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DAFTAR ISI

BAGAIMANA MEMAKAI MANUAL INI


KETERANGAN UMUM 1
Buku Pedoman Reparasi ini menguraikan prosedur servis RANGKA / BODI PANELS
untuk sepedamotor HONDA CITY SPORT - ONE. / SISTEM PEMBUANGAN GAS 2
Ikuti petunjuk pada Jadwal Perawatan (Bab 3) untuk
mempertahankan sepedamotor pada kondisi operasional PERAWATAN 3
puncak.

Adalah sangat penting untuk menjalankan perawatan


SISTEM PELUMASAN 4
gratis I dan II pada waktunya. Servis ini mengadakan
penyesuaian terhadap keausan awal yang terjadi dalam
masa pemakaian mula.
SISTEM BAHAN BAKAR 5

MESIN & PERALATAN PENGGERAK


Bab 1 dan 3 berlaku untuk sepedamotor secara keselu- SISTEM PENDINGINAN 6
ruhan.
Bab 2 menggambarkan prosedur untuk pelepasan/pema-
sangan komponen yang mungkin diperlukan untuk men-
PELEPASAN / PEMASANGAN MESIN 7
jalankan servis yang diuraikan pada bab-bab berikutnya.
Bab 4 sampai dengan 19 menguraikan bagian-bagian se-
KEPALA SILINDER / KLEP 8
pedamotor yang dikelompokkan menurut lokasi.

Carilah bab yang Anda inginkan pada halaman ini, kemu-


SILINDER / PISTON 9
dian bacalah daftar isi pada halaman pertama dari bab
itu. KOPLING / KICKSTARTER /
PERALATAN PEMINDAH GIGI 10
Kebanyakan bab dimulai dengan gambar susunan atau
gambar sistem, keterangan servis dan cara mencari
penyebab kesukaran untuk bab itu. Halaman-halaman ALTERNATOR / KOPLING STARTER 11
berikutnya memberikan prosedur servis secara mendetil.

Jika Anda tidak mengetahui sumber penyebab kesukaran, CRANKSHAFT / BALANCER / TRANSMISI 12
bacalah bab 21, MENCARI PENYEBAB KESUKARAN.
RODA DEPAN / SUSPENSI / KEMUDI 13
RANGKA

Semua keterangan, gambar, petunjuk dan spesifi- RODA BELAKANG / SUSPENSI 14


kasi di dalam publikasi ini berdasarkan data-data
produk terakhir yang tersedia pada waktu persi-
apan untuk pencetakan. REM HIDRAULIK 15
PT Astra Honda Motor berhak membuat perubahan
pada setiap waktu tanpa pemberitahuan dan tanpa
BATERAI / SISTEM PENGISIAN 16
ikatan apapun.
SISTEM PENGAPIAN 17
KELISTRIKAN

Dilarang mengutip atau mencetak ulang bagian dari


penerbitan ini tanpa ijin tertulis penerbit.
STARTER LISTRIK 18
Manual ini ditulis untuk orang yang telah memi-
liki pengetahuan dasar perawatan sepedamotor
Honda. LAMPU / METER / SAKLAR-SAKLAR 19
PT ASTRA HONDA MOTOR
DIAGRAM LISTRIK 20
MENCARI PENYEBAB KESUKARAN 21
CATATAN PENTING UNTUK KEAMANAN

Di dalam buku ini tidak dimuat pembahasan secara mendetail mengenai prosedur kerja bengkel
standar, prinsip - prinsip keamanan serta pekerjaan servis standar. 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
SERVICE SERVIS ...................................................1-2
RULES·············································· 1-2 SPESIFIKASI RODA DEPAN / SUSPENSI / KEMUDI ..1-8
FRONT WHEEL/SUSPENSION/
STEERING SPECIFICATIONS ······················1-8
IDENTIFIKASI MODEL ..................................................1-2
MODEL IDENTIFICATION ··························· 1-2 SPESIFIKASI RODA BELAKANG / SUSPENSI............1-8
REAR WHEEL/SUSPENSION
SPECIFICATIONS············································1-8
SPESIFIKASI
GENERALUMUM .....................................................1-4
SPECIFICATIONS······················· 1-4 SPESIFIKASI REM HIDRAULIK....................................1-8

SPESIFIKASI SISTEMSYSTEM
LUBRICATION PELUMASAN ...........................1-5 HYDRAULICBATERAI
SPESIFIKASI BRAKE/ SPECIFICATIONS···1-8
SISTEM PENGISIAN............1-9
SPECIFICATIONS············································ 1-5
SPESIFIKASI SISTEM BAHAN BAKAR .......................1-5 BATTERY/CHARGING
SPESIFIKASI SYSTEM
SISTEM PENGAPIAN.............................1-9
FUEL SYSTEM SPECIFICATIONS··············· 1-5 SPECIFICATIONS············································1-9
SPESIFIKASI SISTEM PENDINGINAN .........................1-5 SPESIFIKASI STARTER LISTRIK.................................1-9
COOLING SYSTEM SPECIFICATIONS······ 1-5 IGNITION SYSTEM SPECIFICATIONS······1-9
SPESIFIKASI KEPALA SILINDER / KLEP....................1-6 SPESIFIKASI LAMPU / METER / SAKLAR ..................1-9
CYLINDER HEAD/VALVES ELECTRIC STARTER SPECIFICATION ····1-9
SPESIFIKASI SILINDER / PISTON ...............................1-6
SPECIFICATIONS··········································· 1-6 NILAI TORSI STANDARD .............................................1-10
LIGHTS/METERS/SWITCHES
SPECIFICATIONS············································1-9
SPESIFIKASI KOPLING / KICKSTARTER
CYLINDER/PISTON SPECIFICATIONS / ····· 1-6 NILAI TORSI MESIN & RANGKA..................................1-10
PERALATAN PEMINDAH GIGI .....................................1-6
STANDARD TORQUE VALUES ··················1-10
CLUTCH/KICKSTARTER/GEARSHIFT TITIK-TITIK PELUMASAN & PERAPATAN ..................1-14
LINKAGEALTERNATOR
SPESIFIKASI SPECIFICATIONS························
/ KOPLING STARTER...1-7 1-6
ENGINE & FRAME TORQUE VALUES ····1-10
PERLETAKAN KABEL & HARNESS............................1-16
SPESIFIKASI CRANKSHAFT / BALANCER
ALTERNATOR/STARTER CLUTCH /
SPECIFICATIONS············································ 1-7
TRANSMISSI..................................................................1-7 LUBRICATION
SISTEM & SEAL
PENGATURAN POINTS
EMISI ···············1-14
.....................................1-25
CRANKSHAFT/BALANCER/ CABLE & HARNESS ROUTING··················1-16
TRANSMISSION SPECIFICATIONS············ 1-7
EMISSION CONTROL SYSTEMS···············1-25

1-1
KETERANGAN UMUM
SERVICE RULES
GENERAL INFORMATION

PERATURAN SERVIS
1. Use genuine Honda or Honda-recommended parts and lubricants or their equivalents. Parts that do not meet Honda's design specifications
1. Pakailah
may sukucadang
cause damage asli Honda atau sukucadang dan pelumas yang direkomendasikan oleh Honda atau ekuivalen
to the motorcycle.
2. Use the special
mereka. tools designed
Sukucadang yangfor this memenuhi
tidak product to avoid damagedesain
spesifikasi and incorrect
Hondaassembly.
dapat menyebabkan kerusakan pada sepedamotor.
3.
2. Use only metric
Pakailah toolstools
special when(kunci
servicing the motorcycle.
perkakas khusus)Metric
yangbolts, nuts anduntuk
dirancang screwsproduk
are not ini
interchangeable with English
untuk menghindari fasteners.
terjadinya kerusakan
4. Install new gaskets,
dan perakitan O-rings,
yang tidak cotter
benar.pins, and lock plates when reassembling.
5.
3. When
Hanya tightening bolts or nuts,
pakai perkakas begin
metris with the
ketika larger diameter
menservis or inner bolt
sepedamotor. first.
Baut, murThen
dantighten
sekrup to the specified
metris tidak torque
dapatdiagonally in incremental
dipertukarkan dengan
steps unless a particular sequence is specified.
pengencang sistem ukuran Inggris.
6. Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly.
4.
7. Pasang
After gasket,check
reassembly, O-ring,all cotter pin,
parts for dan installation
proper lock platesand(pelat pengunci) baru sewaktu perakitan kembali.
operation.
5.
8. Ketika mengencangkan baut atau mur, mulailah dengan
Route all electrical wires as shown in the Cable and Harness Routing baut(page
dengan diameter lebih besar atau baut di sebelah dalam dulu.
1-16).
9. Kemudian
Do not bend orkencangkan secaraDamaged
twist control cables. bersilang dengan
control cablestorsi yang
will not ditentukan
operate smoothly dalam
and maylangkah-langkah
stick or bind. bertahap kecuali jika
ditentukan urutan tertentu yang lain.

MODEL IDENTIFICATION
6. Bersihkan parts (onderdil) dalam cairan pembersih sewaktu dibongkar. Lumasi permukaan luncur sebelum dipasang
kembali.
7. Setelah pemasangan kembali, periksa semua parts terhadap pemasangan dan cara pengoperasian yang benar.
8. Letakkan semua kabel listrik seperti diperlihatkan pada Perletakan Kabel dan Harness (halaman 1-16).
9. Jangan menekuk atau memuntir kabel pengontrol. Kabel pengontrol yang rusak tidak dapat beroperasi dengan lancar dan
dapat mengikat atau menjadi macet.

IDENTIFIKASI MODEL

1-2
KETERANGAN UMUM
SERIALSERI
NOMOR NUMBERS
The frame serial number is stamped on the left side of the steering head.
Nomor seri rangka dicetak pada sisi kiri dari kepala kemudi.

NOMOR SERI RANGKA

The engine
Nomor seriserial
mesin number is stamped
dicetak onbagian
pada sisi the lower
kirileft side ofdari
bawah the crankcase
crankcase. (bak
mesin).

NOMOR SERI MESIN

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

NOMOR IDENTIFIKASI KARBURATOR

1-3
KETERANGAN UMUM
GENERAL SPECIFICATIONS
SPESIFIKASI UMUM
BAGIAN ITEM SPESIFIKASI
SPECIFICATION
DIMENSI
DIMENSIONS Panjang keseluruhan
Overall length 1.932 mm 1,932 mm (76.1 in)
Lebar keseluruhan 682 mm
Overall width 682 mm (26.9 in)
Tinggi keseluruhan 1.042 mm
Overall height 1,042 mm (41.0 in)
Jarak sumbu roda 1.251 mm
Wheelbase 1,251 mm (49.3 in)
Tinggi tempat duduk 751 mm
Seat height
Tinggi pijakan kaki 262 mm 751 mm (29.6 in)
Footpeg
Jarak heightke tanah
terendah 130 mm 262 mm (10.3 in)
Ground
Berat siapclearance
pakai 114 kg 130 mm (5.1 in)
Curb weight
Kapasitas berat maksimum 122 kg 114 kg (251.3 lbs)
RANGKA Maximum
Jenis rangka weight capacity Tipe pipa122gandakg (269.0 lbs)
FRAME Frame type
Suspensi depan Twin tube type
Garpu teleskopik
Front
Jarak suspensionporos depan
pergerakan 81,3 mm Telescopic fork
Front axle
Suspensi travel
belakang Swingarm81.3 mm (3.20
(lengan ayun) in)
Rearpergerakan
Jarak suspension poros belakang 101,8 mmSwingarm
Rear axle
Peredam travel
kejut belakang Tipe pipa101.8
bekerja mmpada
(4.01kedua
in) sisi
Ukuran ban
Rear damper Depan 70/90-17M/CBoth38P side operation tube type
Tire size Belakang
Front 80/90-17M/C 44P
70/90-17M/C 38P
Merek ban DepanRear SRI 80/90-17M/C 44P
Tire brand Belakang
Front SRI SRI
Rem depan Rear Hidraulik SRI
cakram tunggal
Rem belakang
Front brake Hidraulik Hydraulic
cakram tunggalsingle disc
Sudut caster
Rear brake 25° Hydraulic single disc
Panjang
Caster trail
angle 80,0 mm 25°
Kapasitas tangki bahan bakar
Trail length 4,1 liter 80.0 mm (3.15 in)
MESIN Susunan silinder
Fuel tank capacity Silinder tunggal
4.1 litermiring 40°gal,
(1.08 US dari vertikal
0.90 lmp gal)
ENGINE Diameter dan langkah
Cylinder arrangement 58,0 x 47,2 mm
Single cylinder inclined 40° from vertical
3
Volume langkah
Bore and stroke 124,7 cm58.0 x 47.2 mm (2.28 x 1.86 in)
Perbandingan kompresi 10,7 : 1 124.7 cm3 (7.61 cu-in)
Displacement
Peralatan penggerak rantai klep OHC dengan rocker arm, digerakkan rantai
Compression ratio o 10.7:1
Klep masuk membuka ] 10 BTDC (sebelum TMA)
Valve train o Chain driven OHC with rocker arm
menutup ] pada pengangkatan 35 ABDC (sesudah TMB)
Intake
Klep buangvalve membuka opens
] 1 mmat 1.0 mm (0.04 in) lift o 10° BTDC
35 BBDC (sebelum TMB)
menutup closes
] at 1.0 mm (0.04 in) lift
5
o
ATDC 35°(sesudah
ABDC TMA)
Exhaust valve
Sistem pelumasan opens at 1.0 mm (0.04 in) lift 35°
Pompa bertekanan BBDC dengan bak oli basah
Jenis pompa oli closes at 1.0 mm (0.04 in) lift
Trochoid 5° ATDC
Lubrication
Sistem system
pendinginan PendinginanForced pressure
dengan and wet sump
cairan
Oil pump type
Penyaringan udara Trochoid
Elemen kertas kental
Cooling
Berat kosongsystem
mesin 22,3 kg Liquid cooled
KARBURATOR Air filtration
Jenis Viscous paper
Tipe CV (Constant element
velocity)
Engine dry
Diameter weight
throttle 28 mm atau 22.3ekuivalen
kg (49.2 lbs)
CARBURETOR Type CV (Constant velocity) type
PERALATAN Throttle
Sistem bore
kopling 28 mm (1.0
Pelat-majemuk, basahin) or equivalent
DRIVE TRAIN
PENGGERAK Clutchpengoperasian
Sistem system kopling Digerakkan Multi-plate,
kabel wet
Transmissi
Clutch operation system BertautanCabletetap,operating
5-kecepatan
Reduksi primer
Transmission 3,350 (67/20)
Constant mesh, 5 speeds
Reduksi
Primaryakhir
reduction 3,000 (42/14)
3.350 (67/20)
Perbandingan
Final reduction gigi Gigi 1 3,083 (37/12)
3.000 (42/14)
Gear ratio Gigi 21st 1,882 (32/17) 3.083 (37/12)
Gigi 32nd 1,388 (25/18) 1.882 (32/17)
Gigi 43rd 1,095 (23/21) 1.388 (25/18)
Gigi 54th 0,923 (24/26) 1.095 (23/21)
Pola pemindahan gigi 5th Sistem kembali, digerakkan oleh kaki kiri,
0.923 (24/26)
Gearshift pattern 1-N-2-3-4-5 Left foot operated return system
LISTRIK Sistem pengapian Condenser 1 -Discharged
N - 2 - 3 - 4 -Ignition
5 (CDI)
ELECTRICAL Sistem starter
Ignition system Motor starter listrik dengan kickstarter
Condenser Discharged Ignition (CDI)
Sistem pengisian
Starting system AlternatorElectric
denganstarter
single phase
motor withoutput
kickstarter
Regulator
Charging/ system
rectifier SCR shorted Single/ single
phase phase, half wave
output alternator
Regulator/rectifier rectification
SCR shorted, single phase half-wave rectifica-
Sistem penerangan Alternatortion
Lighting system Alternator

1-4
KETERANGAN UMUM
LUBRICATION SYSTEM
SPESIFIKASI SISTEM SPECIFICATIONS
PELUMASAN Satuan: mm
BAGIAN STANDARD BATAS SERVIS Unit: mm (in)
Kapasitas oli mesin Penggantian periodik 1,0 liter - SERVICE
ITEM STANDARD
1,2 liter LIMIT
Pembongkaran mesin -
Engine oil capacity At draining 1.0 liter (1.06 US qt, 0.88 lmp qt) –
Oli mesin yang dianjurkan Federal Oil Supreme Ultratec
At disassembly 1.2 liter (1.27 US qt, 1.06 lmp qt) - –
atau oli mesin 4 tak sejenis
Recommended engine oil Honda "4-stroke motorcycle oil" or an equiv-
dengan klasifikasi API service
alent
SE, SF atau SG
API classification: SE or higher (except oils
Viskositas:
labeled as20W-50
SAE energy conserving on the circular –
Rotor pompa oli Celah pada ujung rotor - label)
API service 0,20
Celah antara rotor dan 0,15 – 0,21
JASO T 903 standard: MA 0,26
rumah Viscosity: SAE 10W-30
Oil pump rotor Celah ke samping rotor
Tip clearance 0,05 – 0,10 – 0,15 0.20 (0.008)
pompa Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.26 (0.010)
Side clearance 0.05 – 0.10 (0.002 – 0.004) 0.15 (0.006)

SPESIFIKASI SISTEM BAHAN BAKAR


FUEL SYSTEM SPECIFICATIONS
BAGIAN SPESIFIKASI
Nomor identifikasi karburator AVK5AD
Main jet ITEM #SPECIFICATIONS
108
Carburetor
Slow jet identification number # 35 AVK5AD
Main jet
Pembukaan pilot screw #108
Lihat halaman 5-23
Slow
Float jet
level (tinggi pelampung) 13 mm #35
1.400 ± 100Refer
-1
Pilot screw
Putaran opening mesin
stasioner menitto page
(rpm)5-23
Float
VakuumlevelPAIR control valve yang ditentukan 60 kPa (450 13mmHg)
mm (0.5 in)
Engine
Jarak mainidle speed
bebas putaran gas tangan 21,400 ± 100 min-1 (rpm)
– 6 mm
PAIR control valve specified vacuum 60 kPa (450 mmHg)
Throttle grip freeplay 2 – 6 mm (0.1 – 0.2 in)
SPESIFIKASI SISTEM PENDINGINAN
BAGIAN SPESIFIKASI
COOLING
Kapasitas cairan SYSTEM
RadiatorSPECIFICATIONS
dan mesin 0,77 liter
pendinginan Tangki cadangan 0,13 liter
2
Tekanan pembebasan tutup ITEM
radiator 108 – 137 kPa (1,1 –SPECIFICATIONS
1,4 kgf/cm , 16 - 20 psi)
Thermostat
Coolant capacity Mulai membuka
Radiator and engine 0.77
69,5liter (0.81 C
– 72,5° US qt, 0.68 lmp qt)
Terbuka penuhtank
Reserve 0.13 liter
80°(0.14
C US qt, 0.11 lmp qt)
Radiator cap relief pressure Pengangkatan klep 108 –minimum
137 kPa (1.1 1.4 kgf/cm2, 16 – 20 psi)
3,5–mm
Cairan antibeku yang dianjurkan Begin to open
Thermostat Honda 69.5 – 72.5°COOLANT
PRE-MIX C (157.1 – 162.5°F)
Fully open 80°C (176°F)
Valve lift 3.5 mm (0.14 in) minimum
Recommended antifreeze Honda PRE-MIX COOLANT

1-5
KETERANGAN UMUM
CYLINDER HEAD/VALVES
SPESIFIKASI SPECIFICATIONS
CYLINDER HEAD/VALVES Satuan: mm
BAGIAN STANDARD BATAS SERVISUnit: mm (in)
SERVICE
ITEM -1 STANDARD 2
Kompresi cylinder pada 530 menit (rpm) 1.344 kPa (13,7 kgf/cm , 195 psi) - LIMIT
-1
Cylinder
Jarak compression
renggang klep at 530 min (rpm) kPa (13.7 kgf/cm2, 195 psi)
IN (masuk) 1,3440,06 - –
Valve clearance IN EX (buang)0.06 (0.002)
0,27 - –
Valve (klep), D.L. valve stem EX IN 0.27 (0.011)
4,975 – 4,990 4,863 –
Valve,guide (bos klep)
valve Valve(tangkai
stem O.D.klep) IN EX 4.9754,965
– 4.990 (0.1959 – 0.1965)
– 4,980 4,8534.863 (0.1915)
valve guide D.D. valve guide EX IN/EX 4.9655,000
– 4.980 (0.1955 – 0.1961)
– 5,012 5,04 4.853 (0.1911)
ValveKerenggangan
guide I.D. IN/EX IN
antara 5.0000,010
– 5.012 (0.1969 – 0.1973)
– 0,037 0,0655.04 (0.198)
Stem-to-guide
valve stem/ clear-
guide IN EX 0.0100,020
– 0.037 (0.0004 – 0.0015)
– 0,047 0,0750.065 (0.0026)
ance Ketinggian valve guide EX IN 0.02011,5
– 0.047 (0.0008 – 0.0019)
– 11,7 0.075
- (0.0030)
Valve guide height IN EX 11.5 –12,3
11.7–(0.4528
12,5 – 0.4606) - –
Lebar dudukan klep EX IN/EX 12.3 –1,0
12.5 (0.4843 – 0.4921) 1,6 –
Valve spring (pegas ValvePanjang
seat widthbebas IN/EX Dalam 1.0 (0.04)
33,50 31,0 1.6 (0.06)
Valve spring
klep) Free length Inner Luar 33.5035,70
(1.319) 34,0 31.0 (1.22)
Rocker arm (pelatuk)/ D.D. rocker arm Outer IN/EX 35.70 (1.406)
10,000 – 10,015 10,1034.0 (1.34)
Rockerarm
rocker arm,shaft Arm (lengan
I.D. pelatuk) IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.10 (0.398)
rocker arm
(poros shaft
pelatuk) ShaftD.L.
O.D.rocker arm shaftIN/EX IN/EX 9.9729,972
– 9.987 (0.3926 – 0.3932)
– 9,987 9,75 9.75 (0.384)
Arm-to-shaft clear-
(poros pelatuk) IN/EX 0.013 – 0.043 (0.0005 – 0.0017) 0.10 (0.004)
ance Kerenggangan antara IN/EX 0,013 – 0,043 0,10
Camshaft Cam armlobe ke
height
shaft IN 29.316 – 29.556 (1.1542 – 1.1636) 29.05 (1.144)
Camshaft Tinggi cam lobe EX IN 29.138 – 29.378
29,316 (1.1472 – 1.1566)
– 29,556 29,0528.85 (1.136)
Cylinder
(poros head warpage
bubungan) (bubungan) EX 29,138 – 29,378– 28,850.05 (0.002)
Perubahan melengkung pada cylinder head - 0,05

CYLINDER/PISTON SPECIFICATIONS
SPESIFIKASI CYLINDER/PISTON Satuan: mm
BAGIAN STANDARD BATAS SERVISUnit: mm (in)
Cylinder D.D. ITEM 58,000 – 58,010
STANDARD 58,05 SERVICE
Kelonjongan - 0,010 LIMIT
Cylinder I.D.
Ketirusan 58.000 – 58.010 (2.2835 - – 2.2839) 0,01058.05 (2.285)
Out-of-round
Perubahan melengkung –- 0,05 0.010 (0.0004)
Piston, D.L. Taper
piston pada jarak 6,5 dari bawah 57,970 – 57,990– 56,670.010 (0.0004)
piston pin, D.D. Warpage
lubang piston pin 13,002 – 13,008– 0.05 (0.002)
13,045
Piston,rings
piston D.L. Piston
pistonO.D.
pin at 6.5 (0.26) from bottom 57.970 – 57.990
12,994 (2.2823 – 2.2831)
– 13,000 12,7056.67 (2.231)
piston pin, piston
Kerengganganhole
Piston pin I.D. piston dan piston pin
antara 13.002 – 13.008
0,002 – 0,014(0.5119 – 0.5121) 0,08 13.045 (0.5136)
ring Piston pin O.D. 12.994 – 13.000 (0.5116 – 0.5118)
Celah pada ujung piston Atas 0,10 – 0,25 0,40 12.70 (0.500)
ring Piston-to-piston pin clearance
Kedua 0.0020,35
– 0.014 (0.0001
– 0,50 – 0.0006) 0,70 0.08 (0.003)
Piston ring end gap Top(side rail)
Oli 0.10 –0,20
0.25–(0.004
0,70 – 0.010) 1,10 0.40 (0.016)
Kerenggangan antara Second
Atas 0.35 –0,045
0.50 (0.014
– 0,075 – 0.020) 0,10 0.70 (0.028)
piston ring dan alurnya Oil (side rail)
Kedua 0.20 –0,015
0.70 (0.008
– 0,050 – 0.028) 0,09 1.10 (0.043)
Piston ring-to-ring
Kerenggangan antara cylinder dan piston Top 0.0450,010
– 0.075
– 0,040 – 0.0030)
(0.0018 0,09 0.10 (0.004)
groove clearance Second 0.01513,016
– 0.050–(0.0006
D.D. kepala kecil connecting rod 13,034– 0.0020) 13,060.09 (0.004)
Cylinder-to-piston
Kerenggangan clearance
antara connecting rod dan piston pin 0.0100,016
– 0.040 (0.0004 – 0.0016)
– 0,040 0,10 0.09 (0.004)
Connecting rod small end I.D. 13.016 – 13.034 (0.5124 – 0.5131) 13.06 (0.514)
Connecting rod-to-piston pin clearance 0.016 – 0.040 (0.0006 – 0.0016) 0.10 (0.004)
SPESIFIKASI KOPLING/KICKSTARTER/PERALATAN PEMINDAH GIGI
BAGIAN STANDARD BATAS SERVIS
CLUTCH/KICKSTARTER/GEARSHIFT
Jarak main bebas clutch lever (handel kopling) 10 –LINKAGE
20 SPECIFICATIONS
-
Clutch (kopling) Panjang bebas pegas 40,0 38,3 Unit: mm (in)
Ketebalan disc (cakram) 2,92 – 3,08 2,85 SERVICE
ITEM melengkung plate (pelat)
Perubahan STANDARD
- 0,20 LIMIT
D.D. clutch
Clutch lever outer
freeplay 1023,000 – 23,021
– 20 (0.4 – 0.8) 23,06 –
Clutch
Clutch outer guide D.L.
Spring free length 22,959
40.0 (1.57)– 22,980 22,9338.3 (1.51)
D.D.
Disc thickness 2.92 – 3.08– (0.116
16,991 17,009– 0.121) 17,042.85 (0.112)
D.L. mainshaft pada clutch outer
Plate guide
warpage 16,966 – 16,984 – 16,590.20 (0.008)
Kickstarter
Clutch outer I.D. D.L. spindle 13,966
23.000 – 13,984
– 23.021 (0.9055 – 0.9063) 13,9023.06 (0.908)
Clutch outer guide D.D.
O.D. pinion gear 14,016
22.959 – 14,034
– 22.980 (0.9039 – 0.9047) 14,0822.93 (0.903)
I.D 16.991 – 17.009 (0.6689 – 0.6696) 17.04 (0.671)

1-6
KETERANGAN UMUM
SERVICE
SPESIFIKASI ALTERNATOR/STARTER
ITEM CLUTCH
STANDARD Satuan: mm
LIMIT
Mainshaft O.D. at clutch outer guide BAGIAN STANDARD
16.966 – 16.984 (0.6680 – 0.6687) BATAS
16.59 SERVIS
(0.653)
Starter driven gear
Kickstarter Spindle O.D. D.D. 13.966 – 13.984 22,010
(0.5498 –– 0.5506)
22,031 22,08
13.90 (0.547)
Pinion gear I.D D.L. 14.016 – 14.034 45,660
(0.5518 –– 0.5525)
45,673 45,60
14.08 (0.554)

ALTERNATOR/STARTER CLUTCH SPECIFICATIONS


Unit: mm (in)
SPESIFIKASI CRANKSHAFT/BALANCER/TRANSMISSI Satuan:
SERVICE mm
ITEM BAGIAN STANDARD
STANDARD BATASLIMIT
SERVIS
Crankshaft
Starter driven gear Keolengan I.D. -
22.010 – 22.031 (0.8665 – 0.8674) 0,1222.08 (0.869)
Kerenggangan radial kepalaO.D. besar connecting rod– 45.673 0,06
45.660 – 0,014
(1.7976 – 1.7981) 0,0545.60 (1.795)
Kerenggangan ke samping kepala besar connecting - 0,6
rod
CRANKSHAFT/BALANCER/TRANSMISSION
Transmissi
SPECIFICATIONS
D.D. gear (roda gigi)
17,08
18,07
M4, M5
C1
17,016 – 17,034
18,000 – 18,021
C2 23,020 – 23,041 23,09 Unit: mm (in)
C3 20,020 – 20,041 20,10 SERVICE
ITEM STANDARD
D.D. bushing C1 15,000 – 15,018 15,10 LIMIT
Crankshaft Runout C2 20,020
– – 20,041 20,10
0.12(0.005)
D.L. bushing
Connecting rod big end radialC1
clearance 17,959
0.006 – 0.014 (0.0002 – 17,980
– 0.0006) 17,90
0.05 (0.002)
C2
Connecting rod big end side clearance 22,986
– – 23,005 22,47
0.6 (0.02)
Transmission Kerenggangan
Gear I.D. gear M4, C1M5 17.016 – 17.034 0,020
(0.6699– –0,062
0.6706) 0,1017.08 (0.672)
ke bushing C1C2 18.000 – 18.021 0,015
(0.7087– –0,055
0.7095) 0,1018.07 (0.711)
D.L. mainshaft C2M4 23.020 – 23.041 16,966
(0.9063 – 0.9071)
16,984 16,93
23.09 (0.909)
D.L. countershaft C3C1 20.020 – 20.041 14,966
(0.7882 – 0.7890)
14,984 14,90
20.10 (0.791)
Bushing I.D. C1C2 15.000 – 15.018 19,978
(0.5906 – 0.5913)
19,989 19,92
15.10 (0.594)
C2C3 20.020 – 20.041 19,978
(0.7882 – 0.7890)
19,989 19,92
20.10 (0.791)
Kerenggangan
Bushing O.D. gear C1M4 17.959 – 17.980 0,032
(0.7070– –0,068
0.7079) 0,1017.90 (0.705)
ke shaft C2C3 22.986 – 23.005 0,031
(0.9050– –0,063
0.9057) 0,1022.47 (0.885)
Kerenggangan
Gear-to-bushing C1C1 0,016––0.0024)
0.020 – 0.062 (0.0008 0,052 0,100.10 (0.004)
clearance
bushing ke shaft C2C2 0,031–0.0022)
0.015 – 0.055 (0.0006 – 0,063 0,100.10 (0.004)
Shift fork, D.L. shift
Mainshaft fork shaft
O.D. M4 16.966 – 16.984 9,986
(0.6680– –9,995
0.6687) 9,9316.93 (0.667)
shift fork shaft D.D. shift O.D.
Countershaft fork C1 14.966 – 14.984 10,000
(0.5892 – 0.5899)
10,018 10,03
14.90 (0.587)
Ketebalan cakar shift fork
C2 19.978 – 19.989 4,93 – 5,00
(0.7865 – 0.7870) 4,8219.92 (0.784)
Shift drum D.L. shift drum C3Sisi kanan 19.978 – 19.989 25,959
(0.7865 – 0.7870)
25,980 25,90
19.92 (0.784)
Gear-to-shaft clear- M4 Sisi kiri 24,959
0.032 – 0.068 (0.0013 – 24,980
– 0.0027) 24,90
0.10 (0.004)
ance
D.D. shift drum C3Sisi kanan 26,000
0.031 – 0.063 (0.0012 – 26,021
– 0.0025) 26,50
0.10 (0.004)
journal
Bushing-to-shaft C1Sisi kiri 25,000
0.016 – 0.052 (0.0006 – 25,033
– 0.0020) 25,50
0.10 (0.004)
clearance C2 0.031 – 0.063 (0.0012 – 0.0025) 0.10 (0.004)
Shift fork, shift Shift fork shaft O.D. 9.986 – 9.995 (0.3931 – 0.3935) 9.93 (0.391)
fork shaft Shift fork I.D. 10.000 – 10.018 (0.3937 – 0.3944) 10.03 (0.395)
Shift fork claw thickness 4.93 – 5.00 (0.194 – 0.197) 4.82 (0.190)
Shift drum Shift drum O.D. Right side 25.959 – 25.980 (1.0220 – 1.0228) 25.90 (1.020)
Left side 24.959 – 24.980 (0.9826 – 0.9835) 24.90 (0.980)
Shift drum journal Right side 26.000 – 26.021 (1.0236 – 1.0244) 26.50 (1.043)
I.D. Left side 25.000 – 25.033 (0.9843 – 0.9855) 25.50 (1.004)

1-7
KETERANGAN UMUM
FRONT WHEEL/SUSPENSION/STEERING
SPESIFIKASI SPECIFICATIONS
RODA DEPAN/SUSPENSI/KEMUDI Satuan: mm
BAGIAN STANDARD BATAS SERVIS Unit: mm (in)
Kedalaman minimum alur kembang - Sampai keSERVICE
ITEM STANDARD
indikator LIMIT
Minimum udara
Tekanan tire tread Pengendara
depth saja 200 kPa (2,00 – kgf/cm2, 29 To
- indicator
ban
Colddingin
tire pressure Driver only (2.00 kgf/cm2, 29 psi)
200 kPapsi) –
Pengendara dan
Driver andpembonceng
passenger 200 kPa200
(2.00kPa 2
(2,00
kgf/cm psi) 2, 29
kgf/cm
, 29 - –
Axle runout psi) – 0.2 (0.01)
Keolengan poros
Wheel rim runout Radial –- 0,2 2.0 (0.08)
Keolengan Radial Axial –- 2,0 2.0 (0.08)
pelek
Fork roda Aksial Spring free length 257.1 (10.12) - 2,0 252.0 (9.92)
Garpu PanjangPipe
bebas pegas
runout 257,1 – 252,0 0.20 (0.008)
Kebengkokan pipa
Recommended fork fluid ULTRA CUSHION OIL- 10W or equivalent0,20 –
Minyak garpu yang dianjurkan
Fluid level ULTRA CUSHION OIL 10W
85.5 (3.37) - –
Fluid capacity 53.5 ± 1.0 (1.81 ± 0.03 US oz, 1.88 ± 0.04
cm3sejenisnya
atau

Tinggi permukaan minyak lmp oz) 85,5 -
53,5 ± 1,0 cm
3
Kapasitas minyak -

REAR WHEEL/SUSPENSION SPECIFICATIONS


SPESIFIKASI RODA BELAKANG/SUSPENSI Satuan: Unit:
mm mm (in)
BAGIAN STANDARD BATAS SERVIS
SERVICE
Kedalaman minimum alur ITEM
kembang STANDARD
- Sampai ke LIMIT
Minimum tire tread depth – indikator
To indicator
2
Tekanan udara
Cold tire pressure Pengemudi saja
Driver only 225(2.25
225 kPa kPakgf/cm
(2,25 2kgf/cm
, 33 psi), 33 psi) - –
2
ban dingin Pengemudi
Driver anddan pembonceng
passenger 225(2.25
225 kPa kPakgf/cm
(2,25 kgf/cm
2
, 33 psi), 33 psi) - –
Keolengan
Axle runout poros –- 0,2 0.2 (0.01)
Keolengan pelek
Wheel rim runout Radial
Radial –- 2,0 2.0 (0.08)
roda Aksial
Axial –- 2,0 2.0 (0.08)
Rantai roda
Drive chain Ukuran/sambungan
Size/link 428/116
428/116 - –
Jarak lenturan
Slack 20(0.8
20 – 30 – 30– 1.2) - –

HYDRAULIC
SPESIFIKASIBRAKE SPECIFICATIONS
REM HIDRAULIK Satuan: mm
BAGIAN STANDARD BATAS SERVIS
Unit: mm (in)
Depan Minyak rem yang ditentukan DOT 3 atau DOT 4 -
SERVICE
ITEMkeausan brake pad
Indikator STANDARD
- Sampai ke alurLIMIT
Front Ketebalan brake
Specified brakedisc
fluid 3,8 – 4,2
DOT 3 or DOT 4 3,5 –
Perubahan melengkung
Brake pad wear indicatorbrake disc -– 0,10 To groove
D.D.Brake
master cylinder
disc thickness 12,700 – 12,743
3.8 – 4.2 (0.15 – 0.17) 12,755 3.5 (0.14)
D.L.Brake
master
discpiston
warpage 12,657 – 12,684 – 12,645 0.10 (0.004)
D.D.Master
caliper cylinder
cylinder I.D. 12.70025,400 – 25,450
– 12.743 (0.5000 – 0.5017) 25,460 12.755 (0.5022)
D.L.Master
caliperpiston
piston
O.D. 12.65725,318 – 25,368
– 12.684 (0.4983 – 0.4994) 25,310 12.645 (0.4978)
Belakang Minyak remcylinder
Caliper yang ditentukan
I.D. DOT 3 atau DOT –4 1.0020)
25.400 – 25.450 (1.0000 -25.460 (1.0024)
Indikator keausan brake pad
Caliper piston O.D. - – 0.9987)
25.318 – 25.368 (0.9968 Sampai ke alur (0.9965)
25.310
Rear Ketebalan brake
Specified brakedisc
fluid DOT 3,8
3 or –DOT
4,2 4 3,5 –
Perubahan melengkung
Brake pad wear indicatorbrake disc -– 0,10 To groove
D.D.Brake
master cylinder
disc thickness 12,700 – 12,743
3.8 – 4.2 (0.15 – 0.17) 12,755 3.5 (0.14)
D.L.Brake
master
discpiston
warpage 12,657 – 12,684 – 12,645 0.10 (0.004)
D.D.Master
caliper cylinder
cylinder I.D. 12.70032,030 – 32,080
– 12.743 (0.5000 – 0.5017) 32,090 12.755 (0.5022)
D.L.Master
caliperpiston
piston
O.D. 12.65731,948 – 31,998
– 12.684 (0.4983 – 0.4994) 31,940 12.645 (0.4978)
Caliper cylinder I.D. 32.030 – 32.080 (1.2610 – 1.2630) 32.090 (1.2634)
Caliper piston O.D. 31.948 – 31.998 (1.2578 – 1.2598) 31.940 (1.2575)

1-8
KETERANGAN UMUM
BATTERY/CHARGING SYSTEM SPECIFICATIONS
SPESIFIKASI BATERAI/SISTEM PENGISIAN
BAGIAN SPESIFIKASI
ITEM SPECIFICATIONS
Baterai Kapasitas 12 V – 3,5 Ah
Battery Capacity 12 V - 3.5 Ah
Kebocoran arus listrik maksimum 0,1 mA
Currento leakage
o 0.1 mA max.
Voltase (20 C/68 F) Bermuatan penuh 13,0 – 13,2 V
Voltage Fully charged 13.0 – 13.2 V
(20°C/68°F) Perlu diisi kembali Di bawah 12,4 V
Needs charging Below 12.4 V
Arus pengisian Normal 0,4 A x 5 – 10 jam
Charging current Normal 0.4 A x 5 – 10 h
Cepat 3 A x 30 menit
Quick 3 A x 30
-1 min.
Alternator Kapasitas 106 kW/5.000 menit (rpm)
Alternator Capacity o o 106 kW/5,000 min-1 (rpm)
0.2Ω– 1.2 Ω
Tahanan kumparan pengisian (20 C/68 F) 0,2 – 1,2
Charging coil resistance (20°C/68°oF) o
Tahanan kumparan
Lighting penerangan
coil resistance (20°F)
(20°C/68 C/68 F) 0.05Ω– 1.0-1 Ω
0,05 – 1,0
Voltase yang diatur regulator/rectifier (output penerangan)
Regulator/rectifier regulated voltage (Lighting output) 12,6 – 13,6 V/5.000 menit min
12.6 – 13.6 V/5,000 (rpm)
-1
(rpm)

SPESIFIKASI
IGNITION SISTEM
SYSTEM PENGAPIAN
SPECIFICATIONS
BAGIAN SPESIFIKASI
Busi ITEM
Standard CR8E (NGK) atau U24ESR-NSPECIFICATION
(DENSO)
Spark plug Pilihan Standard CR9E (NGK) atau U27ESR-N
CR8E (NGK) or(DENSO)
U24ESR-N (DENSO)
Jarak renggang kutub busi Optional 0,70CR9E
– 0,80(NGK)
mm or U27ESR-N (DENSO)
Voltase puncak
Spark plug gap ignition coil (coil pengapian) minimum
0.70100 V mm (0.028 – 0.032 in)
– 0.80
Voltase puncak
Ignition coil peakignition
voltage pulse generator minimum 0,7 V100 V minimum
(pembangkit
Ignition pulse pulsa pengapian)
generator peak voltage 0.7 V minimum
Waktu
Ignitionpengapian
timing ("F"(tanda
mark) "F) 12° BTCD (sebelum TMA) pada 12 ° BTDCstasioner
putaran at idle

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

SPESIFIKASI LAMPU/METER/SAKLAR
LIGHTS/METERS/SWITCHES
BAGIAN SPECIFICATIONS
SPESIFIKASI
Bola lampu Lampu besar 12 V – 18/18 W x 2
Lampu rem/belakang 12 V – 18/5 W
ITEM SPECIFICATION
Lampu sein 12 V – 10 W x 4
Bulbs Headlight 12 V - 18/18 W x 2
Lampu senja 12 v – 3,4 W x 2
Brake/tail light 12 V - 18/5 W
Lampu instrumen LED
Turn signal light 12 V - 10 W x 4
Indikator sinar jauh LED
Position light 12 V - 3.4 W x 2
Indikator lampu sein LED
Instrument light LED
Indikator neutral LED
High beam indicator LED
Indikator posisi gigi transmissi LED
Turn signal indicator LED
Sekering Utama 15 A
Neutral indicator LED
Tambahan 10 A
Gear position indicator LED
Tahanan sensor thermo 50° C (122° F) 133,9 – 178,9 Ω
Fuse Main fuse 15 A
120° Sub fuse° F)
C (248 14,9 – 17,3 Ω 10 A
Thermo sensor resistance 50°C (122°F) 133.9 – 178.9 Ω
120°C (248°F) 14.9 – 17.3 Ω

1-9
KETERANGAN UMUM
STANDARD
NILAI TORSITORQUE VALUES
STANDARD
TORSI TORQUE TORSI TORQUE
JENISFASTENER TYPE
PENGENCANG N.m (kgf.m, JENIS PENGENCANG FASTENER TYPE N.m (kgf.m,
N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)
lbf.ft) lbf.ft)
5 mm bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1)
baut dan mur 5 mm 5,2 (0,5; 3,8) sekrup 5 mm 4,2 (0,4; 3,1)
6 mm bolt and nut 6 mm screw 9.0 (0.9, 6.6)
baut danSH
(Include mur 6 mm
flange bolt) sekrup 6 mm 9,0 (0,9; 6,6)
10 (1.0, 7) 6 mm flange bolt
(termasuk SH flange bolt) 10 (1,0; 7) flange bolt 6 mm (kepala 8 mm,
8 mm bolt and nut 22 (2.2, 16) (8 mm head, small flange) and nut 12 (1.2, 9)
baut dan mur 8 mm 22 (2,2; 16) flange kecil) dan mur 12 (1,2; 9)
10 mm
baut boltmur
dan and10nutmm 34 (3,5; 25)34 (3.5, 25) 8 mmdan
flange bolt 8 mm flange
murbolt and nut 27 (2,8; 20) 27 (2.8, 20)
12 mm bolt and nut
baut dan mur 12 mm 55 (5,6; 41)55 (5.6,flange
41) bolt 1010mmmmdan
flange
murbolt and nut 39 (4,0; 29) 39 (4.0, 29)

ENGINE & FRAME TORQUE VALUES


•NILAI TORSIlisted
Torque specifications MESIN
below are for& RANGKA
specified fasteners.
•• Others should be
Spesifikasi tightened
torsi to standard
yang tertera torque adalah
di bawah values listed
untukabove.
pengencang tertentu.
• Yang lain harus dikencangkan dengan nilai torsi standard yang tertera di atas.
FRAME/BODY PANELS/EXHAUST SYSTEM
RANGKA/BODY PANELS/SISTEM PEMBUANGAN GAS
BAGIANITEM JUMLAH DIA. ULIRTHREAD TORSI TORQUECATATAN
Q'T
REMARKS
Y(mm) DIA. N.m
(mm)(kgf.m;N·m (kgf·m, lbf·ft)
lbf.ft)
Exhaust
Exhaustpipe
pipecover
coverbolt
bolt 2 2 6 6 13 (1,3; 10)13 (1.3, 10)
Muffler
Muffler joint
joint bolt
bolt 3 3 6 6 13 (1,3; 10)13 (1.3, 10)

MAINTENANCE
PERAWATAN
Q'T THREAD TORQUE
BAGIANITEM JUMLAH DIA. ULIR TORSI CATATAN REMARKS
Y DIA. (mm) N·m (kgf·m, lbf·ft)
(mm) N.m (kgf.m; lbf.ft)
Spark plug 1 10 16 (1.6, 12)
Busi 1 10 16 (1,6; 12)
Air cleaner housing
Air cleaner housingcover
coverscrew
screw 5 5 5 5 1,0 (0,1; 0,7)1.0 (0.1, 0.7)
Valve
Valve adjusting
adjustinglock
locknut
nut 2 2 5 5 10 (1,0; 7) 10 (1.0,Oleskan
7) oli Apply engine oil to the
threads and seating sur-
mesin pada ulir
face.
dan permuka-
Crankshaft hole cap 1 30 8.0 (0.8, an
5.9)duduk.
Timing hole cap
Crankshaft hole cap 1 1 30 14 8,0 (0,8; 5,9)6.0 (0.6, 4.4)
Oil drain bolt cap
Timing hole 1 1 14 12 6,0 (0,6; 4,4)25 (2.5, 18)
Oil drain bolt SYSTEM
LUBRICATION 1 12 25 (2,5; 18)

Q'T THREAD TORQUE


SISTEM PELUMASAN
ITEM REMARKS
Y DIA. (mm) N·m (kgf·m, lbf·ft)
BAGIAN JUMLAH DIA. ULIR TORSI CATATAN
Oil pump cover bolt 2 5 5.0 (0.5, 3.7)
(mm) N.m (kgf.m; lbf.ft)
Oil pump
FUEL cover bolt
SYSTEM 2 5 5,0 (0,5; 3,7)
Q'T THREAD TORQUE
ITEM
SISTEM BAHAN BAKAR REMARKS
Y DIA. (mm) N·m (kgf·m, lbf·ft)
SE valve lockBAGIAN
nut JUMLAH DIA.
1 ULIR – TORSI 9.8 (1.0, 7.2) CATATAN
Carburetor drain screw 1(mm) –N.m (kgf.m; lbf.ft)
1.5 (0.2, 1.1)
SE valve
Throttle lockholder
cable nut screw 1 2 - 5 9,8 (1,0; 7,2)
3.4 (0.3, 2.5)
Carburetor drain
Vacuum piston hose screw
joint plate screw 1 1 - 4 1,5 (0,2; 1,1)
2.1 (0.2, 1.5)
Throttle cable holder screw 2 5 3,4 (0,3; 2,5)
Vacuum chamber cover screw 2 4 2.1 (0.2, 1.5)
Vacuum piston hose joint plate
Float chamber screw 3 4 2.1 (0.2, 1.5)
screw 1 4 2,1 (0,2; 1,5)
Air cut-off valve cover screw 2 4 2.1 (0.2, 1.5)
Vacuum chamber cover screw 2 4 2,1 (0,2; 1,5)
Main
Float jet
chamber screw 3 1 4 – 2,1 (0,2; 1,5)
2.1 (0.2, 1.5)
Slow jet valve cover screw
Air cut-off 2 1 4 – 2,1 (0,2; 1,5)
1.5 (0.2, 1.1)
SE
Mainvalve
jet body mounting screw 1 2 - 5 2,1 (0,2; 1,5)
3.4 (0.3, 2.5)
PAIR check valve cover bolt
Slow jet 1 2 - 5 1,5 (0,2; 1,1)
5.0 (0.5, 3.7)
Fuel
SE valvevalve
auto bodymounting
mountingnut sscrew 2 1 5 16 3,4 (0,3; 2,5)27 (2.8, 20)
PAIR check valve cover bolt 2 5 5,0 (0,5; 3,7)
Fuel auto valve mounting nut 1 16 27 (2,8; 20)

1-10
KETERANGAN UMUM
COOLING
SISTEMSYSTEM
PENDINGINAN
BAGIAN JUMLAH THREAD
Q'T DIA. ULIR TORSITORQUE CATATAN
ITEM REMARKS
Y DIA. (mm)N.m (kgf.m;
(mm) N·m (kgf·m,
lbf.ft) lbf·ft)
Coolingfan
Cooling fanassembly
assembly mounting
mounting boltbolt 2 2 6 6 8.46,2)
8,4 (0,9; (0.9, 6.2)
Coolingfan
Cooling fanmotor
motorshroud
shroud mounting
mounting screw
screw 3 3 4 4 2,8 (0,3;
2.82,1)
(0.3, 2.1)
Coolingfan
Cooling fanmounting
mountingnut
nut 1 1 3 3 1,0 (0,1; (0.1, 0.7) OleskanApply
1.00,7) cairanlocking
pengunci
agent to
pada ulir.the threads.
Waterpump
Water pumpimpeller
impeller 1 1 7 7 10 (1,0;107)(1.0, 7)

ENGINE REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN MESIN
BAGIAN JUMLAH THREAD
Q'T DIA. ULIR TORSI TORQUE CATATAN
ITEM REMARKS
Y DIA.
(mm) (mm)
N.m (kgf.m;(kgf·m,
N·m lbf.ft) lbf·ft)
Engine
Enginehanger
hangernutnut (atas) (upper) 1 1 10 10 59 (6,0;5944)
(6.0, 44)
(bawah)(lower) 1 1 10 10 59 (6,0;5944)
(6.0, 44)
(depan)(front) 1 1 10 10 59 (6,0;5944)
(6.0, 44)
Drive
Drive sprocket
sprocketfixing
fixingplate
platebolt
bolt 2 2 6 6 10 (1,0;107)(1.0, 7)
CYLINDER HEAD/VALVES
CYLINDER HEAD/VALVES THREAD TORQUE
Q'T
ITEM
BAGIAN JUMLAHY DIA. ULIR TORSI REMARKS
CATATAN
DIA. (mm) N·m (kgf·m, lbf·ft)
(mm) N.m (kgf.m; lbf.ft)
Cylinder head cover bolt 2 6 10 (1.0, 7)
Cylinder head cover bolt 2 6 10 (1,0; 7)
Camshaft holder mounting nut 4 8 29 (3.0, 21) Apply engine oil to the
Camshaft holder mounting nut 4 8 29 (3,0; 21) Oleskan oli mesin pada
threads and seating sur-
ulir dan permukaan
face. duduk
Cam sprocket mounting bolt 2 5 9,0 (0,9; 6,6)
Cam sprocket mounting bolt 2 5 9.0 (0.9, 6.6)
Rocker arm shaft stopper bolt 2 5 9,0 (0,9; 6,6)
Rocker arm shaft stopper bolt 2 5 9.0 (0.9, 6.6)
Cam chain tensioner lifter plug 1 6 4,0 (0,4; 3,0)
Cam chain tensioner lifter plug 1 6 4.0 (0.4, 3.0)
CYLINDER/PISTON
CYLINDER/PISTON
BAGIAN JUMLAH THREAD
Q'T DIA. ULIR TORSITORQUE CATATAN
ITEM REMARKS
Y (mm)
DIA. (mm)N.m (kgf.m; lbf.ft) lbf·ft)
N·m (kgf·m,
Cylinderstud
Cylinder studbolt
bolt 4 4 8 8 - – Lihat halaman 9-10
See page 9-10

CLUTCH/KICKSTARTER/GEARSHIFT LINKAGE
KOPLING/KICKSTARTER/PERALATAN PEMINDAH GIGI
BAGIAN JUMLAH THREAD
Q'T DIA. ULIR TORSI TORQUE CATATAN
ITEM REMARKS
Y DIA. (mm)N.m (kgf.m;
(mm) N·m (kgf·m,
lbf.ft) lbf·ft)
Clutch
Clutchcenter
centerlock
locknut
nut 1 1 14 14 74 (7,5;7455)
(7.5, 55) OleskanApply engine
oli mesin oil to the
pada
ulir dan permukaan duduk sur-
threads and seating
face.
Clutch
Clutchlifter
lifterplate
platebolt
bolt 4 4 6 6 12
12 (1,2; 9)(1.2, 9) Oleskan oli mesin pada
Primary
Primary drivegear
drive gearlock nutnut
lock 1 1 14 14 64 (6,5;6447)
(6.5, 47) ulir dan permukaan
Apply engineduduk
oil to the
Oleskanthreads
cairan and seating sur-
pengunci:
Shift drum stopper arm bolt 1 6 12 (1,2; 9) face. 10-23
Lihat halaman
Shift drum stopper arm bolt 1 6 12 (1.2, 9) Apply locking agent:
Shift drum stopper plate bolt 1 6 12 (1,2; 9) See page 10-23
Shift drum return
Gearshift stopperspring
plate bolt
pin 1 1 8 6 25 (2,5;12 (1.2, 9)
18)
Gearshift return spring pin 1 8 25 (2.5, 18)
ALTERNATOR/STARTER
ALTERNATOR/STARTER CLUTCH
CLUTCH
BAGIAN JUMLAH DIA. ULIRTHREAD TORSI TORQUE
Q'T CATATAN
ITEM REMARKS
Y (mm) DIA. N.m
(mm)(kgf.m;N·m
lbf.ft)
(kgf·m, lbf·ft)
Starterclutch
Starter clutchsocket
socket bolt
bolt 6 6 6 6 16 (1,6; 12) Oleskan
16 (1.6, 12) cairan
Apply locking Lihat
pengunci: agent:
halaman 11-11 See page 11-11
Flywheelnut
Flywheel 1 1 12 12 64 (6,5; 12)64 (6.5, Oleskan
47) oli mesin
Applypada
engineulir
oil to the
dan permukaan duduk.
threads and seating sur-
Stator mounting socket bolt 3 6 10 (1,0; 7) face.
Ignition
Stator pulse generator
mounting socket boltmounting bolt 2 3 6 6 10 (1,0; 7) 10 (1.0,Oleskan
7) cairan pengunci: Lihat
Ignition pulse generator mounting bolt 2 6 10 (1.0,halaman
7) 11-6Apply locking agent:
See page 11-6

1-11
KETERANGAN UMUM
FRONT
RODAWHEEL/SUSPENSION/STEERING
DEPAN/SUSPENSI/KEMUDI
BAGIAN JUMLAH DIA.
Q'T ULIR THREAD TORSI TORQUE CATATAN
ITEM REMARKS
Y(mm) DIA. N.m
(mm)(kgf.m;N·m
lbf.ft)
(kgf·m, lbf·ft)
Front axlenut
Front axle nut 1 1 12 12 59 (6,0; 44) U-nut
59 (6.0, 44) U-nut
Front brake discbolt
Front brake disc bolt 4 4 8 8 42 (4,3; 31) 42 (4.3,ALOC
31) bolt; ganti
ALOC dengan yang baru
bolt; replace
Fork socket bolt 2 8 20 (2,0; 15) Oleskan cairan pengunci
with new ones. pada ulir
Steering stem
Fork socket boltnut 1 2 26 8 - 20 (2.0,Lihat
15) hal.13-25 Apply locking agent to
Steering stem top thread 1 26 - Lihat hal.13-25the threads.
Bottom
Steering bridge
stem nutpinch bolt 4 1 10 26 64 (6,5; 47) – See page 13-25
Handlebar
Steering stem top threadnut
mounting 1 1 10 26 59 (6,0; 44) – U-nut See page 13-25
Grip end screw 2 6 9,0 (0,9; 6,6)
Bottom bridge pinch bolt 4 10 64 (6.5, 47)
Clutch lever pivot bolt 1 6 2,0 (0,2; 1,5)
Handlebar mounting nut 1 10 59 (6.0, 44) U-nut
Clutch lever pivot nut 1 6 9,8 (1,0; 7,2) Tahan pivot bolt ketika
Grip end screw 2 6 9.0 (0.9, 6.6)
mengencang-kan nut.
Clutch lever pivot bolt 1 6 2.0 (0.2, 1.5)
Clutch lever pivot nut 1 6 9.8 (1.0, 7.2) Hold the pivot bolt
RODA BELAKANG/SUSPENSI when tightening the nut.
BAGIAN JUMLAH DIA. ULIR TORSI CATATAN
REAR WHEEL/SUSPENSION (mm) N.m (kgf.m; lbf.ft)
Rear Axle nut 1 Q'T12 THREAD59 (6,0; 44) TORQUE U-nut
Driven sprocket nut ITEM 4 Y 10 64 (6,5; N·m
DIA. (mm) 47) (kgf·m, U-nut
lbf·ft)
REMARKS
Rear brake
Rear axle nutdisc bolt 4 1 8 12 42 (4,3; 31) ALOC
59 (6.0, 44) bolt; ganti
U-nutdengan yang baru
Driven sprocket nut 4 10 64 (6.5, 47) U-nut
Rear brake disc bolt 4 8 42 (4.3, 31) ALOC bolt; replace
Shock absorber upper mounting 1 10 39 (4,0; 29) U-nut with new ones.
bolt
Shock absorber upper mounting bolt 1 10 39 (4.0, 29)
Shock absorber lower mounting 1 10 44 (4,5; 32)
Shock absorber lower mounting nut 1 10 44 (4.5, 32) U-nut
nut
Swingarm pivot nut 1 12 12 54 (5,5; 40) 54 (5.5, 40)
Swingarm pivot nut 1
Drive chain
Drive chainslider
sliderscrew
screw 2 2 6 6 6,0 (0,6; 4,4)6.0 (0.6, 4.4)
Driven sprocket
Driven sprocketstud
studbolt
bolt 4 4 10 10 28 (2,9; 21) 28 (2.9,Oleskan
21) Apply
cairan lockingpada
pengunci agentulir.
to
the threads.
Footpeg holder mounting bolt 2 6 9.8 (1.0, 7.2)
Footpeg holder mounting bolt 2 6 9,8 (1,0; 7,2)
HYDRAULIC BRAKE
Q'T THREAD TORQUE
REM HIDRAULIK ITEM Y DIA. (mm) N·m (kgf·m, lbf·ft)
REMARKS
Brake hose oilBAGIAN
bolt JUMLAH DIA.
4 ULIR 10 TORSI 34 (3.5, 25) CATATAN
(mm) N.m (kgf.m; lbf.ft)
Front master cylinder reservoir cover screw 2 4 1.5 (0.2, 1.1)
Brake hose oil bolt 4 10 34 (3,5; 25)
Rear master cylinder reservoir cover screw 2 4 1.5 (0.2, 1.1)
Front master cylinder reservoir
Front brake light switch screw 1 4 1.2 (0.1, 0.9)
cover screw 2 4 1,5 (0,2; 1,1)
Brake lever pivot
Rear master bolt reservoir
cylinder 1 6 1.0 (0.1, 0.7)
Brake lever
cover screwpivot nut 2 1 4 6 1,5 (0,2; 1,1)5.9 (0.6, 4.4)
Front brake
Front brakecaliper mounting
light switch bolt
screw 1 2 4 8 1,2 (0,1; 0,9)30 (3.1, 22) ALOC bolt; replace
Brake lever pivot bolt 1 6 1,0 (0,1; 0,7) with new ones.
Front brake
Brake leverpad pinnut
pivot plug 1 2 6 10 5,9 (0,6; 4,4)2.5 (0.3, 1.8)
Front brake
Front brakepad hanger
caliper pin
mounting bolt 2 2 8 10 30 (3,1; 22) 17 (1.7,ALOC
13) bolt, ganti dengan yang
Rear brake pad hanger pin 1 10 17 (1.7,baru.
13)
Brake brake
Front caliperpad
bleedpin
valve
plug 2 2 10 8 2,5 (0,3; 1,8)5.4 (0.6, 4.0)
Front brakecylinder
Rear master pad hangerpush pin
rod lock nut 2 1 10 8 17 (1,7; 13) 17 (1.7, 13)
Rear brake cylinder
Rear master pad hanger hose pin
joint screw 1 1 10 4 17 (1,7; 13)1.5 (0.2, 1.1) Apply locking agent to
Brake caliper bleed valve 2 8 5,4 (0,6; 4,0) the threads.
Rear
Brake master cylinder
caliper pin bolt push rod 2 8 17 (1.7, 13)
lock
Brakenut
caliper torque nut 1 2 8 8 17 (1,7; 13) 22 (2.2, 16) Apply locking agent to
Rear master cylinder hose joint the threads.
screw 1 4 1,5 (0,2; 1,1) Oleskan cairan pengunci pada ulir.
LIGHTS/METERS/SWITCHES
Brake caliper pin bolt 2 8 17 (1,7; 13)
Brake caliper torque nut 2 Q'T 8 THREAD 22 (2,2; 16) TORQUE Oleskan cairan pengunci pada ulir.
ITEM REMARKS
Y DIA. (mm) N·m (kgf·m, lbf·ft)
LAMPU/METER/SAKLAR
Thermo sensor 1 – 8.8 (0.9, 6.5) Apply liquid sealant to
BAGIAN JUMLAH DIA. ULIR TORSI the threads.
CATATAN
Gear position switch rotor socket bolt 1(mm) 6N.m (kgf.m; lbf.ft)
10 (1.0, 7)
Thermo sensor 1 - 8,8 (0,9; 6.5) Oleskan cairan pengunci pada ulir.
OTHERS
Gear position switch rotor socket
bolt 1 6 10 (1,0; 7)

1-12
KETERANGAN UMUM
LAIN-LAIN Q'T THREAD TORQUE
ITEM REMARKS
BAGIAN JUMLAH Y ULIRDIA. (mm) TORSI
DIA. N·m (kgf·m, lbf·ft) CATATAN
Sidestand pivot bolt 1 (mm) 10N.m (kgf.m; lbf.ft)
18 (1.8, 13)
Sidestandpivot
Sidestand pivot
nutbolt 1 1 10 10 18 (1,8; 13)44 (4.5, 32) Hold the pivot bolt
Sidestand pivot nut 1 10 44 (4,5; 32) Tahan pivot bolt
whenketika
tightening the nut.
Pillion step holder mounting socket bolt 4 8 26.5 (2.7,mengencangkan
20) nut.
Pillion box
Utility stepscrew
holder mounting 4 4 0.7 (0.1, 0.5)
socket bolt 4 8 26,5 (2,7; 20)
Utility box screw 4 4 0,7 (0,1; 0,5)

1-13
KETERANGAN UMUM
LUBRICATION & SEAL
TITIK2 PELUMASAN POINTS
& PERAPATAN
ENGINE
MESIN
MATERIAL BAHAN LOCATION LOKASI REMARKS CATATAN
Liquid sealant (Three bond Right crankcase mating surface
Liquid sealant (Three bond 1215 atau Permukaan penyatuan right crankcase (bak mesin kanan) See page 12-24 Lihat hal. 12-24
1215 or equivalent)
sejenisnya) Alternator/ignition
Permukaan pulse generatoralternator/ignition
perapatan wire grommet sealing sur-generator wire
pulse
face grommet
Engine
Oli oil
mesin Oil pumpSeluruh
rotor entire surface oil pump rotor
permukaan
Water pump shaft outer
Permukaan luarsurface
water pump shaft
Starter clutch rolling surface
Permukaan gelinding starter clutch
Starter reduction
Permukaan gear journal
shaft journal surface
starter reduction gear shaft
Right crankshaft
Permukaan outerluar
surface
right crankcase
Left crankshaft
Permukaan starterluncur
driven left
gearcrankcase
sliding surface
starter driven gear
CamshaftSeluruh
plungerpermukaan
entire surfacecamshaft plunger
Permukaan
Decompressor cam innerdalam decompressor cam
surface
Cam chain Seluruh permukaan cam chain
entire surface
CylinderPermukaan
inner surfacedalam cylinder
Permukaan
Piston outer surface and luar piston
piston ringdan seluruh
entire surfacepermukaan piston ring
Seluruh
Clutch disc entire permukaan
surface clutch disc
Each oil Masing2
seal lip bibir oil seal
Masing2
Each bearing rotating bidang
area rotasi bantalan
Masing2
Each gear teeth gigi roda gigi
Masing2 O-ring
Each O-ring
Multi-purpose grease
Multi-purpose grease Each oil Masing2 bibir oil
seal lip (clutch seal
lifter arm,(clutch lifterspindle)
gearshift arm, gearshift spindle)
Molybdenum oil solution
Molybdenum oil solution (a (sebuah Permukaan luncur
Valve stem sliding surface and stem endvalve stem dan ujung stem
campuran dariengine
mixture of 1/2 ½ oli oil
mesin
and dan ½Piston pinPermukaan luar piston pin
outer surface
gemuk molybdenum
1/2 molybdenum disulfide)
disulfide Permukaan luar clutch outer guide
Clutch outer guide outer surface
grease) Permukaan luncur clutch lifter arm dan ujung arm
Clutch lifter arm sliding surface and arm end
Permukaan journal kiri shift drum
Shift drum left journaljournal
Permukaan surfacekanan gearshift spindle
GearshiftPermukaan
spindle rightdalamjournalbalancer
surface driven gear
BalancerBubungan
driven gearcamshaft
inner surface
CamshaftPermukaan
lobes luar rocker arm shaft
Rocker arm shaft outerdalam
Permukaan surfacelubang clutch lifter arm (right crankcase cover)
Clutch lifter arm hole dalam
Permukaan inner surface (right pinion
kickstarter crankcase cover)
Kickstarter pinion inner
Permukaan luarsurface
shift fork shaft
Shift forkPermukaan
shaft outer surface
berputar roda gigi M4, M5, C1, C2, C3
M4, M5,Seluruh
C1, C2, C3 permukaan
gear rotating bushing
surfaceroda gigi C1, C2
Alur-alur
C1, C2 gear bushing shift forksurface
entire roda gigi M3, C4, C5
Cairan pengunci M3, C4, Ulir rightshift
C5 gear crankcase cover plate bolt
fork grooves Lihat hal. 10-8
Locking agent Ulir mainshaft
Right crankcase cover plate bearing setting plate bolt
bolt threads See page 10-8 Lihat hal. 12-22
Bersihkan dari gemuk Mainshaft Bidang
bearingtirus left plate
setting crankshaft
bolt threads See page 12-22
Degrease Bidangtapered
Left crankshaft tirus flywheel
area
Flywheel tapered area

1-14
KETERANGAN UMUM
FRAME
RANGKA
BAHAN LOKASI CATATAN
MATERIAL LOCATION REMARKS
Urea based multi-purpose grease Permukaan gelinding inner race dan outer race Minimum 3 g
Urea based
dengan sifat multi-purpose
tahan tekanan tinggi Inner race
Bibirand outer race
steering head rolling surface
bearing dust seal 3 g minimum on eachmasing2
pada race
grease with extreme pressure
(ump: Shell ALVANIA EP2 atau Steering head bearing dust seal lips 3 g minimum race
agent (example: Shell ALVA-
EXCELITE
NIA EP2 orEP2 buatan KYODO
EXCELITE EP2
YUSHI, Japan, atau
manufactured by KYODO sejenisnya)
Multi-purpose
YUSHI, japan,grease
or equivalent) Permukaan axle shaft
Multi-purpose grease Permukaan
Axle shaft surface luncur swingarm pivot bolt
Swingarm pivotbibir
Bidang boltdan permukaan
sliding surface dalam speed sensor
Bidang luncur seat lock
Speed sensor lip area and inner surface
Bidang luncur gearshift tie rod
Seat lock sliding area
Bidang luncur sidestand pivot bolt
Gearshift tie rod sliding area
Bidang luncur centerstand pivot
Sidestand pivot bolt sliding area
Bidang luncur gearshift pedal pivot
Centerstand
Ujungpivot
dan sliding
bidangarea luncur throttle cable 0,1 – 0,2 g
Gearshift pedalluncur
Bidang pivot sliding
clutcharea
lever pivot bolt
Throttle cable end
Bidang and brake
luncur slidingpedal
area pivot 0.1 – 0.2 g
ClutchBidang
lever pivot boltkickstarter
luncur sliding areapedal pivot dan bola baja
Brake Bibir
pedal masing2
pivot sliding
dust area
seal
Kickstarter
Masing2pedalO-ring
pivot sliding area and steel ball
Silicone grease Each dust seal lip
Bagian dalam throttle cable boot
Each O-ring
Permukaan luncur brake caliper pin bolt Minimum 0,4 g
Silicone grease Throttle cable boot inside
Permukaan luncur brake lever pivot bolt 0,1 g
Brake O-ring rearbolt
caliper pin brake padsurface
sliding hanger pin 0.4 g minimum
Brake Bidang
lever pivotkontak brake surface
bolt sliding lever (master piston) 0.1 g 0,1 g
Bidang
Rear brake padkontak
hanger rear master cylinder push rod (master cylinder
pin O-ring
Brake piston dan alur area
lever contacting boot)(master piston) 0.1 g Masing2 0,1 g
Minyak rem DOT 3 atau DOT 4 Bidang
Rear master luncurpush
cylinder brakerodmaster piston
contacting area (master cylinder 0.1 g each
piston Bidang
and bootluncur
groove)brake caliper piston dan piston seal
Molybdenum
DOT 3 or DOT oil 4solution (sebuah Brake Bagian
brake fluid dalamsliding
master piston clutcharea
cable boot
campuran dari ½ oli mesin dan ½ Brake Bagian dalamsliding
caliper piston SE valve cable
area and bootseal
piston
molybdenum
Molybdenumdisulfide grease)
oil solution (a Clutch cable boot inside
Minyak
mixturegarpu
of 1/2suspensi
engine oil and O-ring
SE valve cablefork
bootcap
inside
1/2 molybdenum disulfide Bibir2 fork oil seal/dust seal
grease)Bond A atau sejenisnya
Honda Permukaan luar left handlebar dan throttle pipe (bidang kontak grip
Fork fluid rubber)
Fork cap O-ring
Permukaan
Fork oil seal/dust sealpenyatuan
lips air cleaner connecting hose
Honda Bond A or equivalent Left handlebar and throttle pipe outer surface (grip rubber con-
tacting area)
Air cleaner connecting hose mating surface

1-15
KETERANGAN UMUM
PERLETAKAN KABEL & HARNESS
KAWAT SAKLAR KAWAT TOMBOL STARTER KAWAT SAKLAR
LAMPU LAMPU DIMMER KAWAT SAKLAR
LAMPU SEIN
KAWAT TOMBOL
KAWAT SAKLAR
KLAKSON
DEPAN LAMPU REM

KAWAT SAKLAR KABEL


KANAN KOPLING

KABEL GAS KAWAT SAKLAR


KIRI STANG STIR

KAWAT SAKLAR
KAWAT SAKLAR KOPLING
DEPAN LAMPU REM
KABEL SE VALVE
WIRE HARNESS UTAMA
SUB HARNESS
COMBINATION METER
CONNECTOR 3P
LAMPU BESAR
CONNESCTOR 3P
CONNECTOR 3P (HITAM) (HITAM) LAMPU
LAMPU SEIN/SENJA SEIN/SENJA KIRI
KANAN DEPAN
SLANG REM DEPAN

CONNECTOR 3P
SPEES SENSOR

CONNECTORS:
KAWAT KUNCI KONTAK · COMBINATION METER 9P (MERAH)
· COMBINATION METER 9P
· COMBINATION METER 6P (HITAM)

KAWAT KAWAT SPEED SENSOR


KLAKSON
CONNECTOR 20P
COMBINATION METER SLANG REM DEPAN
KABEL KOPLING KABEL GAS
KAWAT SAKLAR KIRI STANG STIR

KAWAT SAKLAR
KABEL SE VALVE KANAN STANG STIR

1-16
KETERANGAN UMUM

SUB HARNESS
KABEL KOPLING
KABEL GAS COMBINATION METER

SLANG REM DEPAN

3P CONNECTOR
SPEED SENSOR

RELAY
LAMPU SEIN

CONNECTORS:
· COMBINATION METER 9P (MERAH)
· COMBINATION METER 9P
· COMBINATION METER 6P (HITAM)

KAWAT SPEED SENSOR KAWAT KLAKSON KABEL SE VALVE

KABEL KOPLING
KABEL GAS
KAWAT KUNCI KONTAK
SLANG REM DEPAN

SLANG PAIR AIR FILTER-


ke- UDARA TERBUKA

SLANG SIPHON RADIATOR


WIRE HARNESS
RELAY LAMPU SEIN UTAMA

KAWAT
KLAKSON

CONNECTOR SAKLAR MOTOR KIPAS


KABEL KOPLING

CONNECTORS: KAWAT KABLE KABEL GAS


· SAKLAR POSISI RODA GIGI 6P
PRIMER MASSA
· ALTERNATOR/IGNITION PULSE GENERATOR 4P
PENGAPIAN
· STARTER MOTOR 2P

SLANG SIPHON RADIATOR IGNITION COIL STAY

1-17
KETERANGAN UMUM

WIRE HARNESS UTAMA

SLANG ATAS RADIATOR

CONNECTOR 2P
SAKLAR MOTOR KIPAS

SUB HARNESS
COMBINATION METER KABEL SE VALVE

KAWAT SPEED SENSOR

KAWAT THERMO SENSOR

KAWAT KUNCI KONTAK


CONNECTORS:
· SAKLAR POSISI RODA GIGI 6P
· ALTERNATOR/IGNITION PULSE GENERATOR 4P
· STARTER MOTOR 2P
SLANG PAIR AIR FILTER
-ke- UDARA TERBUKA

SLANG PAIR AIR FILTER KAWAT PRIMER KABEL GAS


-ke-CONTROL VALVE COIL PENGAPIAN
KABEL
MASSA
SLANG REM DEPAN

KABEL FILTER

KAWAT RELAY
LAMPU SEIN

SLANG BAWAH KABEL BUSI


KABEL STARTER MOTOR RADIATOR

1-18
KETERANGAN UMUM

SLANG PAIR AIR FILTER -


ke- UDARA TERBUKA

SLANG PAIR CHECK VALVE -ke- SLANG PAIR AIR FILTER-ke


PAIR CONTROL VALVE HOSE - SLANG CONTROL VALVE

SLANG ATAS RADIATOR


SLANG VAKUUM
FUEL AUTO VALVE

KAWAT THERMO
SENSOR

Arah band screw :

SLANG VAKUUM
PAIR CONTROL
VALVE Sisi insulator : SLANG
Sebelah PERNAFASAN
dalam CRANKCASE

SLANG
PEMBUANGAN
Arah clip slang : CARBURETOR

CLIP SLANG VAKUUM


PAIR CONTROL VALVE CLIP SLANG VAKUUM
FUEL AUTO VALVE

1-19
KETERANGAN UMUM

KAWAT ALTERNATOR/ SLANG SIPHON RADIATOR


KAWAT SAKLAR
POSISI RODA GIGI IGNITION PULSE GENERATOR Arah band
screw :

45°
KABEL STARTER
MOTOR

KAWAT SAKLAR
MOTOR KIPAS

SLANG BAWAH RADIATOR

30° Arah terminal kabel


starter motor :

SLANG AIR
(POMPA AIR - CYLINDER)

KABEL MASSA

Sebelah luar
WATER PUMP BLEED HOSE

Arah band screw :

SLANG ATAS RADIATOR KAWAT TERMO


SENSOR TERMINAL MASSA

Arah band screw :

Sebelah dalam

SLANG AIR Kepit kawat


(RUMAH THERMOSTAT - motor kipas.
CYLINDER HEAD)

KAWAT SAKLAR MOTOR KIPAS

SLANG BAWAH RADIATOR

SLANG AIR
(POMPA AIR – CYLINDER)

KABEL STARTER MOTOR

1-20
KETERANGAN UMUM

SLANG VAKUUM SLANG VAKUUM


FUEL AUTO VALVE FUEL AUTO VALVE

SLANG BAHAN BAKAR


SLANG BAHAN
BAKAR
SLANG VAKUUM
KABEL SE VALVE
FUEL AUTO VALVE

SLANG LUBANG
UDARA
KARBURATOR

SLANG
PELUAPAN

SLANG BAHAN BAKAR

SLANG VACUUM ATAS


PISTON
KARBURATOR

Arah clip slang :

SLANG PEMBUANGAN SLANG PEMBUANGAN


PERNAFASAN KARBURATOR

SLANG
PELUAPAN

1-21
KETERANGAN UMUM
SLANG SIPHON CONNECTOR WIRE HARNESS KAWAT RELAY SLANG LUBANG
RADIATOR 2P SAKLAR UTAMA LAMPU SEIN UDARA
MOTOR KIPAS KARBURATOR

SLANG PAIR AIR FILTER


-ke- UDARA TERBUKA

KABEL SE VALVE

Tempatkan slang siphon radiator CONNECTOR KAWAT SLANG PAIR AIR FILTER
SLANG VACUUM PISTON
antara penahan pada PAIR PRIMER (HITAM/KUNING) -ke- CONTROL VALVE
KARBURATOR
control valve. COIL PENGAPIAN

KAWAT SAKLAR
BELAKANG LAMPU REM WIRE HARNESS UTAMA

KAWAT RELAY
LAMPU SEIN

SLANG REM BELAKANG

1-22
KETERANGAN UMUM

KAWAT LAMPU IGNITION CONTROL


REM/BELAKANG MODULE (ICM)

KABEL POSITIF (+) BATERAI

KABEL NEGATIF (-) SAKLAR RELAY STARTER


BATERAI

SEKERING
UTAMA 15A

KAWAT FUEL LEVEL SENSOR

REGULATOR/ WIRE HARNESS UTAMA


RECTIFIER

SEKERING TAMBAHAN 10A KAWAT SAKLAR


BELAKANG LAMPU REM

Tempatkan wire harness utama


antara pembimbing pada inner
fender belakang.

DIODE
WIRE HARNESS UTAMA
IGNITION CONTROL
MODULE (ICM)
KABEL NEGATIF (-) BATERAI

SEKRING
TAMBAHAN 10A

SEKRING
UTAMA 15A

KABEL KUNCI
TEMPAT DUDUK

SAKLAR RELAY STARTER

KABEL POSITIF (+) BATERAI

1-23
KETERANGAN UMUM

KAWAT LAMPU SEIN KIRI BELAKANG

KAWAT LAMPU SEIN


KANAN BELAKANG

KAWAT LAMPU REM/


BELAKANG

Kokohkan penempatan
SLANG PEMBUANGAN KAWAT ALTERNATOR/ slang pembuangan
KARBURATOR IGNITION PULSE GENERATOR karburator dengan klem.

IGNITION PULSE
GENERATOR

KAWAT SAKLAR
POSISI RODA GIGI

1-24
KETERANGAN UMUM
EMISSION
SISTEM CONTROL SYSTEMS
PENGATURAN EMISI
SOURCE OF EMISSIONS
SUMBER EMISI
The combustion process produces carbon monoxide and hydrocarbons (HC). Controlling hydrocarbon emission is very important because, under
certain conditions,
Proses Pembakaran theymenghasilkan
react to form photochemical smog when
karbon monoksida subject to sunlight.
dan hidrokarbon (HC). Carbon monoxide
Pengaturan emisidoes not react in
hidrokarbon the same
adalah way, penting
sangat but it is
toxic.karena, di bawah kondisi tertentu, mereka bereaksi untuk membentuk photochemical smog ketika terkena sinar matahari.
oleh
Karbon monoksida
Honda Motor tidak
Co., Ltd. bereaksi
utilizes dengan cara
lean carburetor yangassama,
settings well astetapi
otheriasystems,
beracun.
to reduce carbon monoxide, oxides of nitrogen and hydrocar-
bons.
CRANKCASE
Honda Motor Co., EMISSION
Ltd. memanfaatkanCONTROLpenyetelan SYSTEM
karburator yang miskin maupun sistem lain, untuk mengurangi karbon
monoksida, oksida nitrogen dan hidrokarbon.
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned
to the combustion chamber through the air cleaner housing and carburetor.

SISTEM PENGATURAN EMISI CRANKCASE


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

AIR SEGAR

BLOW-BY GAS
KARBURATOR

RUMAH AIR
CLEANER

SLANG PERNAPASAN
CRANKCASE

1-25
KETERANGAN UMUM
EXHAUST
SISTEM EMISSION
PENGATURAN CONTROL
EMISI SYSTEM
GAS PEMBUANGAN
Sistem pengaturan emisi gas pembuangan terdiri atas sebuah pulse secondary air supply system (sistem penyaluran pulsa udara sekunder) dan
The exhaustkarburator
penyetelan emission control systemtidak
yang miskin, is composed of a pulsepenyetelan
perlu melakukan secondary kecuali
air supply system and
penyetelan lean carburetor
putaran stasioner settings, no adjustment
dengan throttle should
stop screw. be
Sistem
made except
pengaturan idlegas
emisi speed adjustmentadalah
pembuangan with the throttle
terpisah daristop screw.
sistem The exhaust
pengaturan emisiemission control system is separate from the crankcase emission
crankcase.
control system.
SECONDARY AIR SUPPLY SYSTEM
SECONDARY AIR SUPPLY SYSTEM
Pulse secondary air supply system (sistem penyaluran pulsa udara sekunder) memasukkan udara yang telah disaring ke dalam gas pembuangan di
The pulse
dalam secondary
lubang air supply
pembuangan. system
Udara segarintroduces
tersedot kefiltered
dalam air into pembuangan
lubang the exhaust gases in the
dengan exhaust port.PAIR
beroperasinya Fresh air isSecondary
(Pulse drawn intoAir
theInjection)
exhaust control
port
by the function of the PAIR (Pulse Secondary Air Injection) control valve.
valve.
This charge
Pengisian of fresh
udara airini
segar promotes burningpembakaran
memperlancar of the unburned exhaust
gas-gas gases andyang
pembuangan changes a considerable
belum amount
terbakar habis of hydrocarbons
dan mengubah and besar
sejumlah carbonhidrokarbon
monox-
ide into
dan relatively
karbon harmless
monoksida carbon
menjadi dioxide
karbon and dan
dioksida water vapor.
uap air yang relatif tidak berbahaya.
The reed
Reed valve
valve prevents
(katup buluh) reverse air flow
mencegah aliranthrough the system.
balik udara melaluiThe PAIR
sistem. control
PAIR valve
control reacts
valve to high
bereaksi intake manifold
terhadap vacuum
vakuum tinggi and will
di dalam cut off
intake the
manifold
supply
dan akanof menghentikan
fresh air duringpenyaluran
engine deceleration,
udara segar thereby preventing
sewaktu afterburn in the
mesin berdeselerasi exhaust system.
(mengurangi kecepatan perputaran), dengan demikian mencegah
terjadinya afterburn (pembakaran susulan) di dalam sistem pembuangan gas.
No adjustments to the secondary air supply system should be made, although periodic inspection of the components is recommended.
Tidak perlu dilakukan penyetelan kepada secondary air supply system, namun disarankan untuk melakukan pemeriksaan periodik dari komponen-
komponen

PAIR AIR FILTER


PAIR CONTROL VALVE

KARBURATOR

PAIR CHECK VALVE


RUMAH SARINGAN UDARA

LUBANG
PEMBUANGAN GAS

UDARA SEGAR

UDARA VAKUUM

SISTEM PENGATURAN EMISI SUARA


NOISE EMISSION
DILARANG MENGUTAK-ATIK CONTROL SYSTEM EMISI SUARA: Peraturan lokal melarang tindakan-tindakan berikut atau yang
SISTEM PENGATURAN
mengakibatkannya: (1) Pelepasan
TAMPERING WITH THE NOISE CONTROL SYSTEM atau dibuat tidak dapat beroperasinya Local
IS PROHIBITED: oleh seseorang, selain the
law may prohibit untuk tujuanacts
following perawatan, perbaikan
or the causing atau
thereof:
penggantian,
(1) The removaldariorsetiap peralatan
rendering atau elemen
inoperative perancangan
by any person, yangfordipasang
other than purposespada sebuah kendaraan
of maintenance, repair oruntuk tujuan pengaturan
replacement, suara
of any device sebelum
or element
of design incorporated
penjualan atau penyerahan into any vehicle
kepada for the purpose
pelanggan of noise
akhir atau control
sewaktu prior to dipakai;
kendaraan its sale or
(2)delivery to thekendaraan
pemakaian ultimate customer or while itatau
setelah peralatan is inelemen
use;
(2) the use oftelah
perancangan the vehicle afteratau
dilepaskan suchdibuat
devicetidak
or element of design oleh
dapat beroperasi has been removed or rendered inoperative by any person.
seseorang.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
DIANTARA TINDAKAN-TINDAKAN YANG DIANGGAP SEBAGAI PENGUTAK-ATIKAN ADALAH TINDAKAN YANG TERDAFTAR DI BAWAH INI:
1.Pelepasan
1. Removal dari,
of, oratau
puncturing of the
pelubangan muffler,
knalpot, baffles,untuk
peralatan headermengatur
pipes or aliran
any other
gas, component which
pipa pendahulu conducts exhaust gases.
atau
2. setiap
Removal of, or puncturing
komponen of any part of
lain yang menyalurkan gasthe intake system.
pembuangan.
3. Lack of proper maintenance.
2. Pelepasan dari, atau pelubangan dari setiap bagian dari sistem pemasukan udara.
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the manufacturer.
3. Kekurangan perawatan yang memadai.
4. Penggantian setiap bagian bergerak dari kendaraan, atau bagian dari sistem pembuangan gas atau
sistem pemasukan udara, dengan bagian lain selain yang telah ditentukan oleh pabrik pembuat
sepedamotor.

1-26
2. RANGKA/BODY PANELS/SISTEM PEMBUANGAN GAS

LOKASI
BODYBODY PANEL...........................................
PANEL LOCATION····························· 2-2 2-2 PIVOT COVER ........................................................
HEADLIGHT UPPER COVER ·····················2-11 2-12

PETA
BODYPELEPASAN BODY PANEL
PANEL REMOVAL .......................
CHART ·············· 2-2
2-2 LUGGAGE BOX...................................................... 2-13
PIVOT COVER················································2-12

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


SERVICE INFORMATION ····························· 2-3
2-3 UNDER COWL ........................................................
LUGGAGE BOX··············································2-13 2-13

MENCARI PENYEBAB KESUKARAN


TROUBLESHOOTING ................... 2-3
···································· 2-3 SPAKBOR
UNDERDEPAN ................................................. 2-14
COWL················································2-13

TRIM
TRIMCLIPS ............................................................
CLIPS ······················································ 2-4
2-4 PEGANGAN TANGAN ············································2-14
FRONT FENDER BELAKANG ...................... 2-14

TEMPAT DUDUK .................................................... 2-5


SEAT ··································································· 2-5 RIGHT
REARFRONT
GRIPSIDE COVER ................................. 2-15
·····················································2-14

FRONT
FRONTUPPER COVER
UPPER ......................................... 2-5
COVER·································· 2-5 BODY COVER.........................................................
RIGHT FRONT SIDE COVER······················2-15 2-16

CENTER
CENTERBODY COVER/RADIATOR
BODY SHROUD..... 2-6
COVER/RADIATOR SPAKBOR BELAKANG.......................................... 2-17
BODY COVER·················································2-16
SHROUD····························································· 2-6
HANDLEBAR LOWER COVER .............................. 2-8 REAR INNER
REAR FENDER...........................................
FENDER 2-18
···············································2-17
HANDLEBAR LOWER COVER ···················· 2-8
HANDLEBAR UPPER COVER ............................... 2-9 LEFT CRANKCASE
REAR REAR COVER
INNER FENDER ....................... 2-18
·································2-18
HANDLEBAR UPPER COVER ······················ 2-9
FRONT VISOR ........................................................ 2-11 KNALPOT ............................................................... 2-19
LEFT CRANKCASE REAR COVER ···········2-18
FRONT VISOR ················································2-11
HEADLIGHT UPPER COVER................................. 2-11
EXHAUST PIPE/MUFFLER ·························2-19

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

HANDLEBAR UPPER COVER

FRONT VISOR

SPAKBOR DEPAN
BODY COVER

RIGHT FRONT SIDE COVER

PIVOT COVER
UNDER COWL

HEADLIGHT FRONT UPPER COVER


UPPER COVER TEMPAT DUDUK

LUGGAGE BOX PEGANGAN TANGAN


BELAKANG

SPAKBOR
BELAKANG

HANDLEBAR
LOWER COVER

CENTER BODY COVER/


RADIATOR SHROUD REAR INNER
FENDER
LEFT CRANKCASE
REAR COVER

BODYPELEPASAN
PETA PANEL REMOVAL
BODY CHART
PANEL

2-2
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
SERVICE INFORMATION
KETERANGAN SERVIS
UMUM
GENERAL
•• Bagian
This ini covers
section meliputi pelepasan
removal dan pemasangan
and installation of the bodybody panels
panels dan sistem
and exhaust pembuangan gas.
system.
•• Luka bakar dapat terjadi jika sistem pembuangan gas tidak dibiarkan
Serious burns may result if the exhaust system is not allowed to cool before components mendingin dulu
are removed sebelum komponen-komponen
or serviced.
• dilepaskan
Always replaceatau
the diservis.
muffler gasket and exhaust pipe gasket with new ones after removing the exhaust pipe/muffler from the engine.
•• Selalu
When ganti muffler
installing gasketsystem,
the exhaust dan exhaust
loosely pipe
installgasket
all of dengan yang Always
the fasteners. baru setelah
tightenmelepaskan
the exhaust pipa knalpot
pipe joint nutsdari mesin.
first, then tighten the
• mounting fasteners.
Ketika memasang sistem pembuangan gas, pasang semua pengencang pipa knalpot dengan longgar dulu. Selalu
• Always inspect mur
kencangkan the exhaust systempipa
sambungan for leaks afterpada
knalpot installation.
cylinder head dulu, kemudian baru mur-mur pemasangan yang lain.
• Selalu periksa sistem pembuangan gas terhadap kebocoran setelah pemasangan.
TORQUE VALUES
TORSI PENGENCANGAN
Footpeg holder
Footpeg holder mounting
mountingbolt
bolt 9.8 N·m
9,8 N.m (1,0(1.0 kgf·m,
kgf.m, 7,27.2 lbf·ft)
lbf.ft)
Exhaust pipe
Exhaust pipe cover
coverbolt
bolt 13 N·m
13 N.m (1,3(1.3 kgf·m,
kgf.m, 10 10 lbf·ft)
lbf.ft)
Mufflerjoint
Muffler jointbolt
bolt 13 N·m
13 N.m (1,3(1.3 kgf·m,
kgf.m, 10 10 lbf·ft)
lbf.ft)

TROUBLESHOOTING
MENCARI PENYEBAB KESUKARAN
Excessive
Suara exhaust
knalpot noise
yang berlebihan
•• Broken
Sistemexhaust system gas pecah
pembuangan
•• Exhaust gas leak gas pembuangan
Ada kebocoran
Poor performance
Unjuk kerja sepedamotor
• Deformed exhaust system lemah
•• Exhaust
Sistemgas leak
pembuangan gas berubah bentuk
•• Clogged muffler gas pembuangan
Ada kebocoran
• Knalpot tersumbat

2-3
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
TRIMCLIPS
TRIM CLIPS
REMOVAL
PELEPASAN
Release the trim clip
Lepaskan clipbydengan
pushing menekan
in the centerpin
pintengah
and pull ke
it
out. dan menarik clip keluar.
dalam

CENTER PIN TRIM CLIP

INSTALLATION
PEMASANGAN
Sebelum memasang
Before installing the trim clip, clip,thenaikkan
trim raise center pincenter pin
by spread-
ing the pin
dengan tip and pushingujung
merentangkan it back.
pin dan mendorongnya ke CENTER PIN
atas.

TRIM CLIP

Align the clip


Jajarkan holes and install
lubang-lubang clipthedan
trim clip,
pasangthen lock
trim itclip
by ,
pushing in the center pin until the pin head is flush with the TRIM CLIP
kemudian kunci dengan mendorong center pin ke dalam
clip head.rata dengan kepala clip.
sampai

CENTER PIN

2-4
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
SEAT
TEMPAT DUDUK
Unlockkunci
Buka the seat with duduk
tempat the ignition key.anak kunci kontak.
dengan
Remove thekedua
Lepaskan two nuts
mur and seat.
dan tempat duduk. SEAT
Pemasangan
Installation is inadalah dalam
the reverse urutan
order terbalik dari
of removal.
pelepasan.
NUTS

FRONT UPPER COVER


Lepaskan
Remove thesebagai berikut:
following:
-– Specialscrew
Special screw from rearkhusus)
(sekrup upper side
dari sisi belakang atas.
-– Trimclip
Trim clipdari
from front
sisi upperatas
depan side(hal.
(page2-4)
2-4)
-– Twospecial
Dua specialscrews
screws from both sides
dari kedua sisi
BeHati-hati
careful not to dam-
agar tidak Remove right/left
Lepaskan front upper
right/left front covers
upperby releasing
covers thedengan
hooks
age the hooks
merusak hooks and
dan and bosses. hooks (kaitan) dan bosses (tonjolan).
melepaskan
bosses.
bosses. Installation in theadalah
Pemasangan reverse order of removal.
dalam urutan terbalik dari
pelepasan.
TRIM CLIP
BOSSES
LEFT FRONT
UPPER COVER
SPECIAL
SCREWS

RIGHT FRONT
UPPER COVER

HOOKS

2-5
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
CENTER BODY COVER/RADIATOR
COVER/RADIATOR SHROUD
SHROUD PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan sebagai berikut:
-Remove
Front upper cover (hal. 2-5)
the following:
- Tempat duduk (hal. 2-5)
-– Pivot
Frontcovers
upper cover (page 2-5)
(hal. 2-12)
– Seat (page 2-5)
- Dua special screws
– Pivot covers (page 2-12)
-– Empat screws
Two special (sekrup)
screws
Lepaskan center body cover/radiator shroud dengan
– Four screws
melepaskan sebagai
Remove the center berikut:
body cover/radiator shroud by releasing
Be careful not to dam-
Hati-hati agar tidak
-the Enam
following:
bosses pada radiator shroud dari grommets
age the bosses, tabs pada luggage box dan rangka.
merusak bosses, tabs – Six bosses on the radiator shroud from the grommets on
and slots. - Tabs (lidah pemasangan) pada body cover dari slots
dan slots. the luggage box and frame
(lubang pemasangan) pada center body
– Tabs on the body cover from the slots on the center body
cover/radiator shroud.
cover/radiator shroud
Lepaskan front turn signal light/position light 3P
Disconnect the front turn signal light/position light 3P
connectors (Hitam) (connectors lampu sein/lampu senja
(Black) connectors.
depan).
Pemasangan
Installation in theadalah dalam
reverse order urutan terbalik dari
of removal.
pelepasan.
SCREWS
FRONT TURN SIGNAL LIGHT/POSITION BOSSES
LIGHT 3P (BLACK) CONNECTORS
CENTER BODY COVER/
RADIATOR SHROUD

GROMMETS

SPECIAL SCREWS TABS

2-6
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
DISASSEMBLY/ASSEMBLY
PEMBONGKARAN/PERAKITAN
Buka kunci
Unlock luggage
the luggage boxbox
lid lid (tutup
using kotak
ignition key. bagasi) dengan
anak kunci kontak.
Remove the two screws and special screws.
Lepaskan kedua screws dan special screws.
BeHati-hati
careful not to dam-
agar Slide
Geserthe
tidak Geser radiatorshrouds
radiator
radiator shrouds forward
shrouds ke
ke depan anddan
depan release
dan its slots slots-
lepaskan
lepaskan from
slots-
age the hooks,
merusak hooks, slots the
nyahooks
slots nya dari on thepada
dari hooks
hooks centercenter
pada body cover,
center body then
body separate
cover,
cover, kemudian
kemudianthe shrouds
by releasing the tabs dengan
and tabs. pisahkan on the lower side.
dan tabs. pisahkan shrouds dengan melepaskan
melepaskan tabstabs
padapada
sisisisi
bawah.
Remove the following:
Lepaskan sebagai berikut:
– Luggage box lid
-– Luggage
Spring box lid (tutup kotak bagasi)
-– Spring (pegas)
Retainer
-– Retainer
Key cylinder
- Key cylinder (silinder kunci)
Assembly is in the reverse order of disassembly.
Perakitan adalah dalam urutan terbalik dari pembongkaran.
SPRING CENTER SPECIAL SCREWS
BODY
RETAINER COVER

SCREWS

HOOKS SLOTS

KEY CYLINDER

LUGGAGE BOX LID TABS RADIATOR SHROUD

MIDDLECOWL
MIDDLE COWL
Lepaskan
Remove thesebagai berikut
following dari radiator
from radiator shroud:
shroud:
Sisi kiri diperlihatkan: SCREWS
-– Lima
Five screws
screws
-– Middle
Middlecowl
cowl RADIATOR
Assembly isadalah
Perakitan in the reverse order ofterbalik
dalam urutan disassembly.
dari SHROUD
pembongkaran.

MIDDLE COWL

FRONT TURN SIGNAL UNIT


FRONT SEIN
(LAMPU TURN SIGNAL UNIT
DEPAN)
Remove thesebagai
Lepaskan following from radiator
berikut shroud:
dari radiator shroud:
Sisi kiri diperlihatkan: FRONT TURN
-– Tiga
Three screws
screws SIGNAL UNIT
-– Front
Frontturn
turnsignal
signal unit
unit RADIATOR
Assembly is inadalah
the reverse order of urutan
disassembly. SHROUD
Perakitan dalam terbalik dari
pembongkaran.

SCREWS

2-7
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
HANDLEBAR LOWER
HANDLEBAR LOWER COVER
COVER
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Remove thefront
Lepaskan frontupper
upper cover
cover (page 2-5).
(hal. 2-5). SE VALVE CABLE
WAVE
Remove thesebagai
Lepaskan following:
berikut: WASHER
-– Screw
Screw
-– Washer
Washer
-– SE
SEvalve
valve lever
lever
-– Wave
Wavewasher
washer
Disconnect kabel
Lepaskan the SESEvalve cable
valve from
dari SEthe SE valve
valve lever.lever.

WASHER SCREW SE VALVE LEVER


Lepaskan
Remove thesebagai berikut:
following:
SE VALVE CABLE HOLDER
-– Screw
Screw/SE/ SEvalve
valvecable
cable holder
holder
-– Empat
Four screws
screws from
darithe lower
sisi front
depan side
bawah
-– Dua
Twoscrews
screws dari
fromsisi
the belakang
lower rear bawah
side
-– Special
Specialscrew
screw from the rear
dari sisi side
belakang
Remove the handlebar lower cover by releasing its slots from
BeHati-hati
careful not to dam- Lepaskan
the tabs on the handlebar upper cover. dengan melepaskan
handlebar lower cover
agar tidak
age the tabs slots-nya dari tabs pada handlebar upper cover.
merusak tabsand
danslots.
slots Pull down the handlebar lower cover and pull it backward,
Tarik ke bawah handlebar lower cover dan tarik ke
then disconnect the following connectors:
belakang, kemudian lepaskan connectors sebagai
– Horn switch connector
berikut:
-– Horn
Turnswitch connector
signal switch (connector tombol klakson)
connector
-– Turn
Starter switch
signal connector
switch connector (connector saklar lampu
– Lighting switch connectors
sein)
-Pull
Starter switch connector (connector SCREW
out the SE valve cable from the holetombol
on thestarter)
handlebar
-lower
Lighting
cover. switch connectors (connector-connector
saklar lampu)
Route the wires
Alurkan kawatand
dan Installation
Tarik keluarinkabel
the reverse orderdari
SE valve of removal.
lubang pada handlebar
cables
kabelproperly
dengan (page
benar lower cover.
1-16). Pemasangan adalah dalam urutan terbalik dari
(hal. 1-16).
pelepasan.
SPECIAL SCREW
SCREWS
HANDLEBAR
LOWER COVER
SE VALVE

TURN SIGNAL SWITCH


CONNECTOR
SLOTS/TABS

HORN SWITCH
CONNECTOR

LIGHTING SWITCH
CONNECTORS

STARTER SWITCH
CONNECTOR

2-8
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
HANDLEBAR UPPER
HANDLEBAR UPPER COVER
REMOVAL
PELEPASAN
Remove thehandlebar
Lepaskan handlebar lower cover
cover(page
(hal. 2-8).
2-8).
KACA SPION
Geser bootskeoff,atas,
boots
Slide the longgarkan
loosen murand
the lock nuts pengunci dan
remove the
lepaskan kaca spion
rearview mirrors dengan
by turning memutarnya berlawanan
it counterclockwise. BOOTS
arah jarum jam.

Lepaskan kedua screws dari sisi bawah. MUR


Tarik handlebar upper cover ke atas dan lepaskan PENGUNCI
dimmer switch connector (saklar dimmer) dan
combination meter
Remove the two 20Pfrom
screws connector.
the lower side.
Pull up the handlebar
Lepaskan upper cover
screw (sekrup) danand disconnect
throttle upperthehousing
dimmer
switch connector and combination meter 20P connector.
(rumah atas kabel gas) dengan melepaskan kaitan tab
Remove
di the screw(rumah
lower housing and the bawah).
throttle upper housing by unhook-
ing the lower housing tab.
Lepaskan
Disconnectthrottle cable
the throttle (kabel
cable fromgas) dari throttle
the throttle pipe. pipe.
Longgarkan throttle
Loosen the throttle cable
cable locklock
nut nut (murthe
and pull pengunci
cable outkabel
from
the throttle
gas) lower
dan tarik housing
kabel keluaranddari
the throttle
hole onlower
the handlebar
housing
upper cover.
(rumah bawah kabel gas) dan lubang pada handlebar
upper cover.

SCREW HANDLEBAR UPPER COVER COMBINATION METER


20P CONNECTOR
UPPER DIMMER
HOUSING SWITCH
CONNECTOR

THROTTLE
CABLE

TAB

LOCK NUT

LOWER SCREWS
HOUSING

THROTTLE CABLE

2-9
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
INSTALLATION
PEMASANGAN
Oleskan
Apply 0.10,1 – 0.2– g0,2 g gemuk
of grease to thepada ujung
throttle cablethrottle
end andcable
slid-
ing area.
(kabel gas) dan bidang peluncuran.
Alurkan throttle cable melalui lubang pada handlebar
RouteAlurkan
the wireskawat
and Route the throttle cable through the hole on the handlebar
upper cover dan throttle lower housing (rumah bawah
cables properly (page upper cover and the throttle lower housing, then tighten the
dan kabel dengan kabel gas), kemudian kencangkan lock nut (mur
1-16). lock nut.
benar (hal. 1-16). pengunci).
Connect the throttle cable end to the throttle pipe.
Hubungkan ujung
Install the lower throttle
housing to cable pada throttle
the handlebar while pipe.
aligning its
Pasang lower
boss with the holehousing pada handlebar (stang stir)
on the handlebar.
sementara mentepatkan boss-nya dengan lubang pada
Install the throttle upper housing while aligning its slot with
handlebar.
the tab onthrottle
Pasang the lower housing.
upper housing sementara mentepatkan
Install and tighten the
slot-nya dengan tab pada screw.lower housing.
Pasang
Connect dan kencangkan
the dimmer switch screw.
connector and combination meter
20P connector. dimmer switch connector (saklar dimmer)
Sambungkan
dan combination meter 20P connector.
Install the handlebar upper cover, then install and tighten the
Pasang
two screws.handlebar upper cover, kemudian pasang dan
kencangkan kedua screws.
HANDLEBAR UPPER COVER COMBINATION METER
20P CONNECTOR
DIMMER
Tepatkan
SWITCH
CONNECTOR

THROTTLE
LOWER CABLE
HOUSING

THROTTLE
CABLE LOCK NUT
SCREW UPPER HOUSING

SCREWS
Align

Install the
Pasang rearview
kaca spion mirrors
denganbymemutarnya
turning it clockwise, then
searah jarum
KACA SPION
tightenkemudian
jam, the lock nuts and set the boots
kencangkan mur in position. dan geser
pengunci
boots
Install pada posisi pemasangannya.
the handlebar lower cover (page 2-8).
BOOTS
Pasang handlebar lower cover (hal. 2-8).

MUR
PENGUNCI

2-10
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
VISOR
FRONT VISOR
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Be careful
Hati-hati agarnot
tidak Remove thesebagai
to Lepaskan following:
berikut:
damage the front VISOR COVERS SPECIAL
merusak permukaan -– Dua Twospecial
specialscrews
screws from the front
dari sisi depanside SCREWS
visor surface.
front visor. -– Dua
Twoscrews
screws dari
fromsisi
the belakang
rear side
-– Visor
Right/left
coversvisor covers
kanan/kiri
-– Dua
Twoscrews/rubbers
screws/rubbers from the front
dari sisi depanside FRONT VISOR
– Front visor
- Front visor
Remove the front
Lepaskan frontvisor by releasing
visor dengan its lower slots.
melepaskan slots SCREWS
Installation is in the reverse order of removal.
bawahnya.
Pemasangan adalah dalam urutan terbalik dari
pelepasan.

SCREWS/
RUBBERS

SLOTS

HEADLIGHTUPPER
HEADLIGHT UPPERCOVER
COVER
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Remove thesebagai
Lepaskan following:
berikut:
SPECIAL SCREW
–- Front
Frontvisor
visor (hal.
(page2-11)
2-11)
–- Front
Frontupper
upper cover
cover (page 2-5)
(hal. 2-5)
–- Special
Special screw
screw from
dari sisi atas side
the upper
– Two screws from right/left side
- Dua screws dari sisi kanan/kiri
Remove the headlight upper cover from headlight unit by
sliding it backward.
Lepaskan headlight upper cover dari unit lampu besar
dengan menggesernya
Installation ke belakang.
in the reverse order of removal.

Pemasangan adalah dalam urutan terbalik dari


pelepasan.

HEADLIGHT
SCREWS UPPER COVER

2-11
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
PIVOT COVER
PIVOT COVER
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
RIGHT PIVOT
RIGHT PIVOTCOVERCOVER
Lepaskan
Remove theketiga specialscrews.
three special screws (sekrup khusus).
Release the tabs on the right front body cover by sliding the
BeHati-hati
careful not to dam-
agar right pivot cover
tidak Lepaskan forward
tabs pada andfront
right remove it. cover
body dengan
age the tabs
tabs and
dan slots.
slots. menggeser right pivot cover ke depan dan
merusak Installation is in the reverse order of removal.
TABS
melepaskannya.

Pemasangan adalah dalam urutan terbalik dari


pelepasan.

SPECIAL
SCREWS

RIGHT PIVOT COVER

LEFT PIVOT
LEFT PIVOTCOVER
COVER
Lepaskan
Remove thekedua special
two special screws.
screws.
Release the tabs on the body cover by sliding the left pivot TABS
Be Hati-hati agar
careful not tidak cover forward and remove it.
to dam-
merusak tabsand
age the tabs danslots.
slots.
Lepaskan tabs pada body cover dengan menggeser left
Installation
pivot coveriskeindepan
the reverse
dan order of removal.
melepaskannya.

Pemasangan adalah dalam urutan terbalik dari


pelepasan.

SPECIAL
SCREWS

LEFT PIVOT COVER

2-12
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
LUGGAGEBOX
LUGGAGE BOX
(KOTAK BAGASI)REMOVAL/INSTALLATION
Remove the following:
PELEPASAN/PEMASANGAN
LUGGAGE BOX BOLTS
Lepaskan sebagai
– Center body berikut: shroud (page 2-6)
cover/radiator
– Two luggage box mounting bolts
- Center body cover/radiator shroud (hal. 2-6) HOOK
-Remove
Dua luggage box mounting
the turn signal bolts
relay from (bautonpemasangan
the stay the luggage
box. bagasi)
kotak
Release the hook on the luggage box by pulling it backward
Lepaskan
and removeturn signal
it from relay (relay lampu sein) dari stay
the frame.
pada luggage box.
Installation is in the reverse order of removal.
Lepaskan hook (kaitan) pada luggage box dengan
menariknya ke belakang dan melepaskannya dari
rangka. TURN
SIGNAL
Pemasangan adalah dalam urutan terbalik dari RELAY
pelepasan.

UNDER COWL
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Lepaskan
Remove theketiga special
three special screws
screws (sekrup
and mount khusus) dan
rubbers.
Slightlyrubbers
mount spread the under
(karet cowl and remove it from the stay.
pemasangan).
Installation is under
Rentangkan in the reverse order of
cowl sedikit danremoval.
lepaskan dari stay.
Pemasangan adalah dalam urutan terbalik dari
pelepasan.
UNDER COWL

SCREWS/MOUNT RUBBERS

2-13
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
FRONT FENDER
(SPAKBOR DEPAN)
REMOVAL/INSTALLATION
Remove the following:
PELEPASAN/PEMASANGAN
– Four bolts/collars
Lepaskan sebagai
– Speed sensor wireberikut:
clamp
– Front fender
- Empat bolts/collars FRONT FENDER COLLARS
-– Speed
Front fender
sensorstay
wire clamp
-Installation
Front fender
is in (spakbor
the reversedepan)
order of removal.
- Front fender stay
Pemasangan adalah dalam urutan terbalik dari
pelepasan.

BOLTS
FRONT
FENDER STAY
WIRE CLAMP

REAR GRIP
REAR GRIP
(PEGANGAN TANGAN BELAKANG)
Unlock the seat
Lepaskan withtempat
kunci the ignition key. dengan anak kunci
duduk
kontak.
Remove the following: BOLTS
– Four rear
Lepaskan grip mounting
sebagai berikut:bolts REAR GRIP
-– Empat
Rear grip
rear grip mounting bolts (baut pemasangan
pegangan
Installation is tangan belakang)
in the reverse order of removal.
- Rear grip

Pemasangan adalah dalam urutan terbalik dari


pelepasan.

2-14
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
RIGHTFRONT
RIGHT FRONTSIDE
SIDECOVER
COVER
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Remove theright
Lepaskan rightpivot
pivotcover
cover (hal.
(page2-12).
2-12).
Lepaskan kunci
Unlock the seat withtempat duduk
the ignition key. dengan anak kunci
kontak.
Remove thesebagai
Lepaskan following:
berikut:
-– Kedua special screws
Two special screws (sekrup
from khusus)
the upper side dari sisi atas
-– Screw
Screwdari
fromsisi
thebawah
lower side
Lepaskan right front side cover dengan melepaskan
BeHati-hati
careful not tidak Remove the right front side cover by releasing the tabs on the
to dam-
agar
age the tabs. tabs
front pada
side bysisi depan
pulling dengan menariknya
it downward, then pull it ke bawah,
forward to
merusak tabs.
kemudian tarikonkethedepan
release the tabs untuk melepaskan tabs pada
rear side.
sisi belakang.
Installation is in the reverse order of removal.
Pemasangan adalah dalam urutan terbalik dari
pelepasan.
TABS

SPECIAL SCREW

RIGHT FRONT SIDE COVER

SCREW

TABS

2-15
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
COVER
BODY COVER
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
Lepaskan sebagai berikut:
-Remove
Rear grip (hal. 2-14)
the following:
- Pivot covers (hal. 2-12)
– Rear grip (page 2-14)
- Right front side cover (hal. 2-15)
– Pivot covers (page 2-12)
-– Dua
Rightscrews daricover
front side sisi kiri
(page 2-15)
-– Screw dari sisi kanan
Two screws from the left side
-– Dua
Screwspecial
from screws
the rightdari
side sisi belakang atas
Lepaskan
– Two special screws from thesebagai
bosses/tabs/hooks berikut:
rear upper side
-Release the following
Tabs pada bosses/tabs/hooks:
sisi depan kiri dengan menarik left body
BeHati-hati
careful not to dam-
agar tidak cover ke bawah.
– Tabs on the left front side by pulling the left body cover
age the bosses,
merusak bosses, tabs
tabs - Tabs dan hooks pada kedua sisi dari slots pada rear
downward.
– Tabsfender
inner
and hooks.
hooks.
dan and hooks on both sides from slots on the rear inner
- Bosses
fender pada kedua sisi dari grommets dengan sedikit
– merentangkan
Bosses on both body cover
sides from the grommets by slightly
- Slot di bawah
spreading rearcover
the body center cowl dari hook pada unit
– lampu rem/belakang
Slot under dengan
the rear center menarik
cowl from thebody cover
hook ke
on the
depan
brake/tail light unit by pulling the body cover forward
Lepaskan seat lock cover dengan melepaskan hook-nya
Remove
dari boss thepada
seat lock
bodycover by releasing
cover, kemudian its lepaskan
hook from seat
the
boss
lock on the dari
cable bodytabs
cover, thencover.
pada release the seat lock cable from
the tabs on the
Lepaskan seatcover.
lock cable dari cable holder (pegangan
Release
kabel) the danseatlepaskan
lock cable dari
from the
keycable holder and
cylinder, discon-
kemudian
nect it frombody
lepaskan the key cylinder, then remove the body cover.
cover.
Pemasangan
Installation adalah
is in the reverse dalam urutan terbalik dari
order of removal.
pelepasan.
SEAT LOCK CABLE SLOT HOOK
KEY
TABS SPECIAL SCREWS

BOSS SEAT LOCK SEAT LOCK CABLE


HOOK COVER BODY COVER

BOSSES

TABS/HOOKS

TABS

2-16
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
DISASSEMBLY/ASSEMBLY
PEMBONGKARAN/PERAKITAN
Lepaskan
Remove thesebagai berikut:
following:
-– Empat screws/rear
Four screws/rear center
center cowl
cowl
-– Spring/cable
Spring/cable holder/key
holder/key cylinder
cylinder
BeHati-hati
careful not to dam-
Lepaskan
Remove thescrew
screwdan
and side
side garnish dengan
garnish by melepaskan
releasing the hooks
agar tidak hooks dari slots pada body cover.
merusak hooks and
age the hooks dan from the slots on the body cover.
slots. Perakitan adalah dalam urutan terbalik dari
slots. Assembly is in the reverse order of disassembly.
pembongkaran.
KEY CYLINDER
SCREWS

RIGHT
LEFT BODY COVER BODY
COVER

CABLE
HOLDER

SPRING

LEFT SIDE GARNISH

REAR CENTER
COWL

RIGHT SIDE GARNISH


REAR FENDER
REAR FENDER
(SPAKBOR BELAKANG)
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Remove thesebagai
Lepaskan following:
berikut:
TABS
-– Dua
Twoscrews/washers
screws/washers from
dari the
sisilower
bawah side
-– Dua
Twoscrews/collars
screws/collars from the lower
dari sisi bawahside
-– Twospecial
Dua
Remove
special screws
screws from kedua
the rear fenderdari
both sides
by releasingsisi
the tabs and pulling it
BeHati-hati
careful not tidak Lepaskan
to dam-
agar backward. spakbor belakang dengan melepaskan tabs
age the rear fender. dan menariknya ke belakang.
rear fender.
merusak Installation is in the reverse order of removal.
Pemasangan adalah dalam urutan terbalik dari
pelepasan. REAR FENDER

SCREWS/ SCREWS/ SPECIAL


WASHERS COLLARS SCREWS

2-17
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
REAR INNER
INNER FENDER
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Remove thesebagai
Lepaskan following:
berikut:
WIRE HARNESS
-– Body
Bodycover
cover(hal.
(page2-16)
2-16)
-– Rear
Rearfender
fender (hal.
(page2-17)
2-17)
-– Unit
Brake/tail
lampu light unit (page 19-6)
rem/belakang (hal. 19-6)
-– Dua
Twobolts/collar
bolts/collarsdari
from both sides
kedua sisi SCREWS
– Screw from right side
- Screw dari sisi kanan Groove
– Screw from lower right side
- Screw dari sisi kanan bawah
Hati-hati agar tidak Remove the rear
Be careful not to dam- Lepaskan rear inner
innerfender by pulling
fender denganit backward.
menariknya ke
merusak rear inner
age the rear inner
belakang.
Release the main wire harness from the groove on the rear
fender. inner fender.
Lepaskan wire harness utama dari alur pada rear inner
fender.
Hati-hati agar tidak Installation is in the reverse order of removal.
Route the wire har-
ness properly (page Pemasangan adalah dalam urutan terbalik dari
merusak rear inner pelepasan.
1-16).
fender.

BOLTS/
REAR INNER FENDER COLLARS

LEFT CRANKCASE REAR COVER


LEFT
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Remove thesebagai
Lepaskan following:
berikut:
NUT
FOOTPEG
-– Left
Leftpivot
pivotcover
cover(hal.
(page2-12)
2-12)
HOLDER
-– Nut
Nut(mur)
-– Bolt
Bolt(baut)
Turn the left footpeg holder downward.
Putar footpeg holder kiri ke bawah.

BOLT
Lepaskan
Remove thekedua bolts
two bolts dan
and leftleft crankcase
crankcase rear rear cover.
cover. LEFT CRANKCASE
Installation is in the reverse order of removal. REAR COVER
Pemasangan adalah dalam urutan terbalik dari
TORQUE:
pelepasan.
Footpeg holder mounting bolt:
9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
TORSI:
Footpeg holder mounting bolt:
9,8 N.m (1,0 kgf.m; 7,2 lbf.ft)

BOLTS

2-18
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
EXHAUST PIPE/MUFFLER
EXHAUST PIPE/MUFFLER
(KNALPOT) REMOVAL
PELEPASAN
Lepaskan
Remove theunder
under cowl
cowl (hal.
(page2-13).
2-13).
Lepaskan
Remove theexhaust pipe joint
exhaust pipe joint nuts.
nuts.

JOINT NUTS
Remove thesebagai
Lepaskan following:
berikut:
NUT RUBBER COLLAR
– Nut
- Nut
-– Washer
Washer
– Bolt
- Bolt
– Washer
-– Washer
Collar
-– Collar
Mount rubber
- Mount rubber (karet pemasangan)
Remove the exhaust pipe/muffler as assembly.

Lepaskan exhaust pipe/muffler sebagai satu susunan.

WASHERS BOLT

Remove theexhaust
Lepaskan exhaust pipe
pipe gasket.
gasket.

GASKET

2-19
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
DISASSEMBLY/ASSEMBLY
PEMBONGKARAN/PERAKITAN
Lepaskan
Remove thesebagai berikut:
following:
-– Dua
Twoscrews/exhaust pipeguard
screws/exhaust pipe guard
-– Dua
Twobolts/empat washers/dua
bolts/four washers/two insulators/exhaust
insulators/exhaust pipe
pipe cover
– cover
Three bolts/muffler/gasket
- Tiga bolts/muffler/gasket
Assembly is in the reverse order of disassembly.
Perakitan adalah dalam urutan terbalik dari
pembongkaran.
Always replace the muffler gasket with a new one whenever
CATATAN:
the muffler is removed from the exhaust pipe.
Selalu ganti gasket muffler dengan yang baru setiap kali
TORQUE:
muffler dilepaskan dari exhaust pipe.
Muffler joint bolt:
13 N·m (1.3 kgf·m, 10 lbf·ft)
TORSI:
Exhaust pipe
Muffler joint cover bolt:
bolt:
1313N.m
N·m(1,3
(1.3kgf.m;
kgf·m, 10
10 lbf.ft)
lbf·ft)
Exhaust pipe cover bolt:
13 N.m (1,3 kgf.m; 10 lbf.ft)

GASKET
MUFFLER

BOLTS/WASHERS
13 N·m (1.3 kgf·m, 10 lbf·ft)
13 N·m (1.3 kgf·m, 10 lbf·ft)

COVER

SCREWS

EXHAUST PIPE GUARD


INSULATORS
EXHAUST PIPE

2-20
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
INSTALLATION
PEMASANGAN
NUT

WASHER

MOUNT RUBBER

COLLAR

GASKET

EXHAUST PIPE/
MUFFLER

MUFFLER MOUNTING BOLT WASHER


EXHAUST PIPE JOINT NUTS
Install
Pasang a new exhaust
sebuah pipeexhaust
gasket gasket topipe
the exhaust port lubang
baru pada of the
cylinder
pembuanganhead. dari cylinder head.
CATATAN:
Always replaceexhaust
Selalu ganti the exhaust
pipe pipe gasket
gasket with ayang
dengan new baru
one
whenever
setiap kalithe exhaustpipe
exhaust pipe dilepaskan.
is removed.

GASKET
Pasang
Install thekaret
mountpemasangan dan collar
rubber and collar into thekestay.
dalam stay.
Set the exhaust
Tempatkan pipe/muffler
exhaust in position.
pipe/muffler pada posisinya. NUT RUBBER COLLAR
Temporarily
Untuk install pasang
sementara the following:
sebagai berikut:
-– Bolt
Bolt
– Washers
- Washers
– Nut
- Nut
– Exhaust pipe joint nuts
- Exhaust pipe joint nuts

WASHERS BOLT

2-21
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
Tighten the exhaust
Kencangkan pipepipe
exhaust jointjoint
nuts.nuts.
Kencangkan
Tighten the muffler mounting nut.nut.
muffler mounting
After the installation,
Setelah pemasangan, inspect the exhaust
periksalah systempembuangan
sistem for leaks.
gas terhadap kebocoran.

JOINT NUTS
STUD BOLT REPLACEMENT
PENGGANTIAN STUD BOLT
Remove theexhaust
Lepaskan exhaust pipe/muffler
pipe/muffler (page 2-19).
(hal. 2-19).
Duduk dengan penuh
Thread two nuts onto the stud and tighten them together, and
Pasang dua on
use a wrench nuts pada
them studthe
to turn dan kencangkan
stud bolt out. mereka
satu sama lain, kemudian pakailah kunci
Install new stud bolts into the cylinder head untilpas
it is untuk
fully
memutar stud bolt keluar.
seated as shown.
Install thedua
Pasang exhaust
studpipe/muffler
bolts baru(page
ke 2-21).
dalam cylinder head
sampai ia telah duduk dengan penuh seperti
diperlihatkan.

Pasang exhaust pipe/muffler (hal. 2-21).

2-22
3. PERAWATAN

SERVICE INFORMATION
KETERANGAN ·····························
SERVIS ..................... 3-23-2 SECONDARYAIR
SECONDARY AIRSUPPLY
SUPPLY SYSTEM ········3-15
SYSTEM...3-15
JADWAL PERAWATAN
MAINTENANCE ..................... 3-43-4
SCHEDULES······················ RANTAI
DRIVERODA.......................................3-16
CHAIN ················································3-16
SALURAN BAHAN BAKAR ............... 3-5 MINYAK REM.........................................3-18
FUEL LINE ························································ 3-5 BRAKE FLUID ················································3-18
CARA KERJA GAS TANGAN ............ 3-5 KEAUSAN BRAKE PADS .....................3-19
THROTTLE
CARA OPERATION
KERJA ······························
CUK ............................ 3-63-5 BRAKEREM
SISTEM PADS WEAR·····································3-19
.........................................3-20
AIR CLEANER
CHOKE .................................... 3-63-6
OPERATION······································ SAKLAR
BRAKE LAMPU
SYSTEMREM ..........................3-20
············································3-20
CRANKCASE BREATHER................. 3-7 ARAH SINAR LAMPU BESAR ..............3-21
AIR CLEANER·················································· 3-6 BRAKE LIGHT SWITCH ······························3-20
BUSI .................................................... 3-7 SISTEM KOPLING .................................3-21
RENGGANG
CRANKCASEKLEP ............................. 3-93-7
BREATHER····························· STANDARD SAMPING..........................3-21
HEADLIGHT AIM··········································3-21
OLI MESIN .......................................... 3-11 SUSPENSI .............................................3-22
SPARK PLUG ···················································· 3-7 CLUTCH SYSTEM ·········································3-21
ENGINE OIL STRAINER SCREEN..... 3-13 MUR, BAUT, PENGENCANG ................3-22
VALVE CLEARANCE ····································· 3-9 SIDESTAND·····················································3-21
PUTARAN STASIONER MESIN ......... 3-13 RODA / BAN ..........................................3-23
CAIRAN
ENGINE PENDINGIN RADIATOR ...... 3-14
OIL····················································3-11 BANTALAN KEPALA KEMUDI .............3-24
SUSPENSION···················································3-22
SISTEM PENDINGINAN ..................... 3-14
ENGINE OIL STRAINER SCREEN·············3-13 NUTS, BOLTS, FASTENERS ························3-22

ENGINE IDLE SPEED ··································· 3-13 WHEELS/TIRES ·············································3-23

RADIATOR COOLANT································· 3-14 STEERING HEAD BEARINGS·····················3-24

COOLING SYSTEM·······································3-14

3-1
PERAWATAN
SERVICE INFORMATION
KETERANGAN SERVIS
MAINTENANCE

GENERAL
UMUM
•• Place
Letakkan sepedamotor
the motorcycle pada
on level permukaan
surface mendatar
before starting sebelum memulai sesuatu pekerjaan.
any work.
•• Gasoline
Bensin issangat mudah
extremely terbakar
flammable anddan dapat meledak
is explosive pada kondisi
under certain tertentu.
conditions.
•• Work in a well
Bekerjalah di ventilated area. Smoking
tempat dengan or allowing
ventilasi flames or
baik. Merokok sparks
atau in the worklidah
membiarkan area api
or where
atau the gasoline
percikan apiis di
stored can cause
tempat kerja aatau
fire or
di
explosion.
tempat di mana bensin disimpan dapat menyebabkan kebakaran atau ledakan.
•• The
Gas exhaust
buangcontains poisonousgas
mengandung carbon monoxide
karbon gas thatberacun
monoksida may cause loss of
yang consciousness
dapat and maykesadaran
menghilangkan lead to death.
dan Rundapat
the engine in an open
menyebabkan
area or with an
kematian. exhaust mesin
Jalankan evacuation systemterbuka
di tempat in an enclosed
atau diarea.
tempat tertutup yang dilengkapi dengan sistem penghisapan gas buang.

SPECIFICATIONS
SPESIFIKASI
BAGIAN
ITEM SPESIFIKASI
SPECIFICATIONS
Throttle
Jarak maingripbebas
freeplay
throttle grip (putaran gas tangan) 2 –26– mm6 mm (0.1 – 0.2 in)
Spark plug
Busi Standard Standard CR8E
CR8E (NGK)atau
(NGK) or U24ESR-N
U24ESR-N (DENSO)
(DENSO)
Pilihan Optional CR9E
CR9E (NGK)atau
(NGK) or U27ESR-N
U27ESR-N (DENSO)
(DENSO)
Sparkrenggang
Jarak plug gap kutub busi 0.70
0,70 – 0.80mm
– 0,80 mm (0.028 – 0.032 in)
Valve clearance
Renggang klep IN (masuk) IN 0.06
0,06 mm mm (0.002 in)
EX (buang) EX 0.27
0,27 mm mm (0.011 in)
Engine oiloli
Kapasitas capacity
mesin At draining
Pada pembongkaran mesin 1,01.0 liter (1.06 US qt, 0.88 lmp qt)
liter
At
Pada penggantian disassembly
periodik 1,21.2 liters (1.27 US qt, 1.06 lmp qt)
liter
Recommended
Oli mesin yang engine oil
direkomendasikan Honda
Federal Oil "4-stroke
Supreme motorcycle
Ultratecoil" or oli
atau an mesin
equivalent
4 tak sejenis
API classification: SE or higher (except oils labeled as energy
dengan klasifikasi API service SE, SF atau SG
conserving on the circular API service label)
Viskositas:
JASO T 903 SAE 20W-50
standard: MA
-1
Putaran stasioner mesin 1.400 ± 100 menit
Viscosity: SAE 10W-30 (rpm)
Cairan
Engineantibeku
idle speedyang dianjurkan Honda
1,400PRE-MIX
± 100 minCOOLANT
-1
(rpm)
Rantai roda
Recommended antifreeze Ukuran/sambungan 428/116
Honda PRE-MIX COOLANT
Drive chain Jarak lenturanSize/link 20 428/116
– 30 mm
Minyak rem yang ditentukan Slack DOT20 3 atau
– 30 mmDOT(0.84– 1.2 in)
Specified
Jarak mainbrake
bebasfluid
handel kopling 10 DOT
– 20 3mm or DOT 4
2
Clutch lever freeplay
Tekanan Depan Pengendara saja 20010kPa– 20(2,00
mm (0.4 – 0.8
kgf/cm , in)
29 psi)
Cold tire
udara banpressure Front
Pengendara danDriver only
pembonceng 200200kPa kPa(2,00 kgf/cm22,,29
(2.00kgf/cm 29 psi)
dingin Belakang Driver and passenger
Pengendara saja 225200kPa kPa(2,25 kgf/cm22,,33
(2.00kgf/cm 29 psi)
Rear
Pengendara danDriver only
pembonceng 225225kPa kPa(2,25 kgf/cm22,,33
(2.25kgf/cm 33 psi)
psi)
Ukuran ban Depan Driver and passenger 225 –kPa
70/90 17M/C kgf/cm2, 33 psi)
(2.25 38P
Tire size Belakang Front 70/90-17M/C
80/90 – 17M/C 44P 38P
Merek ban Depan Rear SRI80/90-17M/C 44P
Tire brand Belakang Front SRISRI
Rear SRI
Kedalaman alur telapak Depan Sampai ke batas indikator
Minimum tire tread depth Front To indicator
ban minimum Belakang Sampai ke batas indikator
Rear To indicator

3-2
PERAWATAN
TORQUE
NILAI VALUES
TORSI
Spark plug
Busi 16 N.m16(1,6
N·mkgf.m;
(1.6 kgf·m, 12 lbf·ft)
12 lbf.ft)
Air cleaner
Air cleaner housing
housingcover
coverscrew
screw 1.0(0,1
1,0 N.m N·mkgf.m;
(0.1 kgf·m, 0.7 lbf·ft)
0,7 lbf.ft)
Valve adjusting
Valve adjustinglock
locknut
nut 10 N.m10(1,0
N·mkgf.m;
(1.0 kgf·m, 7 lbf·ft) Oleskan
7 lbf.ft) Apply
oli engine
mesinoil pada
to the threads and seating
ulir dan sur-
permukaan
face.
dudukan.
Crankshaft hole
Crankshaft holecapcap 8.0(0,8
8,0 N.m N·mkgf.m;
(0.8 kgf·m, 5.9 lbf·ft)
5,9 lbf.ft)
Timing hole
holecapcap 6.0(0,6
6,0 N.m N·mkgf.m;
(0.6 kgf·m, 4.4 lbf·ft)
4,4 lbf.ft)
Oil drain
drain bolt
bolt 25 N.m25(2,5
N·mkgf.m;
(2.5 kgf·m, 18 lbf·ft)
18 lbf.ft)
Rear axle
Rear axlenut
nut 59 N.m59(6,0
N·mkgf.m;
(6.0 kgf·m, 44 lbf·ft)
44 lbf.ft) U-nut
U-nut
Rear master
Rear mastercylinder push
cylinder rodrod
push locklock
nut nut 17 N.m17(1,7
N·mkgf.m;
(1.7 kgf·m, 13 lbf·ft)
13 lbf.ft)

TOOLSPERKAKAS
KUNCI

Lock nut wrench Valve adjusting wrench Timing cap wrench


07708-0030100 07708-0030300 07709-0010001

3-3
PERAWATAN
MAINTENANCE SCHEDULES
JADWAL PERAWATAN
Perform
JalankanthePemeriksaan
Pre-ride inspection in the Owner's
Sebelum Jalan Manual
di dalamat each scheduled
Buku Pedomanmaintenance
Pemilikperiod.
pada masing-masing periode perawatan yang
dijadwalkan. P: Periksa dan Bersihkan, Setel, Lumasi atau Ganti bila perlu. B:A:
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. Bersihkan.
Adjust. L: G: Ganti. L: Lumasi.
Lubricate.
Bagian-bagian berikut memerlukan pengetahuan mekanis tertentu. Beberapa bagian (terutama yang ditandai * dan **) dapat
The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more technical infor-
memerlukan lebih banyak informasi tehnis dan perkakas khusus. Hubungi AHASS Anda.
mation and tools. Consult an authorized Honda dealer.
FREQUENCYYANG LEBIH → PEMBACAAN ODOMETER (km) - CATATAN 1
WHICHEVER
FREKUENSI DULU DI-
COMES LIHAT
ODOMETER READING (NOTE 1)

CAPAI FIRST PG I PG II PG III HALA-MAN
REFER TO
BAGIAN YANG DISERVIS x 1,000 km 1 4 8 12 PAGE
500 2.000 4.000 8.000 12.000
x 1,000 mi 0.6 2.5 5 7.5
* SALURAN BAHAN BAKAR P P P 3-5
ITEMS NOTE MONTHS 6 12 18
* CARA KERJA GAS TANGAN P P P 3-5
* FUEL LINE I I I 3-5
* CARA KERJA CUK P P P 3-6
* THROTTLE OPERATION I I I 3-5
SARINGAN UDARA Catatan 2 SETIAP 16.000 km: G 3-6
* CHOKE OPERATION I I I 3-6
PERNAPASAN BAK MESIN Catatan 3 B B B 3-7
AIR CLEANER NOTE 2 EVERY 16,000 km (10,000 mi) 3-6
BUSI P P P G P 3-7
R
* JARAK RENGGANG KLEP P P P P P 3-9
CRANKCASE BREATHER NOTE 3 C C C 3-7
OLI MESIN G G SETIAP 2.000 km: G 3-11
SPARK PLUG I R I 3-7
** SARINGAN KASA OLI B 3-13
* VALVE CLEARANCE I I I I 3-9
* PUTARAN STASIONER MESIN P P P P P 3-13
ENGINE OIL R R 3-11
CAIRAN PENDINGIN RADIATOR Catatan 4 P 3-14
** ENGINE OIL STRAINER SCREEN C 3-13
* SISTEM PENDINGINAN P 3-14
* ENGINE IDLE SPEED
* SECONDARY AIR SUPPLY SYSTEM Catatan 5 I I I P I 3-13
3-15
RADIATOR
RANTAI RODA COOLANT NOTE P 4 SETIAP 500 km: P & L I 3-14
3-16
* MINYAK
COOLINGREM SYSTEM Catatan 4 P P I P 3-14
3-18
* KEAUSAN
SECONDARY AIR
BRAKE PADS SUPPLY SYSTEM NOTE 5 P P P I 3-15
3-19
DRIVEREM
SISTEM CHAIN P P PEVERY 1,000 P km (600 Pmi) I, L 3-16
3-20
BRAKE LAMPU
* SAKELAR FLUID REM NOTE 4 P PI I P I 3-18
3-20
BRAKE
* ARAH PADS
SINAR WEAR
LAMPU BESAR P P P PI I P I 3-19
3-21
BRAKE SYSTEM
SISTEM KOPLING P P P I PI I P I 3-20
3-21
* STANDARD
BRAKE LIGHTSAMPINGSWITCH P PI I P I 3-20
3-21
** SUSPENSI
HEADLIGHT AIM P PI I P I 3-21
3-22
CLUTCH SYSTEM
* MUR, BAUT, PENGENCANG P P I PI I I 3-21
3-22
SIDESTAND
** RODA/BAN Catatan 3 P P P PI I P I 3-21
3-23
*** BANTALAN
SUSPENSION KEPALA KEMUDI P I I P I 3-22
3-24
* NUTS, BOLTS, FASTENERS I I 3-22
** WHEELS/TIRES I I I 3-23
* **Harus
STEERING
diservis HEAD BEARINGS
oleh AHASS, kecuali jika pemilik mempunyai kunci perkakas yang tepat I dan I 3-24
data servis yang diperlukan, dan mempunyai ketrampilan mekanis untuk mengerjakannya.
** *DemiShould be serviced
keamanan, bymenganjurkan
kami an authorized Honda
agar dealer, unless the ownerini
pekerjaan-pekerjaan has properdilakukan
hanya tools and oleh
service data and is mechanically qualified.
AHASS.
** In the interest of safety, we recommend these items be serviced only by an authorized Honda dealer.
Honda recommends that an authorized Honda dealer should road test your motorcycle after each periodic maintenance is carried out.
CATATAN:
1. Pada pembacaan odometer lebih tinggi, ulangilah pada interval frekuensi yang ditentukan di atas.
NOTES:
2. Servis lebih sering jika dikendarai di daerah yang luar biasa basah atau berdebu.
1. At higher odometer readings, repeat at the frequency interval established here.
3. Servis lebih sering jika dikendarai dalam hujan atau dengan gas penuh.
2. Service more frequently when riding in unusually wet or dusty areas.
4. Ganti
3. Service moresetiap 2 tahun.
frequently whenPenggantian memerlukan
riding in rain or ketrampilan mekanis.
at full throttle.
4. Replace every 2 years. Replacement requires mechanical skill. Penggantian memerlukan ketrampilan mekanis.
5. Ganti PAIR air filter setiap 3 tahun atau 24.000 km.
5. Replace the PAIR air filter every 3 years or 24,000 km. Replacement requires mechanical skill.

3-4
PERAWATAN
FUEL LINEBAHAN BAKAR
SALURAN
Remove thebody
Lepaskan bodycover
cover (page 2-16).
(hal. 2-16).
Check the fuel line for deterioration, damage or leakage. FUEL LINE
Periksa thefuel
Replace line if (saluran
fuel line necessary. bahan bakar) terhadap
pemburukan kondisi, kerusakan atau kebocoran.
Install the bodybahan
Ganti saluran cover (page
bakar2-16).
bila perlu.

Pasang body cover (hal. 2-16).

THROTTLE
CARA OPERATION
KERJA GAS TANGAN
Check forterhadap
Periksa any deterioration
pemburukanor damage to the
kondisi atauthrottle cable.
kerusakan
Check throttle
pada the throttle grip (kabel
cable for smooth
gas).operation.
PeriksaCheck that grip
throttle the 2 – 6 mm (0.1 – 0.2 in)
throttle opens
(putaran gasandtangan)
automatically closes in
terhadap all steering kerja.
kelancaran posi-
tions.
Periksa bahwa throttle (gas tangan) membuka dan
secara otomatis
If the throttle menutup
grip does notpada semua
return posisilubricate
properly, kemudi.the
Jika throttle grip tidak dapat kembali dengan
throttle cable, clean and lubricate the throttle grip housing. benar,
lumasi kabel gas, bersihkan dan lumasi throttle grip
If the throttle
housing (rumah gripputaran
still does
gasnottangan).
return properly, replace the
throttle cable.
Jika throttle grip tetap tidak dapat kembali dengan
benar,
With theganti kabel
engine gas.turn the handlebar all the way to the
idling,
Sementara
right and left mesin
to ensure berputar stasioner,
that the idle speed doesputar stang stir
not change. If
seluruhnya ke kanancheck
idle speed increases, dan kiri
the untuk
throttlememastikan
grip freeplay bahwa
and
putaran stasioner
throttle cable tidak berubah. Jika putaran stasioner
connection.
naik, periksa jarak main bebas throttle grip dan
Measure the throttle grip freeplay at the throttle grip flange.
sambungan kabel gas.
FREEPLAY: 2 – 6 mm (0.1 – 0.2 in)
Ukur jarak main bebas throttle grip pada flens throttle
Throttle grip freeplay can be adjusted at the adjuster.
grip.
Remove the right pivot cover (page 2-12).
JARAK MAIN BEBAS: 2 – 6 mm
Loosen the lock nut and turn the adjuster until the correct
freeplay is obtained.
Tighten the lock nut while holding the adjuster.
Recheck the throttle operation.
Jarak main bebas throttle grip dapat disetel pada
Install the(penyetel).
right pivot cover (page 2-12). LOCK NUT
adjuster

Lepaskan right pivot cover (hal. 2-12)

Longgarkan lock nut (mur pengunci) dan putar adjuster


(penyetel) sampai jarak main bebas yang tepat
diperoleh.
Kencangkan lock nut sementara menahan adjuster.

Periksa kembali cara kerja kabel gas.

ADJUSTER
Pasang right pivot cover (hal. 2-12).

3-5
PERAWATAN
CHOKE OPERATION
CARA KERJA CUK
Periksa
Check forcara kerjalever
choke choke lever (handel
operation cuk) dan
and lubricate lumasi
the cable if
required.
kabel jika perlu.
Inspect the cable for cracks which could allow moisture to
Periksa
enter. kabel terhadap retak-retak yang dapat
menyebabkan masuknya
Replace the cable kelembaban.
if necessary.
Ganti kabel bila perlu.

CHOKE LEVER

AIR CLEANER
AIR CLEANER
(SARINGAN UDARA)
Remove the right front side cover (page 2-15).
Lepaskan right front side cover (hal. 2-15). AIR CLEANER HOUSING COVER
Remove the five screws and air cleaner housing cover.
Lepaskan kelima sekrup dan air cleaner housing cover.

SCREWS
Remove
Lepaskan and
dandiscard
buangtheairair cleanerelement
cleaner elementsesuai
in accordance
dengan
with the maintenance schedule (page 3-4).
jadwal perawatan (hal. 3-4).
Replace the element any time if it is excessively dirty or dam-
Ganti element setiap kali ia telah menjadi sangat kotor
aged.
atau rusak.
Install the removed parts in the reverse order of removal.
TORQUE:parts yang telah dilepaskan dalam urutan
Pasang
Air cleaner
terbalik housing cover screw:
dari pelepasan.
1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)
TORSI:
Air cleaner housing cover screw:
1,0 N.m (0,1 kgf.m; 0,7 lbf.ft)

AIR CLEANER ELEMENT

3-6
PERAWATAN
CRANKCASE BREATHER
(PERNAPASAN BAK MESIN)
• Service more frequently when ridden in rain, at full throt-
CATATAN:
• tle, or after
Harus the motorcycle
lebih is washed
sering diservis overturned. dalam BREATHER HOSE
jikaordikendarai
hujan,
Remove the leftdengan
pivot covergas penuh, atau setelah
(page 2-12).
sepedamotor dicuci atau terbalik.
Check the crankcase breather hose for deterioration, damage
or loose connection. Make sure that the hoses are not kinked,
Lepaskan left pivot cover (hal. 2-12).
pinched or cracked.
Periksa crankcase
Replace the breatherhose
crankcase breather hose (slang pernapasan
if necessary.
bak mesin) terhadap pemburukan kondisi, kerusakan
atau hubungan longgar. Pastikan bahwa slang-slang
tidak kusut, terjepit atau retak.

Ganti crankcase breather hose bila perlu.

CATATAN:
•• Service
Harus if diservis
the depositsjikalevel can be adanya
terlihat seen in theendapan
transparentdi
section
dalamofbagian
the air cleaner housing
transparan breather
dari drain hose.
air cleaner housing CLAMP
breather drain hose (slang
Check the air cleaner housing breather drain hose. pembuangan
pernapasan rumah saringan udara).
If necessary, release the clamp and remove the drain plug
from the drain hose, then drain the deposits into a suitable
Periksa
container.air cleaner housing breather drain hose.
Reinstall
Jika the lepaskan
perlu, drain plug. clamp (klem) dan lepaskan drain
plug (penyumbat pembuangan) dari drain hose,
kemudian buanglah endapan dalam tempat penampung
yang cocok.

Pasang kembali drain plug.


DRAIN PLUG

SPARK PLUG (BUSI)


REMOVAL
PELEPASAN
Disconnect spark
Lepaskan the spark
plugplug
capcap.
(topi busi).
SPARK PLUG CAP

Bersih
Clean di sekitar
around the Remove thebusi
Lepaskan spark plug using
dengan a spark plug kunci
menggunakan wrench.
busi.
dasar
spark busi
plug dengan
base with
udara dari Inspect oratau
Periksa replace
gantithebusi
spark plug as
seperti described
diuraikan di in the mainte-
dalam jadwal
compressed air
kompressor sebelum nance schedule
perawatan (hal.(page
3-4).3-4).
before removing the
melepaskan
spark plug,busi,
anddan
be
pastikan
sure that no debris is
bahwa kotoran tidak
allowed
dapattomemasuki
enter the
combustion chamber.
ruang pembakaran.

SPARK PLUG

3-7
PERAWATAN
INSPECTION
PEMERIKSAAN
Bersihkan
Clean electrodes
the spark (elektroda)
plug electrodes busi brush
with a wire dengan sikat
or special
kawat
plug atau special plug cleaner (alat pembersih busi).
cleaner. CENTER ELECTRODE
Periksa
Check theinsulator
insulator terhadap retak-retak
for cracks or atau
damage, and thekerusakan,
electrodes
danwear,
for electrodes
fouling orterhadap keausan, pengotoran atau
discoloration.
perubahan warna.
Replace the spark plug if necessary.
SelaluAlways the Ganti busi bila perlu.
usebusi
gunakan
yang spark
specified plug RECOMMENDED SPARK PLUG:
ditentukan
untuk BUSI YANG DIANJURKAN:
Standard: NGK: CR8E
on thissepedamotor
motorcycle.
ini. Standard: DENSO:
NGK: U24ESR-N
CR8E
DENSO: U24ESR-N
Optional: NGK: CR9E
Pilihan: NGK: CR9E
DENSO: U27ESR-N
DENSO: U27ESR-N

INSULATOR SIDE ELECTRODE

Measure
Ukur therenggang
jarak gap between the center
antara centerand side electrodes
electrode with
(elektroda
a feeler gauge.
tengah) dan side electrode (elektroda samping) dengan
sebuah feeler gauge (voeler busi). 0.70 – 0.80 mm
SPARK PLUG
JARAK GAP: 0.70
RENGGANG – 0.80
BUSI: mm– (0.028
0,70 0,80 mm– 0.032 in) (0.028 – 0.032 in)
If necessary,
Bila adjustjarak
perlu, setel the gap by bending
renggang the side menekuk
busi dengan electrode
carefully.
side electrode dengan hati-hati.

INSTALLATION
PEMASANGAN
Install and
Pasang hand
dan tighten the spark
kencangkan plug tocylinder
busi pada the cylinder
head,head,
dan SPARK PLUG SPARK PLUG CAP
then tighten the
kencangkan spark
busi plug torsi
dengan to theyang
specified torque dengan
ditentukan using a
spark plug wrench.
menggunakan kunci busi.
TORQUE:16
TORSI: N·m(1,6
16 N.M (1.6kgf.m;
kgf·m,12
12 lbf.ft)
lbf·ft)
Connect the spark plug cap.
Pasang spark plug cap (topi busi).

3-8
PERAWATAN
VALVE CLEARANCE
RENGGANG KLEP
INSPECTION
PEMERIKSAAN
CATATAN:
•• Inspect
Periksa anddan
adjust the valve
setel clearance
renggang while
klep the engine
dengan is
mesin
cold (below
dalam 35°C/95°F).
keadaan dingin (di bawah 35° C).
•• After the valve
Setelah clearance inspection,
pemeriksaan checkklep,
renggang the engine idle
periksa
speed (page 3-13).
putaran stasioner mesin (hal. 3-13).
•• Valve clearance inspection/adjustment
Pemeriksaan/penyetelan renggangcan be donedapat
klep with
the engine installed in the frame.
dilakukan dengan mesin terpasang pada rangka.
Remove the cylinder head cover (page 8-6).
Lepaskan cylinder head cover (hal. 8-6). TIMING HOLE CAP
Remove the timing hole cap and crankshaft hole cap.
Lepaskan timing hole cap dan crankshaft hole cap.
TOOL:
Timing cap
KUNCI wrench
PERKAKAS: 07709-0010001
Timing cap wrench or equivalent
07709-0010001
atau sejenisnya

CRANKSHAFT HOLE CAP

Rotate the crankshaft


Putar crankshaft counterclockwise
berlawanan arah jarumandjamalign
danthe "T"
mark on the flywheel with flywheel
the index (roda
notch gila)
on thedengan
left crank- INDEX NOTCH
tepatkan tanda "T" pada
case
indexcover.
notch (takik penunjuk) pada left crankcase cover.

"T" MARK

The index
Index line line on the
(garis cam sprocket
penunjuk) padamust
cambesprocket
flush with the
harus
cylindertingginya
head surfacedengan
as shown.permukaan cylinder head ROCKER ARMS
sama
seperti diperlihatkan.
Make sure the piston is at TDC (Top Dead Center) on the
compression stroke.
This position
Pastikan can piston
bahwa be obtained
beradaby confirming
pada TDC that there
(Top Deadis
slack in the
Center) [TMArocker arm.
(Titik If Atas)]
Mati there ispada
no slack, it is because
langkah the
kompressi.
piston is moving through the exhaust stroke to TDC. Rotate
the crankshaft
Posisi one full
ini dapat turn anddengan
diperoleh match upmemastikan
the "T" mark bahwa
again.
ada kerenggangan pada rocker arm.
Jika tidak ada kerenggangan, berarti bahwa piston
bergerak melalui langkah buang ke TDC.
Putar crankshaft satu putaran penuh dan tepatkan
tanda "T" sekali lagi. INDEX LINE

3-9
PERAWATAN
Check the
Periksa valve clearance
renggang by memasukkan
klep dengan inserting a feeler gauge
sebuah
between the adjusting screw and valve stem. screw ADJUSTING SCREW
feeler gauge (lidah voeler) antara adjusting
(sekrup penyetel) dan valve stem (tangkai klep).
VALVE CLEARANCE:
RENGGANG KLEP:
IN:(masuk):
IN 0.06 mm (0.0020,06in)mm
EX:(buang):
EX 0.27 mm (0.011
0,27in)
mm

FEELER GAUGE
ADJUSTMENT
PENYETELAN
Setel dengan
Adjust melonggarkan
by loosening the lock nutlock
and nut (mur
turning the pengunci)
adjusting ADJUSTING WRENCH LOCK NUT
dan memutar
screw until thereadjusting screw
is slight drag (sekrup
on the feelerpenyetel)
gauge. sampai
ada tahanan sedikit pada feeler gauge.
Apply engine oil to the lock nut threads and seating surface.
Hold
Oleskanthe adjusting screw pada
oli mesin and tighten
ulir the lock pengunci
mur nut to the spec-
dan
ified torque. duduk.
permukaan
TOOLS:
Tahan adjusting screw dan kencangkan lock nut dengan
Valve adjusting wrench
torsi yang ditentukan.
07708-0030300
Lock nut wrench 07708-0030100
KUNCI PERKAKAS:
TORQUE:10 N·mwrench
Valve adjusting (1.0 kgf·m, 7 lbf·ft)
07708-0030300
Lock nutthewrench
Recheck valve clearances.07708-0030100
LOCK NUT
TORSI: 10 N.m (1,0 kgf.m; 7 lbf.ft) WRENCH FEELER GAUGE
Install thekembali
Periksa cylinderjarak
head renggang
cover (pageklep.
8-7).
Apply engine
Pasang oil tohead
cylinder new cover
O-rings(hal.
and install
8-7). them to each hole
cap.
Oleskan oli mesin pada O-ring baru dan pasang pada
masing-masing hole cap (tutup lubang).

O-RINGS
Install and
Pasang tighten
dan the timing
kencangkan holehole
timing cap cap
and crankshaft hole
dan crankshaft
cap tocap
the dengan
specifiedtorsi
torque. TIMING HOLE CAP
hole yang ditentukan.

TORSI:
TORQUE:
Timing hole cap:
Timing hole cap:
6,0 N.m (0,6 kgf.m; 4,4 lbf.ft)
6.0 N·m hole
Crankshaft (0.6 kgf·m,
cap: 4.4 lbf·ft)
Crankshaft hole cap: 5,9 lbf-ft)
8,0 N.m (0,8 kgf.m;
8.0 N·m (0.8 kgf·m, 5.9 lbf·ft)

CRANKSHAFT HOLE CAP

3-10
PERAWATAN
ENGINE OIL
OLI MESIN
PEMERIKSAAN
OIL TINGGI PERMUKAAN
LEVEL INSPECTION
OLI MESIN
Hold the motorcycle
Letakkan in an pada
sepedamotor upright position.
posisi tegak.
Start the engine and let it idle for 3 – 5 minutes.
Hidupkan mesin dan biarkan berputar stasioner selama
Stop
3 - 5the engine and wait 2 – 3 minutes.
menit.
Matikanthe
Remove mesin dan cap/dipstick
oil filler tunggu 2 - 3andmenit.
wipe it clean.
Insert the oil filler cap/dipstick, but do not screw it in.
Lepaskan oil filler cap/dipstick (tutup pengisian
Remove the pengukur)
oli/tangkai oil filler cap/dipstick
dan sekaand check the oil level.
bersih.
Masukkan oil filler cap/dipstick, tanpa menyekrupnya ke
dalam.

Keluarkan oil filler cap/dipstick dan periksa tinggi


permukaan oli.

FILLER CAP/DIPSTICK

If thetinggi
Jika level permukaan
is below the oli
lower mark ontanda
di bawah the dipstick,
terendah fillpada
the
crankcase with recommended oil.
dipstick, isilah crankcase dengan oli yang dianjurkan.

UPPER

LOWER

Viskositas lain yang


Other viscosities RECOMMENDED
OLI MESIN YANG ENGINE
DIANJURKAN:OIL:
diperlihatkan pada
shown in the chart Honda Oil
"4-stroke motorcycle
Federal Supreme Ultratecoil" or oli
atau an equivalent
mesin 4 tak
maypeta dapatwhen
be used dipakai
the API classification:
sejenis SE or higher
dengan klasifikasi (except oils
API service SE,labeled
SF atauas
jika suhu
average rata-rata
temperature
SGenergy conserving
Viskositas: SAEon 20W-50
the circular API service label)
didaerah
in your riding area is JASO T 903 standard: MA
pengendaraan anda
within the indicated Viscosity: SAE 10W-30
berada di dalam
range.
daerah jangkauan
yang diperlihatkan

Periksa
Check bahwa
that O-ring
the O-ring is inberada dalam kondisi
good condition, replace baik, ganti
it if neces-
sary. O-RING
bila perlu
Apply engine oil to the O-ring and install it to the filler cap/
Oleskan oli mesin pada O-ring dan pasang pada filler
dipstick.
cap/dipstick.
Install the oil filler cap/dipstick.
Pasang oil filler cap/dipstick.

FILLER CAP/DIPSTICK

3-11
PERAWATAN
ENGINE OIL CHANGE
PENGGANTIAN OLI MESIN
Warm up themesin.
Panaskan engine.
Stop
Matikan mesinand
the engine danremove the oil
lepaskan oil filler
filler cap/dipstick.
cap/dipstick.

FILLER CAP/DIPSTICK

Place an oil bak


Letakkan pan under the engine di
penampung to catch the engine
bawah mesinoil,untuk
then
remove the drainolibolt/sealing SEALING WASHER
menampung mesin, washer.
kemudian lepaskan drain
bolt/sealing
Drain the engine washer (baut pembuangan oli/washer
oil completely.
perapat).
Install a new sealing washer onto the drain bolt.
Keluarkan oli mesin
Install and tighten the seluruhnya.
drain bolt/sealing washer to the speci-
fied torque.
Pasang sebuah sealing washer baru pada drain bolt.
TORQUE:25
Pasang dan N·m (2.5 kgf·m, drain
kencangkan 18 lbf·ft)
bolt/sealing washer
dengan torsi yang ditentukan.
TORSI: 25 N.m (2,5 kgf.m; 18 lbf.ft)

BOLT

Fillmesin
Isi the engine witholi
dengan themesin
recommended engine oil(hal.
yang dianjurkan (page3-11).
3-11).
O-RING
ENGINE OIL CAPACITY:
1.0 liter (1.06
KAPASITAS USMESIN:
OLI qt, 0.88 Imp qt) at draining
1.2 liters
1,0 liter (1.27
padaUS qt, 1.06 Impperiodik
penggantian qt) at disassembly
1,2 liter pada pembongkaran mesin
Check the oil level and install the oil filler cap/dipstick (page
3-11).
Periksa tinggi permukaan oli dan pasang oil filler
Make sure there
cap/dipstick are3-11).
(hal. no oil leaks.

Pastikan bahwa tidak ada kebocoran oli.

FILLER CAP/DIPSTICK

3-12
PERAWATAN
ENGINE OIL
OIL STRAINER
STRAINERSCREEN
SCREEN
(SARINGAN KASA OLI MESIN)
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Remove theright
Lepaskan rightcrankcase
crankcase cover
cover(page
(hal. 10-5).
10-5).
Be careful
Hati-hati agarnot to
tidak Pull the
Tarik oiloil strainerscreen
strainer screen keluar
out of the
daricrankcase.
crankcase.
damage
merusak the oil
oil strainer Wash the oil strainer screen thoroughly in nonflammable or
strainer screen. Cucilah
high flashoilpoint
strainer screen
solvent secara
until all menyeluruh
accumulated dirt hasdalam
been
cairan
removed.pembersih yang tidak dapat terbakar atau
mempunyai titik api tinggi sampai semua kotoran yang
Blow terkumpul
telah dry it with compressed
telah dicuciair to clean completely.
bersih.
Before installing the strainer, it should be examined closely
for damage,dengan
Keringkan and maketiupan
sure the sealing
udara darirubber is good condi-
compressor untuk
tion.
membersihkannya secara menyeluruh.
Sebelum memasang strainer, periksalah dengan
seksama terhadap kerusakan, dan pastikan bahwa
karet perapat berada dalam kondisi baik.
OIL STRAINER SCREEN
Install
Pasang the oil
oil strainer
strainerscreen withdengan
screen the thin edge
ujungfacing
yangin and
tipis
flange side facing
menghadap ke updalam dan sisi yang mempunyai ARAH OIL STRAINER SCREEN :
as shown.
pinggiran
Install menghadap
the right crankcasekecover
atas(page
seperti diperlihatkan.
10-10).
Pasang right crankcase cover (hal. 10-10).

CRANKCASE

PUTARAN STASIONER
ENGINE IDLE SPEED MESIN
•• Inspect
Periksaanddan
adjust
seteltheputaran
idle speed after all
stasioner other engine
setelah semua
maintenance items have
bagian perawatan beenyang
mesin performed and are
lain telah within
dijalankan
specifications.
dan sesuai dengan spesifikasi.
•• The engineharus
Mesin must be dalam
warm for keadaan
accurate idlepanas
speed inspec-
untuk
tion and adjustment.
pemeriksaan danTenpenyetelan
minutes of stop-and-go riding is
putaran stasioner
sufficient.
yang akurat. Sepuluh menit pengendaraan
Warm berhenti-jalan
up the engine adalah
for aboutcukup.
10 minutes.
Panaskan mesin selama kira-kira
Connect a tachometer and check the idle 10 menit.
speed.
IDLE SPEED:
PUTARAN 1400 ± 100 min
STASIONER:
-1
1.400(rpm)
-1
± 100 menit (rpm)
If the putaran
Jika idle speed is out of di
stasioner specification, turn theputar
luar spesifikasi, throttle stop
throttle
screw as required
stop screw to obtaindiperlukan
sebanyak the specifieduntuk
idle speed.
mendapatkan
Lightly
putaranopen the throttle
stasioner for 2 – 3 times, then check the
yang ditentukan.
engine
Bukalah idlethrottle
speed again.
(gas tangan) 2 – 3 kali, kemudian
periksa putaran stasioner mesin sekali lagi.

THROTTLE STOP
SCREW

3-13
PERAWATAN
RADIATOR COOLANT
CAIRAN PENDINGIN RADIATOR
Support thesepedamotor
Letakkan motorcycle inpada
upright position.
posisi tegak.
GARIS "UPPER" LEVEL RESERVE
Check the coolant level of the reserve tank with the engine TANK
Periksa
running attinggi
normalpermukaan cairan pendingin dari tangki
operating temperature.
cadangan sementara mesin dalam keadaan hidup pada
The level
suhu should
operasi be between the "UPPER" and "LOWER"
normal.
level lines with the motorcycle in an upright position.
Tinggi permukaan
If necessary, harus berada
add recommended di antara
coolant garis tinggi
as follows:
permukaan "UPPER" dan "LOWER" dengan
sepedamotor pada posisi tegak.
Bila perlu, tambahkan cairan pendingin yang
direkomendasikan sebagai berikut:
"LOWER"
LEVEL

Buka kunci tempat duduk dan buka tempat duduk


Unlock and
dengan open the seat anak
menggunakan using kunci
ignition key.
kontak.
RESERVE TANK CAP
Lepaskan
Remove thereservereservetank
tankcapcap(tutup tangki
and add the cadangan)
coolant to dan
the
tambahkan
"UPPER" levelcairanline withpendingin
recommended ke coolant.
garis permukaan
"UPPER" (teratas) dengan cairan pendingin yang
RECOMMENDED COOLANT:
dianjurkan.
Honda PRE-MIX COOLANT
CAIRAN PENDINGIN YANG DIANJURKAN:
Hondathe
Reinstall PRE-MIX COOLANT
reserve tank cap.
Tutup kembali reserve tank cap.
Check if apakah
Periksa there are ada
any coolant leaks cairan
kebocoran when thependingin
coolant level
jika
decreases very rapidly.
tinggi permukaan cairan pendingin turun dengan sangat
cepat.
If the reserve tank becomes completely empty, there is a pos-
Jika
sibilitytangki cadangan
of air getting into themengering sama sekali, ada
cooling system.
kemungkinan
Be sure to remove masuknya udarathekecooling
any air from dalam sistem
system as
pendinginan.
described on page 6-6.
Pastikan untuk mengeluarkan udara dari sistem
pendinginan seperti diuraikan pada halaman 6-6.
COOLING
SISTEM SYSTEM
PENDINGINAN
Periksa
Check thejalan lintasan
radiator udara radiator
air passages terhadap
for clogging sumbatan
or damage.
Straighten
atau bent fins, and remove insects, mud or other
kerusakan.
obstructions sirip-sirip
Luruskan with compressedyangairbengkok,
or low waterdan
pressure.
keluarkan
Replace the lumpur
serangga, radiator atau
if thepenghalang
air flow is restricted over udara
lain dengan more
than kompressor
dari 20 % of the radiating
atau airsurface.
bertekanan rendah.
Ganti radiator jika aliran udara terbatas untuk lebih dari
20% permukaan radiator.

Inspect the
Periksa water
water hoses(slang-slang
hoses for cracks or
air)deterioration,
terhadap retak-and
replace
retak them
atau if necessary.kondisi, dan ganti bila perlu.
pemburukan WATER HOSES
Check thekekencangan
Periksa tightness of alldari
watersemua
hose band screws
water (page
hose 6-
band
10).
screws (sekrup pita pengikat slang air) (hal. 6-10).

3-14
PERAWATAN
SECONDARY AIR
AIR SUPPLY SYSTEM
SYSTEM
Remove thecenter
Lepaskan center body cover/radiator
cover/radiatorshroud
shroud(page 2-6).
(hal. 2-6).
PAIR AIR FILTER-ke-
Check the PAIR air filter-to-control valve hose for cracks, CONTROL VALVE HOSE
deterioration, damage or loose connection.
Periksatheslang
Check PAIR valve-to-control
PAIR check air filter – ke – hose
valve control valve
for dam-
terhadap
age or looseretak-retak,
connection. pemburukan kondisi, kerusakan
atau sambungan longgar.
Make
Periksasureslang
that the hosescheck
PAIR are notvalve
cracked
– and
ke replace if neces-
– control valve
sary.
terhadap kerusakan atau sambungan longgar.
If the hose show any signs of heat damage, inspect the PAIR
Pastikan
check valvebahwa slang-slang tidak retak dan ganti bila
(page 5-24).
perlu.

Jika slang menunjukkan tanda-tanda kerusakan akibat


panas, periksalah PAIR check valve (hal. 5-24).

PAIR CHECK VALVE-ke-


CONTROL VALVE HOSE

Inspect oratau
Periksa replace
gantithePAIR
PAIRair air filter
filter seperti
as described in thedi
diuraikan
maintenance
jadwal perawatan schedule (page
(hal. 3-4).
3-4), PAIR AIR FILTER
Remove the PAIR air filter (page 5-26).
Check the filter and replace if it is dirty or damaged.
Lepaskan PAIR air filter (hal. 5-26).
Install
Periksa thefilter
PAIR airganti
dan filter bila
(pageia5-26).
kotor atau rusak.

Pasang PAIR air filter (hal. 5-26).

3-15
PERAWATAN
DRIVE CHAIN
DRIVE CHAIN(RANTAI RODA)
DRIVE CHAIN KEKENDURAN
PEMERIKSAAN SLACK INSPECTION
RANTAI RODA
Jangan sekali-kali
Never inspect and Turn the kunci
Putar ignition switch
kontakOFF, kesupport the motorcycle
posisi with its
OFF, letakkan
memeriksa dan
adjust the drive chain
menyetel rantai roda
centerstand andpada
sepedamotor shift the transmission
standard into neutral.
utamanya dan masukkan
while the engine is transmissi ke dalam
sewaktu mesin dalam Check the slack in the netral.
drive chain lower run midway between
keadaanrunning.
hidup. Periksa kekenduran pada bagian bawah rantai
the sprockets.
ditengah-tengah di antara sprockets.
DRIVE CHAIN
LENTURAN
SLACK: RANTAI RODA: 20 – 3020
mm– 30(0.8mm
– 1.2 in)

PERINGATAN
Lenturan rantai yang berlebihan, 50 mm atau lebih,
Excessive
dapat chain slack,kerusakan
menimbulkan 50 mm (2.0pada
in) orrangka.
more, may damage
the frame.

20 – 30 mm (0.8 – 1.2 in)

ADJUSTMENT
PENYETELAN
Longgarkan
Loosen the axle axle nut.
nut.
Longgarkan lock SLOT AXLE NUT
Loosen the lock nutsnuts
and dan putar
turn the adjusting
adjusting nuts nuts sampai
until the cor- LOCK NUT
lenturan
rect drive rantai roda is
chain slack yang tepat telah diperoleh.
obtained.
Pastikan bahwa garis penunjuk pada kedua adjusting
Make sure
plates telahthe disetel
index lines
padaon both
jarakadjusting platespada
yang sama are aligned
ujung
with the rear end of the axle slots in the swingarm.
belakang dari axle slots (lubang poros) pada swingarm
Tighten the axle nut to the specified torque.
(lengan ayun).
TORQUE:59 axle
Kencangkan N·m nut
(6.0dengan
kgf·m, 44torsi yang ditentukan.
lbf·ft)
Hold the adjusting
TORSI: nuts kgf.m;
59 N.m (6,0 and tighten the lock nuts.
44 lbf.ft)
Recheck the drive chain slack and free wheel rotation.
Tahan adjusting nuts dan kencangkan lock nuts.
Periksa kembali lenturan drive chain dan kebebasan
perputaran roda.
ADJUSTING NUT INDEX LINES
CLEANING AND
PEMBERSIHAN LUBRICATION
DAN PELUMASAN
If the rantai
Jika drive chain
roda becomes
menjadiextremely
sangat dirty,
kotor,it should be
ia harus
removed anddancleaned prior to lubrication. RETAINING CLIP
dilepaskan dibersihkan sebelum dilumasi.
Remove the left crankcase rear cover (page 2-18).
Carefully remove
Lepaskan the retaining
left crankcase rearclip with(hal.
cover pliers.
2-18).
Remove the master link and link plate, and disconnect the
drive chain.
Dengan hati-hati lepaskan retaining clip dengan tang.
Remove the master
Lepaskan drive chain.
link dan link plate, dan lepaskan
sambungan rantai roda.
Lepaskan rantai roda.

Clean the chain


Bersihkan with
rantai non-flammable
dengan or high flashyang
cairan pembersih point tidak
sol-
vent and wipe it dry. PEMBERSIHAN SIKAT LUNAK
dapat terbakar atau mempunyai titik api tinggi dan seka
Be sure the chain has dried completely before lubricating.
kering. CAIRAN
Inspect the bahwa
Pastikan drive chain for possible
rantai telah damage or wear.
mengering seluruhnya PEMBERSIH
Replace any
sebelum chain that has damaged rollers, loose fitting
melumasinya.
links, or otherwise
Periksa rantai rodaappears unserviceable.
terhadap kerusakan atau keausan.
Installing a new chain on badly
Ganti rantai roda yang mempunyai worn sprockets
rollerswill
yangcause the
rusak,
new chainlinks
fitting to wearlonggar,
quickly. atau bagaimanapun juga
Inspect and replace the sprocket as necessary. SEKA DAN
tampaknya tidak dapat diperbaiki lagi. KERINGKAN
Pemasangan rantai roda baru pada sprockets yang
sangat aus akan mengakibatkan keausan cepat pada
rantai yang baru.
Periksa dan ganti sprocket bila perlu.

3-16
PERAWATAN
Lubricatedrive
Lumasi the drive
chainchain withroda)
(rantai #80 –dengan
90 gear gear
oil oroil
drive
(oli
chain lubricant.
transmissi) Wipe atau
# 80-90 off the excess
drive oil or
chain drive chain
llubricant lubri- DRIVE CHAIN
(pelumas
cant. roda).
rantai Seka oli atau pelumas rantai roda
berlebihan.

#80 – 90 GEAR OIL OR


DRIVE CHAIN LUBRICANT

Measure
Ukur theantara
jarak distance between dari
rentangan a span
41 of 41(40
pins pinslinks)
(40 links)
dari
fromcenter
pin pin center to center
ke pin pin center by holding
(pusat so that all links are
pin) dengan
straight.
memegangnya sehingga semua links adalah lurus.

DRIVE CHAIN
PANJANG LENGTH
RANTAI RODA(41 pins/40
(41 links)
pins/40 links)
STANDARD:
STANDARD: 508 mm508
(20.0mm
in) BATAS SERVIS: 518 mm (20.4 in)
BATAS
SERVICESERVIS: 518 mm
LIMIT: 518 mm (20.4 in)

SPROCKET INSPECTION
PEMERIKSAAN SPROCKET
Remove theleft
Lepaskan leftcrankcase
crankcase rear
rearcover
cover(page
(hal.2-18).
2-18).
AUS
Inspect the drive and driven sprocket teeth for wear or dam-
Periksa gigiif necessary.
age, replace drive sprocket (penggerak) dan driven
sprocket (yang digerakkan) terhadap keausan atau
Never use a new
kerusakan, gantidrive
bila chain
perlu.on worn sprockets.
Both chain and sprockets must be in good condition, or new
replacement
Jangan chain willmemakai
sekali-kali wear rapidly.
rantai roda baru di atas
sprocket yang aus.
Baik rantai roda maupun sprockets harus berada dalam
kondisi baik, atau rantai pengganti akan cepat
mengalami keausan.
RUSAK BAIK

3-17
PERAWATAN
BRAKE FLUID
MINYAK REM
PERINGATAN
Minyak rem yang tertumpah dapat merusak parts
Spilled dicat,
yang fluid canatau
damage painted,
terbuat plastic
dari or rubber
plastik atauparts.
karet.
Place a rag over these parts whenever the
Letakkan kain lap menutupi parts ini setiap kali system is serviced.
sistem
diservis.
• Do not mix different types of fluid, as they are not com-
• patible
Jangan with mencampurkan
each other. bermacam-macam jenis
• Do not allow
minyak rem,foreign
oleh material
karena to enter the
mereka system
tidak when
cocok satu
filling
samathe reservoir.
lain.
•• AJagalah
low fluidagar
level may
bendabe due to wear
asing tidakof the brakememasuki
dapat pads. If
the brakeketika
sistem pads are worn reservoir.
mengisi and caliper pistons are pushed
• out, this accounts
Tinggi permukaan for aminyak
low fluidremlevel. If the
yang brake rendah
terlalu pads
are not worn
mungkin and fluid level
disebabkan olehis keausan
low, checkbrakethe entire sys-
pads. Jika
tem
brakefor leaks
pads(page
telah3-20).
aus dan caliper pistons terdorong
keluar, ini merupakan penyebab rendahnya tinggi
permukaan minyak rem. Jika brake pads tidak aus
dan permukaan minyak rem rendah, periksalah
keseluruhan sistem terhadap kebocoran (hal. 3-20).

FRONT
REM BRAKE
DEPAN
Putar
Turn thestang stir so
handlebar sedemikian rupa issehingga
that the reservoir reservoir
level and check the
mendatar
front brake dan
fluid periksalah
level throughtinggi permukaan
the sight glass. minyak rem
melalui kaca pengintaian.
If the level is near the "LOWER" level line, check the front
brake pads for wear (page 3-19).
Jika tinggi permukaan dekat garis permukaan
"LOWER", periksalah brake pads depan terhadap
keausan (hal. 3-19).

"LOWER" LEVEL LINE

REAR
REM BRAKE
BELAKANG
Support thesepedamotor
Letakkan motorcycle on di
a level
atassurface, and check
permukaan the rear
mendatar,
brakeperiksalah
dan fluid level.tinggi permukaan minyak rem belakang.
If the level is near the "LOWER" level line, check the rear
Jika
braketinggi permukaan
pads for wear (pagedekat
3-19). dengan garis permukaan
"LOWER", periksalah brake pads belakang terhadap
keausan (hal. 3-19).

"LOWER" LEVEL

3-18
PERAWATAN
BRAKE PADS
KEAUSAN WEAR
BRAKE PADS
FRONTPADS
BRAKE BRAKE PADS
DEPAN
Check thebrake
Periksa brakepads
pads for wear. keausan.
terhadap
Always replace the Replace the brake pads if either pad is worn to the bottom of
Selalu
brake padsganti
as a brake
set to Gantilah
wear brake pads jika salah satu pad telah aus
indicator.
pads assure
sebagaieven
satudisc
set sampai bagian bawah dari wear indicator (indikator
untuk memastikan For brake pad replacement (page 15-8).
keausan).
pressure.
tekanan merata pada
disc.
Untuk penggantian brake pad (hal. 15-8).

WEAR INDICATOR

REAR
BRAKEBRAKE PADS
PADS BELAKANG
Periksa
Check thebrake
brakepads terhadap
pads for wear. keausan.
Selalu ganti brake Gantilahthe
brake WEAR INDICATOR
Always replace the Replace brakepads
padsjika salahpad
if either satu pad telah
is worn to theaus
bottom of
pads sebagai
brake pads as satu
a setset
to sampai
wear bagian bawah dari wear indicator.
indicator.
untuk memastikan
assure even disc
tekanan merata pada For brake pad replacement (page 15-10).
pressure.
disc.
Untuk penggantian brake pad (hal. 15-10).

3-19
PERAWATAN
BRAKE
SISTEM SYSTEM
REM
INSPECTION
PEMERIKSAAN
Tekan handel
Firmly apply therem
brakeatau
leverpedal remand
or pedal, dengan kuat,nodan
check that air
periksa bahwa
has entered tidak ada udara yang memasuki sistem.
the system. DEPAN: BRAKE HOSE
Jika
If the handel rem feels
lever or pedal atausoft
pedal rem when
or spongy terasa lunak bleed
operated, atau
the air from
seperti the system.
sepons ketika ditekan, keluarkan udara dari
sistem.
For brake air bleeding (page 15-6).
Inspectprosedur
Untuk the brake pengeluaran
hoses and fittings
udarafordari
deterioration,
sistem rem cracks
(hal.
and signs of leakage.
15-6).
Tighten any loose fittings.
Replace hoses
Periksa and fittings
brake hose as(slang
required.
rem) dan peralatan
pemasangannya terhadap pemburukan kondisi, retak-
retak atau tanda-tanda kebocoran.
Kencangkan peralatan pemasangan yang longgar.
Gantilah hoses (slang-slang) dan fittings (peralatan
pemasangan) bila perlu.
BELAKANG:

BRAKE HOSE
BRAKE PEDAL
PENYETELAN HEIGHTADJUSTMENT
TINGGI PEDAL REM
Longgarkan
Loosen locknut
the lock nutand
(mur
turnpengunci) danuntil
the push rod putar
thepush rod
correct
sampai
pedal ketinggian
height pedal yang tepat telah diperoleh.
is obtained. PUSH ROD
Setelah penyetelan, kencangkan lock nut dengan torsi
After adjustment, tighten the lock nut to the specified torque.
yang ditentukan.
TORQUE:17 N·m (1.7 kgf·m, 13 lbf·ft)
TORSI: 17 N.m (1,7 kgf.m; 13 lbf.ft)
For standard brake pedal height (page 15-19).
Untuk ketinggian pedal rem standard (hal. 15-19).

LOCK NUT
BRAKE LIGHT SWITCH
BRAKE LIGHT
(SAKLAR LAMPU REM) SWITCH
TheSaklar lampulight
front brake rem Setel
Adjust brake
the brakelight
lightswitch
switch(saklar lampu
so that the brakerem) sehingga
light comes on
depan
switch doestidak
not lampu
just priorrem mulai
to the brakemenyala tepatengaged.
actually being sebelum rem sendiri BRAKE LIGHT SWITCH
requirememerlukan
adjustment. mulai bekerja.
If the light fails to come on, adjust the switch so that the light
penyetelan. Jika
comeslampu remproper
on at the tidaktime.
mau hidup, setel saklar sehingga
lampu rem menyala pada waktu yang tepat.
Hold the switch body and turn the adjuster. Do not turn the
CATATAN:
switch body.
Tahan badan saklar dan putar adjuster (penyetel).
Jangan memutar badan saklar.

ADJUSTER

3-20
PERAWATAN
HEADLIGHT
PENYETELANAIM ARAH SINAR
LAMPU BESAR
Support the motorcycle in an upright position.
HEADLIGHT UNIT
Adjust thearah
Setel headlight
sinar Adjust
Letakkanthe headlight aim vertically
sepedamotor by loosening
pada posisi tegak. the headlight
aim as besar
lampu specified by
sesuai beam adjusting bolt and moving the headlight unit.
local laws
dengan and
undang- Setel arah sinar lampu besar dalam arah vertikal
undang dan
regulations. dengan melonggarkan adjusting bolt (baut penyetelan)
peraturan lokal. sinar lampu besar dan menggerakkan headlight unit.

ADJUSTING BOLT
CLUTCH
CLUTCH SYSTEMSYSTEM
(SISTEM KOPLING)
Measure the clutch
Ukur jarak main lever
bebasfreeplay
handelat the end ofpada
kopling the clutch
ujung
lever.
handel kopling. 10 – 20 mm (0.4 – 0.8 in)
FREEPLAY: 10 – 20 mm (0.4 – 0.8 in)
JARAK MAIN BEBAS: 10 – 20 mm

Loosen the lock


Longgarkan locknut and
nut turnpengunci)
(mur the adjusting
dannut to adjust
putar the
adjusting ADJUSTING NUT
freeplay.
nut (mur penyetel) untuk menyetel jarak main bebas.
Tighten the lock
Kencangkan nutnut
lock while holding the
sementara adjustingadjusting
menahan nut. nut.
If proper freeplay cannot be obtained, or the clutch slips dur-
ing jarak
Jikatest ride,main bebas yang
disassemble benarthe
and inspect tidak dapat
clutch diperoleh,
(page 10-13).
atau kopling slip sewaktu test pengendaraan, bongkar
dan periksa kopling (hal. 10-13).

LOCK NUT
SIDESTAND
SIDESTAND
(STANDARD SAMPING)
Support thesepedamotor
Letakkan motorcycle with
padaits standard
centerstandutamanya.
Check the sidestand spring for damage or loss of tension.
Periksa
Check thesidestand spring (pegas
sidestand assembly standard
for freedom samping)
of movement and
terhadap kerusakan
lubricate the sidestand atau
pivotkehilangan
if necessary.tegangan.
Periksa sidestand samping terhadap kebebasan
pergerakan dan lumasi sidestand pivot (engsel standard
samping) bila perlu.

SPRING

SIDESTAND

3-21
PERAWATAN
SUSPENSION
SUSPENSI
FRONT SUSPENSION
PEMERIKSAAN INSPECTION
SUSPENSI DEPAN
Periksa
Check thepergerakan
action of thefork (garpu)
forks dengan
by operating thememasang rem
front brake and
depan dan menekan
compressing suspensi depan
the front suspension several beberapa
times. kali.
Periksa
Check thekeseluruhan
entire assemblysusunan
for signs ofterhadap tanda-tanda
leaks, damage or loose
fasteners. kerusakan atau kelonggaran pengikat.
kebocoran,
Replace damaged components which cannot be repaired.
Parts suspensi
Loose, wornyang
Ganti komponen-komponen yang rusak yang tidak
or
Tighten all nuts and bolts.
longgar, aus atau
damaged suspension dapat diperbaiki.
rusak dapat
For fork service
Kencangkan
parts impair
mempengaruhi (page mur
semua 13-14).
dan baut.
motorcycle stability
kestabilan dan Untuk menservis fork (hal. 13-14).
and control.
pengendalian
sepedamotor.

FORK

REAR SUSPENSION
PEMERIKSAAN INSPECTION
SUSPENSI BELAKANG
Check the action
Periksa of the rear
bekerjanya shock absorber
shock absorberby compressing
(sokbreker)
the rear end several
belakang dengantimes. menekan bagian belakang
Check the entire
sepedamotor shock absorber
beberapa kali. assembly for leaks, damage
or loose fasteners.
Periksa keseluruhan susunan shock absorber terhadap
Replace damaged components which cannot be repaired.
kebocoran, kerusakan atau kelonggaran pengikat.
Loose, worn or
Tighten all nuts and bolts.
Parts suspensi yang
damaged suspensionGanti komponen-komponen yang rusak yang tidak
longgar, aus atau rusak
For shock
dapat
parts impair
dapat mempengaruhi
absorber service (page 14-12).
diperbaiki.
motorcycle Kencangkan semua mur dan baut.
stability
kestabilan dan
and control.
pengendalian Untuk menservis shock absorber (hal. 14-12).
sepedamoto.

REAR SHOCK ABSORBER


Support the
Topang motorcycle using
sepedamotor a safety
dengan standstand
safety or hoist, raise the
(penopang
rear wheel offatau
pengaman) the ground.
katrol, naikkan roda belakang lepas BUSHINGS
tanah.
Check for worn swingarm bushings by grabbing the rear
wheel and attempting to move the wheel side to side.
Periksa terhadap swingarm bushings (bos lengan ayun)
Replaceaus
yang the bushings
denganif any looseness to
memegang noted.
roda belakang dan
mencoba menggerakkan
For swingarm service (page roda dari sisi ke sisi.
14-13).

Ganti bushings jika ada kelonggaran.

Untuk menservis swingarm (hal. 14-13).

MUR,
NUTS,BAUT, PENGIKAT
BOLTS, FASTENERS
Periksa bahwa semua mur, sekrup dan baut rangka
Check dikencangkan
telah that all chassis nuts, screwsnilai
dengan and bolts
torsi are tightened
mereka to
yang
their correct torque
benar (hal. 1-10). values (page 1-10).
Check thatbahwa
Periksa all cotter pins, safety
semua cotterclips,
pins,hose clamps
safety and cable
clips, hose
stays are in place and properly secured.
clamps (klem slang) dan cable stays ada pada
tempatnya dan telah dikencangkan dengan benar.

3-22
PERAWATAN
WHEELS/TIRES
WHEELS/TIRES
(RODA/BAN) Support
Dukungthe motorcycle using
sepedamotor a safety
dengan stand or hoist,
menggunakan raise the
sebuah
front
safetywheel off the
stand atauground.
katrol, naikkan roda depan lepas
tanah.the front fork leg and move the front wheel sideways
Hold
with force to see if the wheel bearings are worn.
Tahan front fork leg (kaki garpu depan) dan gerakkan
For
rodafront wheelkeservice
depan (pagedengan
samping 13-10). tenaga untuk melihat
apakah wheel bearings (bantalan roda) aus.

Untuk menservis roda depan (hal. 13-10).

WHEEL BEARINGS

Support the
Dukung motorcycle using
sepedamotor a safety
dengan stand or hoist,
menggunakan raise the
sebuah
rear wheel
safety off the
stand ground.
atau katrol, naikkan roda belakang lepas
tanah.
Hold the swingarm and move the rear wheel sideways with
force to see if the wheel and driven flange bearings are worn.
Tahan swingarm dan gerakkan roda belakang ke
For rear wheel
samping denganservice (pageuntuk
tenaga 14-5).melihat apakah bantalan
roda dan bantalan driven flange aus.

Untuk menservis roda belakang (hal. 14-5).

WHEEL BEARINGS

Periksa
Check thetekanan udarawith
tire pressure banadengan sebuah
tire pressure tire when
gauge pressure
the
gauge
tires are(alat
cold.pengukur tekanan udara ban) TIRE PRESSURE GAUGE
dengan ban dalam keadaan dingin.
RECOMMENDED TIRE PRESSURE AND TIRE SIZE:
TEKANAN UDARA BAN DAN UKURAN BAN:
FRONT REAR
Tire pressure 200 225
Driver only DEPAN BELAKANG
kPa (kgf/cm2, psi)
Tekanan udara Pengendara 200
(2.00, 29)225 (2.25, 33)
ban Driver and (2,00; 200
saja 29) (2,25; 33)225
kPa passenger 200(2.00, 29)225 (2.25, 33)
(kgf/cm 2; Pengendara
Tire
psi) size dan (2,00;70/90-
29) (2,25; 80/90-
33)
pembonceng 17M/C 38P 17M/C 44P
Ukuran ban 70/90- 80/90-
17M/C 17M/C 44P
38P

Check theban
Periksa tires terhadap
for cuts, embedded
sayatan,nails,
pakuor other
yangdamage.
tertancap,
Check the front and
atau kerusakan rear wheels for trueness.
lain.
Periksa the
Measure bahwa roda atdepan
tread depth danof the
the center belakang
tires. sebidang
dengan stang stir dalam keadaan lurus.
Replace the tires when the tread depth reaches the following
limits.
Ukur kedalaman alur telapak ban pada bagian tengah
MINIMUM
ban. TIRE TREAD DEPTH
FRONT:
Ganti ban To
jikaindicator
kedalaman alur telapak ban mencapai
batas
REAR: berikut.
To indicator

KEDALAMAN ALUR TELAPAK BAN MINIMUM


DEPAN: Sampai ke indikator
BELAKANG: Sampai ke indikator

3-23
PERAWATAN
STEERING HEAD
HEAD BEARINGS
(BANTALAN KEPALA KEMUDI)
Support the motorcycle using a safety stand or hoist, raise the
Dukung sepedamotor
front wheel dengan sebuah safety stand atau
off the ground.
katrol, naikkan roda depan lepas tanah.
Check that the handlebar moves freely from side to side.
Make sure the control cables do not interfere with the handle-
Periksa bahwa stang stir dapat bergerak dengan bebas
bar rotation.
dari sisi ke sisi. Pastikan bahwa kabel pengontrol tidak
mengganggu perputaran stang stir.

Periksa
Check for bantalan
steering steering stem by
stem bearings dengan memegang
grabbing kaki
the fork legs
and attempting
garpu to move the
dan mencoba front fork forward
menggerakkan to backward.
garpu depan ke
depan dan belakang.
If the steering stem moves unevenly, binds, or has vertical
movement, inspect the steering head bearings (page 13-22).
Jika steering stem bergerak secara tidak merata, terikat,
atau ada pergerakan vertikal, periksalah bantalan
STEM
steering head (kepala kemudi) (hal. 13-22).
BEARINGS

3-24
4. SISTEM PELUMASAN

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

SERVICE INFORMATION
KETERANGAN ····························· 4-3
SERVIS ........................4-3 OIL PUMP··························································4-4
POMPA OLI ............................................. 4-4

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

CAMSHAFT
ROCKER ARM

OIL PUMP

CRANKSHAFT

OIL STRAINER SCREEN

MAINSHAFT

COUNTERSHAFT

4-2
SISTEM PELUMASAN
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
! PERHATIAN
Oli mesin bekas dapat menyebabkan kanker kulit jika berulangkali dibiarkan mengenai kulit untuk waktu lama. Walaupun ini tidak besar
Used engine oilkecuali
kemungkinannya may cause
jika skin
andacancer if repeatedly
menangani oli bekasleftsetiap
in contact
hari, with
tetapthe skin for prolonged
dianjurkan periods.
untuk secara Although
menyeluruh this is unlikely
mencuci unless
tangan anda you
dengan
sabun danused
handle air sesegera mungkin
oil on a daily basis,setelah menangani
it is still advisableolitobekas.
thoroughly wash your hands with soap and water as soon as possible after handling
used oil.
•• Pompa
The oli dapat
oil pump can bediservis
serviceddengan
with themesin
engineterpasang
installed in pada rangka.
the frame.
•• Prosedur
The service servis di dalam
procedures in thisbab ini harus
section must bedijalankan
performeddengan
with themengeluarkan oli mesin.
engine oil drained.
•• Ketika
When melepaskan
removing dan memasang
and installing pompa
the oil pump, oli, jagalah
use care agardust
not to allow debu atautokotoran
or dirt enter thetidak memasuki mesin.
engine.
•• IfJika sebuahofbagian
any portion dari pompa
the oil pump is worn oli telahthe
beyond aus melampaui
specified servicebatas
limit, servis
replaceyang
the oilditentukan,
pump as an gantilah
assembly.pompa oli sebagai sebuah
• After the oil pump has been installed, check that there are no oil leaks.
susunan.
•• Refer to the
Setelah following:
pompa oli telah dipasang, periksalah bahwa tidak ada kebocoran oli.
• –Lihat
Engine oil level
sebagai check (page 3-11)
berikut:
–- Engine oil change
Pemeriksaan (pagepermukaan
tinggi 3-12) oli mesin (hal. 3-11)
- Penggantian oli mesin (hal. 3-12)
SPECIFICATIONS
SPESIFIKASI
Satuan:
Unit: mmmm
(in)
BAGIAN STANDARD BATASSERVICE
SERVIS
ITEM STANDARD
Kapasitas oli Pada penggantian periodik 1,0 liter - LIMIT
Engine oil capacity
mesin Atmesin
Pada pembongkaran draining 1,2 liter 1.0 liter (1.06 US qt, 0.88 lmp qt) - –
Oli mesin yang dianjurkan At disassembly 1.2Supreme
Federal Oil liter (1.27Ultratec
US qt, 1.06
ataulmp
oli qt)
mesin 4 –
Recommended engine oil Honda "4-stroke motorcycle oil" or SE,
tak sejenis dengan klasifikasi API service an equiv-
SF
atau SG alent -
API classification: SE or higher (except oils
Viskositas: SAE 20W-50
labeled as energy conserving on the circular –
Rotor pompa Celah pada ujung rotor - API service label) 0,20
oli Celah antara rotor dan rumah 0,15 – 0,21
JASO T 903 standard: MA 0,26
Celah ke samping rotor 0,05 – 0,10
Viscosity: SAE 10W-30 0,15
Oil pump rotor pompa Tip clearance – 0.20 (0.008)
Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.26 (0.010)
Side clearance 0.05 – 0.10 (0.002 – 0.004) 0.15 (0.006)

NILAI TORSI
TORQUE VALUE
Oil pump cover bolt 5,0 N.m (0,5 kgf.m; 3,7 lbf.ft)
Oil pump cover bolt 5.0 N·m (0.5 kgf·m, 3.7 lbf·ft)

MENCARI PENYEBAB KESUKARAN


TROUBLESHOOTING
Tinggi
Enginepermukaan
oil level too oli
low,terlalu
high rendah, pemakaian oli terlalu tinggi
oil consumption
•• External
Kebocoran oli di luar
oil leaks
•• Worn
Valvevalve
guide atau
guide orstem seal aus
stem seal
•• Worn
Piston ringsrings
piston aus
•• Improperly
Piston ringsinstalled piston ringsdengan benar
tidak terpasang
•• Worn cylinder
Cylinder aus
Engine oil contamination
Pengotoran oli mesin
• Oil not changed often enough
•• Worn
Oil jarang diganti
valve guide or stem seal
•• Worn
Valvepiston
guiderings
atau stem seal aus
•• Improperly
Piston rings aus piston rings
installed
•• From coolant
Piston ringsmixing with oil dengan benar
tidak terpasang
• –Disebabkan
Faulty cylinder head gasket cairan pendingin dengan oli
pencampuran
–- Water leakhead
Cylinder in crankcase
gasket tidak baik
- Ada kebocoran air di dalam crankcase

4-3
SISTEM PELUMASAN
OIL PUMP
POMPA OLI
REMOVAL
PELEPASAN
Remove theright
Lepaskan rightcrankcase
crankcase cover
cover(page
(hal. 10-5).
10-5). OIL PUMP ASSEMBLY
Remove the mounting bolts and oil pump assembly.
Lepaskan mounting bolts (baut-baut pemasangan) dan
oil pump assembly (susunan pompa oli).

BOLTS
DISASSEMBLY
PEMBONGKARAN
Remove theE-clip
Lepaskan E-clipdari
fromoilthe oil pump
pump shaft.
shaft.
E-CLIP

OIL PUMP SHAFT


Remove the oil
Lepaskan oil pump driven
pump gear assembly
driven and disassemble
gear assembly dan BOLTS COVER
them.
bongkarlah.
Remove the bolts, dowel pins and oil pump cover.
Lepaskan bolts, dowel pins dan oil pump cover.

DOWEL PINS DRIVEN GEAR ASSEMBLY


Remove theinner
Lepaskan innerdan
and outer
outer rotors
rotorsfrom
dari the oil pump
oil pump body.
body.
INNER ROTOR OIL PUMP BODY

OUTER ROTOR

4-4
SISTEM PELUMASAN
INSPECTION
PEMERIKSAAN
OIL
OIL PUMP DRIVEN
DRIVEN GEAR/OIL
GEAR/OIL PUMP
PUMPSHAFT/LOCK
SHAFT/LOCK
PIN
PIN
Check the
Periksa oiloil pumpdriven
pump drivengear,
gear,oil
oilpump
pump shaft
shaft and
danlock
lockpin
for wear or damage, replace DRIVEN GEAR LOCK PIN
pin terhadap keausan atauthem if necessary.
kerusakan, ganti bila perlu.

OIL PUMP SHAFT


OIL
OIL PUMP
PUMP
CATATAN:
• Ukur masing-masing kerenggangan pada beberapa
• Measure
titik daneach pakailah
clearance atpembacaan
several points terbesar
and use the untuk
larg-
est reading to compare the service
membandingkan terhadap batas servis. limit.
Jika sebuah
If any partofdari
portion the Temporarily
Untuk install pasang
sementara the outerouter
rotor,rotor,
inner inner
rotor and oildan
rotor pumpoil
oil pump
oil pump aus
is worn shaft into the oil pump body. TIP CLEARANCE:
melampaui
beyond batas
the specified pump shaft ke dalam oil pump body
servis yang ditentukan, Measure the tip clearance.
service limit, replace Ukur kerenggangan pada ujung inner rotor (tip
gantilah
the oil pumpoil as
pumpan
sebagai sebuah
SERVICE
assembly. clearance).
LIMIT: 0.20 mm (0.008 in)
susunan.
BATAS SERVIS: 0,20 mm

Measure
Ukur the body clearance.
kerenggangan body (body clearance).
BODY CLEARANCE:
SERVICE
BATAS SERVIS: 0,26 mm
LIMIT: 0.26 mm (0.010 in)

4-5
SISTEM PELUMASAN
Remove theoil
Lepaskan oilpump
pumpshaft.
shaft.
SIDE CLEARANCE:
Measure the side clearance using a straight edge and feeler
Ukur
gauge.kerenggangan ke samping dengan menggunakan
sebuah mistar pengukur dan sebuah feeler gauge.
SERVICE
LIMIT: SERVIS: 0.15
BATAS 0,15mmmm(0.006 in)

ASSEMBLY
RAKITAN

OIL PUMP BODY

OUTER ROTOR

INNER ROTOR
OIL PUMP COVER
E-CLIP DOWEL PINS

LOCK PIN

5.0 N·m (0.5 kgf·m, 3.7 lbf·ft) DRIVEN GEAR OIL PUMP SHAFT
Oleskan oli mesin
Apply engine pada
oil to the innerseluruh
and outerpermukaan
rotors entireinner dan
surface.
OIL PUMP BODY
outer rotors.
Install the oil pump inner and outer rotors into the oil pump
body.
Pasang oil pump inner dan outer rotors ke dalam oil
pump body.

OUTER ROTOR INNER ROTOR

4-6
SISTEM PELUMASAN
Install
Pasang thelock
lockpin
pinke
into the oiloilpump
dalam pumpshaft, then
shaft, install the oil
kemudian
pump driven gear aligning the oil pumpmentepatkan
driven gear groove DRIVEN GEAR Tepatkan LOCK PIN
pasang oil pump driven gear dengan alur
with lock pin.
oil pump driven gear dengan lock pin.

OIL PUMP SHAFT

Install theoiloilpump
Pasang pumpcover.
cover. Tepatkan
Install
Pasang theoiloilpump
pump driven
driven gear
gearassembly
assemblyinto ke
the dalam
oil pump
oil
body aligning
pump the flat surfaces
body dengan of the oil
mentepatkan pump shaft mendatar
permukaan and inner
rotor.
dari oil pump shaft dan inner rotor.

COVER OIL PUMP BODY


Install thedowel
Pasang dowelpins
pinskeintodalam
the oiloil
pump
pumpbody.
body. BOLTS
Install anddan
Pasang tighten the bolts to thebolts
kencangkan specified torque.torsi yang
dengan
ditentukan.
TORQUE:5.0 N·m (0.5 kgf·m, 3.7 lbf·ft)
TORSI: 5,0 N.m (0,5 kgf.m; 3,7 lbf.ft)

DOWEL PINS

Install theE-clip
Pasang E-clipkeinto the oil
dalam pump
alur shaft groove.
oil pump shaft. E-CLIP

OIL PUMP SHAFT

4-7
SISTEM PELUMASAN
INSTALLATION
PEMASANGAN
Install theoiloilpump
Pasang pumpassembly.
assembly.
OIL PUMP ASSEMBLY
Install and tighten the mounting bolts securely.
Pasang dan kencangkan mounting bolts (baut-baut
Install the right dengan
pemasangan) crankcaseerat.
cover (page 10-10).

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

BOLTS

4-8
5. SISTEM BAHAN BAKAR

COMPONENT
LOKASI LOCATION
KOMPONEN ···························· 5-2
................................. 5-2 INSULATOR ····················································5-22
INSULATOR............................................. 5-22

SERVICE INFORMATION
KETERANGAN ····························· 5-3
SERVIS ............................. 5-3 PILOT SCREW PILOT
PENYETELAN ADJUSTMENT ···················5-23
SCREW................ 5-23

AIR
AIR CLEANERHOUSING
CLEANER HOUSING······························
..........................5-4 5-4 SECONDARY AIR
SECONDARY AIR SUPPLY
SUPPLYSYSTEM ········5-24
SYSTEM..... 5-24

STARTING
STARTING ENRICHMENT(SE)
ENRICHMENT (SE) VALVE
VALVE ····
....5-8
5-8 TANGKI BAHAN
FUEL TANK BAKAR ........................ 5-27
····················································5-27

KARBURATOR
CARBURETOR........................................... 5-9
················································· 5-9 FUEL
FUELAUTO
AUTO VALVE ·····································5-28
................................ 5-28

CARBURETOR
CARBURETORVACUUM
VACUUMPISTON PISTON HOSE
AIR CLEANER················································5-22
HOSE AIR CLEANER ................................. 5-22

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

39 N·m (4.0 kgf·m, 29 lbf·ft)

9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)

5-2
SISTEM BAHAN BAKAR
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
•• Work
Bekerjalah
in a welldiventilated
tempat dengan ventilasi
area. Smoking baik. Merokok
or allowing flames oratau membiarkan
sparks lidahorapi
in the work area atau
where percikan
gasoline api dicantempat
is stored cause akerja
fire oratau di
explo-
tempat dimana bensin disimpan dapat mengakibatkan kebakaran atau ledakan.
sion.
•• Bending
Menekuk atau memilin
or twisting kabel
the throttle gaswill
cable akan mengganggu
impair kelancaran
smooth operation caracause
and could kerjathe
dan dapat
cable menyebabkan
to stick bahwa
or bind, resulting kabel
in loss of macet
vehicleatau
con-
mengikat, sehingga mengakibatkan hilangnya pengontrolan atas kendaraan.
trol.
•• Work
Jika in
kendaraan akan disimpan
a well ventilated untukorwaktu
area. Smoking lebih
allowing lama
flames or dari satu
sparks bulan,
in the workkosongkan
area or wherefloat chamber
gasoline (ruang
is stored canpelampung).
cause a fire orBahan
explo-
sion.
bakar yang tertinggal di dalam float chamber dapat mengakibatkan tersumbatnya jets, sehingga sepedamotor sulit
• Ifdihidupkan
the vehicle isatau
to betidak
stored for more
dapat than onedengan
dikendarai month, drain the float chamber. Fuel left in the float chamber may cause clogged jets, resulting
lancar.
• inSebelum
hard starting or poor driveability.
membongkar karburator, letakkan sebuah tempat penampung di bawah karburator, longgarkan drain screw (sekrup
• Before disassembling
pembuangan) dan the carburetor,
kosongkan place an approved fuel container under the carburetor, loosen the drain screw and drain the carburetor.
karburator.
•• When disassembling the fuel system
Sewaktu membongkar parts sistem bahan parts, note thebakar,
locations of the O-rings.
catatlah Replace them
lokasi O-rings. Gantiwith new ones
dengan on reassembly.
O-ring baru pada waktu perakitan
• After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with a piece of tape to prevent any foreign
kembali.
• material
Setelahfrom dropping into
melepaskan the engine. bungkuslah lubang pemasukan mesin dengan kain lap atau tutup dengan tape untuk
karburator,
• For fuel level sensor inspection (page 19-12).
menghindari jatuhnya benda asing ke dalam mesin.
• Untuk pemeriksaan fuel level sensor (hal. 19-12).
SPECIFICATIONS
SPESIFIKASI
BAGIAN SPESIFIKASI
ITEM SPECIFICATIONS
Nomor identifikasi karburator AVK5AD
Carburetor identification number AVK5AD
Main jet #108
Main jet #108
Slow jet #35
Slow jet #35
Pembukaan pilot screw
Pilot screw opening Lihat halaman
Refer 5-23
to page 5-23
Float level
Float level (tinggi pelampung) 13 mm
13 mm (0.5 in)
-1
Putaran
Engine idle speed mesin
stasioner 1.400
1,400±±100
100menit (rpm)
min-1 (rpm)
Vakuum PAIRvalve
PAIR control control valve vacuum
specified yang ditentukan 6060kPa (450 mmHg)
kPa (450 mmHg)
Jarak main
Throttle bebas
grip throttle grip (putaran gas tangan)
freeplay 2–62 mm– 6(0.1
mm– 0.2 in)

TORQUE
NILAI VALUES
TORSI
SE valve
valvelock
locknut
nut 9.8(1,0
9,8 N.m N·mkgf.m;
(1.0 kgf·m, 7.2 lbf·ft)
7,2 lbf.ft)
Carburetor drain
Carburetor drainscrew
screw 1.5(0,2
1,5 N.m N·mkgf.m;
(0.2 kgf·m, 1.1 lbf·ft)
1,1 lbf.ft)
Throttle cable
cableholder
holderscrew
screw 3,4 N.m
3.4(0,3
N·mkgf.m; 2,5 lbf.ft)
(0.3 kgf·m, 2.5 lbf·ft)
Vacuum pistonhose
Vacuum piston hose joint
joint plate
plate screw
screw 2,1 N.m
2.1(0,2
N·mkgf.m; 1,5 lbf.ft)
(0.2 kgf·m, 1.5 lbf·ft)
Vacuum chamber
Vacuum chamber cover
cover screw
screw 2,1 N.m
2.1(0,2
N·mkgf.m; 1,5 lbf.ft)
(0.2 kgf·m, 1.5 lbf·ft)
Float chamberscrew
Float chamber screw 2,1 N.m
2.1(0,2
N·mkgf.m; 1,5 lbf.ft)
(0.2 kgf·m, 1.5 lbf·ft)
Air
Air cut-off
cut-off valve coverscrew
valve cover screw 2,1 N.m
2.1(0,2
N·mkgf.m; 1,5 lbf.ft)
(0.2 kgf·m, 1.5 lbf·ft)
Main Jet
Main jet 2,1 N.m
2.1(0,2
N·mkgf.m; 1,5 lbf.ft)
(0.2 kgf·m, 1.5 lbf·ft)
Slow jet
Slow jet 1,5 N.m
1.5(0,2
N·mkgf.m; 1,1 lbf.ft)
(0.2 kgf·m, 1.1 lbf·ft)
SE valve body mounting screw 3,4 N.m (0,3 kgf.m; 2,5 lbf.ft)
SE valve body mounting screw 3.4 N·m (0.3 kgf·m, 2.5 lbf·ft)
PAIR check valve cover bolt 5,0 N.m (0,5 kgf.m; 3,7 lbf.ft)
PAIR check valve cover bolt 5.0 N·m (0.5 kgf·m, 3.7 lbf·ft)
Fuel auto valve mounting nut 27 N.m (2,8 kgf.m; 20 lbf.ft)
Fuel auto
Rear shockvalve mounting
absorber nut mounting bolt
upper 27 N·mkgf.m;
39 N.m (4,0 (2.8 kgf·m, 20 lbf·ft)
29 lbf.ft)
Rear shock absorber upper mounting bolt 39 N·m (4.0 kgf·m, 29 lbf·ft)

TOOL PERKAKAS
KUNCI

Carburetor float level gauge


07401-0010000

5-3
SISTEM BAHAN BAKAR
AIR CLEANER
AIR CLEANER HOUSING
HOUSING
REMOVAL
PELEPASAN
Lepaskan
Remove thesebagai berikut:
following:
BOLT BOLTS
–- Center
Center body cover/radiatorshroud
body cover/radiator shroud (hal.2-6)
(page 2-6)
–- Body
Bodycover
cover (hal.
(page2-16)
2-16)
Remove the two bolts and radiator reserve tank from the
Lepaskan kedua
frame to gain bolts
access (baut)
to the dan radiator
rear shock absorberreserve tank
upper mount-
Slightly
Angkat rodalift up the
belakang
rear wheel
sedikittountuk
ease
dari rangka
ing bolt. untuk mendapatkan akses ke rear shock
mempermudah
removal of the rear
absorber upper mounting bolt (baut pemasangan atas
pelepasan rear upper
shock Remove thebelakang).
sokbreker rear shock absorber upper mounting bolt and
shock absorber
absorber mounting turn the upper side of shock absorber backward.
mounting bolt.
bolt. Lepaskan rear shock absorber upper mounting bolt dan
putar bagian atas dari shock absorber ke belakang.

RESERVE
REAR SHOCK ABSORBER TANK
Release the PAIR
Lepaskan PAIR air
air filter
filterfrom
dari the clamps(klem-klem)
clamps on the frame.pada CLAMPS
rangka.

PAIR AIR FILTER


Release
Lepaskan thecarburetor
carburetor air
air vent
venthose
hosefrom
darithe hoseguides
hose guides on
RESONATOR AIR VENT HOSE
the
padaairair
cleaner connecting
cleaner hose.hose.
connecting
Release the clamp and remove the resonator from the con-
Lepaskan
necting hoseclamp dan lepaskan
by releasing resonator
its boss from hole ondari
the frame.
connecting hose (slang penyambung) dengan
melepaskan boss-nya dari lubang pada rangka.
BOSS

CLAMP GUIDE

Loosen the airair


Longgarkan cleaner connecting
cleaner hosehose
connecting band band
screw.screw.
BAND SCREW

5-4
SISTEM BAHAN BAKAR
Disconnect
Lepaskan the crankcasebreather
crankcase breather hose
hosefrom
daritheair
air cleaner
cleaner CRANKCASE
housing.
housing. BREATHER HOSE

Lepaskan
Release rearbrake
the rear brake light
light switch
switch wire wire (kawat
and dust coversaklar
from
lampu
the rem
hooks belakang)
on the dan
air cleaner dust cover dari hooks pada
housing. DUST COVER
air cleaner housing.

BRAKE LIGHT
SWITCH WIRE HOOKS

Remove
Lepaskan the kedua
two air cleaner housinghousing
air cleaner mountingmounting
bolts. bolts AIR CLEANER HOUSING
(baut pemasangan air cleaner housing).
Pull up the air cleaner housing upward and disconnect the
breather
Tarik airdrain hose.housing ke atas dan lepaskan breather
cleaner
drain hose.

DRAIN
BOLTS HOSE
Be careful
Hati-hati agarnot Disconnect the
to Lepaskan
tidak connectinghose
connecting hose from
dari thekarburator
carburetor by pull-
dengan
merusakdamage ing the airair
the menarik
connecting cleaner housing
cleaner backward.
housing ke belakang. CARBURETOR
Remove the air cleaner
connecting hose. Lepaskan housing
cleaner from the
housing dariright
sisiside of frame.
kanan dari
rangka.

AIR CLEANER
HOUSING

5-5
SISTEM BAHAN BAKAR
INSTALLATION
PEMASANGAN
Tempatkan air cleaner
Set the air cleaner housing
housing into ke dalam
the frame from therangka dari
right side.
sisi kanan. CARBURETOR
Connect the air cleaner connecting hose to the carburetor.
Sambungkan air cleaner connecting hose pada
karburator.

AIR CLEANER
HOUSING
Tighten the airair
Kencangkan cleaner connecting
cleaner hose hose
connecting band screw.
band screw. BAND SCREW

BAND SCREW
Connect the breather
Sambungkan drain hosedrain
breather to the joint
hose on the air cleaner
pada joint AIR CLEANER HOUSING
housing.
(penyambung) pada air cleaner housing.
Install and tighten the two air cleaner housing mounting
Pasang dan kencangkan kedua air cleaner housing
bolts.
mounting bolts (baut pemasangan air cleaner housing).

DRAIN
BOLTS HOSE
Route
Alurkan wire the Secure the dust
wire Kokohkan
harness cover and dust
pemasangan rear cover
brake light switch light
dan brake wire with
harness properly the hooks on the air cleaner housing. DUST COVER
dengan benar switch wire (kawat saklar belakang lampu rem) dengan
(page
(hal. 1-16). hooks (kaitan) pada air cleaner housing.

BRAKE LIGHT
SWITCH WIRE HOOKS

5-6
SISTEM BAHAN BAKAR
Route
Alurkan hosethe hose
dengan Connect the crankcase
Sambungkan breather
crankcase hose hose
breather to thepada
air cleaner hous-
air cleaner CRANKCASE
properly
benar(page 1-16).
(hal. 1-16). ing.
housing. BREATHER HOSE

Letakkan resonator
Set the resonator pada
in position while tempatnya sementara
aligning its boss with the
RESONATOR AIR VENT HOSE
hole on the frame.
mentepatkan boss-nya dengan lubang pada rangka.
Connect the resonator to the air cleaner connecting hose and
Sambungkan
secure resonator ke air cleaner connecting hose
it with clamp.
dan kokohkan kedudukannya dengan clamp.
Secure the carburetor air vent hose by hose guide.
Kokohkan pemasangan carburetor air vent hose dengan Tepatkan
hose guide.

CLAMP GUIDE

Secure the PAIR


Kokohkan air filter with
pemasangan PAIRthe clamps
air filterondengan
the frame.
clamps CLAMPS
(klem-klem) pada rangka.

PAIR AIR FILTER


Slightly
Angkat rodalift up the
belakang Set the rearrear
Letakkan shock absorber
shock in position,
absorber then install
(sokbreker and
belakang)
rear wheel
sedikittountuk
ease tighten the rear shock
pada tempatnya, absorber upper
kemudian pasang mounting bolt to the
dan kencangkan BOLT BOLTS
mempermudah
installation of the specified
rear shock torque.absorber upper mounting bolt (baut
pemasangan
rear shockrear shock
absorber pemasangan atas sokbreker belakang) dengan torsi
upper absorber
mountingupper
bolt. TORQUE: 39 N·m (4.0 kgf·m, 29 lbf·ft)
yang ditentukan.
mounting bolt.
Set the radiator reserve tank in position, then install and
TORSI:the39
tighten N.m (4,0
reserve tank kgf.m;
mounting29bolts.
lbf.ft)
Letakkan radiator reserve tank pada tempatnya,
Install the following:
kemudian pasang dan kencangkan reserve tank
– Center bolts
mounting body cover/radiator shroud (pagereserve
(baut-baut pemasangan 2-6) tank).
– Body cover (page 2-16)
Pasang sebagai berikut:
RESERVE
- Center body cover/radiator shroud (hal. 2-6) REAR SHOCK ABSORBER TANK
- Body cover (hal. 2-16)

5-7
SISTEM BAHAN BAKAR
STARTING ENRICHMENT
STARTER ENRICHMENT (SE)VALVE
(SE) VALVE
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Remove thekarburator
Lepaskan carburetor (hal.
(page5-9).
5-9).
Tekan SPRING
Compress the spring and release the SE SE
spring (pegas) dan lepaskan valve
valve cablecable
from dari
the
SE valve.
SE valve.
Installation in theadalah
Pemasangan reverse order
dalamof removal.
urutan terbalik dari
pelepasan.
After installation, check the carburetor SE valve operation
(page 5-8).
Setelah pemasangan, periksa cara kerja SE valve
karburator (hal. 5-8).

SE VALVE SE VALVE CABLE


INSPECTION
PEMERIKSAAN
Periksa
Check theSE
SEvalve
valveterhadap yang berikutnya:
for following:
SE VALVE Posisi
-– SE
SEvalve
valveterhadap gerusan,
for scoring, scratchesgoresan
or wear atau keausan semula :
-– Ujung
Tip ofdari SE valve
the SE valveforterhadap
stepped keausan
wear bertingkat.
– Valve
Valve seat area for
seat scoring,(bidang
area scratches or wear
dudukan valve)
– terhadapgerusan,
Spring for deterioration or damage
goresan atau keausan
-Make
Spring
sure (pegas)
that the SEterhadap pemburukan
valve returns kondisi
to its original atau
position
kerusakan.
when the SE valve lever is in its normal position.
If necessary,
Pastikan disassemble
bahwa SE valvethekembali
carburetor and clean
ke posisi the SE
semulanya
sewaktu handelwithSE
valve air passage valve air
compressed ada(page
pada
5-14).kedudukan
normalnya.

Bila perlu, bongkar karburator dan bersihkan jalan Bidang dudukan


lintasan udara SE valve dengan udara dari kompressor SPRING
Valve
(hal. 5-14).

5-8
SISTEM BAHAN BAKAR
CARBURETOR
KARBURATOR
REMOVAL
PELEPASAN
Lepaskan sebagai berikut:
Remove the following:
-– Center
Center body
body cover/radiator
cover/radiatorshroud
shroud (page
(hal.2-6)
2-6)
-– Right
Rightfront
frontside
side cover
cover (page
(hal. 2-15)
Sekaoff
Wipe bahan bakar
spilled out
Longgarkan
Loosen carburetor
the carburetor drain screwdrain
and drainscrew (sekrup
the fuel from the
yang
fuel tertumpah
immediately. pembuangan
float chamber intokarburator)
an approveddanfuelkeluarkan
container. bahan bakar
dengan segera. dari float chamber (ruang pelampung) ke dalam tempat
After the fuel yang
penampung is completely
sesuai. drained from the float chamber,
tighten the drain screw to the specified torque.
Setelah
TORQUE: bahan bakar
1.5 N·m (0.2telah
kgf·m,dikeluarkan
1.1 lbf·ft) seluruhnya dari
float chamber, kencangkan drain screw dengan torsi
Disconnect
yang the carburetor drain hose from the carburetor.
ditentukan.
TORSI: 1,5 N.m (0,2 kgf.m; 1,1 lbf.ft)
Lepaskan carburetor drain hose (slang pembuangan
karburator) dari karburator. DRAIN SCREW DRAIN HOSE
Remove
Lepaskanthe two air cleaner
kedua housinghousing
air cleaner mountingmounting
bolts. bolts
(baut pemasangan air cleaner housing).

BOLTS
Loosen the throttle
Longgarkan cable
throttle locklock
cable nut and
nut adjusting nut.
(mur pengunci kabel
Release LOCK NUT ADJUSTING NUT
gas) dantheadjusting
cable fromnutthe holder
(mur and disconnect the throttle
penyetelan).
cable end from
Lepaskan the dari
cable throttle drum.dan lepaskan ujung kabel
holder
gas dari throttle drum (teromol gas).

UJUNG KABEL HOLDER


Release
Lepaskanthe PAIR
PAIR air
air filter
filter dari
fromclamps.
the clamps.
PAIR AIR FILTER

CLAMPS

5-9
SISTEM BAHAN BAKAR
Releaseclamp
Buka the clamp
dan and remove resonator
lepaskan the resonator from
dari the con-
connecting BAND SCREW RESONATOR
nectingdengan
hose hose by melepaskan
releasing its boss from thedari
boss-nya hole lubang
on the frame.
pada
rangka.
Loosen the air cleaner connecting hose band screw and dis-
connect the connecting hose from the carburetor.
Longgarkan air cleaner connecting hose band screw
(sekrup pita penjepit slang penghubung dengan
BOSS
saringan udara) dan lepaskan connecting hose dari
karburator.

CLAMP

Loosen the insulator


Longgarkan band screw
insulator band andscrew
disconnect
danthelepaskan
carbure-
tor from insulator.
karburator dari insulator. BAND SCREW

INSULATOR
Lepaskan
Disconnect hoses (slang-slang)
the following berikut
hoses from dari karburator:
the carburetor:
AIR VENT HOSE CARBURETOR
-– Fuel
Fuelhose
hose (slang bahan bakar)
-– Air
Airvent
venthose
hose (slang penghubung ke udara)
-– Vacuum
Vacuumchamber
chamber hose
hose (slang ruangan vakuum)
Remove the carburetor by pulling it upward.
Lepaskan karburator dengan menariknya ke atas.

VACUUM
CHAMBER
FUEL HOSE HOSE
Loosen the SESE
Longgarkan valve locklock
valve nut nut
and dan
remove the SE valve
lepaskan and
SE valve
sealing washer from the carburetor. SE VALVE LOCK NUT
dan sealing washer dari karburator.

SEALING WASHER

5-10
SISTEM BAHAN BAKAR
DISASSEMBLY
PEMBONGKARAN
VACUUM CHAMBER
VACUUM CHAMBER
Vacuum
Vacuum chamber Remove thekedua
chamber Lepaskan two screws while
screws holding the
sementara vacuum chamber
menahan vacuum VACUUM CHAMBER COVER
cover cover
is under spring
berada cover.
di chamber cover (tutup ruangan vakuum).
pressure.
bawah tekanan pegas.

SCREWS
Be careful
Hati-hati agarnot Remove thesebagai
to Lepaskan
tidak following:
berikut: VACUUM
damage
merusak the jet
jet needle. COMPRESSION
– Vacuum chamber cover CHAMBER
needle. - Vacuum chamber cover SPRING
-– Compression
Compression spring
spring (pegas penekan) COVER
-– Diaphragm/vacuum
Diaphragm/vacuum piston
piston

DIAPHRAGM/
VACUUM PISTON
Turn
Putartheneedle
needle holder counterclockwise
holder berlawanan while
arah pressing
jarum itjam
to
unlock the holder.
sementara menekannya untuk melepaskan penguncian
holder.

NEEDLE HOLDER

Lepaskan
Remove sebagai from
the following berikut dari diaphragm/vacuum
diaphragm/vacuum piston:
piston: JET NEEDLE
– Needle holder SPRING
–- Needle
Spring holder
-– Spring (pegas)
Jet needle
- Jet needle

DIAPHRAGM/
NEEDLE HOLDER VACUUM PISTON

5-11
SISTEM BAHAN BAKAR
THROTTLECABLE
THROTTLE CABLEHOLDER
HOLDER
Remove the following:
Lepaskan sebagai berikut:
SCREWS
-– Dua
Twoscrews
screws
-– Throttle
Throttlecable
cable holder
holder

CABLE HOLDER

VACUUM PISTON
VACUUM PISTON HOSE
HOSE JOINT
JOINT
Lepaskan
Remove thesebagai berikut:
following:
HOSE JOINT HOLDER O-RING
-– Screw
Screw PLATE
-– Holderplate
Holder plate
-– Vacuumpiston
Vacuum piston hose
hose joint
joint
-– O-ring
O-ring

SCREW

AIR CUT-OFF
AIR CUT-OFFVALVEVALVE
Remove the following:
Lepaskan sebagai berikut: AIR CUT-OFF VALVE O-RING
– Screws COVER/SPRING
-– Screws
Air cut-off valve cover
-– Air cut-off valve cover
Spring
-– Spring
O-ring
-– O-ring
Diaphragm
- Diaphragm

SCREWS DIAPHRAGM
SE VALVE
SE VALVE BODY
BODY
Lepaskan
Remove thesebagai berikut:
following: SE VALVE BODY
- Screws
– Screws
- SE valve body
– SE valve body
-– O-ring
O-ring

SCREWS O-RING

5-12
SISTEM BAHAN BAKAR
FLOAT CHAMBER
FLOAT CHAMBER
Remove the following:
Lepaskan sebagai berikut:
SCREWS
–- Tiga
Three screws
screws
–- Float
Floatchamber
chamber

FLOAT CHAMBER
Remove theO-ring
Lepaskan O-ring dari
fromalur
the float chamber
chamber.groove.
FLOAT CHAMBER

O-RING

Remove thesebagai
Lepaskan following:
berikut:
FLOAT PIN
-– Float
Floatpin
pin
-– Float
Float
-– Float
Floatvalve
valve

FLOAT FLOAT
JETS
JETS
Handle the
Tangani jetsjets with
dengan Lepaskan
Remove thesebagai berikut:
following:
care, they canmereka
hati-hati, easily
–- Slow
Slowjet
jet SLOW JET
be scored
mudah tergerus or
atau -– Main
tergores.
Mainjet
jet
scratched. -– Needle
Needle jet
jet MAIN
JET
Damageakan
Kerusakan to theterjadi
pilot Turn
Putarthe pilot
pilot screwkeindalam
screw and carefully count the
dan dengan number
cermat or
hitung
screw
padaseat will occur
dudukan pilot turns untilputaran
jumlah it seats lightly.
sampai ia duduk dengan ringan.
screw
if thejika pilot
pilot screw
screw is Note the number
Catatlah jumlahof turns for reference
putaran sebagaiwhen reinstalling
referensi the WASHER
ketika
dikencangkan terhadap
tightened against the pilot screw. kembali pilot screw.
memasang
dudukannya.
seat.
Remove
Lepaskan thesebagai
following:
berikut: SPRING
–- Pilotscrew
Pilot screw
O-RING
–- Spring
Spring
–- Washer
Washer
–- O-ring PILOT SCREW NEEDLE JET
O-ring

5-13
SISTEM BAHAN BAKAR
CARBURETOR CLEANING
PEMBERSIHAN KARBURATOR
Blow open the fuel
Tiuplah terbuka jalan passage
lintasanfrom the valve
bahan bakarseat
dariside
sisi with
compressed air and clean the strainer screen. STRAINER SCREEN
valve seat (dudukan valve) dengan udara dari
kompressor dan bersihkan strainer screen.

Tiupan
VALVE SEAT udara

Blowterbuka
Tiup open airjalan
and fuel passages
lintasan in the
udara dancarburetor body withdi
bahan bakar
compressed air.karburator dengan udara dari kompressor. CARBURETOR BODY
dalam badan
Check each part for wear or damage and replace them if nec-
Periksa
essary. masing-masing part terhadap keausan atau
kerusakan dan ganti bila perlu.

INSPECTION
PEMERIKSAAN
VACUUMCHAMBER
VACUUM CHAMBER
Inspect the
Periksa following:
sebagai berikut:
JET NEEDLE
-– Jet
Jetneedle
needle for steppedkeausan
terhadap wear bertingkat SPRING
-– Vacuum
Vacuumpiston
piston terhadap
for wear orkeausan
damage atau kerusakan
-– Diaphragm
Diaphragmterhadap
for pin holes, deterioration
lubang or damage kondisi
kecil, pemburukan
– atau
Spring for deterioration or damage
kerusakan
-– Spring
Needleterhadap
holder forpemburukan
damage kondisi atau kerusakan
-Air
Needle holder
will leak terhadap
out of the vacuumkerusakan
chamber if the diaphragm is
damaged in any way, even if only a pin hole.
Udara akan bocor keluar dari vacuum chamber jika
diaphragm ada kerusakan, bahkan walaupun hanya
berupa sebuah lubang kecil.
DIAPHRAGM/
NEEDLE HOLDER VACUUM PISTON

FLOAT/FLOATVALVE
FLOAT/FLOAT VALVE
Inspect the
Periksa following:
sebagai berikut:
PIN VALVE SEAT
-– Float
Float for fuel insidebahan
terhadap or otherbakar
damagedi dalamnya atau
– kerusakan
Float valvelain
tip for stepped wear or contamination
-– Ujung
Float valve
floatseat for scores,
valve terhadapscratches and damage
keausan bertingkat atau
pengotoran
Push the pin on the float valve end and make sure that it
-returns
Dudukan
withoutfloat valve terhadap gerusan, goresan dan
binding.
kerusakan

Dorong pin pada ujung float valve dan pastikan bahwa


ia kembali tanpa mengikat.

FLOAT VALVE FLOAT

5-14
SISTEM BAHAN BAKAR
FLOAT LEVEL(TINGGI PELAMPUNG)
FLOAT LEVEL
Set the float level
Letakkan level With the float
Sementara floatvalve valve
seated and the floatdan
terduduk arm float
just touching the
arm tepat
gauge sehingga
gauge so that it ia
is valve, measure the float levelfloat
with level
the special toolspecial
as shown. FLOAT LEVEL GAUGE
menyentuh valve, ukurlah dengan tool
tegak lurus terhadap
perpendicular to the seperti diperlihatkan.
muka
float float chamber
chamber face at FLOAT
the highestpada posisi
position of LEVEL: 13 mm (0.5 in)
tertinggi dari float.
FLOAT LEVEL: 13 mm
the float.
TOOL:
KUNCI PERKAKAS:
Carburetor float level gauge 07401-0010000
Carburetor float level gauge 07401-0010000
The float cannot be adjusted.
Float (pelampung)
Replace tidak dapat
the float assembly if the disetel.
float level is out of specifi-
Ganti
cation.susunan float jika float level di luar spesifikasi.

JETS/PILOT SCREW
Inspect the
Periksa following:
sebagai berikut:
SLOW JET
-– Each jet for clog,jet
Masing-masing wear or damage
terhadap sumbatan, keausan atau
– Pilot screw for wear or damage
kerusakan
–-Spring for deterioration or damage MAIN
Pilot screw terhadap keausan atau kerusakan JET
- Spring
Replace theterhadap
damaged pemburukan kondisi atau kerusakan
parts if necessary.

Ganti parts yang rusak bila perlu.

SPRING

PILOT SCREW NEEDLE JET

SE
SE VALVE
VALVE BODY
Periksa jalan
Inspect the lintasan
SE valve udara SE
air passages valve
in the di dalam
carburetor badan
body and
SE valve body
karburator danforSEclog.
valve body terhadap sumbatan. SE VALVE BODY
If air passage is clogged, blow open with compressed air
Jika
(page jalan
5-14). lintasan udara tersumbat, tiuplah terbuka
dengan udara dari kompressor (hal. 5-14).
Refer to page 5-8 for SE valve inspection.
Lihat hal. 5-8 untuk pemeriksaan SE valve.

CARBURETOR BODY
AIR CUT-OFF
AIR CUT-OFF VALVE
VALVE
Inspect the
Periksa following:
sebagai berikut:
COVER ROD
-– Diaphragm
Diaphragm forterhadap
pin holes, deterioration or other
lubang kecil, damage
pemburukan
– kondisi
Diaphragm
ataurod for wear or
kerusakan damage at the tip.
lain.
-– Diaphragm
Spring for deterioration
rod terhadap or damage
keausan atau kerusakan
– pada
Air passages
ujungnya.in the carburetor body and air cut-off valve
cover for
- Spring clog or pemburukan
terhadap restriction kondisi atau kerusakan.
-If Jalan lintasan
air passage udara diblow
is clogged, dalam badan
open with karburator
compressed dan
air
air 5-14).
(page cut-off valve cover terhadap sumbatan atau
pembatasan

Jika lintasan udara tersumbat, tiuplah terbuka dengan


udara dari kompressor (hal. 5-14).
DIAPHRAGM

5-15
SISTEM BAHAN BAKAR
ASSEMBLY
PERAKITAN
3.4 N·m (0.3 kgf·m, 2.5 lbf·ft) SPRING DIAPHRAGM/ 2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
VACUUM PISTON
THROTTLE JET NEEDLE
CABLE HOLDER VACUUM
CHAMBER COVER
DIAPHRAGM
2.1 N·m (0.2 kgf·m,
1.5 lbf·ft) SPRING

COMPRESSION
AIR CUT-OFF VALVE COVER
SPRING

O-RING
O-RING
FLOAT NEEDLE HOLDER
FLOAT
FLOAT
O-RING PIN
O-RING
FLOAT CHAMBER
SE VALVE BODY
O-RING 3.4 N·m (0.3 kgf·m, 2.5
2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
lbf·ft)
PILOT SCREW

SPRING
PILOT SCREW
DRAIN SCREW
1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) 2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
SLOW JET MAIN JET O-RING JOINT
NEEDLE
1.5 N·m (0.2 kgf·m, 1.1 lbf·ft) JET 2.1 N·m (0.2 kgf·m, 1.5 lbf·ft) HOLDER PLATE

AIR CUT-OFF VALVE


AIR CUT-OFF VALVE
Install a new
Pasang O-ringO-ring
sebuah onto thebaru
carburetor
padabody with its
badan flat side
karburator O-RING DIAPHRAGM
facing thesisinya
dengan carburetor body
yang side. menghadap ke sisi badan
datar
karburator.
Install the diaphragm into the carburetor body while aligning
its rod with the hole on the carburetor body.
Pasang diaphragm ke dalam badan karburator Sisi badan:
sementara mentepatkan tangkainya dengan lubang
pada badan karburator.

Tepatkan
Be careful
Hati-hati agarnot Install thespring
to Pasang
tidak springdan
and air
air cut-off
cut-off valve
valve cover.
cover.
menjepit
pinch diaphragm.
the diaphragm.
SPRING AIR CUT-OFF
Install anddan
Pasang tighten the screws screws
kencangkan to the specified
dengantorque
torsi while
yang VALVE COVER
holding the air cut-off valve cover.
ditentukan sementara menahan air cut-off valve cover.
TORQUE:2.1
TORSI: N·m(0,2
2,1 N.m (0.2kgf.m;
kgf·m, 1,5
1.5 lbf.ft)
lbf·ft)

SCREWS

5-16
SISTEM BAHAN BAKAR
SEVALVE
SE VALVEBODY BODY
Pasang
Install theSE
SEvalve
valvebody
body dan O-ring
and new baru.
O-ring.
O-RING SE VALVE BODY
Install anddan
Pasang tighten the screws toscrews
kencangkan the specified
dengantorque.
torsi yang
ditentukan.
TORQUE: 3.4 N·m (0.3 kgf·m, 2.5 lbf·ft)
TORSI: 3,4 N.m (0,3 kgf.m; 2,5 lbf.ft)

SCREWS

JETS
Damage akan Install thepilot
to the pilot
Kerusakan Pasang pilotscrew
screw dengan
with thespring,
spring, washer dannew
washer and O-ring
O-
terjadiseat
screw pada occur baru.
dudukan
will ring. SLOW JET
pilot
if thescrew
pilot jika pilot
screw is
• Install the pilot screw and return it to its original position
tightened against the • Pasang pilot screw dan kembalikan ke posisi semula
screw dikencangkan MAIN
terhadap dudukannya. as noted during removal.
seat. seperti telah dicatat selama pelepasan. JET
• Perform the pilot screw adjustment if a new pilot screw is
• Lakukan penyetelan pilot screw jika sebuah pilot
installed (page 5-23).
screw baru telah dipasang (hal. 5-23).
Tangani jetsjets
Handle the dengan
with Install thesebagai
Pasang following:
berikut: WASHER
hati-hati,
care, they canmereka
easily
mudah tergerus atau – Needle
- Needle jet jet
be scored or
tergores.
scratched. -– Main
Mainjetjet SPRING
-– Slow
Slowjetjet
O-RING
TORQUE:
TORSI:
Main
Main jet:
jet: 2,1 N.m
2.1 (0,2
N·m kgf.m; 1,5 lbf.ft)
(0.2 kgf·m, 1.5 lbf·ft) PILOT SCREW NEEDLE JET
Slow jet:
Slow jet: 1,5 N.m
1.5 (0,2
N·m kgf.m; 1,1 lbf.ft)
(0.2 kgf·m, 1.1 lbf·ft)
FLOAT CHAMBER
CHAMBER
Letakkan
Set the floatfloat valve
valve pada
to the float.
float.
Pasang floatpada
Install thefloat to thebadan karburator.
carburetor body. FLOAT PIN

Insert the float pin through the body and float.


Masukkan floatthepin
Make sure that melalui
float badan
level is karburator
correct dan float.
(page 5-15).

Pastikan bahwa float level adalah tepat (hal. 5-15).

FLOAT FLOAT
Pasang
Install sebuah
a new O-ring
O-ring into baruchamber
the float ke dalam
groove. alur float
Install
chamber.the float chamber. FLOAT CHAMBER

Pasang float chamber.

O-RING

5-17
SISTEM BAHAN BAKAR
Install
Pasang anddan
tighten the float chamber
kencangkan screws screws
float chamber to the specified
dengan
torque.
torsi yang ditentukan. SCREWS

TORQUE: 2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)


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

VACUUM
VACUUMPISTON PISTON HOSEHOSE JOINT
JOINT
Pasang sebuah O-ring baru
Install a new O-ring to the vacuum pada vacuum
piston piston hose
hose joint.
joint.
Insert the hose joint into the carburetor body. O-RING JOINT SCREW Tepatkan
Masukkan hose joint ke dalam badan karburator.
Install the holder plate while aligning its cutout with the boss
on the carburetor body.
Pasang holder plate sementara mentepatkan potongan
Install and tighten the screw to the specified torque.
padanya dengan boss pada badan karburator.
Pasang dan kencangkan sekrup dengan torsi yang
ditentukan.

TORQUE: 2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)


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

HOLDER PLATE

THROTTLECABLE
THROTTLE CABLEHOLDER
HOLDER
Install
Pasang thethrottle
throttlecable
cable holder.
holder.
SCREWS
Install
Pasang anddan
tighten the screws toscrews
kencangkan the specified
dengantorque.
torsi yang
ditentukan.
TORQUE: 3.4 N·m (0.3 kgf·m, 2.5 lbf·ft)
TORSI: 3,4 N.m (0,3 kgf.m; 2,5 lbf.ft)

CABLE HOLDER

VACUUM
VACUUM CHAMBER
CHAMBER
Install
Pasang thejet
jetneedle
needle into the diaphragm/vacuum
ke dalam piston.piston.
diaphragm/vacuum
JET NEEDLE
Install the spring onto the needle holder and set the needle SPRING
holder into the vacuum piston.
Pasang spring pada needle holder dan letakkan needle
holder ke dalam vacuum piston.

DIAPHRAGM/
NEEDLE HOLDER VACUUM PISTON

5-18
SISTEM BAHAN BAKAR
Turn theneedle
Putar needle holder
holder clockwise
searah while
jarum pressing it until it
jam sementara
locks.
menekannya sampai ia terkunci.
Holder flanges and piston grooves should be fitted after turn-
Holder
ing. flanges dan alur piston harus dipasang setelah
memutarnya.

NEEDLE HOLDER
Be careful
Hati-hati agarnot to
tidak Install thediaphragm/vacuum
Pasang diaphragm/vacuum piston
pistoninto the carburetor
ke dalam badanbody VACUUM
damage
merusak the jet
jet needle. by aligning the
karburator tab of the
dengan diaphragm with
mentepatkan tab the groove
dari of car-
diaphragm COMPRESSION
SPRING CHAMBER
needle. buretor body.
dengan alur pada badan karburator. COVER
Lift the bottom of the piston with your finger to set the dia-
Angkat
phragm ribbagian bawah
into the dari
groove piston
in the dengan
carburetor jari-jari untuk
body. Tepatkan
Install the compression
menempatkan spring and ke
tulang diaphragm vacuum
dalamchamber cover
alur di dalam
Be careful
Hati-hati agarnot to
tidak while lifting
badan the piston in place.
karburator.
pinch the diaphragm
menjepit Install the screws before releasing the vacuum piston.
between
antara the chamber
chamber cover Pasang compression spring dan vacuum chamber cover
dan badan
cover andkarburator.
carburetor sementara mengangkat piston pada tempatnya.
body. Pasang screws sebelum melepaskan vacuum piston.

DIAPHRAGM/
VACUUM PISTON
Check that
Periksa the spring
bahwa is installed
spring correctly dengan
telah dipasang by pushing the
benar
bottom ofmendorong
dengan the piston with yourbawah
bagian finger piston
and make sure that the
dengan COMPRESSION
piston returns
jari-jari back in placebahwa
dan memastikan smoothly.
piston bergerak kembali SPRING
pada tempatnya dengan lancar.

VACUUM PISTON

Vacuum
Vacuum chamber Tighten the screws
chamber Kencangkan to the specified torque
sekrup-sekrup dengan whiletorsi
holdingyang
the
VACUUM CHAMBER COVER
coverberada
cover is under vacuum chamber
spring ditentukan
di bawah cover. menahan vacuum chamber cover.
sementara
pressure.
tekanan pegas.
TORSI:
TORQUE:2,12.1
N.m (0,2
N·m (0.2kgf.m;
kgf·m,1,5
1.5lbf.ft)
lbf·ft)

SCREWS

5-19
SISTEM BAHAN BAKAR
INSTALLATION
PEMASANGAN
Install a new
Pasang sealing
sebuah washerwasher
sealing and SEbaru
valvedanlockSE
nut valve
to the car-
lock
buretor body, then karburator,
tighten the lock nut to thekencangkan
specified torque. SE VALVE LOCK NUT
nut pada badan kemudian lock
nut dengan torsi yang ditentukan.
TORQUE:9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
TORSI: 9,8 N.m (1,0 kgf.m; 7,2 lbf.ft)

SEALING WASHER

Route
Alurkan hosesthe hoses
dengan Connect the following
Sambungkan hoses topada
hoses berikut the carburetor:
karburator.
properly
benar(page 1-16).
(hal. 1-16). AIR VENT HOSE CARBURETOR
-– Fuel
Fuelhose
hose
-– Air
Airvent
venthose
hose
-– Vacuum
Vacuumchamber
chamber hose
hose

VACUUM
CHAMBER
FUEL HOSE HOSE
Install thekarburator
Pasang carburetor pada
to the insulator.
insulator.
BAND SCREW
Tighten the band screw until the distance between the band
Kencangkan band
ends is 12.0 – 14.0 mmscrew
(0.47 –sampai
0.55 in).jarak antara ujung-
ujung band adalah 12,0 – 14,0 mm

12.0 – 14.0 mm
(0.47 – 0.55 in)

INSULATOR
Connect the connecting
Sambungkan hosehose
connecting to thepada
carburetor.
karburator. BAND SCREW RESONATOR
Tighten the air cleaner connecting hose band screw.
Kencangkan air cleaner connecting hose band screw.
Install the resonator to the connecting hose while aligning its
boss withresonator
Pasang the hole onpada
the frame, then secure
connecting hoseitsementara
with clamp.
mentepatkan boss-nya dengan lubang pada rangka, Tepatkan
kemudian kokohkan kedudukannya dengan clamp.

CLAMP

5-20
SISTEM BAHAN BAKAR
Secure the PAIR
Kokohkan air filter with
pemasangan PAIR theair
clamps.
filter dengan clamps.
PAIR AIR FILTER

CLAMPS

Connect the throttle


Sambungkan ujungcable end cable
throttle to the throttle drum and
pada throttle set dan
drum the
cable to the cable
tempatkan kabelholder.
pada cable holder.
Adjust the throttle cable free play (page 3-5).
Setel jarak main bebas throttle cable (hal. 3-5).

CABLE END HOLDER

Set the air cleaner


Tempatkan housing
air cleaner in position.
housing pada posisinya.
Install and tighten the two air cleaner housing mounting
Pasang
bolts. dan kencangkan kedua air cleaner housing
mounting bolts (baut pemasangan rumah saringan
After installation, check the following:
udara).
– Secondary air leak around the insulator and connecting
Setelah
hose pemasangan, periksa berikutnya:
- Kebocoran udara sekunder di sekitar insulator dan
Install the following:
connecting hose
– Center body cover/radiator shroud (page 2-6)
– Rightberikutnya:
Pasang front side cover (page 2-15)
- Center body cover/radiator shroud (hal. 2-6)
- Right front side cover (hal. 2-15)
BOLTS

5-21
SISTEM BAHAN BAKAR
CARBURETOR VACUUM PISTON HOSE
VACUUM PISTON
HOSE AIR CLEANER
AIR CLEANER
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Remove theluggage
Lepaskan luggage box
box (page 2-13).
(hal. 2-13).
AIR CLEANER HOUSING BOLT
Disconnect the vacuum piston hose from the carburetor vac-
uum piston vacuum
Lepaskan pistonhousing.
hose air cleaner hose dari carburetor vacuum
piston
Removehose air cleaner
the bolt housing.
and housing.
Lepaskan bolt dan housing.
Connect the vacuum piston hose to the housing.
Set the housingvacuum
Sambungkan to the frame, then
piston install
hose padaandhousing.
tighten the bolt.
Tempatkan housing
Install the luggage pada2-13).
box (page rangka, kemudian pasang
dan kencangkan bolt.

Pasang luggage box (hal. 2-13).

VACUUM PISTON HOSE

AIRCLEANER
AIR CLEANER ELEMENT
ELEMENT
Lepaskan
Remove the bolt danvacuum
bolt and vacuum piston
piston hose
hose air air housing
cleaner cleaner
AIR CLEANER LID TABS
housing dari rangka
from the frame (hal. 5-22).
(page 5-22).
Open the air cleaner lid by releasing the tabs.
Remove the air cleaner element.
Buka air cleaner lid dengan melepaskan tabs.
Inspect the air
Lepaskan element and element.
cleaner clean or replace if necessary.
Install the air cleaner element into the housing.
Periksa
Close theelement dan
air cleaner lid.bersihkan atau ganti bila perlu.
Install theair
Pasang vacuum piston
cleaner hose air
element ke cleaner housing and tighten
dalam housing.
the boltair
Tutup (page 5-22).lid.
cleaner

Pasang vacuum piston hose air cleaner housing dan


kencangkan bolt (hal. 5-22). AIR CLEANER ELEMENT

INSULATOR
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Remove thekarburator
Lepaskan carburetor (hal.
(page5-9).
5-9).
BAND SCREW
Longgarkan insulator bandandscrew
Loosen the insulator band screw remove dan
the insulator.
lepaskan
Install the insulator while aligning its stopper tab with the
insulator.
PAIR air control valve vacuum hose joint.
Pasang
Tighten theinsulator sementara
band screw until thementepatkan stopper
distance between tab-
the band
nya
endsdengan
is 12.0 –PAIR air control
14.0 mm valvein).
(0.47 – 0.55 vacuum hose joint.
Kencangkan band screw sampai jarak antara ujung-
Install the carburetor (page 5-20). 12.0 – 14.0 mm
ujung band adalah 12,0 – 14,0 mm. (0.47 – 0.55 in)
Pasang karburator (hal. 5-20).

Tepatkan
INSULATOR

5-22
SISTEM BAHAN BAKAR
PILOT SCREWPILOT
PENYETELAN ADJUSTMENT
SCREW
• Pilot screw telah disetel awal di pabrik dan tidak
• The pilot screw is factory pre-set and no adjustment is
necessary unless penyetelan
memerlukan the pilot screwkecuali bila pilot screw
is replaced.
telah diganti.
• Use a tachometer with graduations of 50 min-1 (rpm) or
• Pakailah sebuah tachometer dengan skala 50
smaller-1that will accurately indicate a 50 min-1 (rpm)
menit (rpm) atau lebih kecil yang dapat
change.
memperlihatkan dengan akurat perubahan 50
IDLE DROP
menit
-1
(rpm).PROCEDURE
Kerusakan
Damageakan pilot IDLE
to theterjadi 1. TurnDROP
the pilotPROCEDURE
screw until it seats lightly, then back it out
padaseat
screw dudukan pilot 1. toPutar
will occur pilot screwgiven.
the specification sampai ia duduk dengan ringan,
screw
if thejika screw
screw is kemudian
This putar kembali
is an initial keluar
setting prior to sesuai
the finaldengan
pilot screw
dikencangkan terhadap
tightened against the spesifikasi yang diberikan.
adjustment.
kedudukannya.
seat. Ini merupakan penyetelan awal sebelum
penyetelan
INITIAL akhir dari pilot screw.
OPEN-
ING: 1 – 1/4 turns out
PEMBUKAAN AWAL: 1 – ¼ putaran keluar
2. Warm up the engine to normal operating temperature.
2. 10
Panaskan
minutes ofmesin sampai
stop-and-go suhuisoperasi
riding normal.
sufficient.
10 menit
3. Stop pengendaraan
the engine berhenti-dan-jalan
and connect the adalah
tachometer, according to
cukup.
the manufacturer’s instructions.

3. Matikan mesin dan sambungkan tachometer, PILOT SCREW


sesuai petunjuk
4. Disconnect pabrik.
the vacuum hose of PAIR control valve, then
connect the vacuum pump and plug the vacuum port. VACUUM PUMP
4. Lepaskan vacuum hose dari PAIR control valve,
Apply the specified vacuum to the pump
PAIR dan
control valve PLUG VACUUM HOSE
kemudian sambungkan vacuum sumbat
vacuum
lubang hose moredengan
vakuum than 60 plug.
kPa (450 mmHg) (make sure
the secondary air does not leak).
Hubungkan vakuum yang ditentukan pada PAIR
control valve vacuum hose sebanyak lebih dari 60
kPa (450 mmHg) (pastikan bahwa udara sekunder
tidak bocor).

5. Hidupkan mesin dan setel putaran stasioner


dengan throttle stop screw.
-1
PUTARAN STASIONER: 1.400 ± 100 menit
(rpm)

5. Start
6. Putar the engine and adjust
pilot screw the idleatau
masuk speedkeluar
with the dengan
throttle
stop screw. untuk mendapatkan putaran mesin
perlahan
tertinggi.
IDLE SPEED: 1,400 ± 100 min-1 (rpm)
7. Secara ringan buka throttle 2 – 3 kali, kemudian
6. Turn
setelthe pilot screw
putaran in or out
stasioner slowlythrottle
dengan to obtain thescrew.
stop highest
engine speed.
8. Putar open
7. Lightly pilot the throttlesecara
screw berangsur
2–3 times, ke the
then adjust dalam
idle-1
sampai
speed withputaran mesin
the throttle turun sebesar 100 menit
stop screw.
(rpm).
8. Turn the pilot screw in gradually until the engine speed
9. drops
Putarbypilot min-1 (rpm).
100screw keluar ke pembukaan final.
9. Turn the pilot screw outward to final opening.
PEMBUKAAN FINAL: ¾ putaran keluar dari THROTTLE STOP SCREW
posisi yang diperoleh pada langkah 8
FINAL OPENING: 3/4 turns out from the position
obtained in step 8
10. Lepaskan plug dari vacuum port, kemudian
lepaskan the
10. Disconnect vacuum pump
plug from dan sambung
the vacuum port, then vacuum
remove
hose
the dari PAIR
vacuum pump control valve.
and connect the vacuum hose of PAIR
control valve.
11. Setel kembali putaran stasioner dengan throttle
11. Readjust the idle speed with the throttle stop screw.
stop screw.
-1
IDLE SPEED:STASIONER:
PUTARAN 1,400 ± 100 min1.400
(rpm)± 100 menit-1
(rpm)

5-23
SISTEM BAHAN BAKAR
SECONDARY
SECONDARY AIRAIR SUPPLY
SUPPLY SYSTEM
SYSTEM
SYSTEM INSPECTION
PEMERIKSAAN SYSTEM
Start the engine
Hidupkan mesinand warm
dan it up to normal
panaskan sampaioperating
ke suhutempera-
operasi
ture.
normal. PAIR AIR FILTER-ke-PAIR
Lepaskan
Remove thecenter
center body
body cover/radiator shroud
cover/radiator shroud (hal.
(page 2-6).
2-6). CONTROL VALVE HOSE

Disconnectslang
Lepaskan the PAIR
PAIRairair
filter-to-PAIR
filter – ke –control valve hose.
PAIR control valve.
Check that the hose joint of the air filter is clean and free car-
bon deposits.
Periksa bahwa hose joint (penyambung slang) dari air
filter
If theadalah
port isbersih
carbondan bebas
fouled, dari the
check endapan
PAIR karbon.
check valve
(page 5-24).
Jika lubang kotor dengan karbon, periksa PAIR check
valve (hal. 5-24).

PAIR AIR FILTER

Lepaskan PAIR
Disconnect the control
PAIR controlvalve
valve vacuum hosefrom
vacuum hose (slang
the
vakuum) dariand
control valve control
plug itvalve
to keepdan sumbatlah
air from entering.agar udara
tidak dapat
Connect the masuk.
vacuum pump to the PAIR control valve. PAIR AIR FILTER-ke-PAIR
Sambungkan vacuum pump (pompa vakuum) ke PAIR CONTROL VALVE HOSE
TOOL:
control valve.
Vacuum pump Commercially available VACUUM PUMP
KUNCI
Start thePERKAKAS:
engine and open the throttle slightly to be certain
Vacuum pump in through the Dapat VACUUM HOSE
that air is sucked PAIR airdibeli di pasaran
filter-to-PAIR con-
trol valve hose.
Hidupkan
If the air is mesin danin,buka
not drawn checkgas tangan
the PAIR sedikit untuk
air filter-to-PAIR
memastikan bahwa
control valve hose for udara tersedot masuk melalui slang
clogging.
PAIR air filter – ke – PAIR control valve.
Withudara
Jika the engine
tidak running,
tersedotgradually apply vacuum
masuk, periksalah to PAIR
slang PAIR
control valve.
air filter – ke – PAIR control valve terhadap sumbatan.
Check that the air intake port stops drawing air, and that the
vacuum does not bleed.
Sementara mesin dalam keadaan hidup, secara
berangsur
SPECIFIED kenakan
VACUUM: vakuum pada
60 kPa (450PAIR control valve.
mmHg)
Periksa bahwa lubang pemasukan udara berhenti
If the air is drawn
menyedot udara,in, dan
or if the specified
bahwa vacuum
tidak ada iskebocoran
not main-
tained, replace the PAIR control valve.
vakuum.

VAKUUM YANG DITENTUKAN: 60 kPa (450 mmHg)

Jika udara tersedot masuk, atau jika vakuum yang


ditentukan tidak dapat dipertahankan, gantilah PAIR
control valve.

PAIR CHECK VALVE


PEMERIKSAAN INSPECTION
PAIR CHECK VALVE
Lepaskan
Remove thecenter
center body
body cover/radiator shroud
cover/radiator shroud (hal.2-6).
(page 2-6).
BOLT/COLLAR
Remove the radiator mounting bolt/collar and release the
Lepaskan radiator mounting bolt/collar (baut
radiator from the stay, then move the radiator forward.
pemasangan/collar radiator) dan lepaskan radiator dari
Remove
stay, the thermostat
kemudian housing
gerakkan mounting
radiator bolt.
ke depan.

Lepaskan thermostat housing mounting bolt (baut


pemasangan thermostat).

STAY BOLT

5-24
SISTEM BAHAN BAKAR
Remove thekedua
Lepaskan two bolts
boltsand
danthe check
check valve
valve coverdari
cover from the
cylinder head CHECK VALVE COVER
cyllinder headcover.
cover.
Remove the PAIR check valve.
Lepaskan PAIR check valve.

BOLTS CHECK VALVE

Check the
Periksa reed(buluh)
reed for fatigue or damage
terhadap and replace
kelelahan the PAIR
atau kerusakan
checkganti
dan valvePAIR
if necessary.
check valve bila perlu. CHECK VALVE
ReplacePAIR
Ganti the PAIR
checkcheck
valvevalve if the
jika check
check valveseat
valve seat rubber
rubber
is cracked,
(karet deteriorated
dudukan) or damaged,
retak-retak, ada orpemburukan
if there is clearance
kondisi
between
atau the reed andatau
kerusakan, seat. jika ada kerenggangan antara
reed dan dudukan.

SEAT RUBBER REED

Install thecheck
Pasang checkvalve
valve dan
and check
checkvalve
valvecover.
cover. CHECK VALVE COVER
Install and
Pasang tighten
dan the two bolts
kencangkan to the
kedua specified
bolts dengan torsi yang CHECK VALVE
torque.
ditentukan.
TORQUE: 5.0 N·m (0.5 kgf·m, 3.7 lbf·ft)
TORSI: 5,0 N.m (0,5 kgf.m; 3,7 lbf.ft)

BOLTS

Set the radiator


Tempatkan to the stay,
radiator padathen install
stay, and tighten
kemudian the radia-
pasang dan BOLT/COLLAR
tor mounting bolt/collar.
kencangkan radiator mounting bolt/collar (baut
pemasangan/collar
Install and tighten theradiator).
thermostat housing mounting bolt.
Install thedan
Pasang center body cover/radiator
kencangkan shroud
thermostat (page 2-6).
housing bolt (baut
pemasangan rumah thermostat).

Pasang center body cover/radiator shroud (hal. 2-6).

STAY BOLT

5-25
SISTEM BAHAN BAKAR
PAIR AIR FILTER REMOVAL/
PELEPASAN/PEMASANGAN
INSTALLATION
PAIR AIR FILTER
Remove thecenter
Lepaskan center body
body cover/radiator
cover/radiatorshroud
shroud(page 2-6).
(hal. 2-6). PAIR AIR FILTER-ke- PAIR AIR FILTER
Release the following hoses from the clamps and disconnect CONTROL VALVE HOSE
Lepaskan hoses
them from the PAIR(slang-slang)
air filter. berikut dari clamps dan
– PAIR air
lepaskan filter-to-control
mereka dari PAIRvalve hose
air filter.
– PAIR air filter-to-open air hose
- Slang PAIR air filter - ke – control valve
- Slang PAIR air filter – ke – udara terbuka

PAIR AIR FILTER-


CLAMPS KE-OPEN AIR HOSE
Install theairairfilter
Pasang filterdengan
with its tanda
arrow panahnya
mark facingmenghadap
the PAIR con-
ke
trol valve
sisi PAIR side.
control valve. PAIR AIR FILTER
Install the center body cover/radiator shroud (page 2-6).
Pasang center body cover/radiator shroud (hal. 2-6).

TANDA PANAH Sisi PAIR control valve

PAIR CONTROL VALVE REMOVAL/


PELEPASAN/PEMASANGAN
INSTALLATION
PAIR CONTROL VALVE
Remove theluggage
Lepaskan luggage box
box (page 2-13).
(hal. 2-13).
VACUUM HOSE
Lepaskan slang-slang berikutfrom
Disconnect the following hoses dari the PAIR
PAIR control
control valve:
valve:
-– slang
Vacuum hose
vakuum
-– slang
PAIRPAIR
checkcheck
valve-to-control
valve – kevalve hose valve
– control

PAIR CHECK VALVE-ke-


CONTROL VALVE HOSE
Disconnectslang
Lepaskan the PAIR
PAIR control valve-to-air
control valve – kefilter hose.
- air filter. PAIR CONTROL BOLT
Remove the bolt and PAIR control valve. VALVE-KE-AIR
Installationbolt
Lepaskan is indan
the reverse order ofvalve.
PAIR control removal.
FILTER HOSE
Route
Alurkan the hoses
slang-slang
dengan benar(page
properly (hal.1-16).
1.16). Pemasangan adalah dalam urutan terbalik dari
pelepasan.

PAIR CONTROL
VALVE

5-26
SISTEM BAHAN BAKAR
FUEL TANK
(TANGKI BAHAN BAKAR)
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Remove the following:
Lepaskan sebagai berikut:
– Seat (page 2-5)
–- Tempat
Body cover (page
duduk 2-16)
(hal. 2-5)
- Body cover
Disconnect the (hal. 2-16)
fuel level sensor 2P connector.

Lepaskan fuel level sensor 2P connector.

FUEL LEVEL SENSOR 2P CONNECTOR

Remove thesebagai
Lepaskan following:
berikut:
– Four bolts BOLTS
-– Empat bolts
Fuel tank
- Fuel tank FUEL TANK
Clamp the fuel hose.
Sekalah bahan bakar Klem slang bahan bakar.
Wipe
yang the spilled
tertumpah out Disconnect the fuel hose and vacuum hose from fuel auto
dengan
segera. Pemasangan
fuel immediately. valve. adalah dalam urutan terbalik dari
pelepasan.
Route the hoses and Installation is in the reverse order of removal.
wire properly
Alurkan dan Lepaskan slang bahan bakar dan slang vakuum dari
(page
slang
benar fuel auto valve.
kawat dengan 1-16).
(hal. 1-16).

VACUUM HOSE FUEL HOSE

5-27
SISTEM BAHAN BAKAR
FUEL AUTO
FUEL AUTO VALVE
VALVE
REMOVAL
PELEPASAN
Remove thefuel
Lepaskan fueltank
tank(hal.
(page5-27).
5-27).
FUEL AUTO VALVE
Loosen the lock nut and remove the fuel auto valve from the
Longgarkan
fuel tank. lock nut (mur pengunci) dan lepaskan fuel
auto valve dari fuel tank.

LOCK NUT

Remove theyang
Lepaskan following from
berikut thefuel
dari fuelauto
autovalve:
valve:
– O-ring O-RING
-– O-ring
Fuel strainer screen
- Fuel strainer screen

STRAINER
FUEL AUTO VALVE
SCREEN
Clean the fuel
Bersihkan strainer
fuel screen
strainer using compressed
screen air.
dengan menggunakan
STRAINER SCREEN
udara dari kompressor.

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

O-RING

5-28
SISTEM BAHAN BAKAR
Pasang
Install thefuel
fuelstrainer
strainer screen ke dalam
screen into the fuelfuel
autoauto valve.
valve.
STRAINER SCREEN

FUEL AUTO VALVE

Set the fuel auto


Tempatkan valveauto
fuel in specified
valve angle.
dengan sudut yang
ditentukan.
30 ° ± 3 °

FUEL AUTO VALVE

Hold thefuel
Tahan fuelauto
auto valve
valve and
dantighten the locklock
kencangkan nut to thedengan
nut speci-
fied torque.
torsi yang ditentukan. FUEL AUTO VALVE
TORQUE: 27 N·m (2.8 kgf·m, 20 lbf·ft)
TORSI: 27 N.m (2,8 kgf.m; 20 lbf.ft)
Install the fuel tank (page 5-27).
Pasang fuel tank (hal. 5-27).

LOCK NUT

INSPECTION
PEMERIKSAAN
Lepaskan
Disconnect fuel hose
the fuel (slang
hose frombahan bakar) and
the carburetor dariplace
karburator
a suit-
dan
able letakkan
container.pada penampung yang cocok. FUEL HOSE
Lepaskan
Disconnectslang vakuum
the fuel fuelvacuum
auto valve auto valve
hosedari
fromjoint.
the joint.
Sambungkan sebuah pompa
Connect a commercially vakuum
available vacuumyang
pumpdapat
to thedibeli
fuel
auto valve vacuum
dipasaran pada slanghose.vakuum fuel auto valve.
Fuel should flow out from the fuel hose when vacuum pres-
Bahan bakar harus mengalir keluar dari slang bahan
sure is applied.
bakar ketika tekanan vakuum dikenakan.
• If the fuel flow is restricted, check the fuel strainer screen
• andJikafuelaliran
tank cap breather
bahan hole for
bakar clog.
terbatas, periksa fuel
• Ifstrainer
above items are normal,
screen replace
dan fuel tankthecap
fuel auto valve with
breather hole
a(lubang
new one. pernapasan tutup tangki bahan bakar)
terhadap sumbatan.
• Jika hal-hal tersebut di atas adalah normal, ganti POMPA VAKUUM
fuel auto valve dengan yang baru.

5-29
CATATAN
6. SISTEM PENDINGINAN

POLA ALIRAN
SYSTEM FLOWSISTEM........................... 6-2
PATTERN···························· 6-2 THERMOSTAT......................................... 6-7
THERMOSTAT ·················································6-7

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


SERVICE INFORMATION 6-3
····························· 6-3 THERMOSTAT
THERMOSTATHOUSING
HOUSING ....................... 6-8
·····························6-8

MENCARI PENYEBAB····································
TROUBLESHOOTING KESUKARAN ....6-4 6-4 RADIATOR............................................... 6-9
RADIATOR ························································6-9

PENGETESAN SISTEM...........................
SYSTEM TESTING 6-5
·········································· 6-5 POMPA
WATERAIR .............................................
PUMP 6-13
················································6-13

PENGGANTIAN COOLANT·························
COOLANT REPLACEMENT ....................6-6 6-6 RADIATOR
RADIATORRESERVE TANK..................
RESERVE TANK 6-17
·····················6-17

6-1
SISTEM PENDINGINAN
SYSTEM FLOWSISTEM
PATTERN
COOLING SYSTEM

POLA ALIRAN
SIPHON HOSE
RADIATOR
WATER HOSES

RESERVE TANK

THERMOSTAT

WATER HOSES

WATER PUMP

6-2
SISTEM PENDINGINAN
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
! AWAS
Membuka
Removingradiator capcap
the radiator (tutup
whileradiator) sewaktu
the engine mesin
is hot can allowdalam keadaan
the coolant panas
to spray dapat mengakibatkan
out, seriously scalding you. bahwa
coolant
Always(cairan pendingin)
let the engine menyemprot
and radiator keluar,
cool down sehingga
before removingmenimbulkan luka bakar karena air mendidih.
the radiator cap.
Selalu biarkan mesin dan radiator menjadi dingin dulu sebelum membuka radiator cap.

CATATAN
•• Use
Sewaktu menambahkan
only genuine Honda PRE-MIX atau COOLANT
mengganticontaining
coolant, corrosion
hanya pakai Honda
inhibitors, PRE-MIX
specially COOLANT
recommended asli yangengines
for aluminum mengandung zat
when adding
orpencegah
replacing thekarat, yang khususnya dianjurkan untuk mesin aluminium.
coolant.
Honda Honda
Genuine PRE-MIX COOLANT
PRE-MIX COOLANT asliis adalah
excellentbaik sekali untuk
at preventing mencegah
corrosion karat dan
and overheating. Thepanas berlebihan.
effects last for up to 2Pengaruh
years. ini dapat
• The coolant selama
bertahan should be 2 inspected
tahun. and replaced properly by following the maintenance schedule (page 3-4).
•• Use any genuine
Coolant harus Honda PRE-MIX
diperiksa COOLANT
dan diganti without diluting
sebagaimana mestinyawithdengan
water. mengikuti jadwal perawatan (hal. 3-4).
•• DO NOT useHonda
Gunakan non-ethylene
PRE-MIX glycol coolant, tap
COOLANT water,
tanpa nor mineral water when
mencampurkannya adding
dengan air.or replacing the coolant.
• Use of improper
JANGAN coolant
memakai may cause damage,
non-ethylene glycol such as corrosion
coolant, air PAM,inatau
the engine, blockage
air mineral of the
ketika cooling passage
menambahkan or mengganti
atau the radiator coolant.
and premature
wear of the watercoolant
Penggunaan pump seal.
yang tidak sesuai dapat menimbulkan kerusakan, seperti karat pada mesin, rintangan pada jalan
lintasan
• Add coolingpendinginan
system at theatau radiator
reserve tank. dan keausan
Do not removedini dari sealcap
the radiator pompa
exceptair.
to refill or drain the system.
•• All
Tambahkan
cooling systemsistem pendinginan
services can be donepada reserve
with tank.
the engine Jangan
installed in melepaskan
the frame. radiator cap kecuali untuk
• Avoid
mengisispilling coolant
kembali on mengosongkan
atau painted surfaces. sistem.
•• After
Semuaservicing the system,
pekerjaan sistemcheck for leaks with
pendinginan dapat a cooling system
dilakukan tester.mesin terpasang pada rangka.
dengan
•• For the thermo
Jangan sensor inspection
menumpahkan coolant(page 19-14).
di atas permukaan yang dicat.
•• For the cooling
Setelah fan motor
menservis switch
sistem, inspectionterhadap
periksalah (page 19-15).
kebocoran dengan sebuah cooling system tester.
• Untuk pemeriksaan thermo sensor (hal. 19-14).
• Untuk pemeriksaan saklar motor kipas (hal. 19-15).
SPECIFICATIONS
SPESIFIKASI
BAGIAN ITEM SPESIFIKASI SPECIFICATIONS
Kapasitas
Coolant capacity coolant RadiatorRadiator
dan mesinand engine 0,77 liter 0.77 liter (0.81 US qt, 0.68 lmp qt)
(cairan pendingin) ReserveReserve
tank (tangki
tank cadangan) 0,13 liter 0.13 liter (0.14 US qt, 0.11 lmp qt)
2
Tekanan pembebasan
Radiator cap radiator cap (tutup radiator)
relief pressure 108–137108kPa (1,1
– 137 kPa–(1.1
1,4 –kgf
1.4/cm ; 16-20
kgf/cm 2
, 16 psi)
– 20 psi)
Thermostat
Thermostat Mulai membuka
Begin to open 69,5 – 72,5° 69.5
C – 72.5°C (157.1 – 162.5°F)
TerbukaFully
penuhopen 80° C 80°C (176°F)
Pengangkatan
Valve liftvalve (klep) Minimum 3,5 mm 3.5 mm (0.14 in) minimum
Cairan antibekuantifreeze
Recommended yang dianjurkan Honda PRE-MIX HondaCOOLANT
PRE-MIX COOLANT

TORQUE VALUES
NILAI TORSI
Cooling
Cooling fanassembly
fan assembly mounting
mounting bolt
bolt 8,4 N.m 8.4
(0,9N·m (0.96,2
kgf.m; kgf·m, 6.2 lbf·ft)
lbf.ft)
Cooling
Cooling fanmotor
fan motorshroud
shroud mounting
mounting screw
screw 2,8 N.m 2.8
(0,3N·m (0.32,1
kgf.m; kgf·m, 2.1 lbf·ft)
lbf.ft)
Cooling
Cooling fanmounting
fan mountingnut
nut 1,0 N.m 1.0
(0,1N·m (0.10,7
kgf.m; kgf·m, 0.7 lbf·ft) OleskanApply
lbf.ft) cairanlocking agent to the threads.
pengunci
Water pump impeller 10 N·m (1.0 kgf·m, 7 lbf·ft) pada ulir.
Water pump impeller 10 N.m (1,0 kgf.m; 7 lbf.ft)

6-3
SISTEM PENDINGINAN
TOOLS
KUNCI PERKAKAS

Driver Bearing remover shaft Remover weight


07749-0010000 07936-KC10100 07741-0010201

Bearing remover head, 14 mm Oil seal driver attachment, 36 mm


07WMC-KFG0100 07945-4150400

MENCARI PENYEBAB KESUKARAN


TROUBLESHOOTING
Suhu
Enginemesin terlalu too
temperature tinggi
high
•• Thermostat
Thermostat macet
stuck tertutup
closed
•• Faulty radiator
Radiator cap cap
tidak bekerja dengan baik
•• Insufficient coolanttidak cukup
Jumlah coolant
•• Passage blocked di
Jalan lintasan in radiator, hoses or hoses
dalam radiator, water jacket
atau water jacket tersumbat
•• Air in system
Udara di dalam sistem
• Faulty cooling fan motor
• Motor kipas pendingin tidak bekerja dengan baik
• Faulty water pump
• Pompa air tidak bekerja dengan baik
Engine temperature too low
• Thermostat
Suhu stuck open
mesin terlalu rendah
•Coolant
Thermostat
leak macet terbuka
• Faulty water pump mechanical seal
Coolant bocor O-ring
• Deteriorated
•• Faulty
Mechanical
radiatorseal
cap pompa air tidak bekerja dengan baik
•• Damaged
Pemburukan kondisi O-ring
or deteriorated cylinder head gasket
•• Loose hosecap
Radiator connection or clamp
tidak bekerja dengan baik
•• Damaged
Cylinderor deteriorated
head hoses atau ada pemburukan kondisi
gasket rusak
•• Damaged
Sambungan radiator
hose atau clamp longgar
• Hoses rusak atau ada pemburukan kondisi
• Radiator rusak

6-4
SISTEM PENDINGINAN
SYSTEM TESTING
PENGETESAN SISTEM
RADIATOR CAP/SYSTEM
PEMERIKSAAN PRESSURE
RADIATOR CAP/
INSPECTION
TEKANAN SISTEM
Remove thecenter
Lepaskan center body
body cover/radiator
cover/radiatorshroud
shroud(page 2-6).
(hal. 2-6).
Remove the radiator cap.
Lepaskan radiator cap.

RADIATOR CAP
Wet the sealing
Basahkan surfaces ofperapatan
permukaan the cap, then install
dari cap,thekemudian
cap onto
the tester.cap pada tester. RADIATOR CAP TESTER
pasang
Pressurize the radiator cap using the tester. Replace the radia-
Naikkan tekanan
tor cap if it does not holdpada
pressure,radiator pressuredengan
or if relief cap is too
menggunakan
high or too low. Ittester. Ganti
must hold radiator pressure
the specified cap jikaforiaat least
tidak
dapat menahan tekanan, atau jika tekanan pembebasan
6 seconds.
terlalu tinggi atau rendah.
RADIATOR
Ia harus dapat CAP RELIEFtekanan
menahan PRESSURE:yang ditentukan untuk
108 – 137 kPa
sekurangnya (1.1 – 1.4 kgf/cm2, 16 – 20 psi)
6 detik.

TEKANAN PEMBEBASAN RADIATOR CAP:


2
108–137 kPa (1,1 – 1,4 kgf/cm ; 16-20 psi)

RADIATOR CAP

Naikkan
Pressurize tekanan radiator,
the radiator, mesin
engine and hosesdan
usinghoses (slang-
the tester, and
slang)
check fordengan
leaks. menggunakan tester, dan periksa RADIATOR CAP TESTER
terhadap kebocoran.
CATATAN
Excessive pressure
Tekanan can damage
berlebihan dapatthe merusak
cooling system compo-
komponen-
komponen
nents. Do notsistem
exceedpendinginan. Jangan
137kPa (1.4 kgf/cm 2
, 20melampaui
psi). 137
2
kPa (1,4 kgf/cm ; 20 psi).
Repair or replace components if the system will not hold the
specified pressure for at least 6 seconds.
Perbaiki atau ganti komponen-komponen jika sistem
Remove
tidak the tester.
dapat menahan tekanan yang ditentukan untuk
sekurangnya 6 detik.

Lepaskan tester.

Install
Pasang theradiator
radiator cap.
cap.
Install the center body cover/radiator shroud (page 2-6).
Pasang center body cover/radiator shroud (hal. 2-6).

RADIATOR CAP

6-5
SISTEM PENDINGINAN
COOLANT REPLACEMENT
PENGGANTIAN COOLANT
PENGGANTIAN/AIR BLEEDING
REPLACEMENT/AIR BLEEDING
(PEMBUANGAN UDARA PALSU)
Remove the following:
Lepaskan sebagai berikut:
– Center body cover/radiator shroud (page 2-6)
– Body cover (page 2-16)
- Center body cover/radiator shroud (hal. 2-6)
– Radiator cap (page 6-5)
- Body cover (hal. 2-16)
-Remove
Radiatorthecap
drain bolt6-5)
(hal. and sealing washer from the water
pump cover and drain the coolant.
Lepaskan
Reinstall thedrain bolt with
drain bolt dan sealing
a new sealingwasher
washer. dari water
pump cover
Install and (tutup
tighten pompa
the drain bolt.air) dan keluarkan coolant
(cairan pendingin).

Pasang kembali drain bolt dengan sebuah sealing


washer baru dan kencangkan drain bolt.
DRAIN BOLT/SEALING WASHER

Remove thereserve
Lepaskan reserve tank
tank cap.
cap (tutup tangki cadangan). SIPHON TANK CAP BOLTS
Disconnect the siphon hose from the radiator. HOSE
Drain the coolant from the reserve tank.
Lepaskan siphon hose dari radiator.
Remove thecoolant
Keluarkan two bolts,
dariempty the coolant
reserve tank. and rinse the inside
of the reserve tank with water.
Lepaskan keduahose
Install the siphon bolt,to kosongkan
the clamps and connectdan
coolant it tobilas
the
bagian
radiator.dalam dari reserve tank dengan air.

Pasang siphon hose pada clamps dan sambungkan ke


radiator.

RESERVE TANK

Use onlymenambahkan
Ketika genuine Hondaatau PRE-MIX COOLANT
mengganti containing
coolant, hanya
corrosionHonda
inhibitorsPRE-MIX
recommended for aluminum FILLER
pakai COOLANT asli engines
yang
when adding orzat
mengandung replacing
pencegahthe coolant.
karat yang dianjurkan untuk
mesin-mesin aluminium.
KetikaWhen filling
mengisi the
sistem Fill the system with the recommended coolant through the
Isi
fillersistem
openingdengan neck. yang dianjurkan melalui
up to fillercoolant
atausystem or tank
reserve reserve tank
dengan
coolant (periksa tinggi
with a coolant
lubang pengisian sampai ke leher pengisian.
permukaan
(checkingcoolant),
coolant
RECOMMENDED COOLANT:
COOLANT YANG DIANJURKAN:
letakkan sepedamotor
level), support the di Honda PRE-MIX
Honda PRE-MIX COOLANT COOLANT
atas permukaan
motorcycle on a level
mendatar. Bleed air from
Buanglah the palsu
udara systemdari
as follows:
sistem sebagai berikut:
surface.
1. Shift the transmission into neutral.
1. Start
Masukkan transmissi
the engine and let it ke
idledalam
for 2 –netral.
3 minutes.
Hidupkan mesin dan biarkan berputar stasioner
2. Snap the throttle
selama 3 – 4 times to bleed air from the system.
2-3 menit.
2. Stop
3. Hentakkan
the enginegasandtangan
add the 3coolant
- 4 kali
up untuk membuang
to the filler neck.
udara dari sistem.
4.
3. Install the radiator
Matikan mesin capdan(page 6-5).
tambahkan coolant sampai ke
leher pengisian.
4. Pasang radiator cap (hal. 6-5).

6-6
SISTEM PENDINGINAN

CATATAN
Hanya
Use onlypakai Honda
genuine HondaPRE-MIX
PRE-MIXCOOLANT asli yang
COOLANT containing
corrosion inhibitors
mengandung recommended
zat pencegah for aluminum
karat yang dianjurkanengines
untuk TANK CAP
when adding oraluminium
mesin-mesin replacing theketika
coolant.menambahkan atau
mengganti
Remove thecoolant.
reserve tank cap and fill the reserve tank to the
Lepaskan
"UPPER" levelreserve
line.tank cap dan isi reserve tank sampai
ke garis permukaan "UPPER".
RECOMMENDED COOLANT:
Honda YANG
COOLANT PRE-MIX COOLANT
DIANJURKAN:
Honda PRE-MIX COOLANT
Install the following:
Pasang sebagai
– Reserve berikut:
tank cap
-– Reserve
Radiatortank cap 6-5)
cap (page
-– Radiator cap(page
Body cover (hal. 2-16)
6-5)
-– Body
Center body(hal.
cover cover/radiator
2-16) shroud (page 2-6) GARIS "UPPER" LEVEL
- Center body cover/radiator shroud (hal. 2-6)
THERMOSTAT
THERMOSTAT
REMOVAL
PELEPASAN
Drain the coolant
Keluarkan (page
coolant 6-6).
(hal. 6-6).
BOLTS
Remove thebolts
Lepaskan boltsdan
and thermostat
thermostat housing
housingcover.
cover.

COVER
Remove thethermostat
Lepaskan thermostat from the thermostat
dari thermostat housing.
housing.
THERMOSTAT

INSPECTION
PEMERIKSAAN
Visually inspectthermostat
Periksalah the thermostatsecara
for damage.
visual terhadap
Check for damage of the seal ring. THERMOSTAT SEAL RING
kerusakan.
Periksa terhadap kerusakan dari seal ring.

6-7
SISTEM PENDINGINAN
Wear Pakailah
insulated sarung
gloves Heat the water
Panaskan air with an electric
dengan komporheating
listrikelement
sampaito operating
ke suhu
tanganandberisolasi
adequate dan
eye temperature for
operasional 5 minutes.
sampai 5 menit.
perlindungan mata
protection. Keep
yang memadai.
Suspend the
Gantung thermostatdiindalam
thermostat heatedair
water
yangto check its operation.
dipanaskan untuk
flammable
Jauhkan materials
bahan-bahan memeriksa cara kerjanya.
THERMOSTAT BEGIN TO OPEN:
yangaway
dapatfrom the
mudah
terbakarelectric
dari heating
kompor 69.5 – 72.5°C (157.1 – 162.5°F)
THERMOSTAT MULAI MEMBUKA:
listrik. Do
element. Jaga agar
not let
thermostat atau
69,5 –LIFT:
VALVE 72,5° C
the thermostat or
thermometer tidak
thermometer touch 3.5 mm (0.14 in) minimum at 80°C (176°F) THERMOMETER
PENGANGKATAN VALVE:
menyentuh panci,
the pan,karena
or youakan
will
minimum
Replace 3,5 mm pada
the thermostat if the80° C open at a temperatures
valve
getmengakibatkan
false reading.
other than those specified.
pembacaan yang
salah. Ganti thermostat jika valve membuka pada suhu lain
daripada yang ditentukan.
THERMOSTAT

INSTALLATION
PEMASANGAN
Pasang
Install thethermostat pada
thermostat into housingwith
the housing dengan
its holelubangnya
facing up
menghadap
as shown. ke atas seperti diperlihatkan. THERMOSTAT HOLE

Install thethermostat
Pasang thermostat housing
housing cover
coveronto
pada thehousing.
housing.
Install and tighten the housing cover bolts. BOLTS
Pasang dan kencangkan housing cover bolts.
Fill the system with the recommended coolant and bleed any
Isi
air sistem dengan coolant yang dianjurkan dan buanglah
(page 6-6).
udara palsu yang ada (hal. 6-6).

COVER

THERMOSTAT HOUSING
THERMOSTAT HOUSING
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Lepaskan
Remove theluggage
luggage box (hal. 2-13).
box (page 2-13).
BAND SCREWS THERMOSTAT HOUSING
Drain the coolant
Keluarkan coolant (page
(hal.6-6).
6-6).
Disconnect the thermo sensor connector.
Lepaskan
Loosen the thermo sensor
water hose bandconnector.
screws and disconnect the water
Longgarkan
hoses from thewater hose
thermostat band screws dan lepaskan
housing.
water hoses (slang-slang air) dari thermostat housing.
Remove the bolt and thermostat housing.
Lepaskan bolt dan thermostat housing.
Route thekawat
Alurkan wire and
dan Install thethermostat
Pasang thermostat housing
housingin dalam
the reverse orderterbalik
urutan of removal.
dari
hoses
hosesproperly
dengan (page
benar pelepasan.
Tighten the band screws as specified (page 6-10).
(hal. 1-16).
1-16). Kencangkan band screws seperti ditentukan (hal. 6-10).
Fill the system with the recommended coolant and bleed any
air (page
Isi 6-6). dengan coolant yang dianjurkan dan
sistem THERMO SENSOR
keluarkan udara palsu
Install the luggage yang2-13).
box (page ada (hal. 6-6). CONNECTOR BOLT
Pasang luggage box (hal. 2-13).

6-8
SISTEM PENDINGINAN
RADIATOR
RADIATOR
REMOVAL
PELEPASAN
Lepaskan
Remove theluggage
luggage box (page
(hal. 2-13).
2-13).
Drain the coolant
Keluarkan (page
coolant (hal.6-6).
6-6). 2P CONNECTOR

Disconnect the fan motor 2P connector.


Lepaskan fan motor 2P connector.

Disconnect siphon
Lepaskan the siphon
hose hose from
dari the radiator.
radiator.
Loosen the band SIPHON HOSE
Longgarkan bandscrew
screwanddandisconnect
lepaskan the lower
lower radiator
radiator
hose from
hose thebawah
(slang radiator.radiator) dari radiator.

LOWER
RADIATOR
HOSE

BAND SCREW

Loosen the water


Longgarkan hose
water band
hose screw
band and dan
screw disconnect the upper
lepaskan upper
radiator hose. BAND SCREW
radiator hose (slang atas radiator).

UPPER RADIATOR HOSE


Remove thebolt
Lepaskan boltdan
and collar.
collar. BOLT/COLLAR RADIATOR
Remove the radiator from the stay by pulling it upward.
Lepaskan radiator dari stay dengan menariknya ke atas.

STAY

6-9
SISTEM PENDINGINAN
INSTALLATION
PEMASANGAN
Be careful
Hati-hati agarnot Install the
to Pasang
tidak radiator radiator
susunan assemblydengan
by inserting the boss boss
memasukkan into the
ke BOLT/COLLAR
damagesirip
the radiator. stay. stay.
radiator dalam RADIATOR
merusak
fins.
Install and tighten the bolt/collar.
Pasang dan kencangkan bolt/collar.

STAY
Connect the upper
Sambungkan radiator
upper hosehose
radiator to theke
radiator.
radiator.

UPPER RADIATOR HOSE


Connect the siphon
Sambungkan hosehose
siphon and lower
dan radiator hose to the
lower radiator radia-
hose ke
tor.
radiator. LOWER
RADIATOR
HOSE

SIPHON HOSE

For band
Untuk arah band screw Tighten the waterwater
screw Kencangkan hose band screwsband
hose as shown.
screws seperti
direction (page 1-16). diperlihatkan.
(hal. 1-16).
After installation, check the radiator and radiator hoses for
leaks.
Setelah pemasangan, periksa radiator dan radiator
hoses (slang-slang radiator) terhadap kebocoran.

0 – 1.0 mm (0 – 0.04 in)

6-10
SISTEM PENDINGINAN
Connect the fan fan
Sambungkan motor 2P connector.
motor 2P connector (connector 2P 2P CONNECTOR
motor kipas).
Fill the system with the recommended coolant and bleed any
air (page 6-6).
Isi sistem dengan coolant yang dianjurkan dan buanglah
Install the
udara luggage
palsu (hal. box
6-6).(page 2-13).

Pasang luggage box (hal. 2-13).

DISASSEMBLY
PEMBONGKARAN
Disconnect fan
Lepaskan the fan motor
motor switch
switch connector.(connector saklar
connector FAN MOTOR SWITCH CONNECTOR
motor
Removekipas).
the following:
– Bolts/ground
Lepaskan terminal
sebagai berikut:
– Cooling fan assembly
- Bolts (baut-baut)/ground terminal (terminal massa)
- Cooling fan assembly (susunan kipas pendingin)

BOLTS/GROUND
COOLING FAN ASSEMBLY TERMINAL
–- Nut
Nut(mur) COOLING FAN
–- Cooling
Coolingfan
fan (kipas pendingin)

NUT

Release thekawat
Lepaskan wire from
darithe clamp.
clamp. FAN MOTOR SCREWS/WASHERS
Remove thesebagai
Lepaskan following:
berikut:
–- Screws/washers
Screws/washers
–- Fan motor
Fan motor

CLAMP

6-11
SISTEM PENDINGINAN
ASSEMBLY
PERAKITAN

RADIATOR
1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)

FAN MOTOR SHROUD

BOLTS/
WASHERS
8.4 N·m (0.9 kgf·m, 6.2 lbf·ft)

COOLING FAN

FAN MOTOR

SCREWS/
WASHERS FAN MOTOR WIRE
2.8 N·m (0.3 kgf·m, 2.1 lbf·ft)

Install
Pasang thefan
fanmotor
motor pada
onto the
fanfan motor
motor shroud.
shroud.
FAN MOTOR SCREWS/WASHERS
Install
Pasang anddan
tighten the screws/washers
kencangkan to the specified
screws/washers dengan torque.
torsi
yang ditentukan.
TORQUE:2.8 N·m (0.3 kgf·m, 2.1 lbf·ft)
Secure the fan motor wire with the clamp.
TORSI: 2,8 N.m (0,3 kgf.m; 2,1 lbf.ft)

Kokohkan pemasangan kawat fan motor dengan clamp.

FAN
MOTOR
SHROUD CLAMP

Install thecooling
Pasang coolingfan
fanpada
onto the fan motor
poros shaftshaft
fan motor while(poros
aligning
the flatkipas)
surfaces. Tepatkan
motor sementara mentepatkan permukaan-
permukaan datar.

COOLING FAN

6-12
SISTEM PENDINGINAN
Apply locking
Oleskan agent
cairan to the cooling
pengunci fancooling
pada ulir nut threads.
fan nut. COOLING FAN
Install anddan
Pasang tightenkencangkan
the nut to the specified torque. torsi yang
nut dengan
ditentukan.
TORQUE:1.0 N·m (0.1 kgf·m, 0.7 lbf·ft)
TORSI: 1,0 N.m (0,1 kgf.m; 0,7 lbf.ft)

NUT

Install
Pasang thefan
fanmotor
motorassembly
assembly onto the radiator.
(susunan motor kipas) FAN MOTOR SWITCH CONNECTOR
Set
padatheradiator.
ground terminal in position, then install and tighten
the bolts to ground
Letakkan the specified torque.pada tempatnya, kemudian
terminal
pasang
TORQUE:8.4 N·m (0.9 kgf·m, bolts
dan kencangkan dengan torsi yang
6.2 lbf·ft)
ditentukan.
Connect the fan motor switch connector.
TORSI: 8,4 N.m (0,9 kgf.m; 6,2 lbf.ft)
Sambungkan fan motor switch connector (connector
saklar fan motor).

BOLTS/GROUND
FAN MOTOR ASSEMBLY TERMINAL

WATER PUMP
WATER PUMP
(POMPA AIR)
SEALS INSPECTION
PEMERIKSAAN SEALS
Remove theunder
Lepaskan undercowl
cowl (hal.
(page2-13).
2-13).
Check forterhadap
Periksa signs of seal leakage. kebocoran seal.
tanda-tanda
If water
Jika adaleaks through theair
kebocoran bleed hose, replace
melalui bleedthehose,
mechanicalganti
seal (page 6-13).
mechanical seal (sil mekanis) (hal. 6-13).
If oilada
Jika leakskebocoran
through theolibleed hose,bleed
melalui replace the oil
hose, sealoil(page
ganti seal
6-13).
(sil oli) (hal. 6-13).
A small amount of "weeping" from the bleed hose is normal.
Sejumlah kecil "tangisan" dari bleed hose adalah
normal.

BLEED HOSE

REMOVAL/DISASSEMBLY
PELEPASAN/PEMBONGKARAN
Drain the coolant
Keluarkan (page
coolant (hal.6-6).
6-6). O-RING COVER
Remove thesebagai
Lepaskan following:
berikut:
-– Dua
Twobolts
bolts
-– Drain
Drainbolt/sealing
bolt/sealing washer
washer
-– Water
Waterpump
pump cover
cover
-– O-ring
O-ring

BOLTS DRAIN BOLT/SEALING WASHER

6-13
SISTEM PENDINGINAN
Remove theright
Lepaskan rightcrankcase
crankcase cover
cover(page
(hal. 10-5).
10-5). IMPELLER
Hold the water pump shaft and remove the impeller and plain
Tahan
washer. water pump shaft (poros pompa air) dan
lepaskan impeller dan plain washer.

PLAIN WASHER
Remove thewater
Lepaskan waterpump
pumpdriven
drivengear
gearassembly
assembly and
dan washer
from the dari
rightright
crankcase cover cover
and disassemble them. WASHER DRIVEN GEAR ASSEMBLY
washer crankcase dan bongkar.

Check the
Periksa water
water pumpdriven
pump drivengear,
gear,water
waterpump
pumpshaft
shaft and
dan LOCK PIN
lock pin
lock pinfor wear or damage,
terhadap keausanreplace
atau them if necessary.
kerusakan, ganti bila
DRIVEN GEAR
perlu.

WATER PUMP SHAFT

Remove the mechanical


Lepaskan mechanicalsealseal
using the special menggunakan
dengan tools.
REMOVER HEAD MECHANICAL SEAL
special tools.
TOOLS:
BearingPERKAKAS:
KUNCI remover head, 14 mm 07WMC-KFG0100
Remover weight 07741-0010201
Bearing remover
Bearing removershaft
head, 14 mm 07936-KC10100
07WMC-KFG0100 WEIGHT
Remover weight 07741-0010201
Bearing remover shaft 07936-KC10100

REMOVER SHAFT

6-14
SISTEM PENDINGINAN
Remove theoil
Lepaskan oilseal.
seal.
OIL SEAL

ASSEMBLY/INSTALLATION
PERAKITAN/PEMASANGAN
WATER PUMP SHAFT LOCK PIN

WASHER

MECHANICAL SEAL
WATER PUMP COVER

PLAIN WASHER

O-RING

WATER PUMP
DRIVEN GEAR

OIL SEAL
IMPELLER
10 N·m (1.0 kgf·m, 7 lbf·ft)

SEALING WASHER

Be careful
Hati-hati agarnot Drive a new
to Dorong
tidak oil seal
masuk into the
sebuah oil right
sealcrankcase
baru kecover withright
dalam its
OIL SEAL
damage
merusak theoil
bibir oilseal. marked side cover
seal crankcase facing up until itsisinya
dengan is fully seated.
yang diberikan tanda
lips. menghadap ke atas sampai ia telah duduk sepenuhnya.

6-15
SISTEM PENDINGINAN
Be careful
Hati-hati agarnot to
tidak Install a new
Pasang mechanical
sebuah seal using theseal
mechanical specialbaru
tool as dengan
shown.
damagebibir
the DRIVER
merusak menggunakan special tools seperti diperlihatkan.
mechanical
mechanical seal seal.
lips. TOOLS:
Driver PERKAKAS:
KUNCI 07749-0010000
Oil seal driver ATTACHMENT
attachment, 36 mm
Driver 07945-4150400
07749-0010000
Oil seal driver
attachment, 36 mm 07945-4150400

MECHANICAL SEAL
Install thelock
Pasang lock pin
pin to the water
pada waterpump
pump shaft, then kemudian
shaft, install the
water pump
pasang driven
water geardriven
pump aligninggear
the driven
dengangearmentepatkan
groove with Tepatkan LOCK PIN
the lock
alur pin.gear dengan lock pin.
driven DRIVEN GEAR

WATER PUMP SHAFT

Install thewasher
Pasang washerpada
to thewater
water pump
pump shaft.
shaft.
WASHER DRIVEN GEAR ASSEMBLY
Apply engine oil to the water pump shaft outer surface.
Oleskan oli mesin pada permukaan luar water pump
Install the water pump driven gear assembly into the right
shaft.
crankcase cover.
Pasang water pump driven gear assembly ke dalam
right crankcase cover.

Install theplain
Pasang plain washer
washerand impeller
dan to thepada
impeller waterwater
pump shaft.
pump
PLAIN WASHER
shaft.

IMPELLER

6-16
SISTEM PENDINGINAN
Hold thewater
Tahan waterpump
pump shaft
shaftand tighten
dan the water water
kencangkan pump impel-
pump
ler to the specified torque. IMPELLER
impeller dengan torsi yang ditentukan.
TORQUE:10
TORSI: N·m
10 N.m (1.0kgf.m;
(1,0 kgf·m,77lbf.ft)
lbf·ft)
Install the
Pasang rightcrankcase
right crankcase cover.
cover (page 10-10).

Install a new
Pasang O-ring
sebuah to thebaru
O-ring water pump
pada cover.
water pump cover. COVER
Install thewater
Pasang waterpump
pump cover.
cover.

O-RING

Install
Pasangand dantighten the bolts,bolts,
kencangkan draindrain
bolt and
bolt new
dan sealing
sealing
washer. BOLTS
washer baru.
Fill the system with the recommended coolant and bleed any
Isi (page
air sistem6-6).
dengan coolant yang dianjurkan dan buanglah
udara palsu (hal. 6-6).

DRAIN BOLT/SEALING WASHER


RADIATOR RESERVE TANK
RADIATOR
(TANGKI RESERVE
CADANGAN TANK
RADIATOR)
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Remove
Lepaskan thebody
bodycover
cover (hal.
(page2-16).
2-16).
SIPHON OVERFLOW HOSE BOLTS
Drain the coolant from the reserve
Keluarkan coolant dari reserve tanktank (hal.
(page6-6).
6-6). HOSE
Remove
Lepaskan thebolts
boltsdan
and reserve
reserve tank.
tank.
Disconnect the overflow and siphon
Lepaskan overflow dan siphon hoses hoses from
dari the reserve
reserve tank.
tank.
Installation is in the reverse order of removal.
Pemasangan adalah dalam urutan terbalik dari
Route
Alurkan thedengan
hoses hoses
Fill the system with the recommended coolant and bleed any
pelepasan.
properly
benar(page
(hal. 1-16). air (page 6-6).
Isi sistem dengan coolant yang dianjurkan dan buanglah
udara palsu (hal. 6-6).

RESERVE TANK

6-17
CATATAN
7. PELEPASAN / PEMASANGAN MESIN

COMPONENT LOCATION ···························· 7


LOKASI KOMPONEN ......................... 7-27-2 ENGINE REMOVAL
PELEPASAN MESIN········································7-4
.......................... 7-4

SERVICE INFORMATION
KETERANGAN ·····························
SERVIS ..................... 7-37-3 ENGINE INSTALLATION
PEMASANGAN ······························7-7
MESIN ...................... 7-7

7-1
PELEPASAN / PEMASANGAN MESIN
COMPONENT LOCATION
ENGINE REMOVAL/INSTALLATION

LOKASI KOMPONEN
9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)

59 N·m (6.0 kgf·m, 44 lbf·ft)

59 N·m (6.0 kgf·m, 44 lbf·ft)

10 N·m (1.0 kgf·m, 7 lbf·ft)

7-2
PELEPASAN / PEMASANGAN MESIN
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
•• When
Sewaktu melepaskan/memasang
removing/installing mesin,
the engine, tape bungkus
the frame rangka
around di sekitar
the engine mesinfor
beforehand dengan pita sebelumnya untuk melindungi rangka
frame protection.
agar
• The tidak tergores.
following components can be serviced with the engine installed in the frame.
• –Komponen-komponen
Oil pump (page 4-4) berikut dapat diservis dengan mesin terpasang pada rangka.
–- Clutch
Oil pump
(page(pompa
10-12) oli) (hal. 4-4)
–- Gearshift linkage (page
Clutch (kopling) (hal. 10-21)
10-12)
–- Stator/ignition pulse(peralatan
Gearshift linkage generator (page 11-5) gigi) (hal. 10-21)
pemindah
–- Flywheel (page 11-7)
Stator/ignition pulse generator (hal. 11-5)
–- Starter motor
Flywheel (page
(roda 18-6)
gila) (hal. 11-7)
• The following
- Starter components
motor (hal. 18-6)require engine removal for service.
• – Cylinder head/valves (page
Untuk menservis komponen-komponen 8-16) berikutnya, mesin harus diturunkan dulu.
–- Camshaft
Cylinder (page 8-8)
head/valves (hal. 8-16)
–- Cylinder/piston
Camshaft (hal.(page8-8)9-4)
–- Crankshaft/balancer
Cylinder/piston (hal. (page
9-4)12-8)
–- Transmission (page 12-14)
Crankshaft/balancer (hal. 12-8)
- Transmissi (hal. 12-14)
SPECIFICATIONS
SPESIFIKASI
BAGIAN ITEM SPESIFIKASISPECIFICATIONS
Kapasitas oli mesin
Engine oil capacity PadaAt
penggantian
draining periodik 1,01.0
liter
liter (1.06 US qt, 0.88 lmp qt)
PadaAt
pembongkaran
disassembly mesin 1,21.2
liter
liter (1.27 US qt, 1.06 lmp qt)
Berat
Enginekosong mesin
dry weight 22,3 kg 22.3 kg (49.2 lbs)

TORQUE VALUES
NILAI TORSI
Engine
Engine hangernut
hanger nut (upper)
(atas) 59 59
N·mN.m
(6.0(6,0
kgf·m, 44 lbf·ft)
kgf.m; 44 lbf.ft)
(lower)
(bawah) 59 59
N·mN.m
(6.0(6,0
kgf·m,
kgf.m;lbf·ft)
44 44 lbf.ft)
(front)
(depan) 59 59
N·mN.m
(6.0(6,0
kgf·m, 44 lbf·ft)
kgf.m; 44 lbf.ft)
Drive
Drive sprocketfixing
sprocket fixingplate
platebolt
bolt 10 10
N·mN.m
(1.0(1,0
kgf·m, 7 lbf·ft)
kgf.m; 7 lbf.ft)
Footpegholder
Footpeg holdermounting
mounting bolt
bolt 9.89,8
N·mN.m
(1.0(1,0
kgf·m, 7.2 lbf·ft)
kgf.m; 7,2 lbf.ft)
Water
Waterhose
hoseband
band screw
screw – SeeLihat hal. 6-10
page 6-10

7-3
PELEPASAN / PEMASANGAN MESIN
ENGINE REMOVAL
PELEPASAN MESIN
Drain the engine
Keluarkan oil (page
oli mesin (hal.3-12).
3-12). NUT
Drain the coolant
Keluarkan coolant(page 6-6).
(hal. 6-6). FOOTPEG HOLDER
Remove the following:
Lepaskan sebagai berikut:
– Gearshift pedal (page 10-24)
-– Gearshift
Carburetorpedal
(page(pedal
5-9) pemindah gigi) (hal. 10-24)
-– Karburator (hal. 5-9) (page 2-19)
Exhaust pipe/muffler
-– Exhaust pipe/muffler
Left crankcase (hal.(page
rear cover 2-19)2-18)
-Remove the bolt, rear
Left crankcase nut cover
and right(hal.footpeg
2-18) holder from the
Support the footpeg frame.
holder footpeg
Dukung to prevent the Lepaskan bolt, nut, dan right footpeg holder dari
holder
brake hose
untukfrom being rangka.
mencegah
kerusakan pada brake
damaged.
hose.
BOLT
Disconnect spark
Lepaskan the spark
plugplug
capcap.
(topi busi).
ADJUSTING CLUTCH
Loosen the lock
Longgarkan locknutnut
and(mur
adjusting nut, then
pengunci) dandisconnect
adjusting the
nut NUT
clutchpenyetel),
(mur cable from kemudian
the clutch lifter arm. clutch cable (kabel
lepaskan
kopling) dari clutch lifter arm (lengan pengangkat
kopling).

SPARK
LIFTER ARM LOCK NUT PLUG CAP
Release therubber
Lepaskan rubber cap
cap. (topi karet).
CLAMP STARTER MOTOR CABLE
Remove the starter
Lepaskan starter motor
motorterminal nut and
terminal starter
nut (murmotor cable
terminal
and release
starter it from
motor) danthe starter
clamp. motor cable (kabel starter
motor)
Removedanthe lepaskan darimounting
starter motor clamp. bolt and ground cable.
RUBBER
Lepaskan starter motor mounting bolt (baut CAP
pemasangan starter motor) dan ground cable (kabel
massa).

BOLT GROUND CABLE NUT


Loosen the water
Longgarkan hosehose
water band screws
band and disconnect
screws dan the water
lepaskan
hoses. hoses (slang air). WATER HOSES
water

BAND SCREWS

7-4
PELEPASAN / PEMASANGAN MESIN
Disconnect thealternator/ignition
Lepaskan alternator/ignition pulse generator
pulse 4P connec-
generator 4P
tor and geardan
position 4P CONNECTOR
connector gearswitch 6P switch
position connector.
6P connector.

6P CONNECTOR

Disconnect slang
Lepaskan the PAIR control
PAIR valve-to-check
control valve – kevalve hose valve
– check from FUEL AUTO VALVE
the cylinder PAIR CONTROL VALVE-
dari cylinderhead cover.
head cover. ke-CHECK VALVE HOSE VACUUM HOSE
Disconnect the PAIR control valve vacuum hose and fuel
Lepaskan PAIR hose
auto valve vacuum control
from valve
the cylinder head.hose (slang
vacuum
vakuum PAIR control valve) dan fuel auto valve vacuum
hose (slang vakuum fuel auto valve) dari cyllinder head.

PAIR CONTROL VALVE VACUUM HOSE


Disconnect crankcase
Lepaskan the crankcase breatherhose
breather hose dari
fromcrankcase.
the crankcase.
CLAMP CRANKCASE
Release thecarburetor
Lepaskan carburetor drain
drainhose
hosefrom
darithe clamp.
clamp. BREATHER HOSE

CARBURETOR DRAIN HOSE


Loosen the axle
Longgarkan nut,nut
axle lock(mur
nuts and adjusting
poros), locknuts.
nuts (mur-mur ADJUSTING NUT
pengunci) dan adjusting nuts (mur-mur penyetel).
Push the rear wheel forward and make a drive chain slack
fully.
Dorong roda belakang ke depan dan kendurkan rantai
roda sepenuhnya.

LOCK NUT AXLE NUT

7-5
PELEPASAN / PEMASANGAN MESIN
Remove thekedua
Lepaskan two bolts.
bolts. FIXING PLATE
Turn the
Putar fixing
fixing platedan
plate and lepaskan
remove thefixing
fixingplate
plate dan
and drive
drive
sprocket.
sprocket.

BOLTS
DRIVE SPROCKET
Lepaskan
Release thehoses berikutnya
following darithe
hoses from clamp.
clamp. BREATHER CLAMP
– Breather drain hose DRAIN HOSE
- Breather drain hose
– Carburetor drain hose
-– Carburetor drain hose
Radiator overflow hose
- Radiator overflow hose

OVERFLOW
CARBURETOR DRAIN HOSE HOSE
Ketinggian
The dongkrak
jack height must Support the
Topang enginedengan
mesin using a jack or other adjustable
menggunakan support
dongkrak to
atau
harus be
terus-menerus
continually ease ofpendukung
engine hangerlain
bolts removal. BOLT/NUT
alat yang dapat disetel untuk
disetel
adjusted untuk
to relieve mempermudah pengeluaran engine hanger bolts (baut-
Remove the following:
membebaskan
stress.
ketegangan. baut gantungan mesin).
– Front engine hanger nut
– Upper engine
Lepaskan sebagaihanger nut
berikut:
– Lower engine hanger nut
- Mur penggantung depan mesin
During
Selama engine
pelepasan -Remove the engine hanger
Mur penggantung atas bolts
mesinand engine from the frame.
mesin, pegang
removal, mesin
hold the - Mur penggantung bawah mesin
dengan
engine kokoh and
securely dan
jaga
be agarnot
careful tidak
to Keluarkan engine hanger bolts dan mesin dari rangka.
merusak
damage therangka
frame
dan mesin.
and engine.

7-6
PELEPASAN / PEMASANGAN MESIN
ENGINE INSTALLATION
PEMASANGAN MESIN
CATATAN:
•• Perhatikan arah dari
Note the direction of theengine
engine hanger bolts (baut-baut
hanger bolts.
penggantung mesin).
• Place the jack or other adjustable support under the
• Letakkan
engine. dongkrak atau alat pendukung lain yang
• dapat disetel
The jack di bawah
height must be mesin.
continually adjusted to relieve
• Ketinggian dongkrak
stress for ease harus terus menerus disetel
bolt installation.
• untuk membebaskan
Carefully align the mounting points ketegangan
with the jack tountuk
pre-
vent damage topemasangan
mempermudah engine, frame, water
bolts hose, wires and
(baut).
cables. hati-hati jajarkan titik-titik pemasangan
• Dengan
• dengan
Loosely dongkrak
install all the
untuk engine mountingkerusakan
mencegah bolts and nuts,
pada
then tighten
mesin, the bolts
rangka, waterand nuts to(slang
hoses the specified torque.
air), kawat-kawat
• dan
Route the water hoses, wires and cables properly (page 1-
kabel-kabel.
16).
• Pasang semua engine mounting bolts dan nuts (baut
dan mur pemasangan mesin) dengan longgar,
kemudian kencangkan bolts dan nuts dengan torsi
yang ditentukan.
During engine • Alurkan water hoses (slang-slang air), kawat-kawat
installation, hold the dan kabel-kabel dengan benar (hal. 1-16).
engine securely and
Selama pemasangan
be careful not to Letakkan mesininpada
Place the engine rangka
the frame anddan pasang
loosely installsemua bolts
all the bolts
mesin, pegang
damage the mesin
frame dan nuts dengan longgar.
and nuts. BOLT/NUT
dengan kokoh dan
and engine.
jaga agar tidak Tighten the engine hanger nuts to the specified torque.
Kencangkan engine hanger nuts (mur-mur penggantung
merusak rangka
dan mesin. mesin) dengan torsi yang ditentukan.
TORQUE:
Front engine hanger nut:
TORSI:
59 N·m
Front (6.0 kgf·m,
engine hanger44nut:
lbf·ft)
Upper
59 N.mengine
(6,0 hanger
kgf.m; nut:
44 lbf.ft)
59 N·m
Upper (6.0 kgf·m,
engine hanger44nut:
lbf·ft)
59 N.m
Lower (6,0 hanger
engine kgf.m; nut:
44 lbf.ft)
Lower engine
59 N·m hanger
(6.0 kgf·m, 44 nut:
lbf·ft)
59 N.m (6,0 kgf.m; 44 lbf.ft)

Secure the following


Kokohkan hoseshoses
pemasangan with the clamp.dengan clamp.
berikut BREATHER CLAMP
-– Breather drain
Breather drain hose
hose DRAIN HOSE
-– Carburetor drain
Carburetor drain hose
hose
-– Radiatoroverflow
Radiator overflow hose
hose

OVERFLOW
CARBURETOR DRAIN HOSE HOSE

Install thedrive
Pasang drivechain
chain over theroda)
(rantai drive sprocket.
di atas drive sprocket.
DRIVE FIXING PLATE
Install the drive sprocket to the countershaft.
Pasang
Install thedrive sprocket
fixing plate andpada
rotatecountershaft.
it to align the bolt holes.
Install andfixing
Pasang tightenplate
the drive
dansprocket fixing plate
putar dengan bolts to the
mentepatkan
specified torque.bolt.
lubang-lubang
TORQUE:10 N·m (1.0 kgf·m, 7 lbf·ft)
Pasang dan kencangkan drive sprocket fixing plate bolts
dengan torsi yang ditentukan.

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

DRIVE SPROCKET BOLTS

7-7
PELEPASAN / PEMASANGAN MESIN
Connect the crankcase
Sambungkan breather
crankcase hose to
breather the crankcase.
hose ke crankcase. CLAMP CRANKCASE
Secure the carburetor
Kokohkan pemasangandrain hose with thedrain
carburetor clamp.hose dengan BREATHER HOSE
clamp.

CARBURETOR DRAIN HOSE


Connect the PAIR
Sambungkan slangcontrol
PAIR valve-to-check
control valve –valve hose to the
ke - check FUEL AUTO VALVE
cylinder headcylinder
cover. head cover. PAIR CONTROL VALVE-
valve pada VACUUM HOSE
ke-CHECK VALVE HOSE
Connect the PAIR control valve vacuum hose and fuel auto
Sambungkan PAIR
valve vacuum hose tocontrol valvehead.
the cylinder vacuum hose dan fuel
auto valve vacuum hose pada cylinder head.

PAIR CONTROL VALVE VACUUM HOSE


Connect the alternator/ignition
Sambungkan pulse
alternator/ignition generator
pulse 4P connector
generator 4P
and gear position
connector dan gearswitch 6P connector.
position switch 6P connector. 4P CONNECTOR

6P CONNECTOR

Connect the water


Sambungkan hoses and
water tighten
hoses danthe band screws as spec-
kencangkan band
ified (page 6-10).ditentukan (hal. 6-10). WATER HOSES
screws seperti

BAND SCREWS

7-8
PELEPASAN / PEMASANGAN MESIN
Install anddan
Pasang tighten the starter motor
kencangkan mounting
starter motor bolt and ground
mounting bolt CLAMP STARTER MOTOR CABLE
cable. pemasangan starter motor) dan ground cable
(baut
(kabel massa).
Install and tighten the starter motor terminal nut and starter
motor cable and secure it with the clamp.
Pasang dan kencangkan starter motor terminal nut dan RUBBER
Reposition
starter the cable
motor rubberdan
cap.kokohkan pemasangannya
CAP
dengan clamp.

Pasang kembali rubber cap (topi karet).

BOLT GROUND CABLE NUT


Connect
Sambungkanthe clutch cablecable
clutch to the (kabel
clutch lifter arm. pada clutch
kopling)
CLUTCH
lifter arm.
Connect the spark plug cap to the spark plug.
Sambungkan spark plug cap (topi busi) pada busi.

SPARK
LIFTER ARM PLUG CAP
Install theright
Pasang rightfootpeg
footpegholder,
holder, nut and
danbolt.
bolt. NUT
FOOTPEG HOLDER
Tighten the nut first.
Kencangkan
Tighten the boltnuttodulu.
the specified torque.
Kencangkan bolt dengan torsi yang ditentukan.
TORQUE:9.8 N·m (1.0 kgf·m, 7.2 lbf·ft)
TORSI: 9,8 N.m (1,0 kgf.m; 7,2 lbf.ft)
Install the following:
– Left crankcase rear cover (page 2-18)
– Exhaust
Pasang pipe/muffler
sebagai berikut:(page 2-21)
– Carburetor (page 5-20)
-– Left crankcase
Gearshift pedalrear
(pagecover (hal. 2-18)
10-25)
- Exhaust pipe/muffler (hal. 2-21)
-Adjust the following:
Karburator (hal. 5-20)
-– Gearshift pedal
Drive chain (hal.
slack 10-25)
(page 3-16)
– Throttle grip freeplay (page 3-5) BOLT
Setel sebagai
– Clutch leverberikut:
freeplay (page 3-21)

-Fill the engine with


Kekenduran thechain
drive recommended engine
(rantai roda) oil3-16)
(hal. (page 3-12).
-Fill
Jarak main bebas
the system putaran
with the gas tangan
recommended (hal.
coolant and3-5)
bleed any
-airJarak
(pagemain
6-6). bebas handel kopling (hal. 3-21)

Isi mesin dengan oli mesin yang dianjurkan (hal. 3-12).

Isi sistem dengan coolant yang dianjurkan dan buanglah


udara palsu bila ada (hal. 6-6).

7-9
CATATAN
8. KEPALA SILINDER / KLEP

COMPONENT
LOKASI LOCATION
KOMPONEN ···························· 8-2
............................8-2 CAMSHAFT·······················································8-8
CAMSHAFT ...........................................8-8
KETERANGAN SERVIS ........................8-3 CAMSHAFT HOLDER ...........................8-13 8
SERVICE INFORMATION ····························· 8-3 CAMSHAFT HOLDER ··································8-13
MENCARI PENYEBAB KESUKARAN ..8-5 CYLINDER HEAD ..................................8-16
TROUBLESHOOTING ···································· 8-5 CYLINDER HEAD··········································8-16
KOMPRESSI CYLINDER.......................8-6 CAM CHAIN TENSIONER LIFTER........8-25
CYLINDER HEAD COVER ....................8-6
CYLINDER COMPRESSION·························· 8-6 CAM
CAMCHAIN
CHAINTENSIONER
TENSIONERSLIDER
LIFTER .......8-27
···········8-25

CYLINDER HEAD COVER ···························· 8-6 CAM CHAIN TENSIONER SLIDER ···········8-27

8-1
KEPALA SILINDER / KLEP
COMPONENT
LOKASI LOCATION
KOMPONEN
CYLINDER HEAD/VALVES

10 N·m (1.0 kgf·m, 7 lbf·ft)

29 N·m (3.0 kgf·m, 21 lbf·ft)

4.0 N·m (0.4 kgf·m, 3.0 lbf·ft)

9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)

8-2
KEPALA SILINDER / KLEP
SERVICE INFORMATION
KETERANGAN SERVIS
UMUM
GENERAL
• Bab ini meliputi pekerjaan servis dari cylinder head, valves, rocker arms dan camshaft.
• This section covers service of the cylinder head, valves, rocker arms and camshaft.
• Pekerjaan servis camshaft dan cyllinder head memerlukan penurunan mesin.
• The camshaft and cylinder head service requires engine removal.
•• Be
Hati-hati agar
careful not tidak merusak
to damage the matingpermukaan-permukaan
surfaces when removingpenyatuan
the cylinderketika melepaskan
head cover cylinder
and cylinder head. head
Do notcover
tap thedan cylinder
cylinder headhead.
cover
Jangan ketuk cylinder head cover dan
and cylinder head too hard during removal. cylinder head terlalu keras pada waktu pelepasan.
•• When
Sewaktu pembongkaran,
disassembling, mark andtandai dan
store the simpanlahparts
disassembled parts yang that
to ensure telah dibongkar
they untuk
are reinstalled memastikan
in their bahwa mereka dipasang
original locations.
kembali
• Clean pada lokasi parts
all disassembled merekawithsemula.
cleaning solvent and dry them by blowing them off with compressed air before inspection.
•• Camshaft
Bersihkan andsemua
rocker parts yang dibongkar
arm lubricating dengan
oil is fed throughlarutan pembersih
oil passage dan keringkan
in the cylinder dengan
head (stud meniup
bolt hole) mereka holder.
and camshaft denganClean
udara
thedari
oil
kompressor
passage before sebelum diperiksa.
assembling them.
• Minyak pelumasan camshaft dan rocker arm disalurkan melalui jalan lintasan oli di dalam cylinder head (lubang stud hole)
dan camshaft holder. Bersihkan jalan lintasan oli sebelum merakit mereka.
SPECIFICATIONS
SPESIFIKASI
BAGIAN STANDARD BATAS SERVIS Unit: mm (in)
Kompresi cylinder pada 530
-1
menit (rpm) 1.344 kPaSTANDARD
(13,7 - SERVICE
ITEM 2
kgf/cm , 195 psi) LIMIT
-1 2
Cylinder
Jarak compression
renggang klep at 530 min (rpm) IN (masuk)1,344 kPa
0,06 (13.7 kgf/cm , 195 psi) - –
Valve clearance IN EX (buang)0.06 (0.002)
0,27 - –
Valve (klep), D.L. valve stem EX IN 0.27 (0.011)
4,975 – 4,990 4,863 –
Valve,guide (bos klep)
valve Valve stem O.D. klep)
(tangkai IN EX 4.9754,965
– 4.990– (0.1959
4,980 – 0.1965) 4,853 4.863 (0.1915)
valve guide
D.D. valve guide EX IN/EX 4.965 – 4.980 (0.1955
5,000 – 5,012 – 0.1961) 5,04 4.853 (0.1911)
Valve guide
(bosI.D.
klep) IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.04 (0.198)
Stem-to-guide clear- IN
Kerenggangan antara IN 0.010 – 0.037
0,010 – (0.0004
0,037 – 0.0015) 0,065 0.065 (0.0026)
ance valve stem/ guide EX 0.0200,020
– 0.047– (0.0008
0,047 – 0.0019) 0,075 0.075 (0.0030)
EX
Valve guide height valve IN
Ketinggian IN 11.5 –11,5
11.7–(0.4528
11,7 – 0.4606) - –
guide EX EX
12.3 – 12.5 (0.4843
12,3 – 12,5 – 0.4921) - –
Valve seat width IN/EX 1.0 (0.04)
1,0 1,6 1.6 (0.06)
Lebar dudukan klep IN/EX
Valve spring Free length
Panjang bebas Inner 33.5033,50
(1.319) 31,0 31.0 (1.22)
Valve spring (pegas Dalam
Outer 35.7035,70
(1.406) 34.0 (1.34)
klep) Luar 34,0
Rocker arm, Arm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.10 (0.398)
Rocker armshaft
(pelatuk)/ D.D. rocker arm IN/EX 10,000 – 10,015 10,10
rocker arm Shaft O.D. IN/EX 9.972 – 9.987 (0.3926 – 0.3932) 9.75 (0.384)
rocker arm shaft (poros (lengan pelatuk)
Arm-to-shaft clear-
pelatuk) IN/EX 0.0139,972
– 0.043
– (0.0005
9,987 – 0.0017) 9,75 0.10 (0.004)
ance D.L. rocker arm shaft IN/EX
(poros pelatuk)
Camshaft Cam lobe height IN 29.316 – 29.556 (1.1542 – 1.1636) 29.05 (1.144)
Kerenggangan antara IN/EX 0,013 – 0,043 0,10
EX 29.138 – 29.378 (1.1472 – 1.1566) 28.85 (1.136)
arm ke shaft
Cylinder head warpage – 0.05 (0.002)
Camshaft Tinggi cam lobe IN 29,316 – 29,556 29,05
(poros bubungan) (bubungan) EX 29,138 – 29,378 28,85
Perubahan melengkung pada cylinder head - 0,05
TORQUE VALUES
NILAI TORSI
Cylinder head cover bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)
Camshaft holder mounting nut 29 N·m (3.0 kgf·m, 21 lbf·ft) Apply engine oil to the threads and seating surface.
Cylinder head cover
Cam sprocket bolt bolt
mounting 10 N.m (1,0(0.9
9.0 N·m kgf.m; 7 lbf.ft)
kgf·m, 6.6 lbf·ft)
Camshaft holder
Rocker arm shaftmounting nut
stopper bolt 29 N.m (3,0(0.9
9.0 N·m kgf.m; 21 6.6
kgf·m, lbf.ft)
lbf·ft) Semprotkan oli mesin pada ulir dan
Cam chain tensioner lifter plug 4.0 N·m (0.4 kgf·m, 3.0 lbf·ft) permukaan duduk.
Cam sprocket mounting bolt 9,0 N.m (0,9 kgf.m; 6,6 lbf.ft)
Rocker arm shaft stopper bolt 9,0 N.m (0,9 kgf.m; 6,6 lbf.ft)
Cam chain tensioner lifter plug 4,0 N.m (0,4 kgf.m; 3,0 lbf.ft)

8-3
KEPALA SILINDER / KLEP
TOOLS
KUNCI PERKAKAS

Valve spring compressor Valve spring compressor attachment Valve guide driver, 5.0 mm
07757-0010000 07959-KM30101 07942-8920000

Seat cutter, 24 mm (45° EX) Seat cutter, 29 mm (45° IN) Flat cutter, 27 mm (32° EX)
07780-0010600 07780-0010300 07780-0013300

Flat cutter, 30 mm (32° IN) Interior cutter, 26 mm (60° EX) Interior cutter, 30 mm (60° IN)
07780-0012200 07780-0014500 07780-0014000

Cutter holder, 5.0 mm Valve guide reamer, 5.0 mm Tensioner stopper


07781-0010400 07984-MA60001 070MG-0010100

8-4
KEPALA SILINDER / KLEP
Valve guide adjusting driver
07743-0020000

TROUBLESHOOTING
MENCARI PENYEBAB KESUKARAN
•• Engine
Persoalan
top-endpada ujung-atas
problems usuallymesin
affect biasanya mempengaruhi
engine performance. unjuk kerja
These problems can mesin. Persoalan
be diagnosed ini dapat didiagnosa
by a compression dengan
test, or by tracing test
top-end
kompressi,
noise atau dengan
with a sounding rod ormenelusuri
stethoscope.suara ujung-atas dengan tangkai suara atau stethoscope.
•• IfJika unjuk kerjaisrendah
the performance poor at lowpada kecepatan
speeds, check forrendah, periksalah
white smoke terhadapbreather
in the crankcase asap hose.
putih Ifpada crankcase
the hose is smoky, breather seized(slang
check for ahose piston
pernapasan bak mesin). Jika hose berasap, periksalah terhadap kemacetan piston rings.
rings.
Kompressi
Compressionterlalu
too low, rendah, mesinor
hard starting sulit
poordihidupkan
performance atau unjuk
al low kerja lemah pada kecepatan rendah
speed
•• Valves:
Valves (klep-klep):
–- Incorrect
Penyetelan valveklep tidak benar
adjustment
–- Burned
Klep terbakar atau bengkok
or bent valve
–- Incorrect
Valve timing
valve (tertib
timing waktu klep) tidak benar
–- Weak
Valvevalve
spring (pegas klep) lemah
spring
–- Uneven
Valve seating (dudukan klep) tidak merata
valve seating
–- Valve
Valvestuck
(klep) open
macet terbuka
•• Cylinder
Cylinderhead:
head:
–- Leaking
Cylinder or head
damaged
gasketcylinder
bocor head gasket
atau rusak
–- Warped
Cylinder or head
crackedadacylinder head melengkung atau retak
perubahan
–- Loose spark plug
Busi longgar
•• Faulty cylinder,
Cylinder, piston
piston atauorpiston
piston rings
rings tidak
(page bekerja
9-4). dengan baik (hal. 9-4).
Compression too high, over-heating or knocking
Kompressi
• Excessiveterlalu tinggi, over-heating
carbon build-up on piston head (panas berlebihan)
or combustion chamberatau knocking (mesin mengelitik)
• Pembentukan karbon berlebihan pada kepala piston atau ruang pembakaran
Excessive smoke
• Worn valve stem or valve guide
Asap berlebihan
• Damaged stem seal
•• Faulty
Valvecylinder,
stem atau valve
piston guide rings
or piston aus (page 9-4).
• Stem seal rusak
•Excessive noisepiston atau piston rings tidak bekerja dengan baik (hal. 9-4).
Cylinder,
• Incorrect valve adjustment
• Sticking
Suara valve or broken valve spring
berlebihan
• Worn or damaged camshaft
• Penyetelan valve (klep) tidak benar
• Worn rocker arm and/or shaft
•• Worn
Valverocker
menonjol atau
arm and valve
valve stemspring
end patah
•• Worn
Camshaft aus atau
cam sprocket teeth rusak
•• Worn
Rocker
andarm
loosedan/atau
cam chain shaft aus
•• Worn
Rocker arm dancam
or damaged ujung valve
chain stem aus
tensioner
•• Faulty
Gigi cam sprocket
cylinder, pistonausor piston rings (page 9-4).
•RoughCamidlechain aus atau longgar
•• LowCam chain tensioner
cylinder compression aus atau rusak
•• Faulty
Cylinder, piston atau piston rings tidak bekerja dengan baik (hal. 9-4).
fuel system

Putaran stasioner kasar


• Tekanan kompressi cylinder rendah
• Sistem bahan bakar tidak bekerja dengan baik

8-5
KEPALA SILINDER / KLEP
CYLINDER COMPRESSION
KOMPRESSI CYLINDER
Warm the engine
Panaskan mesintokenormal
suhu operating temperature.
operasi normal.
COMPRESSION GAUGE
Matikan mesin.
Stop the engine.
Lepaskan busi (hal. 3-7).
Remove the
Pasang spark plug (page
compression gauge 3-7).
(alat pengukur kompressi)
pada
Installlubang busi.
the compression gauge into the spark plug hole.
Putar kunci kontak ke posisi ON.
Turn the ignition
Masukkan switchke
transmissi ON.
dalam netral.
Shift the
Putar transmission
mesin dengan into neutral.
starter motor.
Buka
Crank gas tanganwith
the engine sama sekalimotor.
the starter dan putar mesin dengan
starter motor sampai pembacaan gauge berhenti naik.
ToUntuk
avoidmenghindari
discharging Open the throttle all the way and crank the engine with the
the battery,muatan
menghabiskan do not starter motor until the gauge reading stops rising.
STANDARD:
operate
listrik the jangan
baterai, starter 2
1.344 kPa (13,7 kgf/cm ; 195 psi) pada 530 menit
-1
jalankan
motor for starter lebih7
more than
STANDARD:
(rpm)
1,344 kPa (13.7 kgf/cm2, 195 psi) at 530 min-1(rpm)
dariseconds.
7 detik.
If compression
Jika kompressiis high, it indicates
tinggi, that carbonbahwa
menunjukkan depositskerak
have
accumulated
karbon on the
telah combustion
terkumpul chamber
pada and/or
ruang the piston
pembakaran
head.
dan/atau kepala piston.
If compression is low, pour 3 – 5 cc (0.1 – 0.2 oz) of engine
Jika kompressi
oil into rendah,
the cylinder tuangkan
through – 5 hole
the spark3plug cc oli
andmesin ke
recheck
dalam cylinder
the compression. melalui lubang busi dan periksa
kembali kompressi.
If the compression increases from the previous value, check
the cylinder,
Jika pistonnaik
kompressi and dari
pistonnilai
ringssebelumnya,
for the following:
periksalah
cylinder, piston dan piston
– Leaking cylinder head gasket rings terhadap berikutnya:
-– Cylinder headring
Worn piston gasket bocor
-– Piston
Worn ring aus and piston
cylinder
- Cylinder dan piston aus
If the compression is the same as the previous value, check
Jika kompressi sama seperti nilai sebelumnya, periksa
the valves for leakage.
valves terhadap kebocoran.

CYLINDERHEAD
CYLINDER HEADCOVER
COVER
REMOVAL
PELEPASAN
Remove thecenter
Lepaskan center body
body cover/radiator
cover/radiator shroud (page 2-6).
Remove the radiator mounting bolt/collar,shroud
release(hal. 2-6).
the radiator BOLT/COLLAR
Hati-hati agarnot
Be careful tidak from the stayradiator
to Lepaskan and move mounting
it forward. bolt/collar (baut/collar
merusak
damage radiator.
the radiator. pemasangan radiator), lepaskan radiator
Remove the thermostat housing mounting bolt. dari stay dan
gerakkan ke depan.

Lepaskan thermostat housing mounting bolt (baut


pemasangan rumah thermostat).

STAY BOLT

8-6
KEPALA SILINDER / KLEP
Disconnect slang
Lepaskan the PAIR check
PAIR valve-to-control
check valve – ke valve hose valve
- control from
BOLTS/RUBBER SEALS
the cylinder
dari cylinderhead cover.
head cover.
Remove the cylinder head cover bolts, rubber seals, cylinder
Lepaskan cylinder
head cover and head cover bolts, rubber seals,
packing.
cylinder head cover dan packing.

SLANG COVER/PACKING
INSTALLATION
PEMASANGAN
Install a new
Pasang packing
sebuah into thebaru
packing cylinder
ke head
dalamcover groove.
alur cylinder
Installcover.
the cylinder head cover onto the cylinder head. PACKING COVER
head

Pasang cylinder head cover pada cylinder head.

Check if apakah
Periksa the rubberrubber
seals are in good
seals condition,
dalam kondisireplace
baik, them
ganti
if necessary. TANDA "UP"
bila perlu.
Install the rubber seals to the cylinder head cover with their
Pasang
"UP" marksrubber seals
facing up. pada cylinder head cover dengan
tanda "UP" mereka menghadap ke atas.

RUBBER SEALS
Install
Pasang anddan
tighten the cylinder cylinder
kencangkan head coverhead
bolts to the speci-
cover bolts BOLTS
fied torque.
dengan torsi yang ditentukan.
TORQUE:10
TORSI; 10 N.m N·m(1,0
(1.0kgf.m;
kgf·m, 77 lbf·ft)
lbf.ft)
Connect the PAIR check valve-to-control valve hose to the
Sambungkan
cylinder slang PAIR check valve – ke – control
head cover.
valve pada cylinder head cover.

SLANG

8-7
KEPALA SILINDER / KLEP
Set the radiator
Letakkan in positionpada
radiator while inserting
posisinyathe boss into the
sementara BOLT/COLLAR
stay, then installboss
memasukkan and tighten the radiator
ke dalam mounting bolt/col-
stay, kemudian pasang
lar.
dan kencangkan radiator mounting bolt/collar
(baut/collar pemasangan
Install and tighten radiator).
the thermostat housing mounting bolt.
Install thedan
Pasang center body cover/radiator
kencangkan shroud
thermostat (page 2-6).
housing mounting
bolt (baut pemasangan rumah thermostat).

Pasang center body cover/radiator shroud (hal. 2-6).

STAY BOLT
CAMSHAFT
CAMSHAFT
(POROS BUBUNGAN)
REMOVAL
PELEPASAN
Remove thesebagai
Lepaskan following:
berikut: PLUG
– Engine (page
- Mesin (hal. 7-4)7-4)
-– Cylinder
Cylinderhead
head cover
cover (page 8-6)
(hal. 8-6)
Make sure the piston is at TDC (Top Dead Center) on the
Pastikan bahwa
compression strokepiston berada pada TDC (Top Dead
(page 3-9).
Center) [TMA (Titik Mati Atas)] pada langkah
Remove the(hal.
kompressi cam 3-9).
chain tensioner lifter plug and O-ring.

Lepaskan cam chain tensioner lifter plug dan O-ring.

O-RING
Turn the cam
Putar cam chain tensioner
chain lifter shaft
tensioner fully shaft
lifter in (clockwise)
(poros TENSIONER LIFTER
pengangkatan penegang rantai bubungan)damaging
and secure it using a tensioner stopper to prevent secara
the cam chain.
penuh ke dalam (searah putaran jarum jam) dan
kokohkan dengan menggunakan sebuah tensioner
TOOL:
stopper untuk mencegah kerusakan pada cam chain.
Tensioner stopper 070MG-0010100

KUNCI PERKAKAS:
Tensioner stopper 070MG-0010100

TENSIONER STOPPER
Be careful agar
Hati-hati not tocam Remove thecam
let Lepaskan camsprocket
sprocket bolts.
bolts (baut-baut cam sprocket). BOLTS
the cambolts
sprocket sprocket
tidak
jatuh
bolts fallkeinto
dalam
the
crankcase.
crankcase.

8-8
KEPALA SILINDER / KLEP
Hati-hati
Be careful agar
not tocam Remove thecam
let Lepaskan camsprocket
sprocket from the camshaft.
dari camshaft.
sprocket
the camtidak terjatuh
sprocket fall
CAM CHAIN
ke dalam
into crankcase.
the crankcase.

Remove thecam
Lepaskan cam sprocket
sprocket from the cam
dari cam chain.
chain.
Ikatlah
Attach sepotong
a piece ofkawat
wire
pada cam
to the cam chain
chainagar
to
tidak terjatuh
prevent it fromkefalling
dalam
crankcase.
into the crankcase.

CAMSHAFT SPROCKET
Remove thesnap
Lepaskan snap ring
ring dari
fromalur
groove in the
pada camshaft
camshaft holder.
holder.
SNAP RING

CAMSHAFT HOLDER
Remove thecamshaft
Lepaskan camshaft from
dari the camshaft holder
camshaft holder while hold-
sementara
ing the rocker armsarms
to easeuntuk
camshaft removal. ROCKER ARMS CAMSHAFT
menahan rocker mempermudah pelepasan
camshaft.

CAMSHAFT HOLDER

8-9
KEPALA SILINDER / KLEP
PEMERIKSAAN
INSPECTION
CAMSHAFT
CAMSHAFTBEARINGBEARING
(BANTALAN POROS BUBUNGAN)
Turn the outer race of each bearing with your finger.
The bearings should turn smoothly and quietly. BEARING
Putar outer race (cincin luar) dari masing-masing
Also check that the bearing inner race fits tightly on the cam-
bearing (bantalan) dengan jari-jari.
shaft.
Bantalan-bantalan harus berputar dengan halus dan
Replace
tanpa the camshaft assembly if the bearings do not turn
suara.
smoothly,
Juga quietly
periksa or if they
bahwa fit loosely
bearing inneronrace
the camshaft.
(cincin dalam
bantalan) duduk dengan erat pada camshaft.

Ganti susunan camshaft jika bantalan-bantalan tidak


berputar dengan halus, tanpa suara atau jika mereka
duduk dengan longgar pada camshaft.

DECOMPRESSOR CAM
DECOMPRESSOR CAM
Letakkan camshaft
Place the camshaft dengan
with the camsisi cam sprocket
sprocket side facing down as
shown.
menghadap ke bawah seperti diperlihatkan.
DECOMPRESSOR CAM
Turn the
Putar decompressorcam
decompressor cam dengan
with yourjari-jari.
finger.
Make sure the
Pastikan decompressor
bahwa cam only turn
decompressor camcounterclockwise
hanya dapat
and does not
berputar turn arah
dalam clockwise.
berlawanan putaran jarum jam dan
tidak
If the dapat berputar
decompressor dalam
cam arahreplace
is faulty, jarum the
jam.camshaft as an
assembly.
Jika decompressor cam tidak bekerja dengan baik,
gantilah camshaft sebagai sebuah susunan.

CAM LOBE
CAM LOBE
(BUBUNGAN CAM)
Check thepermukaan
Periksa cam lobe surfaces
cam for scoring
lobe or evidence
terhadap of insuf-
gerusan atau
ficient lubrication.
tanda-tanda kekurangan pelumasan.
Measure the height of each cam lobe.
Ukur ketinggian masing-masing cam lobe.
SERVICE LIM-
BATAS
ITS: SERVIS: IN: IN: 29,05
29.05mm
mm (1.144 in)
EX: 28,85 mm Udara
EX: 28.85 mm (1.136 in)
Bersihkan
Clean the oil jalan
passagelintasan oli dari
of the camshaft camshaft
using dengan
compressed air.
menggunakan udara dari kompressor.

8-10
KEPALA SILINDER / KLEP
INSTALLATION
PEMASANGAN
Apply engine oli
Semprotkan oilmesin
to the pada
camshaft bearings
bidang rotating camshaft
perputaran area and
decompressor BEARINGS
bearings dan cam inner surface.
permukaan dalam decompressor cam.
Apply molybdenum
Semprotkan larutanoilmolybdenum
solution to theoilcam lobes.
pada cam lobes.

DECOMPRESSOR
CAM LOBES

Make sure bahwa


Pastikan the tabtab
of Install thecamshaft
Pasang camshaftke
into the camshaft
dalam camshaftholder
holderwhile holding
sementara
the rocker armsrocker
to ease camshaft ROCKER ARMS TAB
the camshaft
dari is facing
camshaft menahan arms installation.
untuk mempermudah
menghadapupward.
ke atas. pemasangan camshaft.

CAMSHAFT HOLDER
Make sure
Pastikan the snap
bahwa Install thesnap
snap Pasang snapring
ringke
into the groove
dalam of the
alur dari camshaftholder.
camshaft holder.
ringring
telahisduduk
firmlydengan
seated
SNAP RING
kokoh diin dalam alur.
the groove.

CAMSHAFT HOLDER
BeHati-hati
careful not to jam
agar cam Rotatecrankshaft
Putar the crankshaft counterclockwise
berlawanan andjam
arah jarum align
danthe "T"
mark on the flywheel INDEX NOTCH
thechain
cam dan timing
chain and tepatkan tanda "T" with
padathe index notch
flywheel on the
dengan left crank-
index notch
sprocket
timing tidakon
sprocket macet
the case cover.
(takik penunjuk) pada left crankcase cover.
pada crankshaft
crankshaft when
sewaktu memutar
rotating the
crankshaft.
crankshaft.

TANDA "T"

8-11
KEPALA SILINDER / KLEP
Apply engine oil
Semprotkan oli tomesin
the campada
chainseluruh
entire surface.
permukaan cam SPROCKET
CAM CHAIN
chain.
Install the cam chain over the cam sprocket so that the index
line of the cam sprocket is flush with the cylinder head upper
Pasang
surface ascam chain di atas cam sprocket sehingga index
shown.
line (garis penunjuk) dari cam sprocket adalah sebidang
Align the bolt
dengan holes on the atas
permukaan cam sprocket
cylinderand camshaft.
head seperti
diperlihatkan.

Jajarkan lubang-lubang bolt (baut) pada cam sprocket


dan camshaft.

Jajarkan INDEX LINE


Be careful agar
Hati-hati not tocamlet Install and
Pasang tighten
dan the cam cam
kencangkan sprocket mounting
sprocket bolts tobolts
mounting the
BOLTS
sprocket
the cambolts tidak
sprocket specified torque
(baut-baut while holding
pemasangan the crankshaft.
cam sprocket) dengan torsi
jatuh
bolts fallkeinto
dalam
the yang ditentukan sementara menahan crankshaft.
crankcase.
crankcase.
TORQUE:9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)

TORSI: 9,0 N.m (0,9 kgf.m; 6,6 lbf.ft)

Remove thetensioner
Lepaskan tensioner stopper
stopperfrom
darithe camchain
cam chain tensioner
tensioner
lifter. TENSIONER STOPPER
lifter.

TENSIONER LIFTER
Apply engine
Oleskan oil topada
oli mesin a newsebuah
O-ring O-ring
and install
baruitdan
to the cam
pasang
chain tensioner
pada cam chain lifter.
tensioner lifter.
Install and tighten the cam chain tensioner lifter plug to the
Pasang
specified dan kencangkan cam chain tensioner lifter plug
torque.
dengan torsi yang ditentukan.
TORQUE:4.0 N·m (0.4 kgf·m, 3.0 lbf·ft)
TORSI:
Install the4,0 N.m (0,4 kgf.m; 3,0 lbf.ft)
following:
– Cylinder
Pasang head cover
sebagai (page 8-7)
berikut:
-– Cylinder
Engine (page
head7-7)
cover (hal. 8-7)
- Mesin (hal. 7-7)

O-RING PLUG

8-12
KEPALA SILINDER / KLEP
CAMSHAFT HOLDER
CAMSHAFT HOLDER
REMOVAL
PELEPASAN
Remove thesebagai
Lepaskan following:
berikut: NUTS/WASHERS
-– Mesin
Engine(hal.
(page 7-4)
7-4)
-– Cylinder
Cylinderhead
head cover
cover (page
(hal. 8-6)
-– Cam
Camsprocket
sprocket (page 8-8)
(hal. 8-8)
Loosen the cylinder
Longgarkan head head
cylinder bolts alternately in several steps.
bolts (baut-baut cylinder
Be careful head) secara bergantian dalam beberapa langkah.
Loosen the camshaft holder mounting nuts in a crisscross pat-
Hati-hati agar not to let
camshaft
the camshaft
holder holder
mounting nuts tern in several steps and remove the washers, nuts and cam-
dan washers
mountingtidak
nutsjatuh
and Longgarkan camshaft holder mounting nuts (mur-mur
shaft holder assembly.
ke dalamfall
washers crankcase.
into the pemasangan camshaft holder) dalam pola bersilangan
crankcase. dalam beberapa langkah dan lepaskan washers, nuts
dan camshaft holder assembly.

CAMSHAFT HOLDER ASSEMBLY BOLTS


Remove theyang
Lepaskan following from
berikut darithe cylinderhead:
cylinder head:
PLUNGER/SPRING
-– Dua
Twodowel
dowelpins
pins
-– Plunger
Plunger
-– Spring
Spring

DOWEL PINS
DISASSEMBLY
PEMBONGKARAN
Lepaskan
Remove thecamshaft
camshaft (hal.
(page8-8).
8-8).
BOLTS
Lepaskan
Remove the rocker armshaft
rocker arm shaft stopper
stopper bolts. bolts (baut-baut
rocker arm shaft stopper).

Push the rocker


Dorong rockerarmarm
shaftsshafts
from the rightsisi
dari side kanan
as shown.
seperti SHAFTS ROCKER ARMS
diperlihatkan.
Remove the rocker arm shafts and rocker arms from the cam-
shaft holder.
Lepaskan rocker arm shafts dan rocker arms dari
camshaft holder.

CAMSHAFT HOLDER

8-13
KEPALA SILINDER / KLEP
INSPECTION
PEMERIKSAAN
ROCKER ARM/ROCKER
ARM/ROCKER ARM
ARMSHAFT
SHAFT
Check thepermukaan
Periksa sliding surface of each
luncur rocker
dari arm and rocker
masing-masing arm
rocker
shaft for OIL HOLE
arm danwear or damage.
rocker arm shaft terhadap keausan atau
Check the
kerusakan. oil hole for clog of each rocker arm.
Periksa lubang
Measure the rockerminyak
arm I.D.dari masing-masing rocker arm
terhadap
SERVICEsumbatan.
LIMIT:
Ukur 10.10 mm (0.398 in)
D.D. rocker arm.
Measure SERVIS:
BATAS the rocker arm shaft
10,10 mm O.D. at three points.
SERVICE
Ukur D.L. rocker arm shaft pada tiga titik.
LIMIT: 9.75 mm (0.384 in)
BATAS SERVIS: 9,75 mm
Calculate the rocker arm-to-shaft clearance.
Hitung kerenggangan antara rocker arm – ke – shaft.
BATAS SERVIS: 0,10 mm ROCKER ARM SHAFT
SERVICE
LIMIT: 0.10 mm (0.004 in)
Bersihkan
Clean the oiljalan lintasan
passages of oli
the dari camshaft
camshaft holderholder
using dengan
a com-
menggunakan
pressed air. udara kompressor. PASSAGES

Check the oil passage for clogs.


Periksa jalan lintasan oli terhadap sumbatan.

ASSEMBLY
PERAKITAN

9.0 N·m (0.9 kgf·m, 6.6 lbf·ft)

CAMSHAFT HOLDER

ROCKER ARMS ROCKER ARM SHAFTS

8-14
KEPALA SILINDER / KLEP
Apply molybdenum
Semprotkan larutanoilmolybdenum
solution to each rockerpermukaan
oil pada arm shaft
outer surface. ROCKER ARMS SHAFTS
luar masing-masing rocker arm shaft.
Set the rocker arm into the camshaft holder and install the
Letakkan
rocker arm rocker
shaft intoarm
the ke dalamholder
camshaft camshaft
throughholder dan
the rocker
pasang
arm. rocker arm shaft ke dalam camshaft holder
melalui rocker arm.

CAMSHAFT HOLDER
Align the lubang-lubang
Jajarkan bolt holes of thebaut
camshaft
dari holder and holder
camshaft rocker arm
dan
shaft using
rocker arma shaft
flat blade screwdriver.
dengan menggunakan sebuah obeng
minus.
Install and tighten the rocker arm shaft stopper bolts to the
specified torque.
Pasang dan kencangkan rocker arm shaft stopper bolts
TORQUE:9.0
dengan N·m ditentukan.
torsi yang (0.9 kgf·m, 6.6 lbf·ft)
Install the camshaft (page 8-11).
TORSI: 9,0 N.m (0,9 kgf.m; 6,6 lbf.ft)
Pasang camshaft (hal. 8-11)

INSTALLATION
PEMASANGAN
Apply engine oil
Semprotkan to the camshaft
oli mesin plunger
ke seluruh entire surface.
permukaan camshaft
PLUNGER SPRING
plunger.
Install the following to the cylinder head:
–Pasang
Two dowel pins
yang berikutnya pada cylinder head:
– Spring
–- Dua dowel pins
Plunger
- Spring
- Plunger

DOWEL PINS
Install thecamshaft
Pasang camshaft holder
holder onto
padathe cylinderhead.
cylinder head.
NUTS/WASHERS
Apply engine oil to the camshaft holder mounting nut threads
Semprotkan
and oli mesin pada ulir camshaft holder
seating surface.
mounting nuts (mur pemasangan) dan permukaan
Be careful not to let Install the washers and camshaft holder mounting nuts and
duduk.
the washers and tighten the nuts to the specified torque in a crisscross pattern
Hati-hati
camshaft agar
holder in several washers
Pasang steps. dan camshaft holder mounting nuts
washers dan camshaft
mounting nuts fall
holder mounting nuts
dan kencangkan
TORQUE:29 N·m (3.0 nutskgf·m,
dengan torsi yang ditentukan
21 lbf·ft)
into the crankcase. dalam pola bersilangan dalam beberapa langkah.
tidak jatuh ke dalam
crankcase. Tighten the cylinder head bolts alternately in several steps.
TORSI: 29 N.m (3,0 kgf.m; 21 lbf.ft)
Install the following:
– Cam sprocket
Kencangkan (page 8-11)
cylinder head bolts (baut-baut cylinder
–head)
Cylinder
secarahead cover (page
bergantian 8-7) beberapa langkah.
dalam CAMSHAFT HOLDER ASSEMBLY BOLTS
– Engine (page 7-7)
Pasang sebagai berikut:
- Cam sprocket (hal. 8-11)
- Cylinder head cover (hal. 8-7)
- Mesin (hal. 7-7)

8-15
KEPALA SILINDER / KLEP
CYLINDER HEAD
CYLINDER HEAD
REMOVAL
PELEPASAN
Lepaskan
Remove thesebagai berikut:
following:
- Busi (hal. 3-7) RADIATOR STAY
– Spark plug (page 3-7)
- Mesin (hal. 7-4)
– Engine (page 7-4)
-– Camshaft
Camshaft holder (hal. 8-13)
holder (page 8-13)
Remove thebolt
Lepaskan boltdan
andradiator
radiator stay
stayfrom
dari the cylinder
cylinder head.
head.

BOLT
Be careful
Hati-hati agarnot Remove thecylinder
to let Lepaskan
cylinder cylinderhead
head bolts
bolts and
dancylinder
cylinderhead.
head.
the cylinder
head bolts head
tidak jatuh ke
CYLINDER
• Attach a piece of wire to the cam chain to prevent it from
dalam into the • Ikatlah sepotong kawat pada cam chain untuk
crankcase.
bolts fall
falling into
menjaga thetidak
agar crankcase.
jatuh ke dalam crankcase.
crankcase.
•• Jangan
Do not tap the cylinder
ketuk cylinder head
headtoo hard and
terlalu do dan
keras not damage
jangan
the mating surface with a screwdriver.
merusak permukaan penyatuan dengan sebuah
obeng.

CAM CHAIN BOLTS


Remove thedowel
Lepaskan dowelpins
pins dan
and gasket.
gasket. GASKET

DOWEL PINS

Remove thecam
Lepaskan camchain
chain guide.
guide.

CAM CHAIN GUIDE

8-16
KEPALA SILINDER / KLEP
DISASSEMBLY
PEMBONGKARAN
To prevent
Untuk loss of
menghindari Lepaskan
Remove thevalve springcotters
valve spring cotters dengan
using menggunakan
the special tools.
VALVE SPRING COMPRESSOR
tension,
hilangnya do not
tegangan, special tools.
jangan compress
tekan valve thesprings
valve TOOLS:
lebih daripada
springs more yang
than Valve spring
KUNCI compressor
PERKAKAS: 07757-0010000
diperlukan
necessary untuk
to remove Valve springcompressor
Valve spring compressor 07757-
melepaskan cotters.
the cotters. attachment
0010000 07959-KM30101
Valve spring compressor attachment 07959-
KM30101

ATTACHMENT COTTERS
Mark all parts
Tandai semua during
parts Remove thesebagai
Lepaskan following:
berikut:
disassembly so they
VALVE
selama pembongkaran
– Spring retainer
sehingga
can bemereka dapat
installed in -– Spring retainer
dipasang pada
Inner and outer valve springs STEM SEAL
theirlokasinya
original -– Inner
semula. Valvedan outer valve springs
locations. -– Valve
Stem seal OUTER SPRING
-– Stem seal
Spring seat
- Spring seat

SPRING SEAT

INNER SPRING
SPRING RETAINER

INSPECTION
PEMERIKSAAN
CAM CHAIN
CAM CHAINGUIDEGUIDE
Periksa
Check thecamcamchain
chainguide
guide terhadap keausan
for excessive berlebihan
wear or damage,
atau kerusakan,
replace ganti bila perlu.
if necessary. CAM CHAIN GUIDE

CYLINDER
CYLINDER HEAD HEAD
Use care
Hati-hati agarnot to
tidak Remove the carbon deposits fromatau
Bersihkan ruang pembakaran the combustion chamber or
lubang pembuangan
merusak
damage ruang
the exhaust port. COMBUSTION CHAMBER
dari kerak karbon.
pembakaran
combustion atau
chamber
permukaan cylinder Check the spark plug hole and valve area for cracks.
or cylinder head Periksa lubang busi dan daerah klep terhadap retak-
headsurface.
gasket gasket. Replace the cylinder head if necessary.
retak.

Ganti cylinder head bila perlu.

8-17
KEPALA SILINDER / KLEP
Be careful
Hati-hati agarnot Check thecylinder
to Periksa
tidak cylinderhead
head for warpageperubahan
terhadap with a straight edge and
melengkung
damagepermukaan
merusak feeler gauge.
the gasket dengan mistar lurus dan feeler gauge (lidah voeler).
gasket.
surface.
SERVICE
BATAS SERVIS: 0,05 mm
LIMIT: 0.05 mm (0.002 in)

VALVE
VALVE SPRING
Check the valve
Periksa valvesprings for fatigue
springs or damage.
terhadap kelelahan atau
kerusakan.
Measure the free length of the inner and outer valve springs.
SERVICE
Ukur LIM-
panjang INNER:
bebas 31.0
dari inner mm (1.22
(dalam) danin)outer (luar) INNER SPRING OUTER SPRING
ITS: springs (pegas
valve OUTER:
klep). 34.0 mm (1.34 in)
Replace the
BATAS springs if
SERVIS: they are shorter
INNER: 31,0 mm than the service limits.
OUTER: 34,0 mm

Ganti springs jika mereka lebih pendek dari batas


servis.

VALVE
VALVE
Check that
Periksa the valve
bahwa valvemoves smoothly
(klep) in thedengan
bergerak guide. lancar di
Inspectguide
dalam each valve
(bos).for bending, burning, scratches or abnor-
mal stem masing-masing
Periksa wear. valve terhadap kebengkokan,
Measure and
keadaan record each
terbakar, valveatau
goresan stemkeausan
O.D. stem (tangkai)
yang tidak normal.
Ukur dan catat
SERVICE LIM-D.L. masing-masing valve stem.
ITS: IN: 4.863 mm (0.1915 in)
BATAS SERVIS: IN: EX: 4,863
4.853 mm
mm (0.1911 in)
EX: 4,853 mm

VALVE
VALVE GUIDE
VALVE
Valve GUIDE
guide harus di-ream untuk menghilangkan semua
pembentukan
Ream the valvekarbon
guide tosebelum
remove mengukur
any carbon build-up before
D.D. guide.the guide I.D.
measuring VALVE GUIDE REAMER
• Gunakan cutting oil pada reamer selama
• Use cutting oil on the reamer during this operation.
pengerjaan ini.
• Take care not to tilt or lean the reamer in the guide while
• reaming. agar the tidak
Hati-hatiOtherwise, valves maymemiringkan atau
be installed slanted,
mencondongkan reamer di dalam guide sementara
causing oil leakage from the stem seal and improper valve
meng-reaming.
seat Dalam
contact. This may hal ini,
prevent valves
valve mungkin akan
seat refacing.
terpasang miring, mengakibatkan kebocoran
• Insert the reamer from the combustion chamber side oli dari
of
stem
the headseal dan kontak
and always valve
rotate the seat
reamer (dudukan klep)
clockwise.
yang tidak benar. Ini dapat berakibat bahwa valve
TOOL:seat tidak dapat di-refacing (dibentuk kembali
Valve guide reamer, 5.0 mm
permukaannya) 07984-MA60001
• Masukkan reamer dari sisi ruang pembakaran dari
cylinder head dan selalu putar reamer searah
dengan arah perputaran jarum jam.
KUNCI PERKAKAS:
Valve guide reamer, 5,0 mm 07984-MA60001

8-18
KEPALA SILINDER / KLEP
Ukur D.D.
Measure masing-masing
each valve
valve guide I.D. and guide
record dan
it. catat.
SERVICE
BATAS SERVIS: IN/EX: 5,04 mm
LIMIT: D.L. masing-masing
Kurangi IN/EX: 5.04valve
mm (0.198 in) D.D. guide
stem dari
pasangannya untuk mendapatkan kerenggangan
Subtract each valve stem O.D. from the corresponding guide
antara stem-ke-guide.
I.D. to obtain the stem-to-guide clearance.
SERVICE
BATAS LIM- IN:
SERVIS: IN: 0,065
0.065 mm
mm (0.0026 in)
ITS: EX: 0,075
EX: 0.075 mm
mm(0.0030 in)
Jika kerenggangan antara stem-ke-guide melampaui
If the servis,
batas stem-to-guide
tentukanclearance exceeds guide
apakah sebuah the service
baru limit,
determine if a new guide with standard dimensions would
dengan ukuran standard akan membawa kerenggangan
bring the clearance within tolerance.
ke dalam toleransi lagi.
If so, replace any guides as necessary and ream to fit.
Jika demikian, gantilah guides sebagaimana diperlukan
If the stem-to-guide clearance exceeds the service limit with a
dan
new ream
guide,agar pas. the valve.
also replace
Jika kerenggangan antara stem-ke-guide tetap
• Inspect and
melampaui reface
batas the valve
servis denganseatssebuah
whenever the valve
guide baru,
guidesvalve
gantilah are replaced
juga. (page 8-20).
• Periksa dan reface valve seats (dudukan klep) setiap
kali valve guides diganti (hal. 8-20).
VALVE GUIDEVALVE
PENGGANTIAN REPLACEMENT
GUIDE
•• Refinish
Refinish (haluskan
the valve seats whenevervalve
permukaan) the valve
seatsguides are
(dudukan
replaced
klep) to prevent
setiap kaliuneven seating.
valve guides diganti untuk
menghindari
Chill new valve dudukan
guides in ayang tidak
freezer merata.
section of refrigerator for
about an hour.
Dinginkan valve guides baru dalam bagian freezer dari
Do not memakai
Jangan use a torch to
obor Heat the
lemari escylinder
selamahead to 130
kira-kira – 140°C
satu jam. (266 – 284°F) with a
heatmemanaskan
untuk the cylinder hot plate or oven. Do not heat the cylinder head beyond
cylinder head;
head; ini cause
it may dapat 150°C (302°F).
Panaskan Use temperature
cylinder head ke 130 indicator sticks,C available
- 140° dengan
menyebabkan perubahan from welding
warping. kompor listrik supply stores,Jangan
atau oven. to be sure the cylinder cylinder
memanaskan head is
melengkung. heated to the proper temperature.
head melampaui 150° C. Pakailah batang indikator
suhu, yangburns,
To avoid dapatwear
dibeliinsulated
di toko perlengkapan
gloves when handling the
pengelasan,
heated cylinderuntuk
head. memastikan bahwa cylinder head
dipanaskan sampai ke suhu yang tepat.

Untuk menghindari luka-luka bakar, pakailah sarung


Supportberisolasi
tangan the cylinderketika
head and drive out cylinder
menangani the valvehead
guides from
the combustion chamber side of the cylinder head. VALVE GUIDE DRIVER
yang telah dipanaskan.
TOOL: cylinder head dan dorong keluar valve guides
Topang
Valve
dari guide
sisi driver,
ruang 5.0 mm dari cylinder
pembakaran 07942-8920000
head.

KUNCI PERKAKAS:
Valve guide driver, 5,0 mm 07942-8920000

While the cylinder


Sewaktu cylinder head
headis still
masihheated, take off a new
dipanaskan, valve
keluarkan
guides from the freezer. VALVE GUIDE
valve guides baru dari freezer. ADJUSTING DRIVER
Drive themasuk
Dorong guides into the cylinder
guides ke dalam headcylinder
to the specified height
head sampai
from
ke the cylinder
ketinggian head.
yang ditentukan dari cylinder head.
TOOL:
KUNCI PERKAKAS:
Valve guide adjusting driver 07743-0020000
Valve guide adjusting driver 07743-0020000
SPECIFIED HEIGHT:
KETINGGIAN YANG DITENTUKAN:
IN: 11.5 –– 11.7
IN: 11,5 11,7mm
mm(0.4528 – 0.4606 in)
EX: 12.3 –– 12.5
EX: 12,3 12,5mm
mm(0.4843 – 0.4921 in)
Let the cylinder head cool to room temperature.
Biarkan cylinder head mendingin kembali ke suhu
ruangan.
VALVE GUIDE

8-19
KEPALA SILINDER / KLEP
Ream a new
Lakukan valve guides.
pekerjaan reaming pada valve guides baru.
VALVE GUIDE REAMER
KUNCI PERKAKAS;
TOOL:guide reamer, 5.0 mm
Valve 07984-MA60001
•Valve guide reamer,
Gunakan cutting oil5.0 pada
mm reamer07984-MA60001
selama pengerjaan
• ini.
Use cutting oil on the reamer during this operation.
•• Hati-hati
Take care notagar tidakthe reamer
to tilt or lean memiringkan atau
in the guide while
mencondongkan
reaming. Otherwise, reamer di dalam
the valves may beguide sementara
installed slanted,
meng-
causingreaming.
oil leakageDalam hal stem
from the ini, valves
seal andmungkin akan
improper valve
terpasang
seat contact.miring,
This may mengakibatkan kebocoran
prevent valve seat refacing oli dari
• stem the dan
Insertseal reamerkontak
fromvalve seat (dudukan
the combustion klep)side
chamber yang
of
tidak benar.head
the cylinder Ini and
dapat berakibat
always bahwa
rotate the reamervalve seat
clockwise.
tidak dapat di-refacing (dibentuk kembali
Clean the cylinder head thoroughly to remove any metal par-
permukaannya).
ticles after reaming and reface the valve seat (page 8-21).
• Masukkan reamer dari sisi ruang pembakaran dari
cylinder head dan selalu putar reamer searah dengan
arah perputaran jarum jam.
Bersihkan cylinder head secara menyeluruh untuk
membuang partikel-partikel logam setelah pekerjaan
reaming dan reface (bentuk kembali permukaan) valve
seat (hal. 8-21).
VALVE SEAT INSPECTION
Clean the intake and exhaust
PEMERIKSAAN VALVE valves
SEATthoroughly to remove
carbon deposits. HAND LAPPING TOOL
Oleskan selapisan tipis Prussian Blue pada masing-
masing muka
Apply thin coatvalve.
of Prussian Blue to each valve face.
Tap thevalve
Ketok valvebeberapa
against thekali
valve seat several
terhadap valve times
seat using
dengan a
hand lapping toolsebuah
menggunakan without rotating valve to make
hand lapping a clearputar
tool (alat pat-
tern. tanpa memutar valve untuk mendapatkan pola
klep)
yang jelas.

Remove thevalve
Keluarkan valve dan
and inspect
periksathe valvevalve
muka seat face.
seat.
• The valve cannot be ground. If the valve face is burned or
• badly
Valveworntidak
or if dapat digerinda.
it contacts Jika muka
the seat unevenly, replacevalve
the
terbakar atau sangat aus atau jika ia menyentuh
valve.
dudukannya secara tidak merata, gantilah valve.
Inspect the valve seat face for:
Periksa muka
• Damaged valve seat (dudukan klep) terhadap:
face:
– Replace the valve and reface the valve seat.
•• Uneven
Kerusakan pada muka:
seat width:
–-Ganti valve
Replace the valve dan reface
and reface (bentuk
the valve seat. kembali
permukaan) valve seat.
• Lebar dudukan tidak merata: LEBAR SEAT
KERUSAKAN
- Ganti valve dan reface valve seat. PADA MUKA TIDAK MERATA

•• Contact
Bidangarea (too high
kontak or too low
(daerah area):terlalu tinggi atau
kontak
– terlalu
Refacerendah):
the valve seat.
- Reface valve seat.

TERLALU RENDAH TERLALU TINGGI

8-20
KEPALA SILINDER / KLEP
Inspect the
Periksa width
lebar ofvalve
dari the valve
seatseat.
(dudukan klep).
The valve seat contact should be within the specified width
and evenvalve
Kontak seatthe
all around harus berada di dalam lebar yang
circumference.
ditentukan dan harus merata seluruhnya
STANDARD:
di 1.0 mm (0.04 in)
sekitar kelilingnya.
SERVICE
LIMIT:
STANDARD: 1.6
1,0mm
mm(0.06 in)
BATAS SERVIS: 1,6 mm
If the valve seat width is not within specification, reface the
valve seat.
Jika lebar valve seat tidak sesuai dengan spesifikasi,
reface (bentuk kembali permukaan) valve seat. LEBAR KONTAK
VALVE SEAT

VALVE SEATREFACING
VALVE SEAT REFACING
•• Follow the refacing
Ikuti petunjuk manufacturer’s
refacing dari pabrik. operating instruc-
• tions.
Reface valve seat (bentuk kembali permukaan
• Reface
dudukanthe klep)
valve setiap
seat whenever theguide
kali valve valve telah
guide diganti.
has been
• replaced.
Hati-hati agar tidak menggerinda valve seat lebih
• Be careful not to grind the seat more than necessary. 45°
daripada yang diperlukan.

60°

32°

If the bidang
Jika contact area is tooterlalu
kontak high on tinggi
the valve,
padathe seat mustseat
valve, be KONTAK TERLALU TINGGI
LEBAR SEAT
lowered using
(dudukan a 32°
klep) flat cutter.
harus diturunkan dengan menggunakan LAMA
sebuah 32° flat
If the contact cutter.
area is too low on the valve, the seat must be
raised using a 60° inner cutter.
Jika bidang kontak terlalu rendah pada valve, seat
harus dinaikkan dengan menggunakan sebuah 60° 32°
inner cutter.
KONTAK TERLALU RENDAH
LEBAR SEAT
LAMA

60°

Reface the valve


Reface valve seat
seat Use a 45° menggunakan
Dengan cutter, remove any roughness
sebuah 45°or cutter,
irregularities from
hilangkan KEKASARAN
dengan with
setuah 45°° cutter
a 45 cutter the seat.
kekasaran atau ketidak-teraturan dari valve seat.
sewaktu
when sebuah
a valve valve
guide is
guide telah diganti.
replaced. TOOLS:
KUNCI PERKAKAS:
Seat cutter, 24 mm (45° EX) 07780-0010600
Seat cutter, 24 mm (45° EX) 07780-0010600
Seat cutter, 29 mm (45° IN) 07780-0010300
Seat cutter, 29 mm (45° IN) 07780-0010300
Cutter holder,
Cutter holder,5.05.0mm
mm 07781-0010400
07781-0010400

VALVE SEAT CUTTER

8-21
KEPALA SILINDER / KLEP
Using 32°menggunakan
Dengan cutter, remove the
32top 1/4 of the
° cutter, existing ¼
buanglah valve seat
bagian
material.dari bahan valve seat (dudukan klep) yang ada
teratas
sekarang.
TOOLS: LEBAR SEAT LAMA
Flat cutter, 27 mm (32° EX) 07780-0013300
Flat cutter,
KUNCI 30 mm (32° IN)
PERKAKAS: 07780-0012200
Cutter holder, 5.0 mm 07781-0010400
Flat cutter, 27 mm (32° EX) 07780-0013300
Flat cutter, 30 mm (32° IN) 07780-0012200
Cutter holder, 5.0 mm 07781-0010400 32°

Using 60°menggunakan
Dengan 60°bottom
cutter, remove the 1/4buanglah
cutter, of the old ¼
seat.
bagian
Remove the
terbawah daricutter and inspect
seat (dudukan) thelama.
yang area you have just LEBAR SEAT LAMA
removed. cutter dan periksa bidang yang baru telah
Lepaskan
dibuang.
TOOLS:
Interior cutter, 26 mm (60° EX) 07780-0014500
KUNCI PERKAKAS:
Interior cutter, 30 mm (60° IN) 07780-0014000
Interior cutter, 26 mm (60° EX) 07780-0014500
Cutter holder, 5.0 mm 07781-0010400
Interior cutter, 30 mm (60° IN) 07780-0014000
Cutter holder, 5.0 mm 07781-0010400

60°

Using
Dengana 45° cutter, cut the seat
menggunakan 45° cutter,
to proper
sebuah width. potong seat
Make sureyang
ke lebar that all pitting and irregularities are removed.
benar.
Pastikanif bahwa
Refinish necessary. semua lubang dan ketidak-teraturan LEBAR SEAT
telah dihilangkan.
STANDARD SEAT WIDTH:
Refinish
1.0 mm(haluskan
(0.04 in) permukaan) bila perlu.

LEBAR SEAT STANDARD:


1,0 mm

45°

Setelah memotong
After cutting the seat,dudukan, oleskan
apply lapping lappingtocompound
compound the valve
(ambril) pada
face and lap muka
the valve valve
using dan skir klep dengan
light pressure. HAND
menggunakan tekanan ringan. LAPPING TOOL
• Excessive lapping pressure may deform or damage the
seat.
•• Change
Tekanan theskir klep
angle of yang
lappingberlebihan dapattomerubah
tool frequently prevent
bentuk atau merusak
uneven seat wear. dudukan klep.
•• Lapping
Ubah kemiringan
compound can lapping tool sering-sering
cause damage untuk
if it enters between
mencegah keausan
the valve stem and guide. dudukan klep yang tidak
merata.
•AfterLapping
lapping,compound
wash any residual compound off the
dapat menyebabkan cylinder
kerusakan
head and valve.
bila ia masuk antara valve stem dan guide.
Recheck the seat contact after lapping.
Setelah men-skir klep, cucilah sisa ambril yang
tertinggal dari cylinder head dan valve.

Periksa kembali bidang kontak valve seat (dudukan


klep) setelah selesai diskir.

8-22
KEPALA SILINDER / KLEP
ASSEMBLY
PERAKITAN

COTTERS

RETAINER

OUTER SPRING
INNER SPRING

SPRING SEAT
STEM SEAL

VALVE GUIDE

CYLINDER HEAD

INTAKE

EXHAUST VALVE

Clean the cylinder


Bersihkan susunan headcylinder
assembly head
with solvent
denganandcairan
blow
through all oil
pembersih passages
dan tiuplahwith compressed
melalui semuaair.
jalan lintasan oli
dengan udara VALV
Install the springdari kompressor.
seats and new valve stem seals.
Lubricatespring
Pasang each valve
seats stem and stem
dan valve stemend withbaru.
seals molybdenum
oil solution.
To damage to Lumasi
avoidmenghindari
Untuk Insert themasing-masing
intake and exhaustvalve
valvesstem
into thedan
valveujung
guides.stem
the seal,
kerusakan turnseal,
pada the dengan larutan molybdenum oil.
putar valve
valve perlahan-
slowly when
lahan sewaktu Masukkan intake dan exhaust valves (klep masuk dan
inserting.
memasukkannya. buang) ke dalam valve guides (bos klep).

SPRING SEAT STEM SEAL

Install
Pasangthe inner
inner and
dan outer
outer valve
valve springs
springs with klep
(pegas the tightly
dalam
wound coilsdengan
dan luar) facing the combustion
gulungan yangchamber
rapat side.
menghadap ke
sisi ruang pembakaran.
INNER SPRING OUTER SPRING

SISI RUANG PEMBAKARAN

8-23
KEPALA SILINDER / KLEP
Oleskan gemuk pada Pasang spring retainer.
Grease the cotters
cotters to
untuk Install the spring retainer.
ease installation.
mempermudah To
VALVE SPRING COMPRESSOR
Tekan
Compress valve
the spring dengan
valve spring menggunakan
using special
the special tools tools
and install
pemasangan.
prevent loss of dan pasang valve cotters.
Untuk the valve cotters.
tension, do not
mencegah
compresshilangnya
the valve TOOLS:PERKAKAS:
tegangan, jangan KUNCI
spring more than Valve spring
Valve springcompressor
compressor 07757-0010000
07757-0010000
tekan valve spring
necessary.
lebih daripada yang Valve spring
Valve springcompressor
compressor
diperlukan. attachment
attachment 07959-KM30101
07959-KM30101

ATTACHMENT COTTERS
Letakkan cylinder head Letakkan suitable tool (kunci perkakas yang sesuai)
Support
di atasthe cylinder
permukaan Place valve
pada a suitable tool onto the valve stem.
stem.
headmeja
above the untuk
kerja work TOOL YANG SESUAI
menghindari kerusakan
Tap the tool gently to seat the cotters firmly using a plastic
bench surface to Ketuk tool dengan ringan untuk mendudukkan cotters
pada valve. hammer.
prevent valve dengan kokoh dengan menggunakan sebuah palu
damage. plastik.

VALVE STEM

INSTALLATION
PEMASANGAN
DoJaga agar debu
not allow dan
dust and Clean any bahan
Bersihkan gasket material fromtertinggal
gasket yang the cylinder
dariand cylinder
cylinder
kotoran dirt
tidaktomemasuki
enter the head permukaan
mating surfaces. CAM CHAIN GUIDE
dan penyatuan cylinder head.
crankcase.
crankcase.
Install the cam chain guide while aligning its bosses with the
Pasang cam and
cylinder grooves chain guide
its end sementara
with the mentepatkan
left crankcase groove.
bosses-nya dengan alur-alur cylinder dan ujungnya
dengan alur pada left crankcase.

Tepatkan Tepatkan
Install thedowel
Pasang dowelpins
pinsdan
and gasket
new gasket.
baru. GASKET

DOWEL PINS

8-24
KEPALA SILINDER / KLEP
Route thecam
Alurkan camchain
chain melalui
through the cylinder
cylinder head
head andpasang
dan install the
cylinder head CYLINDER
headonto
padathecylinder.
cylinder.
Hati-hati agarnot
Be careful to let Loosely install the cylinder head bolts.
cylinder
head bolts tidak jatuh
the cylinder headke Pasang cylinder head bolts (baut-baut cylinder head)
dalam into the dengan longgar dulu.
crankcase.
bolts fall
crankcase.

CAM CHAIN BOLTS


Install theradiator
Pasang radiator stay
stayto pada
the cylinder headhead
cylinder while aligning
sementaraits
hole with the boss
mentepatkan on the cylinder
lubangnya denganhead.boss pada cylinder RADIATOR STAY
Install and tighten the bolt.
head.
Pasang
Install thedan kencangkan bolt.
following:
– Camshaft
Pasang holder
sebagai (page 8-15)
berikut:
– Engine (page 7-7)
-– Camshaft
Spark plugholder
(page (hal.
3-8) 8-15)

- Mesin (hal. 7-7)


- Busi (hal. 3-8)

BOLT Tepatkan
CAM
CAMCHAIN
CHAINTENSIONER LIFTERLIFTER
TENSIONER
(PENGANGKAT PENEGANG RANTAI CAM)
REMOVAL
PELEPASAN
Remove themesin
Lepaskan engine(hal.
(page 7-4).
7-4). PLUG
Remove the cam chain tensioner lifter plug and O-ring.
Lepaskan cam chain tensioner lifter plug dan O-ring.

O-RING
Turn the
Putar cam cam chaintensioner
chain tensionerlifter
liftershaft
shaft secara
fully in penuh
(clockwise)
ke TENSIONER LIFTER
and secure
dalam it using putaran
(searah a tensionerjarum
stopperjam)
to prevent
dan damaging
amankan
the cam chain.
dengan menggunakan sebuah tensioner stopper untuk
menghindari bahwa ia merusak cam chain.
TOOL:
Tensioner
KUNCI stopper
PERKAKAS: 070MG-0010100
Tensioner stopper 070MG-0010100

TENSIONER STOPPER

8-25
KEPALA SILINDER / KLEP
Remove the cam
Lepaskan cam chain
chaintensioner lifter lifter
tensioner mounting bolts. bolts
mounting
TENSIONER LIFTER BOLTS
(baut-baut
Remove thepemasangan cam chain
cam chain tensioner tensioner
lifter and gasket.lifter).

Lepaskan cam chain tensioner lifter dan gasket.

GASKET
INSPECTION
PEMERIKSAAN
Check the
Periksa lifterkerja
cara operation:
lifter:
TENSIONER LIFTER TENSIONER STOPPER
-– Cam
The chain
cam chain tensioner
tensioner lifter
lifter shaft
shaft should
tidak bolehnotmasuk
go into the
ke
cam chain
dalam camtensioner lifter body
chain tensioner when
lifter bodyit isketika
pushed.ia
– didorong.
When it is turned clockwise with a tensioner stopper, the
cam ia
- Jika chain tensioner
diputar lifter shaft
searah jarumshould
jam be pulled into
dengan the
sebuah
cam chain stopper,
tensioner tensioner lifter
cam body. chainThe cam chainlifter
tensioner tensioner
shaft
lifter ditarik
harus shaft should spring
ke dalam camoutchain
of thetensioner
cam chainliftertensioner
body.
lifterchain
Cam body as soon as the
tensioner tensioner
lifter stopper
shaft harus is released.
meloncat keluar
dari cam chain tensioner lifter body segera setelah
TOOL:
tensioner stopper dilepaskan.
Tensioner stopper 070MG-0010100
KUNCI PERKAKAS:
Tensioner stopper 070MG-0010100

INSTALLATION
PEMASANGAN
Install a sebuah
Pasang new gasket on the
gasket barucam chain
pada camtensioner lifter and
chain tensioner
installdan
them to the cylinder. GASKET
lifter pasang mereka pada cylinder.

TENSIONER LIFTER

Install anddan
Pasang tighten the cam chain
kencangkan camtensioner mountingmounting
chain tensioner bolts.
BOLTS
bolts.

8-26
KEPALA SILINDER / KLEP
Remove thetensioner
Lepaskan tensioner stopper
stopperfrom
darithe camchain
cam chain tensioner
tensioner
lifter. TENSIONER STOPPER
lifter.

TENSIONER LIFTER
Apply engine
Oleskan oil topada
oli mesin a newsebuah
O-ring O-ring
and install
baruitdan
to the cam
pasang
chain cam
pada tensioner
chainlifter.
tensioner lifter.
Install and tighten the cam chain tensioner lifter plug to the
Pasang
specifieddan kencangkan cam chain tensioner lifter plug
torque.
dengan torsi yang ditentukan.
TORQUE:4.0 N·m (0.4 kgf·m, 3.0 lbf·ft)
TORSI: 4,0 N.m (0,4 kgf.m; 3,0 lbf.ft)
Install the engine (page 7-7)
Pasang mesin (hal. 7-7).

O-RING PLUG

CAM CHAIN
CHAIN TENSIONER
TENSIONER SLIDER
SLIDER
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Lepaskan
Remove thesebagai berikut:
following:
- Cam sprocket (hal. 8-8) CAM CHAIN TENSIONER SLIDER PLATE
–- Flywheel
Cam sprocket
(hal. (page
11-7)8-8)
– Flywheel (page 11-7)
Lepaskan
Remove the tensioner guideplate
tensioner guide plate
bolt,bolt,
plateplate danchain
and cam cam
chain tensioner
tensioner slider. slider.
Install the cam chain tensioner slider and tensioner guide
Pasang cam chain tensioner slider dan tensioner guide
plate while aligning its hole with the boss on the crankcase.
plate sementara mentepatkan lubangnya dengan boss
Install and tighten the tensioner guide plate bolt.
pada crankcase.
Install
Pasang thedan
following:
kencangkan tensioner guide plate bolt.
– Cam sprocket (page 8-11)
Pasang sebagai berikut:
– Flywheel (page 11-12)
- Cam sprocket (hal. 8-11)
- Flywheel (hal. 11-12) Tepatkan BOLT
INSPECTION
PEMERIKSAAN
Check the cam
Periksa camchain tensioner
chain for excessive
tensioner wear or keausan
terhadap damage,
CAM CHAIN TENSIONER SLIDER
berlebihan atau kerusakan,
replace if necessary. ganti bila perlu.

8-27
CATATAN
9. SILINDER / PISTON

COMPONENT
LOKASI LOCATION
KOMPONEN ···························· 9-2
............................9-2 TROUBLESHOOTING
MENCARI PENYEBAB ····································9-3
KESUKARAN ..9-3
KETERANGAN SERVIS ........................9-3
SERVICE INFORMATION ····························· 9-3 CYLINDER/PISTON
CYLINDER/PISTON...............................9-4
········································9-4
9

9-1
SILINDER / PISTON
COMPONENT
LOKASI LOCATION
KOMPONEN
CYLINDER/PISTON

9-2
SILINDER / PISTON
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
• Bab ini meliputi perawatan cylinder dan piston. Agar dapat menservis parts ini, mesin harus dilepaskan dari rangka.
• This section covers maintenance of the cylinder and piston. To service these parts, the engine must be removed from the frame.
•• Hati-hati agar
Take care not to tidak
damagemerusak dinding
the cylinder wallcylinder dan piston.
and piston.
•• Hati-hati
Be agar
careful not tidak merusak
to damage permukaan
the mating penyatuan
surfaces when removingketika melepaskan
the cylinder. cylinder.
Do not tap Jangan
the cylinder ketuk
too hard cylinder
during terlalu keras pada
removal.
• waktu pelepasan.
Camshaft and rocker arm lubricating oil is fed through an oil passage in the cylinder. Clean the oil passage before installing cylinder.
• Minyak pelumasan camshaft dan rocker arm disalurkan melalui jalan lintasan oli di dalam cylinder. Bersihkan jalan lintasan oli
sebelum memasang cylinder.
SPECIFICATIONS
SPESIFIKASI
Satuan: mm Unit: mm (in)
BAGIAN STANDARD BATAS SERVISSERVICE
Cylinder D.D. ITEM 58,000 STANDARD
– 58,010 58,05 LIMIT
Cylinder Kelonjongan
I.D. 58.000 –- 58.010 (2.2835 – 2.2839) 0,010 58.05 (2.285)
Out-of-round
Ketirusan - – 0,010 0.010 (0.0004)
Taper melengkung
Perubahan - – 0,05 0.010 (0.0004)
Piston, D.L.Warpage
piston pada jarak 6,5 dari bawah 57,970 – 57,990– 56,67 0.05 (0.002)
Piston,
piston pin, Piston O.D. at 6.5 (0.26) from bottom 57.970 – 57.990 (2.2823 – 2.2831) 56.67 (2.231)
piston
pistonpin, pis- D.D.Piston
rings pinpiston
lubang hole I.D.
pin 13.002 –13,002
13.008 –
(0.5119
13,008– 0.5121) 13,045 13.045 (0.5136)
ton ring
D.L.Piston
pistonpin
pinO.D. 12.994 –12,994
13.000 –
(0.5116
13,000– 0.5118) 12,70 12.70 (0.500)
Piston-to-piston
Kerenggangan pin clearance
antara piston dan piston pin 0.002 – 0.014
0,002(0.0001
– 0,014– 0.0006) 0,08 0.08 (0.003)
Piston ring end gap
Celah pada ujung piston ring Top Atas 0.10 – 0.25 (0.004
0,10 – 0,25– 0.010) 0,40 0.40 (0.016)
SecondKedua 0.35 – 0.50
0,35 – 0,500.020)
(0.014 – 0,70 0.70 (0.028)
Oil (side rail) 0.20 – 0.70 (0.008 – 0.028) 1.10 (0.043)
Oli (side rail) 0,20 – 0,70 1,10
Piston ring-to-ring Top 0.045 – 0.075 (0.0018 – 0.0030) 0.10 (0.004)
Kerenggangan antara piston Atas 0,045 – 0,075 0,10
groove clearance Second 0.015 – 0.050 (0.0006 – 0.0020) 0.09 (0.004)
ring dan alurnya Kedua 0,015 – 0,050 0,09
Cylinder-to-piston clearance 0.010 – 0.040 (0.0004 – 0.0016) 0.09 (0.004)
Connecting rod small end I.D. 13.016 – 13.034 (0.5124 – 0.5131) 13.06 (0.514)
Kerenggangan
Connecting antara cylinder
rod-to-piston dan piston
pin clearance 0,010(0.0006
0.016 – 0.040 – 0,040– 0.0016) 0,09 0.10 (0.004)
D.D. kepala kecil connecting rod 13,016 – 13,034 13,06
Kerenggangan antara connecting rod dan piston pin 0,016 – 0,040 0,10
TORQUE VALUE
NILAI TORSI
Cylinder stud bolt – See page 9-10
Cylinder stud bolt - Lihat hal. 9-10

TROUBLESHOOTING
MENCARI PENYEBAB KESUKARAN
Compressionterlalu
Kompressi too low, hard starting
rendah, mesinor poordihidupkan
sulit performance at low
atau speed
unjuk kerja lemah pada kecepatan rendah
•• Leaking
Cylinderor head
damaged cylinder
gasket bocor head
ataugasket
rusak
•• Worn,
Pistonstuck
rings or aus,
broken pistonatau
macet ringspatah
•• Worn or damaged
Cylinder dan pistoncylinder
ausandataupiston
rusak
• Loose spark plug
• Busi longgar
Compression too high, overheating or knocking
• Excessiveterlalu
Kompressi carbon build-up on piston or combustion
tinggi, overheating chamber atau knocking (mesin ngelitik)
(panas berlebihan)
•Excessive
Pembentukan
smoke karbon berlebihan pada piston atau ruang pembakaran
• Faulty cylinder, piston and piston rings
Asap berlebihan
• Improper installation of piston rings
•• Scored or scratched
Cylinder, piston dan piston or cylinder
piston wall dalam keadaan baik
rings tidak
•Abnormal
Pistonnoise
rings(piston)
tidak terpasang dengan baik
•• Worn
Piston ataupin
piston dinding cylinder
or piston pin hole tergerus atau tergores
• Faulty cylinder, piston or piston ring
Suara
• Worn tidak normalrod
connecting (piston)
small end
• Piston pin atau lubang piston pin aus
• Cylinder, piston atau piston ring tidak dalam keadaan baik
• Connecting rod small end (kepala kecil batang penggerak) aus

9-3
SILINDER / PISTON
CYLINDER/PISTON
CYLINDER/PISTON
CYLINDER REMOVAL
PELEPASAN CYLINDER
Remove thesebagai
Lepaskan following:
berikut:
WATER HOSE BAND SCREW
– Cylinder head (page 8-16)
- Cylinder head (hal. 8-16)
-– Cam
Camchain
chain tensioner
tensioner lifter
lifter (page 8-25)
(hal. 8-25)
Loosen the water hose band screw and disconnect the water
hose.
Longgarkan water hose band screw (sekrup pita
penjepit slang air) dan lepaskan water hose (slang air).

Lift the cylinder


Angkat cylinder and
danremove it, being
lepaskan, careful
sambil not to damage
berhati-hati agar
the piston with the studdengan
bolts. stud bolts. CYLINDER
tidak merusak piston
•• Ikat
Attachsepotong kawat
a piece of wire to thepada camto prevent
cam chain chain it untuk
from
mencegahnya
falling into the jatuh ke dalam crankcase.
crankcase.
•• Jangan mengetuk
Do not tap cylinder
the cylinder terlalu
too hard and keras
do not dan
damagejangan
the
merusak permukaan
mating surface with a penyatuan
screwdriver.dengan
sebuah obeng minus.

CAM CHAIN
Remove thedowel
Lepaskan dowelpins
pins dan
and gasket.
gasket.
GASKET

DOWEL PINS
PISTON REMOVAL
PELEPASAN PISTON
Place asebuah
Letakkan clean shop Remove thepiston
kain Lepaskan pistonpin
pin clips
clips dengan
with pliers.
tang lancip.
towelmenutupi
lap bersih over the
crankcase
crankcase untuk
to prevent
mencegah jatuhnya
the piston pin clips
piston pinfalling
from clips keinto
dalam
the
crankcase.
crankcase.

PISTON PIN CLIPS

9-4
SILINDER / PISTON
Push the piston
Dorong piston pin out of the
keluar piston
dari anddan
piston connecting rod, rod
connecting and
remove the piston. PISTON
(batang penggerak), dan keluarkan piston.

PISTON PIN
Spread each piston
Rentangkan ring and remove
masing-masing pistonit by
ringlifting
dan up a point
keluarkan
opposite the gap. PISTON RING
dengan mengangkatnya ke atas pada sebuah titik
berseberangan dengan celahnya.
• Do not damage the piston ring by spreading the ends too
CATATAN:
far.
• Jangan merusak piston ring dengan merentangkan
• Be careful not to damage the piston when the piston ring
ujung-ujungnya terlalu jauh.
removal.
• Hati-hati agar tidak merusak piston pada waktu
pelepasan piston ring.

Never use
Jangan Clean carbon
a wire Bersihkan
sekali-kali deposits
kerak karbonfrom
darithealur-alur
piston ring grooves
piston with a
ring dengan
memakai sikat
brush; it willkawat,
damage used piston
ia sebuah ringring
that bekas
will be yang
discarded. PISTON PISTON RING
piston tidak dipakai lagi.
akan merusakthealur-alur.
grooves.

INSPECTION
PEMERIKSAAN
CYLINDER
CYLINDER
Periksa dinding
Check the cylinder
cylinder wall forterhadap
scratches goresan
and wear.dan keausan.
Measure the cylinder I.D. at three levels on the X and Y axis.
Ukur D.D. cylinder pada tiga tingkat pada poros X dan
Take the maximum reading to determine the cylinder wear.
Y. Ambil pembacaan maksimum untuk menentukan
keausan
SERVICEcylinder.
LIMIT: 58.05 mm (2.285 in)
BATAS SERVIS: 58,05 mm
Calculate the cylinder-to-piston clearance (page 9-6). CYLINDER
Hitung kerenggangan antara cylinder-ke-piston
(hal. 9-6).

9-5
SILINDER / PISTON
Calculateketirusan
Hitung the cylinder
dantaper and out-of-round
kelonjongan at three
cylinder padalevels
tiga
on the X and
tingkat padaY axis. TakeXthe dan
poros maximum reading to
Y. Ambil determine
pembacaan
the taper and out-of-round.
maksimum untuk menentukan ketirusan dan
kelonjongan.
SERVICE LIMITS: TOP
Taper:SERVIS:
BATAS 0.010 mm (0.0004 in)
Out-of-round:
Ketirusan: 0,010 mmmm (0.0004 in)
0.010
Kelonjongan: 0,010 mmand an oversize piston fitted if MIDDL
The cylinder must be rebored
the service limits are exceeded.
The following
Cylinder harusoversize pistons
di-rebore are available:
(di korter) dan sebuah oversize
These parts ini
Nomor numbers
dapat piston dipasang bila
0.25 mm (0.010 in): batas
13102-KWC-305 dilampaui.
servis telah
berubah
may change ta