45°

60°

32°

Jika daerah
If the kontak
contact area isterlalu tinggi
too high on pada valve,
the valve, theseat
seatharus
must
be lowereddengan 32° flat cutter. 32° flat cutter.
using amenggunakan KONTAK TERLALU TINGGI LEBAR SEAT LAMA
diturunkan
If the contact area is too low on the valve, the seat must
Jika daerah
be raised kontak
using a 60° terlalu
interior rendah
cutter. pada valve, seat
harus dinaikkan dengan menggunakan 60° interior 32°
Refinish the seat to specifications, using a 45 ° finish cut-
cutter.
ter.
Haluskan permukaan seat sesuai dengan spesifikasi,
dengan menggunakan 45° finish cutter. KONTAK TERLALU RENDAH LEBAR SEAT LAMA

60°

Refacetheseat
Reface seatdengan
with a Pakailah
Use a 4545° ° seatseat cutter,
cutter, hilangkan
remove kekasaran
any roughness atau
or irregu-
45° °cutter
45 cutterwhenever
seiap kalia ketidak-teraturan dari seat.
larities from the seat.
sebuahvalve
valveguide
guideis KEKASARAN
diganti. TOOLS:
replaced. TOOLS:
Seatcutter,
Seat cutter, 27.5
27.5mmmm(45°
(45°IN)
IN) 07780-0010200
07780-0010200
Seatcutter,
Seat cutter, 24
24mmmm(45°
(45°EX)
EX) 07780-0010600
07780-0010600
Cutterholder,
Cutter holder, 5.0
5.0 mm
mm 07781-0010400
07781-0010400

Pakailah
Use a 3232° flatcutter,
° flat cutter,remove
hilangkan
the ¼
topbagian
1/4 of teratas dari
the existing
bahan
valve valve seat yang ada sekarang.
seat material.

TOOLS:
TOOLS: LEBAR SEAT LAMA
Flatcutter,
Flat cutter, 27
27 mm
mm (32°
(32°IN)
IN) 07780-0013300
07780-0013300
Flat cutter, 22 mm (32°EX)
Flat cutter, 22 mm (32° EX) 07780-0012601
07780-0012601
Cutterholder,
Cutter holder, 5.0
5.0 mm
mm 07781-0010400
07781-0010400

32°

7-22
CYLINDER HEAD/VALVE
Use a 60°60°
Pakailah interior cutter,cutter,
interior removehilangkan
the bottom¼1/4bagian
of the
existing valve
terbawah seat material.
dari bahan valve seat yang ada sekarang.
LEBAR SEAT LAMA
TOOLS:
TOOLS:
Interiorcutter,
Interior cutter, 26
26 mm
mm (60°
(60°IN)
IN) 07780-0014500
07780-0014500
Interiorcutter,
Interior cutter, 22
22 mm
mm (60°
(60°EX)
EX) 07780-0014202
07780-0014202
Cutterholder,
Cutter holder, 5.0
5.0 mm
mm 07781-0010400
07781-0010400

60°

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

45°

CATATAN:
• • Excessive
Tekanan skir klep pressure
lapping yang berlebihan dapatormerubah
may deform damage
bentuk
the seat.atau merusak seat.
• • Change
Ubah sudutthe angle
dari oflapping
lappingtool
tool sering-sering
frequently to prevent
untuk
uneven seat wear.
menghindari keausan seat yang tidak merata.
• • Do not allow
Jagalah lapping
agar compound
lapping to enter(ambril)
compound the guides.
tidak
After cutting the
memasuki seat, apply lapping compound to the
guides.
valve face, and lap the valve using light pressure. HAND-LAPPING TOOL
Setelah memotong seat, oleskan lapping compound
After muka
pada lapping, washdan
valve, anyskirresidual
klep compound off the cylin-
dengan menggunakan
der head
tekanan and valve and recheck the seat contact.
ringan.
Assemble the cylinder head (page 7-16).
Setelah menskir klep, cucilah compound yang tersisa
dari cylinder head dan valve dan periksa kembali kontak
seat.

Rakit cylinder head (hal. 7-16).

7-23
CYLINDER HEAD/VALVE
CAM CHAIN TENSIONER
PELEPASAN
REMOVAL
Lepaskan flywheel
Remove the (hal.
flywheel 10-8).
(page 10-8).
TENSIONER SPRING PUSH ROD
Remove the
Lepaskan camcam chaintensioner
chain tensionersealing
sealing washer/bolt,
washer/bolt,
tensionerspring
tensioner springdan
andpush
the push
rod. rod.

SEALING WASHER/BOLT
Lepaskan
Remove thepivot
pivotbolt, washer,
bolt, washer,tensioner
tensionerarm/collar
arm/collar dan
and
the tensioner
tensioner roller.roller. TENSIONER ROLLER PIVOT BOLT/
WASHER

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

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

7-24
CYLINDER HEAD/VALVE
Periksa check
Inspect the valve
check valvediin the
dalam
pushpush
rod forrod
wearterhadap
or dam-
keausan
age. atau kerusakan.

CHECK VALVE

INSTALLATION
PEMASANGAN
Install the
Pasang camcam
chainchain tensioner
tensioner roller,roller,
collar,collar, tensioner
tensioner arm
armpivot
dan and the pivot bolt/washer,
bolt/washer, thenkencangkan
kemudian tighten it to the spec-
dengan TENSIONER ROLLER COLLAR
ifiedyang
torsi torque.
ditentukan.
TORQUE: 16 N·m (1.6 kgf·m, 12 lbf·ft)
TORSI: 16 N.m (1,6 kgf.m; 12 lbf.ft)

TENSIONER ARM PIVOT BOLT/WASHER

Install the
Pasang pushpush
rod.rod.
Install the tensioner spring with its tapered side facing Sisi meruncing PUSH ROD
Pasang tensioner spring dengan ujungnya yang
down.
meruncing menghadap ke bawah.
Install and tighten the sealing bolt with a new sealing
washer to the specified torque.
Pasang dan kencangkan sealing bolt dengan sebuah
TORQUE:
sealing washer22 N·m
baru(2.2 kgf·m,
dengan 16 lbf·ft)
torsi yang ditentukan.

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

TENSIONER SEALING
SPRING WASHER/BOLT

Remove cam
Lepaskan the chain
cam tensioner
chain tensioner sealing
sealing bolt bolt and
dan washer.
washer. 4,0 – 5,0 cc oli mesin ke dalam push rod. 4.0 – 5.0 cc
Tuangkan
Pour 4.0 – 5.0 cc of engine oil into the push rod.
Pasang dan tighten
Install and kencangkan sealing
the sealing boltbolt
withdengan
a new sebuah
sealing
sealing
washer. washer baru.
Install the flywheel (page 10-12).
Pasang flywheel (hal. 10-12).

SEALING
WASHER/BOLT

7-25
CYLINDER HEAD/VALVE
OIL STOPPER PLATE
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan flywheel
Remove the (hal.
flywheel 10-8).
(page 10-8).
Lebar pelapisan: 6.5 ± 1.0 mm
Lepaskan
Remove the boltbolt
danand
oil stopper plate.
oil stopper plate. ±dari ujung
Apply locking agent to the bolt threads
Oleskan zat pengunci pada ulir bolt seperti as specified.
ditentukan.
Install the
Pasang oil stopper
oil stopper plate
plate danand tighten thebolt.
kencangkan bolt.
Install the flywheel (page 10-12).
Pasang flywheel (hal. 10-12).

BOLT PLATE

7-26
8. CYLINDER/PISTON

COMPONENT
LOKASI LOCATION ···························· 8-2
KOMPONEN-KOMPONEN......8-2 TROUBLESHOOTING ····································8-4
TROUBLESHOOTING ...........................8-4
8
SERVICE INFORMATION
KETERANGAN ····························· 8-3
SERVIS ........................8-3 CYLINDER/PISTON ········································8-5
CYLINDER/PISTON ...............................8-5

8-1
CYLINDER/PISTON
LOKASI KOMPONEN
CYLINDER/PISTON

10 N·m (1.0 kgf·m, 7 lbf·ft)

8-2
CYLINDER/PISTON
KETERANGAN SERVIS
SERVICE INFORMATION
GENERAL
UMUM
• This section covers service of the cylinder and piston. These services can be performed with the engine installed in the frame.
•• Bab ini
Take caremeliputi servis dari
not to damage thecylinder
cylinderdan
wallpiston. Pekerjaan servis ini dapat dilakukan dengan mesin terpasang pada rangka.
and piston.
•• Be carefulagar
Hati-hati not to damage
tidak the mating
merusak dindingsurfaces
cylinderwhen removing the cylinder. Do not tap the cylinder too hard during removal.
dan piston.
•• Clean all disassembled
Hati-hati parts with
agar tidak merusak cleaning solvent
permukaan and dry
penyatuan themmelepaskan
ketika by blowing them off with
cylinder. compressed
Jangan air before
mengetuk inspection.
cylinder terlalu keras
sewaktu pelepasan.
•SPECIFICATIONS
Bersihkan semua parts yang dibongkar dengan larutan pembersih dan keringkan dengan meniup dengan udara dari
kompressor sebelum pemeriksaan.
Unit: mm (in)
SERVICE
SPESIFIKASI ITEM STANDARD
LIMIT
Satuan: mm
Cylinder I.D. 50.005 – 50.015 (1.9687 – 1.9691) 50.05 (1.970)
BAGIAN Out-of-round STANDARD – BATAS 0.10SERVIS
(0.004)
Cylinder D.D.Taper 50,005 – 50,015
– 50,05 0.10 (0.004)
Kelonjongan
Warpage - – 0,10 0.05 (0.002)
Piston, piston Ketirusan
Piston mark direction -
"IN" mark facing toward the intake side 0,10 –
rings Perubahan
Piston O.D.bentuk melengkung -
49.980 – 49.995 (1.9677 – 1.9683) 0,05 49.91 (1.965)
Piston, Arah tanda
Piston pada
O.D. piston point
measurement 10 mm (0.4 Tanda
in) from "IN"
bottommenghadap
of skirt ke - –
piston rings Piston pin bore I.D. sisi pemasukan
13.002 – 13.008 (0.5119 – 0.5121) 13.03 (0.513)
D.L. piston
Piston pin O.D. 49,980
12.994 – 13.000 – 49,995
(0.5116 – 0.5118) 49,9112.98 (0.511)
Titik pengukuran D.L. piston
Piston-to-piston pin clearance 10 mm dari
0.002 – 0.014 (0.0001 – 0.0006) bagian bawah - 0.075 (0.0030)
piston
Piston ring-to-ring Top 0.015 – 0.050 (0.0006 – 0.0020) 0.09 (0.004)
D.D. lubang
groove piston pin
clearance 13,002 – 13,008 13,03
D.L. piston pin Second 0.015 – 0.050 (0.0006 –
12,994 – 13,0000.0020) 12,98 0.09 (0.004)
(Riken)
Jarak renggang antara
Piston ring-to-ring piston-ke-piston
Top pin 0,002 – 0,014
0.015 – 0.045 (0.0006 – 0.0018) 0,075 0.09 (0.004)
Jarak renggang
groove antara piston ring- Paling atas
clearance 0,015 –0,050 0,09
ke-alurnya Second Kedua 0.015 – 0.045 (0.0006 – 0.0018) 0,09 0.09 (0.004)
(Teikoku)(Riken) 0,015 – 0,050
Jarak renggang
Piston ring endantara
gap piston Topring- Paling atas 0,015 –
0.10 – 0.25 (0.004 0,045
– 0.010) 0,09 0.5 (0.02)
ke-alurnya
(Riken) (Teikoku) Second Kedua 0.10 – 0.25 (0.004
0,015 – 0,045
– 0.010) 0,09 0.5 (0.02)
Celah pada ujung piston ring Paling
Oil (side rail) atas 0,10 – 0,25
0.20 – 0.70 (0.008 – 0.028) 0,5 1.1 (0.04)
(Riken)
Piston ring end gap Top Kedua 0.10 – 0.25 (0.004
0,10 ––0,250.010) 0,5 0.5 (0.02)
(Teikoku) Second Oli (side0.10
rail)– 0.25 (0.004
0,20 ––0,700.010) 1,1 0.5 (0.02)
Celah pada ujung piston ring rail)
Oil (side Paling atas 0,10 ––0,25
0.20 – 0.70 (0.008 0.028) 0,5 1.1 (0.04)
Cylinder-to-piston (Teikoku)
clearance Kedua 0.010 – 0.035 0,10 – 0,25
(0.0004 – 0.0014) 0,5 0.10 (0.004)
Connecting rod small end I.D. Oli (side13.016
rail) – 13.034
0,20(0.5124
– 0,70 – 0.5131) 1,1 13.05 (0.514)
Jarak renggang
Connecting antara cylinder-ke-piston
rod-to-piston pin clearance 0.016 – 0.0400,010 – 0,035
(0.0006 – 0.0016) 0,10 0.07 (0.003)
D.D. kepala kecil connecting rod 13,016 – 13,034 13,05
Jarak renggang antara connecting rod-ke-piston pin 0,016 – 0,040 0,07
TORQUE VALUES
Cam chain guide roller pin bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)
TORSI PENGENCANGAN
Cylinder stud bolt – See page 8-8
Cam chain guide roller pin bolt 10 N.m (1,0 kgf.m; 7 lbf.ft)
Cylinder stud bolt - Lihat hal. 8-8

8-3
CYLINDER/PISTON
TROUBLESHOOTING
TROUBLESHOOTING
Compressionterlalu
Kompressi too low, hard starting
rendah, mesinor poor
sulit performance
dihidupkan at low
atau speed
unjuk kerja buruk
• Leaking cylinder head gasket
pada kecepatan rendah
• Worn, stuck or broken piston ring
•• Worn
Cylinder head gasket
or damaged bocor
cylinder and piston
•• Bent connecting
Piston ring aus,rod
macet atau patah
•• Cylinder
Cylinderhead/valve aus atau(page
dan pistonproblem rusak7-5)
•Compression
Connectingtoorod bengkok
high, overheating or knocking
•• Excessive
Persoalancarbon
pada cylinder head/valve
built-up on (hal.or7-5)
piston head combustion chamber
Excessive smoke
Kompressi terlalupiston
• Worn cylinder, tinggi,or overheating
piston rings atau knocking
•• Improper
Ada pembentukan
installationkarbon
of pistonsecara
rings berlebihan pada piston head (kepala piston) atau di ruang pembakaran
• Scored or scratched piston or cylinder wall
• Cylinder
Asap head/valve problem (page 7-5)
berlebihan
•Abnormal
Cylinder, piston atau piston rings aus
noise
•• Worn
Pemasangan
piston pinpiston rings
or piston pintidak
holebenar
•• Worn cylinder,
Piston piston cylinder
atau dinding or pistontergerus
rings atau tergores
•• Worn connecting
Persoalan pada rod smallhead/valve
cylinder end (hal. 7-5)

Suara tidak normal


• Piston pin atau lubang piston pin aus
• Cylinder, piston atau piston rings aus
• Kepala kecil connecting rod aus

8-4
CYLINDER/PISTON
CYLINDER/PISTON
PELEPASAN CYLINDER
CYLINDER REMOVAL
CATATAN:
• • Cylinder dan piston
Cylinder and pistoncandapat diservis with
be serviced dengan mesin
the engine
terpasang
installed onpada rangka.
the frame.
Lepaskan
Remove thesebagai berikut:
following:
- –Cylinder head (hal. 7-12) BOLTS
Cylinder head (page 7-12)
- –Dua
Twobolts
bolts
- –Lower
Lowerside cover
side coverstay
stay

LOWER SIDE
COVER STAY
Hati-hati
Be careful agar
not totidak
drop - –CamCam chain
chain guide
guide roller
roller pinpin bolt/sealingwasher
bolt/sealing washer
menjatuhkan guide
the guide roller into - –Guide
Guide roller
roller GUIDE ROLLER
roller ke dalam
the crankcase.
crankcase.

ROLLER PIN BOLT/


SEALING WASHER

Be careful
Hati-hati not to - –Cylinder
agar tidak Cylinder
merusak
damagepermukaan
the mating
penyatuan.
surface.

CYLINDER

- –Gasket
Gasket
GASKET
- –Dowel
Dowel pins
pins

DOWEL PINS

8-5
CYLINDER/PISTON
PISTON REMOVAL
PELEPASAN PISTON
Place a clean
Letakkan kain shop Remove the piston pin clip with pliers.
lap Lepaskan piston pin clip dengan tang. PISTON PIN
towel over the
bersih di atas Push the piston pin out of the piston and connecting rod,
crankcase agar clip Dorong
crankcase to prevent pistonthe
and remove pinpiston.
keluar dari piston dan connecting rod,
the clip
tidak from
dapat falling
jatuh ke dan keluarkan piston.
into
dalamthecrankcase.
crankcase.

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

Jangan
Neversekali-kali
use a wire Bersihkan endapan
Clean carbon depositskarbon
from thedaripiston
alur-alur piston with
ring grooves ring
memakai sikat kawat, dengan PISTON RING BEKAS
brush; it will damage a used piston
sebuah ringpiston
that will
ringbe bekas
discarded.
yang tidak dipakai
ia akan merusak alur.
the groove. lagi.
Blow the oil passage with compressed air, if necessary.

Tiuplah jalan lintasan oli dengan udara dari kompressor,


bila perlu.

ALUR-ALUR PISTON RING


INSPECTION
PEMERIKSAAN
CYLINDER
CYLINDER
Inspectdinding
Periksa the cylinder wallterhadap
cylinder for scratches and wear.
goresan dan keausan.
Measure
Ukur dan and
catatrecord
D.D. the cylinder
cylinder I.D.tiga
pada at three levels
tingkat padain
both the
poros X Xdan
and Y.Y axis.
AmbilTake the maximum
bacaan maksimum reading to
untuk
determine the cylinder wear.
menentukan keausan cylinder.
SERVICE
LIMIT:SERVIS: 50,05
BATAS 50.05 mm
mm(1.970 in)
Hitung jarak
Calculate renggang
the cylinder-ke-piston.
cylinder-to-piston clearance.
For measurement
Untuk of thepiston
pengukuran D.L. piston(hal. (page 8-8).
O.D.8-8).
SERVICE
BATAS SERVIS: 0,10 mm
LIMIT: 0.10 mm (0.004 in)

8-6
CYLINDER/PISTON
Hitung ketirusan
Calculate dan for
the cylinder kelonjongan cylinder pada
taper and out-of-round tiga
at three
levels inpada
tingkat an X and Y axis.
poros Take the
X dan Y. maximum reading to
Ambil pembacaan
determine untuk
maksimum the taper and out-of-round.
menentukan kedua pengukuran. Y

SERVICE LIMITS: X
BATAS SERVIS: 0.10 mm (0.004 in) ATAS
Taper:
Ketirusan: 0,10 mm
Out-of-round: 0.10 mm (0.004 in)
Kelonjongan: 0,10 mm
The cylinder must be rebored and an oversize piston fit- TENGAH
Nomor-nomor parts ted if the harus
Cylinder service dikorter
limits are dan
exceeded.
oversize piston harus
ini dapat berubah dipasang jika batas servis dilampaui.
These parts numbers The following oversize pistons are available:
tanpa pemberitahuan Oversize pistons berikut tersedia:
may be tertulis.
changed 0.25 mm (0.010 in): 13102-KWB-306 BAWAH
without written 0,25
0.50mm: 13102-KWB-305
mm (0.020 in): 13103-KWB-306
permission. 0,50
0.75mm: 13103-KWB-305
mm (0.030 in): 13104-KWB-306
0,75
1.00mm: 13104-KWB-305
mm (0.040 in): 13105-KWB-306
1,00 mm: 13105-KWB-305
The cylinder must be rebored so that the clearance for an
Cylinder
oversizeharus
piston dikorter
is 0.010 sehingga
– 0.035 mmjarak renggang
(0.0004 untuk
– 0.0014 in).
sebuah oversize piston adalah 0,010 – 0,035 mm.
Check the cylinder for warpage by placing a straight
edge and a feeler gauge across the stud holes as shown.
Periksa cylinder terhadap perubahan bentuk
SERVICE dengan meletakkan sebuah mistar lurus
melengkung
LIMIT:
dan feeler gauge 0.05 mm (0.002
antara in)
lubang-lubang stud seperti
diperlihatkan.

BATAS SERVIS: 0,05 mm

PISTON/PISTON
PISTON/PISTONRING
RING
Selalu
Alwaysganti piston
replace the Periksa piston
Inspect the rings
piston ringsterhadap kehalusan
for smooth movementpergerakan
by rotating
rings sebagai sebuah them. The rings should be able to move in their grooves
piston rings as a set. dengan memutar mereka. Rings harus dapat bergerak
set. without catching.
dalam alurnya tanpa menyangkut.
Push the ring until the outer surface of the piston ring is
nearly ring
Tekan flush sampai
with the permukaan
piston and measure
luar darithepiston
clearance
ring
using arata
hampir feelerdengan
gauge. piston dan ukur jarak renggang
dengan
SERVICE menggunakan
LIMITS: feeler gauge.
Top: 0.09 mm (0.004 in)
BATAS SERVIS:
Second: 0.09 mm (0.004 in)
Atas: 0,09 mm
Kedua: 0,09 mm

Masukkan
Insert the piston ringring into
secara tegaklurus
the bottom ke cylinder
of the dalam
squarelybawah
using the PISTON RING
bagian daripiston crown.dengan mendorongnya
cylinder
Measure
dengan the ringpiston.
mahkota end gap.
Ukur celah pada
SERVICE LIMITS:ujung ring.
Top: 0.5 mm (0.02 in)
BATAS SERVIS:
Second: 0.5 mm (0.02 in)
Atas: 0,5 mm
Oil (side rail): 1.1 mm (0.04 in)
Kedua 0,5 mm
Oli (side rail): 1,1 mm

8-7
CYLINDER/PISTON
Ukur D.L. the
Measure piston pada
piston sebuah
O.D. titik 10 mm
at a point mm (0.4
dari in)
bagian
from
bawah dan 90°
the bottom 90° lubang
anddari pistonpin
to the piston pin.
hole.

SERVICE
BATAS SERVIS: 49,91 mm
LIMIT: 49.91 mm (1.965 in) 90°
Untuk pengukuran D.D. cylinder (hal. 8-6). 10 mm (0.4 in)
For measurement of the cylinder I.D. (page 8-6).
Hitung jarak renggang cylinder- ke-piston.
Calculate the cylinder-to-piston clearance.
BATAS SERVIS: 0,10 mm
SERVICE
LIMIT: 0.10 mm (0.004 in)

Measure
Ukur D.D. piston
lubangpin borepin
piston I.D.pada
in anporos
X andXYdan
axis.
Y.
Take pembacaan
Ambil the maximum reading tountuk
maksimum determine I.D.
menentukan D.D.
SERVICE
BATAS
LIMIT:SERVIS: 13,03 mm(0.513 in)
13.03 mm
Ukur D.L. piston
Measure pin pada
the piston tigaattitik.
pin O.D. three points.
BATAS
SERVICE SERVIS: 12,98 mm
LIMIT:
Hitung 12.98
jarak renggang mm (0.511 in) pin.
piston-ke-piston
Calculate
BATAS the piston-to-piston
SERVIS: 0,075 mm pin clearance.
SERVICE
LIMIT: 0.075 mm (0.0030 in)

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

CYLINDER STUD BOLT


REPLACEMENT
PENGGANTIAN CYLINDER STUD BOLT
If replacing
Sewaktu the cylindercylinder
mengganti stud bolts, be sure
stud to install
bolts, them
pasanglah
as shown.
sebagai berikut.
Thread dua
Pasang two nuts
nutspada
onto stud
the stud
bolts,bolt,
dan and tighten them
kencangkan satu
together,
sama lain,then use a wrench
kemudian pakailahonkunci
thempas to turn the stud
padanya bolt
untuk
out.
memutar stud bolt keluar.
Install and tighten new stud bolts to the specified torque.
Pasang
TORQUE:6 dan N·m
kencangkan stud4.4bolts
(0.61 kgf·m, lbf·ft)baru dengan torsi
yang ditentukan.
After tightening
TORSI: the stud
6 N.m (0,61 bolts,
kgf.m; 4,4check
lbf.ft)that the length from
the bolt head to the crankcase surface is within specifica-
Setelah
tion. mengencangkan stud bolts, periksa bahwa 176.0 ± 1.0 mm (6.93 ± 0.04 in)
panjang dari kepala bolt sampai permukaan crankcase
adalah sesuai dengan spesifikasi.

8-8
CYLINDER/PISTON
PISTON INSTALLATION
PEMASANGAN PISTON
Bersihkan
Clean thekepala
piston piston, alur-alur
heads, ring ringand
grooves danskirts.
skirts (rok).
Carefullypiston
Pasang install the piston
rings rings onto
dengan the piston
hati-hati padawith their
piston TANDA RING KEDUA TANDA RING ATAS
markings
dengan facing up.
tanda-tandanya menghadap ke atas. ("RN" atau "A") ("R" atau "T")

CATATAN:
• Be careful not to damage the piston and piston rings
• Hati-hati agar tidak merusak piston dan piston rings
during installation.
• selama
Do not confuse the top and second rings.
pemasangan.
• • Jangan
When installing the oilrings
pertukarkan ring, paling
install the
atasspacer
denganfirstyang
and
then the side rails. RING ATAS
kedua.
Do not align the gaps • Stagger
Ketikathememasang
piston ring end
oil gaps
ring, 120 degrees
pasang apartdulu,
spacer from
of the oil ring side each other as shown. 120° RING
kemudian
Stagger pasang
the side side rails.
rails gaps as shown. KEDUA
rails.
After installation, celah
the piston rings should be free 120°
Jangan sejajarkan Selang-selingkan pada ujung piston ring to rotate
sejarak 120°
in the groove.
celah-celah dari oil 120 derajat dari masing-masing seperti diperlihatkan.
ring side rails. Selang-selingkan celah pada ujung side rail seperti
diperlihatkan.

Setelah pemasangan, piston rings harus dapat berputar


bebas di dalam alur-alurnya.
SIDE RAILS
SPACER

20 mm (0.8 in) ATAU LEBIH

Letakkan kain lap


Place a clean shopmenutupi crankcase
towel over untuk mencegah
the crankcase to prevent
the dirt, dust
masuknya or piston
kotoran, debupinatau
clipspiston
from pin
entering
clips the crank-
ke dalam
case.
crankcase.
Be careful not to Clean the gasket mating surfaces of the crankcase and
Hati-hati
damageagar tidak
the gasket cylinder thoroughly.
Bersihkan permukaan-permukaan penyatuan gasket
merusak permukaan-
mating surfaces. dari crankcase
Apply engine dan
oil tocylinder secara menyeluruh.
the connecting rod small end inner
permukaan penyatuan surface.
gasket.
Semprotkan oli pada permukaan dalam kepala kecil
connecting rod.

Apply engineolioilpada
Semprotkan to thepermukaan
piston pin hole
dalaminner surface
lubang and
piston
piston PISTON PIN
pin dan pin outer surface.
permukaan luar piston pin. TANDA"IN"
Install the
Pasang piston
piston with thetanda
dengan "IN" mark
"IN" facing the intake
menghadap ke side.
sisi
Instal the piston pin.
pemasukan.
Pasang piston pin.

PISTON

8-9
CYLINDER/PISTON
Install the
Pasang newpin
piston piston
clipspin clips.
baru.

CATATAN:
• Make sure the piston pin clips are seated securely.
• • Do
Pastikan bahwa
not align pistonpin
the piston pinclip
clips telah
end gapduduk dengan
with the piston
kokoh.
cutout.
• Jangan mentepatkan celah pada ujung piston pin
clip dengan potongan pada piston.

CLIP
CYLINDER INSTALLATION
PEMASANGAN CYLINDER
Do notmemakai
Jangan Install the
reuse the Pasang dowel
dowel pins
pins danand a newgasket
sebuah gasket.baru.
kembali
gasket, gasket,
replace with a
GASKET
gantilah dengan
newyang
one.
baru.

DOWEL PINS
Apply engineolioilpada
Semprotkan to thecylinder
cylinderbore
bore,(lubang
piston outer sur-
cylinder),
face, pistonluar
permukaan ring piston,
groovesalur-alur
and piston rings.ring dan piston
piston
rings.
Route the cam chain through the cylinder.
Be careful not to Install the cylinder over the piston while compressing the
damage the piston Alurkan cam with
piston rings chainyour
melalui cylinder.
fingers.
rings and cylinder
Hati-hati agar tidak Pasang cylinder di atas piston sementara menekan
bore.
merusak piston rings piston rings dengan jari-jari.
dan lubang dalam
cylinder.

CAM CHAIN
Hati-hati
Be careful agar drop Pasang
not totidak camcam
Install the chain guide
chain roller,
guide sealing
roller, newwasher
sealingbaru dan
washer
menjatuhkan guide
the guide roller into cam
andchain guide
the cam roller
chain pin roller
guide bolt. pin bolt. GUIDE ROLLER ROLLER PIN BOLT
roller ke dalam Kencangkan
the crankcase. Tighten the roller
roller pin
pin bolt
boltto the specified
dengan torque.
torsi yang ditentukan.
crankcase.
TORQUE:10 N·m (1.0 kgf·m, 7 lbf·ft)
TORSI: 10 N.m (1,0 kgf.m; 7 lbf.ft)

SEALING WASHER

8-10
CYLINDER/PISTON
Pasang lower
Install the side
lower sidecover
coverstay
staysementara mentepatkan
while aligning its tab with
the bolt dengan
tab-nya boss on the
boltcylinder, then install
boss pada and tighten
cylinder, kemudianthe Tepatkan BOLTS
bolts. dan kencangkan bolts.
pasang
Install the cylinder head (page 7-19).
Pasang cylinder head (hal. 7-19).

LOWER SIDE
COVER STAY

8-11
MEMO
9. CLUTCH/GEARSHIFT LINKAGE

LOKASI KOMPONEN-KOMPONEN......9-2
COMPONENT LOCATION ···························· 9-2 RIGHT
RIGHTCRANKCASE COVER...............9-5
CRANKCASE COVER·······················9-5

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


SERVICE INFORMATION ····························· 9-3 CLUTCH.................................................9-9
CLUTCH·····························································9-9
9
TROUBLESHOOTING ...........................9-4
TROUBLESHOOTING ···································· 9-4 GEARSHIFT
GEARSHIFT LINKAGE..........................9-27
LINKAGE ································9-28

9-1
CLUTCH/GEARSHIFT LINKAGE
LOKASI KOMPONEN
CLUTCH/GEARSHIFT LINKAGE

17 N·m (1.7 kgf·m, 13 lbf·ft)

10 N·m (1.0 kgf·m, 7 lbf·ft)

54 N·m (5.5 kgf·m, 40 lbf·ft)

54 N·m (5.5 kgf·m, 40 lbf·ft)

5 N·m (0.51 kgf·m, 3.7 lbf·ft)

9-2
CLUTCH/GEARSHIFT LINKAGE
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
• This section covers service of the clutch (centrifugal clutch and manual clutch) and gearshift linkage. These service can be done
• with
Babtheiniengine
meliputi installed
serviceindaritheclutch
frame.(kopling) (centrifugal clutch dan manual clutch) dan gearshift linkage (peralatan pemindah
• Engine oil viscosity, oil level and
gigi). Pekerjaan-pekerjaan theini
servis use of oildilakukan
dapat additives dengan
have anmesin
effect on clutch operation.
terpasang Oil additives of any kind are specifically
pada rangka.
not recommended. When the clutch does not disengage or the motorcycle creeps with clutch disengaged, inspect the engine oil
• and
Viskositas oli mesin, tinggi permukaan
oil level before servicing the clutch system. oli dan penggunaan oil additives (campuran penambahan pada oli) mempengaruhi
cara kerja clutch. Khususnya oil additives dari jenis apapun tidak boleh dipakai. Jika clutch tidak dapat dilepaskan atau
sepedamotor merangkak maju sewaktu clutch dilepaskan, periksalah oli mesin dan tinggi permukaan oli sebelum menservis
SPECIFICATIONS
clutch system.
Unit: mm (in)
SPESIFIKASI SERVICE
ITEM STANDARD
Satuan: mm LIMIT
BAGIAN
Manual clutch Disc thickness Four bolts STANDARD
2.00 – 2.20 (0.079 – 0.087) BATAS 1.82SERVIS
(0.072)
type
Manual clutch Tebal disc 2,00 – 2,20 1,82
Six bolts 2.30 – 2.50 (0.091 – 0.098) 2.08 (0.082)
Perubahan bentuk melengkung type plate - 0,20
Tinggi
Plate bebas
warpageclutch spring 5,01 – 4,63 0.20 (0.008)
Clutch
Clutchouter guide
spring Four bolts D.D.
5.01 (0.197) 16,991 – 17,009 17,0494.63 (0.182)
free height type D.L. 22,959 – 22,980 22,940
D.D. primary driven gear Six bolts 4.89 (0.193) 23,000 – 23,021 23,074.52 (0.172)
D.L. mainshaft pada clutch type outer guide 16,966 – 16,984 16,87
Centrifugal clutch Clutch
D.D. outer
clutch drum I.D. 16.991 – 17.009 (0.6689
104,0 – 0.6696)
– 104,2 17.049 (0.6712)
104,3
guide O.D. 22.959 – 22.980 (0.9039 – 0.9047) 22.940 (0.9031)
Tebal clutch weight lining 1,5 1,0
Primary driven gear I.D. 23.000 – 23.021 (0.9055 – 0.9063) 23.07 (0.908)
D.D. one-way clutch drum 42,000 – 42,020 42,04
Mainshaft O.D. at clutch outer
D.L. one-way clutch roller
guide 16.966 – 16.984 (0.6680
4,990 – 0.6687)
– 5,000 4,9716.87 (0.664)
Centrifugal clutch D.D. primary drive
Clutch drum I.D. gear 19,030 – 19,058
104.0 – 104.2 (4.09 – 4.10) 19,11104.3 (4.11)
D.L. crankshaft
Clutch pada thickness
weight lining primary drive gear1.5 (0.06) 18,967 – 18,980 18,92 1.0 (0.04)
One-way clutch drum I.D. 42.000 – 42.020 (1.6535 – 1.6543) 42.04 (1.655)
One-way clutch roller O.D. 4.990 – 5.000 (0.1965 – 0.1969) 4.97 (0.196)
TORSI PENGENCANGAN Primary drive gear I.D. 19.030 – 19.058 (0.7492 – 0.7503) 19.11 (0.752)
Crankshaft O.D. at primary drive
Oil centrifugal filter cover bolt
gear – 18.980 zat
5 N.m (0,51 kgf.m; 3,7 lbf.ft)18.967 Oleskan (0.7467 – 0.7472)
pengunci pada ulir, Lihat hal.18.92
3-12 (0.745)
Shift drum stopper arm bolt 10 N.m (1,0 kgf.m; 7 lbf.ft) Oleskan zat pengunci pada ulir, Lihat hal. 9-30
Shift return spring pin 30 N.m (3,1 kgf.m; 22 lbf.ft)
TORQUE
Gearshift cam VALUES
plate bolt 17 N.m (1,7 kgf.m; 13 lbf.ft) Oleskan zat pengunci pada ulir, Lihat hal. 9-29
Centrifugal clutch lock nut 54 N.m (5,5 kgf.m; 40 lbf.ft) Oleskan oli pada ulir dan permukaan duduk
Oil centrifugal
Clutch filternut
center lock cover bolt 545N.m
N·m (5,5
(0.51kgf.m;
kgf·m,403.7 lbf·ft)
lbf.ft) Apply locking
Oleskan oli padaagent to the
ulir dan threads; See
permukaan dudukpage 3-12
Shift drum
Clutch lifterstopper
plate boltarm bolt 1210 N·m
N.m (1.0kgf.m;
(1,2 kgf·m,9 7lbf.ft)
lbf·ft) Apply locking agent to the threads; See page 9-31
Shift return spring pin 30 N·m (3.1 kgf·m, 22 lbf·ft)
Gearshift cam plate bolt 17 N·m (1.7 kgf·m, 13 lbf·ft) Apply locking agent to the threads; See page 9-30
Centrifugal clutch lock nut 54 N·m (5.5 kgf·m, 40 lbf·ft) Apply engine oil to the threads and seating surface
Clutch center lock nut 54 N·m (5.5 kgf·m, 40 lbf·ft) Apply engine oil to the threads and seating surface
Clutch lifter plate bolt (Four bolts 12 N·m (1.2 kgf·m, 9 lbf·ft)
type)
Clutch lifter plate bolt (Six bolts 7 N·m (0.71 kgf·m, 5.2 lbf·ft)
type)

9-3
CLUTCH/GEARSHIFT LINKAGE
TOOLS
Universal holder Clutch center holder Lock nut wrench 20 x 24 mm
07725-0030000 07HMB-HB70100 07716-0020100

Extension bar
07716-0020500

TROUBLESHOOTING
TROUBLESHOOTING
Faulty clutch operation can usually be corrected by adjusting the clutch system.
Cara kerja
Clutch slipsclutch
when yang tidak benar biasanya dapat diperbaiki dengan menyetel clutch system.
accelerating
• Incorrect
Clutch clutch adjustment
slip sewaktu berakselerasi
• Worn clutch disc
•• Weak
Penyetelan clutch tidak benar
clutch spring
•• Faulty
Clutchclutch
disc aus
weight
•• Molybdenum
Clutch springs lemah additive
or graphite
•Motorcycle
Clutch weight tidakclutch
creeps with bekerja dengan benar
disengaged (when idling)
•• Faulty
Ada additive molybdenum
clutch weight springs atau graphite
• Faulty clutch weights
• Idle speed too
Sepedamotor high (pagemaju
merangkak 3-12) sewaktu clutch dilepaskan (mesin berputar stasioner)
•HardClutch weight
to shift springs tidak bekerja dengan benar
•• Damaged
Clutch weights tidak
gearshift bekerja dengan benar
spindle
•• Damaged stopper plate
Putaran stasioner terlaluandtinggi
pin (hal. 3-12)
• Loose stopper plate bolt
• Incorrect sulit
Transmissi clutchdipindahkan
adjustment
• Loose gearshift cam plate bolt
• Gearshift spindle rusak
•Transmission jumps
Stopper plate danoutpinof gear
rusak
•• Damaged stopper
Stopper plate boltarm
longgar
• Damaged gearshift cam plate
•• Loose
Penyetelan clutch
gearshift camtidak
platebenar
bolt
• Gearshift cam plate bolt longgar
Gearshift pedal will not return
• Weak or broken gearshift spindle return spring
Transmissi meloncat
• Bent gearshift spindle keluar dari gigi
• Stopper arm rusak
• Gearshift cam plate rusak
• Gearshift cam plate bolt longgar

Gearshift pedal tidak mau kembali


• Gearshift spindle return spring lemah atau patah
• Gearshift spindle bengkok

9-4
CLUTCH/GEARSHIFT LINKAGE
RIGHT CRANKCASE COVER
PELEPASAN
REMOVAL
Keluarkan
Drain the oli mesin
engine oil(hal.
(page3-10).
3-10).
Remove the following: BOLT
Sewaktu melepaskan Lepaskan sebagai berikut:
When removing the – Footpeg bar (page 2-18)
kickstarter pedal, - Footpeg bar (hal. 2-18)
kickstarter pedal, – Bolt
tandai posisi pedal - –Bolt
untukmark the pedal
memastikan Kickstarter pedal
position to ensure
lokasinya the
semula.
- Kickstarter pedal
original position.

KICKSTARTER PEDAL
Longgarkan boltsin adalam
Loosen the bolts polapattern
crisscross bersilangan
in severaldalam
steps
GUIDE/BOLT
and remove
beberapa them dan
langkah and lepaskan,
guide. juga guide.
Be careful not to Remove the right crankcase cover.
Hati-hati agar tidak Lepaskan right crankcase cover.
damage the mating
merusak permukaan
surface.
penyatuan.

RIGHT CRANKCASE COVER BOLTS


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

GASKET
DISASSEMBLY
PEMBONGKARAN
Remove the
Lepaskan following:
sebagai berikut: ADJUSTER/
NUT/WASHER/O-RING
– Clutch adjuster lock nut LIFTER BOSS
- –Clutch adjuster lock nut
Washer
- –Washer
O-ring
- –O-ring
Clutch adjuster/lifter boss
- Clutch adjuster/lifter boss

9-5
CLUTCH/GEARSHIFT LINKAGE
Lepaskan clutch
Remove the adjuster
clutch bolt.
adjuster bolt.

CLUTCH ADJUSTER BOLT


Remove the
Lepaskan following:
sebagai berikut:
CLUTCH LIFTER BOSS
– Snap
- Snap ring ring
– Clutch lifter boss
- –Clutch lifter boss
Spring
- Spring

SNAP RING SPRING


KICKSTARTER SPINDLE
KICKSTARTER SPINDLE OIL OIL
SEALSEAL
Check that
Periksa bahwathe kickstarter
kickstarter spindle
spindle oil seal is in good
berada con-
dalam
dition, baik,
kondisi replace it if bila
ganti necessary.
perlu.
If replacing the oil seal, install it until it is fully seated.
Jika mengganti oil seal, pasang sampai ia telah duduk
sepenuhnya.

KICKSTARTER SPINDLE OIL SEAL


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

9-6
CLUTCH/GEARSHIFT LINKAGE
ASSEMBLY
PERAKITAN
Makebahwa
Pastikan sure that Install the
the Pasang
snap following:
sebagai berikut:
snap CLUTCH LIFTER BOSS
ring ring
telahisduduk
firmly - –Spring
Spring
seated
denganinkokoh
the groove.
pada - –Clutch
Clutch lifter
lifter boss
boss
alur. – Snap ring
- Snap ring

SPRING SNAP RING

Install the
Pasang clutch
clutch adjuster
adjuster bolt.
bolt.

CLUTCH ADJUSTER BOLT


Install the
Pasang clutch adjuster/lifter
clutch adjuster/lifter boss
bossinto
kethedalam
right crank-
right
case cover aligning its boss with the hole in thedengan
crank- Tepatkan
crankcase cover dengan mentepatkan boss-nya
case cover.
lubang pada crankcase cover.
Apply engine oil to a new O-ring.
Semprotkan oli mesin
Install the O-ring ontopada sebuah
the clutch O-ring baru.
adjuster/lifter boss.
Pasang O-ring ke dalam clutch adjuster/lifter boss.

ADJUSTER/
LIFTER BOSS O-RING
Install the
Pasang washer
washer danand clutch
clutch adjuster
adjuster lock
lock nut.
nut. LOCK NUT
Adjust the clutch system (page 3-19) after installing the
Setel
right clutch system
crankcase (hal. 3-19) setelah memasang right
cover.
crankcase cover.

WASHER

9-7
CLUTCH/GEARSHIFT LINKAGE
INSTALLATION
PEMASANGAN
Oleskan gemuktopada
Apply grease bibir kickstarter
the kickstarter spindlespindle
oil sealoil seal.
lips.

KICKSTARTER SPINDLE OIL SEAL


Hati-hati
Be careful agar drop Bersihkan
not totidak Clean thepermukaan penyatuan
gasket mating surfacegasket
of the dari crankcase
crankcase and
menjatuhkan
any benda- dan
foreign materials rightright
crankcase cover,cover,
crankcase being careful
dengan notberhati-hati
to damage them.
agar DOWEL PINS
benda asing ke dalam
into the engine. tidak merusak mereka.
mesin.
Install the dowel pins and a new gasket onto the crank-
case.
Pasang doweloilpins
Apply engine to thedan sebuah
gearshift gasket
spindle baru
journal area.pada
crankcase.

Semprotkan oli mesin pada daerah gearshift spindle


journal.

GASKET
Hati-hati agar tidak
Be careful not to Pasang right
Install the crankcase
right crankcasecover.
cover.
GUIDE/BOLT
merusak
damage bibirthe Install theright
Pasang right crankcase
crankcase cover
cover bolts
boltsanddan
guide,guide,
then
kickstarter
kickstarteroiloilseal.
seal tighten thekencangkan
kemudian bolts in a crisscross pattern pola
bolts dalam in several steps.
bersilangan
lips. dalam beberapa langkah.

RIGHT CRANKCASE COVER BOLTS


Pasang kickstarter
Install the pedalpedal
kickstarter padatoposisinya semula
its original seperti
position as
marked during removal. BOLT
telah ditandai pada waktu pelepasan.
Install and
Pasang dantighten the bolt.
kencangkan bolt dengan erat.
Install the footpeg bar (page 2-18).
Pasang footpeg bar (hal. 2-18)
Fill the engine with recommended engine oil (page 3-10).
Isilah mesin dengan oli mesin yang dianjurkan (hal. 3-
Make sure there are no oil leaks.
10).
Check the
Pastikan clutchtidak
bahwa system kebocoran (page
adaadjustment oli. 3-19).
Periksa penyetelan clutch system (hal. 3-19).

KICKSTARTER PEDAL

9-8
CLUTCH/GEARSHIFT LINKAGE
CLUTCH
CLUTCH (KOPLING)
PELEPASAN
REMOVAL
CATATAN:
• Clutch system dapat diservis dengan mesin
• Clutch system can be serviced with the engine
terpasang
installed onpada rangka.
the frame.
Remove the following:
Lepaskan sebagai berikut: LIFTER CAM PLATE
- –Right
Right crankcase
crankcase cover
cover (page
(hal. 9-5)
9-5)
- –Engine
Engine oiloil centrifugal
centrifugal filter
filter (page
cover(hal.
cover 3-11)
3-11)
Remove the
Lepaskan clutch
clutch lever
lever danand the lifter
clutch clutchcam
lifterplate.
cam plate.

CLUTCH LEVER
Tekuk
Bend keup atas tabof
the tab dari
thelock
lockwasher
washeruntuk membebaskan
to clear the lock nut
groove.
alur lock nut. TAB LOCK NUT

Pasang clutch
Install the center
clutch centerholder
holderdengan menggunakan
using proper bolts or
screws.
bolts atau screws yang tepat. LOCK NUT WRENCH CENTRIFUGAL
CLUTCH LOCK NUT
Remove the centrifugal clutch lock nut using the special
Lepaskan
tools. centrifugal clutch lock nut dengan
menggunakan
TOOLS: special tools.
TOOLS:
Lock nut wrench, 20 x 24 mm 07716-0020100
Lock nut wrench, 20 x 24 mm 07716-0020100
Extension bar 07716-0020500
Extension bar 07716-0020500
Clutchcenter
Clutch center holder
holder 07HMB-HB70100
07HMB-HB70100

CLUTCH CENTER
EXTENSION BAR HOLDER

Lepaskan washer
Remove the danand
washer locklock
washer.
washer.
LOCK WASHER WASHER

9-9
CLUTCH/GEARSHIFT LINKAGE
Lepaskan clutch
Remove the weight
clutch assembly.
weight assembly.

CLUTCH WEIGHT ASSEMBLY


Remove the
Lepaskan clutch
clutch lifterlifter bearing.
bearing.
CLUTCH LIFTER BEARING

Hold the
Tahan clutch
clutch lifterlifter plate
plate danand removeclutch
lepaskan the clutch center
center lock
lock nut using the special tool. CLUTCH CENTER LOCK NUT LIFTER PLATE
nut dengan menggunakan special tool.
LOCK NUT WRENCH
TOOLS:
TOOLS:
Universal holder 07725-0030000
Universal holder 07725-0030000
Lock nut wrench, 20 x 24 mm 07716-0020100
Lock nut wrench, 20 x 24 mm 07716-0020100
Extension bar
Extension bar 07716-0020500
07716-0020500

UNIVERSAL HOLDER EXTENSION BAR

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

WASHER

9-10
CLUTCH/GEARSHIFT LINKAGE
Remove the
Lepaskan twooil
kedua oil separator
separator plate
plate mounting bolts.

BOLTS
Remove the
Lepaskan centrifugal
centrifugal clutch
clutch outer,
outer, manual
manual clutch
clutch dan and
oil-
the oil separator plate as an assembly. MANUAL CLUTCH CENTRIFUGAL
separator plate sebagai sebuah assembly (susunan). CLUTCH OUTER

OIL SEPARATOR PLATE


Remove the
Lepaskan collar
collar darifrom the crankshaft.
crankshaft.
Remove the clutch outer guide COLLAR COLLAR
Lepaskan clutch outer guide danand collar
collar darifrom the main-
mainshaft.
shaft.

CLUTCH OUTER GUIDE

9-11
CLUTCH/GEARSHIFT LINKAGE
PEMBONGKARAN/PEMERIKSAAN
CENTRIFUGAL CLUTCH
DISASSEMBLY/INSPECTION
CENTRIFUGAL CLUTCH
ONE-WAYCLUTCH
ONE-WAY CLUTCH
Temporarily
Untuk sementara install the centrifugal
pasang centrifugalclutch
clutchouter
outertopada
the
crankshaft.
crankshaft.
Tahan crankshaft
Hold the crankshaftdanand putar centrifugal
turn the centrifugalclutch
clutch outer
outer
by hand.
dengan tangan.
Make sure
Pastikan that centrifugal
bahwa the centrifugal
clutchclutch
outer outer
hanyaonly turns
berputar
counterclockwise as shown and does not turn clockwise.
dalam arah berlawanan dengan jarum jam seperti
Remove the dan
diperlihatkan centrifugal clutchberputar
tidak dapat outer from the crankshaft.
dalam arah jarum
jam.

Lepaskan centrifugal clutch outer dari crankshaft.

Remove the
Lepaskan snap
snap ringring
danand retainer.
retainer.
SNAP RING

RETAINER
Be carefulagar
Hati-hati not to Remove the
lose Lepaskan
tidak following:
sebagai berikut:
thekehilangan clutch
clutch rollers and – Rollers
SPRING ROLLER
rollers clutch - –Rollers
dan springs.
clutch Springs
springs. - –Springs
One-way clutch inner
- –One-way
Washerclutch inner
- Washer

CLUTCH INNER WASHER


Ganti clutchtherollers
Replace clutch Periksa rollers
Check the rollers terhadap keausan
for excessive wear or berlebihan
damage. atau
sebagai sebuah
rollers as aset.
set. kerusakan.
Measure the one-way clutch roller O.D.
SERVICE
Ukur D.L. one-way clutch roller. ROLLER
LIMIT: 4.97mm (0.196 in)
BATAS SERVIS: 4,97 mm
Replace Check the springs for fatigue or damage.
Ganti clutchthe clutch Periksa
springs springs terhadap keletihan atau kerusakan.
springs
sebagai as aset.
sebuah set.

SPRING

9-12
CLUTCH/GEARSHIFT LINKAGE
Periksa one-way
Check the clutch
one-way clutchinner
inner terhadap
for wear orkeausan
damage.atau
kerusakan.

CLUTCH INNER

CLUTCH
CLUTCHOUTER/SUB-GEAR
OUTER/SUB-GEAR
Hati-hati
Be carefulagar tidak
not to Remove the
lose Lepaskan spring
spring retainer
retainer danand spring.
spring.
kehilangan PIN SPRING RETAINER/SPRING
thepin.
pin.

Lepaskan pin,pin,
Remove the snap ringring
snap danand
sub-gear.
sub-gear.
PIN SNAP RING
Check the
Periksa sub-gear
sub-gear for wear
terhadap or damage.
keausan atau kerusakan.

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

9-13
CLUTCH/GEARSHIFT LINKAGE
CLUTCH
CLUTCHWEIGHT
WEIGHT
Periksa clutch
Check the weight
clutch assembly
weight assembly terhadap kerusakan.
for damage.
Measure
Ukur tebalthe clutch
clutch weight
weight lining thickness.
lining.
SERVICE
BATAS
LIMIT:SERVIS: 1,0 mm (0.04 in)
1.0 mm

Remove the
Lepaskan E-clips.
E-clips.
E-CLIPS

Lepaskan side plate, friction spring dan spring seat. R


e SPRING SEAT
move the side plate, friction spring and spring seat.

FRICTION SPRING

SIDE PLATE
Secara bergantian
Alternately angkat
lift the clutch clutch
weights, weights,
then remove kemudian
the clutch
lepaskan clutch
weights and weights dan springs.
springs. CLUTCH WEIGHTS

SPRINGS

9-14
CLUTCH/GEARSHIFT LINKAGE
Lepaskan damper
Remove the rubbers
damper darifrom
rubbers drive
theplate.
drive plate.
RUBBERS

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

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

PRIMARY DRIVE GEAR

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

9-15
CLUTCH/GEARSHIFT LINKAGE
PERAKITAN CENTRIFUGAL
CENTRIFUGAL CLUTCH ASSEMBLY CLUTCH

SPRING SEAT
CLUTCH WEIGHT E-

DAMPER RUBBER SPRING

DRIVE PLATE

SIDE PLATE
SPRING RETAINER
FRICTION SPRING

SPRING WASHER
SPRING
RETAINER

SNAP RING
PIN
SUB-GEAR

SNAP RING ROLLER CLUTCH INNER CENTRIFUGAL CLUTCH OUTER

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

DRIVE PLATE
Hook the
Kaitkan springspada
springs to theclutch
clutch weights
weights so that theirujung-
sehingga open
ends facing theyang
drive terbuka
plate side. CLUTCH WEIGHTS
ujung mereka menghadap ke sisi drive
Install the clutch weights and springs onto the drive plate
plate.
as shown.
Pasang clutch weights dan springs pada drive plate
seperti diperlihatkan.

SPRINGS

9-16
CLUTCH/GEARSHIFT LINKAGE
Pasang spring
Install the seat,
spring friction
seat, frictionspring
springdan
andside
side plate
plate pada
to the CLUTCH WEIGHT
clutchweight
clutch weightassembly
assemblyseperti
as shown.
diperlihatkan.

SIDE PLATE

SIDE PLATE

SPRING
SEAT

FRICTION SPRING
AlignTepatkan
the openujung Install the
end of Pasang new baru
E-clips E-clips while compressing
sementara the side
menekan side plate.
plate.
terbuka dari E-clips E-CLIPS BOSS
the E-clips and bosses
dan bosses dari side
of the side plate.
plate.

SIDE PLATE
CLUTCH
CLUTCH OUTER/SUB-GEAR
OUTER/SUB-GEAR
Pasang sub-gear dengan
Install the sub-gear mentepatkan
by aligning lubangnya
its hole and dan
primary drive
potongan pada primary drive gear.
gear cut-out. PIN
Check that the snap Install the snap ring.
ring is seated in the
Periksa bahwa snap Pasang snap ring.
groove.
ring
Be duduknot
careful to lose Install the pin.
dengan
benar di dalamthealur.
pin.
Hati-hati agar tidak Pasang pin. Tepatkan
kehilangan pin.

SNAP RING SUB-GEAR


Masukkan
Insert the ujung yangof tertekuk
bent end the springdari
intospring ke dalam
the hole on the
springpada
lubang retainer.
spring retainer. SPRING RETAINER SPRING
Coil the spring
Gulungkan intoke
spring thedalam
spring retainer, making sure
spring retainer, that
dengan
the spring isbahwa
memastikan set between
springthe retainer andantara
ditempatkan tab. retainer
dan tab.

Masukkan
UJUNG
YANG
TERTEKUK
TAB dan LUBANG

9-17
CLUTCH/GEARSHIFT LINKAGE
Pasang
Install thespring retainer/springto pada
spring retainer/spring clutch
the clutch outer outer
while
aligning thementepatkan
sementara straight end of spring
ujung with dari
lurus the hole on the
spring ke Tepatkan
sub-gear
dalam and aligning
lubang the retainer
pada sub-gear groove
dan with the pin.
mentepatkan alur (ALUR dan PIN)
retainer dengan pin.

Tepatkan (UJUNG
LURUS dan
SUB-GEAR LUBANG)
Check cara
Periksa the sub-gear operation
kerja sub-gear by moving
dengan it and make
menggerakkannya
sure
dan that it returns
memastikan without
bahwa binding. tanpa mengikat.
ia kembali

SUB-GEAR

ONE-WAY
ONE-WAY CLUTCH
CLUTCH
Pasang washer
Install the washerdan
and one-way clutch inner
one-way clutch innerinto
kethe
dalam
cen-
trifugal clutch
centrifugal outer.
clutch outer. CLUTCH INNER

WASHER
Install the
Pasang springs
springs danand rollers
rollers as shown.
seperti diperlihatkan.
SPRING ROLLER

9-18
CLUTCH/GEARSHIFT LINKAGE
Install the
Pasang retainer.
retainer.
SNAP RING
Check bahwa
Periksa that thesnap Install the
snap Pasang snap
snap ring
ring into theerat
dengan groove of the one-way
ke dalam alur dariclutch
one-
ring
ring duduk dengan
is seated outer securely.
in the way clutch outer.
benar pada alurnya.
groove.

RETAINER
Untuk sementara
Temporarily pasang
install centrifugalclutch
the centrifugal clutchouter
outer topada
the
crankshaft.
crankshaft.
Hold the crankshaft and turn the centrifugal clutch outer
by hand.
Tahan crankshaft dan putar centrifugal clutch outer
Make sure
dengan that the centrifugal clutch outer only turns
tangan.
counterclockwise
Pastikan as shown clutch
bahwa centrifugal and does nothanya
outer turn clockwise.
berputar
Remove
dalam theberlawanan
arah centrifugal clutch
jarum outer from thediperlihatkan
jam seperti crankshaft.
dan tidak dapat berputar searah jarum jam.

Lepaskan centrifugal clutch outer dari crankshaft.

PEMBONGKARAN MANUAL
MANUAL CLUTCH CLUTCH
DISASSEMBLY
Lepaskan
Remove the clutch lifter
clutch plate
lifter plateassembly
assemblydan
and washer dari
washer from
clutch outer.outer.
the clutch CLUTCH LIFTER PLATE
WASHER

CLUTCH OUTER
Remove the
Lepaskan following:
sebagai berikut:
CLUTCH LIFTER PLATE SPRING
– Bolts
- –Bolts
Clutch lifter plate
- –Clutch lifter plate
Spring
- –Spring
Clutch center
- –Clutch
Clutch discs
center
- –Clutch
Clutch plates
discs
- Clutch plates

CLUTCH CENTER/
BOLTS DISCS/PLATES

9-19
CLUTCH/GEARSHIFT LINKAGE
Putar clutch
Turn the spring
clutch seat
spring seatsampai
until its tabs-nya bertepatan
tabs are aligned with
the slots slots
dengan on the clutch
pada lifter plate,lifter
clutch then plate,
remove kemudian
it. TABS SLOTS
lepaskan.

SPRING SEAT CLUTCH LIFTER PLATE


PEMERIKSAAN MANUAL
MANUAL CLUTCH CLUTCH
INSPECTION
CLUTCH
CLUTCHLIFTER
LIFTERBEARING
BEARING
Untuk sementara
Temporarily installpasang clutch
the clutch lifter
lifter bearing
bearing ke dalam
to the clutch
lifter plate. CLUTCH LIFTER BEARING
clutch lifter plate.
Turn the inner race of the clutch lifter bearing with your
finger.
Putar inner race dari clutch lifter bearing dengan jari-jari.
The bearing
Bantalan should
harus turn dengan
berputar smoothlyhalusand quietly.
dan tanpa suara.
Also check
Juga periksathat the bearing
bahwa bearingouter race
outer raceof the bearing
dari fits
bearing
tightly in the clutch lifter plate.
duduk dengan erat pada clutch lifter plate.
Replace the bearing if the inner race does not turn
smoothly,
Ganti quietly,
bearing jika orinner
if therace
outertidak
race berputar
fits loosely in the
dengan
clutch lifter plate.
halus, tanpa suara, atau jika outer race duduk dengan
longgar di dalam clutch lifter plate.

CLUTCH LIFTER PLATE


CLUTCH
CLUTCHSPRING
SPRING
Periksa alur-alur
Check the groovesdan
andtabs
tabsdari clutch
of clutch spring
spring terhadap
for damage.
kerusakan.
Check the spring for fatigue or other damage. Four bolts type shown:
Measure
Periksa the clutch
spring spring
terhadap free height.
keletihan atau kerusakan lain.
SERVICE LIMIT:
Ukur ketinggian bebas clutch spring.
FOUR BOLTS TYPE:4.63 mm (0.182 in)
BATAS SERVIS:
SIX BOLTS 4,63 mm
TYPE: 4.52 mm (0.178 in)

CLUTCH SPRING

CLUTCH
CLUTCHCENTER CENTER
Periksa alur-alur
Check the dariofclutch
grooves centercenter
the clutch terhadap kerusakan
for damage or
atau
wearkeausan
caused yangby thedisebabkan oleh clutch plates.
clutch plates. CLUTCH CENTER
Replace
Ganti bila ifperlu.
necessary.

GROOVES

9-20
CLUTCH/GEARSHIFT LINKAGE
CLUTCH
CLUTCHDISC
DISC
GantiReplace
clutch discs
the clutch Replace
dan Ganti the discs
clutch clutch jika
discs if they show
mereka signs of scoring
memperlihatkan or
tanda-
platesand
discs sebagai
platessatu discoloration.
as a tanda gerusan atau perubahan warna. Four bolts type shown:
set.
set. Measure the thickness of each clutch disc.
Ukur tebal masing-masing
SERVICE LIMIT: clutch disc.
FOURSERVIS:
BATAS BOLTS TYPE:1.82
1,82 mm mm (0.072 in)
SIX BOLTS TYPE: 2.08 mm (0.082 in)

CLUTCH
CLUTCHPLATE
PLATE
GantiReplace
clutch discs dan Periksa
the clutch Check eachmasing-masing clutch on
clutch plate for warpage plate terhadap
a surface plate
platesand
discs sebagai
platessatu using a feeler
as a perubahan gauge.
bentuk melengkung di atas surface plate
set.
set. (pelat pengukur kedataran) dengan menggunakan
SERVICE
feeler gauge.
LIMIT: 0.20 mm (0.008 in)
BATAS SERVIS: 0,20 mm

CLUTCH
CLUTCHOUTER/CLUTCH
OUTER/CLUTCH OUTER
OUTER GUIDE
GUIDE
Periksa
Check the primary driven gear teeth for wear or keausan
gigi-gigi primary driven gear terhadap damage.
Check
atau the slots of the clutch outer for damage or wear
kerusakan.
causedslots
Periksa by the clutch
dari discs.
clutch outer terhadap kerusakan atau
keausan
Measureyang disebabkan
the primary oleh
driven clutch
gear I.D. discs.
SERVICE
Ukur D.D. primary driven
LIMIT: gear.
23.07 mm (0.908 in)
BATAS SERVIS: 23,07 mm
Measure the clutch outer guide I.D. and O.D.
Ukur D.D. dan
SERVICE D.L. clutch outer guide.
LIMITS:
I.D.: SERVIS:
BATAS 17.049 mm (0.6712 in)
D.D.: 17,049mm
O.D.: 22.940 mm(0.9031 in)
D.L.: 22,940 mm

MAINSHAFT
MAINSHAFT
Ukur D.L. mainshaft
Measure pada
the mainshaft clutch
O.D. outer outer
at clutch guide.guide.
BATAS SERVIS: 16,87 mm
SERVICE
LIMIT: 16.87 mm (0.664 in)

9-21
CLUTCH/GEARSHIFT LINKAGE
PERAKITAN MANUAL CLUTCH (TIPE EMPAT BAUT)
CLUTCH SPRING CLUTCH CENTER
SPRING SEAT

PRESSURE PLATE
LIFTER PLATE
WASHER

CLUTCH OUTER

CLUTCH PLATES

BOLTS
12 N·m (1.2 kgf·m, 9 lbf·ft)

CLUTCH DISC B
(ID MARK: BLUE PAINT)

CLUTCH DISC A
Coat the
Lapisi clutch
clutch discs
discs with oil.
dengan oli.
CLUTCH SPRING
GantiReplace the clutch
clutch discs dan Install the items in the following
Pasang bagian-bagian dalam urutan sequence:
berikut:
platesand
discs sebagai
platessatu
as a – Clutch spring CLUTCH
set.
set. - –Clutch
Clutch spring
center CENTER
Jangan
Do not confuse the - –Clutch
Clutch center
disc A
mempertukarkan
disc A with disc disc
B. - –Clutch
Clutch plate
disc A
A dengan disc B. - –Clutch
Clutch disc B (ID mark: Blue paint on a tab)
plate
- –Clutch
Clutch plate
disc B (tanda Identifikasi: cat Biru pada sebuah
– Clutch disc A
tab)
– Pressure plate
- Clutch plate DISC A
- Clutch disc A
- Pressure plate CLUTCH
PLATES

DISC A

DISC B
(ID MARK: BLUE PAINT) PRESSURE PLATE

9-22
CLUTCH/GEARSHIFT LINKAGE
Tempatkan
Set the springspring
seat seat dengan
with its pinggirannya
chamfered edge facing yang
the
clutch lifter
dipotong plate as shown
menghadap ke while
clutchaligning
lifter its tab with
plate the
seperti Tepatkan (TABS dan SLOTS)
slot on the plate.
diperlihatkan sementara mentepatkan tab-nya dengan
Turn
slot clutch spring seat about 45°.
the plate.
pada
Putar clutch spring seat sebanyak kira-kira 45°.

SPRING SEAT CLUTCH LIFTER PLATE


SPRING SEAT
Putar 45°

Ujung yang di potong CLUTCH LIFTER PLATE

Install the
Pasang clutch
clutch lifter
lifter plate.
plate.
Temporarily install the bolts. CLUTCH LIFTER PLATE BOLTS
Untuk sementara pasang bolts.
Align the tabs of the clutch discs.
Tepatkan tabs dari clutch discs.

Tepatkan
Install the
Pasang washer
washer onto
pada the clutch
clutch outer.outer.
Install the clutch center assembly CLUTCH CENTER ASSEMBLY
Pasang clutch center assembly ke into theclutch
dalam clutch outer.
outer.

WASHER CLUTCH OUTER

9-23
CLUTCH/GEARSHIFT LINKAGE
PERAKITAN MANUAL CLUTCH (TIPE ENAM BAUT)

CLUTCH CENTER

CLUTCH SPRING

LIFTER PLATE

BOLTS
7 N·m (0.71 kgf·m, 5.2 lbf·ft)

CLUTCH PLATES

CLUTCH OUTER

WASHER

PRESSURE PLATE

CLUTCH DISC

9-24
CLUTCH/GEARSHIFT LINKAGE
INSTALLATION
PEMASANGAN
Install the
Pasang collar
collar padaonto the mainshaft.
mainshaft.
COLLAR COLLAR
Apply engine oil to the
Semprotkan oli mesin pada clutchpermukaan
outer guideluar
outer surface.
clutch outer
Install the clutch outer guide.
guide.
Install the
Pasang collar
clutch ontoguide.
outer the crankshaft.

Pasang collar pada crankshaft.

CLUTCH OUTER GUIDE


Apply molybdenum
Semprotkan disulfide
molybdenum oil to the
disulfide oil primary drive gear
pada permukaan
inner surface.
dalam primary drive gear.
Apply engine oil to the primary drive gear teeth.
Semprotkan oli mesin pada gigi-gigi primary drive gear.

Tepatkan potongan-potongan
Align the cut-outs of the primarydari primary
drive drive
gear and gear
sub-gear Tepatkan
as shown, thenseperti
engage diperlihatkan,
the primary drive/driven MANUAL CLUTCH
dan sub-gear kemudiangears.
saling
hubungkan primary clutch,
Install the manual drive/driven gears.clutch outer and oil
centrifugal
separator plate as assembly.
Pasang manual clutch, centrifugal clutch outer dan oil
separator plate sebagai sebuah kesatuan.

CENTRIFUGAL
OIL SEPARATOR PLATE CLUTCH OUTER
Install and
Pasang dantighten the two oil
kencangkan separator
kedua plate mounting
oil separator plate
bolts.
mounting bolts.

BOLTS

9-25
CLUTCH/GEARSHIFT LINKAGE
Install the
Pasang washer
washer onto
pada the mainshaft.
mainshaft.
BOLTS
Tighten the clutch lifter plate
Kencangkan clutch lifter plate bolts to the
bolts specified
dengan torsitorque.
yang
TORQUE:12 N·m (1.2 kgf·m, 9 lbf·ft)
ditentukan.

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

WASHER

Apply engineoli
Semprotkan oil mesin
to the clutch
pada center
ulir-ulirlock nut threads
clutch and
center lock UNIVERSAL
seating surface. LIFTER PLATE LOCK NUT
nut dan permukaan duduk. HOLDER WRENCH
Install the
Pasang clutch
clutch center
center lock
lock nut.
nut.
Hold the clutch lifter plate and tighten the clutch center
Tahan
lock nut to the specified torquekencangkan
clutch lifter plate dan clutchtools.
using the special center
lock nut dengan torsi yang ditentukan dengan
TOOLS:
menggunakan special tools. EXTENSION
Universal holder 07725-0030000 BAR
Lock nut wrench, 20 x 24 mm
TOOLS: 07716-0020100
Universal
Extension holder
bar 07725-0030000
07716-0020500
Lock nut wrench, 20 x 24 mm 07716-0020100
TORQUE:54
Extension barN·m (5.5 kgf·m, 40 lbf·ft) 07716-0020500

TORSI: 54 N.m (5,5 kgf.m; 40 lbf.ft)


CLUTCH CENTER LOCK NUT

Apply engineolioil mesin


Semprotkan to the clutch lifter bearing
pada clutch and install
lifter bearing danit
into theke
pasang clutch
dalamlifter plate.lifter plate.
clutch CLUTCH LIFTER BEARING

CLUTCH LIFTER PLATE


Pasang clutch
Install the weight
clutch weightassembly
assembly keinto
dalam
the clutch
clutch outer
outer
sementara mentepatkan
while aligning the splines splines (seplain-seplain)
of the clutch dari
weight assembly Align
and crankshaft.
clutch weight assembly dan crankshaft.

CLUTCH WEIGHT ASSEMBLY

9-26
CLUTCH/GEARSHIFT LINKAGE
Install a sebuah
Pasang new lock lock
washer onto the
washer crankshaft
baru aligning its
pada crankshaft
inner tabmentepatkan
with the groove LOCK WASHER Tepatkan
dengan tabofdalamnya
the clutch weight
denganassembly.
alur dari
clutch weight assembly.

Install the
Pasang washer
washer with itstanda
dengan "OUT"OUT
SIDE"SIDE"
mark menghadap
facing out.
keluar. "OUT SIDE"

WASHER
Apply engineolioil mesin
Semprotkan to the centrifugal clutch
pada ulir-ulir lock nut threads
centrifugal clutch
andnut
seating surface. CENTRIFUGAL EXTENSION BAR
lock dan permukaan duduk. CLUTCH LOCK NUT
Install the clutch center holder using proper bolts or
screws. clutch center holder dengan menggunakan
Pasang
bolts atau
Install thescrews yangclutch
centrifugal benar.
lock nut.
Pasang
Tightencentrifugal clutchclutch
the centrifugal lock nut.
lock nut to the specified
torque using centrifugal
Kencangkan the special tools.
clutch lock nut dengan torsi
yang ditentukan dengan menggunakan special tools.
TOOLS:
Lock nut wrench, 20 x 24 mm 07716-0020100
TOOLS:
Extension bar 07716-0020500
Lock nut wrench, 20 x 24 mm 07716-0020100
Clutch center
Extension barholder 07HMB-HB70100
07716-0020500
Clutch center holder 07HMB-HB70100
TORQUE:54 N·m (5.5 kgf·m, 40 lbf·ft)
LOCK NUT
TORSI: 54 N.m (5,5 kgf.m; 40 lbf.ft) WRENCH CLUTCH CENTER

If any
Jika of the
salah satucentrifugal clutch lock
alur centrifugal clutchnutlock
groove
nut istidak
not
aligned withdengan
the lock washer tab, further TAB LOCK WASHER
bertepatan lock washer tab,tighten the cen-
kencangkan
trifugal clutch
centrifugal lock
clutch locknut
nutand align
lebih thedan
lanjut centrifugal
tepatkanclutch
alur
lock nut groove with the lock washer tab.
centrifugal clutch lock nut dengan lock washer tab.
Bend the lock washer tab against the centrifugal clutch
lock nut groove.
Tekuk lock washer tab pada alur centrifugal clutch lock
nut.

9-27
CLUTCH/GEARSHIFT LINKAGE
Pasang clutch
Install the lever
clutch leverpada gearshift
onto spindlespindle
the gearshift sementara
while
aligning its punch
mentepatkan mark with
tanda-tanda thedengan
titik index line on the
index linespindle.
(garis LIFTER CAM PLATE
Install thepada
penunjuk) clutch lifter cam plate onto the clutch lifter
spindle.
bearing.
Pasang clutch lifter cam plate pada clutch lifter bearing.
Install the following:
Pasang
– Engine sebagai berikut: filter cover (page 3-11)
oil centrifugal
– Right crankcase cover (page 9-8)
- Engine oil centrifugal filter cover (hal. 3-11)
- Right crankcase cover (hal. 9-8)

CLUTCH LEVER Tepatkan

GEARSHIFT LINKAGE
GEARSHIFT LINKAGE
REMOVAL
PELEPASAN
Remove the
Lepaskan clutch
clutch (page 9-9).
Remove the bolt(hal.
and 9-9).
the gearshift pedal.
Sewaktu melepaskan
When removing the Lepaskan bolt dan gearshift pedal.
gearshift
gearshift pedal,pedal,
mark
tandai
the posisi
pedal pedalto
position
untuk
ensurememastikan
the original
posisi semula.
position.

BOLT GEARSHIFT PEDAL

Bersihkan
Clean the gearshift spindle
spindlethoroughly
secara menyeluruh untuk
to prevent the dirt
or dust from entering
menghindari masuknya the kotoran
engine. atau debu ke dalam
mesin.

GEARSHIFT SPINDLE
Lepaskan sebagai berikut: R
e STOPPER ARM/BOLT
- Shift drum stopper arm/bolt m
- Return spring o
v
e
the following:
– Shift drum stopper arm/bolt
– Return spring

RETURN SPRING

9-28
CLUTCH/GEARSHIFT LINKAGE
Remove the
Lepaskan gearshift
gearshift spindle
spindle by holding
dengan down the
menekan gear-
gearshift
shiftke
arm as shown. GEARSHIFT
arm bawah seperti diperlihatkan. SPINDLE

GEARSHIFT ARM

Remove the
Lepaskan boltbolt
danand the gearshift
gearshift cam plate.
cam plate.
BOLT

GEARSHIFT
CAM PLATE

Remove the
Lepaskan gearshift
gearshift drum
drum pinsdan
pins andstopper
stopper plate
plate pins
pins
fromgearshift
the gearshift GEARSHIFT
dari drum.drum. DRUM PINS

STOPPER
GEARSHIFT DRUM PLATE PINS

INSPECTION
PEMERIKSAAN
Periksa gearshift
Check the gearshiftspindle
spindleterhadap tekukan,
for bend, wear keausan
or damage.
Check
atau the gearshift arm spring and return spring for
kerusakan. GEARSHIFT ARM GEARSHIFT
damagegearshift
Periksa or fatigue.
arm spring dan return spring terhadap SPINDLE
Check theatau
kerusakan gearshift arm for wear or damage.
keletihan.
Periksa gearshift arm terhadap keausan atau
kerusakan.

GEARSHIFT
ARM SPRING RETURN SPRING

9-29
CLUTCH/GEARSHIFT LINKAGE
Inspectgearshift
Periksa the gearshift spindle
spindle oil seal
oil seal for deterioration
terhadap pemburukanor
damage,
kondisi ataureplace if necessary.
kerusakan, ganti bila perlu.
If replacing the oil seal, install it until it is fully seated.
Jika oil seal diganti, pasang sampai ia telah duduk
dengan penuh.

OIL SEAL
PEMASANGAN
INSTALLATION
Oleskan gemuktopada
Apply grease bibir gearshift
the gearshift spindlespindle
oil sealoillips.
seal.

OIL SEAL
Pasang kelima
Install the gearshiftdrum
five gearshift drum pins
pins anddantwo dua stopper
stopper plate
plate
pins pins
to thepada lubang-lubang
holes pada
on the gearshift gearshift drum.
drum. Tepatkan GEARSHIFT
Install the
Pasang gearshiftcam
gearshift cam plate
plate while aligningmentepatkan
sementara the holes on DRUM PINS
the plate with pada
lubang-lubang the stopper plate pins.
plate dengan stopper plate pins.

STOPPER
PLATE PINS
GEARSHIFT DRUM
Oleskan zat pengunci
Apply locking agent to pada gearshiftcam
the gearshift camplate
plate
boltbolt
as
specified,
seperti then install
ditentukan, and tighten
kemudian pasangit dan
to the specified
kencangkan Lebar pelapisan: 6.5 ± 1.0 mm
torque.torsi yang ditentukan.
dengan dari ujung

TORQUE: 17 N·m (1.7 kgf·m, 13 lbf·ft)


TORSI: 17 N.m (1,7 kgf.m; 13 lbf.ft)

BOLT

9-30
CLUTCH/GEARSHIFT LINKAGE
Install the
Pasang gearshiftspindle
gearshift spindle so that the shift
sedemikian return spring
sehingga shift
pin is spring
locatedpin
between GEARSHIFT ARM GEARSHIFT
return terletakboth ends
antara of theujung
kedua returndari
spring as
return SPINDLE
shown.
spring seperti diperlihatkan.
Insert the gearshift spindle completely while holding
down the gearshift
Masukkan gearshiftarm as shown.
spindle sama sekali sementara
menahan ke bawah gearshift arm seperti diperlihatkan.

SPRING PIN SPRING ENDS


Apply locking
Oleskan agent topada
zat pengunci the shift
shiftdrum stopper
drum stopper arm boltbolt
arm as
specified. Lebar pelapisan: 6.5 ± 1.0 mm
seperti ditentukan. dari ujung.
Set the return spring end along the crankcase wall as
shown.
Tempatkan ujung return spring di sepanjang dinding
Install the seperti
crankcase stopperdiperlihatkan.
arm/bolt, then tighten it to the specified
torque. BOLT
Pasang
TORQUE: stopper arm/bolt,
10 N·m (1.0 kgf·m, 7 kemudian
lbf·ft) kencangkan
dengan torsi yang ditentukan.

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

RETURN SPRING END STOPPER ARM

Install the
Pasang gearshift
gearshift pedalpedal
padatoposisinya
its original position
semula as
seperti
marked
telah during
ditandai removal.
pada waktu pelepasan.
Install and
Pasang dantighten the bolt.
kencangkan bolt.
Install the
Pasang clutch
clutch (page
(hal. 9-25).
9-24).

BOLT GEARSHIFT PEDAL

9-31
MEMO
10. ALTERNATOR/STARTER CLUTCH

LOKASI KOMPONEN-KOMPONEN......10-2
COMPONENT LOCATION ·························· 10-2 STATOR.................................................10-6
STATOR ···························································10-6

KETERANGAN SERVIS ........................10-3


SERVICE INFORMATION ··························· 10-3 FLYWHEEL/STARTER CLUTCH··············10-8
FLYWHEEL/STARTER CLUTCH ..........10-8

LEFT
LEFT CRANKCASE COVER
CRANKCASE COVER .................10-4
·······················10-4
10

10-1
ALTERNATOR/STARTER CLUTCH
LOKASI KOMPONEN
ALTERNATOR/STARTER CLUTCH

40 N·m (4.1 kgf·m, 30 lbf·ft)

10-2
ALTERNATOR/STARTER CLUTCH
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
• This section covers service of the alternator and starter clutch.
•• These services
Bab ini can
meliputi be done
servis dari with the engine
alternator installed
dan starter in the frame.
clutch.
•• For (page ini
alternator inspectionservis
Pekerjaan-pekerjaan 15-7). dilakukan dengan mesin terpasang pada rangka.
dapat
•• For ignition
Untuk pulse generator
pemeriksaan inspection
alternator (page 16-7).
(hal. 15-7)
• Untuk pemeriksaan ignition pulse generator (hal. 16-7).
SPECIFICATIONS
SPESIFIKASI Unit: mm (in)
Satuan: mm SERVICE
BAGIAN ITEM STANDARD
STANDARD BATAS SERVIS
LIMIT
Starter
D.L. driven
starter geargear
driven bossboss
O.D. 45.660 – 45.673
45,660 (1.7976 – 1.7981)
– 45,673 45,2 45.2 (1.78)

TORSI PENGENCANGAN
TORQUE VALUE
Flywheel
Flywheel nut
nut 4040
N.m
N·m(4,1
(4.1kgf.m;
kgf·m,30 lbf·ft) Semprotkan
30lbf.ft) oli pada
Apply oil toulir
thedan permukaan
threads and duduk
seating surface
Starter clutch mounting
Starter clutch mounting torx
torx bolt
bolt 6 16
N.mN·(1,6 kgf.m;
m (1.6 1212
kgf·m, lbf·ft) Semprotkan
lbf.ft) oli pada
Apply ulir dan
locking permukaan
agent duduk: Lih.hal.10-12
to the threads and seating
surface: See page 10-12

TOOLS
Flywheel holder Flywheel puller, 28 mm
07725-0040001 07933-KG20000

10-3
ALTERNATOR/STARTER CLUTCH
LEFT CRANKCASE COVER
PELEPASAN
REMOVAL
Keluarkan oli mesin
Drain the engine oil (hal.
(page3-10).
3-10).
GEARSHIFT PEDAL
Remove the
Lepaskan following:
sebagai berikut:
- –Left crankcase
Left crankcase rear cover
rear cover(hal. 2-19)
(page 2-19)
- –Ignition control
Ignition module
control module(ICM)
(ICM)(hal. 16-9)
(page 16-9)
Remove the bolt and gearshift pedal.
Sewaktu melepaskan Lepaskan bolt dan gearshift pedal.
When removing the
gearshift pedal,
gearshift pedal,pedal
tandai posisi mark
the pedal
untuk position to
memastikan
ensure the semula.
posisi original
position.

BOLT
Release the
Lepaskan air air supply
supply hoses
hoses darifrom the guides.
guides. GUIDES
Disconnect the following:
Lepaskan sebagai berikut:
- –Alternator
Alternator wire
wire (Yellow) (Kuning)
connector connector
- –Ignition
Ignition pulse
pulse generator
generator wireconnector
wire (Blue/yellow) connector
(Biru/kuning)
Remove the wire band boss.
Lepaskan wire band boss.

WIRE
BAND
BOSS

WIRE CONNECTORS
Disconnect
Lepaskan the alternator
alternator 2P connector.
2P connector.

2P CONNECTOR
Longgarkan boltsin adalam
Loosen the bolts polapattern
crisscross bersilangan
in severaldalam
steps
beberapa langkah
and remove them dan
and lepaskan
guide. mereka dan guide. LEFT CRANKCASE COVER

The left crankcase Remove the left crankcase cover.


Left crankcase cover Lepaskan left crankcase cover.
cover (stator) is
(stator) tertarik
magnetically
secara magnetisattached
pada
to thejadi
flywheel, flywheel, be
berhati-
carefulselama
hatilah during
removal.
pelepasan.

BOLT/GUIDE BOLTS

10-4
ALTERNATOR/STARTER CLUTCH
Remove the
Lepaskan gasket
gasket danand dowel
dowel pins.
pins.
GASKET

DOWEL PINS
PEMASANGAN
INSTALLATION
Hati-hati not to Bersihkan
agar tidak
Be careful bahan-bahan
Clean any gasket gasket
material from dari
the left permukaan
crankcase cover
merusak
damagepermukaan mating surface.
the mating penyatuan left crankcase cover. GASKET
penyatuan.
surface. Install the dowel pins and a new gasket.
Pasang dowel pins dan gasket baru.

DOWEL PINS
Left crankcase cover Pasang left crankcase cover.
The left crankcase Apply engine oil to the starter reduction gear journal of
tertarik secara Pasang bolts dan guide, kemudian kencangkan bolts
the left crankcase cover LEFT CRANKCASE COVER
covermagnetis
is magnetically
pada
attached to the Installpola
dalam the left crankcasedalam
bersilangan cover.beberapa langkah.
flywheel, jadi berhati- Install the bolts and guide, then tighten the bolts in a
flywheel, be careful
hatilah sewaktu crisscross pattern in several steps.
during installation.
pemasangan.

REDUCTION
GEAR
JOURNAL

BOLT/GUIDE BOLTS

Connect thealternator
Hubungkan alternator2P
2Pconnector
connector

2P CONNECTOR

10-5
ALTERNATOR/STARTER CLUTCH
Lepaskan
Disconnect sebagai berikut:
the following:
GUIDES
– Alternator wire (Yellow) connector
- –Alternator wire connector
Ignition pulse generator (Kuning)
wire (Blue/yellow) connector
- Install
Ignition
thepulse generator
wire band boss.wire connector (Biru/kuning)
Install the air supply hoses to the guides.
Pasang wire band boss.
Pasang air supply hoses pada guides.
WIRE
BAND
BOSS

WIRE CONNECTORS
Install thegearshift
Pasang gearshift pedal
pedal in(pedal
its original position gigi
pemindah as
marked during
persneling) padaremoval.
posisinya semula seperti telah ditandai GEARSHIFT PEDAL
Install
pada and tighten
waktu the bolt.
pelepasan.
Install the
Pasang danfollowing:
kencangkan bolt.
– Ignition control module (ICM) (page 16-9)
Pasang
– Left sebagai
crankcaseberikut:
rear cover (page 2-19)

- Fill the engine


Ignition controlwith the recommended
module engine oil (page 3-
(ICM) (hal. 16-9)
- 10)
Left. crankcase rear cover (hal. 2-19)

Isilah mesin dengan oli mesin yang dianjurkan (hal. 3-


10).

BOLT

STATOR
REMOVAL
PELEPASAN
Remove the
Lepaskan left left c