Buku Pedoman Reparasi Beat PDF

DAFTAR ISI
CARA MEMAKAI BUKU INI

KETERANGAN UMUM 1
Buku Pedoman Reparasi ini menguraikan prosedur servis RANGKA / BODY PANELS
untuk skuter HONDA BEAT. / SISTEM PEMBUANGA
PEMBUANGAN
N GAS
2
Ikuti petunjuk pada Jadwal Perawatan (Bab 3) untuk mem-
pertahankan skuter pada kondisi operasional puncak. PERAWATAN 3
Adalah sangat penting untuk menjalankan perawatan
berkala 1 dan 2 pada waktunya. Servis ini mengadakan
SISTEM PELUMASAN 4
penyesuaian terhadap keausan awal yang terjadi dalam K
A
masa pemakaian mula. R
E
SISTEM BAHAN BAKAR 5
G
Bab 1 dan 3 berlaku untuk skuter secara keseluruhan. G
Bab 2 menggambarkan prosedur untuk pelepasan/pema-
N
E PENURUNAN / PEMASANGAN MESIN 6
sangan komponen yang mungkin diperlukan untuk men- P
N
jalankan servis yang diuraikan pada bab-bab
bab-bab berikutnya. A
T CYLINDER HEAD/VAL
HEAD/VALVES/CYLINDER/PISTON
VES/CYLINDER/PISTON 7
Bab 4 sampai dengan 17 menguraikan bagian-bagian A
L
skuter yang dikelompokkan menurut lokasi. A
R KICKSTARTER / DRIVE PULLEY /
E DRIVEN PULLEY / CLUTCH
8
Carilah bab yang Anda inginkan pada halaman ini, kemu- P
dian bacalah daftar isi pada halaman pertama dari bab &
itu. N
I
S FINAL REDUCTION 9
E
Kebanyakan bab dimulai dengan gambar susunan atau M
gambar sistem, keterangan servis dan cara mencari CRANKCASE / CRANKSHAFT 10
penyebab kesukaran untuk bab itu. Halaman-halaman
berikutnya memberikan prosedur servis secara mendetil.
RODA DEPAN / SUSPENSI / KEMUDI 11
Jika Anda tidak mengetahui sumber penyebab kesukaran, A
bacalah bab 19, TROUBLESHOOTING
TROUBLESHOOTING.. K
G
N RODA BELAKANG / SUSPENSI 12
A
R
SISTEM REM 13
Semua keterangan, gambar, petunjuk dan spesiﬁ- BATERAI / SISTEM PENGISIAN / ALTERNATOR
ALTERNATOR 14
kasi di dalam publikasi ini berdasarkan data-data
produk terakhir yang tersedia pada waktu persi-
apan untuk pencetakan. N SISTEM PENGAPIAN 15
A
K
I
PT Astra
Astra Honda Motor berhak membuat perubahan R
pada setiap waktu tanpa pemberitahuan dan tanpa T SISTEM STARTER LISTRIK 16
S
I
ikatan apapun. L
E
K LAMPU / METER / SAKLAR-SAKLAR 17
Dilarang mengutip atau mencetak ulang bagian dari
penerbitan ini tanpa ijin tertulis penerbit.
DIAGRAM LISTRIK 18
Buku Pedoman ini ditulis untuk orang yang te-
lah memiliki pengetahuan dasar perawatan skuter
Honda. TROUBLE SHOOTING 19
CATATAN PENTING UNTUK KEAMANAN
Di dalam buku ini tidak dimuat pembahasan secara mendetail mengenai prosedur kerja bengkel
standar,, prinsip - prinsip keamanan serta pekerjaan servis standar.
standar standar. Adalah penting untuk
mengetahui bahwa buku ini hanya memuat beberapa peringatan terhadap cara-cara servis
tertentu yang dapat menimbulkan KECELAKAAN BADANIAH kepada mekanik atau dapat
merusak kendaraan atau menyebabkannya tidak aman untuk dikendarai.
Harap dimengerti
dimengerti bahwa peringatan-peringatan
peringatan-peringatan ini tidak
tidak dapat
dapat meliputi
meliputi semua cara-cara pelak-
sanaan servis, baik yang dianjurkan
dianjurkan oleh Honda maupun
maupun yang tidak, ataupun akibat-akibat
akibat-akibat yang
mungkin berbahaya yang timbul dari setiap cara pelaksanaan servis, juga bahwa Honda tidak
dapat menyelidiki semua cara - cara tersebut.
Setiap orang yang menggunakan prosedur kerja ataupun tool, balk yang dianjurkan oleh Honda
maupun tidak, harus meyakinkan dirinya sendiri dengan pasti bahwa keamanan pribadi maupun
keamanan kendaraan tidak terancam oleh cara pelaksanaan servis ataupun tool yang dipilih.
1. KETERANGAN UMUM
SPESIFIKASI RODA BELAKANG/

PERATURAN SERVIS
SERVICE RULES ...................................
.....................
???????????
?????????????????????? ..............
??????????? 1
1-2
-21-2 SUSPENSI
REAR .......................................
..................................................
WHEEL/SUSPENSION ........... 1-7
SPECIFICATIONS ?????????????????????
????????????????????? 1-7
IDENTIFIKASI MODEL ..................................
....................
MODEL IDENTIFICATION ..............
?????????????
?????????? ??? 1-2 1-2 SPESIFIKASI SISTEM REM .......................
....................... 1-7
BRAKE SYSTEM SPECIFICATIONS ????? 1-7
SPESIFIKASI UMUM .....................................
.....................................
GENERAL SPECIFICATIONS??????????? 1-41-4 SPESIFIKASI B ATERAI/SISTEM
PENGISIA
PENGISIAN/AL
N/ALTERNA
TERNATOR
BATTERY/CHARGING TOR .....
..........
SYSTEM/ ..........
..........
........
... 1-8
SPESIFIKAS
SPESIFIKASII SISTEM
LUBRICATION PELUMASAN .....
PELUMASAN
SYSTEM .........
......
.. 1-5 ALTERNATOR SPECIFICATIONS ?????? 1-8
SPECIFICATIONS ?????????????????????
????????????????????? 1-5 SPESIFIKASI SISTEM PENGAPIAN.......... 1-8
SPESIFIKAS
SPESIFIKASII SISTEM BAHAN BAKAR ....
.......
... 1-5 IGNITION SYSTEM SPECIFICATIONS ?? 1-8
FUEL SYSTEM SPECIFICATIONS???????
SPECIFICATIONS??????? 1-5 SPESIFIKASI SISTEM STARTER
SPESIFIKASI CYLINDER HEAD/VALVES.... 1-5 LISTRIK.....................................
LISTRIK.....................
ELECTRIC STARTER SYSTEM ..................................
.................. 1-8
CYLINDER HEAD/VALVES SPECIFICATION ??????????????????????
?????????????????????? 1-8
SPECIFICATIONS
SPESIFIKASI ????????????????????? 1-5
?????????????????????
CYLINDER/PISTON................ 1-6 SPESIFIKASI LAMPU/METER/
LIGHTS/METERS/SWITCHES
SAKLAR.......................................
SAKLAR......................................................
............... 1-8
SPECIFICATION ??????????????????????
?????????????????????? 1-8
SPESIFIKASI KICKSTARTER/DRIVE
CYLINDER/PISTON SPECIFICATIONS ?? 1-6
PULLEY/DRIV
PULLEY/DRIVEN
EN PULLEY/CL
PULLEY/CLUTCH
UTCH .....
..........
.......
.. 1-6 NILAI
NILAI TORSI STANDARD
STANDARD .....
..........
..........
..........
..........
....... 1-9
KICKSTARTER/DRIVE PULLEY/DRIVEN STANDARD TORQUE VALUES ????????? 1-9
PULLEY/CLUTCH
SPESIFIKASI FINAL SPECIFICATIONS
FINAL ???
REDUCTION........... 1-6
REDUCTION................
..... 1-6 NILAI TORSI
TORSI MESIN & RANGKA............... 1-9
ENGINE & FRAME TORQUE VALUES ?? 1-9
FINAL REDUCTION
SPESIFIKASI SPECIFICATIONS?? 1-6
CRANKCASE/ TITIK-TITIK PELUMASAN &
CRANKSHAFT...............................................
CRANKSHAFT............................................... 1-6 LUBRICATION & SEAL POINTS ???????
PERAPATAN ......................................
................... 1-12
.........................
...... 1-12
CRANKCASE/CRANKSHAFT
SPECIFICATIONS
SPESIFIKASI RODA ?????????????????????
??????????????
DEPAN/ ??????? 1-6 PERLETAKA
PERLETAKAN
CABLE N KABEL
& HARNESS & HARNESS.......
HAR
ROUTING NESS.......
???????? 1-141-14
SUSPENSI/ KEMUDI .....................................
..................................... 1-7
FRONT WHEEL/SUSPENSION/STEERING SISTEM-SIS
SISTEM-SISTEM
EMISSION TEM PENGATURAN
PENGAT
CONTROL URAN EMISI..
SYSTEMS??????? 1-241-24
SPECIFICATIONS ?????????????????????
????????????????????? 1-7
1-1
KETERANGAN UMUM
SERVICE RULES
GENERALINFORMATION
PERATURAN SERVIS
1. Use genuine Honda or Honda-recommended
Honda-recommended parts and lubricants lubricants or their equivalents.
equivalents. Parts that don’t meet
meet Honda’s design specifications
specifications
1. Pakailah parts
Pakailah
may cause parts dan
damage dan pelumas
to the scooter.asli Honda atau yang direkomendasikan oleh Honda atau sejenisnya. Parts yang Parts yang tidak memenuhi
2. spesifikasi
Use the specialrancangan
special Honda
tools designed fordapat mengakibatkan
this product kerusakan
to avoid damage pada skuter.
and incorrect assembly.
assembly.
2.
3. Pakailah
Use special
only metric tools
toolstools yang
tools yang
when telah dirancang
servicing the scooter. untuk
Metricproduk ini untuk
bolts, nuts menghindari
and screws
screw kerusakan dan
s are not interchangeable
interchangeable kesalahan
with pada pemasangan.
English fasteners.
3.
4. Hanya
Install new
newpergunakan metric
gaskets, O-rings, tools
tools
cotter
cotte ketika
r pins, and menservis
and lock plates
plates whenskuter. Baut, mur dan sekrup metric tidak dapat dipertukarkan dengan
reassembling.
5. When tightening
pengencang bolts or
sistem nuts, begin with the
Inggris. the larger diameter or inner bolt first.
first. Then tighten to the specified
specified torque diagonally in incremental
incremental
4. steps unless a gasket
Pasanglah particular sequence
, O-ring is specified.
, cotter pin,
pin, dan lock plates baru
plates baru ketika perakitan kembali.
6.
5. Clean
Ketika parts in cleaning
mengencangkan
mengenc solvent
angkan bautupon
ataudisassembly.
disas sembly.
mur, Lubricate
Lubrica
mulailah
mulaila te any sliding
h dengan slidi
bautngdengan
surfaces
denga before reassembly.
n diameter yang lebih besar atau
atau baut di sebelah
sebelah dalam
7. After reassembly,
reasse mbly, check all parts for proper installation
inst allation and
and operation.
dulu. Kemudian kencangkan dengan torsi pengencangan yang telah ditentukan secara bersilang dalam langkah-langkah
8. Route all electrical
peningkatan wiresbila
kecuali as shown from page 1-14,
telah ditentukan urutan Cable and Harness Routing.
tertentu.
6. Bersihkan parts
Bersihkan parts yang yang telah dilepaskan dalam larutan pembersih. Lumasi semua permukaan luncur sebelum perakitan kembali.
7. Setelah perakitan
perakitan kembali,
kembali, periksalah
periksalah semua bagian terhadap pemasangan dan dan pengoperasian yang benar.
MODEL IDENTIFICATION
8. Alurkan semua
semua kawat listrik sepertiseperti diperlihatkan
diperlihatkan mulai halaman
halaman 1-14, Perletakan Kabel dan Harness.
IDENTIFIKASI MODEL
1-2
KETERANGAN UMUM
The frame
Nomor serial
seri numberdicetak
rangka is stamped on the
pada seat stay
seat stay as(penahan
shown. sadel) seperti
NOMOR SERI RANGKA
diperlihatkan.
The engine
Nomor seriserial
mesin number is stamped
dicetak pada sisionkiri
thebawah
lower left
dariside of the crankcase.
crankcase (bak
crankcase (bak mesin).
NOMOR SERI MESIN
The carburetor
Nomor identification
identifikasi karburator number is pada
dicetak stamped
sision
kirithe leftbadan
dari side ofkarburator.
the carburetor
body. NOMOR IDENTIFIKASI KARBURATOR
1-3
KETERANGAN UMUM
GENERAL SPECIFICATIONS
SPESIFIKASI UMUM
BAGIAN SPESIFIKASI
ITEM SPECIFICATIONS
DIMENSI Panjang menyeluruh 1.859 mm
DIMENSIONS Overall length 1,850 mm (72.8 in)
Lebar menyeluruh 676 mm
Overall width 676 mm (26.6 in)
Tinggi menyeluruh 1.053 mm
Overall height
Jarak sumbu roda 1.240 mm 1,040 mm (40.9 in)
W h e el b a s e
Tinggi tempat duduk 737 mm 1,240 mm (48.8 in)
S e at h e ig h
Tinggi pijakan kakit 260 mm 7 37 mm (29.0 in)
Footpeterendah
Jarak g height ke tanah 135 mm 260 mm (10.2 in)
G r o u n d c l e a
Berat motor siap pakai r an c e 89,2 kg 1 35 mm (5.3 in)
RANGKA Curb rangka
Jenis weight Jenis under bone 89.2 (tulang
kg (196.bawah)
7 lbs)
FRAME Frame typdepan
Suspensi e Garpu teleskopik Under bone type
Jarak
Front pergerakan
suspension poros depan 80,5 mm Telescopic fork
Suspensi
Front axle travelbelakang Unit swing (unit
80berayun)
.5 mm (3.17 in)
Jarak
Rear spergerakan
uspension poros belakang 75,0 mm Unit swing
Ukuran
Rear axlban e trav depan
el 80/90-14M/C 40 75.0 mm (2.95 in)
Ukuran ban
Front tire size belakang 90/90-14M/C 46P
80/90 - 14M/C40P
Merek
Rear tirban e size (Depan/Belakang)
(Depan/Belakang) SRI FT235 90/90 - 14M/C46P
Rem
Tire bdepan
rand SRI (Front/Rem
Rear) cakram hidraulik
FT235
Rem belakang Mekanis, mendahului-mengikuti
mendahului-mengikuti
Front brake Hydraulic disc brake
Sudut caster 26° 30′
Rear brake Mechanical leading trailing
Panjang trail 79,0 mm
Caster angle 26°30’
Kapasitas tangki bahan bakar 3,3 liter
Trail length 79.0 mm (3.11 in)
MESIN Diameter dan langkah 50,0 x 55,0 mm
Fuel tank capacity 3 3.3 liter (0.87 US gal, 0.73 lmp gal)
Volume langkah 108,0 cm
ENGINE Bore and strokekompressi
Perbandingan 9,2 : 1 50.0 x 55.0 mm (1.97 x 2.17 in)
D is p l a c e m en
Peralatan penggerak klept 1 08.0 cm3 (6.59
2 klep, SOHC digerakkan cu-in)
rantai tunggal
C o m p r e s si o n ra ti
Klep masuk membuka ] pada peng- o 9 .
10° BTDC (sebelum TMA)5 : 1
Valve train menutup ] angkatan 35° ABDC (setelah 2 valveTMB), single chain driven SOHC
Intakbuang
Klep e valve membukao]p1enmm s at 1 mm (0.04 i25
n) °l BBDC
ift 1 0 ° BTDC
(sebelum TMB)
menutup c]loses at 1 mm (0.04 i0n°) liATDC
ft 35° ABDC
(setelah TMA)
Sistem
Exhauspelumasan
t valve opens at 1 mm (0.04 iDi
n) bawah
lift 2 5 ° BBDC
tekanan paksaan dgn bak oli basah
Jenis pompa oli closes at 1 mm (0.04 iTrochoid
n) lift 0° ATDC
Sistem pendinginan
Lubrication system Pendinginan udara Forceddenganpressurepaksaan
and wet sump
Saringan
Oil pump udara type Saringan kertas Trochoid
Berat
Coolinkosong
g system mesin 24,9 kg Forced air cooled
KARBURATOR Jenis
Air filkarburator
tration CV (constant V velocity)
iscous paper element
Diameter
Engine dry throttle
weight 22 mm atau ekuivalennya
24.9 kg (54.9 lbs)
PERALATAN
CARBURETOR Sistem
Carburekopeling
tor type Kopeling kering, CVjenis(conssentrifugal
tant velocityotomatis
)
PENGGERAK Throttle bore 2,68 : 1 - 0,85 : 1
22 mm (0.9 in) or equivalent
DRIVE TRAIN Perbandingan
Clutch system drive belt (sabuk penggerak) Dry, automatic centrifugal clutch
Reduksi akhir
Drive belt ratio 10,625 (51/18 2x.645/12)
8 : 1 - 0.85 : 1
KELISTRIKAN Sistem pengapian
Final reduction DC – CDI 10.625 (51/18 x 45/12)
ELECTRICAL Sistem
Ignitionstartersystem Kickstarter dan DC motor
-CDI starter listrik
Sistem pengisian Alternator dengan output fase tunggal
Starting system Kickstarter with electric starter motor
Regulator/rectifier Fase tunggal/dibuka oleh SCR, pembetulan setengah
Charging system Single phase output alternator
gelombang
Regulator/rectifier SCR shorted/single phase, half wave rectification
Sistem penerangan Alternator
Lighting system Alternator
1-4
KETERANGAN UMUM
LUBRICATION SYSTEM
SPESIFIKASI SISTEM SPECIFICATIONS
PELUMASAN Satuan: mm
BAGIAN STANDARD BATAS SERVIS Unit: mm (in)
Kapasitas oli Pada penggantian oli 0,7 liter - SERVICE
mesin ITEM
Pada pembongkaran mesin 0,8 liter STANDARD - LIMIT
Oli mesin
Engine oil yang dianjurkan
capacity After drainingFederal Oil0.7 Supreme
liter (0.7Flick atau
US qt, 0.6oli
lmp qt) –
mesin
After disassembly 4 tak sejenis dengan klasifikasi
0.8 liter (0.8 US qt, 0.7 lmp qt) - –
Recommended engine oil API serviceHonda
SG, "4-stroke motorcycle oil" or equivalent
Viskositas: motor
SAE 10W-30
oil JASO MB
Rotor pompa Jarak renggang pada ujung 0,15 API service classification: SG or0,20
higher
oli rotor (except oils labeled as energy conserving on –
Jarak renggang antara rotor 0,15 – 0,21the circular API service label) 0,35
dan rumah JASO T 903 standard: MB
Jarak renggang ke samping 0,05 – 0,10Viscosity: SAE 10W-30 0,12
Oil pump rotor rotor pompa Tip clearance 0.15 (0.006) 0.20 (0.008)
Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014)
Side clearance 0.05 – 0.10 (0.002 – 0.004) 0.12 (0.005)
SPESIFIKASI SISTEM BAHAN BAKAR

FUEL SYSTEMBAGIAN
SPECIFICATIONS SPESIFIKASI
Nomor identifikasi karburator AVK2CH
Main jet ITEM # 100
SPECIFICATIONS
Slow jet
Carburetor identification number # 35
AVK2CH
Tahanan
Main jet listrik SE thermal valve 3,2 – 5,6 #100
Ω (20°C)
Float level (tinggi permukaan pelampung)
Slow jet 13,0 #35
mm
Pembukaan
SE thermal valveawal pilot screw
resistance Lihat
3.2 – 5.6 Ω (25°5-20
halaman C/77°F)
–1
Putaran
Float levelstasioner 1.700 ±13.0
100mmmenit
(0.51 (rpm)
in)
Vakuum
Pilot screwyang ditentukan
initial opening untuk PAIR control valve 60 kPa (450
See pagemmHg)
5-20
Jarak
Engine idle speed putaran gas tangan
main bebas 1,700 2±
– 100
6 mmmin-1 (rpm)
PAIR control valve specified vacuum 60 kPa (450 mmHg)
Throttle grip free play 2 – 6 mm (0.1 – 0.2 in)
SPESIFIKASI CYLINDER HEAD/VALVES Satuan: mm

CYLINDER HEAD/VALVES
BAGIAN SPECIFICATIONS
STANDARD BAGIAN
Kompressi cylinder 1314 kPa (13,4 kgf/cm2, 191 -
Unit: mm (in)
psi) pada 520 min -1(rpm)
SERVICE
Perubahan bentuk melengkung
ITEMpada cylinder head -
STANDARD 0,05
LIMIT
Rocker arm D.D. rocker arm IN/EX 10,000 – 10,015 2 10,04
Cylinder compression 1314 kPa (13.4 kgf/cm , 191 psi) at 520 min -1
(masuk/ –
(rpm)
buang)
Cylinder head warpage – 0.05 (0.002)
D.L. rocker arm shaft IN/EX 9,972 – 9,987 9,91
Rocker arm Rocker arm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) 10.04 (0.395)
Jarak renggang arm ke shaft IN/EX 0,013 – 0,043 0,08
Rocker arm shaft O.D. IN/EX 9.972 – 9.987 (0.3926 – 0.3932) 9.91 (0.390)
Camshaft Tinggi cam lobe (bubungan) IN 32,4006 – 32,6406 32,37
Arm to shaft clearance IN/EX 0.013 – 0.043 (0.0005 – 0.0017) 0.08 (0.003)
EX 32,0064 – 32,2464 31,97
Camshaft
Valve, ValveCam lobe height
clearance (jarak renggang IN IN 32.4006 – 32.6406 (1.27561 – 1.28506) - 32.37 (1.274)
0,14 ± 0,02
valve guide klep) EX 32.0064 – 32.2464 (1.26009 – 1.26954) 31.97 (1.259)
EX 0,14 ± 0,02 -
Valve, valve Valve clearance IN 0.14 ± 0.02 (0.006 ± 0.001) –
D.L. valve stem IN 4,975 – 4,990 4,90
guide EX 0.14 ± 0.02 (0.006 ± 0.001) –
EX 4,955 – 4,970 4,90
Valve stem O.D. IN 4.975 – 4.990 (0.1959 – 0.1965) 4.90 (0.193)
D.D. valve guide IN/EX 5,000 – 5,012 5,03
EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 (0.193)
Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.03 (0.198)
Jarak renggang stem-ke-guide IN 0,010 – 0,037 0,08
Stem-to-guide clearance IN 0.010 – 0.037 (0.0004 – 0.0015) 0.08 (0.003)
EX 0,030 – 0,057 0,10
EX 0.030 – 0.057 (0.0012 – 0.0022) 0.10 (0.004)
Proyeksi valve guide di atas IN/EX 9,1 – 9,3 -
Valve guide projection above IN/EX 9.1 – 9.3 (0.36 – 0.37) –
cylinder head
cylinder head
Lebar valve seat IN/EX 1,0 1,5
Valve seat width IN/EX 1.0 (0.04) 1.5 (0.06)
Panjang bebas valve spring IN/EX 29,78 29,11
Valve spring free length IN/EX 29.78 (1.172) 29.11 (1.146)
1-5
KETERANGAN UMUM
CYLINDER/PISTON SPECIFICATIONS
SPESIFIKASI CYLINDER/PISTON Satuan: mm
BAGIAN STANDARD BATAS SERVISUnit: mm (in)
Cylinder D.D. 50,000 – 50,015 50,10 SERVICE
ITEM STANDARD
Kelonjongan - 0,05 LIMIT
Cylinder I.D.
Ketirusan 50.005 – 50.015
- (1.9687 – 1.9691)
0,05 50.10 (1.972)
Out-of-round
Perubahan bentuk melengkung - – 0,05 0.05 (0.002)
Piston, piston Taper
D.L. piston 49,970 – 49,990 – 49,90 0.05 (0.002)
rings, piston Warpage – 0.05 (0.002)
pin
Piston, piston Piston
Titik O.D.
pengukuran D.L. piston 49.970
6,0 mm– dari
49.990 (1.9673 – 1.9681)
bagian - 49.95 (1.967)
rings, piston pin Piston O.D. measurement point 6.0 (0.24)
bawah from bottom of skirt
piston –
Piston
D.D. lubangpin bore I.D.pin
piston 13.002
13,002––13.008
13,008(0.5119 – 0.5121)
13,04 13.04 (0.513)
Piston
D.L. pistonpinpin
O.D. 12.994
12,994––13.000
13,000(0.5116 – 0.5118)
12,96 12.96 (0.510)
Piston-to-piston
Jarak renggang antarapin clearance 0.002
0,002––0.014
0,014(0.0001 – 0.0006)0,02 0.02 (0.001)
piston-ke-piston pin
Piston ring-to-ring Top 0.015 – 0.050 (0.0006 – 0.0020) 0.08 (0.003)
groove
Jarak clearance
renggang Ring paling atas
Second 0,015––0.050
0.015 0,050(0.0006 – 0.0020)0,08 0.08 (0.003)
piston
Pistonring-ke-alurnya
ring end gap Ring
Top kedua 0,015
0.10 – 0,050
– 0.25 (0.004 – 0.0020) 0,08 0.45 (0.018)
Celah pada ujung Ring paling atas
Second 0,10––0.25
0.10 0,25(0.004 – 0.0020) 0,45 0.45 (0.018)
piston ring Ring kedua
Oil (side rail) 0,10––0.70
0.20 0,25(0.008 – 0.028) 0,45 –
Cylinder-to-piston clearance Ring oli (side 0,20 –– 0,70
0.015 0.045 (0.0006 – 0.0018) - 0.09 (0.004)
Connecting rod small end I.D. rail) 13.010 – 13.028 (0.5122 – 0.5129) 13.05 (0.514)
Jarak renggang
Connecting antara cylinder-ke-piston
rod-to-piston pin clearance 0,015––0.034
0.010 0,045(0.0004 – 0.0013)0,09 0.05 (0.002)
D.D. kepala kecil connecting rod 13,010 – 13,028 13,05
Jarak renggang antara connecting rod-ke-piston pin 0,010 – 0,034 0,05
KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH

SPECIFICATIONS
SPESIFIKASI KICKSTARTER/DRIVE PULLEY/ Unit: mm (in)
SERVICE
DRIVEN PULLEY/CLUTCH
ITEM STANDARD Satuan:
LIMIT mm
Drive belt width BAGIAN STANDARD
18.5 (0.73) BATAS SERVIS
17.5 (0.69)
Lebar drive
Movable belt
drive face Bushing I.D. 18,5
22.035 – 22.085 (0.8675 17,5
– 0.8695) 22.11 (0.871)
Movable drive face D.D.O.D.
Boss bushing 22,035
22.010– –22,085
22.025 (0.8665 22,11
– 0.8671) 21.98 (0.865)
D.L. boss
Weight roller O.D. 22,010
15.92 –– 22,025 21,98
16.08 (0.627 – 0.633) 15.3 (0.60)
Clutch D.L. weight
Lining thicknessroller 15,92 – 16,08 – 15,3 2.0 (0.08)
Clutch Ketebalan
Clutch lapisan kanvas
outer I.D. -
112.0 – 112.2 2,0
(4.41 – 4.42) 112.5 (4.43)
Driven pulley D.D. clutch outer
Face spring free length 112,0 – 112,2
124.2 (4.89) 112,5 121.4 (4.78)
Driven pulley Driven face O.D. face spring
Panjang bebas 124,2
33.965 – 33.985 (1.3372 121,4
– 1.3380) 33.94 (1.336)
D.L. driven
Movable face
driven face I.D. 33,965
34.000– –33,985
34.025 (1.3386 33,94
– 1.3396) 34.06 (1.341)
D.D. movable driven face 34,000 – 34,025 34,06
FINAL REDUCTION SPECIFICATIONS

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

BAGIAN SPECIFICATIONS
STANDARD BATAS SERVIS
Crankshaft Jarak renggang ke samping connecting 0,10 - 0,35 0,55
rod Unit: mm (in)
Jarak renggang SERVICE
ITEMradial connecting rod 0 – 0,012 STANDARD 0,05
Keolengan - 0,10 LIMIT
Crankshaft Connecting rod side clearance 0.10 – 0.35 (0.004 – 0.014) 0.55 (0.022)
Connecting rod radial clearance 0 – 0.012 (0 – 0.0005) 0.05 (0.022)
Runout – 0.10 (0.004)
1-6
KETERANGAN UMUM
FRONT WHEEL/SUSPENSION/STEERING
SPESIFIKASI SPECIFICATIONS
RODA DEPAN/SUSPENSI/KEMUDI Satuan: mm
Kedalaman minimum alur telapak ban - Sampai ke indikator SERVICE
ITEM 2 STANDARD
Tekanan udara Pengendara saja 200 kPa (2,00 kgf/cm , 29 psi) - LIMIT
2
ban (dingin)
Minimum Pengendara dan
tire tread depth 200 kPa (2,00 kgf/cm , 29 psi) – - To the indicator
Cold tire pressure pembonceng
Driver only 200 kPa (2.00 kgf/cm2, 29 psi) –
Keolengan axle (poros roda) Driver and passenger - kPa (2.00 kgf/cm2, 290,20
200 psi) –
Keolengan
Axle runout pelek Radial - – 2,0 0.2 (0.01)
roda
Wheel rim runout Aksial
Radial - – 2,0 2.0 (0.08)
Fork (garpu) Panjang bebas pegas
Axial 311,3 – 305,1 2.0 (0.08)
Fork Keolengan
Spring tabung
free length - (12.26)
311.3 0,20 305.1 (12.01)
Minyak garpu
Pipe runoutyang Minyak sokbreker – - 0.2 (0.01)
dianjurkan
Recommended fluid Fork fluid –
Tinggi permukaan
Fluid level 50 50 (2.0) - –
minyak
Fluid capacity 75 ± 1 cm 3
Kapasitas minyak 75 ± 1 cm

3
- –
(2.5 ± 0.03 US oz, 2.6 ± 0.04 Imp oz)
REAR WHEEL/SUSPENSION SPECIFICATIONS

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

SPESIFIKASI SISTEM REM Satuan:Unit:
mm mm (in)
BAGIAN
ITEM STANDARDSTANDARD BATAS SERVIS SERVICE
LIMIT
Jarak main bebas rear brake lever (handel rem blk.) 10 - 20 -
Rear brake lever free play 10 – 20 (0.4 – 0.8) –
D.D. rear brake drum ( tromol rem belakang) 130,0 131,0
Rear brake drum I.D. 130.0 (5.12) 131.0 (5.16)
Minyak rem yang dianjurkan DOT 3 atau 4 -
Specified brake fluid DOT 3 or 4 –
Brake disc Ketebalan 3,3 – 3,7 3,0
Brake disc Thickness 3.3 – 3.7 (0.13 – 0.15) 3.0 (0.12)
(cakram rem) Perubahan bentuk melengkung - 0,10
Warpage – 0.10 (0.004)
Master cylinder D.D. Cylinder 11,000 – 11,043 11,055
Master cylinder Cylinder I.D. 11.000 – 11.043 (0.4331 – 0.4348) 11.055 (0.4352)
D.L. Piston 10,957 – 10,984 10,945
Piston O.D. 10.957 – 10.984 (0.4314 – 0.4324) 10.945 (0.4309)
Caliper D.D. Cylinder 32,030 – 32,080 32,090
Caliper Cylinder I.D. 32.030 – 32.080 (1.2610 – 1.2630) 32.090 (1.2634)
D.L. Piston 31,948 – 31,998 31,94
Piston O.D. 31.948 – 31.998 (1.2578 – 1.2598) 31.94 (1.257)
1-7
KETERANGAN UMUM
BATTERY/CHARGING SYSTEM/ALTERNATOR
SPESIFIKASI BATERAI/SISTEM SPECIFICATIONS
PENGISIAN/ALTERNATOR
BAGIAN SPESIFIKASI
ITEM SPECIFICATIONS
Baterai Kapasitas 12 V – 3,5 Ah
Battery Capacity 12 V – 3.5 Ah
Kebocoran arus listrik maksimum 0,5 mA
Current leakage 0.5 mA max.
Voltase Bermuatan penuh Di atas 12,8 V
Voltage Fully charged Above 12.8 V
Perlu diisi listrik kembali Di bawah 12,3 V
Needs charging Below 12.3 V
Arus pengisian Normal 0,4 A / 5-10 jam
Charging current Normal 0.4 A/5 – 10 h
Cepat 3,0 A / 0,5 jam
Quick 3.0 A/0.5 h -1
Alternator Kapasitas 0,140 kW / 5.000 menit (rpm)
Alternator Capacity 0.140 kW/5,000 min-1 (rpm)
SPESIFIKASI
IGNITION SISTEM
SYSTEM PENGAPIAN
SPECIFICATIONS
BAGIAN SPESIFIKASI
Busi StandardITEM CPR 8EA - 9 (NGK), U24EPR9 (DENSO)
SPECIFICATIONS
Spark plug Untuk pengendaraan
Standard lama pada CPR CPR
9EA 8EA
– 9 (NGK)
– 9 (NGK)
kecepatan tinggi
For extended high speed riding CPR 9EA – 9 (NGK)
Jarak renggang busi 0,80 – 0,90 mm
Spark plug gap 0.80 – 0.90 mm (0.031 – 0.035 in)
Voltase puncak ignition coil minimum 100 V
Ignition coil peak voltage 100 V minimum
Voltase puncak ignition pulse generator minimum 0,7 V
Ignition pulse generator peak voltage 0.7 V minimum
Ignition timing (pengaturan waktu pengapian) 14° sebelum TMA pada putaran stasioner
Ignition timing 14° BTDC at idle speed
ELECTRIC STARTER
SPESIFIKASI SYSTEM
STARTER SPECIFICATION
LISTRIK Satuan: mm
Panjang sikat starter motor 7,0 3,5 SERVICE
ITEM STANDARD
LIMIT
Starter motor brush length 7.0 (0.28) 3.5 (0.14)
SPESIFIKASI LAMPU2 / METER2 / SAKELAR2

BAGIAN SPECIFICATION
SPESIFIKASI
Bola lampu Lampu besar 12 V – 32/32 W
Lampu senja
ITEM 12 V – 3,4 W
SPECIFICATIONS
Bulbs Lampu belakang/rem
Headlight 12 V12
–V 5/18 W W
– 32/32
Lampu seinlight
Position depan 12 V –1210VW– 3.4
x 2W
Lampu sein belakang
Tail/brake light 12 V –1210VW x2 W
– 5/18
Lampu penerangan instrumen
Front turn signal light 12 V –
12 V – 10x W
1,7 W 2 x2
Indikator lampu
Rear turn jauh
signal light 12 V12–V1,7
– 10WW x 2
Indikator lampu sein
Instrument light 12 V – 3,4
12 V – 1.7WW x 2
Sekring Sekring
Highutama
beam indicator 15 12
AX 1
V – 1.7 W
Sekring
Turn tambahan
signal indicator 10 12
AX V 1– 3.4 W
Fuse Main fuse 15 A x 1
Sub fuse 10 A x 1
1-8
KETERANGAN UMUM
STANDARD
NILAI TORSITORQUE VALUES
STANDARD
JENIS TORSI JENIS TORSI
TORQUE TORQUE
PENGIKAT TYPE
FASTENER N.m (kgf.m; lbf.ft) PENGIKATFASTENER TYPE N.m (kgf.m; lbf.ft)
N·m (kgf·m, lbf·ft) N·m (kgf·m, lbf·ft)
Baut dan mur hex 5 mm 5,2 (0,5; 3,8) Sekrup 5 mm 4,2 (0,4; 3,1)
5 mm hex bolt and nut 5.2 (0.5, 3.8) 5 mm screw 4.2 (0.4, 3.1)
Baut dan mur hex 6 mm 10 (1,0; 7) Sekrup 6 mm 9,0 (0,9; 6,6)
6 mm hex bolt
(termasuk bautand nut SH)
flens 10 (1.0, Baut
7) flens 66mm
mm screw 12 (1,2; 9) 9.0 (0.9, 6.6)
Baut dan mur hex bolt)
(Include SH flange 8 mm 22 (2,2; 16) (termasuk NSHF)flange
6 mm bolt
dan mur 12 (1.2, 9)
8 mmdan
Baut hex mur
bolt and
hex nut
10 mm 22
34 (3,5; 25) (2.2, Baut flens 8 mm dan mur and nut
16) (Include NSHF) 27 (2,8; 20)
10 mm
Baut hexmur
dan bolthex
and12
nutmm 34 (3.5, 25)
54 (5,5; 40) 8 mm
Baut flens 10 mm flange bolt and nut
dan mur 39 (4,0; 29) 27 (2.8, 20)
12 mm hex bolt and nut 54 (5.5, 40) 10 mm flange bolt and nut 39 (4.0, 29)
TORSI PENGENCANGAN MESIN & RANGKA

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

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

Oil pump
SISTEM mounting
BAHAN bolt
BAKAR 2 6 10 (1.0, 7)
JUM- DIAMETER TORSI
FUEL SYSTEM
Inlet pipe band screw ITEM 2 Q'TY 5THREAD 2 (0,2; TORQUE
1,5) REMARKS
SE thermal valve body screw 2 DIA.
5 (mm) N·m (kgf·m,
3,4 (0,4; 2,5) lbf·ft)
Inletthermal
SE pipe band screw
valve setting plate screw 1 2 4 5 2 (0.2,
2,1 (0,2; 1,5) 1.5)
SE thermal
Vacuum valve body
chamber screw
cover screw 2 2 4 5 3.41,5)
2,1 (0,2; (0.4, 2.5)
SE thermal
Slow jet valve setting plate screw 1 1 - 4 2.11,1)
1,5 (0,2; (0.2, 1.5)
Main
Vacuum jet chamber cover screw 1 2 - 4 2,1 (0,2;
2.11,5)
(0.2, 1.5)
Needle
Slow jetjet holder 1 1 - – 2,5 (0,3;
1.51,8)
(0.2, 1.1)
Float
Main chamber
jet screw 3 1 4 – 2,1 (0,2;
2.11,5)
(0.2, 1.5)
Needle jet holderdrain screw
Float chamber 1 1 - – 1,5 (0,2; 1,1)
2.5 (0.3, 1.8)
PAIR check valve
Float chamber screw cover screw 2 3 4 4 2,1 (0,2;
2.11,5)
(0.2, 1.5)
Fuel auto valve lock
Float chamber drain screwnut 1 1 16 – 22,5 (2,3;
1.5 17)
(0.2, 1.1)
PAIR check valve cover screw 2 4 2.1 (0.2, 1.5)
Fuel auto valve lock nut
PELEPASAN/PEMASANGAN MESIN 1 16 22.5 (2.3, 17)
JUM- DIAMETER TORSI
ENGINE REMOVAL/INSTALLATION
Engine hanger link nut (sisi mesin) 1 10THREAD 49 (5,0;TORQUE
36)
ITEM Q'TY REMARKS
Engine hanger link nut (Engine side) 1 10 49 (5.0, 36)
1-9
KETERANGAN UMUM
CYLINDER
CYLINDER HEAD/VALVES/CYLINDER/PISTON
HEAD/VALVES/CYLINDER/PISTON
JUM- DIAMETER
THREAD TORSI TORQUE
ITEM
BAGIAN LAH Q'TY ULIR (mm) N.m (kgf.m; lbf.ft) lbf·ft) REMARKS
CATATAN
DIA. (mm) N·m (kgf·m,
Intake shroudmounting
Intake shroud mountingscrew
screw 3 3 5 5 0,8 (0,1;
0.80,6)
(0.1, 0.6)
Exhaust shroudmounting
Exhaust shroud mounting bolt
bolt 1 1 6 6 7 (0,7; 75,1)
(0.7, 5.1)
Cylinder headnut
Cylinder head nut 4 4 7 7 18 (1,8;1813)
(1.8, 13) Oleskan oliApply
pd. uliroil to the threads
Cylinder head bolt 2 6 12 (1,2; 9) Oleskan oli pd. ulir
Cylinder head bolt 2 6 12 (1.2, 9) Apply oil to the threads
Cam sprocket bolt 2 5 8 (0,8; 5,9) Oleskan oli pd. ulir
Cam sprocket bolt 2 5 8 (0.8, 5.9) Apply oil to the threads
Cam chain tensioner lifter screw 1 6 4 (0,4; 3,0)
Cam chain tensioner lifter screw 1 6 4 (0.4, 3.0)
Cylinder head cover special bolt 2 6 12 (1,2; 9)
Cylinder head cover special bolt
Cam chain tensioner slider pivot pin bolt 1 2 6 6 10 (1,0;127)(1.2, 9)
Cam chain tensioner slider pivot pin bolt 1 6 10 (1.0, 7)
KICKSTARTER/DRIVE PULLEY/DRIVENPULLEY/CLUTCH
JUM- DIAMETER
THREAD TORSI TORQUE
ITEM
CATATAN
Left
Left crankcase cover
crankcase cover plate
plate screw
screw 5 5 4 4 3 (0,3; 32,2)
(0.3, 2.2)
Drive pulley face nut
Drive pulley face nut 1 1 14 14 108 (11,0;
108 80)
(11.0, 80)Oleskan oliApply
pd. uliroil to the threads
Clutch/driven pulley
Clutch/driven pulley nutnut 1 1 28 28 54 (5,5; 40)
54 (5.5, 40)
Clutch outer nut 1 12 49 (5,0; 36)
Clutch outer nut 1 12 49 (5.0, 36)
FRONT WHEEL/SUSPENSION/STEERING
RODA DEPAN/SUSPENSI/KEMUDI
JUM- DIAMETER
THREAD TORSI TORQUE
ITEM
BAGIAN Q'TY REMARKS
CATATAN
LAH ULIRDIA.
(mm)(mm)N.m (kgf.m; lbf.ft) lbf·ft)
N·m (kgf·m,
Front axlenut
Front axle nut 1 1 12 12 59 (6,0;5944)
(6.0, 44) U-nut U-nut
Front brakedisc
Front brake discsocket
socket bolt
bolt 4 4 8 8 42 (4,3;4231)
(4.3, 31) ALOC bolt: ALOC bolt:
Handlebar post nut 1 10 59 (6,0; 44) ganti dgn. replace
yg. baru with new ones
Rear brakepost
Handlebar lever
nutpivot bolt 1 1 5 10 1 (0,1;590,7)
(6.0, 44)
Rear brake lever pivotbolt
Rear brake lever pivot nut 1 1 5 5 4,5 (0,5;1 3,3)
(0.1, 0.7)
Bottom bridge
Rear brake leverpinch
pivot bolt
nut 4 1 10 5 64 (6,5;
4.547)
(0.5, 3.3)
Fork socket bolt
Bottom bridge pinch bolt 2 4 8 10 20 (2,0;6415)
(6.5, 47)
Steering stem
Fork socket bolttop thread 1 2 26 8 Lihat hal.20
11-22
(2.0, 15)
Oleskan cairan pengunci
Apply locking agent
Steering stem lock nut 1 26 Lihat hal. 11-22
Steering stem top thread 1 26 See page 11-22
Steering stem lock nut 1 26 See page 11-22
RODA BELAKANG/SUSPENSI
REAR WHEEL/SUSPENSION JUM- DIAMETER TORSI
BAGIAN LAH ULIR THREAD
(mm) N.m (kgf.m; lbf.ft)
TORQUE CATATAN
ITEM Q'TY REMARKS
Rear axle nut 1 16
DIA. (mm) 118 N·m
(12,0; 87) lbf·ft)
(kgf·m, U-nut, Oleskan oli pd. ulir
Engine hanger
Rear axle nut link nut (sisi rangka) 1 1 10 16 69 (7,0;
11851)
(12.0, 87) U-nut, Apply oil to the
threads
Engine hanger link nut (Frame side) 1 10 69 (7.0, 51)
SISTEM REM
BRAKE SYSTEM JUM- DIAMETER TORSI
THREAD TORQUE
Rear brake arm bolt ITEM 1Q'TY 6 10 (1,0; 7) ALOC bolt: ganti dengan
REMARKSyang baru
Brake caliper bleed valve 1 8 6 (0,6; 4,4)
Rear brake
Brake armcylinder
master bolt reservoir cap 2 1 4 6 2 (0,2; 10 (1.0, 7)
1,5) ALOC bolt: replace with a
new one
screw
Brake caliper
Brake pad pinbleed valve 1 1 10 8 6 (0.6,
18 (1,8; 13) 4.4)
Brake master cylinder
Front brake lever reservoir
pivot bolt cap screw 1 2 6 4 1 (0,1; 20,7)
(0.2, 1.5)
Brake brake
Front pad pinlever pivot nut 1 1 6 10 6 (0,6;18 (1.8, 13)
4,4)
Front brakelever
Front brake light pivot
switchbolt
screw 1 1 4 6 1 (0,1; 0,7) 0.7)
1 (0.1,
Brake hose oil bolt nut
Front brake lever pivot 2 1 10 6 34 (3,5;6 25)
(0.6, 4.4)
Front brake
Brake light
caliper switch screw
mounting bolt 2 1 8 4 (0.1, 0.7) ALOC bolt: ganti dengan yang baru
30 (3,1;1 22)
Brake caliper
Brake hose oil pin
bolt 1 2 8 10 18 (1,8;3413)
(3.5, 25)
Brake caliper mounting bolt 2 8 30 (3.1, 22) ALOC bolt: replace with new
ones
Brake caliper pin 1 8 18 (1.8, 13)
1-10
KETERANGAN UMUM
BATTERY/CHARGING SYSTEM/ALTERNATOR
BATTERY/SISTEM PENGISIAN/ALTERNATOR
JUM- DIAMETER
THREAD TORSI TORQUE
ITEM
CATATAN
Cooling fan mounting
Cooling fan mountingboltbolt 3 3 6 6 10 (1,0;107)(1.0, 7)
Flywheel nut
Flywheel nut 1 1 10 10 39 (4,0;3929)
(4.0, 29)
Ignition pulse generator
lgnition pulse generator 2 2 5 5 6 (0,6; 64,4)
(0.6, 4.4)
IGNITION SYSTEM
SISTEM PENGAPIAN
JUM- THREAD TORQUE
ITEM Q'TY DIAMETER TORSI REMARKS
BAGIAN LAH DIA.
ULIR (mm)(mm)N.m (kgf.m;(kgf·m,
N·m lbf.ft) lbf·ft) CATATAN
Key shutter
Key shutter socket
socketbolt
bolt 1 1 6 6 10 (1,0;107)(1.0, 7)
ELECTRIC STARTER SYSTEM
SISTEM STARTER LISTRIK THREAD TORQUE
ITEM JUM-Q'TY DIAMETER TORSI REMARKS
Starter motor case screw 3 4 2 (0.2, 1.5)
Starter motor case screw 3 4 2 (0,2; 1,5)
OTHERS
LAIN-LAIN THREAD TORQUE
ITEM Q'TY REMARKS
JUM- DIA. (mm)
DIAMETER N·m (kgf·m, lbf·ft)
TORSI
BAGIAN
Carburetor throttle cable holder mounting LAH 2 ULIR (mm) 5 N.m (kgf.m;
3.4 lbf.ft)
(0.4, 2.5) CATATAN
screw
Carburetor throttle cable holder 2 5 3,4 (0,4; 2,5)
Brake shoescrew
mounting anchor pin nut 1 8
Brake
(when shoe
using anchor
the stakepin nut
nut) 1 8 20 (2.0, 15)
(sewaktu memakai
(when using stake
the normal nut)nut) 20 (2,0;1815)
(1.8, 13)
(sewaktu memakai
Muffler protector normalbolt
mounting nut) 2 6 18 (1,8;1013)(1.0, 7)
Muffler protector
Sidestand pivot nutmounting bolt 2 1 6 10 10 (1,0; 7)
29 (3.0, 21)
Sidestand pivotbolt
Sidestand pivot nut 1 1 10 10 29 (3,0;
1021)
(1.0, 0.7)
Sidestand pivot bolt 1 10 10 (1,0; 0,7)
1-11
KETERANGAN UMUM
LUBRICATION & SEAL POINTS
TITIK-TITIK PELUMASAN & PERAPATAN
ENGINE
MESIN
MATERIAL LOCATION REMARKS
BAHAN LOKASI CATATAN
Liquid sealant (recommended: Right crankcase mating surface See page 10-9
Liquid sealant (dianjurkan: Permukaan penyatuan right crankcase Lihat hal. 10-9
Three Bond 1207B or Three
Three Bond 1207B atau Three
Bond 1215 or equivalent)
Bond 1215 atau sejenisnya)
Liquid sealant (recommended: Cylinder head mating surface (semicircular area) See page 7-8
Liquid sealant (dianjurkan: Permukaan penyatuan cylinder head (daerah Lihat hal. 7-8
Three Bond 5211C or SHI-
Three Bond 5211C atau setengah lingkaran)
NETSU-SILICONE KE45T or
SHINETSU-SILICONE KE45T
Three Bond 1215 or equiva-
atau
lent)
Three Bond 1215 atau
sejenisnya)
Adhesive (recommended: Cylinder head cover and seal rubber mating surface (hatched See page 7-7
Adhesive
CEMEDINE (dianjurkan:
575 or Three Cylinder head cover dan permukaan penyatuan
area) Lihat hal. 7-7
CEMEDINE
Bond 1194 or575 atau Three
equivalent) seal rubber (daerah penutupan)
Bond 1194 atau sejenisnya)
Locking agent (recommended: Driveshaft bearing set plate bolt threads See page 9-16
Locking agent
Three Bond (dianjurkan:
2415 or 1322N or Ulir driveshaft bearing set plate bolt Lihat hal. 9-16
Air supply pipe mounting bolt threads See page 5-25
Three
LOCKTITE 200 or atau
Bond 2415 1322N
equivalent) Ulir air supply pipe mounting bolt Lihat hal. 5-25
atau LOCKTITE 200 atau
Molybdenum oil solution (a Camshaft cam lobes
sejenisnya)
mixture of 1/2 engine oil and 1/
Molybdenum
2 molybdenumoil solution
disulfide Camshaft cam lobes (bubungan camshaft)
(campuran
grease) dari ½ oli mesin
dan
Molybdenum disulfidedisulfide
½ molybdenum paste Kickstarter spindle sliding surface 0.1 – 0.3 g
grease) Kickstarter driven gear shaft 0.2 – 0.3 g
Molybdenum disulfide paste Permukaan
Kickstarter luncur
driven kickstarter
gear spindle
friction spring sliding area 0,1 –0,3 g
Kickstarter driven gear shaft 0,2 – 0,3 g
Multi-purpose grease Kickstarter spindle dust seal lip
Daerah luncur kickstarter driven gear friction spring
Grease Driven face inner surface 7.0 – 8.0 g
Multi-purpose grease Bibir kickstarter spindle dust seal
(Shell ALVANIA R3 or Movable driven face cam groove 2.0 – 2.5 g
Grease
IDEMITSU(gemuk)
AUTOREX B or Permukaan dalam driven face
Starter pinion gear shaft (both end)
7,0 – 8,00.1
g – 0.3 g
(Shell ALVANIA
equivalent) R3 atau Alur movable driven face cam 2,0 – 2,5 g
Driven face ball bearing and needle bearing
IDEMITSU AUTOREX B atau Starter pinion gear shaft (kedua ujungnya) 0,1 – 0,3 g
Engine oil Oil pump drive gear teeth
sejenisnya) Driven face ball bearing dan needle bearing
(Without molybdenum addi- Oil pump rotor whole surface
tives) Oil pump shaft and pump cover sliding area
Oli mesin Gigi-gigi oil pump drive gear
(Tanpa molybdenum additives) Oil pumppermukaan
Seluruh driven gear teeth
oil pump rotor
Rocker
Daerah luncur oil pumpsurface
arm shaft sliding shaft dan pump cover
Rocker
Gigi-gigiarm
oilroller
pumpsliding
drivenareagear
Camshaft
Permukaan decompressor
luncur rocker rotating
arm surface
shaft 0.5 – 1.0 cc
Camshaft bearing
Daerah luncur rocker arm roller
Cam sprocketberputar
Permukaan teeth camshaft decompressor 0,5 – 1,0 cc
Camshaft bearing
Cam chain whole surface
Gigi-gigi
Timing cam sprocket
sprocket teeth
Seluruh
Piston and permukaan camsurfaces
cylinder sliding chain
Gigi-gigi timing sprocket
Piston pin hole sliding area
Permukaan
Piston luncur
ring whole piston
surface anddan cylinder
ring grooves
Daerah luncur lubang
Piston pin outer surface piston pin
Seluruh permukaan piston ring dan alur ring
Connecting rod small end inner surface
Permukaan luar piston pin
Crankshaft bearings Fill up 2 cc minimum
Permukaan dalam connecting rod small end
Connecting rod big end bearing Fill up 3 cc minimum
(kepala kecil connecting rod)
Valve stem (valve guide sliding area)
Crankshaft bearings Isi dengan minimum 2 cc
Valve stem seal
Connecting rodinner surface
big end bearing (bantalan kepala Isi dengan minimum 3 cc
Bearing area of drive,
besar connecting rod)counter and final shaft
Drive,
Valve counter and final
stem (daerah gear teeth
luncur valve guide)
Cam set plunger whole surface
Permukaan dalam valve stem seal
Ball/needle
Daerah bearingbearing sliding
dari drive,area
counter dan final shaft
Gigi-gigi
Each drive,
O-ring wholecounter
surface dan final gear
Seluruh
Oil permukaan
seal lips cam set plunger
and outer surfaces
Degrease Right crankshaft tapered areabearing
Daerah luncur ball/needle
Seluruh permukaan
Drive/driven pulley facemasing-masing
and drive belt O-ring
Left crankcase cover bearingoil
Bibir dan permukaan luar seal inner surface
bushing
Bersihkan dari gemuk Daerah meruncing dari right crankshaft
Muka drive/driven pulley dan drive belt
Permukaan dalam left crankcase cover bearing
bushing
1-12
KETERANGAN UMUM
RANGKA
FRAME
BAHAN LOKASI CATATAN
MATERIAL LOCATION REMARKS
Multi-purpose grease dengan Steering bearing race Isi dengan minimum 3 g
Multi-purpose
tekanan grease
sangat with
tinggi Steering bearing race
Bibir steering stem dust seal Fill up 3 g minimum
extreme pressure (recom- Steering stem dust seal lip
(dianjurkan: EXCELIGHT EP2
mended: EXCELIGHT EP2
buatan KYODO YUSHI,
manufactured by KYODO
Japan, atau Shell ALVANIA
YUSHI, japan. or Shell ALVA-
EP2 atau sejenisnya)
NIA EP2 or equivalent)
Grease (Shell BEARING Bagian dalam speedometer gear box
Grease Speedometer gear box inside
GREASE HD atau sejenisnya)
(Shell BEARING GREASE
Multi-purpose grease
HD or equivalent) Bibir front wheel dust seal
Permukaan luncur front wheel axle
Multi-purpose grease Front wheel dust seal lip
Seluruh permukaan front wheel distance collar
Front wheel axle sliding surface
Daerah luncur front wheel bearing
Front wheel distance collar whole surface
Bibir speedometer gear box seal
Front wheel
Rear brake bearing
cam dan sliding
shaftarea Oleskan masing-masing
Speedometer gear box seal lip 0,2 – 0,3 g
Rear brake
Rear brakecam and shaft
anchor pin shaft Oleskan Apply eachg0.2 - 0.3 g
0,2 – 0,3
Rear brake
Bibir anchordust
rear brake pin shaft
seal Apply 0.2 - 0.3 g
Rear brake dust
Permukaan seal lip
luncur rear brake lever pivot bolt
Rear brake
Daerah leverthrottle
luncur pivot bolt sliding surface drum
cable-ke-throttle Oleskan 0,1 – 0,2 g
Daerah kontak seat catch
Throttle cable-to-throttle drum (penahan tempat duduk)
sliding area Apply 0.1 - 0.2 g
Daerah centerstand
Seat catch contact areapivot
Daerah sidestand
Centerstand pivot area pivot
Sidestand pivot area
Silicone grease
Silicone grease Bagian dalam
Rear brake cablerearcap brake cable cap boot
boot inside
Daerah kontak
Front brake front brakepiston
lever-to-master lever-ke-master piston
contacting area Oleskan Apply
0,1 g 0.1 g
Daerah luncur front brake lever
Front brake lever pivot sliding area pivot
Daerah luncur
Brake caliper pinbrake
slidingcaliper
area pin Oleskan Apply
minimum0.4 g0,4 g
minimum
Seluruh permukaan brake caliper
Brake caliper dust seal whole surface
dust seal
Speedometer cable
Speedometer cable
Bagian dalam throttle cable boot Oleskan 0,1 g
Throttle cable boot inside Apply 0.1 g
Bagian dalam throttle cable Oleskan minimum 0,2 g
Throttle cable inside Apply 0.2 g minimum
Brake fluid (minyak rem) Bagian dalam dan daerah luncur master cylinder
Brake 3
(DOT fluid
atau DOT 4) Master cylinder inside and sliding area
Seluruh permukaan brake caliper piston seal
(DOT 3 or DOT 4) Brake caliper piston seal whole surface
Seluruh permukaan brake caliper piston
Brake caliper piston whole
Master cylinder piston cup surface
Fork fluid (minyak sokbreker) Master
Bibir cylinder
fork piston
dust seal dancupoil seal
Fork fluid Fork dustpermukaan
Seluruh seal and oil seal
forklips
spring seat O-ring
Adhesive (Honda bond A atau Fork spring
Bagian seathandlebar
dalam O-ring whole gripsurface
rubber
Adhesive
sejenisnya) Handlebar grip rubber inside
Daerah penyatuan PAIR control valve r ubber
(Honda bond A or equivalent) -ke-air cleaner
PAIR control housing
valve rubber-to-air cleaner housing mating area
Daerah penyatuan
Air cleaner connecting airhose-to-housing
cleaner connectingmatinghose-ke-
area
Locking agent (recommended: housing
Centerstand shaft bolt threads See page 10-11
Locking agent
Three Bond (dianjurkan:
2415 or 1322 N or Ulir centerstand shaft bolt Lihat hal. 10-11
Three Bond 200
LOCKTITE 2415or atau 1322 N
equivalent)
atau LOCKTITE 200 atau
sejenisnya)
1-13
KETERANGAN UMUM
CABLE & HARNESS
PERLETAKAN KABELROUTING
& HARNESS
STARTER SWITCH
WIRE DIMMER SWITCH WIRE
LIGHTING SWITCH WIRE
TURN SIGNAL
SWITCH WIRE
RIGHT HANDLEBAR
SWITCH WIRE
FRONT BRAKE HOSE
FRONT BRAKE
LIGHT SWITCH LEFT HANDLEBAR HORN SWITCH
WIRE SWITCH WIRE WIRE
REAR BRAKE CABLE
REAR BRAKE LIGHT

SWITCH WIRE
THROTTLE REAR BRAKE

CABLE
HANDLEBAR SWITCH/
SPEEDOMETER WIRE
FRONT BRAKE
HOSE SPEEDOMETER
CABLE
HANDLEBAR SWITCH/ HANDLEBAR
SPEEDOMETER WIRE SWITCH/ FRONT BRAKE
SPEEDOMETE HOSE
R WIRE
THROTTLE CABLE
SPEEDOMETER
CABLE
REAR BRAKE CABLE
THROTTLE CABLE
HORN
WIRE
IGNITION
SWITCH WIRE
FRONT BRAKE
HOSE
HANDLEBAR SWITCH/
SPEEDOMETER WIRE
SPEEDOMETER
Letakkan penutup kawat terminal
klakson dengan lubang pembuangan
menghadap ke bawah :
1-14
KETERANGAN UMUM
HORN WIRE
SPEEDOMETER CABLE
MAIN WIRE
HARNESS
THROTTLE CABLE
REAR BRAKE CABLE
FRONT BRAKE HOSE
MAIN WIRE
HARNESS
SPEEDOMETER CABLE
FRONT BRAKE HOSE
1-15
KETERANGAN UMUM
MAIN WIRE
HARNESS
Jepit daerah dengan pita putih:
REAR BRAKE CABLE

SIDESTAND SWITCH WIRE
THROTTLE CABLE
BATTERY NEGATIVE BATTERY POSITIVE

(–) CABLE (+) CABLE
FUSE BOX WIRE STARTER RELAY WIRE
1-16
KETERANGAN UMUM
PULSE SECONDARY CRANKCASE

AIR INJECTION (PAIR) BREATHER HOSE
STARTER ENRICHMENT CONTROL VALVE
(SE) THERMAL VALVE WIRE VACUUM HOSE CARBURETOR
AIR VENT HOSE
FUEL VALVE
VACUUM HOSE
THROTTLE CABLE
ALTERNATOR/IGNITION
PULSE GENERATOR WIRE
STARTER MOTOR/
GROUND CABLE
CARBURETOR
SIDESTAND DRAIN HOSE
SWITCH WIRE
AIR SUPPLY PIPE
STARTER ENRICHMENT
(SE) THERMAL VALVE WIRE
CRANKCASE
BREATHER HOSE
ALTERNATOR/
IGNITION PULSE
GENERATOR WIRE
STARTER MOTOR/
GROUND CABLE
1-17
KETERANGAN UMUM
° SISI ATAS CARBURETOR VACUUM

5
7 PISTON HOSE
AIR CLEANER
CONNECTING HOSE BAND
CRANKCASE BREATHER HOSE

SISI ATAS
CARBURETOR VACUUM
PISTON HOSE CLIP
FUEL HOSE
FUEL VALVE
VACUUM HOSE
CARBURETOR AIR
VENT HOSE
THROTTLE CABLE
SISI ATAS
INLET PIPE BAND
PULSE SECONDARY
AIR INJECTION (PAIR)
CONTROL VALVE
VACUUM HOSE
1-18
KETERANGAN UMUM
FUEL LEVEL
SENSOR WIRE GROUND CABLE
REGULATOR/ (KECIL)
SPARK PLUG WIRE RECTIFIER WIRE
BOLT
GROUND CABLE (BESAR)
Sambungan air
supply hose dengan
sisinya yang
bertanda
mengahadap keluar.
TANDA
AIR SUPPLY PIPE
PULSE SECONDARY STARTING ENRICHMENT (SE)

AIR INJECTION (PAIR) AIR SUPPLY HOSE THERMAL VALVE WIRE
CONTROL VALVE
VACUUM HOSE
AIR SUPPLY HOSE
Terpasang
SISI AIR SUPPLY HOSE SPARK PLUG WIRE

ATAS
ALTERNATOR/
STARTER MOTOR/
IGNITION PULSE
GROUND CABLE
HOSE BAND GENERATOR WIRE
1-19
KETERANGAN UMUM
CARBURETOR VACUUM
PISTON HOSE
THROTTLE CABLE
FUEL HOSE
FUEL VALVE
VACUUM HOSE
FUEL HOSE
FUEL VALVE
PULSE SECONDARY VACUUM HOSE
AIR INJECTION (PAIR)
CONTROL VALVE FUEL VALVE
VACUUM HOSE VACUUM HOSE
THROTTLE CABLE
CRANKCASE
BREATHER HOSE
CARBURETOR
DRAIN HOSE
CARBURETOR
AIR VENT HOSE
1-20
KETERANGAN UMUM
GROUND CABLE
STARTER MOTOR CABLE GROUND CABLE
ALTERNATOR/IGNITION PULSE
GENERATOR WIRE
IGNITION PULSE GENERATOR WIRE
1-21
KETERANGAN UMUM
CRANKCASE BREATHER FINAL REDUCTION CASE

DRAIN HOSE BREATHER HOSE
Sewaktu memasang pedal kikstarter

pada posisi standard:
SEJAJAR
REAR BRAKE CABLE

CARBURETOR DRAIN
Waktu memasang Waktu memasang
standard samping pada standard utama pada
posisi standard: posisi standard:
1-22
KETERANGAN UMUM
POSITION LIGHT WIRE
LEFT FRONT TURN RIGHT FRONT TURN

SIGNAL LIGHT WIRE SIGNAL LIGHT WIRE
HEAD LIGHT WIRE
RIGHT REAR TURN

SIGNAL LIGHT WIRE
TAIL/BRAKE LIGHT WIRE
TAIL/BRAKE LIGHT/REAR LEFT REAR TURN SIGNAL

TURN SIGNAL LIGHT WIRE LIGHT WIRE
Tepatkan daerah yang

berpita putih dengan tab
TAIL/BRAKE LIGHT/REAR
TURN SIGNAL LIGHT WIRE
1-23
KETERANGAN UMUM
EMISSION CONTROL
SISTEM-SISTEM SYSTEMSEMISSI
PENGATURAN
SOURCEEMISSI
SUMBER OF EMISSIONS
The combustion process produces carbon monoxide and hydrocarbons. Controlling hydrocarbon emission is very important because, under
Proses pembakaran
certain conditions, theymenghasilkan karbon monoksida
react to form photochemical dan subjected
smog when hidrokarbon. Pengaturan
to sunlight. Carbonemissi hidrokarbon
monoxide adalah
does not react sangat
in the samepenting
way, but oleh
it is
karena,
toxic. pada kondisi tertentu, mereka bereaksi membentuk photochemical smog ketika terkena cahaya matahari. Karbon
monoksida tidak bereaksi dengan cara yang sama, tetapi ia beracun.
Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide, oxides of nitrogen and
hydrocarbons.
Honda Motor Co., Ltd. menggunakan penyetelan karburator yang miskin maupun sistem lain, untuk mengurangi karbon monoksida,
oksida dari nitrogen dan hidrokarbon.
CRANKCASE EMISSION CONTROL SYSTEM
The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned
to the combustion chamber through the air cleaner and carburetor.
SISTEM PENGATURAN EMISSI CRANKCASE
Mesin dilengkapi dengan sistem crankcase (bak mesin) tertutup untuk mencegah pengeluaran emissi bak mesin ke dalam atmosfir.
Blow-by gas (gas hasil pembakaran yang masuk ke dalam bak mesin melalui piston ring ) dikembalikan ke dalam ruang
pembakaran melalui air cleaner (saringan udara) dan karburator.
CARBURETOR
AIR CLEANER
UDARA
BLOW-BY GAS
1-24
KETERANGAN UMUM
EXHAUST
SISTEM EMISSION CONTROL
PENGATURAN EMISSI GAS SYSTEM (PULSE SECONDARY AIR INJECTION SYSTEM)
PEMBUANGAN
(PULSE SECONDARY
The exhaust emission AIR
control system INJECTION
consists SYSTEM)
of a secondary air supply system which introduces filtered air into the exhaust gas in the exhaust
port. Fresh air is drawn into the exhaust port whenever there is a negative pressure pulse in the exhaust system. This charge of fresh air promotes
burning
Sistem of the unburned
pengaturan exhaust
emissi gasgas and changes aterdiri
pembuangan considerable amountsecondary
dari sebuah of hydrocarbons and carbon
air supply monoxide
system into
[sistem relatively harmless
penyaluran carbon
udara kedua]
dioxide and water vapor.
yang memasukkan udara yang telah disaring ke dalam gas pembuangan pada lubang pembuangan. Udara segar ditarik ke dalam
lubang pembuangan
This model setiap
has the pulse kali ada
secondary airpulsa tekanan
injection (PAIR)negatif pada
control sistem
valve gas pembuangan.
and PAIR Suntikan
check valve. PAIR checkudara
valve segar inireverse
prevents meningkatkan
air flow
pembakaran gas pembuangan
through the system. yangvalve
The PAIR control belum terbakar
reacts dan
to high mengubah
intake manifoldsejumlah besar
vacuum and willhidrokarbon dan karbon
cut off the supply monoksida
of the fresh keengine
air during dalam
karbon dioksida
deceleration, danpreventing
thereby uap air yang relatifintidak
afterburn berbahaya.
the exhaust system.
No adjustment to the pulse secondary air injection system should be made, although periodic inspection of the components is recommended.
Model ini mempunyai pulse secondary air injection (PAIR) control valve dan PAIR check valve. PAIR check valve [klep penahan
PAIR] mencegah terjadinya arus udara terbalik melalui sistem. PAIR control valve [klep pengatur PAIR] bereaksi terhadap vakuum
intake manifold [manipol pemasukan] yang tinggi dan akan menutup penyaluran udara segar selama deselerasi mesin, dengan
demikian mencegah terjadinya afterburn [pembakaran susulan] dalam sistem gas pembuangan.
Tidak perlu melakukan penyetelan terhadap pulse secondary air injection system, walaupun disarankan untuk melakukan
pemeriksaan berkala dari komponen-komponennya.
PAIR CONTROL VALVE CHECK VALVE PAIR AIR CLEANER
UDARA SEGAR
UDARA VAKUM
EXHAUST PORT
NOISE EMISSION CONTROL SYSTEM
[SISTEM PENGATURAN EMISSI KEBISINGAN]
DILARANG MENGUTAK-ATIK SISTEM PENGATURAN EMISSI KEBISINGAN: Undang-undang melarang tindakan-tindakan
berikut atau penyebab daripada: (1) Pelepasan atau dibuat tidak bekerjanya oleh seseorang, selain untuk tujuan perawatan,
NOISE EMISSION
perbaikan atau penggantian, CONTROL SYSTEM
dari setiap peralatan atau elemen rancangan yang telah dipasang pada sebuah kendaraan untuk
tujuan
TAMPERINGpengaturan
WITHkebisingan
THE NOISE sebelum
CONTROL penjualan
SYSTEM atauISpenyerahannya
PROHIBITED: Local kepada
lawpelanggan
may prohibit akhir atau sementara
the following ia causing
acts or the dipergunakan:
thereof:
(1) The
atau (2)removal or rendering
pemakaian sebuah inoperative
kendaraan by setelah
any person, other than
peralatan for elemen
atau purposesrancangan
of maintenance, repair or telah
sedemikian replacement, of anyatau
dilepaskan device or element
dibuat tidak
of design
dapat incorporated
bekerja into any vehicle for the purpose of noise control prior to its sale or delivery to the ultimate customer or while it is in use;
oleh seseorang.
(2) ANTARA
DI the use of the vehicle afterYANG
TINDAKAN2 such device or element
DIANGGAP of design has PENGUTAK-ATIKAN
MERUPAKAN been removed or rendered inoperative
ADALAH by any person.
TINDAKAN-TINDAKAN SEPERTI DI
BAWAH INI:
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
1. Melepaskan atau melubangi knalpot, komponen pengaturan aliran, pipa pendahulu atau setiap komponen lain yang
1. Removal of or puncturing
menyalurkan of the muffler, baffles, header pipes or any other component which conducts exhaust gases.
gas pembuangan.
2. Removal of or puncturing
2. Melepaskan atau melubangi of any setiap
part of bagian
the intake system.
dari sistem pemasukan udara.
3. Lack of proper maintenance.
3. Tidak menjalankan perawatan yang layak.
4. Replacing
4. Mengganti anybagian
movingbergerak
parts of the vehicle,
dari or partsatau
kendaraan, of thebagian
exhaustdari
or intake
sistemsystem, with partsatau
pembuangan otherpemasukan,
than those specified
denganbypartthe lain
manufacturer.
daripada
yang telah ditentukan oleh pembuatnya.
1-25
CATATAN
2. RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
LOKASI BODY PANEL..........................

BODY PANEL LOCATIONS????????????? 2-22-2 TEMPAT DUDUK ........................................2-8
SEAT ????????????????????????????????? 2-8
PETA PELEPASAN
BODY BODY CHART
PANEL REMOVAL PANEL.......
?????? 2-2
2-2 GRAB RAIL.................................................
GRAB RAIL ??????????????????????????? 2-8 2-8
KETERANGAN SERVIS ........................2-3

SERVICE INFORMATION ?????????????? 2-3 BODY COVER.............................................
BODY COVER????????????????????????? 2-9 2-9
TROUBLESHOOTING
TROUBLESHOOTING...........................
????????????????? 2-32-3 UNDER COVER
UNDER ........................................
COVER ?????????????????????? 2-10 2-10
FRONT UPPER
FRONT UPPERCOVER
COVER ........................
???????????????? 2-42-4 FLOOR PANEL/FRONT
FLOOR PANEL/FRONTINNER
INNER COVER.. 2-11
COVER 2-11
FRONT HANDLEBAR
FRONT HANDLEBARCOVER
COVER ..............
?????????? 2-52-5 REAR FENDER.........................................
REAR FENDER??????????????????????? 2-11 2-11
REAR HANDLEBAR
REAR HANDLEBARCOVER
COVER ................
??????????? 2-52-5 LEFT CRANKCASE
LEFT CRANKCASECOVER
COVER DUCT .........2-12
DUCT ????? 2-12
FRONT LOWER
FRONT COVER
LOWER COVER.......................2-6
??????????????? 2-6 COOLING FAN
COOLING COVER
FAN ............................
COVER ??????????????? 2-12 2-12
FRONT INNER
FRONT UPPER
INNER UPPERCOVER
COVER ............
????????? 2-6
2-6 TRIM CLIPS
TRIM ..............................................
CLIPS ????????????????????????? 2-13 2-13
FRONT FENDER.................................... 2-7

FRONT FENDER ?????????????????????? 2-7
BATTERY COVER .................................... 2-13
BATTERY COVER ???????????????????? 2-13
LUGGAGE BOX..................................... 2-7

LUGGAGE BOX ??????????????????????? 2-7
EXHAUST PIPE/MUFFLER ...................... 2-14
EXHAUST PIPE/MUFFLER ???????????? 2-14
CENTER BODY COVER ........................2-8

CENTER BODY COVER ???????????????? 2-8
2-1
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
LOKASI BODYLOCATIONS
BODY PANEL PANEL
FRAME/BODYPANELS/EXHAUSTSYSTEM
(8)
(1)
(9) (10)
(2)
(11)
(3)
(6)
(14)
(5) (17)
(13)
(15)
(12)
(7)
(16)
(4)
(1) Front handlebar cover (hal. 2-5) (9) Luggage box (hal. 2-7)
(1) Front handlebar cover (page 2-5) (9) Luggage box (page 2-7)
(2) Rear handlebar cover (hal. 2-5) (10) Grab rail (hal. 2-8)
(2) Rear handlebar cover (page 2-5) (10) Grab rail (page 2-8)
(3) Front upper cover (hal. 2-4) (11) Body cover (hal. 2-9)
(3) Front
(4) Front upper
lower cover
cover(page
(hal. 2-4)
2-6) (11)
(12) Body
Under cover (page
cover 2-9)
(hal. 2-10)
(4) Front
(5) Front lower
fendercover
(hal.(page
2-7) 2-6) (12) Under
(13) Floorcover (page 2-10)
panel/Front inner cover (hal. 2-11)
(5) Front
(6) Front fender (page 2-7)
inner upper cover (hal. 2-6) (13) Floor
(14) Rearpanel/Front inner
fender (hal. cover (page 2-11)
2-11)
(6) Front inner upper
(7) Center body cover cover (page
(hal. 2-8)2-6) (14)
(15) Rear fender (page 2-11)
Left crankcase cover duct (hal. 2-12)
(7) Seat
(8) Center(hal.
body cover (page 2-8)
2-8) (15) Left
(16) crankcase
Cooling cover duct
fan cover (hal.(page
2-12)2-12)
(8) Seat (page 2-8) (16) Cooling
(17) Batteryfan cover
cover (page
(hal. 2-12)
2-13)
(17) Battery cover (page 2-13)
BODY PANEL REMOVAL CHART

PETA PELEPASAN BODY PANEL
• This chart shows removal order of frame covers by means of arrow.
• Peta ini memperlihatkan urutan pelepasan dari penutup rangka dengan perantaraan anak panah.
(5) Front fender (3) Front upper cover (1) Front handlebar cover
(9) Luggage box (4) Front lower cover (2) Rear handlebar cover
(15) Left crankcase cover duct (6) Front inner upper cover (7) Center body cover (10) Grab rail
(16) Cooling fan cover (12) Under cover (8) Seat (11) Body cover
(17) Battery cover (13) Floor panel/Front inner cover (14) Rear fender
2-2
SERVICE INFORMATION
KETERANGAN SERVIS
UMUM
GENERAL
• This
• Babsection coverspelepasan
ini meliputi removal anddan installation of the body
pemasangan bodypanels
panelsand danexhaust
sistemsystem.
pembuangan gas.
• Always
• Selalureplace the exhaust
ganti exhaust pipepipe gasket
gasket after removing
setelah melepaskanthe exhaust
exhaustpipe from
pipe the engine.
(pipa pembuangan gas) dari mesin.
• When
•
installing the exhaust system, loosely install all of the exhaust
Ketika memasang sistem pembuangan gas, pasanglah semua pengikat exhaust pipe fasteners. Always pipe
tighten the exhaust
dengan joint Selalu
longgar. first, then tighten the
kencangkan
mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly.
exhaust joint (penyambung pipa pembuangan gas) dulu, kemudian kencangkan mounting fasteners (pengikat pemasangan).
• Always inspect the
Jika mounting exhaust system
fasteners for leaks dulu,
dikencangkan after installation.
exhaust pipe mungkin tidak akan duduk dengan benar.
• Setelah pemasangan, selalu periksa sistem pembuangan gas terhadap kebocoran.
TORQUE
NILAI VALUES
TORSI
Cooling
Cooling fan
fancover
coverscrew
screw 0.8 (0,1
0,8 N.m N·m kgf.m;
(0.1 kgf·m, 0.6 lbf·ft)
0,6 lbf.ft)
Cooling fan cover bolt
Cooling fan cover bolt 9 N·m (0.9 kgf·m, 6.6 lbf·ft)
9 N.m (0,9 kgf.m; 6,6 lbf.ft)
Muffler mounting
mounting bolt
bolt 5.9 (0,6
5,9 N.m N·m kgf.m;
(0.6 kgf·m, 4.4 lbf·ft)
4,4 lbf.ft)
TROUBLESHOOTING
TROUBLESHOOTING
Suara knalpot
Excessive exhaustberisik
noise
• Broken
• exhaust system gas rusak
Sistem pembuangan
• Exhaust
•
gas leak
Ada kebocoran gas pembuangan
Poor performance
Unjuk kerja lemah
• Deformed exhaust system
Sistemgas
• Exhaust
• pembuangan
leak gas berubah bentuk
Ada kebocoran
• Clogged
• muffler gas pembuangan
• Muffler tersumbat
2-3
FRONT
FRONT UPPER COVER
COVER
REMOVAL/INSTALLATION
PELEPASAN/PEMASANGAN
Lepaskan
Remove thesebagai berikut:
following:
– Two boltsbulb
- Headlight and socket
license plate
(hal. holder
17-6) from the front side LICENSE PLATE HOLDER
– Two screws from the lower front
- Position light bulb socket (hal. 17-6) side
– Six screws from the rear side
- Front turn signal light bulb sockets (hal. 17-8) FRONT UPPER COVER
- Enam screws
Be careful
Hati-hati agarnot to
tidak Remove the front upper cover by releasing the following:
- Front turn signal units kanan/kiri 6P CONNECTOR
damage the tabs,
merusak tabs, stoppers
– Tabs on the
- Headlight lower front
adjusting boltside of the front upper cover from
danslots.
stoppers and slots.
the slots on
- Headlight the front lower cover
retainers
– Stoppers unit
- Headlight around the rear side of the front upper cover BOLTS
from the front inner upper cover and front inner cover
Perakitan adalah dalam urutan terbalik dari
Disconnect the headlight/front turn signal light 6P connector.
pembongkaran.
Remove the two cushion rubbers.
Setel arah sinar headlight (hal. 3-18) setelah
Installation is in
pemasangan the reverse
front order of removal.
upper cover.
TABS
STOPPERS
CUSHION RUBBERS SCREW
DISASSEMBLY/ASSEMBLY
PEMBONGKARAN/PERAKITAN
Remove thesebagai
Lepaskan following:berikut:
–
- DuaHeadlight bulblicense
bolts dan socket (page
plate 17-6)
holder dari sisi depan FRONT TURN
? Position light bulb socket
- Dua screws dari sisi depan (page 17-6)
bawah SIGNAL UNITS
–
- Enam screws dari sisi belakang (page 17-8)
Front turn signal light bulb sockets
– Six screws FRONT UPPER
Lepaskan
– Right/leftfront upper
front turn signalcover
units dengan melepaskan COVER
sebagai
– berikut:
Headlight adjusting bolt
– Headlight retainers
- Tabs
– (lidahunit
Headlight pemasangan) pada sisi depan bawah dari
front upper cover dari slots (lubang2 pemasangan)
Assembly is in the reverse order of disassembly. SCREWS
pada front lower cover
-Adjust the headlight
Stoppers aim (page
(penahan) 3-18) bagian
di sekitar after installing
belakangthe front
dari
upper
frontcover.
upper cover dari front inner upper cover dan
front inner cover.
Lepaskan headlight/front turn signal light 6P connector

(connector 6P lampu besar/lampu sein).
Lepaskan kedua cushion rubbers.

Pemasangan adalah dalam urutan terbalik dari
pelepasan.
BOLT
RETAINERS
HEADLIGHT UNIT
2-4
FRONT HANDLEBAR
FRONT HANDLEBAR COVER
COVER
Longgarkan rear view
Loosen the rearview mirror
mirror lock nuts (mur pengunci
lock nuts.
kaca spion).
Remove the rearview mirrors by turning them counterclock- REAR VIEW MIRRORS
Lepaskan
wise. rear view mirrors (kaca spion) dengan
memutar mereka berlawanan arah jarum jam. FRONT HANDLEBAR COVER
Remove the following:
– Two screws
Lepaskan fromberikut:
sebagai the front side STOPPER
– Two screws from the rear side
- Dua screws dari sisi depan
Hati-hati agarnot
Be careful to -Remove
tidak the front
Dua screws handlebar
dari cover by releasing the following:
sisi belakang BOSSES
merusak
damagebosses, tabs,
the bosses,
stoppers dan slots. – Four bosses
Lepaskan frontonhandlebar
the upper side of the
cover front handlebar
dengan cover
melepaskan
tabs, stoppers and
from the hole on the rear handlebar cover
slots. sebagai berikut:
– Two slots on the upper side of the front handlebar cover
- Empatthebosses
from tabs on the rearsisi
pada handlebar cover
atas dari front handlebar
– cover
Two dari
stoppers on the front handlebar
lubang pada rear handlebar cover from the slots
cover. HOLES
on the combination meter
- Dua slots pada sisi atas dari front handlebar cover
– dari
Hole on pada
tabs the front
rearhandlebar
handlebarcover from the front brake
cover.
master cylinder
- Dua stoppers pada front handlebar cover dari slots SLOT
pada combination
Installation meter.
is in the reverse order of removal.
- Lubang pada front handlebar cover dari front brake
master cylinder
TAB
pelepasan.
SCREW
REAR
REAR HANDLEBAR
HANDLEBAR COVER
COVER
Lepaskan sebagai
Remove the berikut:
following:
- – Front FRONT BRAKE REAR HANDLEBAR COVER
Frontupper
uppercover
cover (hal.
(page2-4)
2-4)
- – Front
Fronthandlebar
handlebar cover (hal. 2-5)
cover (page 2-5) LIGHT SWITCH
REAR BRAKE
CONNECTORS
Lepaskan/keluarkan
Disconnect/release theconnectors/kawat-kawat berikut ini:
following connectors/wires: LIGHT SWITCH
CONNECTORS
-? Speedometer
Speedometer cable dari the
cable from combination meter.
combination meter SPEEDOMETER
- – Horn
Hornconnectors
connectors CABLE
- – Brake light switch
Front/rear connectors
brake light depan/belakang
switch connectors
- – Handlebar
Handlebar switch/speedometer
switch/speedometer wire 4P and 4P
wire 6P connectors
dan 6P
– connectors
Handlebar switch/speedometer wire boss from the han-
dlebar
- Handlebar switch/speedometer wire boss dari
– handlebar
Handlebar switch/speedometer wire from the wire guide
-Remove
Handlebar switch/speedometer wire dari wire guide WIRE
the following:
BOSS
Lepaskan sebagai
– Three screws berikut:
from the front side
– Rear handlebar cover
- Tiga screws dari sisi depan
Route
Alurkan wirethe wire -Installation
harness Rear handlebar
is in thecover
reverse order of removal.
dengan benar
harness (hal. Pemasangan adalah dalam urutan terbalik
properly dari
1-14).
(page 1-14).pelepasan.
HORN
WIRE GUIDE CONNECTORS
SCREWS 4P/6P CONNECTORS
2-5
FRONT
FRONT LOWER
LOWERCOVER
COVER
Lepaskan
following:
- Front
– Frontupper
uppercover
cover (hal.
(page2-4)
2-4)
- Empat
– screwsfrom
Two screws dariboth
sisi sides
depan
– Two
- Bolt screws
dan fromhook
luggage the lower
dari front side
sisi belakang
Remove thewire
Lepaskan frontboss
lowerdari
cover by releasing
lubang the hooks
dari front on its
inner upper
lower side from the under cover.
cover.
Tarik front inner cover sedikit ke belakang untuk
Be careful not to Installation is in the reverse order of removal.
Hati-hati agar
damage the tidak
hooks.
membuat ruangan bagi pelepasan front inner upper
merusak hooks. cover.
Lepaskan bagian atas dari front inner upper cover dari
rear handlebar cover, kemudian tarik ke atas dan
keluarkan.

pelepasan.
SCREWS
FRONT LOWER COVER

HOOKS
FRONT
FRONT INNER
INNER UPPER
UPPER COVER
COVER
Lepaskan
following:
- Front
– Frontupper
uppercover
cover (hal.
(page2-4)
2-4) FRONT INNER UPPER COVER
- Dua
– screws
Four screwsdari
fromkedua sisiside
the front
- Dua
– Boltscrews dari sisi
and luggage hookdepan
from bawah
the rear side HOLE
Lepaskan
Release thefront
wire lower cover
boss from the dengan melepaskan
hole of the hooks
front inner upper BOLT
pada
cover.sisinya yang bawah dari under cover. WIRE BOSS
Slightly pull the front inner cover backward to make space
Hati-hati
Be careful
agarnot to for front inner upper cover removal.
tidak
merusak
damage front inner Release the upper side of the front inner upper cover from the
the front
covercover
dan front
pelepasan.
inner and finner
ront rear handlebar cover, then pull it upward and remove it.
upper cover.
inner upper cover.
Installation is in the reverse order of removal.
LUGGAGE
HOOK
SCREWS
2-6
FRONT FENDER
FRONT FENDER (SPAKBOR DEPAN)
Lepaskan
following:
– Four bolts
- Empat bolts FRONT FENDER
– Front fender
- Front fender
Installation is in the
Pemasangan reversedalam
adalah order of removal.
urutan terbalik dari
pelepasan.
BOLTS
LUGGAGE BOX (KOTAK BAGASI)

Lepaskan
following:
WIRE HARNESS COVER BOLTS
- Baterai
– Battery(hal.
(page14-12)
14-12)
- – ICM (hal. 15-11)
ICM (page 15-11)
- Screw
– Screwdari
fromsisi
thedepan atas side
front upper
- Dua
– Two screwsdari
screws fromkedua sisi
both sides
- Dua
– Twobolts
boltsdan
andcollars
collars dari
fromsisi
the belakang
upper rear atas
side
–
- DuaTwo boltsdari
bolts from thedepan
sisi inner front
dalam side
COLLARS
– Wire
- Wire harness cover
harness cover
Remove the luggage box upward while pulling the wire har-
lurkan wire harness Lepaskan luggage box ke atas sementara menarik wire
dengan benar (hal. ness out of
harness its hole.
keluar dari lubangnya.
1-14)
Route the wire Installation is in the reverse order of removal.
harness properly Pemasangan adalah dalam urutan terbalik dari
(page 1-14) pelepasan. LUGGAGE
SCREWS BOX
WIRE
HARNESS
2-7
CENTER
CENTER BODY
BODY COVER
COVER
Lepaskan kunci
Unlock the seat withtempat duduk
the ignition key. dengan anak kunci
kontak.
Open the seat.
Buka tempat duduk. HOOK SCREWS
Lepaskan sebagai berikut:
? Screw from front upper side
- – Screw
Two screws from
dari sisi frontatas.
depan lower side
– Two screws from both sides
- Dua screws dari sisi depan bawah
-Push
Duathe
screws
upperdari kedua
front side ofsisithe center body cover upward
and release
Dorong ke itatas
fromsisi
thedepan
floor panel.
atas dari center body cover
Hati-hati agarnot
Be careful to dan
tidak lepaskan
Remove dari body
the center panelcover
lantai.
while releasing its hooks from
merusak hooks dan
damage the hooks the slots on the body cover by sliding it forward.
slots.
and slots. Lepaskan center body cover sementara melepaskan
Installation isdari
hooks-nya in the reverse
slots order
pada of body
removal.cover dengan
menggesernya ke depan.

pelepasan.
SLOT
CENTER BODY COVER
TEMPAT
SEAT DUDUK
Lepaskan
Remove thecenter
centerbody
body cover (hal. 2-8).
cover (page 2-8)
LUGGAGE BOX LID
Lepaskan
Unhook the kaitan
luggage dari luggage
box lid boxit.lid (tutup kotak
and remove
bagasi)
Slide thedan
pin lepaskan.
out and remove the seat.
Geser pin keluar dan lepaskan tempat duduk.
pelepasan.
TEMPAT
DUDUK
PIN
GRAB
GRAB RAIL
RAIL (PEGANGAN TANGAN)
Lepaskan kunci
Unlock the seat withtempat duduk
the ignition key. dengan anak kunci
kontak.
Open the seat. GRAB RAIL
Buka tempat duduk.
? Four bolts
- – Empat
Grab rail
bolts
-Installation
Grab rail is in the reverse order of removal.
BOLTS
pelepasan.
2-8
BODY COVER
BODY COVER
Lepaskan sebagai
Remove the berikut:
following:
- – Center
Centerbody
bodycover
cover (hal.
(page2-8)
2-8)
- – Grab
Grabrail
rail(hal.
(page2-8)
2-8)
- – Dua
Two screwsdari
screws from thebawah
sisi lower side
– Special bolt from the lower
- Special bolt dari sisi kiri bawah left side
– Two bolts from the
- Dua bolts dari sisi atas upper side
Hati-hati agarnot
Be careful tidak
to Remove the body
Lepaskan body cover by releasing
cover denganthe following tabs/
melepaskan
merusak
damage hooks dan bosses/hooks:
the hooks tabs/bosses/hooks berikut ini:
tabs.
and tabs. - – Rear shock
Rear shock absorber
absorber cover
cover tab tab dengan
by slightly bending it agak
membengkokkannya
– Grab rail mounting bosses by slightly pulling the body
- Grab
coverrail mounting bosses dengan sedikit menarik
upward
body cover
– Hooks on the ke atas
front side of the body cover by pulling it
- Hooks pada
backward sisi depan dari body cover dengan
menariknya ke belakang
Disconnect the tail/brake light/rear turn signal light 6P con-
nector.
Lepaskan tail/brake light/rear turn signal light 6P
Alurkan wire the
Route wire connector.
harness Installation is in the reverse order of removal.
harness properly Pemasangan adalah dalam urutan terbalik
dengan benar (hal. dari
(page 1-14).
1-14). pelepasan.
BOLTS
BODY COVER
SCREWS
HOOKS/TABS
REAR SHOCK
ABSORBER
COVER TAB
SPECIAL BOLT
GRAB RAIL MOUNTING TAIL/BRAKE LIGHT/REAR TURN
BOSSES SIGNAL LIGHT 6P CONNECTOR
2-9
Lepaskan
Remove the sebagai berikut:
following:
- –Empat screws
Four screws
- – Tail/brake
Tail/brakelight/rear turnsignal
light/rear turn signal
lightlight
unit unit (unit lampu
belakang/lampu rem/lampu
– Right/left body covers sein belakang)
- –Body
Twocovers
screwskanan/kiri
- –Dua screws
Rear shock absorber cover
- Rear shock absorber cover
Assembly is in the reverse order of disassembly.
pembongkaran. TAIL/BRAKE LIGHT/REAR TURN
SIGNAL LIGHT UNIT
SCREWS
SCREWS
BODY COVER
REAR SHOCK
ABSORBER COVER
UNDER
UNDER COVER
COVER
Lepaskan sebagai
Remove the berikut:
following:
- –Dua
Twoscrews
screwsdari sisi
from thedepan
front side HOOKS
- –Empat screws dari kedua
Four screws from both sisi
sides SCREWS
- –Dua screws dari sisi belakang
Two screws from rear side
Lepaskan
Remove theunder coverbydengan
under cover releasing melepaskan
the following: sebagai
berikut:
– Hooks on the front side from the slots on front lower
- Hooks pada sisi depan dari slots pada front lower
cover
cover
– Tabs on both sides from the floor step
- Tabs pada kedua sisi dari floor step
pelepasan.
TABS
UNDER COVER SCREWS
2-10
FLOOR PANEL/FRONT
FLOOR PANEL/FRONT INNER
INNERCOVER
COVER
Lepaskan sebagai
Remove the berikut:
following:
- –Front lower
Front lowercover
cover(hal.
(page2-6)
2-6) FLOOR PANEL/FRONT INNER COVER
- –Front inner
Front innerupper cover (hal.
uppercover (page2-6)
2-6)
- –Body
Bodycover
cover(hal.
(page2-9)
2-9)
- –Under
Undercover
cover(hal. 2-10)
(page 2-10)
Remove the
Lepaskan floor
floor panel/frontinner
panel/front inner cover
cover assembly
assembly bydengan
pulling
it upward while
menariknya ke releasing the screwmelepaskan
atas sementara tabs from the screw
frame. tabs
dari rangka.is in the reverse order of removal.
Installation
pelepasan.
SCREW
TABS
REAR FENDER
REAR FENDER (SPAKBOR BELAKANG)
Lepaskan sebagai
Remove the berikut:
following:
BOSSES HOOKS
- –Body
Bodycover
cover(hal.
(page2-9)
2-9)
- –Fuel tank
Fuel tank(hal.
(page5-26)
5-26) BOLTS
Lepaskan ketiga
Remove the three bolts.
bolts.
Lepaskan
Remove therearrear fender sementara
fender while releasingmelepaskan
the bosses andbosses
hooks
by pulling
dan hooksitdengan
straight back and remove
menariknya it. ke belakang dan
lurus
melepaskannya.
pelepasan.
REAR FENDER
2-11
LEFT CRANKCASE
LEFT CRANKCASE COVER
COVER DUCT
DUCT
Lepaskan sebagai
Remove the berikut:
following:
- – Dua
Twobolts
bolts
- – Left crankcase LEFT CRANKCASE COVER DUCT
Left crankcasecover
cover duct
duct
- – Packing is in the reverse order of removal.
Packing
Installation
Pastikan
Make sure bahwa
the
packing Pemasangan adalah dalam urutan terbalik dari
packing is indalam
berada good
kondisi baik
condition anddan ganti pelepasan.
replace
bila perlu.
it if necessary.
PACKING
BOLTS
COOLING
COOLINGFAN
FANCOVER
COVER
Lepaskan kedua screws dan kedua bolts.
Remove the two screws and two bolts.
Lepaskan starting enrichment (SE) thermal valve wire
Release
dan the starting
starter enrichment
motor wire (SE)guide
dari wire thermal valve
dari wire and
cooling fan SE THERMAL VALVE/STARTER MOTOR WIRE
starter motor wire from the wire guide of the cooling fan
cover.
cover.
Lepaskan
Remove the cooling
coolingfan
fancover.
cover.
lurkan
Route wire Pemasangan
the wire
adalah
Installation is in the reversedalam urutan terbalik
order of removal. dari
harness dengan baik
harness properly pelepasan.
(hal. 1-14) TORQUE:
(page 1-14). SCREW
TORSI:
Cooling fan cover screw:
Cooling fan (0.1
0.8 N·m cover screw:
kgf·m, 0.6 lbf·ft)
0,8fan
Cooling N.m (0,1bolt:
cover kgf.m; 0,6 lbf.ft)
Cooling
9 N·mfan cover
(0.9 bolt:
9 N.m (0,9 kgf.m; 6,6 lbf.ft) JOINT NUTS
COOLING FAN COVER
BOLTS
2-12
TRIM CLIPS
REMOVAL
PELEPASAN
Push the
Tekan centerpin
center pindari
of the trim
trim clip.
clip.
Remove thetrim
Lepaskan trimclip.
clip. CENTER PIN TRIM CLIP
PEMASANGAN
INSTALLATION
Naikkan centerpinpin
Raise the center denganthe
by pushing menekan retaining
retaining tabs back. tabs
kembali. RETAINING TABS
Install the trim clip.
CENTER PIN
Push the trim
Pasang center pin until the pin is flush with the outer casing.
clip.
Tekan center pin sampai pin rata dengan outer casing.
TRIM CLIP
CENTER PIN
TRIM CLIP
BATTERY COVER
BATTERY COVER
Unlock the ignition key.
Buka
Open penguncian
the seat. dengan anak kunci kontak.
Naikkan tempat duduk. BATTERY COVER
Remove the trim clip (see page 2-13).
Remove thetrim
Lepaskan battery
clip cover.
(lihat hal. 2-13).
Lepaskan battery cover.
pelepasan.
TRIM CLIP
2-13
EXHAUST PIPE/MUFFLER
PIPE/MUFFLER (KNALPOT)
PELEPASAN
REMOVAL
Remove the
Lepaskan following:
sebagai berikut:
- – Dua joint
Two joint nuts
nuts
– Two muffler mountingbolts
- Dua muffler mounting bolts
GASKET JOINT
– Exhaust pipe/muffler
- Exhaust pipe/muffler
– Gasket
NUTS
- Gasket
PEMASANGAN
INSTALLATION
Ganti
Replaceexhaust gasket
the exhaust dengan
gasket with yang
a new baru.
one.
Tempatkan
Set the exhaustexhaust pipeonto
pipe flange flange pada
the stud stud
bolts and bolts
install dan
the
pasang joint
joint nuts, but nuts,
do nottetapi jangan
tighten kencangkan
them yet. Install the mereka
muffler
dulu.
mounting bolts, but do not tighten them yet.
Pasang muffler mounting bolts, tetapi jangan
Tighten the joint
kencangkan nuts first,
mereka dulu.then tighten the muffler mounting
bolts to the specified torque.
Kencangkan
TORQUE:59 joint nuts
N·m (6.0 dulu,
kgf·m, kemudian kencangkan
44 lbf·ft)
muffler mounting bolts dengan torsi yang ditentukan.
After installation, make sure the exhaust system does not
leak.
TORSI: 59 N.m (6,0 kgf.m; 44 lbf.ft)
Setelah pemasangan, pastikan bahwa sistem
pembuangan gas tidak bocor.
BOLTS
EXHAUST PIPE/MUFFLER
2-14
3. PERAWATAN
KETERANGAN SERVIS ...........................3-2

SERVICE INFORMATION?????????????? 3-2 OLI FINAL
FINAL DRIVE
DRIVE .....................................3-13
OIL???????????????????? 3-13
JADWAL PERAWATAN
MAINTENANCE ...........................3-4
SCHEDULE ??????????? 3-4 MINYAK
BRAKEREM............................................
FLUID ??????????????????????? 3-14 3-14
SALURAN BAHAN
FUEL LINE BAKAR .....................3-5
??????????????????????????? 3-5 KEAUSAN BRAKE SHOES/PADS...........
BRAKE SHOES/PADS 3-15
WEAR ?????????? 3-15
CARA KERJA OPERATION

THROTTLE THROTTLE .......................3-5
?????????????? 3-5 SISTEM
BRAKEREM ............................................
SYSTEM ????????????????????? 3-15 3-15
AIRAIR
CLEANER ..........................................3-6
CLEANER ???????????????????????? 3-6 BRAKE
BRAKELIGHT
LIGHTSWITCH...........................
SWITCH ?????????????? 3-17 3-17
CRANKCASE BREATHER.......................3-6
CRANKCASE BREATHER?????????????? 3-6 CARA KERJA
BRAKE LOCKBRAKE LOCK???????????
OPERATION ..................3-17
3-17
SPARK PLUG
SPARK (BUSI)
PLUG ...............................3-7
????????????????????????? 3-7 PENYETELAN ARAH
HEADLIGHT AIM LAMPU BESAR ....3-18
???????????????????? 3-18
JARAK RENGGANG
VALVE KLEP......................3-8
CLEARANCE ?????????????????? 3-8 KEAUSAN CLUTCH
CLUTCH SHOES SHOES....................3-18
WEAR??????????????? 3-18
OLIENGINE
MESIN OIL
................................................3-9
?????????????????????????? 3-9 SIDESTAND..............................................
SIDESTAND?????????????????????????? 3-18 3-18
ENGINE OIL
ENGINE STRAINER
OIL STRAINERSCREEN.........3-11
SCREEN?????? 3-11 SUSPENSI ................................................3-19
SUSPENSION????????????????????????? 3-19
PUTARAN
ENGINE STASIONER MESIN.............3-11
IDLE SPEED ????????????????? 3-11 MUR, BAUT,
NUTS, PENGIKAT
BOLTS, ..........................
FASTENERS ??????????? 3-20 3-20
SECONDARY AIR SUPPLY SYSTEM....3-12

SECONDARY AIR SUPPLY SYSTEM ??? 3-12
RODA/BAN ............................................... 3-20
WHEELS/TIRES ?????????????????????? 3-20
DRIVE BELT ...........................................3-13

DRIVE BELT????????????????????????? 3-13
STEERING HEAD BEARINGS ................. 3-21
STEERING HEAD BEARINGS?????????? 3-21
3-1
PERAWATAN
SERVICE INFORMATION
M
AINTENANCE
KETERANGAN SERVIS
UMUM
GENERAL
• ? Gasoline is extremely
Bensin sangat mudahflammable
terbakar and
danis dapat
explosive under certain
meledak conditions.
pada kondisi Work Bekerjalah
tertentu. in a well ventilated area.
di tempat Smoking
dengan or allowing
ventilasi flames or
baik. Merokok
sparks in the work area or where the gasoline is stored can cause a fire or explosion.
atau membiarkan api atau percikan bunga api di tempat kerja atau tempat di mana bensin disimpan dapat menyebabkan
? Ifkebakaran
the engine must
atau be running to do some work, make sure the area is well ventilated. Never run the engine in an enclosed area. The exhaust
ledakan.
• contains
Jika mesin harus hidupmonoxide
poisonous carbon gas that may
untuk melakukan cause loss
sesuatu of consciousness
pekerjaan, pastikanand may tempat
bahwa lead to death.
kerja Run the engineventilasi
mempunyai in an open areaJangan
baik. or with
an exhaust evacuation system in enclosed area.
sekali-kali menjalankan mesin di dalam ruangan tertutup. Gas pembuangan mengandung gas karbon monoksida beracun
? Place the scooter on a level ground before starting any work.
yang dapat menghilangkan kesadaran dan dapat menuju ke kematian. Jalankan mesin di tempat terbuka atau di tempat
tertutup yang mempunyai sistem pemindahan gas pembuangan.
• Letakkan skuter di atas tanah mendatar sebelum memulai sesuatu pekerjaan.
SPECIFICATIONS
SPESIFIKASI ITEM SPECIFICATIONS
Throttle grip freeplay 2 – 6 mm (0.1 – 0.2 in)
BAGIAN
Spark plug Standard SPESIFIKASI
CPR8EA-9 (NGK)
Jarak main bebas throttle grip
For extended high speed riding 2 – 6 mm(NGK)
CPR9EA-9
Busi
Spark plug gap Standard CPR8EA-9
0.80 – 0.90 mm(NGK), (0.031 U24EPR9
– 0.035 in) (DENSO)
Valve clearance Untuk
IN pengendaraan lama pada 0.14
CPR9EA-9 (NGK)
± 0.02 mm (0.006 ± 0.001 in)
kecepatan
EX tinggi 0.14 ± 0.02 mm (0.006 ± 0.001 in)
Jarak renggangengine
Recommended busi oil 0,80 "4-stroke
Honda – 0,90 mm motorcycle oil" or an equivalent motor oil API service
Jarak renggang klep IN (Masuk) 0,14 ± 0,02SG
classification: mm or higher (except oils labeled as energy conserving on
EX (Buang) the0,14 ± 0,02
circular APImm service label)
Oli mesin yang dianjurkan JASO
FederalT 903Oil standard:
Supreme MB Flick atau oli mesin 4 tak sejenis
Viscosity:
dengan SAE 10W-30
klasifikasi API service SG,
Engine oil capacity After draining 0.7Viskositas:
liter (0.7 US qt, 0.6
SAE Imp qt)
10W-30 JASO MB
Kapasitas oli mesin Afterpenggantian
Pada disassembly periodik 0.80,7
liter (0.8 US qt, 0.7 Imp qt)
liter
Engine idle speed Pada pembongkaran mesin 1,700 ± 100 min-1 (rpm)
0,8 liter
Drive belt
Putaran width mesin
stasioner Service
1.700limit:± 100 17.5 mm-1 (rpm)
menit (0.69 in)
Recommended
Lebar drive beltfinal reduction oil Honda
Batas "4-stroke motorcycle
servis: 17,5 mm oil" or an equivalent motor oil API service
Oli final reduction yang dianjurkan classification:
Federal OilSGSupreme or higher (except oils labeled
Flick atau as energy
oli mesin conserving
4 tak sejenison
thedengan
circularklasifikasi
API service label)
API service SG,
JASO T 903 standard:
Viskositas: SAE 10W-30MB JASO MB
Kapasitas oli final Pada penggantian periodik Viscosity:
0,10 liter SAE 10W-30
Final reduction oil
reduction Afterpembongkaran
Pada draining 0.10
0,12liter (0.11 US qt, 0.09 Imp qt)
liter
capacity
Jarak main bebas handel rem Afterbelakang
disassembly 0.12
10 liter
– 20(0.13
mm US qt, 0.11 Imp qt)
Rear brake lever free play
Ketebalan clutch lining (kanvas kopeling) 10 – 20 mm
Batas servis: (0.4 2,0
– 0.8
mm in)
Clutch lining thickness
Tekanan udara ban Pengendara Depan Service limit: 2.0 mm
200 kPa (2,00 kgf/cm , 29 (0.082 in)
psi)
2 2psi)
Cold tire pressure
dingin Driver only
saja Front
Belakang 200 kPa (2.00 kgf/cm , 29
225 kPa (2,25 kgf/cm , 33 psi)
2
Pengendara dan Depan Rear 225200kPa kPa(2.25 kgf/cm
(2,00 , 332,psi)
kgf/cm 29 psi)
2
Driver and passengerBelakang
pembonceng Front 200225kPa kPa (2.00 kgf/cm
(2,25 , 292,psi)
kgf/cm 33 psi)
2
Ukuran ban Depan Rear 225 kPa (2.25
80/90 – 14M/C40P kgf/cm , 33 psi)
Tire size Front
Belakang 80/90
90/90 – 14M/C40P
– 14M/C46P
Merek ban SRI Depan Rear 90/90
FT235 – 14M/C46P
Tire brand SRI Front
Belakang FT235
FT235
Kedalaman minimum alur telapak ban Depan Rear FT235
Sampai ke indikator
Minimum tire tread depth Front
Belakang ToSampai
the indicator
ke indikator
Rear To the indicator
3-2
PERAWATAN
TORQUE
NILAI VALUES
TORSI
Spark plug
Spark plug(busi) 16 N.m
16 N·m (1,6 kgf.m;
(1.6 kgf·m, 12 lbf.ft)
12 lbf·ft)
AirAir
cleaner
cleanerhousing
housingcover
cover screw
screw 1,1 N.m (0,1 kgf.m; 0,8 lbf.ft)
1.1 N·m (0.1 kgf·m, 0.8 lbf·ft)
Valve
Valve adjusting screwlock
adjusting screw lock nut
nut 10 N·m (1.0 kgf·m, 7 lbf·ft)lbf.ft) ApplySemprotkan
10 N.m (1,0 kgf.m; 7 engine oil to oli
themesin
threadspada
and ulir dan
seatingpermukaan
surface. duduk
Engine
Engineoiloil
drain
drainbolt
bolt 24 N.m (2,4 kgf.m; 18
24 N·m (2.4 kgf·m, 18 lbf·ft) lbf.ft)
Engine
Engine oil strainerscreen
oil strainer cap
screen cap 20 N.m
20 N·m (2,0 kgf.m;
(2.0 kgf·m, 15 lbf.ft)
15 lbf·ft)
Final reduction oil check bolt
Final reduction oil check bolt 13 N·m (1.3 kgf·m, 10 lbf·ft) lbf.ft)
13 N.m (1,3 kgf.m; 10
Final reduction oil drain bolt 13 N.m (1,3 kgf.m; 10 lbf.ft)
Final reduction oil drain bolt 13 N·m (1.3 kgf·m, 10 lbf·ft)
TOOLS
TOOLS
Valve adjusting wrench

07908-KE90000
3-3
PERAWATAN
MAINTENANCE SCHEDULE
JADWAL PERAWATAN
Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.
Jalankan Pemeriksaan Sebelum Jalan di dalam Buku Pedoman Pemilik pada masing-masing periode perawatan yang
I:dijadwalkan.
Inspect and Clean, Adjust,dan
P: Periksa Lubricate or Replace
Bersihkan, if Lumasi
Setel, necessary. C: Clean.
atau R: Replace.
Ganti bila A:Bersihkan.
perlu. B: Adjust. L: Lubricate.
G: Ganti. L: Lumasi. PB: Perawatan
The following items require some mechanical knowledge. Certain items (particularly those marked * and(terutama
Berkala. Bagian-bagian berikut memerlukan pengetahuan mekanis tertentu. Beberapa bagian yang ditandai
**) may require * daninfor-
more technical **)
mation
dapat and tools. Consult
memerlukan lebihanbanyak
authorized Honda dealer.
informasi teknis dan perkakas khusus. Hubungi AHASS Anda.
FREQUENCY WHICHEVER
JADWAL PERAWATAN BERKALA, MANA YANG TERCAPAI TERLEBIH DAHULU
COMES FIRST ODOMETER READING (NOTE 1)
FREKUENSI → PEMBACAAN ODOMETER (km) - Catatan 1 LIHAT
REFER TO
X1,000 km 1 4 8 12 HALAMAN
PAGE
↓ PB 1 PB 2 X1,000
PB mi3 0.6 2.5 5 7.5
BAGIAN YANG DISERVIS
ITEMS 500 2.000 Months
4.000 8.000 6 12.000
12 18
* SALURAN
* FUEL LINE BAHAN BAKAR P P P P I P I I 3-5
3-5
** THROTTLE
CARA KERJAOPERATION
GAS TANGAN P P P P I PI I 3-5
3-5
** AIR
AIR CLEANER
CLEANER Catatan 2 NOTE2 SETIAPEVERY
16.000 km: G km (10,000 mi) R
16,000 3-6
3-6
CRANKCASE BREATHER
CRANKCASE BREATHER Catatan 4 NOTE4
B B B B C BC C 3-6
3-6
BUSI
SPARK PLUG P P P G I P
R I 3-7
3-7
* JARAK RENGGANG
* VALVE CLEARANCE KLEP P P P P I I P I I 3-8
3-8
OLI MESINOIL
ENGINE G G SETIAP
R 4.000
R km: GR R 3-93-9
** ENGINE
ENGINE OIL
OILSTRAINER
STRAINERSCREEN
SCREEN - - - B - C 3-11
3-11
* PUTARAN STASIONER
* ENGINE IDLE SPEED
MESIN P P P P I I
P I I
3-11
3-11
* SECONDARY AIR SUPPLY SYSTEM P - - - P 3-12
* SECONDARY AIR SUPPLY SYSTEM I 3-12
* DRIVE BELT SETIAP 8.000 km: P 3-13
* DRIVE BELT EVERY 8,000 km (5,000 mi) I,
SETIAP 24.000 km: G 3-13
EVERY 24,000 km (15,000 mi) R
* OLI FINAL DRIVE Catatan 3 3-13
* FINAL DRIVE OIL NOTE3 3-13
MINYAK REM Catatan 3 P P P P P 3-14
BRAKE FLUID NOTE3 I I I 3-14
KEAUSAN BRAKE SHOES/PADS P P P P P 3-15
BRAKE SHOES /PADS WEAR I I I 3-15
SISTEM REM P P P P P 3-15
BRAKE SYSTEM I I I I 3-15
* SAKELAR LAMPU REM P P P P P 3-17
* BRAKE LIGHT SWITCH I I I 3-17
* CARA KERJA BRAKE LOCK P P P P P 3-17
* BRAKE LOCK OPERATION I I I I 3-17
* ARAH SINAR LAMPU BESAR P P P P P 3-18
* HEADLIGHT AIM I I I 3-18
** KEAUSAN CLUTCH SHOES - - - P - 3-18
** CLUTCH SHOES WEAR I 3-18
STANDARD SAMPING P P P P P 3-18
SIDESTAND I I I 3-18
* SUSPENSI P P P P P 3-19
* SUSPENSION I I I 3-19
* MUR, BAUT, PENGENCANG P P P P P 3-20
* NUTS, BOLTS, FASTENERS I I 3-20
** RODA/BAN Catatan 3 P P P P P 3-20
** WHEELS/TIRES I I
** BANTALAN KEPALA KEMUDI P - - P -I I 3-20
3-21
** STEERING HEAD BEARINGS I I 3-21
* HARUS DISERVIS OLEH AHASS, KECUALI BILA PEMILIK MEMPUNYAI TOOLS YANG TEPAT DAN DATA
* SERVIS
SHOULD
YANGBE SERVICEDDAN
DIPERLUKAN, BY AN AUTHORIZED
MEMPUNYAI Honda MEKANIS
KETRAMPILAN DEALER, UNLESS
UNTUK THE OWNER HAS PROPER TOOLS AND SERVICE
MENGERJAKANNYA.
DATA AND IS MECHANICALLY QUALIFIED.
** DEMI KEAMANAN, KAMI MENGANJURKAN AGAR PEKERJAAN-PEKERJAAN INI HANYA DILAKUKAN OLEH
** AHASS.
IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED Honda
DEALER.
CATATAN:
NOTES:
1. Pada pembacaan odometer lebih tinggi, ulangilah pada interval frekuensi yang ditentukan di atas.
1.2. AtServis
higher odometer readings,
lebih sering repeat at the
jika dikendarai di frequency interval
daerah yang luarestablished here.
biasa basah atau berdebu.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Ganti setiap 2 tahun. Penggantian memerlukan ketrampilan mekanis.
3. Replace every 2 years. Replacement requires mechanical skill.
4. Servis lebih sering jika dikendarai dalam hujan atau dengan gas penuh.
4. Service more frequently when riding in rain or at full throttle.
3-4
PERAWATAN
SALURAN
FUEL LINEBAHAN BAKAR
Lepaskan body
Remove the cover
body cover(hal.
(page2-9)
2-9)
Periksa
Check thefuel hosefor (slang
fuel hose bahan
deterioration, bakar)
damage terhadap
or leakage.
pemburukan kondisi, kerusakan atau kebocoran.
Replace the fuel hose if necessary.
Ganti
Also,fuel hose
check bila hose
the fuel perlu.
fittings for leakage.
Juga,
Installperiksa
the bodyfuel hose
cover fittings
(page 2-9). (peralatan pemasangan
fuel hose) terhadap kebocoran.
Pasang body cover (hal. 2-9)
FUEL HOSE
CARA KERJA
THROTTLE THROTTLE (GAS TANGAN)
OPERATION
CATATAN:
• ? Reusing
Pemakaian kembali
a damaged or throttle cable
abnormally (kabel
bent gas)throttle
or kinked yang
rusak, tertekuk atau bengkok secara tidak normal
cable can prevent proper throttle slide operation and may
dapat
lead to amengganggu
loss of throttle cara kerja
control whilethrottle
riding. slide yang
benar dan dapat mengakibatkan hilangnya
Check for any deterioration or damage to the throttle cable.
pengontrolan atas throttle sewaktu pengendaraan.
Check the throttle grip for smooth operation. Check that the
throttle opens and automatically closes in all steering posi-
Periksa terhadap pemburukan kondisi atau kerusakan
tions.
pada throttle cable. Periksa throttle grip (putaran gas
If the throttle
tangan) terhadap gripkelancaran
does not return properly,
cara kerja. lubricate
Periksa the
bahwa
throttlemembuka
throttle cable. dan secara otomatis menutup kembali
For cable
pada semua lubrication, disconnect the throttle cable at their
posisi kemudi.
pivot points and apply commercially available cable lubricant
or light
Jika weight
throttle oil. tidak kembali dengan benar, lumasi
grip
throttle cable.
If the throttle grip still does not return properly, replace the
Untuk melumasi
throttle cable. cable, lepaskan throttle cable pada titik-
titik perputarannya dan oleskan dengan pelumas kabel
With dapat
yang the engine idling,
dibeli di turn the handlebar
pasaran atau olialldengan
the way to the
berat
right and left to ensure that the idle speed does not change. If
ringan.
idle speed increases, check the throttle grip free play and
throttle
Jika cable routing.
throttle grip tetap tidak dapat kembali dengan
benar, gantilah throttle cable.
Sementara mesin berputar stasioner, putar handlebar

(stang stir) sama sekali ke kanan dan kiri untuk
memastikan bahwa putaran stasioner tidak berubah.
Jika putaran stasioner naik, periksa jarak main bebas
throttle grip dan alur perletakan throttle cable.
Ukur jarak
Measure themain bebas
throttle throttle
grip free play atgrip pada throttle
the throttle grip
grip flange.
flange.
FREEPLAY: 2 – 6 mm (0.1 – 0.2 in)
JARAK MAIN BEBAS: 2 – 6 mm 2 – 6 mm (0.1 – 0.2 in)
3-5
PERAWATAN
Jarak main
Throttle bebas
grip free playthrottle grip dapat
can be adjusted disetel
by turning dengan
the adjuster.
memutar adjuster (penyetel). ADJUSTER
Remove the body cover (page 2-9).
Loosen thebody
Lepaskan lock nut and(hal.
cover turn 2-9).
the adjusting nut as required.
Tighten the lock
Longgarkan locknut.
nut (mur pengunci) dan putar adjusting
nut
Recheck the throttlesebanyak
(mur penyetel) operation. diperlukan.
Install the body
Kencangkan cover
lock nut.(page 2-9).
Periksa kembali cara kerja throttle.
Pasang body cover (hal. 2-9).
LOCK NUT
AIR
AIR CLEANER
CLEANER
CATATAN:
• ? The
Viscous paper
viscous paperelement
element (elemen
cannot bekertas
cleanedkental) tidak
because the
COVER
element
dapat contains a dust adhesive.
dibersihkan oleh karena element ELEMENT
? If the scooter is
mengandung used indebu.
perekat unusually wet or dusty areas,
• more frequent inspections
Jika skuter dipakai di daerah are required.
yang luar biasa basah
atau berdebu, diperlukan pemeriksaan
Remove the screws and air cleaner housing cover yang
fromlebih
the
sering.
right side.
Remove and discard the air cleaner element in accordance
Lepaskan screws dan
with the maintenance air cleaner
schedule (pagehousing
3-4). cover dari sisi
kanan.
Replace the element any time if it is excessively dirty or dam-
Lepaskan
aged. dan buanglah air cleaner element sesuai
dengan jadwal perawatan (hal. 3-4).
Install element
Ganti the removed parts waktu
setiap in the reverse ordermenjadi
ia telah of removal.
sangat
kotor atau
TORQUE: rusak.
Pasang parts housing
Air cleaner yang telah dilepaskan dalam urutan
cover screw: SCREWS
terbalik1.1
dari pelepasan.
N·m (0.1 kgf·m, 0.8 lbf·ft)
TORSI:
Air cleaner housing cover screw:
CRANKCASE BREATHER
1,1 N.m (0,1 kgf.m; 0,8 lbf.ft)
CRANKCASE BREATHER
? Service more frequently when ridden in rain, at full throt-
CATATAN:
tle, or after the scooter is washed or overturned. Service if
• Servis lebih sering jika dikendarai dalam hujan, HOSE CLAMP
the deposit level can be seen in the transparent section of
atau pada gas penuh, atau setelah skuter dicuci
the drain hose.
atau telah terbalik. Lakukan servis bila tinggi
Release the crankcase
permukaan breather
endapan dapatdrain hose dalam
terlihat from the hose
bagian
clamp.
tembus pandang dari drain hose (slang
pembuangan).
Remove the crankcase breather drain hose plug from the hose
end and drain deposits into a suitable container.
Lepaskan crankcase breather drain hose (slang
Install the crankcase
pembuangan breather
pernapasan bakdrain hosedari
mesin) plughose
and set the
clamp
crankcase breather
(klem slang). hose to the hose clamp.
Lepaskan crankcase breather drain hose plug
(penyumbat slang pembuangan pernapasan bak mesin) DRAIN HOSE HOSE PLUG
dari ujung hose dan keluarkan endapan ke dalam
penampung yang sesuai.
Pasang crankcase breather drain hose plug dan

tempatkan crankcase breather hose pada hose clamp.
Check the crankcase breather hose for deterioration, damage
or leakage.
Replace the crankcase breather hose if n ecessary.
Also check the crankcase breather hose fittings for leakage.
Install the body cover (page 2-9).
3-6
PERAWATAN
SPARK PLUG
Lepaskan body cover (hal. 2-9).
Periksa crankcase breather hose terhadap pemburukan
kondisi, kerusakan atau kebocoran.
? Clean around the spark plug base with compressed air ore
removing the plug, and make sure that no debris is
Ganti crankcase breather hose bila perlu.
Juga periksa crankcase breather hose fittings terhadap
?
kebocoran.

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

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

CPR8EA-9 (NGK)
For extended high
BUSI YANG DITENTUKAN:speed riding: CPR9EA-9 (NGK)
Standard:
CPR8EA-9 (NGK), U24EPR9 (DENSO)
Untuk pengendaraan lama pada kecepatan tinggi:
CPR9EA-9 (NGK)
3-7
PERAWATAN
Ukur jarak
Measure therenggang
spark plugbusi antara center
gap between electrodes
the center dan
and side elec-
side electrodes
trodes (elektrode
with a feeler gauge of tengah dan samping) dengan
a wire type.
feeler gauge (alat
If necessary, voeler)
adjust jenis
the gap by kawat.
bending the side electrode
carefully.
Bila perlu, setel jarak renggang busi dengan menekuk
electrode samping dengan hati-hati.
SPARK PLUG GAP: 0.80 – 0.90 mm (0.031 – 0.035 in)
0.80 – 0.90 mm
JARAK RENGGANG BUSI: 0,80 – 0,90 mm
(0.031 – 0.035 in)
angan not overtighten Pasang

Domengencangkan spark
Install and handplug (busi)
tighten the dengan tangan
spark plug to the pada cylinder
cylinder head,
spark plug. head,
theberlebihan.
busi secara kemudian
then tighten kencangkan
the spark busi dengan
plug to the specified torque.torsi yang
ditentukan.
TORQUE:16 N·m (1.6 kgf·m, 12 lbf·ft)
TORSI:
Connect 16the N.m
spark(1,6
plugkgf.m;
cap. 12 lbf.ft)
Pasang spark
Install the plug
center cap
body (topi(page
cover busi).
2-8).
Pasang center body cover (hal. 2-8).
SPARK PLUG CAP SPARK PLUG
JARAK
VALVE RENGGANG
CLEARANCEKLEP
PEMERIKSAAN
INSPECTION
CATATAN:
• ? Inspect
Periksaanddan setel
adjust thejarak
valve renggang klep the
clearance while sementara
engine is
mesin
cold dalam
(below keadaan dingin (di bawah 35° C).
35°C/95°F).
Remove the
Lepaskan following:
sebagai berikut:
PENUNJUK
? Cylinder head cover (page 7-7)
- Cylinder head cover (hal. 7-7)
? Cooling fan cover (page 2-12)
- Cooling fan cover (hal. 2-12)
Rotate the crankshaft clockwise by rotating the cooling fan
Putar crankshaft (poros engkol) searah jarum jam
slowly and align the "T mark" on the flywheel with the index
dengan memutar cooling fan dengan pelan dan
notch on the right crankcase.
mentepatkan "tanda T" pada flywheel dengan index
Make (takik
notch sure the piston ispada
penunjuk) at TDC (Top
right Dead Center)
crankcase (bak on the
mesin
compression
kanan). stroke.
This position can be confirmed by checking that there is slack
in the rocker
Pastikan arm. piston berada pada TDC (Top Dead
bahwa
Center) [TMAslack,
If there is no (TitikitMati
is because
Atas)] the piston
pada is moving
langkah through
kompressi.
the exhaust stroke to TDC.
Posisi ini dapat dipastikan dengan memeriksa bahwa
Rotate
ada the crankshaftpada
kerenggangan one full turnarm.
rocker by rotating the cooling fan TANDA "T"
Jika tidak ada kerenggangan, again.
slowly and match up the "T" mark berarti bahwa piston
sedang bergerak melalui langkah pembuangan ke TDC.
Putar crankshaft satu putaran penuh dengan memutar
cooling fan dengan pelan dan mentepatkan "tanda T"
sekali lagi.
3-8
PERAWATAN
Check the
Periksa jarakvalve clearance
renggang klep by inserting
dengan a feeler gauge
memasukkan feeler
between(lidah
gauge the valve adjustingantara
pengukur) screw and valveadjusting
valve stem. screw FEELER GAUGE
(sekrup penyetelan klep) dan valve stem (tangkai klep).
VALVE CLEARANCE:
IN: 0.14
JARAK ± 0.02 mm (0.006
RENGGANG KLEP:± 0.001 in)
EX:
IN: 0.14 ± 0.02 mm
0,14 0,02 mm (0.006 ± 0.001 in)
EX: 0,14 0,02 mm
Jika jarak
If the valverenggang
clearance klep tidak sesuai,
is incorrect, longgarkan
loosen the valve
valve adjusting
adjusting
screw lockscrew
nut andlock nut the
adjust danvalve
setel jarak renggang
clearance by turningklep
the ADJUSTING SCREW LOCK NUT
dengan
adjustingmemutar
screw until adjusting
there is a screw sampai
slight drag on theada tahanan
feeler gauge.
sedikit
Apply pada
enginefeeler gauge.
oil to the valve adjusting screw lock nut threads
Semprotkan oli mesin pada ulir valve adjusting screw
and seating surface.
Holdnut
lock thedan
adjusting screw and
permukaan tighten the lock nut.
duduk.
Tahan adjusting screw dan kencangkan lock nut.
TOOL:
Valve adjusting wrench
TOOL: 07908-KE90000
Valve adjusting wrench 07908-KE90000
TORSI:
Recheck 10theN.m
valve(1,0 kgf.m; 7 lbf.ft)
clearance.
Install the
Periksa following:
kembali jarak renggang klep.
Pasang
? Cylinder headberikut:
sebagai cover (page 7-7) VALVE ADJUSTING WRENCH
- Cylinder head cover(page
? Cooling fan cover (hal.2-12)
7-7)
- Cooling fan cover (hal. 2-12)
OLI MESIN
ENGINE OIL
PEMERIKSAAN TINGGI PERMUKAAN OLI
OIL LEVEL CHECK
Letakkan
Support theskuter
scooterdiwithatas standard on
its centerstand utamanya di atas
a level surface.
tanah mendatar. FILLER CAP/DIPSTICK
Start the engine
Hidupkan mesinand danletbiarkan
it idle forberputar
3 - 5 minutes.
stasioner selama
Stop the
3-5 menit. engine and wait for 2 - 3 minutes.
Matikan
Removemesinthe oildan
fillertunggu selama
cap/dipstick 2-3
and menit.
wipe off the oil from
the dipstick with a clean cloth.
Lepaskan oil filler cap/dipstick (tutup pengisian
oli/tangkai
Insert the oilpengukur) dan sekalah
filler cap/dipstick oli screwing
without dari dipstick
it in,
remove kain
dengan it andbersih.
check the oil level. UPPER
The level should be between the "UPPER" and "LOWER"
Masukkan oil filler cap/dipstick tanpa menyekrupkannya
level lines of the oil filler cap/dipstick.
ke dalam, lepaskan dan periksa tinggi permukaan oli.
LOWER
Tinggi permukaan harus antara garis tinggi permukaan
"UPPER" (TERATAS) dan "LOWER" (TERBAWAH) dari
oil filler cap/dipstick.
Viskositas lain yang
Other viscosities Jika
If thetinggi permukaan
oil level is below oroli
nearberada di level
the lower bawah lineatau dekat
on the dip-
diperlihatkan pada peta
shown in the chart
dapat dipakai jika suhu
garis tinggi
stick, add permukaanoil terbawah
the recommended dari dipstick,
to the upper level.
may be used di
rata-rata when the
daerah tambahkan oli yang dianjurkan sampai ke tinggi
average temperature RECOMMENDED
permukaan teratas. ENGINE OIL:
pengendaraan anda
in your
berada riding daerah
di dalam area is Honda "4-stroke motorcycle oil" or equivalent motor oil
within the indicated
jangkauan yang OLIAPI classification:
MESIN SG or higher
YANG DIANJURKAN:
diperlihatkan.
range. (exceptOil
Federal oils Supreme
labeled as energy
Flick conserving
atau oli on the circular
mesin 4 tak
API service
sejenis dengan label)
klasifikasi API service SG,
JASO T 903
Viskositas: SAE standard:
10W-30MB JASO MB
3-9
PERAWATAN
Pastikan
Make surebahwa O-ring
the O-ring is inberada dalam kondisi
good condition baik it
and replace danif
ganti bila perlu.
necessary.
O-RING
Coat the O-ring with engine oil and install the oil filler cap/
Lapisi O-ring dengan oli mesin dan pasang oil filler
dipstick.
cap/dipstick.
For engine oil change, see page 3-10.
Untuk penggantian oli mesin, lihat hal. 3-10.
FILLER CAP/DIPSTICK
PENGGANTIAN
OIL CHANGE OLI
CATATAN:
•? Change
Ganti oli
the mesin
engine sewaktu mesin
oil with the dalam
engine warmkeadaan
and the
scooter on level ground to assure complete draining.untuk
panas dan skuter di atas tanah mendatar
memastikan pengeluaran secara menyeluruh.
Support the scooter with its centerstand.
Letakkan skuterwarm
Start the engine, padaitstandard utamanya.
up and stop it.
Hidupkan mesin,
Remove the panaskan
oil filler dan matikan.
cap/dipstick.
Lepaskan oil filler cap/dipstick.
FILLER CAP/DIPSTICK
Place an oilloyang
Letakkan drain pan under the engine
pembuangan oli di to collectmesin
bawah the oil,untuk
then
remove the oil drain
mengumpulkan oli,bolt
danandlepaskan
sealing washer.
oil drain bolt dan
sealing washer.
Slowly apply kickstarter and drain the engine oil.
After draining
Jalankan the oil dengan
kickstarter completely, install
pelan danthekeluarkan
new sealing
oli
washer
mesin. and oil drain bolt.
Tighten the drain bolt to the specified torque.
Setelah mengeluarkan oli secara menyeluruh, pasang
sealing washer baru dan oil drain bolt.
Kencangkan drain
Fill the crankcase bolt
with thedengan torsi yang
recommended ditentukan.
engine oil.
TORSI:
ENGINE24 OIL N.m (2,4 kgf.m; 18 lbf.ft)
CAPACITY:
Isi 0.7 liter (0.7dengan
crankcase US qt, 0.6
oli lmp qt)yang
mesin after dianjurkan.
draining
0.8 liter (0.8 US qt, 0.7 lmp qt) after disassembly
KAPASITAS OLI MESIN: WASHER/DRAIN BOLT
Check the oilpada
0,7 liter level penggantian
(page 3-9). periodik
0,8 liter setelah pembongkaran
Make sure that there are no oil leaks. mesin
Periksa tinggi permukaan oli (hal. 3-9).
Pastikan bahwa tidak ada kebocoran oli.
3-10
PERAWATAN
ENGINE OIL
ENGINE OILSTRAINER
STRAINERSCREEN
SCREEN
(SARINGAN Drain
KASA OLIoil MESIN)
the engine (see page 3-10).
OIL STRAINER SCREEN OIL STRAINER
Remove the
Keluarkan olioil strainer
mesin screen
(lihat cap, O-ring, spring and oil
hal. 3-10). SCREEN CAP
strainer screen.
Keluarkan oil strainer screen cap, O-ring, spring dan oil
Wash the
strainer strainer screen thoroughly in non-flammable or
screen.
high flash point cleaning
Cucilah strainer screensolvent
secarauntilmenyeluruh
all accumulated dirt
dalam
has been removed.
larutan pembersih yang tidak dapat terbakar atau
Blow dry it with compressed air to clean completely.
mempunyai titik api tinggi sampai semua kotoran yang
telah
Beforeterkumpul
installingtelah dibersihkan.
the strainer screen, it should be examined
Keringkan denganandmeniupnya
closely for damage make sure the dengan
sealing udara
rubber isdari
in
good condition.
kompressor untuk membersihkan secara menyeluruh.
Make sure the O-ring is in good condition and replace it if
Sebelum memasang strainer screen, periksalah dengan
necessary.
teliti terhadap kerusakan dan pastikan bahwa sealing SPRING O-RING
Install the
rubber oil strainer
berada dalamscreen andbaik.
kondisi spring with the strainer seal-
ing rubber toward the crankcase.
Pastikan bahwa O-ring dalam kondisi baik dan ganti bila
Coat the O-ring with engine oil and install the oil strainer
perlu.
screen cap.
Pasang oil oil
Tighten the strainer
strainerscreen dantospring
screen cap dengan
the specified strainer
torque.
sealing rubber menghadap ke crankcase.
TORQUE:20
Lapisi N·m (2.0 oli
O-ring dengan kgf·m, 15 lbf·ft)
mesin dan pasang oil strainer
screen cap.
Fill the crankcase with recommended engine oil and check
Kencangkan oil strainer screen cap dengan torsi yang
the engine oil level (page 3-9).
ditentukan.
Make sure that there are no oil leaks.
Isi crankcase yang oli mesin yang dianjurkan dan
periksa tinggi permukaan oli mesin (hal. 3-9).
Pastikan bahwa tidak ada kebocoran oli.
PUTARAN STASIONER
ENGINE IDLE SPEED MESIN
CATATAN:
• ? Inspect
Periksaanddan setelthe
adjust putaran stasioner
idle speed setelah
after all other semua
engine
bagian perawatan
maintenance mesin
items have beenyang lain telah
performed and dijalankan
are within ADJUSTING HOLE CAP
dan adalah sesuai dengan spesifikasi.
specifications.
• ? The
Mesin
engineharus
must bedalam
warm forkeadaan panas
accurate idle untuk
speed inspec-
pemeriksaan
tion danTen
and adjustment. penyetelan putaran stasioner
minutes of stop-and-go riding is
sufficient.
yang akurat. Sepuluh menit pengendaraan jalan-
dan-berhenti
Support the scooteradalah
with itscukup.
centerstand.
Warm up the engine about ten minutes.
Letakkan skuter pada standard utamanya.
Connect a tachometer
Panaskan and check
mesin selama the sepuluh
kira-kira idle speed.
menit.
Hubungkan
IDLE SPEED: 1,700 ± 100
tachometer dan -1
periksa
min putaran stasioner.
(rpm)
-1
PUTARAN
If the engineSTASIONER:
idle speed is out1.700 100 menit
of specification, (rpm)
adjust as fol-
lows:
Jika putaran stasioner mesin tidak sesuai dengan THROTTLE STOP SCREW
Unlock the seat with ignition key.
spesifikasi,
Open the seat.
setel sebagai berikut:
Buka penguncian
Remove the adjusting tempat duduk
hole cap and dengan
turn the anak
throttlekunci
stop
kontak.
screw as required to obtain the specified idle speed.
Naikkan tempat duduk.
Lightly open
Lepaskan the throttle
adjusting holeforcap2 –dan
3 times,
putarthen checkstop
throttle the
engine idle speed again.
screw sebanyak diperlukan untuk mendapatkan putaran
stasioner
Install the yang ditentukan.
removed parts in the reverse order of removal.
Bukalah throttle 2 - 3 kali dengan ringan, kemudian

periksa putaran stasioner mesin sekali lagi.
Pasang parts yang telah dilepaskan dalam urutan

terbalik dari pelepasan.
3-11
PERAWATAN
SECONDARY AIR SUPPLY SYSTEM
SYSTEM
PEMERIKSAAN
INSPECTION
Remove the
Lepaskan airaircleaner
cleanerhousing
housing cover
cover(page
(hal. 3-6).
3-6).
Remove thePAIR
Lepaskan PAIRair
aircleaner
cleaner element.
element.
ELEMENT
CATATAN:
• ? Never
Janganuse sekali-kali memakai
gasoline or low bensin
flash point atauforpelarut
solvents clean-
dengan titik api rendah untuk membersihkan
ing the element. A fire or explosion could result.
Peras larutan Penuhi
element. Dapat mengakibatkan kebakaran atau
Thoroughly wash the element in clean non flammable or high pembersih element
ledakan.
flash point cleaning solvent. sepenuhnya dengan oli
Cucilah
Allow theelement
element todalam larutan pembersih yang tidak
dry thoroughly.
dapat terbakar atau mempunyai titik api tinggi.
After drying, apply 1.0 – 1.5 g of clean engine oil to the entire
surface of the element and rub it with hand to saturate the ele-
Biarkan element mengering secara menyeluruh.
ment with oil.
Setelah mengering, oleskan 1,0 – 1,5 g oli mesin bersih
pada seluruh permukaan
RECOMMENDED ENGINE element
OIL: dan gosok dengan
Cucilah dalam Oleskan 1,0 - 1,5 g
tangan
Honda "4-stroke motorcycle oil"dengan
untuk memenuhi element oli. motor oil
or equivalent
larutan oli mesin bersih
API classification: SG or higher
OLI(except
MESIN YANG DIANJURKAN: pembersih
oils labeled as energy conserving on the circular
Federal Oil Supreme
API service label) Flick atau oli mesin 4 tak
sejenis
JASOdengan klasifikasi
T 903 standard: MBAPI service SG,
Viskositas:
10W-30 JASO MB
Install the
Pasang element.
element.
Install the
Pasang airair cleanerhousing
cleaner housing cover
cover (page
(hal. 3-6).
3-6).
Remove the
Lepaskan bodycover
body cover(hal.
(page2-9).
2-9).
VACUUM HOSE AIR SUCTION JOINT
Check theairairsuction
Periksa suction joint
joint between
antara the
air air cleaner housing
cleaner housing
and PAIRsaringan
(rumah control valve for cracks,
udara) dan deterioration,
PAIR control damage or
valve
loose connections.
terhadap retak-retak, pemburukan kondisi, kerusakan
ika joint
joint show any atau
If thememperlihatkan Checksambungan longgar.
the air supply hose between the PAIR control valve
tanda-tanda
signs of heat damage, and air supply pipe for cracks, deterioration, damage or loose
kerusakan
inspect theakibat
PAIR
Periksa air supply hose antara PAIR control valve dan
connections.
panas,
check valveperiksalah
(page 5- air supply pipe terhadap retak-retak, pemburukan
PAIR check valve. Check the
kondisi, air supplyatau
kerusakan pipesambungan
between thelonggar.
air supply hose and
24).
cylinder head for damage or loose fasteners.
Periksa
Check theair supply
vacuum pipe
hose antara
between air supply
the intake hose
manifold dan
vacuum
cylinder head terhadap kerusakan atau pengikat
joint and PAIR control valve for deterioration, damage or
longgar.
loose connections.
Also check
Periksa that hose
vacuum is notantara
hose kinkedintake
or pinched.
manifold vacuum
oint
Install the removed parts in the reverse order of pemburukan
dan PAIR control valve terhadap removal.
kondisi, kerusakan atau sambungan longgar.
Juga periksa bahwa hose (slang) tidak tertekuk atau

terjepit. AIR SUPPLY HOSE/PIPE
3-12
PERAWATAN
DRIVE BELT
DRIVE BELT
Lepaskan
Remove theleft
leftcrankcase
crankcase cover (hal. 8-5).
cover (page 8-5).
Check the
Periksa drivedrive belt
belt for cracks,
terhadap separationpemisahan
retak-retak, or abnormal or
atau
excessive wear
keausan tidakand replaceatau
normal it if necessary
berlebihan(page
dan8-12).
ganti bila
perlu (hal. 8-11).
DRIVE BELT
Dengan
Using themenggunakan dua
suitable two flat pelatmeasure
plates, datar, ukurlah
the drivelebar
belt
drive
widthbelt seperti diperlihatkan.
as shown. DRIVE BELT
SERVICE
BATAS LIMIT:17,5
SERVIS: 17.5 mm
mm (0.69 in)
Replace
Ganti the drive
drive belt iflebarnya
belt jika it is less than the service
kurang limit servis
dari batas (page
8-12).
(hal. 8-11).
DRIVE BELT
FINAL
FINALDRIVE
DRIVEOIL
OIL
PEMERIKSAAN TINGGI PERMUKAAN OLI
OIL LEVEL CHECK
Pastikan
Make sure bahwa tidakreduction
that the final ada kebocoran
case has no oli pada final
oil leaks.
reduction case. SEALING WASHER
Support the scooter with its centerstand.
Remove the
Letakkan oil check
skuter padabolt.
standard utamanya.
Check whether
Lepaskan the oilbolt.
oil check flows out from the check bolt hole.
If the level
Periksa is lowoli(oil
apakah does notkeluar
mengalir flow out),
dari add the recom-
lubang check
mended oil as described below.
bolt.
Jika tinggi permukaan
RECOMMENDED rendah
FINAL (oli tidak mengalir
REDUCTION OIL: keluar),
tambahkan oli yang dianjurkan seperti diuraikan
Honda "4-stroke motorcycle oil" or equivalent di
motor oil
bawah.
API classification: SG or higher
(except oils labeled as energy conserving on the circular
FINAL REDUCTION
API service label) OIL YANG DIANJURKAN:
Federal Oil Supreme
JASO T 903 standard: MB Flick atau oli mesin 4 tak CHECK BOLT LOWER LEVEL
sejenis dengan klasifikasi
Viscosity: SAE 10W-30 API service SG,
Viskositas: SAE 10W-30 JASO MB
Install the oil check bolt with a new sealing washer and
Pasang
tighten it oil check
to the bolt torque.
specified dengan sebuah sealing washer
baru dan kencangkan dengan torsi yang ditentukan.
3-13
PERAWATAN
OIL CHANGE OLI
PENGGANTIAN
Letakkan
Place an oilsebuah loyang
drain pan underpembuangan oli dicase
the final reduction bawah fina
to collect
DRAIN BOLT SEALING WASHER
the oil, then remove the oil check bolt, oil drain
reduction case untuk menerima oli, kemudian lepaskan bolt and seal-
ingcheck
oil washers.
bolt, oil drain bolt dan sealing washers.
Putar
Slowly turnbelakang
roda dengan
the rear wheel pelanthe
and drain danoil.keluarkan oli.
Setelah mengeluarkan oli secara menyeluruh, pasang
After
oil draining
drain the oil completely,
bolt dengan sebuah sealinginstallwasher
the oil drain
baru bolt
dan
with a new sealing
kencangkan washer
drain bolt and tighten
dengan the drain
torsi yang bolt to the
ditentukan.
specified torque.
Isilah
Fill thefinal
finalreduction casewith
reduction case dengan oli yangoil
recommended dianjurkan
up to the
sampai ke tinggi
correct level permukaan
(see page 3-13). yang tepat (lihat hal. 3-13).
KAPASITAS FINAL REDUCTION OIL:
FINAL REDUCTION
0,10 liter padaOIL CAPACITY:
penggantian periodik
0.10 liter (0.11 US qt, 0.09 lmp qt) after draining CHECK BOLT SEALING WASHER
0,12 liter setelah pembongkaran
0.12 liter (0.13 US qt, 0.11 lmp qt) after disassembly
Pasang oil check bolt dengan sealing washer baru dan
Install the oil check bolt with a new sealing washer and
kencangkan dengan torsi yang ditentukan.
tighten it to the specified torque.
TORSI: 13 N.m
TORQUE:13 N·m(1,3
(1.3kgf.m;
kgf·m,10
10 lbf.ft)
lbf·ft)
BRAKE FLUID
FLUID (MINYAK REM)
CATATAN:
• ? Spilling
Minyakfluidremcan yang tertumpah
damage painted,dapat
plastic merusak
or rubber parts
parts.
yanga dicat,
Place rag over atau
theseterbuat dari plastik
parts whenever atau is
the system karet.
ser-
Tutupilah parts ini dengan kain lap setiap kali
viced.
sistem diservis.
? Do not mix different types of fluid, as they are not com-
patible with each other.
• ? Do Jangan mencampurkan
not allow foreign materialbermacam-macam
to enter the system when jenis
minyak rem, oleh
filling the reservoir. karena mereka tidak cocok satu
sama lain.
? When the fluid level is low, check the brake pads for wear
• (see Jangan sampai
page 3-15). A low benda-benda
fluid level mayasingbe due memasuki
to wear of
sistem
the brakeketika
pads. mengisi reservoir.
• IfJika the tinggi permukaan
brake pads are worn, minyak rem piston
the caliper terlaluisrendah,
pushed
periksalah
out, and thisbrake
accountspads forterhadap keausan
a low reservoir (lihat
level. If hal.
the
3-15).pads
brake Tinggi permukaan
are not worn and the minyak rem is
fluid level yang
low,terlalu
check
entire
rendah system
dapatfordiakibatkan
leaks (page 3-15).
oleh keausan dari brake
pads.
Support
Jikathe scooter
brake padswithtelah
its centerstand.
aus, caliper piston didorong
Turnkeluar, dan ini
the handlebar menyebabkan
to the tinggi permukaan
left so the reservoir is level and
check yang rendah
the front brakedi reservoir
dalam reservoir.
fluid level Jika brake
through the pads
sight
glass.tidak aus dan tinggi permukaan minyak rem
rendah, periksalah keseluruhan sistem terhadap
If the level is near the lower level mark, check the brake pads
kebocoran
for wear (see page(hal. 3-15).
3-15).
Letakkan skuter pada standard utamanya.

Putar handlebar (stang stir) ke kiri sehingga reservoir
mendatar dan periksa tinggi permukaan minyak rem di
dalam front brake reservoir melalui kaca pengintaian.
Jika tinggi permukaan dekat tanda batas permukaan

TANDA TINGGI PERMUKAAN TERENDAH
terendah, periksa brake pads terhadap keausan. (lihat
hal. 3-15).
3-14
PERAWATAN
KEAUSAN BRAKE SHOES/PADS

BRAKE SHOES/PADS WEAR
FRONT
FRONT DISC BRAKE
DISC PADS PADS
BRAKE
(BRAKE PADS CAKRAM DEPAN)
Check the brake pads for wear.
Periksa brake pads terhadap keausan.
Replace the brake pads if either pad is worn to the wear limit
Ganti brake pads jika salah satu pad telah aus sampai
groove.
ke alur batas keausan.
To replace the brake pad, see page 13-8.
Untuk mengganti brake pad, lihat hal. 13-8.
ALUR-ALUR
REAR DRUM BRAKE SHOES BATAS KEAUSAN
(SEPATU REM TEROMOL
REAR DRUM BELAKANG)
BRAKE SHOES
Periksa
Check theposisi
wear indikator keausan
indicator position ketika
when handel
the brake rem
lever is
ditekan.
applied. BELAKANG: TANDA " "
If the indicator aligns with the " " mark, inspect the brake
Jika indikator bertepatan dengan tanda "Δ", periksa
drum (page 13-6).
brake drum (hal. 13-5).
Replace the brake shoes if the drum I.D. is within service
limit. brake shoes jika D.D. drum masih di dalam batas
Ganti
servis.
INDIKATOR KEAUSAN
BRAKE SYSTEM (SISTEM REM)
BRAKE SYSTEM
FRONT DISC BRAKE
(REM CAKRAM
FRONT DEPAN)
DISC BRAKE
Tekan
Firmlyhandel rem
apply the dengan
brake kuatcheck
lever and dan periksa bahwa
that no air tidak
has entered
ada udara yang telah memasuki sistem.
the system.
If thehandel
Jika lever feels soft or
terasa spongy
lunak when
atau operated,
seperti bleed ketika
sepons the air
from the system.
dijalankan, buanglah udara palsu dari sistem.
For air bleeding procedures (page 13-7).
Untuk prosedur pembuangan udara palsu (hal. 13-7).
3-15
PERAWATAN
Inspect the
Periksa brakehose
brake hose (slang
and fittings
rem)fordan
deterioration, cracks,
fittings (alat-alat
or signs of leakage.
pemasangan) terhadap pemburukan kondisi, retak- BRAKE HOSE
Tighten
retak, anytanda-tanda
atau loose fittings.kebocoran.
Replace the hose
Kencangkan fittings and fittings as required.
yang longgar.
Ganti hose dan fittings seperti diperlukan.
REAR DRUM BRAKE

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

sure the cut-out Adjust jarak
the rearmain bebas
brake lever freerear brake
play by turninglever dengan
the rear brake
potongan pada
of the adjusting nut is memutar rearnut.
arm adjusting brake arm adjusting nut (mur penyetelan
adjusting nut telah
seated on the joint lengan rem belakang).
duduk pada joint pin.
pin.
ADJUSTING NUT
3-16
PERAWATAN
BRAKE
BRAKE LIGHT
LIGHTSWITCH
SWITCH
(SAKLAR LAMPU REM)
? The brake light switch on the brake lever cannot be
CATATAN:
• adjusted. If the
Brake light brake pada
switch light switch
brake actuation
lever tidak and dapat
brake
engagement
disetel. Jika arepenjalanan
not synchronized,
brake either replace dan
light switch the
switch or malfunction parts of the system.
pengenaan rem tidak sinkron, gantilah switch atau
parts
Check thatyang tidak light
the brake bekerja dengan
comes baik
on just daritosistem.
prior the brake
actually being engaged.
Periksa bahwa brake light (lampu rem) hidup tepat
For brake light switch inspection (page 16-14).
sebelum rem sebenarnya mulai bekerja.
Untuk pemeriksaan brake light switch (hal. 16-14).
REAR BRAKE FRONT BRAKE

LIGHT SWITCH LIGHT SWITCH
BRAKE LOCK OPERATION

BRAKE
(CARA LOCK
KERJA OPERATION
KUNCI REM)
CATATAN:
• ? Check
Periksathecara
brakekerja brake lock
lock operation aftersetelah
the rear jarak
brake main
lever
bebas
free playrear brakeand
is checked lever telah(page
adjusted diperiksa
3-16).dan disetel LOCK LEVER
(hal. 3-16).
Squeeze the rear brake lever and set the lock lever.
Tekan rear
Check that the brake lever
rear wheel dan completely.
is locked tempatkan lock lever
(handel kunci).
Periksa bahwa roda belakang telah dikunci sama sekali.
BRAKE LEVER
3-17
PERAWATAN
HEADLIGHT AIM
PENYETELAN ARAH SINAR LAMPU
BESAR
CATATAN:
? Adjust the headlight beam as specified by local laws and
• regulations.
Setel arah sinar lampu besar seperti telah
ditentukan oleh undang-undang dan peraturan
Place the scooter on a level ground.
lokal.
Adjust the headlight beam vertically by loosening the head-
Letakkan skuter dibolt.
light aim adjusting atas tanah mendatar.
Hold the headlight aim adjusting bolt and tighten it.
Setel arah sinar lampu besar dalam arah vertikal
dengan melonggarkan headlight aim adjusting bolt baut
penyetelan arah sinar lampu besar).
Tahan headlight aim adjusting bolt dan kencangkan.
HEADLIGHT AIM
ADJUSTING BOLT
KEAUSAN CLUTCH
CLUTCH SHOES SHOES
WEAR
Lepaskan
Remove the clutch
clutchassembly (hal. 8-15).
assembly (page 8-16).
Periksa
Check the clutch shoes for abnormal wear. tidak normal.
clutch shoes terhadap keausan
Ukur ketebalan
Measure dari masing-masing
the thickness of each shoe. shoe.
BATAS
SERVICE SERVIS: 2,0 mm
LIMIT:
Ganti clutch shoes 2.0 jika
mm ketebalan
(0.08 in) mereka kurang dari
batas servis (hal. 8-17).
Replace the clutch shoes if they are less than the service limit
(page 8-18).
Pasang clutch assembly (hal. 8-16).
Install the clutch assembly (page 8-17).
CLUTCH SHOE
SIDESTAND
SIDESTAND (STANDARD SAMPING)
Letakkan skuter
Support the pada
scooter withstandard utamanya.
its centerstand.
Periksa
Check thepegas
sidestandsidestand terhadap
spring for damage kerusakan
or loss of tension.atau
kehilangan tegangan.
Check the sidestand assembly for freedom of movement and
lubricate the sidestand pivot if necessary.
Periksa sidestand assembly terhadap kebebasan
Check the sidestand
pergerakan ignition
dan lumasi cut-off
engsel system: bila perlu.
sidestand
1. Retract the sidestand.
Periksa sistem sidestand ignition cut-off (sistem
2. Start the engine.
pematian pengapian dari standard samping):
3. Move the sidestand full down.
1. Tarik
4. The sidestand
engine shouldke atas.
stop as the sidestand is lowered.
2. Hidupkan mesin.
If there
3. is a problem
Gerakkan withsepenuhnya
sidestand the system, check the sidestand
ke bawah.
switch (page 15-9).
4. Mesin harus berhenti berputar sewaktu sidestand
diturunkan. SIDESTAND
Jika ada persoalan dengan sistem, periksa sidestand

switch (saklar standard samping) (hal. 15-9).
3-18
PERAWATAN
SUSPENSI
SUSPENSION
DEPAN
FRONT
agian suspensi yang
Loose, worn or
longgar, aus atau
Periksa
Check thecara kerja
action forks
of the forks(garpu) dengan
by operating menjalankan
the front brake and
damaged suspension
rusak mempengarui compressing
rem depan danthe front
menekansuspension several
suspensi times.
depan beberapa kali
parts impair scooter
kestabilan dan Check
ke the entire assembly for signs of leaks, damage or loose
bawah.
stability and control.
pengendalian skuter. fasteners.keseluruhan susunan terhadap tanda-tanda
Periksa
kebocoran, kerusakan
Replace damaged atau pengikat
components longgar.
which cannot be repaired.
Tightenkomponen-komponen
Ganti all nuts and bolts. rusak yang tidak dapat
diperbaiki.
For fork service (page 11-11).
Kencangkan semua baut dan mur.

Untuk service fork (hal. 11-11).
FRONT FORK
BELAKANG
REAR
Check thecara
Periksa action of the
kerja shockabsorber
shock absorber by compressing
(peredam it
kejut)
several times.
dengan menekannya beberapa kali.
Check the entire shock absorber assembly for signs of leaks,
Periksa
damage orkeseluruhan susunan shock absorber terhadap
loose fasteners.
tanda-tanda kebocoran, kerusakan atau pengikat
Replace damaged components which cannot be repaired.
longgar.
Tighten all nuts and bolts.
Ganti komponen-komponen rusak yang tidak dapat
For rear shock absorber service (page 12-5).
diperbaiki.
Kencangkan semua baut dan mur.

Untuk servis shock absorber belakang (hal. 12-5).
REAR SHOCK
ABSORBER
Dukung skuter
Support the scooterdengan kokoh
securely and raise dan naikkan
the rear wheel offroda
the
belakang
ground. lepas tanah. ENGINE MOUNTING BUSHINGS
Check for worn engine mounting bushings by grabbing the
Periksa terhadap engine mounting bushings (bos-bos
engine and attempting to move the wheel side to side.
pemasangan mesin) yang aus dengan memegang
For engine
mesin dan bushing
mencoba service
untuk(page 12-6).
menggerakkan roda dari sisi
ke sisi.
Untuk servis engine bushing (hal. 12-6).
3-19
PERAWATAN
NUTS,BAUT,
MUR, BOLTS, FASTENERS
PENGIKAT
Periksa
Check that bahwa semua
all chassis baut
nuts and boltsdan mur rangka
are tightened to theirtelah
cor-
rect torque values
dikencangkan (page 1-9).
dengan nilai torsi mereka yang benar
Check
(hal. that all cotter pins, safety clips, hose clamps and cable
1-9).
stays are bahwa
Periksa in place and
semuaproperly secured.
cotter pins, safety clips, hose
clamps dan cable stays berada pada tempatnya dan
telah dipasang dengan erat.
WHEELS/TIRES
RODA/BAN
Support the
Letakkan scooter
skuter di with
atas its centerstand.
standard utamanya.
WHEEL BEARINGS
Making sure
Pastikan bahwathat fork
the fork
tidakisdapat
not allowed to move,
bergerak, raiseroda
naikkan the
front wheel and check for play.
depan dan periksa terhadap kelonggaran.
Check for
Periksa worn front
terhadap wheel
front bearings
wheel by grabbing
bearings (bantalan the roda
front
wheel and attempting to move the wheel
depan) yang aus dengan memegang roda depan danside to side.
Replace the
mencoba frontmenggerakkan
untuk wheel bearings ifroda
any dari
looseness
sisi keis sisi.
noted.
Ganti
Turn thefront
wheel wheel
and check bearings jika smoothly
that it rotates diketahui withadano
kelonggaran.
unusual noises.
If anyroda
Putar abnormal conditions
dan periksa are suspected,
bahwa inspect
ia berputar denganthehalus
front
wheel adanya
tanpa bearingssuara-suara
(page 11-10).tidak normal.
Jika ada dugaan adaya kondisi-kondisi tidak normal,

periksa front wheel bearings (hal. 11-10).
Dukung skuter
Support the scooterdengan kokoh
securely and danrearnaikkan
raise the wheel. roda
FINAL GEAR SHAFT BEARINGS
belakang.
Check for worn final gear shaft bearings by grabbing the rear
Periksa terhadap final gear shaft bearings (bantalan
wheel and attempting to move the wheel side to side.
poros final gear) yang aus dengan memegang roda
Replace the
belakang danfinal gear shaft
mencoba untukbearings if anyroda
menggerak looseness is
dari sisi
noted.
ke sisi.
Turn the wheel and check that it rotates smoothly with no
Ganti
unusualfinal gear shaft bearings bila diketahui ada
noises.
kelonggaran.
If anyroda
Putar abnormal conditions
dan periksa bahwaare ia
suspected,
berputarcheck thehalus
dengan final
reduction
tanpa (pagesuara-suara
adanya 9-8). tidak normal.
Jika ada dugaan adanya kondisi-kondisi tidak normal,
periksa final reduction (hal. 9-8).
Periksa
Check the tekanan udarawith
tire pressure banthe
dengan air pressure
air pressure gauge
gauge when the
(meter
tires are pengukur
cold. tekanan udara ban) sewaktu ban
dalam keadaan dingin.
RECOMMENDED TIRE PRESSURE:
Driver only:UDARA BAN YANG DIANJURKAN:
TEKANAN
FRONT: 200
Pengendara kPa (2.00 kgf/cm2, 29 psi)
saja:
2 2
DEPAN:
REAR: 225 kPa200 kPa
(2.25 (2,00
kgf/cm , kgf/cm
33 psi) ; 29 psi)
2
BELAKANG:
Driver 225 kPa (2,25 kgf/cm ; 33 psi)
and passenger:
Pengendara
FRONT: 200 dankPa
pembonceng: 2
(2.00 kgf/cm , 29 psi)
2
DEPAN:
REAR: 225 kPa (2.25 200 kPa (2,00
kgf/cm 2 kgf/cm ; 29 psi)
, 33 psi)
2
BELAKANG: 225 kPa (2,25 kgf/cm ; 33 psi)
PRESSURE GAUGE
3-20
PERAWATAN
Periksa
Check the ban terhadap
tires for sayatan,nails,
cuts, embedded pakuoryang tertancap,
other damage.
INDICATOR
Check the front wheel
atau kerusakan lain.and rear wheel for trueness.
Periksa apakah roda depan dan roda belakang
RECOMMENDED TIRE SIZE AND TIRE BRAND:
berjalan lurus dalam satu bidang.
UKURAN BAN DAN FRONT MEREK BAN REAR YANG

DIANJURKAN:
Tire size 80/90-14M/C40P 90/90-14M/C46P
Tire brand SRI FT235 FT235
DEPAN BELAKANG
Measure
Ukuran theban
tread depth at the center of the tires.
80/90- 90/90-
Replace the tires when the tread depth reaches
14M/C40P the following
14M/C46P
limits.
Merek SRI FT235 FT235
ban
MINIMUM TIRE TREAD DEPTH:
Ukur kedalaman alur
FRONT/REAR: telapak
To the ban pada tengah-tengah
indicator
ban.
Ganti ban jika kedalaman telapak ban mencapai
batas sebagai berikut.
KEDALAMAN ALUR TELAPAK BAN MINIMUM:
DEPAN/BELAKANG: Sampai ke indikator
STEERING HEAD
STEERING HEAD BEARINGS
BEARINGS
(BANTALAN KEPALA KEMUDI)
? Check that the control cables do not interfere with handle-
CATATAN:
bar rotation. STEM BEARINGS
• Periksa bahwa kabel-kabel pengontrol tidak
Support the scooterperputaran
mengganggu with its centerstand
handlebar. and raise the front
wheel off the ground.
Letakkan
Check thatskuter pada standard
the handlebar utamanya
moves freely dan naikkan
from side-to-side. If
roda depan lepas tanah.
the handlebar moves unevenly or binds, inspect the steering
Periksa bahwa
head bearings handlebar
(page 11-21). bergerak dengan bebas dari
sisi-ke-sisi. Jika handlebar bergerak secara tidak merata
atau mengikat, periksa steering head bearings (hal. 11-
21).
Hold the scooter

Peganglah skuterand check
dan the steering
periksa steeringhead bearings
head for
bearings
wear by moving
terhadap keausanthedengan
fork forward and backward.
menggerakkan fork ke depan
STEM BEARINGS
dan belakang.
If the steering stem has vertical movement, inspect the steer-
ing head bearing (page 11-21).
Jika steering stem ada pergerakan vertikal, periksalah
steering head bearing (hal. 11-21).
3-21
CATATAN
4. SISTEM PELUMASAN
DIAGRAM SISTEM
LUBRICATION PELUMASAN.........
SYSTEM DIAGRAM????? 4-24-2 TROUBLESHOOTING ........................... 4-3
TROUBLESHOOTING ????????????????? 4-3
KETERANGAN SERVIS ........................

SERVICE INFORMATION ?????????????? 4-3 4-3 OIL
OIL PUMP .............................................. 4-4
PUMP ???????????????????????????? 4-4
4-1
SISTEM PELUMASAN
LUBRICATION SYSTEM DIAGRAM
LUBRICATIONSYSTEM
DIAGRAM SISTEM PELUMASAN
ROCKER ARM SHAFT
CAM SHAFT
PISTON
CRANKSHAFT
OIL PUMP
OIL STRAINER SCREEN
4-2
SISTEM PELUMASAN
KETERANGAN SERVIS
SERVICE INFORMATION
UMUM
GENERAL
! PERINGATAN
Oli mesin bekas dapat menyebabkan kanker kulit jika berulangkali mengenai kulit untuk jangka waktu lama. Walaupun ini kecil
Used engine oil may cause skin cancer if repeatedly left in contact with the skin for prolonged periods. Although this is unlikely
kemungkinannya terjadi
unless you handle usedkecuali
oil on ajika anda
daily menangani
basis, oli bekas
it is still advisable to setiap hari,wash
thoroughly tetapyour
dianjurkan untuk
hands with secara
soap menyeluruh
and water as soonmencuci
as
tangan dengan sabun dan air sesegera
possible after handling used oil. mungkin setelah menangani oli bekas.
•
• Oil pump
The (pompa
oil pump can beoli) dapat diservis
serviced with thedengan mesin terpasang
engine installed pada rangka.
in the frame.
•
•
The service procedures
Prosedur-prosedur in this
servis sectionbab
di dalam mustini be performed
harus withdengan
dijalankan the engine oil drained.
oli mesin dikeluarkan.
•
•
When
Ketikaremoving and installing
melepaskan dan memasangthe oil pump, use berhati-hatilah
oil pump, care not to allow dust
agar or dirt
debu atauto kotoran
enter thetidak
engine.
memasuki mesin.
• If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly.
•
• Jika the
After adaoil
bagian
pumpdari
has oil pump
been yang aus
installed, checkmelampui batas
that there are servis yang ditentukan, gantilah oil pump sebagai sebuah susunan.
no oil leaks.
• Setelah oil pump telah dipasang, periksa bahwa tidak ada kebocoran o li.
SPECIFICATIONS
SPESIFIKASI
Unit: mm (in)
Satuan: mm
BAGIAN STANDARD SERVICE
BATAS SERVIS
ITEM STANDARD
LIMIT
Kapasitas oli Pada penggantian 0,7 liter -
Engine oil capacity After draining 0.7 liter (0.7 US qt, 0.6 lmp qt) –
mesin periodik
After disassembly 0.8 liter (0.8 US qt, 0.7 lmp qt) –
Pada pembongkaran 0,8 liter -
Recommended engine oil
mesin Honda "4-stroke motorcycle oil" or equiva-
lent motor oil
Oli mesin yang dianjurkan Federal Oil Supreme Flick atau
API classification: SGolior mesin
higher 4 tak
sejenis dengan(except
klasifikasi
oils labeled as energy conserving-
API service SG, –
Viskositas: SAEon10W-30 JASO
the circular APIMBservice label)
Oil pump rotor Jarak renggang pada 0,15 JASO T 903 standard: MB 0,20
ujung rotor Viscosity: SAE 10W-30
Oil pump rotor Jarak renggang antaraTip clearance
0,15 – 0,21 0.15 (0.006) 0,35 0.20 (0.008)
rotor dan rumah Body clearance 0.15 – 0.21 (0.006 – 0.008) 0.35 (0.014)
Jarak renggang Sideke clearance
0,05 – 0,10 0.05 – 0.10 (0.002 – 0.004) 0,12 0.12 (0.005)
samping rotor pompa
TORQUE VALUES
NILAI TORSI
Oil pump plate screw 3 N·m (0.3 kgf ·m, 2.2 lbf ·ft)
Oil pump mounting bolt 10 N·m (1.0 kgf ·m, 7 lbf ·ft)
Oil pump plate screw 3 N.m (0,3 kgf.m; 2,2 lbf.ft)
Oil pump mounting bolt 10 N.m (1,0 kgf.m; 7 lbf.ft)
TROUBLESHOOTING
TROUBLESHOOTING
Engine oil level too low, high oil consumption
• External oil leak
• Worn
Tinggi piston ringsoli
permukaan ormesin
incorrect piston
terlalu ring installation
rendah, pemakaian (page
oli7-35)
tinggi
• Worn cylinder (page 7-33)
• Ada kebocoran oli di luar
• Worn valve guide or seal (page 7-24)
• Piston rings aus atau p emasangan piston ring tidak benar (hal. 7-34)
Oil contamination
• Cylinder aus (hal. 7-32)
• Oil
•
not changed
Valve guide atauoften
sealenough
aus (hal. 7-14)
• Clogged oil strainer
• Worn piston rings (page 7-36)
Kontaminasi oli
• Oli jarang diganti
• Oil strainer tersumbat
• Piston rings aus (hal. 7-34)
4-3
SISTEM PELUMASAN
OIL PUMP
POMPA OLI
REMOVAL
PELEPASAN
•
• When
Ketikaremoving the oiloil
melepaskan pump,
pump,do jagalah
not allow atar
dust or dirt
debu
to enter the engine.
atau kotoran tidak memasuki mesin.
Drain the engine oil (page 3-10).
Keluarkan
Remove theollialternator
mesin (hal. 3-10).
(page 14-7).
Lepaskan alternator
Remove the (hal. 14-8).
following:
– Oil pump
Lepaskan coverberikut:
sebagai bolts
– Oil pump cover
- –OilO-ring
pump cover bolts
- –OilOil
pump
pumpcover
driven gear
- –O-ring
Oil pump bolts
- –OilOil pump
pump assembly
driven gear
- Oil pump bolts
- Oil pump assembly
OIL PUMP ASSEMBLY O-RING
OIL PUMP
DRIVEN GEAR
OIL PUMP COVER
Lepaskan oil pump cover dengan

menggunakan baut-baut 5 mm.
OIL PUMP BOLTS
5 mm BOLTS
OIL PUMP
COVER BOLTS
4-4
SISTEM PELUMASAN
INSTALLATION
PEMASANGAN
• When
Ketikainstalling
memasangthe oil
oilpump,
pump,do berhati-hatilah
not allow dust oragar
dirt
•
to enter the engine. OIL PUMP
debu atau kotoran tidak memasuki mesin.
Install the oil pump to the right crankcase.
Pasang oil pump
Install and pada
tighten theright crankcase.
oil pump mounting bolts to the
specified torque.
Pasang dan kencangkan oil pump mounting bolts
TORQUE:10
dengan N·m ditentukan.
torsi yang (1.0 kgf·m, 7 lbf·ft)
BOLTS
Semprotkan
Apply engineolioilmesin
to thepada oil pump
oil pump drivendriven gearoildan
gear and oil
pump
pump DRIVEN GEAR
shaft. shaft. Tepatkan
Install the oil pump driven gear to the oil pump by align-
Pasang oil pump
ing the driven geardriven
cut-outgear pada
with oil oilcut-out.
pump pump dengan
mentepatkan potongan pada driven gear dengan
potongan pada oil pump.
Oleskan oli mesin

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

Pasang dantighten
Install and kencangkan bolts.
the bolts.
Pasang alternator
Install the (hal.
alternator 14-10).
(page 14-9).
Fillcrankcase
Isi the crankcase witholi
dengan engine
mesinoil (page
(hal. 3-10).
3-10).
BOLTS
4-5
SISTEM PELUMASAN
Remove the
Lepaskan following:
sebagai berikut:
– Dowel pins
- Dowel pins
– Screw
- – Screw
Pump plate
- – Pump
Outerplate
rotor
- – Outer
Innerrotor
rotor
- •Inner rotor
Apply engine oil to the inner rotor and outer rotor.
• Assembly is in theoli
Semprotkan reverse
mesinorder
padaofinner
disassembly.
rotor dan outer
rotor.
TORQUE:OIL PUMP PLATE SCREW
3 N·m (0.3 kgf·m, 2.2 lbf·ft)
pembongkaran.
TORSI: OIL PUMP PLATE SCREW

3 N.m (0,3 kgf.m; 2,2 lbf.ft)
DOWEL PINS
PUMP PLATE
OUTER ROTOR
PUMP BODY
SCREW
INNER ROTOR
3 N·m (0.3 kgf ·m, 2.2 lbf ·t)
4-6
SISTEM PELUMASAN
INSPECTION
PEMERIKSAAN
? Measure at several points and use the largest reading
• Ukur
to pada the
compare beberapa
service titik
limit.dan pakailah pembacaan
? Ifterbesar untukofmembandingkannya
any portion the oil pump is worn dengan batas
beyond the
specified
servis. service limits, replace the oil pump and oil
•
pump cover
Jika ada as andari
bagian assembly.
oil pump yang aus melampaui
Tip batas servis yang ditentukan, gantilah oil pump dan
clearance
oil pump cover sebagai sebuah susunan.
Temporarily install the outer, inner rotors and oil pump
driven gear into the oil pump body. Kerenggangan pada ujung
Jarak renggang pada ujung inner rotor inner rotor :
Measure the clearance between the outer rotor and the
inner rotor
Untuk with a feeler
sementara gauge.outer, inner rotors dan oil
pasanglah
pump
SERVICEdriven gear ke dalam oil pump body.
LIMIT: 0.20 mm (0.008 in)
Ukur kerenggangan antara outer rotor dan inner rotor
dengan feeler gauge.
BATAS SERVIS: 0,20 mm
Jarak renggang antara outer rotor dan badan

Body clearance
Ukur jarakthe
Measure renggang
clearanceantara oil pump
between the oil body
pump dan
bodyouter
and
the outer rotor with gauge.
a feeler gauge. Kerenggangan antara
rotor dengan feeler
outer dan badan :
SERVICE
LIMIT: 0.35 mm (0.014 in)
Jarak renggang ke samping rotor pompa

Side clearance
Ukur jarakthe
Measure renggang ke samping
side clearance dengan
using menggunakan
a straight edge and
feeler lurus
mistar gauge.dan feeler gauge. Kerenggangan ke samping:
SERVICE
LIMIT: 0.12 mm (0.005 in)
4-7
CATATAN
5. SISTEM BAHAN BAKAR
LOKASI KOMPONEN
COMPONENT ..............................
LOCATION ?????????????5-2 5-2 PEMBERSIHAN KARBURATOR.............5-17
CARBURETOR CLEANING???????????? 5-17
DIAGRAM SISTEM ..................................

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

SERVICE INFORMATION ??????????????5-4 5-4 PENYETELAN
PILOT SCREWPILOT SCREW................
ADJUSTMENT ????????? 5-20 5-20
TROUBLESHOOTING
TROUBLESHOOTING.............................
?????????????????5-5 5-5 INLET
INLETPIPE
PIPE..............................................
?????????????????????????? 5-22 5-22
AIR CLEANER
AIR HOUSING
CLEANER HOUSING.......................
??????????????5-6 5-6 SECONDARY AIR SUPPLY
SECONDARY AIR SUPPLYSYSTEM
SYSTEM..... 5-23
??? 5-23
PELEPASAN KARBURATOR
CARBURETOR ................. 5-8
REMOVAL ????????????? 5-8 TANGKI BAHAN
FUEL TANK BAKAR ........................5-26
????????????????????????? 5-26
PEMASANGAN
CARBURETORKARBURATOR
INSTALLATION.............
??????? 5-10 5-10 FUEL
FUELAUTO
AUTO VALVE
VALVE ................................
?????????????????? 5-27 5-27
CARBURETOR DISASSEMBLY/
KARBURATOR ........................................ 5-12
ASSEMBLY ?????????????????????????? 5-12
5-1
SISTEM BAHAN BAKAR
LOKASI KOMPONEN
COMPONENT LOCATION
FUELSYSTEM
5-2
SISTEM BAHAN BAKAR
DIAGRAM SISTEM
SYSTEM DIAGRAM
MAIN FUSE SUB FUSE

15A 10A
R/Bl
l l
B B O
/ l
R R / / B
R R G
2P 4P 6P Br 3P Bl
l
B O
/ l
G R / G B
R G
IGNITION CONTROL
BATTERY MODULE (ICM)
IGNITION STARTER
SWITCH ENRICHMENT (SE)
THERMAL VALVE
5-3
SISTEM BAHAN BAKAR
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
? Bending or twisting the control cable will impair smooth operation and could cause the cable to stick or bind, resulting in loss of
• Menekuk atau memilin kabel pengontrol akan mengganggu kelancaran kerjanya dan dapat menyebabkan bahwa kabel macet
vehicle control.
atau in
? Work mengikat, sehinggaarea.
a well ventilated mengakibatkan
Smoking or hilangnya pengaturan
allowing flames atas
or sparks inkendaraan.
the work area or where gasoline is stored can cause a fire
• Bekerjalah
or explosion. di ruangan dengan ventilasi baik. Merokok atau membiarkan lidah api atau percikan bunga api di tempat kerja atau
? When disassembling fuel system parts, note the locations of the O-rings.
di tempat di mana bensin disimpan dapat mengakibatkan kebakaran atau ledakan. Replace them with new ones on reassembly.
?
• Before
Sewaktu membongkar parts sistem bahan bakar, catatlah lokasi O-rings. Gantidrain
disassembling the carburetor, place a suitable container under the carburetor hose.yang
dengan Loosen thepada
baru drainwaktu
screw perakitan
and drain
the carburetor.
kembali.
? After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with pieces of tape to prevent any for-
• Sebelum membongkar
eign material from dropping karburator, letakkan penampung yang sesuai di bawah carburetor drain hose (slang pembuangan
into the engine.
karburator). Longgarkan drain screw (sekrup pembuangan) dan kosongkan karburator.
• Setelah melepaskan karburator, bungkuslah lubang pemasukan mesin dengan kain lap atau tutuplah dengan pita perekat
SPECIFICATIONS
untuk mencegah masuknya benda asing ke dalam mesin.
ITEM SPECIFICATIONS
SPESIFIKASI
Carburetor identification number AVK2CH
Main jet #100
BAGIAN
Slow jet SPESIFIKASI #35
Nomor identifikasi
SE thermal karburator
valve resistance AVK2CH 3.2 – 5.6 Ω (25°C/77°F)
Main
Floatjet
level # 100 13.0 mm (0.51 in)
Slow jet
Pilot screw initial opening # 35 See page 5-20
Tahanan
Engine idlelistrik SE thermal valve
speed 3,2 – 5,6 Ω (20° C) 1,700 ± 100 min-1 (rpm)
Tinggi pelampung
PAIR control valve specified vacuum 13,0 mm 60 kPa (450 mmHg)
Throttle grip awal
Pembukaan free play
pilot screw Lihat halaman 5-20 2 – 6 mm (0.1 – 0.2 in)
-1
Putaran stasioner mesin 1.700 ± 100 menit (rpm)
Vakuum PAIR control valve yang ditentukan 60 kPa (450 mmHg)
TORQUE
Jarak main bebasVALUES throttle grip 2 – 6 mm
Inlet pipe band screw 2 N·m (0.2 kgf ·m, 1.5 lbf ·ft)
NILAI TORSI
SE thermal valve body screw 3.4 N·m (0.4 kgf ·m, 2.5 lbf ·ft)
SE thermal valve setting plate screw 2.1 N·m (0.2 kgf ·m, 1.5 lbf ·ft)
Inlet pipe band screw 2 N.m (0-,2 kgf.m; 1,5 lbf.ft)
SEVacuum
thermal chamber cover screw
valve body screw 3,4 N.m (0,4 N·m
2.1 (0.2
kgf.m; kgf
2,5 ·m, 1.5 lbf ·ft)
lbf.ft)
Slow jet
SE thermal valve setting plate screw 1.5 N·m (0.2 kgf
·m, 1.1 lbf ·ft
2,1 N.m (0,2 kgf.m; 1,5 lbf.ft)
Main jet
Vacuum chamber cover screw 2.1 N·m
2,1 N.m (0,2 (0.2
kgf.m; kgf
1,5 ·m, 1.5 lbf ·ft)
lbf.ft)
Needle
Slow jet jet holder 2.5 N·m (0.3 kgf
·m, 1.8 lbf ·ft)
1,5 N.m (0,2 kgf.m; 1,1 lbf.ft)
Float
Main jet chamber screw 2.1 N·m
2,1 N.m (0,2 (0.2
kgf.m; kgf
1,5 ·m, 1.5 lbf ·ft)
lbf.ft)
Float jet
Needle chamber
holder drain screw 1.5 N·m
2,5 N.m (0,3 (0.2
kgf.m; kgf
1,8 ·m, 1.1 lbf ·ft)
lbf.ft)
PAIR
Float check valve
chamber screwcover screw 2,1 N.m (0,2
2.1kgf.m; 1,5 kgf
N·m (0.2 lbf.ft)
·m, 1.5 lbf ·ft)
Float chamber
Fuel auto valve drain screw
lock nut 1,5 N.m (0,2 kgf.m; 1,1 lbf.ft)
22.5 N·m (2.3 kgf ·m, 17 lbf ·ft)
PAIR check valve cover screw 2,1 N.m (0,2 kgf.m; 1,5 lbf.ft)
Fuel auto valve lock nut 22,5 N.m (2,3 kgf.m; 17 lbf.ft)
TOOLS
TOOLS
Pin driver Carburetor float level gauge
07744-0010100 07401-0010000
5-4
SISTEM BAHAN BAKAR
TROUBLESHOOTING
TROUBLESHOOTING
Mesin
Enginetidak
won’tmau starthidup
?
• No fuel in tank
Tangki bahan bakar kosong
? No
•
fuel to
Bahan carburetor
bakar tidak sampai ke karburator
? Fuel strainer clogged
- Fuel strainer
? Fuel hose clogged tersumbat
- Fuel hose tersumbat
? Fuel tank breather hole clogged
?- Faulty
Lubang fuelpernapasan
auto valve tangki bahan bakar tersumbat
? Float
- Fuellevel
autoincorrect
valve tidak bekerja dengan baik
? Too
• Floatmuch
levelfuel getting
(tinggi to the engine
pelampung) tidak sesuai
? Air cleaner clogged
•
?Terlalu
Flooded banyak bahan bakar yang masuk ke dalam mesin
carburetor
- Air cleaner
? Intake air leak tersumbat
- Karburator
? Fuel banjir
contaminated/deteriorated
? Faulty
• starting enrichment
Ada kebocoran udara masuk (SE) thermal valve
?
•
Clogged starting enrichment
Bahan bakar terkontaminasi/memburuk (SE) circuit kondisinya
? Clogged carburetor slow circuit
• Starting enrichment
? Improper (SE) thermal valve tidak bekerja dengan baik
throttle operation
• Rangkaian starting enrichment
? No spark at plug (faulty ignition system – (SE) tersumbat
page 15-3)
• Rangkaian stasioner karburator tersumbat
Engine stall, hard to start, rough idling
• Caraline
? Fuel kerja throttle tidak benar
restricted
• Tidak ada percikan
? Fuel mixture too lean/rich bunga api pada busi (sistem pengapian tidak bekerja dengan baik – hal. 15-3)
? Fuel contaminated/deteriorated
? Intake
Mesin air leakmendadak, sulit dihidupkan, putaran stasioner kasar
berhenti
? Idle speed misadjusted
• Saluran
? Pilot screw bahan bakar terbatasi
misadjusted
• Campuran
? Fuel bahan hole
tank breather bakar terlalu miskin/kaya
clogged
Bahan
? Air
• cleanerbakar terkontaminasi/memburuk kondisinya
clogged
? Slow
• Ada circuit
kebocoran cloggedudara masuk
? Faulty starting enrichment (SE) thermal valve
• Penyetelan putaran stasioner salah
? Ignition system malfunction (page 15-3)
• Penyetelan pilot screw salah
LeanLubang
• mixturepernapasan tangki bahan bakar tersumbat
?
•
Fuel jets clogged
Air cleaner tersumbat
? Float valve faulty
• Rangkaian
? Float level too stasioner
low tersumbat
• Starting
? Fuel enrichment (SE) thermal valve tidak bekerja dengan baik
line restricted
? Carburetor
• air vent hose
Sistem pengapian tidakclogged
bekerja dengan baik (hal. 15-3)
? Fuel tank breather hole clogged
? Intake airbahan
Campuran leak bakar terlalu miskin
? Vacuum piston faulty
• Fuel jets tersumbat
RichFloat
• mixturevalve tidak bekerja dengan baik
? Air jet clogged
• Float level terlalu rendah
? Float valve faulty
• Saluran
? Float levelbahan
too high bakar terbatasi
? Starting
• Carburetorenrichment
air vent(SE)
hosethermal valve stuck open
tersumbat
?
• Air cleaner element contaminated
Lubang pernapasan tangki bahan bakar tersumbat
? Vacuum piston faulty
• Ada kebocoran udara masuk
Backfiring
• Vacuum or piston
misfiring during
tidak acceleration
bekerja dengan baik
? Fuel mixture too lean
? Ignition system malfunction (page 15-3)
Campuran bahan bakar terlalu kaya
Afterburn
• Air jet when
tersumbatengine braking is used
?
• Lean mixture
Float valve tidak in slow circuitdengan baik
bekerja
? Faulty pulse secondary air injection (PAIR) system
• Float level terlalu tinggi
? Faulty PAIR control valve
• ?Starting enrichment
Faulty PAIR (SE) thermal valve macet terbuka
check valve
• ? Air cleanerhose
Clogged element
of theterkontaminasi
PAIR system
? Ignition
• Vacuum system
pistonmalfunction
tidak bekerja (page 15-3) baik
dengan
Backfiring atau misfiring selama akselerasi

• Campuran bahan bakar terlalu miskin
• Sistem pengapian tidak bekerja dengan baik (hal. 15-3)
Afterburn ketika engine braking dipakai

• Campuran bahan bakar terlalu miskin pada rangkaian stasioner
• Pulse secondary air injection (PAIR) system tidak bekerja dengan baik
- PAIR control valve tidak bekerja dengan baik
- PAIR check valve tidak bekerja dengan baik
- Slang dari PAIR system tersumbat
• Sistem pengapian tidak bekerja dengan baik (hal. 15-3)
5-5
SISTEM BAHAN BAKAR
AIR CLEANER
AIR CLEANER HOUSING
HOUSING
REMOVAL
PELEPASAN
Remove the
Lepaskan following:
sebagai berikut:
PAIR CONTROL VALVE BOLTS
Luggagebox
-? Luggage box(hal.
(page 2-7)
2-7)
? Body cover (page
- Body cover (hal. 2-9) 2-9)
Left
-? Left crankcasecover
crankcase coverduct
duct(hal.
(page 2-12)
2-12)
Remove the
Lepaskan two PAIR
kedua PAIRcontrol valve
control mounting
valve bolts bolts
mounting and
disconnect the valve from the air cleaner housing.
(baut pemasangan
Disconnect PAIR control
the crankcase breather valve)
hose dan
fromlepaskan
the air
valve dari air
cleaner housing.cleaner housing.
Lepaskan crankcase breather hose (slang pernapasan
bak mesin) dari air cleaner housing.

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

Tarik
Pull outkeluar finalreduction
the final reduction breather
breather hose
hose from dari air
the air
cleaner housing.
housing. BOLTS BREATHER HOSE
cleaner
Release the
Lepaskan crankcase
crankcase breather
breather draindrain
hose hose from the
dari clamp.
clamp.
Lepaskan kedua air cleaner housing mounting bolts dari
Remove the two air cleaner housing mounting bolts from
sisi
the kiri.
left side.
BREATHER DRAIN HOSE CLAMP
Remove the
Lepaskan bolt
bolt from
dari sisithe right side.
kanan.
Be Hati-hati
careful not to Disconnect the connecting hose from the carburetor by
agar Lepaskan connecting hose dari karburator dengan
holding the carburetor and pulling the air cleaner housing
damage
tidak the air
merusak air memegang
cleaner
backward. karburator dan menarik air cleaner housing
cleanerconnecting
connecting ke belakang.
hose.
hose. Remove the air cleaner housing from the right side of the
frame.
Lepaskan air cleaner housing dari sisi kanan dari
rangka.
AIR CLEANER
HOUSING
BOLT
5-6
SISTEM BAHAN BAKAR
PEMASANGAN
INSTALLATION
Install the
Pasang air air cleaner
cleaner housing
housing darifrom the right
sisi kanan dariside of the
rangka.
frame. BAND SCREW CONNECTING HOSE
Sambungkan connecting hose ke karburator dengan
Connect the connecting hose to the carburetor by hold-
Be careful not to
Hati-hati agar memegang
ing the carburetor and dan
karburator dengan
carefully hati-hati
pushing the mendorong
air cleaner
damage the air
tidak merusak air air cleaner housing
housing forward. ke depan.
cleaner connecting
cleaner connecting
hose. Set the connecting hose band as shown.
hose. Tempatkan
Tighten the connecting
band screwhose
until band seperti
the band diperlihatkan.
seats on the collar
Kencangkan
as shown. band screw sampai band duduk pada
collar seperti diperlihatkan. 75°
VACUUM PISTON HOSE

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

Set the air cleaner
Tempatkan air housing
cleanerin position.
housing pada posisi
pemasangannya.
Install and tighten the bolt to the right side of air cleaner
housing.
Pasang dan kencangkan bolt pada sisi kanan dari air
cleaner housing.
AIR CLEANER
HOUSING
BOLT
Install and
Pasang dantighten the two
kencangkan boltsbolts
kedua to the left sisi
pada sidekiriofdari
air
cleaner housing. BOLTS BREATHER HOSE
air cleaner housing.
Set the crankcase breather drain hose to the clamp on
Tempatkan crankcase breather drain hose pada clamp
the air cleaner housing.
pada
Insertairthe
cleaner
final housing.
reduction breather hose into the air
Masukkan
cleaner housing.reduction breather hose ke dalam air
final
cleaner housing.
Install the following:
? Left crankcase
Pasang cover duct (page 2-12)
sebagai berikut:
? Body cover (page 2-9)
Luggage
-? Left box cover
crankcase (page 2-7)
duct (hal. 2-12)
- Body cover (hal. 2-9)
- Luggage box (hal. 2-7)
BREATHER DRAIN HOSE CLAMP
5-7
SISTEM BAHAN BAKAR
PELEPASAN
CARBURETORKARBURATOR
REMOVAL
Lepaskan sebagai
Remove the berikut:
following:
Leftcrankcase
-? Left crankcasecover
coverduct
duct(hal.
(page 2-12)
2-12)
Luggagebox
-? Luggage box(hal.
(page 2-7)
2-7)
Place a suitable
Letakkan penampungcontainer
yang under
sesuai the carburetor
di bawah drain
carburetor
hose and drain fuel from the carburetor by loosening
drain hose dan keluarkan bahan bakar dari karburator the
drain screw.
dengan melonggarkan drain screw (sekrup
Tighten the float chamber drain screw to the specified
pembuangan).
torque.
Kencangkan
TORQUE:1.5 float chamber
N·m (0.2 kgf·m, drain screw dengan torsi
1.1 lbf·ft)
yang ditentukan.
TORSI: 1,5 N.m (0,2 kgf.m; 1,1 lbf.ft) FLOAT CHAMBER

DRAIN SCREW
Lepaskan carburetor
Release the drain
carburetor hose
drain dari
hose clamp.
from the clamp.
CLAMP
CARBURETOR DRAIN HOSE

Lepaskan
DisconnectSE
thethermal valvevalve
SE thermal 3P connector.
3P connector.
SE THERMAL VALVE 3P CONNECTOR

Lepaskan
Release thekedua SEthermal
two SE thermal valve
valve wirewire clamps
clamps dari
from the
frame.
rangka. WIRE GUIDE
Release the
Lepaskan SE thermal
kawat valvevalve
SE thermal wire dari
fromwire
the wire guide.
guide.
WIRE CLAMPS
5-8
SISTEM BAHAN BAKAR
Release the
Lepaskan crankcase
crankcase breather
breather draindrain
hose hose from the
dari clamp.
clamp. Kiri: Kanan
Lepaskan kedua air cleaner housing mounting bolts dari
Remove the two air cleaner housing mounting bolts from
sisi kiri.
the left side of air cleaner housing. BOLTS
Lepaskan
Remove the boltbolt
darifrom
sisi the
kanan dari
right airof
side cleaner housing.
air cleaner hous-
ing.
BREATHER
DRAIN HOSE CLAMP
Loosen the lock
Longgarkan lock nut
nut and
dan disconnect the throttle
lepaskan throttle cablecable
dari LOCK NUT THROTTLE CABLE
from the throttle
throttle drum. drum.
Release the air vent hose from the intake shroud.
Lepaskan air vent hose dari intake shroud.
AIR VENT HOSE
Disconnect the vacuum piston hose and fuel hose from

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

karburator dari inlet pipe.
FUEL HOSE VACUUM PISTON HOSE
5-9
SISTEM BAHAN BAKAR
PEMASANGAN
CARBURETOR KARBURATOR
INSTALLATION
Connect the carburetor to the inlet pipe while aligning the
Sambungkan karburator pada inlet pipe sementara
Be Hati-hati to tab of the carburetor with the groove of the inlet pipe.
agar
careful not
mentepatkan tab dari karburator dengan alur dari inlet Tepatkan
tidak merusak inlet
damage the inlet pipe.
pipe. pipe.
Be careful
Hati-hati agarnot to
tidak Connect the airair
Sambungkan cleaner connecting
cleaner hose to hose
connecting the carbure-
pada
tor while holding the carburetor and carefully pushing the CARBURETOR CONNECTING HOSE
damage
merusak the air
air cleaner karburator sementara menahan karburator dan dengan
connecting
cleaner hose.
connecting
air cleaner housing forward.
hati-hati mendorong air cleaner housing ke depan.
hose. Tighten the inlet pipe band screw to the specified torque.
TORQUE:2 N·m
Kencangkan inlet(0.2
pipekgf·m,
band1.5screw
lbf·ft) dengan torsi yang
ditentukan.
Set the air cleaner connecting hose band by the speci-
fied angle.
Tighten 2
TORSI: the connecting
N.m hose
(0,2 kgf.m; 1,5band
lbf.ft)screw until the band
seats on the collar as shown.
Tempatkan air cleaner connecting hose band dengan

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

ATAS
75°
CONNECTING HOSE BAND SCREW
Sambungkan throttlecable
Connect the throttle cable pada
to the throttle
throttle drum drum dan
and install
it to thepada
pasang cablecable
holder.
holder. THROTTLE CABLE
Connect the fuel hose and vacuum piston hose to the
carburetor. fuel hose dan vacuum piston hose pada
Sambungkan
Set the carburetor air vent hose to the intake shroud as
karburator.
shown.
Tempatkan carburetor air vent hose pada intake shroud
seperti diperlihatkan.
AIR VENT VACUUM

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

Kokohkan two SE
SE thermal
thermal valve
valvewire
wireclamps
clampstopada
the
Alurkan
harness wire
properly frame.
rangka. WIRE GUIDE
harness
(pagedengan
1-14).
Set the SE thermal
Tempatkan valve
SE thermal wirewire
valve to the wirewire
pada guide.
guide.
benar (hal. 1-14).
WIRE CLAMPS
Connect the SE
Sambungkan SEthermal
thermalvalve
valve3P
3Pconnector.
connector.
Secure thepemasangan
Kokohkan carburetor drain hose withdrain
carburetor the clamp.
hose dengan
clamp. CLAMP
Adjust the throttle grip free play (page 3-5).
Check the engine idle speed (page 3-11).
Setel jarak main bebas throttle grip (hal. 3-5).
Install the
Periksa following:
putaran stasioner mesin (hal. 3-11).
? Luggage box (page 2-7)
Pasang sebagai berikut:
? Left crankcase cover duct (page 2-12)
- Left crankcase cover duct (hal. 2-12)
5-11
SISTEM BAHAN BAKAR
CARBURETOR DISASSEMBLY/
ASSEMBLY
KARBURATOR
• ? Be carefulketika
Hati-hati when melepaskan
removing thevacuum
vacuum chamber
chamber cover
cover
as
olehit iskarena
under ia
spring pressure.
berada di bawah tekanan pegas.
•
? Before
Sebelum removing the pilot
melepaskan screw,
pilot record
screw, the number
catatlah of
jumlah
turns until it seats lightly, then remove the pilot screw,
putaran
spring, sampai
washer ia O-ring.
and duduk dengan ringan, kemudian
lepaskan pilot screw,
? Damage to the pilot screw spring,
seatwasher danifO-ring.
will occur the screw
• is tightened pilot
Dudukan against the seat.
screw akan mengalami kerusakan
Hold jika
thescrew dikencangkan
carburetor and lightlyterhadap
drive thedudukannya.
float pin from the
throttle drum side. PIN DRIVER
Pegang karburator dan dengan ringan dorong masuk
TOOL:
float pin dari sisi throttle drum.
Pin driver 07744-0010100
TOOL:
Pin driver 07744-0010100
FLOAT PIN
2.1 N·m (0.2 kgf ·m, DIAPHRAGM/

1.5 lbf ·ft) VACUUM PISTON
FLOAT VALVE
VACUUM
CHAMBER COVER FLOAT
FLOAT PIN
SE THERMAL
VALVE COVER
O-RING
DRAIN SCREW SE THERMAL

FLOAT VALVE
1.5 N·m (0.2 kgf ·m, 1.1 lbf ·ft)
CHAMBER
O-RING
COMPRESSION
SPRING O-RING
WASHER
2.1 N·m 2.1 N·m
SPRING SPRING (0.2 kgf ·m, (0.2 kgf ·m,
NEEDLE
1.5 lbf ·ft) 1.5 lbf ·ft)
HOLDER
NEEDLE
PILOT SETTING
JET
SCREW PLATE
O-RING
SLOW JET
JET NEEDLE 1.5 N·m (0.2 kgf ·m, NEEDLE JET HOLDER SE THERMAL
1.1 lbf ·ft) 2.5 N·m (0.3 kgf ·m, 1.8 lbf ·ft) VALVE BODY
MAIN JET
O-RING 3.4 N·m (0.4 kgf ·m, 2.5 lbf ·ft)
2.1 N·m (0.2 kgf ·m, 1.5 lbf ·ft)
5-12
SISTEM BAHAN BAKAR
FLOATCHAMBER
FLOAT CHAMBER
(RUANG PELAMPUNG)
CATATAN:
Handle
• ? Tangani jets dengan
the jets hati-hati.
with care. TheyMereka mudah
can easily sekali
be scored
or scratched.
tergerus atau tergores.
NEEDLE JET
Pasang sebagai
Install the berikut:
following:
-? Slow
Slowjetjet
-? Needle
Needle jetjet NEEDLE JET
? Needle jet holder HOLDER
-? Needle
Main jetjet holder O-RING
- Main jet
Tighten them to the specified torque.
Kencangkan dengan torsi yang ditentukan.
TORQUE:
TORSI:
Slow jet: 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)
Slow
Mainjet: 1,5(0.2
jet: 2.1 N·m N.m (0,2 kgf.m;
kgf·m, 1,1 lbf.ft)
1.5 lbf·ft) WASHER
Main jet:jet holder:
Needle 2,12.5
N.m (0,2
N·m kgf.m;
(0.3 kgf·m,1,5
1.8lbf.ft)
lbf·ft)
Needle jet holder: 2,5 N.m (0,3 kgf.m; 1,8 lbf.ft) MAIN JET
PILOT SCREW SPRING SLOW JET
Kerusakan
Damageakan terjadi
to the pilot Pasang O-ring,
Install the O-ring,washer,
washer,spring
springdan
and pilot
pilot screw
screw anddan
padaseat
dudukan pilot kembalikan keoriginal
return it to its tempatnya semula
position seperti
as noted telahremoval.
during dicatat FLOAT PIN FLOAT VALVE
screw will occur
screw jika
if the pilot
pilot screw
screw is pada waktu
Perform thepelepasan.
pilot screw Jalan prosedur
adjustment penyetelan pilot
procedure if a new
dikencangkan terhadap
tightened against the pilot screw
screw is installed
seperti bila sebuah pilot screw baru telah
(page 5-20).
kedudukannya.
seat. dipasang
Install the(hal.
float5-20).
and float valve in the carburetor body,
then install the float pin through the body and float.
Pasang float dan float valve di dalam badan karburator,
kemudian pasang float pin melalui badan dan float.
FLOAT
Drive the masuk

Dorong float pin lightly
float until
pin the height from
dengan the float
ringan pin
sampai
holder (SE thermal valve side) is 0.15 –
0.55 mm
ketinggian dari float pin holder (sisi SE thermal valve) (0.006
0.0220,15
–
adalah in). – 0,55 mm. PIN DRIVER
TOOL:
TOOL:
Pin driver
Pin driver 07744-0010100
07744-0010100
0.15 – 0.55 mm
(0.006 – 0.022 in)
FLOAT PIN
Install a new O-ring into the float chamber.

Pasang sebuah
Install the O-ring baru ke dalam float chamber
float chamber.
FLOAT CHAMBER
(ruang pelampung). O-RING
Pasang float chamber.
5-13
SISTEM BAHAN BAKAR
Install and
Pasang dantighten the floatfloat
kencangkan chamber screws
chamber to thedengan
screws speci-
fied torque. SCREWS
torsi yang ditentukan.
TORQUE:2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
TORSI: 2,1 N.m (0,2 kgf.m; 1,5 lbf.ft)
VACUUM
VACUUM CHAMBER
CHAMBER
Pasang jet needle,
Install the jet spring
needle, dan
spring andneedle
needleholder
holderkeinto
dalam
the
vacuum
vacuum piston.
piston. VACUUM PISTON
JET NEEDLE
SPRING
NEEDLE HOLDER
Dorong needle
Press the needle holder
holdermasuk
into thekevacuum
dalam piston
vacuum andpiston
turn
the needle
dan putar holder
needleclockwise
holder until
searahyou jarum
feel a click.
jam sampai NEEDLE HOLDER
terasa ada 'klik'.
Be careful not to Install the diaphragm/vacuum piston into the carburetor
Pasang diaphragm/vacuum piston ke dalam badan Tempatkan VACUUM CHAMBER COVER
damage theagar
jet body aligning the diaphragm tab with the groove on the
Hati-hati karburator dengan mentepatkan diaphragm tab dengan
needle.
carburetor body.
tidak merusak jet alur pada badan karburator. SPRING
needle. Hold the vacuum piston almost full open to prevent the
diaphragm from being pinched by the chamber cover.
Tahan vacuum piston hampir terbuka penuh untuk
Install the compression spring into the Tepatkan
menghindari dijepitnya diaphragm olehvacuum
chamberpiston.
cover.
Set the boss of the vacuum chamber cover to the com-
pressioncompression
Pasang spring and install
springthe
kechamber cover. piston.
dalam vacuum
Tempatkan boss dari vacuum chamber cover pada
compression spring dan pasang chamber cover.
DIAPHRAGM/
VACUUM PISTON
5-14
SISTEM BAHAN BAKAR
Install and
Pasang tighten
dan the vacuumvacuum
kencangkan chamberchamber
cover screws to
cover
the specified
screws torque.
(sekrup-sekrup tutup ruang vakuum) dengan SCREWS
Periksa bahwa
Check that spring
the spring telah dipasang
is installed correctly dengan benar
by pushing the
bottom of
dengan the piston with
mendorong bagianyour finger piston
bawah and make sure that
dengan jari- SPRING PISTON
the piston
ari returns back bahwa
dan memastikan in place piston
smoothly.
kembali dengan
lancar ke tempatnya semula.
STARTING
STARTING ENRICHMENT
ENRICHMENT (SE)(SE)
THERMAL
THERMAL VALVE
VALVE
Install a sebuah
Pasang new O-ring into baru
O-ring the groove on the
ke dalam alurSEpada
thermal
SE
valve body.
thermal valve body.
O-RING
SE THERMAL VALVE BODY

Install the SE thermal valve body.
Pasang SE thermal valve body. SE THERMAL
Install and tighten the SE thermal valve body screws to VALVE BODY
Pasang dan kencangkan
the specified torque. SE thermal valve body screws
dengan torsi yang ditentukan.
SCREW
5-15
SISTEM BAHAN BAKAR
Pasang
Install asebuah O-ring
new O-ring baru
to the SEpada SE thermal
thermal valve. valve.
SE THERMAL
Install the
Pasang SESE thermal
thermal valve
valve ke into
dalamthekarburator
carburetorsampai
until it is
ia VALVE
fully seated.
telah duduk sepenuhnya.
O-RING
Tempatkan
Set the SE thermal valve
SE thermal into thedalam
valve ke badan
carburetor karburator
body so that
its center line is parallel with center line of carburetor
sehingga garis tengahnya sejajar dengan garis tengah
body as
badan shown. seperti diperlihatkan.
karburator
Install the setting Pasang setting

Install the plate
setting pada
plate ontoalur
the SE
SE thermal
thermal valve.
valve groove.
Pasang setting SETTING PLATE
plate withplate
the Install and tighten the setting plate screw
dengan ujung yang telah Pasang dan kencangkan setting plate to the specified
screw dengan
chamfered edge torque.
dipotong menghadap ke torsi yang ditentukan.
facing up.
atas. TORQUE:2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
Atur SCREW
Pasang SE SE
Install the thermal valvevalve
thermal covercover
pada to
SEthe
thermal valve
SE thermal
valve.
SE THERMAL
VALVE COVER
5-16
SISTEM BAHAN BAKAR
HOSES(SLANG-SLANG)
HOSES
Sambungkan airvent
Connect the air venthose
hoseand
dancarburetor
carburetordrain
drain hose.
hose.
AIR VENT HOSE
PEMBERSIHAN KARBURATOR
CARBURETOR CLEANING
Remove the
Lepaskan following:
sebagai berikut:
? SE thermal
- SE thermal valve valve
? Diaphragm/vacuum piston
- Diaphragm/vacuum piston
? Float/float valve
-? Float/float valvejet/needle jet/needle jet holder
Main jet/slow
-? Main
Pilotjet/slow jet/needle jet/needle
screw/spring/washer/O-ring
Blow open all air and fuel passagesjet in
holder
the carburetor
-body
Pilotwith
screw/spring/washer/O-ring
compressed air.
Do not use a piece of
wire Jangan memakai
to clean the air Tiuplah semua lubang terbuka dan lintasan bahan bakar
and fuel passage untuk
seutas kawat as it di dalam badan karburator dengan udara dari
membersihkan saluran
could damage the kompressor.
lintasan bahan bakar
carburetor body.
oleh karena dapat
merusak badan
karburator.
5-17
SISTEM BAHAN BAKAR
CARBURETOR INSPECTION
PEMERIKSAAN KARBURATOR
SE
SE THERMAL
THERMAL VALVE
VALVE
PEMERIKSAAN VALVE/NEEDLE
VALVE/NEEDLE INSPECTION
Lepaskan SESE
Remove the thermal valve
thermal (hal.
valve 5-12).
(page 5-12).
VALVE
Inspect valve
Periksa the valve
danand needle
needle for stepped
terhadap wearbertingkat
keausan or dam-
age.
atau kerusakan.
SE THERMAL
VALVE
NEEDLE
PEMERIKSAAN VALVE THERMOWAX
VALVE
Measure THERMOWAX
the resistance atINSPECTION
the connector terminals of the
Ukur tahanan pada connector terminals dari sisi SE
Pemeriksaan tahanan
The SE thermal SE
valve SE thermal
thermal valve. valve side.
thermal valve dapat
resistance inspection CONNECTION: Black – Green/Orange
candilakukan dengan
be done with the HUBUNGAN: Hitam
karburator terpasang STANDARD: 3.2 – 5.6–ΩHijau/Jingga
(at 25 °C/77°F)
carburetor installed STANDARD: 3,2 – 5,6 (pada 25 C)
pada mesin.
to the engine. If the resistance is abnormal, replace the SE thermal
Jika
valve.tahanan tidak normal, gantilah SE thermal valve.
PEMERIKSAAN CARA KERJA VALVE Bl G/O
Jika mesin telah dijalankan, biarkan mendingin (di

bawah 35° C) selama 30 menit atau lebih.
Lepaskan SE thermal valve body (hal. 5-12).

SE THERMAL VALVE 3P
Masukkan slang vinyl ke dalam fuel enrichment circuit CONNECTOR
(rangkaian pengkayaan bahan bakar) dan tiuplah ke
VALVE OPERATION INSPECTION
dalam hose.
If the engine has been running, let it cool down (below
SE THERMAL VALVE
Udara 35 °C (95
harus °F)) for ke
mengalir 30 dalam
minutes or more.
rangkaian.
Remove
Hubungkan the SE12
baterai thermal
V pada valve
SEbody (page valve
thermal 5-12). 3P
connector terminals
Insert a vinyl dan
hosetunggu 5 menit.
into the fuel enrichment circuit and
Masukkan slang vinyl
blow into the hose. ke dalam fuel enrichment circuit
dan tiuplah ke dalam
Air should flow slang.
into the circuit.
Connect the 12 V battery to the SE thermal valve 3P con-
Udara nector
tidak boleh mengalir
terminals ke dalam
and wait r angkaian.
5 minutes.
Insert
Jika cara a tidak
kerja vinyl normal,
hose into the SE
ganti fuelthermal
enrichment
valve.circuit and
blow into the hose.
Pasang AirSE thermal
should notvalve (hal.
flow into 5-15).
the circuit.
If operation is abnormal, replace the SE thermal valve. FUEL ENRICHMENT SE THERMAL VALVE
CIRCUIT 3P CONNECTOR
Install the SE thermal valve (page 5-15).
5-18
SISTEM BAHAN BAKAR
PEMERIKSAAN SISTEM
SYSTEM INSPECTION
? Before
• Sebelumperforming the systempemeriksaan
menjalankan inspection, make sure
sistem,
that the following is normal.
?pastikan
Battery bahwa yang berikut adalah normal.
condition
?- Fuse
Kondisi baterai
- Sekring
Lepaskan center
Disconnect body
the SE covervalve
thermal (hal.3P
2-8).
connector.
If the Jika
enginemesin Turn
telah Lepaskan
has been SE thermal valve 3P connector.
running, letbiarkan
dijalankan, it cool
mendingin
down dulu
(below(di Putar kunci kontak ke "ON".
bawah
35 35 C) F))
C (95
° selama
° 30 Ukur voltase pada sisi wire harness dari SE thermal
for 30
°
menit atau
minutes lebih.
or more. valve connector.
HUBUNGAN: Hitam ( + ) - Hijau/Jingga ( - )

STANDARD:
the ignition switch "ON". ada voltase baterai
Tidak
Measure the
Hidupkan voltage at the wire harness side of SE ther-
mesin.
mal valve
Ukur connector.
voltase pada sisi wire harness dari SE thermal
CONNECTION:
valve connector Black (+) – Green/Orange
sementara mesin dalam (–) keadaan
panas.
STANDARD: No voltage
Start the engine. Hitam ( + ) - Hijau/Jingga ( - )

HUBUNGAN:
Measure the voltage at the wire harness side of SE ther- TO MAIN
STANDARD: Ada
mal valve connector voltase
while baterai
the engine is hot. FUSE
R/Bl
•CONNECTION: Black
Jika ada voltase (+) – Green/Orange
baterai (–)
pada setiap waktu, periksa
STANDARD:
sebagai berikut: Battery voltage
Bl
- Hubungan singkat pada kawat Hijau/Jingga dari
? If there is battery voltage at all time, check the follow-
R/Bl G/O
ing:SE thermal valve R R/Bl
• ?Jika tidak
Short ada in
circuit voltase bateraivalve
SE thermal pada Green/Orange
setiap waktu,
wire sebagai berikut:
periksa
? If- there is no voltage
Rangkaian terbukaatpada
all time, check
kawat the following:
Hitam
?- Open circuit in Black wire
Rangkaian terbuka pada kawat Hitam dari S ICM
? Open circuit in SE thermal valve Black wire and/or
thermal valve dan/atau
Green/Orange wires kawat-kawat Hijau/Jingga.
R R /B l
• ? IfJika kawat-kawat
the wires are normal,adalah normal,
replace the ICMgantilah ICM
with a new
one,
denganand yang
recheck.
baru, dan periksa kembali.
SE THERMAL VALVE
3P CONNECTOR
VACUUM CHAMBER (RUANGAN VAKUUM)
Lepaskan vacuum chamber (hal. 5-12). IGNITION
SWITCH
Periksa sebagai berikut:
-VACUUM
Jet needle terhadap keausan bertingkat
CHAMBER
- Vacuum piston terhadap keausan atau kerusakan
-Remove the vacuum
Diaphragm chamber
terhadap (page kecil,
lubang 5-12). pemburukan
VACUUM PISTON
kondisi
Check theatau kerusakan
following:
? Jet needle for stepped wear
? Vacuum piston for wear or damage
? Diaphragm for pin holes, deterioration or damage
JET NEEDLE
DIAPHRAGM
5-19
SISTEM BAHAN BAKAR
FLOATCHAMBER
FLOAT CHAMBER
Remove the
Lepaskan float
float (page 5-12).(hal. 5-12).
(pelampung) PIN FLOAT
Check the
Periksa float
float for damage.
terhadap kerusakan.
Replace the float if there is fuel in the float.
Ganti float jika ada bahan bakar di dalam float.
Inspect the float valve seat for scores, scratches, clogs
and damage.
Periksa float valve seat (dudukan katub pelampung)
Check the tip of the float valve where it contacts the
terhadap gerusan, goresan, sumbatan dan kerusakan.
valve seat for stepped wear or contamination.
Periksa ujung
Replace the valve dariif the is worndiortempat
floattipvalve di mana ia
contaminated.
mengadakan kontak dengan valve seat terhadap
Check the operation of the float valve.
keausan bertingkat atau k ontaminasi.
Push valve
Ganti the pinbilaon the floataus
ujungnya valve
atauand make sure that it
terkontaminasi. FLOAT VALVE
returns smoothly.
Periksa cara kerja dari float valve. VALVE SEAT
Dorong pin pada float valve dan pastikan bahwa ia
kembali dengan lancar.
Install the
Pasang float
float valve
valve and
dan float
float (page
(hal. 5-13).
5-13).
Set the float level With the float valve seated and the float arm just touch-
Letakkan float level Dengan float measure
ing the valve, valve pada posisi
the float duduk
level danspecial
with the float arm
tool
gauge so that it is
gauge sedemikian tepat menyentuh
as shown. valve, ukur float level (tinggi
perpendicular to the
sehingga ia tegaklurus pelampung) dengan special tool seperti diperlihatkan.
float permukaan
pada chamber face at
float FLOAT LEVEL: 13.0 mm (0.51 in)
the highest point
chamber pada titik of
FLOAT LEVEL: 13,0 mm
the float.
tertinggi dari float. TOOL:
Carburetor float level gauge
TOOL: 07401-0010000
Carburetor floatbe
The float cannot level gauge
adjusted. 07401-0010000
Replace the float assembly if the float level is out of
Float tidak dapat disetel.
specification.
Ganti float assembly (susunan pelampung) bila float
level tidak sesuai dengan spesifikasi.
FLOAT LEVEL GAUGE
PILOT
PILOTSCREW/JETS
SCREW/JETS
Remove pilot screw
Lepaskan pilot screwand
daneach jet (page 5-12). (hal. 5-12).
masing-masing jet
Check the
Periksa following:
sebagai berikut: NEEDLE JET
? Pilot screw needle for wear or damage
-? Pilot screw
Pilot screw needle
springterhadap keausan atau kerusakan
for deterioration
-? Pilot
Eachscrew spring
jet for terhadap pemburukan kondisi
clogging NEEDLE JET
-?Masing-masing jet
Each passage forterhadap
clogging penyumbatan HOLDER
- Masing-masing jalan lintasan terhadap penyumbatan
MAIN JET
SPRING
PILOT SCREW SLOW JET
PILOT SCREWPILOT
PENYETELAN ADJUSTMENT
SCREW
? The pilot screw is factory pre-set and no adjustment is
• Pilot screw
necessary telahthe
unless disetel awal is
pilot screw di replaced.
pabrik dan tidak
diperlukan penyetelan lagi kecuali
? The engine must be warm for accurate jika pilot screw
adjustment.
10 minutes
telah of baru.
diganti stop-and-go riding is sufficient.
• ? Use
Mesina tachometer
harus dalamwith graduations 50 min-1 (rpm)
keadaan of panas untuk
or smaller thatakurat.
penyetelan will accurately
10 menit indicate a 50 min-1 (rpm)
pengendaraan jalan-
change.
dan-berhenti adalah cukup.
-1
• Pakailah tachometer dengan skala 50 menit (rpm)
atau lebih kecil yang dapat dengan akurat
-1
menujukkan perubahan sebesar 50 menit (rpm).
5-20
SISTEM BAHAN BAKAR
IDLEDROP
IDLE DROPPROCEDURE
PROCEDURE (PROSEDUR
Damage to the pilot PENURUNAN PUTARAN
1. Remove the luggage STASIONER)
box (page 2-7).
Kerusakan akan
screw seat pada
terjadi will occur
pilot
Turn the pilot screw clockwise until it seats lightly, and
if the seat
screw pilotjika
screw is 1.
pilot
Lepaskan
then back itluggage box
out to the (hal. 2-7). given.
specification
tightened against the This is an initial
Putar pilot screwsetting
searahprior
jarum to jam
the sampai
final pilot screw
ia duduk
screw dikencangkan
adjustment.
dengan ringan, dan kemudian putar keluar sampai
terhadap dudukannya. seat.
ke spesifikasi
INITIAL yang telah
OPENING: @@@ diberikan.
turns out
Ini merupakan penyetelan awal sebelum
2. Warm the engine
penyetelan up to screw.
akhir pilot operating temperature.
7
PEMBUKAAN
Stop-and-go AWAL:
riding for 101minutes
– /8 putaran keluar
is sufficient.
3. Stop
2. the engine.
Panaskan mesin sampai suhu operasionil.
Connect a tachometer according to the tachometer
Pengendaraaninstructions.
manufacturer’s jalan-dan-berhenti selama 10 menit
adalah cukup.
PILOT SCREW
3. Matikan mesin.
4. Disconnect
Hubungkanthetachometer
vacuum hose from PAIR
sesuai control
dengan valve
petunjuk
and connect the vacuum pump to the PAIR control
pemakaian pabrik VACUUM PUMP PAIR CONTROL VALVE
valve vacuum hose pembuatnya.
joint. Plug the vacuum hose.
5. Apply the specified vacuum to the PAIR control valve
4. Lepaskan vacuum hose dari PAIR control valve dan
vacuum hose more than 60 kPa (450 mm Hg).
hubungkan vacuum pump (pompa vakuum) ke
PAIR control valve vacuum hose joint. Sumbat PLUG
vacuum hose.
5. Terapkan vakuum yang ditentukan pada PAIR

control valve vacuum hose lebih dari 60 kPa (450
mm Hg).
6. Hidupkan mesin dan setel putaran stasioner

dengan throttle stop screw.
-1
PUTARAN STASIONER: 1.700 100 menit
(rpm)
7. Putar pilot screw masuk atau keluar dengan pelan

untuk mendapatkan putaran mesin tertinggi.
6. Start the engine and adjust the idle speed with the
8. throttle
Buka throttle 2 atau 3 kali dengan ringan, kemudian
stop screw. THROTTLE STOP SCREW
setel putaran stasioner dengan throttle screw.
IDLE SPEED: 1,700 ± 100 min -1 (rpm)
-1
7. Turn the pilot screw in or out slowly to obtain the high-
(rpm)
est engine speed.
8. Lightly open the throttle 2 or 3 times then adjust the
9. Putar pilot screw secara berangsur ke dalam
idle speed with the throttle stop screw -1
sampai putaran mesin turun dengan 100 menit
-1
IDLE
(rpm).SPEED: 1,700 ± 100 min (rpm)
9. Turn the pilot screw in gradually until the engine

10. speed
Putar drops
pilot by
screw
@@@ keluar sampai ke pembukaan
min-1 (rpm)
akhir.
10.Turn the pilot screw
PEMBUKAAN outward½
AKHIR: to the final opening.
putaran keluar dari
PILOT SCREW
posisi yang
FINAL diperoleh
OPENING: @@@ pada langkah
turns 9 the posi-
out from
tion obtained in step 9
11. Lepaskan plug (sumbat) dari vacuum hose,
11.Disconnect the plug from the vacuum hose, then
kemudian lepaskan vacuum pump dan hubungkan
remove the vacuum pump and connect the vacuum
vacuum
hose hose
to the PAIRkecontrol
PAIR valve
control valve vacuum
vacuum hose
hose joint.
joint.
12.Readjust the idle speed with the throttle stop screw.
12. IDLE
Setel SPEED:
kembali 1,700
putaran min -1 (rpm)
± 100stasioner dengan throttle
stop screw.
Install the luggage box (page 2-7).
-1
(rpm)
Pasang luggage box (hal. 2-7).
5-21
SISTEM BAHAN BAKAR
INLET
INLETPIPE
PIPE(PIPA MASUK)
REMOVAL
PELEPASAN
Lepaskan sebagai
Remove the berikut:
following:
Kiri: Kanan
-? Left
Leftcrankcase
crankcase cover
coverduct
duct(hal.
(page2-12)
2-12)
Luggage
-? Luggage box(hal.
box 2-7)
(page 2-7) BOLTS
Release the crankcase breather drain hose from the
Lepaskan
clamp. crankcase breather drain hose dari clamp.
Lepaskan ketiga
Remove the airair
three cleaner housing
cleaner housingmounting
mountingbolts.
bolts.
BREATHER
DRAIN HOSE CLAMP
Disconnectfuel
Lepaskan the fuel
autoauto valve
valve vacuumhose
vacuum hose dan
and PAIR
PAIR PAIR CONTROL NUTS
control valve vacuum hose from the inlet
control valve vacuum hose dari inlet pipe. pipe.
VALVE VACUUM
Loosen the inlet pipe band screw. HOSE
Longgarkan
Remove theinlet
nutspipe
andband screw.the inlet pipe from the
disconnect
carburetor.
Lepaskan nuts dan lepaskan inlet pipe dari karburator.
FUEL AUTO
VALVE
VACUUM
HOSE BAND SCREW
Tutuplah lubang Remove the
Lepaskan gasket
gasket danand clean any
bersikan sisagasket
bahan material
gasketfrom
dari
pemasukan cylinder
Seal the cylinder head the inlet pipe mating surface of the cylinder head.
permukaan penyatuan inlet pipe dari cylinder head.
head dengan kain lap GASKET
intake port with a
atau tutup dengan pita
shop towel or cover it
perekat untuk PEMASANGAN
INSTALLATION
with a piece of tape to
menghindari masuknya
prevent
benda any
asing keforeign
dalam Pasang gasket
Install a new baru
gasket to pada cylinder
the cylinder head.
head.
materialmesin.
from
dropping into the
engine.
Sambungkan
Connect the inlet inlet
pipepipe
to thepada karburator
carburetor dengan
by aligning the
tab of the carburetor PAIR CONTROL NUTS
mentepatkan tab dariwith the groove
karburator of the alur
dengan inlet pipe.
dari inlet
Install the inlet pipe mounting nuts and tighten them. VALVE VACUUM
pipe.
HOSE
Tighten inlet
Pasang the inlet
pipepipe band screw
mounting to the
nuts dan specified torque.
kencangkan.
TORQUE:2 N·m (0.2 kgf·m, 1.5 lbf·ft)
Kencangkan inlet pipe band screw dengan torsi yang
ditentukan.
Connect the fuel auto valve vacuum hose and PAIR con-
trol valve vacuum hose to the inlet pipe.
TORSI: 2 N.m (0,2 kgf.m; 1,5 lbf.ft)
Tepatkan
Sambungkan fuel auto valve vacuum hose dan PAIR
control valve vacuum hose pada inlet pipe. FUEL AUTO
VALVE
VACUUM
HOSE BAND SCREW
5-22
SISTEM BAHAN BAKAR
Set the air cleaner
Letakkan air housing in housing
cleaner position. pada tempat
Install and tighten the three bolts. Kanan: Kiri:
pemasangannya. BOLTS
Pasang
Secure danthe kencangkan ketiga bolts.
crankcase breather drain hose with the
clamp.
Kokohkan pemasangan crankcase breather drain hose
dengan clamp.
? Left crankcase cover duct (page 2-12)
? Luggage
Pasang sebagaibox berikut:
(page 2-7)
- Left crankcase cover duct (hal. 2-12)
BOLT BREATHER
DRAIN HOSE CLAMP
SECONDARY
SECONDARY AIR
AIR SUPPLY
SUPPLY SYSTEM
PEMERIKSAAN SISTEM
SYSTEM INSPECTION
Hidupkan mesin and
Start the engine dan warm
panaskan sampai
it up to normalkeoperating
suhu operasi
tem-
perature and stop the engine.
normal dan matikan mesin. AIR INTAKE PORT
Remove the PAIR air cleaner element (page 3-12).
Lepaskan PAIR air cleaner element (hal. 3-12).
Check that the PAIR air intake port is clean and free of
Periksa bahwa PAIR air intake port (lubang pemasukan
carbon deposits.
PAIR) adalah bersihfouled,
If the port is carbon dan bebas dari
check theendapan karbon.
PAIR check valve.
Jika port kotor dengan karbon, periksa PAIR chec
valve.
Remove the
Keluarkan two bolts dan
kedua and lepaskan
disconnectPAIR
the PAIR
controlcontrol
valve
valve
dari airfrom the air
cleaner cleaner
housing housing
(lihat (see page 5-24).
hal. 5-24).
Disconnect the PAIR control valve vacuum hose and VACUUM PUMP
Lepaskan PAIR control valve vacuum hose dan sumbat PAIR CONTROL VALVE
plug the hose.
hose.
Connect the vacuum pump to the PAIR control valve
vacuum hose joint.
Hubungkan vacuum pump pada PAIR control valve
Start the engine and open the throttle slightly to be cer- PLUG
vacuum
tain thathose
air isjoint.
sucked in through the joint of the PAIR
control valve.
Hidupkan mesin
If the air is not drawndan buka the
in, check throttle sedikit
joint and supply untuk
hose
for clogs.
memastikan bahwa udara dihisap masuk melalui joint
dari
WithPAIR control running,
the engine valve. gradually apply vacuum to the
Jika
PAIRudara
controltidak ditarik masuk, periksa joint dan slang
valve.
Check that
saluran the joint
terhadap of the PAIR control valve stops draw-
sumbatan.
ing air, and that the vacuum does not bleed.
Sementara
SPECIFIED mesin VACUUM: dalam
60 kPakeadaan
(450 mm hidup,
Hg) secara
berangsur terapkan vakuum pada PAIR control valve.
If air is drawn
Periksa bahwain, joint
or if dari
the specified vacuum
PAIR control is notterhenti
valve main-
tained, replace the PAIR control valve
menarik udara, dan bahwa vakuum tidak bocor. with a new one.
VAKUUM YANG DITENTUKAN: 60 kPa (450 mm Hg)

Jika udara dihisap masuk, atau jika vakuum yang
ditentukan tidak dapat dipertahankan, gantilah PAIR
control valve dengan yang baru.
5-23
SISTEM BAHAN BAKAR
PAIR CONTROL VALVE REMOVAL/
INSTALLATION
PAIR CONTROL VALVE
Remove the
Lepaskan body
body cover
cover (page
(hal. 2-9).
2-9).
PAIR CONTROL BOLTS
Disconnect
Lepaskan the following:
sebagai berikut: VALVE
? Air supply hose
- Air supply hose
? PAIR control valve vacuum hose
- PAIR control valve vacuum hose
Remove the two PAIR control valve mounting bolts and VACUUM
pull out thekedua
Lepaskan PAIR PAIR
controlcontrol
valve from
valveair cleaner housing.
mounting bolts dan HOSE
Installation
Route the hoses tarik is in the
keluar PAIR reverse
control order
valve dariofair
removal.
cleaner housing.
properly (page 1-14)
lurkan hoses dengan Pemasangan adalah dalam urutan terbalik dari
benar (hal. 1-14)
pelepasan.
AIR SUPPLY HOSE

PEMERIKSAAN PAIR CHECK
PAIR CHECK VALVE VALVE
INSPECTION
Lepaskan
Remove thebody cover
body (hal.
cover 2-9).
(page 2-9).
PAIR CHECK VALVE COVER
Lepaskan
Remove thekedua
two PAIR control valve
PAIR control valve mounting
mounting bolts
bolts(page
(hal.
5-24) dan putar valve sedikit ke atas untuk
5-24) and slightly turn the valve upward to gain access to
mendapatkan
the PAIR check akses
valveke PAIR
cover check valve cover screws
screws.
(sekrup-sekrup PAIR check valve cover).
Remove the two screws and PAIR check valve cover.
Lepaskan kedua screws dan PAIR check valve cover. SCREW
Remove the
Lepaskan PAIR
PAIR check
check valvevalve from control
dari PAIR the PAIR control
valve.
valve. PAIR CHECK VALVE
Ganti
ReplacePAIRthe control jika reed
valve valve
PAIR control (buluh)
if the reed rusak atau
is damaged or
deteriorated,kondisinya,
rubber seat is cracked, deteriorated or RUBBER SEAT
memburuk rubber seat (dudukan karet)
damaged, ormemburuk
retak-retak, if there is clearance
kondisinyabetween the reed
atau rusak, atau and
jika
seat.
ada kerenggangan antara reed dan seat.
Pemasangan
TORQUE: adalah dalam urutan terbalik dari
pelepasan.
Pair check valve cover screw:
2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)
TORSI:
Pair check valve cover screw:
2,1 N.m (0,2 kgf.m; 1,5 lbf.ft)
REED
5-24
SISTEM BAHAN BAKAR
PAIR AIR SUPPLY
PELEPASAN PIPE
PAIR AIR REMOVAL
SUPPLY PIPE
Lepaskan PAIR
Disconnect air supply
the PAIR hose hose
air supply dari pipe.
from the pipe.
PAIR AIR SUPPLY
HOSE
Lepaskan ketiga
Remove the bolts
three dan
bolts andPAIR
PAIRairairsupply
supplypipe.
pipe.
BOLTS
PAIR AIR SUPPLY PIPE
Remove the gasket.

Lepaskan gasket.

INSTALLATION
PEMASANGAN PAIR AIR SUPPLY PIPE
Install a new gasket.
Pasang sebuah gasket baru.
GASKET
Letakkan
Set the PAIRPAIR air pipe
air supply supply pipe pada posisi
in position.
pemasangannya. 6.5 ± 1.0 mm
Apply locking agent to the PAIR air supply pipe mounting
bolts as shown, then install and tighten them. BOLTS (0.26 ± 0.04 in)
Oleskan cairan pengunci pada PAIR air supply pipe
mounting bolts seperti diperlihatkan, kemudian pasang
dan kencangkan.
5-25
SISTEM BAHAN BAKAR
Sambungkan PAIRairairsupply
Connect the PAIR supply hose
hose pada
to the pipe
pipe dengan
so that the
marked
sisi yangside of the dari
bertanda hosehose
is facing out as shown.
menghadap ke luar seperti PAIR AIR
diperlihatkan. SUPPLY HOSE
TANDA
PEMERIKSAAN
INSPECTION
Periksa PAIR
Check the PAIRairairsupply
supply pipe for
terhadap
bend or tekukan
damage. atau
kerusakan.
PAIR AIR
SUPPLY PIPE
FUEL TANK
TANK (TANGKI BAHAN BAKAR)
Lepaskan body
Remove the cover
body (hal.
cover 2-9).
(page 2-9).
FUEL HOSE
Wipe off spilled out Letakkan
Place an tempat
approvedpenampung
container yang
undersesuai di bawah
the fuel fue
auto valve
Sekalah bahan bakar
fuel. and clamp the fuel hose.
auto valve dan jepit fuel hose dengan clamp.
yang tertumpah. Disconnectfuel
Lepaskan the hose
fuel hose
danand vacuum
vacuum hosedari
hose fromfuel
the auto
fuel
auto valve, then pull them out of the hole on the rear
valve, kemudian tarik mereka keluar dari lubang pada
fender.
rear fender (spakbor belakang).
VACUUM HOSE CLAMP
5-26
SISTEM BAHAN BAKAR
Disconnectfuel
Lepaskan the unit
fuel unit 3P connector
3P connector danand release wire
lepaskan the
wire clamp from
clamp dari fuel tank. the fuel tank. BOLTS FUEL TANK BOLTS/COLLARS
Lepaskan
? Two bolts sebagai berikut:
? Two bolts/collars
- Dua bolts
-Slightly lift up the rear side of the luggage box and
Dua bolts/collars
remove the
Installation is fuel tank.
in the reverse order of removal.
Route the hoses and Angkat sisi belakang dari luggage box sedikit dan
wire harness properly lepaskan fuel tank.
(page 1-14).
lurkan hoses dan wire Pemasangan adalah dalam urutan terbalik dari
harness dengan benar pelepasan.
(hal. 1-14)
3P CONNECTOR CLAMP
FUEL
FUEL AUTO
AUTO VALVE
VALVE
PEMERIKSAAN
INSPECTION
Lepaskan body
Remove the cover
body (hal.
cover 2-9).
(page 2-9).
Sekalah bahan bakar FUEL HOSE FUEL AUTO VALVE
Wipe spilled out Letakkan
off tertumpah.
yang
penampung
Place an approved fuelbahan bakar
container yang
under the sesuai di
fuel auto
fuel. valve
bawah and clamp
fuel auto the
valvefuel hose.
dan jepit fuel hose dengan clamp.
Disconnect
Lepaskan thehose.
fuel fuel hose.
Check that the fuel does not come out from the joint of
Periksa bahwa
the fuel auto bahan bakar tidak mengalir keluar dari
valve.
oint dari fuel auto valve.
CLAMP
Sambungkan
Connect a suitable sebuah fuel
fuel drain hosedrain hose
to the fuel (slang
auto valve.
pembuangan FUEL DRAIN HOSE
Place a suitable container under the fuel drain hose. auto
bahan bakar) yang sesuai pada fuel
valve.
Disconnect the vacuum hose from the fuel auto valve
and connect a commercially available vacuum pump to
Letakkan tempat
the diaphragm penampung
vacuum outlet. yang sesuai di bawah fuel
drain hose.
Fuel should flow out from the fuel hose when vacuum is
applied.
Lepaskan vacuum hose dari fuel auto valve dan
If fuel flow is restricted or does not flow, replace the fuel
sambungkan sebuah vacuum pump yang dapat dibeli di
auto valve.
pasaran pada diaphragm vacuum outlet (saluran keluar
vakuum diaphragm).
Bahan bakar harus mengalir keluar dari fuel hose ketika

vakuum diterapkan. VACUUM PUMP
Jika aliran bahan bakar terbatasi atau tidak mengalir,

gantilah fuel auto valve.
5-27
SISTEM BAHAN BAKAR
PELEPASAN
REMOVAL
Remove the
Lepaskan fuel
fuel tank
tank (page
(hal. 5-26).
5-26).
FUEL AUTO VALVE
Place an approved
Wipe off spilled out Letakkan penampungfuel container and drain
bahan bakar yangfuel.
sesuai dan
Seka bahan bakar fuel.
yang
keluarkan
Loosen thebahan bakar.
lock nut and remove the fuel auto valve. LOCK NUT
tertumpah.
Longgarkan lock nut dan keluarkan fuel auto valve.
Lepaskan
Remove thefuel strainer
fuel screen
strainer screendan
andO-ring
O-ring dari
fromfuel
the auto
fuel
auto valve.
valve.
Clean the fuel strainer screen with compressed air. O-RING
Bersihkan fuel strainer screen dengan udara dari
kompressor. STRAINER SCREEN
FUEL AUTO VALVE
PEMASANGAN
INSTALLATION
Pasang
Install a sebuah O-ring
new O-ring baru
to the pada
fuel fuel strainer
strainer screen. screen.
STRAINER SCREEN
O-RING
Install the
Pasang fuel
fuel strainer
strainer screenpada
screen ontofuel
the auto
fuel auto
valvevalve as
seperti
shown.
diperlihatkan. FUEL AUTO VALVE
STRAINER SCREEN
5-28
SISTEM BAHAN BAKAR
Install the
Pasang fuelfuel auto
auto valve
valve danand set it in the
tempatkan padacorrect
sudutangle
yang
as shown.
benar seperti diperlihatkan.
45 ± 3°
Tahan fuelfuel
Hold the auto valve
auto danand
valve kencangkan
tighten thelock
locknut
nutdengan
to the
specified
torsi yang torque.
ditentukan. FUEL AUTO VALVE
TORQUE:22.5 N·m (2.3 kgf·m, 17 lbf·ft)
TORSI: 22,5 N.m (2,3 kgf.m; 17 lbf.ft) LOCK NUT
Install the fuel tank (page 5-26).
Pasang fuel tank (hal. 5-26).
5-29
CATATAN
6. PENURUNAN / PEMASANGAN MESIN
LOKASI KOMPONEN
COMPONENT ............................6-2
LOCATION ????????????? 6-2 PENURUNAN MESIN
ENGINE REMOVAL ............................6-4
??????????????????? 6-4
KETERANGAN SERVIS ........................

SERVICE INFORMATION ?????????????? 6-3 6-3 PEMASANGAN MESIN .........................6-6
ENGINE INSTALLATION ?????????????? 6-6
6-1
PENURUNAN / PEMASANGAN MESIN
COMPONENT LOCATION
ENGINEREMOVAL/INSTALLATION
LOKASI KOMPONEN
49 N.m (5.0 kgf.m, 36 lbf.ft)
6-2
SERVICE INFORMATION
KETERANGAN SERVIS
UMUM
GENERAL
• Support
• Topangthe engine
mesin usingmenggunakan
dengan a jack or other dongkrak
adjustableatau
support
alatto ease of engine
penopang mounting
lain yang dapatbolt removal.
disetel untuk mempermudah pelepasan
• When
engine removing/installing
mounting bolt (bautthepemasangan
engine, tape the frame around the engine beforehand for frame protection.
mesin).
• The following components require engine removal for service.
•
– Ketika menurunkan/memasang
Cylinder mesin, sebelumnya
head/camshaft/cylinder/piston (page 7-10) bungkuslah rangka di sekitar mesin dengan pita untuk melindunginya.
• Komponen-komponen berikut
– Crankcase/crankshaft (page 10-5)) ini memerlukan penurunan mesin agar dapat menservisnya.
- Cylinder head/camshaft/cylinder/piston (hal. 7-10)
• The following components(hal.
- Crankcase/crankshaft can 8-15)
be serviced with the engine installed in the frame.
– Drive pulley (page 8-12)
– Driven pulley/clutch (page 8-16)
•
– Komponen-komponen berikutnya dapat diservis dengan mesin terpasang pada rangka.
Final reduction (page 9-6)
- Drive pulley (hal. 8-11)
– Stator/ignition pulse generator (page 14-7)
– - Carburetor
Driven pulley/clutch
(page 5-8) (hal. 8-15)
- Final reduction
– Oil pump (page 4-4)(hal. 9-6)
- Stator/ignition pulse generator (hal. 14-7)
- Karburator (hal. 5-8)
SPECIFICATIONS
- Oil pump (hal. 4-4)
ITEM SPECIFICATIONS
SPESIFIKASI
Engine dry weight 24.9 kg (54.9 lbs)
Engine oil capacity
BAGIAN After draining 0.7 liter (0.7 US qt, 0.6 lmp qt)
SPESIFIKASI
Berat kosong mesin After disassembly 0.8 liter (0.8 US qt, 0.7 kg
24,9 lmp qt)
Kapasitas oli mesin Pada penggantian periodik 0,7 liter
Setelah pembongkaran mesin 0,8 liter
TORQUE VALUES
Engine hanger link nut (Engine side) 49 N·m (5.0 kgf ·m, 36 lbf ·ft)
NILAI TORSI
Engine hanger link nut (sisi Mesin) 49 N.m (5,0 kgf.m; 36 lbf.ft)
6-3
ENGINE REMOVAL
PENURUNAN MESIN
Remove the
Lepaskan following:
sebagai berikut:
SPRING
Under
- – Under cover(hal.
cover (page 2-10)
2-10) ADJUSTING NUT
– Center body cover
- Center body cover (hal.(page 2-8)
2-8)
– Luggage box (page 2-7)
Remove the rear brake adjusting nut and joint pin from
Lepaskan rear cable.
the rear brake brake adjusting nut dan joint pin dari rear
brake cable.
Remove the return spring from the brake arm.
Lepaskan return spring dari brake arm.
JOINT PIN
BRAKE CABLE
Remove the
Lepaskan cable
cable clamp
clamp bolt.
bolt. BRAKE CABLE
Release the rear brake cable from the cable holder.
Lepaskan rear brake cable dari cable holder.
CABLE CLAMP/ BOLT CABLE HOLDER

Disconnect
Lepaskan the spark
spark plug cap.
plug cap.
Release the spark plug wire clamp from the frame.
Lepaskan spark plug wire clamp dari rangka.
WIRE CLAMP
SPARK PLUG CAP
Remove the bolt and ground cables.

Disconnect
Lepaskan thedan
bolt following
groundconnectors:
cables. BOLT/GROUND CABLES ALTERNATOR 3P
– Alternator 3P connector CONNECTOR
Lepaskan connectors berikut ini:
– Starter motor 2P connector
- – Alternator
SE thermal
3P valve 3P connector
connector
- Starter motor 2P connector
- SE thermal valve 3P connector
SE THERMAL VALVE
3P CONNECTOR
STARTER
MOTOR 2P
CONNECTOR
6-4
Release the
Lepaskan following
wire clamps wire clamps
berikut from
ini dari the frame:
rangka:
SE THERMAL VALVE
- –SESE thermal
thermal valve
valve wire
wire clamp
clamp WIRE CLAMP
– Alternator wire clamp
- – Alternator wire clamp
Starter motor wire clamp
- Starter motor wire clamp
ALTERNATOR
WIRE CLAMP
STARTER MOTOR
WIRE CLAMP
Disconnect
Lepaskan the following:
sebagai berikut: THROTTLE CABLE FUEL HOSE
– Fuel hose
- –Fuel hose
Fuel auto valve vacuum hose
- Fuel auto valve vacuum hose
Loosen the lock nut and disconnect the throttle cable.
Longgarkan lock nut dan lepaskan throttle cable.
LOCK NUT
VACUUM HOSE
Untuk
To menghindari
avoid damage to Lepaskan
Remove therearrear
shock absorber
shock lowerlower
absorber mounting bolt dan
mounting bolt
kerusakanthepada ulirshock
rear and release the rear shock absorber from the engine. SHOCK ABSORBER
rear lepaskan rear shock absorber dari mesin.
shock absorber
absorber mounting
mounting bolt,slightly
bolt threads, angkat
roda belakang sedikit.
lift the rear wheel.
MOUNTING BOLT
Supportrangka
Dukung the frame in upright
pada position.
posisi tegak.
Hold the front
Tahan roda depan.wheel.
Remove the nut and engine hanger link bolt.
Lepaskan nut dan engine hanger link bolt.
Slightly pull the engine straight back and release it from
Tarik mesinhanger
the engine sedikit link.
lurus ke belakang dan lepaskan dari
Turn the
engine rear side
hanger of the engine to
link (penyambung the right andmesin).
penggantung remove
the engine.
Putar bagian belakang dari mesin ke kanan dan
lepaskan mesin.
NUT/BOLT
6-5
PEMASANGAN MESIN
ENGINE INSTALLATION
Maneuver mesin
Gerakkan the engine into therangka
ke dalam frame from
dari the
sisi right
kanansidedari
of
the vehicle.
kendaraan.
Set the engine
Tempatkan mesinstraight
lurus with
denganthe frame
rangkaand danpush the
dorong
engine forward so that the bolt holes are aligned.
mesin ke depan sehingga lubang-lubang bolt telah
Install the engine hanger link bolt from the left side of the
disejajarkan.
scooter.
Install and
Pasang tightenhanger
engine the nut to thebolt
link specified
(bauttorque.
penyambung
penggantung mesin) dari sisi
TORQUE:49 N·m (5.0 kgf·m, 36 lbf·ft)kiri dari skuter.
Pasang dan kencangkan nut dengan torsi yang

ditentukan.
TORSI: 49 N.m (5,0 kgf.m; 36 lbf.ft) NUT/BOLT
Tempatkan
Set the rearshock
shockabsorber
absorberbelakang sedemikian
so that the bolt holesrupa
are
sehingga
aligned. lubang-lubang bolt telah disejajarkan. SHOCK ABSORBER
To ease installation of Install and tighten the rear shock absorber lower mount-
Untuk mempermudah
the rear shock Pasang
ing bolt. dan kencangkan rear shock absorber lower
pemasangan rear shock
absorber mounting mounting bolt (baut pemasangan bawah sokbreker
absorber mounting bolt, belakang.
bolt, slightly lift the
angkat roda belakang
rear sedikit.
wheel.
MOUNTING BOLT
Sambungkan throttle
Connect the throttle cable
cable ke throttle
to the throttledrum.
drum (teromol
Adjust the throttle grip free play (page 3-5). THROTTLE CABLE FUEL HOSE
kabel gas).
Setel
Connectjarak main bebas throttle grip (putaran gas
the following:
tangan) (hal. 3-5).
– Fuel auto valve vacuum hose
– Fuel hose
Sambungkan sebagai berikut:
- Fuel auto valve vacuum hose
- Fuel hose
VACUUM HOSE
Kokohkan
Secure thepemasangan
following wire wire clamps
clamps berikut ini pada
to the frame:
rangka: SE THERMAL VALVE
– SE thermal valve wire clamp WIRE CLAMP
– Alternator wire clamp
- SE
– thermal
Starter valve
motor wire
wire clamp
clamp
- Alternator wire clamp
- Starter motor wire clamp
ALTERNATOR
WIRE CLAMP
STARTER MOTOR
WIRE CLAMP
6-6
Sambungkan connectors
Connect the following berikut ini:
connectors:
BOLT/GROUND CABLES ALTERNATOR 3P
- – Alternator
Alternator3P
3P connector
connector CONNECTOR
– Starter motor wire
- Starter motor wire 2P 2Pconnector
connector
– SE thermal valve 3P connector
- SE thermal valve 3P connector
Route the wire Set the ground cables in position, then install and tighten
lurkan sire Tempatkan
the bolt. kabel-kabel massa pada tempatnya,
harness properly
harness dengan kemudian pasang dan kencangkan bolt.
benar(page
(hal. 1-14).
1-14).
SE THERMAL VALVE
3P CONNECTOR
STARTER MOTOR WIRE

2P CONNECTOR
Secure the spark plug wire clamp to the frame.
Kokohkan pemasangan
Connect the spark plug wire clamp pada
spark plug cap.
rangka.
Sambungkan spark plug cap.
WIRE CLAMP
SPARK PLUG CAP
Set theand
Tempatkan
Install brake cable
brake
tighten through
cable
the the cable
cable (kabel holder.
rem)
clamp/bolt. melalui cable
BRAKE CABLE
Route the rear brake holder.
lurkan rear brake
cable properly
cable dengan Pasang dan kencangkan cable clamp bolt.
benar(page
(hal. 1-14).
1-14).
CABLE CLAMP/ BOLT CABLE HOLDER

Pasang joint
Install the jointpin
pindan
andadjusting
adjusting nut pada
nut to the rear brake
rear brake
cable.
cable. SPRING
Set the return ujung-ujung
spring ends intoreturn
the hole on the left(pegas
crank- ADJUSTING NUT
Tempatkan spring
case and pin on the brake arm.
pengembalian) ke dalam lubang pada left crankcase
dan pin pada
Adjust the brake
rear brakearm (lengan
lever rem).
free play (page 3-16).
Setel jarak main bebas rear brake lever (hal. 3-16).
– Under cover (page 2-10)
Pasang
– Centersebagai berikut:
Luggage
- – Under coverbox (page
(hal. 2-7)
2-10)
- Center body cover (hal. 2-8)
JOINT PIN
BRAKE CABLE
6-7
CATATAN
7. CYLINDER HEAD/VALVES/CYLINDER/PISTON
COMPONENT
LOKASI LOCATION ····························7-2
KOMPONEN-KOMPONEN......7-2 CYLINDER HEAD
CYLINDER HEAD··········································7-14
..................................7-14 7

SERVICE INFORMATION ·····························7-3 CAM
CAMCHAIN
CHAIN GUIDE...............................7-29
GUIDE······································7-29
TROUBLESHOOTING ...........................7-6
TROUBLESHOOTING ····································7-6 CAM
CAMCHAIN
CHAIN TENSIONER SLIDER
TENSIONER SLIDER .......7-30
···········7-30
TEST KOMPRESSI
CYLINDER CYLINDER.............7-7
COMPRESSION TEST ··············7-7 CAM
CAMCHAIN
CHAIN TENSIONER LIFTER........7-31
TENSIONER LIFTER ···········7-31
CYLINDER
CYLINDER HEAD COVER····························7-7
HEAD COVER .................... 7-7 CYLINDER
CYLINDER .............................................7-32
······················································7-32
INTAKE/EXHAUST SHROUDS
INTAKE/EXHAUST SHROUDS .............7-9
·····················7-9 PISTON ..................................................7-34
PISTON ·························· ························ ··········· 7-34
CAMSHAFT ...........................................7-10
CAMSHAFT ························ ························· ···· 7-10
7-1
COMPONENT LOCATION
LOKASI KOMPONEN-KOMPONEN
0.8 N·m (0.1 kgf ·m, 0.6 lbf ·ft)
10 N·m (1.0 kgf ·m, 7 lbf ·ft)
4 N·m (0.4 kgf ·m, 3.0 lbf ·ft)
18 N·m (1.8 kgf ·m, 13 lbf ·ft)
12 N·m (1.2 kgf ·m,

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

7 N·m (0.7 kgf ·m, 5.1 lbf ·ft)
7-2
KETERANGAN SERVIS
SERVICE INFORMATION
GENERAL
UMUM
• This section covers service of the cylinder head, valves, rocker arms, camshaft, cylinder and piston.
•
• Babengine
The ini meliputi
must beservis
removeddarifrom
cylinder head,tovalves,
the frame service rocker arms,
the cylinder camshaft,
head, cylinder dan piston.
valves, camshaft, cylinder and piston.
• Mesin harus dilepaskan dari rangka untuk dapat menservis cylinder head,
• When disassembling, mark and store the disassembled parts to ensure that they are reinstalled valves, camshaft, cylinder
in their original dan piston.
locations.
• Sewaktu
• Clean pembongkaran,
all disassembled parts withtandai dan solvent
cleaning simpanlah parts
and dry themyang dibongkar
by blowing themuntuk memastikan
off with compressed bahwa mereka
air before dipasang kembali
inspection.
pada lokasi
• Camshaft and semula
rocker armmereka.
lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling cylinder
• head.
Bersihkan semua parts yang dibongkar dengan larutan pembersih dan keringkan dengan meniup dengan udara dari
• Be careful not sebelum
kompressor to damagepemeriksaan.
the mating surfaces when removing the cylinder head cover and cylinder head. Do not tap the cylinder head cover
• and cylinder head too
Minyak pelumasan camshaft hard during removal.
dan rocker arm disalurkan melalui jalan lintasan oli di dalam cylinder head. Bersihkan jalan
• Take care not to damage
lintasan oli sebelum merakit the cylinder wallcylinder
kembali and piston.
head.
•
•
When removing the piston, clean carbon
Hati-hati agar tidak merusak permukaan-permukaan and sludge from the penyatuan
top of the cylinder.
ketika melepaskan cylinder head cover dan cylinder head.
Jangan mengetuk cylinder head cover dan cylinder head terlalu keras pada waktu pelepasan.
• Hati-hati agar tidak merusak dinding cylinder dan piston.
CYLINDER HEAD/VALVES SPECIFICATIONS
• Ketika piston dilepaskan, bersihkan karbon dan kotoran dari bagian atas cylinder.
Unit: mm (in)
SPESIFIKASI CYLINDER HEAD/VALVES Satuan: mm
SERVICE
ITEM
BAGIAN STANDARD
STANDARD BATAS LIMIT
SERVIS
2
Tekanan kompressi
Cylinder compression cylinder 1341 kPa (13,4
1314 kPa (13.4 kgf/cm kgf/cm
2 , 191
, 191 psi) psi) -
pada -1 menit -1 (rpm)
520 –
at 520 min (rpm)
Perubahan
Cylinder head bentuk
warpagemelengkung cylinder head -– 0,05 0.05 (0.002)
Rocker
Rocker armarm D.D. rocker arm
Rocker arm I.D. IN/EX
IN/EX 10,000 – 10,015
10.000 – 10.015 (0.3937 – 0.3943) 10,04 10.04 (0.395)
Rocker arm shaft O.D. (MASUK/ 9.972 – 9.987 (0.3926 – 0.3932)
IN/EX 9.91 (0.390)
Arm to shaft clearance BUANG) 0.013 – 0.043 (0.0005 – 0.0017)
IN/EX 0.08 (0.003)
Camshaft D.L. rocker arm
Cam lobe height shaft IN/EX
IN 9,972 – 9,987
32.4006 – 32.6406 (1.27561 – 1.28506) 9,91 32.37 (1.274)
Jarak renggang antara IN/EX
EX 0,013––32.2464
32.0064 0,043 (1.26009 – 1.26954) 0,08 31.97 (1.259)
Valve, valve arm ke shaft
Valve clearance IN 0.14 ± 0.02 (0.006 ± 0.001) –
Camshaft
guide Ketinggian cam lobe IN
EX 32,4006
0.14 – 32,6406
± 0.02 (0.006 ± 0.001)
32,37 –
(bubungan) EX 32,0064 – (0.1959
32,2464– 0.1965) 31,97 4.90 (0.193)
Valve stem O.D. IN 4.975 – 4.990
Valve, valve Jarak renggang klep IN
EX 0,14
4.955 ± 0,02
– 4.970 (0.1951 – 0.1957)
-
4.90 (0.193)
guide EX
Valve guide I.D. IN/EX 0,14
5.000 ± 0,02
– 5.012 (0.1969 – 0.1973) 5.03-(0.198)
D.L. valve stem
Stem-to-guide clearance IN
IN 4,975 – 4,990
0.010 – 0.037 (0.0004 – 0.0015) 4,90 0.08 (0.003)
EX
EX 4,955 – 4,970
0.030 – 0.057 (0.0012 – 0.0022) 4,90 0.10 (0.004)
D.D. valve
Valve guideguide
projection above IN/EX
IN/EX 9.15,000 – 5,012
– 9.3 (0.36 – 0.37) 5,03 –
Jarak renggang
cylinder head stem IN 0,010 – 0,037 0,08
keValve
guideseat width EX
IN/EX 1.00,030
(0.04)– 0,057 0,10 1.5 (0.06)
Valve spring Proyeksi
IN/EX valve guide IN/EX 9,1 – 9,3
29.78 (1.172) 29.11- (1.146)
free length di atas cylinder head
Lebar valve seat IN/EX 1,0 1,5
Panjang bebas IN/EX 29,78 29,11
valve spring
CYLINDER/PISTON SPECIFICATIONS
Unit: mm (in)
SPESIFIKASI CYLINDER/PISTON Satuan: mm
SERVICE
BAGIAN
ITEM STANDARD
STANDARD BATAS SERVIS
LIMIT
Cylinder D.D. 50,005 – 50,015 50,10
Cylinder I.D. 50.005 – 50.015 (1.9687 – 1.9691) 50.10 (1.972)
Kelonjongan - 0,05
Out-of-round – 0.05 (0.002)
Ketirusan - 0,05
Taper – 0.05 (0.002)
Perubahan bentuk melengkung - 0,05
Warpage – 0.05 (0.002)
Piston, piston D.L. piston 49,970 – 49,990 49,95
Piston, piston Piston O.D. 49.970 – 49.990 (1.9673 – 1.9681) 49.95 (1.967)
rings, piston Titik pengukuran D.L. piston 6 mm dari bagian bawah piston -
rings, piston pin Piston O.D. measurement point 6.0 (0.24) from bottom of skirt –
pin D.D. lubang piston pin 13,002 – 13,008 13,04
Piston pin bore I.D. 13.002 – 13.008 (0.5119 – 0.5121) 13.04 (0.513)
D.L. piston pin 12,994 – 13,000 12,96
Piston pin O.D. 12.994 – 13.000 (0.5116 – 0.5118) 12.96 (0.510)
Jarak renggang antara piston-ke- piston pin 0,002 – 0,014 0,02
Piston-to-piston pin clearance 0.002 – 0.014 (0.0001 – 0.0006) 0.02 (0.001)
Jarak renggang Ring paling atas 0,015 – 0,050 0,08
Piston ring-to-ring Top 0.015 – 0.050 (0.0006 – 0.0020) 0.08 (0.003)
antara piston Ring kedua 0,015 – 0,050 0,08
groove clearance Second 0.015 – 0.050 (0.0006 – 0.0020) 0.08 (0.003)
ring-ke-alurnya
Piston
Celah ring end gap Ring paling
pada Top atas 0.10 – 0.25
0,10 (0.004 – 0.010)
– 0,25 0,45 0.45 (0.018)
ujung piston ring Second
Ring kedua 0.10 – 0.25 (0.004
0,10 – 0,25 – 0.010) 0,45 0.45 (0.018)
Oil(side
Ring oli (side rail)
rail) 0.20 – 0.70 (0.008
0,20 – 0,70 – 0.028) - –
Cylinder-to-piston
Jarak clearance
renggang antara cylinder-ke-piston 0.015 – 0.045
0,015 (0.0006 – 0.0018)
– 0,045 0,09 0.09 (0.004)
Connecting rod small end I.D. rod
D.D. kepala kecil connecting 13.010 – 13.028
13,010 – 13,028 (0.5122 – 0.5129) 13,05 13.05 (0.514)
Connecting
Jarak rod-to-piston
renggang pin clearancerod-ke-piston pin
antara connecting 0.010 – 0.034
0,010 – 0,034(0.0004 – 0.0013) 0,05 0.05 (0.002)
7-3
NILAI
TORQUETORSI
VALUES
Cylinder head
Cylinder headcover
coverspecial
special bolt
bolt 12 N.m (1,2(1.2
12 N·m kgf.m; 9 lbf.ft)
kgf·m, 9 lbf·ft)
Cam sprocket bolt
Cam sprocket bolt 8 N.m (0,8 kgf.m; 5,9 lbf.ft)
8 N·m (0.8 kgf·m, 5.9 lbf·ft) Oleskan oli mesin
Apply pada
engine oilulir danthreads
to the permukaan duduk.
and seating surface.
Cylinder head
Cylinder headnut
nut 18 N.m (1,8 kgf.m; 13 lbf.ft)
18 N·m (1.8 kgf·m, 13 lbf·ft) Oleskan oli mesin pada ulir dan permukaan duduk.
Apply engine oil to the threads and seating surface.
Cylinder head bolt 12 N.m (1,2 kgf.m; 9 lbf.ft) Oleskan oli mesin pada ulir dan permukaan duduk.
Cylinder head bolt 12 N·m (1.2 kgf·m, 9 lbf·ft) Apply engine oil to the threads and seating surface.
Exhaust shroud mounting bolt 7 N.m (0,7 kgf.m; 5,1 lbf.ft)
Exhaust shroud mounting bolt 7 N·m (0.7 kgf·m, 5.1 lbf·ft)
Intake shroud mounting screw 0,8 N.m (0,1 kgf.m, 0,6 lbf.ft)
Intake shroud mounting screw 0.8 N·m (0.1 kgf·m, 0.6 lbf·ft)
Cam chain tensioner lifter screw 4 N.m (0,4 kgf.m; 3,0 lbf.ft)
CamCam chaintensioner
chain tensionerslider
lifter screw
pivot pin bolt 4
10 N.mN·m (0.4
(1,0 kgf·m,
kgf.m; 7 3.0 lbf·ft)
lbf.ft)
Cam chain tensioner slider pivot pin bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)
TOOLS
TOOLS
Valve spring compressor Valve spring compressor attachment Valve guide reamer, 5.0 mm
07757-0010000 07959-KM30101 07984-MA60001
Valve guide driver, 5.0 mm Valve guide adjusting driver Cam chain tensioner lifter stopper
07942-MA60000 07743-0020000 070MG-0010100
Seat cutter, 27.5 mm (IN, 45°) Seat cutter, 24 mm (EX, 45°) Flat cutter, 27 mm (IN, 32°)
07780-0010200 07780-0010600 07780-0013300
7-4
Flat cutter, 22 mm (EX, 32°) Interior cutter, 26 mm (IN, 60°) Interior cutter, 22 mm (EX, 60°)
07780-0012601 07780-0014500 07780-0014202
Cutter holder 5.0 mm

07781-0010400
7-5
TROUBLESHOOTING
TROUBLESHOOTING
? Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test or by trac-
• Persoalan pada bagian atasnoises
ing engine mesin biasanya
to the mempengaruhi
top-end with unjuk
a soun ding rod kerja mesin. Persoalan-persoalan ini dapat didiagnosa
or stethoscope.
dengan test kompressi
• If theatau dengan is
performance menelusuri
poor at lowsuara-suara mesin
speeds, check padasmoke
for white bagian
in atas dengan breather
the crankcase tangkai suara
hose. Ifatau stethoscope.
the hose is smoky,
• Jika unjuk kerja mesin buruk pada kecepatan
check for a seized piston ring. rendah, periksalah terhadap asap putih pada crankcase breather hose (slang
pernapasan bak mesin). Jika hose berasap, periksa terhadap piston ring yang macet.
Compression too low, hard starting or poor performance at low speed
• Valves:
Kompressi terlalu rendah, mesin sulit dihidupkan atau unjuk kerja buruk pada kecepatan rendah
– Incorrect valve adjustment
• Valves (klep-klep):
– Burned or bent valves
- Penyetelan valve tidak benar
– Incorrect valve timing
- Valves terbakar –
atau bengkok
Broken valve spring
- Tertib waktu klep –tidak benar
Uneven valve seating
- Valve spring patah
– Valve stuck open
- Valve seating (dudukan
– Weak klep)
valve tidak
springmerata
- Valve macet terbuka
• Cylinder head:
- Valve spring lemah
– Leaking or damaged cylinder head gasket
• Cylinder head: – Warped or cracked cylinder head
- Cylinder head gasket bocor
– Loose atau
spark rusak
plug
- Ada perubahan ? bentuk melengkung atau retak-retak pada cylinder head
Worn cylinder
- Spark plug (busi) longgar
? Worn piston or piston rings
• Cylinder aus ? Bent connecting rod
• Piston atau piston rings aus too high, overheating or knocking
Compression
• Connecting rod •bengkok
Excessive carbon build-up on piston head or on combustion chamber
Excessive
Kompressi terlalu tinggi, smoke
overheating atau knocking
• Worn valve stem or valve guide
• Ada pembentukan karbon secara berlebihan pada piston head (kepala piston) atau di ruang pembakaran
? Damaged stem seal
? Worn cylinder
Asap berlebihan
? Worn piston or piston rings
• Valve stem atau ?valve guide aus
Improper installation of piston rings
• Stem seal rusak ? Scored or scratched piston or cylinder wall
• Cylinder aus
•
Excessive
Piston atau piston rings ausnoise
• Incorrect valve adjustment
• Pemasangan piston rings tidak benar
? Sticking valve or broken valve spring
• Piston atau dinding cylinder tergerus atau tergores
? Excessively worn valve seat
? Worn or damaged camshaft
Mesin berisik ? Worn or damaged cam chain
• Penyetelan klep ?tidak
Worn tepat
cam sprocket teeth
• Valve macet atau ? Wornspring
valve rocker patah
arm and/or shaft
• Valve seat (dudukan
? Worn klep)
or aus berlebihan
damaged cam chain tensioner
• Camshaft aus atau rusakcylinder
? Worn
• Cam chain aus ?atauWorn
rusakpiston or piston rings
• Gigi-gigi cam sprocket aus
Rough idle
• Rocker arm dan/atau shaft
• Low cylinderaus compression
• Cam chain tensioner aus atau rusak
Abnormal noise
• Cylinder aus
• Worn piston pin or piston pin hole
• Piston atau piston rings aus
• Worn connecting rod small end
• Worn cylinder, piston or piston rings
Putaran stasioner kasar
• Piston
Tekanan kompressi ring sticking/scuffing,
cylinder rendah bearing damage
• Clogged oil gallery or oil strainer screen
Suara tidak normal • Internal oil leak
• Piston pin atau • Not using recommended
lubang piston pin aus engine oil
• Kepala kecil connecting rod aus
• Cylinder, piston atau piston rings aus
Piston ring macet/menggeser, kerusakan bearing (bantalan)

• Saluran oli atau oil strainer screen tersumbat
• Ada kebocoran oli di dalam
• Tidak menggunakan oli mesin yang dianjurkan
7-6
CYLINDER
TEST COMPRESSION
KOMPRESSI TEST
CYLINDER
Warm the engine
Panaskan mesinto n ormalsuhu
sampai operating temperature.
operasi normal.
Stop the engine and remove the spark
Matikan mesin dan lepaskan spark plug plugcap
cap(topi
and spark
busi)
plug (page 3-7).
dan spark plug (busi) (hal. 3-7).
Install a compression gauge into the spark plug hole.
Untuk mencegah Pasang compression gauge (meter pengukur
To avoid discharging
menghabiskan muatan Open the throttle
kompressi) ke dalamall the way and
lubang busi.crank the engine with the
thebaterai,
listrik battery,jangan
do not starterthrottle
Buka until the gauge reading
seluruhnya danstops
putarrising.
mesin dengan starter
operate the starter
menjalankan starter sampai pembacaan gauge berhenti naik.within 4 – 7 sec-
The maximum reading is usually reached
motor
motor fordari
lebih more7 than
detik.7 onds.
Pembacaan maksimum
maksimum biasanyabiasanya dicapai
dicapai dalam 4 – 7
seconds. detik.
COMPRESSION PRESSURE:
TEKANAN KOMPRESSI:
1,314 kPa (13.4 kgf/cm 2, 191 2 psi) at 520 min -1(rpm) -1
1.314 kPa (13,4 kgf/cm ; 191 psi) pada 520 menit
(rpm)
If compression is high, it indicates that carbon deposits have
Jika kompressi
accumulated tinggi,
on the ini menunjukkan
combustion bahwa
chamber and/or telah
the piston COMPRESSION GAUGE
terkumpul
crown. endapan karbon pada ruang pembakaran
dan/atau mahkota piston.
mahkota piston.
If compression is low, pour 3 – 5 cc (0.1 – 0.2 oz) of engine
oil into the cylinder through the spark plug hole and recheck
Jika kompressi
kompressi rendah, tuangkan
the compression. tuangkan 3 – 5 cc oli mesin ke
dalam cylinder melalui lubang spark plug dan periksa
If the compression
kembali kompressi.increases from the previous value, check
the cylinder, piston and piston rings.
Jika
• Leakompressi
Leakin
king
g cylin naikhead
cylinder
der darigas
head nilai
ket sebelumnya, periksalah
gasket
cylinder,
• Wo
Worn piston
rn pi
pist
ston dan piston
dan
on ri
ring
ng piston rings.
rings .
Kebocoran
• • Wor
Worn n cyli
cylinde
nderpada
r and cylinder
and pis ton head gasket
piston
• Piston ring aus
If compression is the same as the previous value, check the
• Cylinder dan piston
dan piston aus
valves for leakage.
Jika kompressi sama dengan nilai sebelumnya,
periksalah valves (klep-klep) terhadap kebocoran.
CYLINDER HEAD COVER
CYLINDERREMOVAL
HEAD COVER
PELEPASAN
CRANKCASE
Disconnect the crankcase breather hose. RUBBER SEAL
Jangan sampai
samp
Do not aithe
let Remove the
mesin Lepaskan
oli engine special
center bodybolts,
covermounting rubbers and cylinder
(hal. 2-8). BREATHER
menetes ke atas
oil drip down rangka
to the head cover. HOSE
dari frame
cylinder
fromhead.
the
Lepaskan crankcase breather hose.
cylinder head.
Lepaskan
Remove thespecial bolts,
rubber seal mounting
from rubbers
the cylinder dan cylinder
head cover.
head cover.
Lepaskan rubber seal dari cylinder head cover.
SPECIAL BOLTS/
MOUNTING RUBBERS
PEMASANGAN
INSTALLATION
Make surebahwa
Pastikan the sealseal
rubber is in good
rubber condition
berada pada and replace
kondisi it
baik
if necessary. 5 – 15
15 mm SEAL POINTS
dan ganti bila perlu.
(0.2 –
(0.2 – 0.6
0.6 in)
Apply adhesive (CEMEDINE 575 or Three Bond 1194 or
Oleskan perekat
equivalent) (CEMEDINE
to the cylinder 575mating
head cover atau area
Three Bond
as speci-
1194
fied. atau sejenisnya) pada daerah penyatuan cylinder
head cover seperti ditentukan.
CYLINDER HEAD COVER
7-7
Install the
Pasang seal
seal rubberkeinto
rubber the groove
dalam on the
alur pada cylinder
cylinder headhead
cover.
cover. SEAL RUBBER
CYLINDER HEAD COVER
Apply liquid
Oleskan sealant
liquid (Three
sealant bond perapat)
(cairan 5211C or (Three
SHIN-ETSU-
bond
SILICONE SEAL RUBBER
5211C atauKE45T or Three bond 1215KE45T
SHINETSU-SILICONE or equivalent) to the
atau Three
semicircular
bond 1215 area
atauof sejenisnya)
seal rubber as pada
shown.daerah setengah
lingaran dari seal rubber seperti diperlihatkan.
SEAL POINTS
Pasang mounting
Install the mountingrubbers
rubbersdengan tanda
with their "UP""UP"
markmereka
facing up.
menghadap ke atas. TANDA "UP"
MOUNTING RUBBER
Tempatkan cylinder
Set the cylinder head head
cover cover pada
onto the cylinder
cylinder head.head.
CRANKCASE CYLINDER HEAD COVER
Pasang special
Install the specialbolts dan tighten
bolts and kencangkan
them to dengan torsi
the specified BREATHER
yang ditentukan.
torque. HOSE
TORQUE:12
TORSI: N·m
12 N.m (1.2kgf.m,
(1,2 kgf·m,
kgf.m, 99lbf.ft)
lbf·ft)
lbf.ft)
Connect the crankcase
Hubungkan crankcasebreather
breatherhose.
hose.
Install the
Pasang centerbody
center bodycover
cover (hal.
(page2-8).
2-8).
SPECIAL BOLTS
7-8
INTAKE/EXHAUST
INTAKE/EXHAUSTSHROUDS
SHROUDS
(SELUBUNGREMOVAL/INSTALLATION
PEMASUKAN/PENGELUARAN)
PEMASUKAN/PENGELUARAN)
Remove the following: STARTER MOTOR SE THERMAL VALVE
Lepaskan
– Center sebagai
body cover berikut:
(page 2-8) WIRE CLAMP WIRE CLAMP
– Luggage box (page
- Center body cover (hal. 2-7) 2-8)
– Inlet pipe (page 5-22)
– Muffler
- Inlet pipe (page 2-14)
(hal. 5-22)
–
- Muffler (hal. 2-14)pipe (page
PAIR air supply (page 5-25)
-Release
PAIR air
thesupply
followingpipe (hal.
wire 5-25)from intake shroud:
clamps
Lepaskan
– wirewire
Spark plug clampsclampberikut dari intake shroud:
– Alternator
- Spark wire clamp
plug wire clamp (penjepit kabel busi)
clamp
– SE thermal valve wire clamp
- Alternator wire clamp
clamp
– Starter motor wire clamp clamp
- SE thermal valve wire clamp
-Remove
Starterthe
motor
threewire clamp
screws and a bolt. ALTERNATOR
Remove the intake/exhaust shrouds by releasing the tabs of SPARK PLUG WIRE CLAMP WIRE CLAMP
Lepaskan ketiga screws dan sebuah bolt.
intake shroud from the slot of the exhaust shroud.
Lepaskan
Remove theintake/exhaust
rubber seal. shrouds dengan melepaskan
tabs dari intake shroud dari slot pada exhaust shroud.
Installationrubber
Be sure to align the Lepaskan is in theseal.
reverse order of removal.
"IN" mark and "EX"
mark Pastikan untuk
on the rubber
TORQUE:
Pemasangan adalaha dalam urutan terbalik dari
mentepatkan
mentepatka
seal with the inlet"IN"
n tanda side Intake shroud mounting screw:
pelepasan.
dan "EX" pada rubber TORSI:0.8 N·m (0.1 kgf·m, 0.6 lbf·ft)
and exhaust side of
seal dengan sisi masuk Intake shroud
cylinder head. Exhaust shroudmounting
mounting screw:
bolt:
dan keluar dari cylinder
0,8 N.m(0.7
7 N·m (0,1kgf·m,
kgf.m;5.10,6 lbf.ft)
lbf·ft)
head.
Exhaust shroud mounting bolt:
7 N.m (0,7 kgf.m; 5,1 lbf.ft)
SCREWS
INTAKE SHROUD 0.8 N·
N·m (0.1 kgf ·m, 0.6 lbf ·ft)
RUBBER SEAL
EXHAUST SHROUD
BOLT
7 N·
N·m (0.7 kgf ·m, 5.1 lbf ·ft)
7-9
CAMSHAFT
CAMSHAFT
PELEPASAN
REMOVAL
Lepaskan
following:
- Mesin
– (hal.
(hal.
Engine 6-4)
6-4)
(page 6-4)
INDEX NOTCH
- Cylinder
– Cylinderhead
headcover (hal. 7-7)
cover (page 7-7)
- Cooling
– Coolingfan
fancover
cover(hal.
(page2-12)
2-12)
- Intake/exhaust
– Intake/exhaust shroud (hal. 7-9)
shroud (page 7-9)
Rotatecrankshaft
Putar the crankshaft clockwise
searah by rotating
perputaran jarumthejam
cooling fan
dengan
slowly andcooling
memutar align thefan
"T" dengan
mark on the flywheel
pelan dan with the index
mentepatkan
notch on
tanda the pada
"T" right crankcase.
flywheel dengan index notch (takik
penunjuk) pada right crankcase.
Make sure the piston is at TDC (Top Dead Center) on the
compression stroke.
Pastikan bahwa piston berada pada TDC (Top Dead
This position can be confirmed by checking that there is slack
Center) [TMA = Titik Mati Atas] pada langkah
in the rocker arm.
kompressi. TANDA "T"
If there is no slack, it is because the piston is moving through
Posisi ini dapat
the exhaust dipastikan
stroke to TDC. dengan memeriksa bahwa
ada kerenggangan pada rocker
Rotate the crankshaft one full turn by arm.
rotating the cooling fan
Jika tidak ada kerenggangan,
slowly and match up the "T" mark again. disebabkan oleh karena
piston sedang bergerak melalui langkah pembuangan
Make
ke TDC.sure that the index line on the cam sprocket is flush
TANDA " "
with the
Putar the top surfac
surfacesatu
crankshaft e of cylinde
cy linderr head
putaran penuhand dengan
that the "memutar
that " mark
on the cam
cooling fansprocket
denganis pelan
facing up
dan as mentepatkan
shown (TDC ontanda the com-
"T"
pression
sekali lagi.stroke).
If the cam
cam sprocket
sprocket " " mark is not facinfacingg up, turn
turn the cool-
ing fan (crankshaft)
Pastikan bahwa index one revolution
line (garis and realign thepada
penunjuk) "T" mark
cam
with the index
sprocket adalahnotch on the right
segaris dengancrankcase.
permukaan atas dari
cylinder head dan bahwa tanda "O" pada cam sprocket
menghadap ke atas seperti diperlihatkan (TDC pada
langkah kompressi).
Jika tanda "O" cam sprocket tidak menghadap ke atas,
putar cooling fan (crankshaft) satu putaran dan tepatkan
tanda "T" kembali dengan index notch pada right
crankcase. INDEX LINE
Longgarkan lock
Loosen the lock nutsnuts dan adjusting
and adjusting screws dengan
screws fully.
penuh. SCREWS
LOCK NUTS
Lepaskan
Remove thescrew
screw dan O-ringfrom
and O-ring darithe
camcamchain
chain tensioner
tensioner
SCREW O-RING
lifter.
lifter.
7-10
Install the
Pasang specialtool
special toolke into the tensioner
dalam tensionerbody
bodyanddan
turnputar
the
tool clockwise until it stops turning.
tool searah perputaran jarum jam sampai ia berhenti LIFTER STOPPER
Hold the tensioner lifter by pushing the tool while aligning
berputar.
the tabs oftensioner
Tahan the tool withlifter
the grooves
denganof themendorong
tensioner lifter.tool
sementara
TOOL: mentepatkan tabs dari tool dengan alur-alur
dari
Cam chain tenlifter.
tensioner sioner 070MG-0010100
lifter stopper
TOOL:
Cam chain tensioner lifter stopper 070MG-
0010100
Tepatkan
Putar cooling
Turn the coolingfanfan
(crankshaft)
(crankshaft ) satu
(crankshaft) oneputaran
revolutiondan tepatkan
and realign
kembali tanda
the "T" mark with"T" dengan
the index notchindex
on the notch pada right
right crankcase. TANDA" "
BOLTS
crankcase.
Make sure
sure that
that the cam sprocke
sprockett " " mark isis not facing
facing up.
up.
Remove the
Pastikan bolts, cam
bahwa tanda sprocket from the
"O" pada camcamshaft
sprocketand tidak
cam
Letakkan
Place akain
shoplap pada
pada
chain off the cam
towel at sprocket.
bagianthe
cranakcase
menghadap
yang
ke atas.
Attach a piece of wire to the cam chain to prevent it from fall-
opening of the
terbuka untuktomenjaga
crankcase ing into thebolts,
prevent crankcase.
Lepaskan
agar cam sprocket bolts cam sprocket dari camshaft dan cam
the cam sprocket bolts chain lepas dari cam sprocket.
tidak jatuh ke dalam
from falling into the
crankcase. Ikatkan seutas kawat pada cam chain agar ia tidak jatuh
crankcase.
ke dalam crankcase.
CAM CHAIN
CAM SPROCKET
Remove the
Lepaskan boltdari
bolt from the cylinder
cylinder head.head.
BOLT
Lepaskan
Remove the camshaft darithecylinder
camshaft from sementara
headwhile
cylinder head holding
ROCKER ARMS CAMSHAFT
menahan
the rocker rocker
arms toarms untuk mempermudah pelepasan.
ease removal.
7-11
INSTALLATION
PEMASANGAN
Apply engine
Oleskan oil to the
oli mesin padacamshaft bearings
camshaft and decompressor
bearings dan daerah
cam rotating area.
perputaran decompressor cam.
Apply molybdenum
Oleskan larusan oil solution to theoilcam
molybdenum lobes.cam lobes
pada
(bubungan cam).
Pastikan
Make surebahwa
the tabstabs
tabof
osf Pasang
Install thecamshaft ke dalam
camshaft into cylinder
the cylinder head head sementara
while holding the
dari camshaft dan ROCKER ARMS CAMSHAFT
the camshaft and menahan
rocker arms torocker arms
ease installation. untuk mempermudah
decompressor cam
decompressor cam pemasangan.
menghadap ke sisi ruang
are facing the
pembakaran.
combustion chamber
side..
side
TAB
Install and
Pasang tighten
dan the bolt. bolt.
kencangkan BOLT
Putar
Rotate crankshaft
the crankshaftsearah perputaran
clockwise and align jarum
the "T" jam
markdan
on
tepatkan tanda
the flywheel with "T" pada notch
the index flywheel
on thedengan index notch
right crankcase.
(takik penunjuk) pada right crankcase. INDEX NOTCH
TANDA"T"
7-12
Apply engine
Oleskan oli oil to the pada
mesin cam chain
camandchain
cam sprocket teeth.cam
dan gigi
sprocket. TANDA" "
Install the cam chain on the cam sprocket. CAM CHAIN
Install the cam sprocket to the camshaft then make sure that
Pasang
the indexcam
line chain
on thepada cam sprocket.
cam sprocket is flush with the cylinder
Pasang
head and that the " " mark pada
cam sprocket camshaft
on the cam sprocketkemudian
is facing
pastikan bahwa index lines (garis penunjuk)
down as shown (TDC on the exhaust stroke). pada cam
sprocket rata dengan cylinder head dan bahwa tanda
"O" pada cam sprocket sedang menghadap ke bawah
seperti diperlihatkan (TDC pada langkah pembuangan).
CAM SPROCKET
INDEX LINES
Oleskan oli mesin

Apply engine pada
oil to the permukaan
seating duduk
surface and dan
thread of ulir dari
the cam
cam sprocket
sprocket bolts. bolts.
BOLTS 2
Install and tighten the cam sprocket bolts to specified torque
Letakkan
Place a kain
shop lap Pasang
pada
towel dan kencangkan
in the sequence
at shown. cam sprocket bolts dengan
lubang dari crankcase
torsi yang ditentukan pada urutan yang diperlihatkan.
the opening of the
untuk mencegah
crankcase to prevent
jatuhnya cam sprocket TORQUE:8 N·m (0.8 kgf·m, 5.9 lbf·ft)
boltthe
ke cam sprocket
dalam bolt TORSI: 8 N.m (0,8 kgf.m; 5,9 lbf.ft)
crankcase.
crankcase.
Lepaskan
Remove the camcamchain
chaintensioner
tensioner lifter
lifterstopper dan install
stopper and pasang a
STOPPER SCREW
sebuah
new O-ringO-ring
to thebaru padatensioner
cam chain cam chain lifter.tensioner lifter.
Install anddan
Pasang tighten the screw to screw
kencangkan the specified
dengantorque.
torsi yang
ditentukan.
TORSI:
Install the4following:
N.m (0,4 kgf.m; 3,0 lbf.ft)
– Intake/exhaust shroud (page 7-9)
– Cooling fan cover
- Intake/exhaust shroud (page 2-12)
(hal. 7-9)
– Cylinder head cover (page
- Cooling fan cover (hal. 2-12) 7-7)
- – Cylinder
Engine (page 6-6) (hal. 7-7)
head cover
-Adjust
Mesinthe
(hal. 6-6)
valve clearance (page 3-8).
Setel jarak renggang klep (hal. 3-8). O-RING

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

camshaft sebagai sebuah kesatuan.
7-13
CAMSHAFT
CAMSHAFT
Turn the
Putar outerrace
outer race (lingkaran
of each camshaftluar) bearing with your fin-
dari masing-masing
ger. The bearing
camshaft bearing should turn smoothly
(bantalan camshaft)and qu ietly. jari-jari.
dengan BEARING
Also check
Bearing thatberputar
harus the bearing inner race
dengan fitsdan
halus tightly on the
tanpa cam-
suara.
shaft.
Juga periksa bahwa bearing inner race (lingkaran dalam
Replace the
bantalan) camshaft
duduk denganassembly
erat padaif thecamshaft.
bearing does not turn
smoothly, quietly, or if they fit
Ganti camshaft assembly jika bearing loosely on the tidak
camshaft.
berputar
dengan halus, tanpa suara, atau jika mereka duduk
dengan longgar pada camshaft.
Periksa
Check thecam lobes
cam lobes (bubungan)
for excessive wear terhadap
and damage.keausan
berlebihan dan kerusakan.
Measure the height of each cam lobe.
Ukur ketinggian dari masing-masing cam lobe.
BATAS
SERVICE SERVIS:
LIMIT:
IN: 32,37 mm
IN: 32.37mm(1.274 in)
EX: 31,97 mm
EX: 31.97mm(1.259 in)
CYLINDER
CYLINDERHEAD
HEAD
PELEPASAN
REMOVAL
•• Ketikaremoving
When melepaskan cylinderhead
the cylinder headnuts,
nutsalways
(mur kepala
replace
silinder), selalu ganti cylinder head
the cylinder head gasket and cylinder gasketgasket dan
with new
cylinder gasket dengan yang baru.
ones. INDEX NOTCH
– Engine (page 6-4)
- – Mesin (hal.head
Cylinder 6-4)cover (page 7-7)
- – Cylinder
Coolinghead cover(page
fan cover (hal.2-12)
7-7)
- – Cooling fan cover
Intake/exhaust (hal.(page
shroud 2-12)7-9)
- Intake/exhaust shroud (hal. 7-9)
Rotate the crankshaft clockwise by rotating the cooling fan
slowly and align the "T" mark on the flywheel with the index
Putar crankshaft searah dengan perputaran jarum jam
notch on the right crankcase.
dengan memutar cooling fan dengan pelan dan
Make sure the tanda
mentepatkan piston is
"T"at pada
TDC (Top Dead dengan
flywheel Center) on the
index TANDA"T"
compression
notch stroke.
pada right crankcase.
This position
Pastikan can be
bahwa confirmed
piston by checking
berada pada TDCthat there
(TopisDead
slack
in the rocker
Center) arm. = Titik Mati Atas] pada langkah
[TMA
If there is no slack, it is because the piston is moving through
kompressi.
the exhaust stroke to TDC.
Rotate ini
Posisi the crankshaft one full turn
dapat dipastikan by rotating
dengan the cooling
memeriksa fan
bahwa
slowly and match up the "T"
ada kerenggangan pada rocker arm. mark again.
Jika tidak ada kerenganggan, disebabkan oleh karena
piston sedang bergerak melalui langkah pembuangan
ke TDC.
Putar crankshaft satu putaran penuh dengan memutar
cooling fan dengan pelan dan mentepatkan tanda "T"
sekali lagi.
7-14
Pastikan
Make surebahwa
that theindex
indexline
line pada
on thecam
cam sprocket
sprocket isadalah
flush
TANDA" "
rata
with dengan permukaan
the top surface atashead
of cylinder dariand
cylinder
that thehead dan
" " mark
bahwa tanda
on the cam "O" pada
sprocket cam
is facing sprocket
up as shown (TDCmenghadap ke
on the com-
atas seperti diperlihatkan (TDC pada langkah
pression stroke).
kompressi).
If the cam sprocket " " mark is not facing up, turn the cool-
ing fan
Jika (crankshaft)
tanda "O" pada one revolution
cam andtidak
sprocket realign the "T" mark
menghadap ke
with the index notch on the right crankcase.
atas, putar cooling fan (crankshaft) satu putaran dan
tepatkan kembali tanda "T" dengan index notch pada
right crankcase.
INDEX LINE
Lepaskan
Remove thescrew
screw dan O-ringfrom
and O-ring dari the
camcamchain
chaintensioner
tensioner
SCREW O-RING
lifter.
lifter.
Pasang special
Install the specialtool
toolke dalam
into tensioner
the tensioner body
body dan
and turnputar
the
tool
tool searah
clockwisejarum
untiljam sampai
it stops ia berhenti berputar.
turning.
LIFTER
Tahan
Hold the tensioner
tensioner lifter lifter dengan
by pushing mendorong
the tool tool
while aligning
sementara mentepatkan
the tabs of the tool with the tabs darioftool
grooves dengan alur-alur
the tensioner lifter.
dari tensioner lifter.
TOOL:
Cam chain tensioner
TOOL: 070MG-0010100
lifter chain
Cam stopper tensioner 070MG-0010100
lifter stopper
Tepatkan
Letakkan kain lap pada Lepaskan

Remove thebolts,
bolts,cam sprocketfrom
cam sprocket darithe
camshaft
camshaftdan cam
and cam
CAM CHAIN
lubang
Place adari crankcase
shop towel at chain
chain lepas
off thedari
cam cam sprocket.
sprocket.
untuk menghindari
the opening of the
jatuhnya cam Attach a piece of wire to the cam chain to prevent it from fall-
crankcase tosprocket
prevent Ikat seutas kawat pada cam chain untuk mencegahnya
boltthe
ke cam
dalam crankcase. ing into the crankcase.
sprocket bolt atuh ke dalam crankcase.
crankcase.
BOLTS
CAM SPROCKET
7-15
Lepaskan
Remove thecylinder
cylinderhead
head bolts.
bolts.
NUTS BOLTS
Loosen the cylinder
Longgarkan head
cylinder nutsnuts
head in a crisscross
dalam polapattern in two or
bersilangan
three steps.
dalam dua atau tiga langkah.
Remove the nuts and plates.
Lepaskan nuts dan plates.
PLATES
Lepaskan
Remove thespring
springdan plunger.
and plunger.
PLUNGER
SPRING
Remove thecylinder
Lepaskan cylinderhead.
head.
CYLINDER HEAD
Remove the gasket and dowel pins.
INSTALLATION
Clean the cylinder
Lepaskan gasket and
dancylinder head mating surface.
dowel pins.
Install the dowel pins and a new gasket onto the cylinder. DOWEL PINS
PEMASANGAN
Bersihkan permukaan penyatuan cylinder dan cylinder
head.
Pasang dowel pins dan sebuah gasket baru pada
cylinder.
GASKET
7-16
Alurkan
Route thecam chainthrough
cam chain melaluithecylinder
cylinderhead daninstall
head and pasangthe
cylinder
cylinder head pada
head onto thecylinder.
cylinder.
CAM CHAIN
CYLINDER HEAD
Apply engine oil to the plunger whole surface.

Oleskan
Install theoli mesinand
plunger pada seluruh permukaan plunger.
spring.
Pasang plunger dan spring.
PLUNGER
SPRING
Semprotkan
Apply engineoli oilmesin ke permukaan
to the seating duduk
surface and dan
threads of ulir
the dari
cyl-
cylinder
inder headhead
nuts.nuts.
InstallPasang plates
the plates dan kencangkan
and tighten the cylinder NUTS
cylinder
head nutshead nuts dalam
in a crisscross polatobersilangan
pattern the specified dengan
torque. torsi BOLTS
yang ditentukan.
TORQUE:18 N?m (1.8 kgf?m, 13 lbf?ft)
Apply engine oil to the seating surface and threads of the cyl-
inder head mounting bolts, then install and tighten them to
Semprotkan oli mesin pada permukaan duduk dan ulir
the specified torque.
dari cylinder head mounting bolts, kemudian pasang
dan kencangkan dengan torsi yang ditentukan.
TORQUE:12 N?m (1.2 kgf?m, 9 lbf?ft)
PLATES
Putar
Rotatecrankshaft searah
the crankshaft jarumand
clockwise jam danthe
align tepatkan tanda
"T" mark on
the flywheel
"T" with the index
pada flywheel notchindex
dengan on the right
notchcrankcase.
pada right
crankcase. INDEX NOTCH
TANDA"T"
7-17
Semprotkan
Apply engine oli mesin
oil to pada
the cam gigi
chain andcam chain dan
cam sprocket teeth.cam
sprocket.
Install the cam chain on the cam sprocket. CAM CHAIN
Install the cam sprocket to the camshaft then make sure that
Pasang
the indexcam
linechain
on thepada cam sprocket.
cam sprocket is flush with the cylinder
Pasang cam sprocket pada camshaft kemudian TANDA" "
head and " " mark is facing up as shown (TDC on the com-
pastikan bahwa index line pada cam sprocket adalah
pression stroke).
rata dengan cylinder head dan tanda "O" menghadap ke
atas seperti diperlihatkan (TDC pada langkah
kompressi).
INDEX LINES
CAM SPROCKET
Letakkan kain lap Semprotkan

Apply engine oli
oil mesin pada permukaan
to the seating duduk
surface and thread of dan ulir
the cam
menutupi
Place lubang
a shop dari
towel at dari cam bolts.
sprocket sprocket bolts.
BOLTS
crankcase untuk
the opening of the
mencegah to agar cam Install and tighten the cam sprocket bolts to specified torque
crankcase prevent Pasang dan kencangkan cam sprocket bolts dengan
sprocket bolt tidak jatuh in the sequence of the cam sprocket numbers.
the cam sprocket bolt torsi yang ditentukan dalam urutan dari nomor cam
ke dalam crankcase.
from falling into the sprocket.
crankcase. TORQUE:8 N?m (0.8 kgf?m, 5.9 lbf?ft)
NOMOR CAM SPROCKET
Lepaskan
Remove the camcamchain
chaintensioner
tensionerlifter
lifterstopper
stopper dan pasang
and install a
STOPPER SCREW
sebuah O-ring baru pada cam chain tensioner
new O-ring to the cam chain tensioner lifter. lifter.
Pasang
Install anddan kencangkan
tighten the screw to screw dengan
the specified torsi yang
torque.
ditentukan.
TORQUE:4 N?m (0.4 kgf?m, 3.0 lbf?ft)
TORSI:
Install the4following:
N.m (0,4 kgf/m, 3,0 lbf.ft)
– Intake/exhaust shroud (page 7-9)
– Engine (page 6-6)
- Intake/exhaust shroud (hal. 7–9)
-Adjust
Mesinthe
(hal. 6-6)
valve clearance (page 3-8).
Setel jarak renggang klep (hal.3-8).
O-RING
DISASSEMBLY
PEMBONGKARAN
ROCKER ARM/SHAFT
ROCKER ARM/SHAFT
Screw the 5mm bolt into the threaded hole in the rocker arm
shaft and pull it out of the camshaft holder. ROCKER ARMS
Sekrupkan 5 mm bolt ke dalam lubang berulir di dalam
Remove the rocker arms.
rocker arm shaft dan tarik keluar dari camshaft holder.
Keluarkan rocker arms.
BOLT
ROCKER ARM SHAFT
7-18
CAMSHAFT
CAMSHAFT
Lepaskan boltand dan
Remove the bolt camshaft
camshaft with its tabdengan tab-nya
facing down.
menghadap ke bawah. CAMSHAFT
BOLT
TAB
VALVE
VALVE
To prevent
Untuk loss of
mencegah Remove thevalve
Lepaskan valve cotters
cottersusing the valve
dengan spring compressor.
menggunakan valve
tension,
hilangnya do not
tegangan, VALVE SPRING COMPRESSOR
spring compressor.
jangan
compress tekan valve
the valve
springs lebihmore
dari pada TOOLS:
springs than TOOLS:
yang diperlukan
necessary to removeuntuk Valve spring compressor 07757-0010000
Valve spring compressor 07757-0010000
melepaskan cotters.
the cotters. Valve spring compressor attachment 07959-KM30101
Valve spring compressor attachment 07959-M30101
Mark all parts

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

VALVE SPRING
VALVE SPRING RETAINER
Avoiduntuk
Hindari damaging the Lepaskan
merusak Remove the endapan karbon form
carbon deposits dari ruang pembakaran
the combustion dan
chamber
permukaan penyatuan
cylinder and clean off
mating bersihkan thepermukaan
dari cylinder head gasket head
cylinder surface.
g asket. COMBUSTION CHAMBER
cylinder
surfacedan
andpermukaan
valve seat
valve seat .
surfaces.
7-19
ASSEMBLY
PERAKITAN
COTTERS
VALVE SPRING
SPRING RETAINER
SPRING SEAT
VALVE STEM SEAL

EXHAUST ROCKER ARME
VALVE GUIDE
EXHAUST ROCKER CLIP

ARM SHAFT
INLET ROCKER
ARM SHAFT
BOLT
INLET ROCKER ARM
CAMSHAFT
INLET VALVE EXHAUST VALVE
VALVE
VALVE
Blow through
Tiuplah dengan the oil passage
udara dariin kompressor
the cylinder head with com-
melalui jalan
pressed air.
lintasan oli di dalam cylinder head.
Apply engine
Oleskan oil to the
oli mesin innerpermukaan
pada surface of new valve dari
dalam stem seals.
valve VALVE
Installseals
stem the valve
baru. spring seats and new valve stem seals.
Pasang
Coat the valve spring
valve stem seatssurface
sliding dan valve
with stem
engineseals
oil. baru.
Insert the valves into the valve guides while turning them SPRING SEAT
Lapisi
slowlypermukaan luncur
to avoid damage valve
to the stem
valve dengan
stem seals. oli mesin.
Masukkan valves ke dalam valve guides sementara
memutar mereka pelan-pelan untuk menghindari
kerusakan pada valve stem seals.
STEM SEAL
7-20
Install thevalve
Pasang valve springs
springswithdengan
the tightly woundyang
lilitan coils facing
rapat
the combustion
menghadap ke chamber.
ruang pembakaran.
Ke ruang
pembakaran
Install the
Pasang valvespring
valve springretainer.
retainer.
VALVE SPRING COMPRESSOR
Untuk
To mencegah
prevent loss of Install thevalve
Pasang valve cotters
cottersusing the valvemenggunakan
dengan spring compressor.
valve
hilangnya tegangan,
tension, do not spring compressor.
jangan
compress tekan
the valve
valve TOOLS:
TOOLS:
spring lebih more
spring dari pada
than
yang diperlukan untuk
Valve
Valve spring compressor
spring compressor 07757-
07757-0010000
necessary to install 0010000
memasang cotters. Valve spring compressor
the cotters. Valve spring compressor attachment 07959-
attachment 07959-KM30101
KM30101
Topang cylinder
Support head di
the cylinder Letakkan tool yang
Place a suitable sesuai
tool onto thepada
valve valve
stem. stem.
atas permukaan meja
head above the work TOOL YANG SESUAI
kerja bench
untuk mencegah Tap the tool gently to seat the cotters firmly using a plastic
surface to Ketuk tool dengan ringan untuk mendudukkan cotters
kerusakan pada valve. hammer.
prevent valve dengan erat dengan menggunakan palu plastik.
damage.
VALVE STEM
CAMSHAFT
CAMSHAFT
Oleskan
Apply 0.50,5 – 1,0
– 1.0 cc cc
of oli mesin
engine oilpada
to thedaerah perputaran
decompressor cam
decompressor
rotating area andcam dan camshaft
camshaft bearing. bearing.
Apply molybdenum oil solution to the cam lobes.
Oleskan larutan molybdenum oil pada cam lobes.
Install the camshaft with its tab and tab of the decompressor
Pasang camshaft
cam is facing dengan
combustion chambertab-nya
side. dan tab dari
decompressor cam menghadap ke sisi ruang
pembakaran.
TAB
TAB
7-21
Install and
Pasang tighten
dan the bolt. bolt.
kencangkan
BOLT
ROCKER
ROCKERARM
ARM
Semprotkan oli tomesin
Apply engine oil padasurface
the sliding permukaan
and rollerluncur
surfacedan
of
permukaan gelinding dari rocker arm.
the rocker arm.
ROCKER ARMS
Semprotkan
Apply engine oli mesin
oil to pada surface
the sliding permukaan
of the luncur dari
rocker arm
rocker arm shaft.
shaft.
ROCKER ARM SHAFTS
Pasang rocker
Install the rockerarms
arms pada
to the cylinder head.
cylinder head.
ROCKER ARM SHAFTS
Pasang exhaus
Install the exhaustrocker
rockerarm shaft (poros
armshaft into therocker
exhaustarm dari
rocker
klep buang)
arm and ke dalam
cylinder exhaust
head until rocker
it is fully arm dan cylinder
seated.
head sampai ia telah duduk sepenuhnya.
Insert the inlet rocker arm shaft into the cylinder head using a
screwdriverinlet
Masukkan whilerocker
aligning
armtheshaft
cut-out of the
(poros shaft arm
rocker with dari
the
stud bolt hole on cylinder head.
klep masuk) ke dalam cylilnder head dengan
menggunakan obeng sementara mentepatkan potongan
dari shaft dengan lubang stud bolt pada cylinder head.
Tepatkan
7-22
INSPECTION
PEMERIKSAAN
CYLINDERHEAD
CYLINDER HEAD
Periksa
Check the lubang busihole
spark plug danand
daerah valvefor
valve areas terhadap
cracks. retak-
Check the cylinder head for warpage with a straight edge and
retak.
a feeler gauge.
Periksa cylinder head terhadap perubahan bentuk
melengkung dengan sebuah mistar lurus dan feeler
gauge.
SERVICE
LIMIT: 0.05 mm (0.002 in)
ROCKERARM/SHAFT
ROCKER ARM/SHAFT
Disassemble
Bongkar the cylinder
cylinder head7-18).
head (hal. (page 7-18).
Check the
Periksa rockerarm
rocker armshafts
shafts dan
and rocker
rockerarms
armsforterhadap
wear or
damage.
keausan atau kerusakan.
Turn the rocker arm roller with your finger.
Putar rocker
The roller arm
should turn roller (penggelinding
smoothly and quietly. rocker arm)
dengan jari-jari.
Measure
Roller the I.D.
harus of each
berputar rocker halus
dengan arm. dan tanpa suara.
SERVICE
Ukur D.D. dari masing-masing
LIMIT: IN/EX: 10.04rocker arm. in)
mm (0.395
BATAS SERVIS: IN/EX: 10,04 mm
Measure the O.D. of each rocker arm shaft.
Ukur D.L. dari masing-masing rocker arm shaft.
SERVICE
BATAS
LIMIT: SERVIS: IN/EX: 9,91mm
IN/EX: 9.91 mm(0.390 in)
Hitung jarak
Calculate therenggang rocker arm-ke-shaft.
rocker arm-to-shaft clearance.
BATAS
SERVICE
SERVIS: IN/EX: 0,08 mm
LIMIT: IN/EX: 0.08 mm (0.003 in)
VALVESPRING
VALVE SPRING
Disassemble
cylinder head7-18).
Measure
Ukur the free
panjang length
bebas of the
dari valve
valve springs.
springs.
SERVICE
LIMIT: IN/EX: 29.11 mm (1.146 in)
Ganti springs jika mereka lebih pendek dari batas servis.
Replace the springs if they are shorter than the service limit.
7-23
VALVE/VALVE
VALVE/VALVE GUIDE
GUIDE
Disassemble
cylinder head7-18).
Check that
Periksa the valve
bahwa valvemoves smoothly
bergerak in the halus
dengan guide. di dalam
Check
guide. each valve for bend, burn, scratch or abnormal wear.
Periksa
Measuremasing-masing valve
each valve stem O.D. andterhadap
record it. kebengkokan,
keadaan terbakar, goresan atau keausan tidak normal.
SERVICE
LIMIT:
Ukur IN/EX: valve
D.L. masing-masing 4.90 mm (0.193
stem dan in)
catat.
Selalu putar
Always the Ream
reamer
rotate Ream valve guide
the valve guideuntuk menghilangkan
to remove pembentukan
any carbon build up before
searah
reamer jarum jam, karbon
clockwise, sebelum
measuring mengukur guide.
the guide. VALVE GUIDE REAMER
jangan sekali-kali
never Masukkan reamer
Insert the reamer fromdari
the sisi ruang chamber
combustion pembakaran
side ofdari
the
berlawanan arah jarum cylinder head dan selalu putar reamer searah jarum
counterclockwise cylinder head and always rotate the reamer clockwise.
jam ketika
when inserting, am.
memasukkannya, TOOL:
removing dan
mengeluarkannya and
Valve guide reamer, 5.0 mm
reaming. TOOL: 07984-MA60001
selama pekerjaan
reaming. Valve guide reamer, 5.0 MM 07984-MA60001
Periksa
Inspect anddan reface
reface the Ukur D.D.each
Measure masing-masing valve
valve guide I.D. andguide
recorddan
it. catat.
valve seats setiap kali
valve seats whenever
valve guides diganti BATAS SERVIS: IN/EX: 5,03 mm
the valve guides are SERVICE
(hal. 7-26).
replaced (page 7-26). LIMIT: IN/EX: 5.03 mm (0.198 in)
Kurangi D.L. masing-masing valve stem dari D.D. guide
Subtract
yang each valve stem
bersangkutan untukO.D. from the corresponding
mendapatkan guide
jarak renggang
I.D. to obtain the stem-to-guide clearance.
stem-ke-guide
SERVICE
BATAS
LIMIT:
SERVIS: IN: 0,08 mm
IN: 0.08 mm (0.003 in)
EX: 0,10 mm
EX: 0.10 mm (0.004 in)
Jika
If thejarak renggang clearance
stem-to-guide stem-ke-guide
exceedsmelampaui
the service batas
limit,
servis,
determine tentukan
if a newapakah sebuah
guide with guide
standard baru dengan
dimensions would
ukuran
bring thestandard
clearanceakan
within membawa
tolerance. jarak renggang ke
dalam toleransi.
If so, replace any guides as necessary and ream to fit (page 7-
Jika
25). demikian, ganti guides yang diperlukan dan ream
If thepas
agar stem-to-guide
(hal. 7-25).clearance exceeds the service limit with
new jarak
Jika guide, also replace stem-ke-guide
renggang the valve. melampaui batas
servis dengan sebuah guide baru, ganti valve juga.
7-24
VALVE GUIDEVALVE
PENGGANTIAN REPLACEMENT
GUIDE
Disassemble
cylinder head 7-18).
VALVE GUIDE DRIVER
Chill new valve
Dinginkan valveguides in abaru
guides freezer for about
dalam 1 hour.
bagian freezer dari
lemari es selama kira-kira 1 jam.
CATATAN:
• Be sure to wear heavy gloves to avoid burns when han-
• Pastikan
dling untukcylinder
the heated memakai sarung tangan berat untuk
head.
menghindari
• Using a torch toluka-luka bakar sewaktu
heat the cylinder head maymenangani
cause war-
cylinder head yang telah dipanaskan.
page.
Jangan
• • Drive newmenggunakan obor untuk
guides from the camshaft memanaskan
side while the cylin-
cylinder head karena
der head is still heated. dapat mengakibatkan
perubahan bentuk melengkung.
Heat the cylinder head to 130 – 140°C (275 – 290°F) with a
• Dorong masuk guides baru dari sisi camshaft
hot plate or oven. Do not heat the cylinder head beyond
sementara cylinder head masih dipanaskan.
150°C (300°F). Use temperature indicator sticks, available
from welding supply stores, to be sure the cylinder head is VALVE GUIDE
Panaskan
heated to the cylinder head sampai 130 - 140° C dengan
proper temperature.
kompor listrik atau oven. Jangan memanaskan cylinder
Support
head the cylinder150
melampaui head and drive the valve guides out of
° C. Pakailah tongkat indikator
suhu, yang dapat dibeli darichamber
the cylinder head from the combustion toko side.
pemasok
perlengkapan pengelasan, untuk memastikan bahwa
TOOL: head telah dipanaskan sampai ke suhu yang
cylinder
Valve guide driver, 5.0 mm
tepat. 07942-MA60000
Take outcylinder
Topang new valve guides
head from
dan the freezer.
dorong keluar valve guides VALVE GUIDE ADJUSTING DRIVER
dari cylinder
Drive head
new valve dari into
guides sisi ruang pembakaran.
the cylinder head to the specified
TOOL:
height from the cylinder head.
Valve guide driver, 5,0 mm 07942-MA60000
TOOL:
Keluarkan
Valve guidevalve guides
adjusting baru dari freezer.
driver 07743-0020000
Dorong masuk valve guides baru ke dalam cylinder
VALVE
head GUIDE
sampai PROJECTION:
ke ketinggian yang ditentukan dari cylinder
IN/EX: 9.1 – 9.3 mm (0.36 – 0.37 in) 9.1 – 9.3 mm
head. (0.36 – 0.37 in)
Let the cylinder head cool to room temperature.
TOOL:
Valve guide adjusting driver 07743-0020000
PROJEKSI VALVE GUIDE: VALVE GUIDE

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

Masukkan reamerhead thoroughly
dari to remove
sisi ruang any metal dari
pembakaran par-
ticles after reaming and reface the valve seat (page
cylinder head dan selalu putar reamer searah dengan 7-26).
arah perputaran jarum jam.
TOOL;
Valve guide reamer, 5.0 mm 07984-MA60001
Bersihkan cylinder head secara menyeluruh untuk

membuang partikel-partikel logam setelah pekerjaan
reaming dan reface (bentuk kembali permukaan) valve
seat (hal. 7-26).
7-25
VALVE SEAT INSPECTION/REFACING
PEMERIKSAAN/REFACING VALVE SEAT
Disassemble
cylinder head7-18).
Clean the intake
Bersihkan intakeand exhaustdan
(masuk) valves thoroughly
exhaust to remove
(buang) valves
carbon deposits.
(klep) secara menyeluruh untuk menghilangkan
endapan karbon.
Apply a light coat of Prussian Blue to the valve seats.
Tap the valve against the valve seat several times using a
Oleskan lapisan
hand-lapping tool,ringan
withoutPrussian Blue
rotating the pada
valve valvea seats
to make clear
(dudukan
pattern. klep).
Ketuk valve terhadap valve seat beberapa kali dengan
menggunakan hand-lapping tool (alat skir klep dengan
tangan), tanpa memutar valve agar mendapatkan pola
elas.
TheValves
valvestidak dapat
cannot be Remove thevalve
Lepaskan valvedan
andperiksa
inspect the valve
valve seat
seat face.
face.
digerinda.
ground. IfJika
the muka
valve
valve The valve
Kontak seatseat
valve contact should
harus be within
di dalam theyang
lebar specified width
ditentukan
face terbakar,
is burned,sangat
badly
aus atau jika ia and even all around the circumference.
dan merata sepanjang kelilingnya.
worn or if it contacts
engkontak seat secara
the seat unevenly, STANDARD: 1.0 mm (0.04 in)
tidak merata, gantilah STANDARD: 1,0 mm
replace the valve.
valve. SERVICE
BATAS
LIMIT: SERVIS: 1,5
1.5 mm
mm (0.06 in)
Jika lebar valve seat di luar spesifikasi, reface valve
If the valve seat width is not within specification, reface the
seat (bentuk kembali permukaan dudukan klep) (lihat
valve seat (see page 7-26).
hal. 7-26).
LEBAR SEAT
Inspect the
Periksa valve
muka seat seat
valve face for:
terhadap:
•
• Damaged
Kerusakan face:
pada muka:
–- Replace the valve
Ganti valve dan and reface
reface the seat
valve valve seat
• Uneven seat width:
• Lebar seat tidak merata:
– Bent or collapsed valve stem; Replace the valve and
- Valve stem bengkok atau runtuh. Ganti valve dan
reface the valve seat
reface valve seat
MUKA RUSAK LEBAR SEAT TIDAK MERAT
• • Contact
Daeraharea (too (terlalu
kontak low or too high area):
rendah atau terlalu tinggi):
–- Reface
Refacethe valveseat
valve seat
TERLALU RENDAH TERLALU TINGGI
7-26
• • Follow the refacer
Ikuti petunjuk manufacturer’s
pemakaian pabrikoperating
pembuat instructions.
refacer.
• • Be careful not to grind the seat more than necessary.
Hati-hati agar tidak menggerinda seat lebih
daripada yang diperlukan.
45°
60°
32°
Jika
If thedaerah
contactkontak terlalu
area is too hightinggi
on thepada valve,
valve, seat
the seat harus
must be KONTAK TERLALU TINGGI LEBAR SEAT LAMA
lowered using
diturunkan a 32° flat
dengan cutter.
menggunakan 32° flat cutter.
If the contact area is too low on the valve, the seat must be
Jika daerah kontak terlalu rendah pada valve, seat
raised using a 60° interior cutter. 32°
harus
Refinishdinaikkan dengan menggunakan
the seat to specifications, 60° cutter.
using a 4 5 ° finish interior
cutter.
Haluskan permukaan seat sesuai dengan spesifikasi,
dengan menggunakan 45° finish cutter. KONTAK TERLALU RENDAH LEBAR SEAT LAMA
60°
Reface
Reface theseat
seatdengan
with a Pakailah 45° cutter,
Use a 45° seat seat remove
cutter, any
hilangkan kekasaran
roughness atau
or irregularities
sebuah 45 cutter
° setiap
45 cutter whenever
° a ketidak-teraturan
from the seat. dari seat .
kali sebuah valve guide KEKASARAN
valve guide is
diganti. TOOLS:
replaced.
TOOLS:
Seat cutter, 27.5 mm (45 IN) 07780-0010200
Seat cutter, 27.5 mm (45 ° IN) 07780-0010200
Seat cutter, 24 mm (45 EX) 07780-0010600
Seat cutter, 24 mm ° EX)
Cutter holder, 5.0 (45
mm 07780-0010600
07781-0010400
Cutter holder, 5.0 mm 07781-0010400
Pakailah
Use a 32°32 flat cutter,
° cutter,
flat hilangkan
remove ¼ bagian
the top 1/4 teratasvalve
of the existing dari
bahan valve
seat material. seat yang ada sekarang.
TOOLS:
TOOLS:
LEBAR SEAT LAMA
Flat
Flat cutter, 27mm
cutter, 27 mm(32(32 IN)
° IN) 07780-0013300
07780-0013300
Flat
Flat cutter, 22mm
cutter, 22 mm(32(32 EX)
° EX) 07780-0012601
07780-0012601
Cutter
Cutter holder, 5.0mm
holder, 5.0 mm 07781-0010400
07781-0010400
32°
7-27
Use a 60° interior
Pakailah cutter, remove
60° interior cutter,thehilangkan
bottom 1/4 of
¼thebagian
exist-
ing valve seat material.
terbawah dari bahan valve seat yang ada sekarang. LEBAR DUDUKAN
LAMA
TOOLS:
TOOLS:
Interior
Interior cutter, 26mm
cutter, 26 mm(60
(60 IN)
° IN) 07780-0014500
07780-0014500
Interior
Interior cutter, 22mm
cutter, 22 mm(60
(60 EX)
° EX) 07780-0014202
07780-0014202
Cutter holder, 5.0
Cutter holder, 5.0 mmmm 07781-0010400
07781-0010400
60°
Dengan menggunakan
Using a 45° seat cutter, cutsebuah
the seat 45 ° seat
to the width.potong
cutter,
proper
seat sampai lebar yang benar.
VALVE SEAT WIDTH: 1.0 mm (0.04 in)
LEBAR VALVE SEAT: 1,0 mm 1.0 mm (0.04 in)
Make sure that all pitting and irregularities are removed.
Pastikan bahwa semua lubang-lubang dan ketidak-
teraturan telah dihilangkan.
45°
CATATAN:
• Tekanan skir klep yang berlebihan dapat merubah
bentuk atau merusak seat .
• ? Excessive
Ubah sudutlapping
daripressure
lappingmay
tooldeform or damage
sering-sering the
untuk
seat.
mencegah keausan seat yang tidak merata.
•
• Change
Jagalahtheagar
angle lapping
of lapping tool frequently
compound to prevent
(ambril) tidak
uneven seat wear.
memasuki guides.
• Do not allow lapping compound to enter the guides.
Setelah memotong
After cutting the seat, seat, oleskancompound
apply lapping lapping to
compound
the valve
pada muka
face, and lap valve, dan
the valve skirlight
using klep dengan menggunakan
pressure. HAND-LAPPING TOOL
tekanan ringan.
After lapping, wash any residual compound off the cylinder
head and valve and recheck the seat contact.
Setelah menskir klep, cucilah compound yang tersisa
Assemble
dari thehead
cylinder cylinder
dan head (page
valve dan7-20).
periksa kembali kontak
seat.
7-28
CAM
CAM CHAIN
CHAINGUIDE
GUIDE
PELEPASAN
REMOVAL
Remove the
Lepaskan cylinderhead
cylinder head (hal.
(page7-14).
7-14).
Lepaskan cam
Remove the camchain
chainguide.
guide.
CAM CHAIN GUIDE

PEMASANGAN
INSTALLATION
Pasang cam
Install the camchain guideby
chain guide dengan
aligningmentepatkan bosses
the bosses of the cam
dari cam chain CAM CHAIN GUIDE
chain guide withguide dengan
grooves of the alur-alur
cylinder. pada cylinder.
Install the
Pasang cylinder
cylinder head(hal.
head (page7-16).
7-16).
Tepatkan
PEMERIKSAAN
INSPECTION
Periksa daerah
Check the slidingluncur
area ofdari camchain
the cam chain guide
guide terhadap
for excessive
keausan berlebihan
wear or damage. atau kerusakan.
CAM CHAIN GUIDE
7-29
CAM CHAIN
CAM CHAINTENSIONER
TENSIONERSLIDER
SLIDER
REMOVAL
PELEPASAN
Remove thesebagai
Lepaskan following:
berikut:
PIVOT PIN BOLT
– Drive
- Drive pulley(hal.
pulley (page 8-12)
8-11)
– Cylinder head (page 7-14)
- Cylinder head (hal. 7-14).
Remove the pivotpin
Lepaskan pivot pinbolt.
bolt.
Lepaskan
Remove theO-ring
O-ringdan
andcam
cam chain tensionerslider.
chain tensioner slider.
O-RING
TENSIONER SLIDER
PEMASANGAN
INSTALLATION
Install thecam
Pasang cam chain
chain tensioner
tensionerslider to the
slider left crankcase.
pada sisi kiri dari
crankcase.
Coat a new O-ring with engine oil and install it into the pivot O-RING
pin bolt groove.
Lapisi sebuah O-ring baru dengan oli mesin dan pasang
ke dalam alur pivot pin bolt.
TENSIONER SLIDER
Pasang pivot
Install the pivot pin boltinto
pin bolt ke the
dalam lubang
cam chain cam slider
tensioner chain
tensioner sliderit to
hole and tighten dan kencangkan
the specified dengan torsi yang
torque. PIVOT PIN BOLT
ditentukan.
– Cylinder head (page 7-16)
- Cylinder
– head(page
Drive pulley (hal. 8-13)
7-16)
- Drive pulley (hal. 8-12)
7-30
INSPECTION
PEMERIKSAAN
Check the
Periksa slidingluncur
daerah area ofdari
the cam
camchain
chaintensioner slider
tensioner for
slider
excessive wear or damage.
terhadap keausan berlebihan atau kerusakan.
TENSIONER SLIDER
CAM
CAM CHAIN
CHAINTENSIONER
TENSIONERLIFTER
LIFTER
PELEPASAN
REMOVAL
•• Camcam
The chain
chaintensioner
tensioner lifter
lifter dapat
can be diservis dengan
serviced with the
SCREW LIFTER STOPPER
mesininstalled
engine terpasang pada
in the rangka.
frame.
Lepaskan luggage box (hal. 2-7).
Remove the luggage box (page 2-7).
Lepaskan tensioner screw dan O-ring.
Remove the tensioner screw and O-ring.
Pasang special tool ke dalam tensioner body dan putar
Install the special tool into the tensioner body and turn the GASKET
tool searah jarum jam sampai ia berhenti berputar.
tool clockwise until it stops turning.
Tahan tensioner lifter dengan mendorong tool
Hold the tensioner lifter by pushing the tool while aligning
sementara mentepatkan tabs dari tool dengan alur-alur
the tabs of the tool with the grooves of the tensioner lifter.
dari tensioner lifter.
TOOL:
TOOL:
Cam chain tensioner
Cam
lifterchain
stoppertensioner 070MG-0010100
lifter stopper 070MG-0010100 TENSIONER
Remove the bolts and cam chain tensioner lifter. O-RING LIFTER BOLTS
Lepaskan bolts dan cam chain tensioner lifter.
Remove the
Lepaskan gasketdari
gasket fromtensioner
the tensioner lifter.
lifter.
PEMASANGAN
INSTALLATION
Pasang
Install thecam
cam chain tensioner
chain tensioner lifter
lifter stopper
stopper dantheputar
and turn ten-
CAM CHAIN TENSIONER LIFTER BOLTS
tensioner
sioner shaftshaft searah
clockwise with jarum jamthedengannya
it to retract untuk
tensioner fully.
menarik tensioner
Install a new gasket,secara penuh.
cam chain tensioner lifter and tighten the
Pasang
bolts. sebuah gasket baru, cam chain tensioner lifter
Remove
dan the cam chain
kencangkan bolts.tensioner lifter stopper.
Lepaskan cam chain tensioner lifter stopper.
GASKET
7-31
Install a new
Pasang O-ring
sebuah to the baru
O-ring cam chain
padatensioner
cam chainlifter.
tensioner
Install and tighten the screw to the specified torque.
lifter. SCREW
Pasang dan kencangkan screw dengan torsi yang
ditentukan.
Install the luggage box (page 2-7).
TORSI: 4 N.m (0,4 kgf.m; 3.0 lbf.ft)
Pasang luggage box (hal. 2-7).
O-RING
PEMERIKSAAN
INSPECTION
Periksa cara
Check the camkerja
chaincam chainlifter
tensioner tensioner lifter:
operation:
TENSIONER SHAFT
- Tensioner
– The tensioner shaft
shafttidak boleh
should not gomasuk kebody
into the dalam
whenbodyit is
ketika
pushed.ia didorong.
– When
- Jika ia itdiputar
is turned clockwise
searah jarumwithjam
the dengan
cam chain camtensioner
chain
lifter stopper, the tensioner shaft should be
tensioner lifter stopper, tensioner shaft harus ditarikpulled into the
body. The shaft should protrude from the
ke dalam body. Shaft harus menonjol keluar dari body body as soon as
the cam chain tensioner lifter stopper is
segera setelah cam chain tensioner lifter stopper released.
dilepaskan.
TENSIONER LIFTER LIFTER STOPPER
CYLINDER
CYLINDER
PELEPASAN
REMOVAL
CATATAN:
Ikatlaha piece
• • Attach seutas kawat
of wire to the pada cam
cam chain chain ituntuk
to prevent from
CYLINDER
mencegahnya
falling jatuh ke dalam crankcase.
into the crankcase.
• • Be careful agar
Hati-hati not totidak
damage the mating
merusak surfaces penyatuan
permukaan by using a
screwdriver when removing the
karena mencongkel cylinder. obeng
dengan ketika
melepaskan
Remove cylinder.
the cylinder head (page 7-14).
Remove the cylinder.
Lepaskan cylinder head (hal. 7-14).
Lepaskan cylinder.
7-32
INSTALLATION
Lepaskan gasket dan dowel pins.
PEMASANGAN
Clean the cylinder mating surface.
Install dowel
Bersihkan pins and a new
permukaan gasket. cylinder.
penyatuan GASKET
Pasang dowel pins dan sebuah gasket baru.
DOWEL PINS
Ikatlah
Attach seutasofkawat
a piece wire Semprotkan
to thepada permukaan
cylinder dalam
inner surface andcylinder
piston
pada cam chain untuk PISTON RINGS CAM CHAIN
to the cam chain to dan piston
rings. rings.
mencegahnya agarfalling
prevent it from tidak
jatuh ke dalam Route the cam chain through the cylinder and install the cyl-
into the crankcase. Alurkan cam chain melalui cylinder dan pasang cylinder
crankcase. inder over the piston while compressing the piston ring with
dari
youratas piston
finger. sementara menekan piston ring dengan
ari-jari.
Install the cylinder head (page 7-16).
Pasang cylinder head (hal. 7-16).
CYLINDER
PEMERIKSAAN
INSPECTION
Lepaskan cylinder
Remove the cylinder(hal.
(page7-32).
7-32).
Periksa
Inspect thediameter cylinder
cylinder bore for wearterhadap
or d amage.keausan atau
kerusakan.
Measure the cylinder I.D. in the X and Y axis at three levels.
Ukur D.D.
Take the cylinder
maximum padato poros
reading determineX dan Y pada
the cylinder tiga
wear.
tingkat.
SERVICE
Ambil pembacaan maksimum untuk menentukan
LIMIT: 50.10 mm (1.972 in)
keausan cylinder.
Calculate the taper and out-of-round at three levels in the X
BATAS SERVIS:
and Y axis. Take the50,10 mm reading to determine both
maximum
measurements.
Hitung ketirusan dan kelonjongan pada tiga tingkat pada
poros X dan Y. Ambil pembacaan maksimum untuk
SERVICE LIMIT:
menentukan kedua pengukuran.
Taper: 0.05 mm (0.002 in)
Out ofSERVIS:
BATAS round: 0.05 mm (0.002 in)
Ketirusan: 0,05 mm
The cylinder must be rebored and an oversize piston/piston
Kelonjongan: 0,05 mm
rings fitted if the service limits are exceeded.
Cylinder harusoversize
The following dikorterpistons/piston
dan oversize piston/piston
rings rings
are available:
dipasang jika batas servis dilampaui.
0.25 mm (0.0098 in)
Oversize pistons/piston rings berikut tersedia:
0.50 mm (0.0197 in)
0,25 mm(0.0295 in)
0.75 mm
0,50 mm(0.0394 in)
1.00 mm
0,75 mm
The piston
1,00 mmto cylinder clearance for the oversize piston must
be: 0.015 – 0.045 mm (0.0006 – 0.0018 in).
Jarak renggang antara piston-ke-cylinder untuk oversize
Check the cylinder for warpage with a straight edge and
piston harus sebesar: 0,015 – 0,045mm.
feeler gauge in the directions as shown.
Periksa cylinder terhadap perubahan melengkung
dengan mistar lurus dan feeler gauge dalam arah-arah
SERVICE
seperti diperlihatkan.
LIMIT: 0.05 mm (0.002 in)
7-33
STUD BOLT REPLACEMENT
PENGGANTIAN STUD BOLT
Remove the
Lepaskan cylinder(hal.
cylinder (page 7-32).
7-32).
Threaddua
two nuts STUD BOLTS A
Putar nutsonto the stud
(mur) and tighten
pada them together,
stud dan kencangkanand
use wrench on them to turn the stud bolt out.
mereka satu sama lain, dan pakailah kunci pas pada 177.5 – 178.5 mm (6.99 – 7.03 in)
mereka untuk
Install new memutar
stud bolts A,stud boltthe
B into keluar.
crankcase and tighten
them.
Pasang stud bolts A, B baru ke dalam crankcase dan
After crankcase stud bolts installation, check that the length
kencangkan.
from the bolt head to the crankcase surface is within specifi-
cation. pemasangan crankcase stud bolts, periksa
Setelah
bahwa
SPECIFIEDpanjang dari kepala
LENGTH bolt
177.5 – sampai
178.5 ke permukaan
mm (6.99 – 7.03 in)
crankcase adalah sesuai dengan spesifikasi.
Install the cylinder (page 7-33).
PANJANG YANG DITENTUKAN: 177,5 – 178,5 mm
Pasang cylinder (hal. 7-33).
STUD BOLTS B
177.5 – 178.5 mm (6.99 – 7.03 in)
PISTON
PELEPASAN
REMOVAL
Remove the
Lepaskan cylinder(hal.
cylinder (page 7-32).
7-32). PISTON
PISTON PIN
Hati-hati agar piston pin Lepaskan piston pin clips dengan tang.
Be careful
clips tidaknot to let
jatuh ke Remove the piston pin clips with the pliers.
Dorong piston pin keluar dari piston dan connecting rod,
the piston
dalam pin clips
lubang dari Push the piston pin out of the piston and connecting rod, then
kemudian lepaskan piston.
fall into the opening
crankcase. remove the piston.
of the crankcase.
PISTON PIN CLIP
angan
Do merusak
not damagepiston Spread each piston
the Renggangkan ring and remove
masing-masing it byring
piston lifting
danupkeluarkan
at a point
ring dengan
piston opposite mengangkatnya
ring by dengan the gap. ke atas pada sebuah titik di
merenggangkan
spreading theujung-
ends seberang celah.
ujungnya terlalu jauh.
too far.
PISTON RING
7-34
use a wire Bersihkan
Never sekali-kali
Jangan Clean carbon endapan
deposits karbon
from the dari alur-alurwith
ring grooves ring dengan
a ring that
memakai
brush, sikat
it willkawat,
damageia sebuah ring yang tidak dipakai lagi.
will be discarded.
akan merusak alur.
the groove.
PEMASANGAN
Semprotkan oli mesin pada masing-masing ring dan
INSTALLATION
alur ring.
Hati-hati agar tidak Pasang piston rings dengan hati-hati ke dalam alur-alur
Apply ring
piston engine oil to each
dengan ring and ring
tanda-tanda groove. ke atas.
menghadap
merusak piston dan
rings.
Be careful not to Jangan
•Carefully mempertukarkan
install ringthe
the piston rings into paling
pistonatas dengan
ring grooves
damage the piston withring
the markings
kedua. facing up.
and rings. • Untuk memasang oil ring, pasang spacer dulu,
• Do not confuse the top and second rings.
kemudian pasang side rails.
? To install the oilcelah
Selang-selingkan ring, install the spacer
pada ujung first,ring
piston thensejarak
install
120the side rails.
derajat dari masing-masing.
Selang-selingkan celah
Stagger the piston ring pada120
end gaps ujung side
degrees apart railfrom
seperti
each
diperlihatkan.
other.
Stagger the side rail end gaps as shown.
RING TANDA
TANDA
TERATAS
120°
120° RING TERATAS

RING KEDUA 120°
RING KEDUA
RING OLI
SIDE RAIL
SPACER
20 mm
atau lebih
20 mm
atau lebih
7-35
Semprotkan olito the
Apply engine oil mesin pada rod
connecting lubang kepala
small end hole. kecil
connecting rod.
CONNECTING ROD
Pasang piston
Install the piston dengan tanda
with the "IN" "IN"
mark menghadap
facing the intake ke
side.sisi
pemasukan. TANDA"IN"
Apply engine oil to the piston pin and install it. PISTON PIN
Semprotkan oli mesin pada piston pin dan pasang.
Hati-hati agar piston pin Pasang piston pinpin

clips baru.
Be careful not to let Install new piston clips.
clips tidak jatuh ke
the piston pin clips Pastikan
dalam lubang dari • ? Make sure bahwa piston pin clips
the piston pin clips telahsecurely.
are seated duduk dengan
fall into the opening
crankcase. ? Doerat.
not align the piston pin clip end gap with the piston
of the crankcase.
• Jangan mentepatkan celah pada ujung piston pin
cut-out.
clip dengan potongan pada piston.
Install the cylinder (page 7-33).
Pasang cylinder (hal.7-33).
CLIP
PEMERIKSAAN
INSPECTION
Lepaskan piston
Remove the piston(hal.
(page7-34).
7-34).
Periksa piston
Inspect the piston rings terhadap
rings for movementpergerakan
by rotating thedengan
rings.
memutar
The rings rings.
shouldRings
be ableharus dapat
to move inbergerak dalam
their grooves alur-
without
alur mereka tanpa menyangkut.
catching.
Dorong
Push thering
ring sampai
until the permukaan
outer surfaceluar daripiston
of the pistonringring
is
hampir rata dengan piston dan ukur jarak renggang
nearly flush with the piston and measure the ring-to-groove
ring -ke-alur.
clearance.
BATAS SERVIS:
SERVICE LIMIT:
Atas/Kedua: 0,08 mm
Top/Second: 0.08 mm (0.003 in)
7-36
Insert eachmasing-masing piston
Masukkan piston ring into the bottom of the
ring secara cylinder
tegaklurus
squarely
ke usingbagian
dalam the piston.bawah dari cylinder dengan
Measure the ring end gap.
menggunakan piston.
Ukur celah pada ujung ring.
SERVICE LIMIT:
Top/Second 0.45 mm (0.018 in)
BATAS SERVIS:
Atas/Kedua: 0,45 mm
Periksa
Check thepermukaan
piston outer luar piston
surface terhadap
for scratches or goresan
damage. atau
kerusakan.
Measure the piston pin hole. Take the maximum reading to
determine I.D.
Ukur lubang piston pin. Ambil pembacaan maksimum
untuk
SERVICEmenentukan D.D.
LIMIT: 13.04 mm (0.513 in)
Measure the piston pin O.D. at piston and connecting rod
Ukur
slidingD.L. piston pin pada piston dan daerah luncur
areas.
connecting rod.
SERVICE
LIMIT: SERVIS: 12.96
BATAS 12,96mmmm(0.510 in)
Calculate
Hitung the renggang piston-ke-
jarak piston-to-piston pin clearance.
piston pin.
SERVICE
LIMIT: 0.02 mm (0.001 in)
Ukur D.L.the
Measure piston
pistonpada
O.D. titik
at thesejauh 6,0mm
point 6.0 mm(0.24
dariin)
bagian
from
the bottom dan
bawahnya and 90
90°° to thelubang piston
dari piston pin hole.pin.
SERVICE
LIMIT: 49.95 mm (1.967 in)
Hitung jarak renggang cylinder -ke- piston (D.D. cylinder:
Calculate
Lihat the cylinder-to-piston clearance (cylinder I.D.: See
hal. 7-33).
page 7-33).
SERVICE
LIMIT: 0.09 mm (0.004 in)
Measure
Ukur thekepala
D.D. connecting
kecil rod small endrod.
connecting I.D.
BATAS
SERVICE SERVIS: 13,05 mm
LIMIT: 13.05connecting
Hitung jarak renggang mm (0.514 in)
rod -ke- piston pin.
CalculateSERVIS:
BATAS the connecting
0,05rod-to-piston
mm pin clearance.
SERVICE
LIMIT: 0.05 mm (0.002 in)
7-37
CATATAN
7-39
8. KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
LOKASI KOMPONEN-KOMPONEN......8-2 DRIVE BELT ..........................................8-11

COMPONENT LOCATION ····························8-2 DRIVE BELT ···················································8-12
KETERANGAN SERVIS ........................8-3 DRIVE PULLEY......................................8-11 8

SERVICE INFORMATION ·····························8-3 DRIVE PULLEY···································· ·········· 8-12
TROUBLESHOOTING ...........................8-4 CLUTCH/DRIVEN PULLEY ................... 8-15

TROUBLESHOOTING ····································8-4 CLUTCH/DRIVEN PULLEY ························ 8-16
LEFT CRANKCASE COVER .................8-5

LEFT CRANKCASE COVER ························· 8-5
8-1
COMPONENT LOCATION
KICKSTARTER/DRIVE PULLEY/DRIVENPULLEY/CLUTCH
108 N·m (11.0 kgf ·m, 80 lbf ·ft)
49 N·m (5.0 kgf ·m, 36 lbf ·ft)
8-2
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
• This section covers maintenance of the kickstarter, drive pulley, driven pulley and clutch.
?
• Babservices
These ini meliputi perawatan
can be done with dari kickstarter,
the engine drive
installed pulley,
in the driven pulley dan clutch.
frame.
?
• Avoid getting servis
Pekerjaan grease ini
anddapat
oil on dilakukan
the drive belt and drive/driven
dengan pulley faces
mesin terpasang padainrangka.
order to prevent belt slippage.
?
•
DoJagalah
not apply grease
agar to thedan
gemuk weight rollers.
oli tidak mengenai drive belt dan drive/driven pulley faces supaya belt tidak slip.
• Jangan mengoleskan gemuk pada weight rollers.
SPECIFICATIONS
SPESIFIKASI Satuan: mm
Lebar drive belt 18,5 17,5 SERVICE
ITEM STANDARD
Movable drive face D.D. bushing 22,035 – 22,085 22,11 LIMIT
Drive belt width D.L. boss 18.5 (0.73)
22,010 – 22,025 21,98 17.5 (0.69)
Movable drive face D.L. Bushing I.D.
weight roller 22.035
15,92 – 22.085 (0.8675 15,3
– 16,08 – 0.8695) 22.11 (0.871)
Clutch Boss O.D.
Tebal lining - 22.010 – 22.025 (0.8665 – 0.8671)
2,0 21.98 (0.865)
D.D.Weight
clutch roller
outer O.D. 15.92– –112,2
112,0 16.08 (0.627 – 0.633)
112,5 15.3 (0.60)
Clutch pulley
Driven Lining
Panjang thickness
bebas face spring 124,2 – 121,4 2.0 (0.08)
D.L. driven face I.D.
Clutch outer 112.0 – 112.2
33,965 (4.41 – 4.42)
33,985 33,94 112.5 (4.43)
Driven pulley D.D.Face springdriven
movable free length
face 124.2 –
34,000 (4.89)
34,025 34,06 121.4 (4.78)
Driven face O.D. 33.965 – 33.985 (1.3372 – 1.3380) 33.94 (1.336)
Movable driven face I.D. 34.000 – 34.025 (1.3386 – 1.3396) 34.06 (1.341)
NILAI TORSI
TORQUE VALUES
Left crankcase cover plate screw 3 N.m (0,3 kgf.m; 2,2 lbf.t)
Drive pulley face nut 108 N.m (11,0 kgf.m; 80 lbf.ft) Oleskan oli mesin pada ulir dan
Left crankcase cover plate screw 3 N·m (0.3 kgf·m, 2.2 lbf·ft)permukaan duduk
Clutch/driven pulley
Drive pulley face nutnut 54 N.m (5,5108
kgf.m;
N·m40 lbf.ft)
(11.0 kgf·m, 80 lbf·ft) Apply engine oil to the threads and seating sur-
Clutch outer nut 49 N.m (5,0 kgf.m; 36 lbf.ft) face
Clutch/driven pulley nut 54 N·m (5.5 kgf·m, 40 lbt·ft)
Clutch outer nut 49 N·m (5.0 kgf·m, 36 lbt·ft)
TOOLS
TOOLS
Clutch center holder Socket wrench, 39 x 41 mm Clutch spring compressor

07724-0050002 07GMA-KS40100 07LME-GZ40201
Driver Pilot, 28 mm Pilot, 20 mm

07749-0010000 07746-0041100 07746-0040500
8-3
Flywheel holder Bearing remover, 20 mm Fork seal driver attachment, 35.2 mm

07725-0040001 07931-MA70000 07947-KA20200
Attachment, 28 x 30 mm
07946-1870100
TROUBLESHOOTING
TROUBLESHOOTING
Mesin
Enginehidup tapiscooter
starts but skuterwon’t
tidakmove
mau bergerak
Drivedrive
? Worn
• belt belt
aus
Ramp plate
? Damaged
• ramprusak
plate
? Worn
• or shoe
Clutch damaged
ausclutch shoe
atau rusak
? Broken
• Drivendriven face spring
face spring patah
Engine stalls or scooter creeps
Mesin maticlutch
• Broken tiba-tiba atau skuter merangkak
shoe spring
• Clutch shoe spring patah
Poor performance at high speed or lack of power
? Wornkerja
Unjuk drive belt
buruk pada kecepatan tinggi atau
? Weak driven
kekurangan face spring
tenaga
? Worn weight rollers
• Drive belt aus
? Contaminated pulley faces
• Driven face spring lemah
• Weight rollers aus
• Pulley faces terkontaminasi
8-4
LEFT
LEFT CRANKCASE
CRANKCASE COVER
COVER
PELEPASAN
REMOVAL
Remove the
Lepaskan left
left crankcasecover
crankcase cover duct
duct (page 2-12)
(hal. 2-12) CARBURETOR DRAIN
Remove the
Lepaskan following:
sebagai berikut: BOLTS
HOSE CLAMP
- ?Cover
Cover bolts
bolts
? Carburetor
- Carburetor draindrainhose
hose clamp
clamp
? Rear brake cable
- Rear brake cable clampclamp
- ?Vent
Vent holecover
hole cover
Remove the
Lepaskan leftleft crankcase cover.
crankcase cover.
REAR BRAKE
CABLE CLAMP VENT HOLE COVER
Lepaskan
Remove thekedua dowel
two dowel pins,pins, cover from
cover gasket gasket dari
the left left
crank-
crankcase.
case.
GASKET
Clean the gasket mating surface.
Bersihkan permukaan penyatuan gasket.
PEMASANGAN
Bersihkan oli dan gemuk dari bearing bushing pada left
crankcase cover.
Pasang kedua dowel pins.

Pasang cover gasket baru.
DOWEL PINS
INSTALLATION
Pasang
Clean anyleft crankcase
oil and cover
grease from pada bushing
the bearing left crankcase
on the left CARBURETOR DRAIN
dengan
crankcasementepatkan
cover. dowel pins dengan lubang-lubang. BOLTS
HOSE CLAMP
Pasang carburetor drain hose clamp, rear brake cable
Install the two dowel
clamp, vent hole cover dan kencangkan left crankcase
left crankcase
cover bolts dalamcover onto
pola the left crankcase
bersilangan dalamby aligning
dua the
atau tiga
dowel
langkah. pins with the holes.
Install the carburetor drain hose clamp, rear brake cable
Pasang left crankcase
clamp, vent hole cover cover duct (hal.
and tighten 2-12)
the left crankcase cover
bolts in a crisscross pattern in two or three steps.
Install the left crankcase cover duct (page 2-12)
REAR BRAKE
CABLE CLAMP VENT HOLE COVER
PEMBONGKARAN
DISASSEMBLY
Naikkan
Raise thelock
locktabs
tabs dari leftleft
of the crankcase
crankcasecover
cover plate
plate dan
and
lepaskan
remove thescrews.
screws.
LOCK TABS/SCREWS
8-5
Lepaskan
Remove thekickstarter
kickstarter driven gear while
driven gear sementara
turning memutar
the kick-
kickstarter spindle.
starter spindle. KICKSTARTER DRIVEN GEAR
Remove the thrust washer.
Lepaskan thrust washer.
THRUST WASHER
Sebelum melepaskan
Before removing kickstarter
the kickstarter pedal,
pedal, tandai
mark the pedal
pedal and
dan spindle untuk posisi pemasangan
spindle for proper installation position. yang benar. KICKSTARTER PEDAL TANDA
Remove the
Lepaskan boltdan
bolt andkickstarter
the kickstarter pedal.
pedal.
BOLT
Lepaskan dust
Remove the dustseal
seal dari
fromleft
thecrankcase cover.
left crankcase cover.
DUST SEAL
Lepaskan snap
Remove the snapring
ringdan
andwasher
washer dari
fromkickstarter spindle.
the kickstarter spin-
dle. WASHER
SNAP RING
8-6
Lepaskan
Unhook thekaitan
returnreturn
springspring
from dari pin on
the pin pada
the crankcase
crankcase
KICKSTARTER SPINDLE RETURN SPRING
cover.
cover.
Remove the kickstarter spindle and return spring.
Lepaskan kickstarter spindle dan return spring.
PIN
Lepaskan
Remove thespindle
spindlebushing dancollar.
bushing and collar.
BUSHING
ASSEMBLY
COLLAR
PERAKITAN
KICKSTARTER SPINDLE
COLLAR
BUSHING *1 3 N·m (0.3 kgf ·m, 2.2 lbf ·ft)
RETURN SPRING
DRIVEN GEAR
*2
COVER PLATE
FRICTION SPRING
THRUST WASHER
SNAP RING
WASHER
DUST SEAL
KICKSTARTER PEDAL
*1: Oleskan 0.1 – 0.3 g

BOLT
*2: Oleskan 0.2 – 0.3 g
8-7
Install thebushing
Pasang bushing and
dancollar intoke
collar thedalam
left crankcase cover.
left crankcase
cover. BUSHING
COLLAR
Oleskan
Apply 0.10,1 – g0,3
– 0.3 of g molybdenum
molybdenum disulfide
disulfide pastepaste
to the pada
kick-
kickstarter spindle.
starter spindle.
Kaitkan
Hook theujung pendek
short end dari spring
of the spring pada groove.
to the spindle alur spindle.
Install
Pasang spindle
the spindle dan spring
and return return into
spring ke dalamcover
the crankcase crankcase
while RETURN SPRING Kaitkan
settingsementara
cover the return meletakkan
spring along return
the guide on the
spring crankcase
di sepanjang
cover.pada crankcase cover.
guide
Hold the kickstarter spindle in position.
Tahan kickstarter spindle pada posisinya.
KICKSTARTER SPINDLE UJUNG PENDEK
Tetap Keep
tahanholding
kickstarter Install thewasher
the Pasang washer pada
onto the kickstarterspindle
kickstarter spindle dan
and set the snap
tempatkan
spindlekickstarter
sampai snap ring ring to the kickstarter spindle groove.
spindle snap ring pada alur kickstarter spindle.
telah dipasang untuk
until the snap ring is
mencegah terlepasnya
installed in order to
spring dari guide.
prevent the spring
from coming off from
the guide.
WASHER SNAP RING
8-8
Hook the
Kaitkan longpanjang
ujung end of the
darireturn spring
return to pada
spring the pin
pinonpada
the
crankcase cover.
crankcase cover. UJUNG PANJANG PIN
Apply grease
Oleskan gemukto apada
new dust
bibirseal
dustlip.seal baru.
Install the
Pasang dustseal
dust sealsampai
until it ia
is flush with the left
rata dengan left crankcase
crankcase
cover.
cover.
DUST SEAL
Sewaktu memasang
When installing the Pasang kickstarter
Install the kickstarterpedal
pedal pada posisinya
in its original semula
position seperti
as marked
kickstarter pedal pada
kickstarter pedal to telah
duringditandai
removal pada waktu
and tighten thepelepasan
bolt. dan kencangkan KICKSTARTER PEDAL TANDA
posisi standard, lihat
the standard position, bolt.
hal. 1-14.
see page 1-14.
BOLT
Pasang thrust
Install the thrustwasher
washer pada crankcase
onto the crankcasecover.
cover.
THRUST WASHER
8-9
Apply 0.20,2
Oleskan – –
0.30,3
g g
of molybdenum
molybdenum disulfide
disulfide paste
pastetopada
the
driven gear
driven gear shaft.
shaft. DRIVEN GEAR
Apply molybdenum
Oleskan molybdenumdisulfide paste to paste
disulfide the friction
padaspring slid-
daerah
ing area.
luncur friction spring. WELD BEAD
Depress the kickstarter pedal and hold it.
Tekan kickstarter pedal dan tahan.
Install the driven gear while aligning the friction spring hook
with the groove
Pasang driven ingear
the crankcase cover,
sementara and return thekaitan
mentepatkan kick-
starter spindle
friction spring to engagealur
dengan the pada
drivencrankcase
gear teeth and spindle
cover, dan
gear teeth before
kembalikan the weld spindle
kickstarter bead point.
untuk menghubungkan
gigi driven gear dan gigi spindle gear sebelum weld
bead point (titik manik pengelasan).
Tepatkan
FRICTION SPRING
Pasang
Install theleft crankcasecover
left crankcase cover
plateplate dan kencangkan
and tighten the screws to
screws dengan
the specified torsi yang ditentukan.
torque.
TORQUE:3
TORSI: N·m
3 N.m (0.3kgf.m;
(0,3 kgf·m,2,2
2.2 lbf.ft)
lbf·ft)
Bend the lock tabs of the cover plate against the screw heads.
Tekuk lock tabs dari cover plate terhadap kepala screw.
LOCK TABS/SCREWS
INSPECTION
PEMERIKSAAN
Inspect the
Periksa following:
sebagai berikut:
RETURN SPRING
-? Spindle
Spindleterhadap
for wear keausan
or damageatau kerusakan
? Gear teeth for wear or damage
- Gigi gear terhadap keausan atau kerusakan
? Return spring for weakness or damage COLLAR
- Return spring terhadap kelemahan atau kerusakan
? Bushing for wear or damage
- Bushing terhadap keausan atau kerusakan
SPINDLE
BUSHING
-? Driven
Drivengear
gearterhadap
for wear orkeausan
damageatau kerusakan STARTER
? Friction spring for weakness or damage
- Friction spring terhadap kelemahan atau kerusakan FRICTION SPRING
RATCHET TEETH
? Starter ratchet teeth for wear or damageatau kerusakan
- Gigi starter ratchet terhadap keausan
DRIVEN GEAR
8-10
-? Journals
Journals dari crankcase
of the crankcase cover terhadap
cover for wear orkeausan
damage atau
kerusakan.
JOURNALS
DRIVE
DRIVEBELT
BELT
PENGGANTIAN
REPLACEMENT
CATATAN:
• Drive
? The belt
drive dapat
belt can bediservis
serviceddengan
with the mesin
engine terpasang
installed in
pada rangka.
the frame.
Remove the
Lepaskan drivepulley
drive pulleyface
face (hal.
(page8-11).
8-11).
Remove the
Lepaskan drivebelt
drive beltdan
andganti
replace it with yang
dengan a newbaru.
one.
Install the drive pulley face (page 8-12).
Pasang drive pulley face (hal. 8-12).
BELT
DRIVE PULLEY
DRIVE PULLEY
PELEPASAN
REMOVAL
CATATAN:
• Drive pulley dapat diservis dengan mesin terpasang
? The
padadrive pulley can be serviced with the engine installed
rangka.
in the frame.
Lepaskan left
Remove the crankcase
left crankcase cover (hal. 8-5).
cover (page 8-5).
NUT/WASHER/ DRIVE PULLEY FACE
Tahan
Hold themuka drive face
drive pulley pulley
withdengan special
special tool tool dan
and loosen the RATCHET PLATE
longgarkan
drive pulley drive pulley face nut.
face nut.
TOOL:
TOOL:
Clutch center
Clutch center holder
holder 07724-0050002
07724-0050002
? Nut
-? Nut
Washer
-? Washer DRIVE FACE FIN
Starter ratchet plate
-? Starter
Drive ratchet
face fin plate
- Drive face fin
CLUTCH CENTER HOLDER
8-11
Geser lepas
Slide off drivebelt
the drive belt dari
from thedrive pulley boss
drive pulley bossby dengan
squeez-
memencet drive
ing the drive belt.belt. BOSS
BELT
Lepaskan
Remove themovable driveface
movable drive face assembly
assembly while sementara
holding the
menahan
back of thebagian belakang
face (ramp daridrive
plate) and face (ramp
face boss. plate) dan MOVABLE DRIVE FACE ASSEMBLY
drive face boss.
BOSS
PEMASANGAN
INSTALLATION
Clean any oli
Bersihkan oil dan
and gemuk
grease from the drive
dari drive faceface
danand thebelt.
drive drive
belt. MOVABLE DRIVE FACE ASSEMBLY
Hati-hati agar movable Pasang movable drive face assembly pada crankshaft
drive
Be face not
careful assembly
to get Install the movable
sementara menahan drive
rampface assembly onto the crankshaft
plate.
tidak terbongkar dan while holding the ramp plate.
the movable drive
pastikan untuk
face assembly
memasang assembly
disassembled and be
sampai duduk dengan
sure to install the
penuh.
assembly until fully
seated.
Tekan
Compressdriven face spring
the driven dengan
face spring memencet
by squeezing the drive
drive belt
belt
until there
sampai adais enough
cukup slack to installuntuk
kekenduran the drive belt to the drive
memasang drive DRIVE BELT
pulley
belt padaboss.
drive pulley boss.
8-12
Be careful
Hati-hati agarnot to Tempatkan
tidak Set the drive drive belt
belt onto thepada drive boss
drive pulley pulley
by boss dengan
squeezing it to
DRIVE PULLEY FACE
damage the spline. memencetnya
merusak obtain the clearanceuntuk
betweenmendapatkan kerenggangan
the belt and shaft.
antara
Install belt dan shaft.
the drive pulley face while aligning its splines with
Pasang
crankshaftdrive
splines.pulley face sementara mentepatkan
splines-nya dengan crankshaft splines.
Tepatkan
Pastikan
Make surebahwa
that thedrive
drivepulley
pulley face
face isduduk sepenuhnya
fully seated on the
pada drive pulley
drive pulley boss. boss.
Duduk sepenuhnya (Drive pulley face and
Install the
Pasang drive
drive facefin
face findan
andratchet
ratchet plate.
plate. RATCHET PLATE DRIVE FACE FIN
Apply engine
Oleskan oil to the
oli mesin d riveulir
pada pulley face
drive nut threads
pulley face and
nut seat-
dan
ing surface then install it with the washer.
permukaan duduk kemudian pasang dengan washer.
Hold the drive pulley face with the special tool and tighten CLUTCH
Tahan
the nut todrive pulley torque.
the specified face dengan special tool dan CENTER
kencangkan nut dengan torsi yang ditentukan. HOLDER
TOOL:
Clutch center holder
TOOL: 07724-0050002
Clutch center holder 07724-0050002
Install the left crankcase cover (page 8-5).
Pasang left crankcase cover (hal. 8-5).
NUT
WASHER
PEMERIKSAAN
INSPECTION
DRIVE
DRIVEPULLEY
PULLEYFACE
FACE
Periksa
Check thedrive
drivepulley faceforterhadap
pulley face scratches,goresan,
scoring or gerusan
damage.
atau kerusakan. DRIVE PULLEY FACE
8-13
? Drive face boss
- Driven face boss
? Ramp plate
- Ramp plate
? Slide pieces
-? Slide pieces
Weight rollers
- Weight rollers
Clean any oil and Assembly is in the reverse order of disassembly.
ersihkanfrom
grease the Perakitan
weight adalah dalam urutan terbalik dari
rollers
weightdan and pembongkaran.
movable
rollers
drive face
movable dari
drive oli
face.
dan gemuk.
MOVABLE DRIVE FACE DRIVE FACE BOSS
Sisi left
crankcase cover
RAMP PLATE
WEIGHT ROLLERS
SLIDE PIECES
PEMERIKSAAN
INSPECTION
WEIGHT
WEIGHTROLLER
ROLLER
Periksa masing-masing
Check each rollerwear.
roller for abnormal terhadap keausan tidak
normal.
Measure the weight roller O.D.
Ukur D.L. weight roller.
SERVICE
LIMIT:SERVIS: 15,3
BATAS 15.3 mm
mm(0.60 in)
MOVABLE
MOVABLEDRIVE
DRIVEFACE
FACEBOSS
BOSS
Periksa
Check thedrive face
drive face bossboss terhadap
for wear keausan atau
or damage.
kerusakan.
Measure the drive face boss O.D.
Ukur D.L. drive face boss.
SERVICE
BATAS
LIMIT:SERVIS: 21,9821.98 mmmm(0.865 in)
8-14
MOVABLEDRIVE
MOVABLE DRIVE FACE
FACE
Check the
Periksa movabledrive
movable driveface
face for scratches,
terhadap scoringgerusan
goresan, or dam-
age. MOVABLE DRIVE FACE
atau kerusakan.
Measure
Ukur D.D.the drive
drive facebushing.
face bushing I.D.

SERVICE
LIMIT: 22.11 mm (0.871 in)
CLUTCH/DRIVEN
CLUTCH/DRIVENPULLEY
PULLEY
PELEPASAN
REMOVAL
CATATAN:
• Clutch/driven pulley dapat diservis dengan mesin
? The clutch/driven pulley can be serviced with the engine
installed
terpasangin the frame.
pada rangka.
Remove the
Lepaskan left
left crankcase cover
crankcase cover (page 8-5).
(hal. 8-5).
CLUTCH OUTER NUT/WASHER
Hold the
Pakailah special tool Tahan clutchouter
clutch outerdengan
with the special
special tool
tool and
danremove the
lepaskan
ketika
Use the
melonggarkan nut.
special tool nut.
lock nut.
when loosening the
Menahan roda belakang TOOL:
lock nut.
atau rem belakang TOOL:
Flywheel holder 07725-0040001
Holding theakan
rear
merusak sistem final Flywheel holder 07725-0040001
wheel or rear brake
reduction. Remove the washer and clutch outer.
will damage the final
Lepaskan washer dan clutch outer.
reduction system.
FLYWHEEL HOLDER
angan
Do notoleskan gemuk
get grease on Tahan
Hold the clutch/driven
clutch/drivenpulley
pulleyassembly dan compress
assembly and tekan drive
the
pada CLUTCH/DRIVEN PULLEY ASSEMBLY
the drive
drive shaft
shaft splines
splines face
drive spring dengan
face spring memutar
by turning movable
movable driven
driven face face
clockwise
dari sebelah dalam
from the driven face searah jarum jam sampai ia berhenti.
until it stops.
driven face.
inside.
8-15
Untuk menghindari
To avoid injury luka-
to Lepaskan
Remove the clutch/driven
clutch/drivenpulley
pulleyassembly
assembly dari
from drive belt
the drive
luka pada
your jari-jari,
finger, do not dengan menahan
belt by holding the movable drivenface.
movable driven face. BELT
jangan lepaskan
release the driven
driven
pulley sementara Remove the drive belt from the clutch/driven pulley assem-
pulley while removing Lepaskan drive beltthe
dari clutch/driven pulley assembly
melepaskan drive belt. bly while removing clutch/driven pulley assembly from
the drive belt. If sementara melepaskan clutch/driven pulley assembly
ika dilepaskan drive the drive shaft.
released drive face dari drive shaft.
ace spring akan
spring
memanjang will extend
dengan tiba-
suddenly
tiba dan movable driven and
movable driven
ace akan berputar,face
will turn,
sehingga resulting in
menimbulkan
luka-luka pada
injury to yourjari-jari.
finger.
CLUTCH/DRIVEN PULLEY ASSEMBLY

PEMASANGAN
INSTALLATION
Bersihkan
Clean any oil oli and
dangrease
gemuk darithe
from driven
drivenface
facedan
and drive
drive belt.
belt.
Tahan clutch/driven CLUTCH/DRIVEN
Hold the clutch/drivenpulley
pulleyassembly
assembly anddan compress
tekan drivethe
face PULLEY ASSEMBLY
drive spring
face spring dengan memutar
by turning movable movable driven
driven face face
clockwise
searah jarum jam sampai ia berhenti.
until it stops.
MOVABLE DRIVEN FACE
Untuk menghindari
To avoid injury to Tempatkan
luka- Set the drive drive belt
belt onto the pada
pulley alur pulley
groove sementara
while holding the
luka pada jari-jari,
your finger, do not menahan movable
movable driven face.driven face.
jangan lepaskan driven
BELT
release the driven
pulley sementara
pulley while installing
memasang drive belt.
the drive belt. If
ika dilepaskan drive
released drive face
ace spring akan
memanjang springdengan
will extend
tiba-
suddenly
tiba dan movable driven and
movable driven
ace akan berputar, face
will turn,menimbulkan
sehingga resulting in
luka-luka
injury to pada
your jari-jari.
finger.
MOVABLE DRIVEN FACE

Jangan oleskan gemuk Pasang clutch/driven pulley assembly pada driveshaft.
Do not get grease on Install the clutch/driven pulley assembly onto the driveshaft. CLUTCH/DRIVEN PULLEY ASSEMBLY
pada drive shaft splines
the drive shaft splines
dari sebelah dalam
from the driven
driven face.
face
inside.
8-16
Bersihkan oli and
Clean any oil dangrease
gemuk darithe
from clutch outer.
clutch outer.
Install theclutch
Pasang clutchouter
outer while aligning
sementara its splines with
mentepatkan drive-
splines-
shaftdengan
nya splines.driveshaft splines. Tepatkan
CLUTCH OUTER
Pasang washer
Install the washerdan
and clutch
clutch outer nut.
outer nut.
FLYWHEEL HOLDER
Hold the
Tahan clutch
clutch outer
outer with the
dengan special
special tool
tool andkencangkan
dan tighten the
clutch outer
clutch outer nut
nutto the specified
dengan torque.
TOOL:
TOOL:
TORQUE:49
TORSI: N·m
49 N.m (5.0kgf.m;
(5,0 kgf·m,36
36 lbf.ft)
lbf·ft)
Pasang left
left crankcasecover (hal. 8-5).
cover (page 8-5).
NUT/WASHER
PEMBONGKARAN
DISASSEMBLY
CLUTCH/DRIVEN
CLUTCH/DRIVEN PULLEY
PULLEY
Tempatkan clutch
Set the clutch spring
spring compressor
compressor pada
onto the clutch/driven
clutch/driven pul-
CLUTCH SPRING COMPRESSOR
ley by aligning
pulley denganthe bosses of the compressor
mentepatkan bosses dari withcompressor
the holes of
the clutch.
dengan lubang-lubang dari clutch. CLUTCH/DRIVEN
PULLEY
TOOL:
TOOL:
Clutch spring
Clutch spring compressor
compressor 07LME-GZ40201
07LME-GZ40201
Untuk
To mencegah
prevent Hold theclutch/driven
loss of Tahan clutch/driven pulley
pulley by turning memutar
dengan the clutch spring
clutch
hilangnya tegangan,
tension, compressor
do not spring clockwise.
compressor searah jarum jam.
jangan tekan driven
compress face
the driven
spring lebih daripada
face spring more than
yang diperlukan untuk
necessary to remove
melepaskan
the clutch/
clutch/driven driven
pulley nut.
pulley nut.
CLUTCH/DRIVEN
PULLEY
8-17
Hold the
Tahan clutch
clutch springcompressor
spring compressor in a vise.
pada sebuah catok.
SOCKET WRENCH CLUTCH/DRIVEN
Remove the clutch/driven
Lepaskan pulley nut
clutch/driven using the
pulley specialdengan
nut tool. PULLEY NUT
menggunakan special tool.
TOOL:
Socket wrench, 39 x 41 mm 07GMA-KS40100
TOOL:
Longgarkan clutchspring
Loosen the clutch springcompressor
compressor secaraand
gradually berangsur
remove
dan lepaskan sebagai berikut: CLUTCH ASSEMBLY
the following:
- Clutch assembly
-? Spring
Clutch assembly
seat
? Spring seat SPRING SEAT
- Driven face spring
? Driven face spring
- Driven pulley assembly
? Driven pulley assembly
DRIVEN
DRIVEN PULLEY ASSEMBLY FACE
CLUTCH
CLUTCH
Remove the
Lepaskan three E-clips
ketiga E-clips and
danwashers.
washers.
E-CLIPS/WASHERS
Remove the
Lepaskan clutchshoes
clutch shoes dari
fromdrive
the drive plate.
plate.
Remove the
Lepaskan clutchshoe
clutch shoesprings.
springs.
Remove the
Lepaskan damperrubbers
damper rubbers from the drive
dari drive plate.
plate.
SPRINGS
DAMPER RUBBERS DRIVE PLATE
8-18
DRIVEN
DRIVENPULLEY
PULLEY
Remove the
Lepaskan sealcollar.
seal collar.
SEAL COLLAR
Remove the
Lepaskan guidepins
guide pinsdan
and guide
guiderollers
rollersfrom
darithe driven
driven face.
face.
Remove the
Lepaskan movabledriven
movable drivenface
face from the driven
dari driven face.
face. O-RINGS
Remove theO-rings
Lepaskan O-rings dan
and oil
oil seals
sealsfrom
darithemovable
movable driven
driven
face.
face.
OIL SEALS
MOVABLE
DRIVEN FACE
GUIDE PINS
DRIVEN FACE
GUIDE
ROLLERS
ASSEMBLY
PERAKITAN
GUIDE PINS
GUIDE ROLLERS
OIL SEALS
O-RINGS
SEAL COLLAR
DRIVEN FACE SPRING DRIVEN FACE
MOVABLE DRIVEN FACE

SPRING SEAT
WASHERS
E-CLIPS
CLUTCH SHOES
SPRINGS
CLUTCH DRIVEN PULLEY NUT DAMPER RUBBERS
54 N·m (5.5 kgf ·m, 40 lbf ·ft) DRIVE PLATE
DRIVEN PULLEY
Apply engine
DRIVEN oil to new oil seal lips and install them into the
PULLEY
movable driven face. O-RINGS
Oleskan oli mesin pada bibir oil seal baru dan pasang
Coat
ke new movable
dalam O-rings with engine
driven face.oil and install them into the OIL SEALS
movable driven face grooves.
Lapisi O-rings baru dengan oli mesin dan pasang ke
dalam alur-alur movable driven face.
8-19
Bersihkan oli and
Clean any oil dangrease
gemuk dari pulley
from face.
the pulley face.
PINS/ROLLERS
Pasang movable
Install the movabledriven
drivenface
face pada driven
onto the face.
driven face.
Install the
Pasang guiderollers
guide rollersdan
and guide
guide pins.
pins.
Apply 2.0 – 2.5 g of grease (Shell ALVANIA R3 or
Oleskan 2,0 – 2,5 g gemuk (Shell ALVANIA R3 atau
IDEMITSU AUTOREX B or equivalent) to each guide
IDEMITSU AUTOREX B atau sejenisnya) pada masing-
groove.
masing alur guide.
MOVABLE DRIVEN FACE
Pasang seal
Install the sealcollar
collarpada
to thedriven
drivenpulley.
pulley.
SEAL COLLAR
CLUTCH
CLUTCH
Pasang damper
Install the rubbers pada
damperrubbers drive
onto the plate.
drive plate.
DRIVE PLATE
DAMPER RUBBERS
Pasang
Install theshoe springsinto
shoe springs kethe
dalam
clutch clutch
shoes asshoes
shown.seperti
diperlihatkan. CLUTCH SHOES SPRINGS
Install the clutch shoes into the drive plate by aligning the
shoe grooves and damper rubbers.
Pasang clutch shoes ke dalam drive plate dengan
mentepatkan alur-alur shoe dan damper rubbers.
DRIVE PLATE
8-20
Install the
Pasang washersdan
washers and E-clips.
E-clips.
WASHERS/E-CLIPS
CLUTCH/DRIVEN
CLUTCH/DRIVEN PULLEY
PULLEY
Rakit sebagai
Assemble berikut:
the following:
CLUTCH ASSEMBLY
-? Driven
Drivenpulley
pulleyassembly
assembly
-? Driven
Drivenface
facespring
spring
-? Spring
Springseat
seat SPRING SEAT
-? Clutch
Clutchassembly
assembly
DRIVEN
DRIVEN PULLEY ASSEMBLY FACE
Tempatkan clutch compressor

Set the clutch spring spring over
compressor di atas
the clutch/driven pul- Tepatkan
clutch/driven pulley the
ley assembly aligning assembly
bosses of dengan mentepatkan
the compressor with the (BOSSES/ HOLES
bosses dariclutch.
holes of the compressor dengan lubang-lubang dari
clutch.
TOOL:
TOOL:
Clutch spring compressor 07LME-GZ40201
Compress
Clutch the driven
spring face spring while 07LME-GZ40201
compressor aligning the cutout of
To prevent loss of the pulley nut threads with the drive plate hole and install the
Untuk mencegah
tension, do not clutch/driven
Tekan drivenpulley
facenut.spring sementara mentepatkan
hilangnya tegangan,
compress the potongan dari ulir pulley nut dengan lubang drive plate
jangan tekan driven face dan pasang clutch/driven pulley nut.
driven face spring
spring lebih daripada
more untuk
yang diperlukan than
merakitnecessary
clutch/drivento CLUTCH SPRING Tepatkan (CUTOUT/
pulley nut. Jangan
assemble the COMPRESSOR PLATE HOLES
merusak clutch/driven
ulir pulley nut.
pulley nut.
Do not damage the
pulley nut threads.
Hold the
Tahan spring
spring compressor pada
compressor in a vice.
sebuah catok.
CLUTCH SPRING
Tighten the clutch/driven
Kencangkan pulley
clutch/driven nut using
pulley the socket
nut dengan wrench
memakai COMPRESSOR
to the specified torque.
socket wrench dengan torsi yang ditentukan.
TOOL:
TOOL:
TORQUE:54
TORSI: N·m
54 N.m (5.5kgf.m;
(5,5 kgf·m,40
40 lbf.ft)
lbf·ft)
Lepaskan
Remove thespring
spring compressor daritheclutch/driven
compressor from clutch/driven pulley
pulley
assembly.
assembly.
SOCKET WRENCH
8-21
INSPECTION
PEMERIKSAAN
CLUTCH OUTER
CLUTCH OUTER
Check the clutch outer for wear or damage.
Periksa clutch outer terhadap keausan atau kerusakan.
Measure
Ukur D.D.the clutchouter.
clutch outer I.D.
BATAS
SERVICESERVIS: 112,5 mm
LIMIT: 112.5 mm (4.43 in)
DRIVEN
DRIVENFACE
FACESPRING
SPRING
Ukur panjang
Measure bebas
the driven driven
face face
spring freespring.
length.
SERVICE
LIMIT: 121.4 mm (4.78 in)
DRIVEN FACE
DRIVEN FACE
Check the driven face for scratches, scoring or damage.
Periksa
Measure driven face
the driven faceterhadap
boss O.D. goresan, gerusan atau
kerusakan.
Ukur D.L. driven face boss.
SERVICE
LIMIT: SERVIS: 33.94
BATAS 33,94mm mm(1.336 in)
8-22
MOVABLE
MOVABLEDRIVEN
DRIVENFACE
FACE
Check the
Periksa movabledriven
movable drivenface
face terhadap
for scratches, scoringgerusan
goresan, or dam-
age.
atau kerusakan.
Check the
Periksa guide grooves
alur-alur guideforterhadap
stepped wear or damage.
keausan bertingkat
Measure
atau the movable driven face I.D.
kerusakan.
Ukur D.D. movable driven face.
SERVICE
LIMIT:SERVIS: 34,06
BATAS 34.06 mm
mm(1.341 in)
PEMERIKSAAN
DRIVEN FACEDRIVEN FACE
BEARING BEARING
INSPECTION
Juga
Also periksa bahwa
check that bearingouter
the bearing outerrace
race
fitsduduk
tightlydengan
in the
erat pada
driven driven face.
face.
Install the driven face to the driveshaft.
Pasang driven face pada driveshaft.
Turn the driven face with your hand. The bearing should turn
Putar
smoothlydriven face dengan tangan. Bearing harus
and quietly.
berputar dengan
Replace the bearingshalus dando
if they tanpa suara.
not turn smoothly, quietly, or
Ganti
if theybearings jika
fit loosely on mereka tidak
the driven faceberputar dengan halus,
(page 8-23).
tanpa suara, atau jika mereka duduk dengan longgar
pada driven face (hal. 8-23).
DRIVEN FACE
DRIVEN FACE BEARING

PENGGANTIAN
REPLACEMENTDRIVEN FACE BEARING
Lepaskan
Remove the driven faceneedle
driven face needle
bearingbearing
using thedengan
special
menggunakan
tools. special tools. BEARING REMOVER
TOOLS:
TOOLS:
Bearing remover, 20 mm 07931-MA70000
Bearing remover, 20 mm 07931-MA70000 ATTACHMENT
Fork seal driver attachment,
Forkmm
35.2 seal driver attachment, 35.2 07947-KA20200
mm 07947-KA20200
NEEDLE BEARING
Lepaskan
Remove the snap
snapring
ringdan
anddorong ball
drive the bearing
ball bearingkeluar
out ofdari
the
driven
drivenface.
face. BEARING
SNAP RING
8-23
Isilah ball ball
Pack new bearing baru
bearing dengan
with greasegemuk (Shell ALVANIA
(Shell ALVANIA R3 or
DRIVER
IDEMITSU
R3 AUTOREX
atau IDEMITSU B or equivalent).
AUTOREX B atau sejenisnya).
SisiThe sealed
tertutup side
dari of
ball Pasang ball
Install the ballbearing
bearing secara
into the tegaklurus ke dalam
driven face squarely driven
until it is
ball bearing
bearing is facing
menghadap ke face sampai
fully seated, ia the
using telah duduk
special tools. sepenuhnya, dengan
driven face.
the driven menggunakan special tools.
face. TOOLS:
TOOLS:
Driver 07749-0010000
Driver
Pilot, 28 mm 07749-0010000
07746-0041100
Pilot, 28 mm 07746-0041100
PILOT
BALL BEARING
Pasang snap
Install the snapring
ring dengan kokoh
to the groove on pada alur face
the driven pada driven
securely.
face.
Apply 7.0 – 8.0 g of grease (Shell ALVANIA R3 or
IDEMITSU
Oleskan 7,0AUTOREX
– 8,0 g gemukB or equivalent) to the driven
(Shell ALVANIA face
R3 atau
inner surface.
IDEMITSU AUTOREX B atau sejenisnya) pada
permukaan dalam driven face.
SNAP RING
Apply grease
Oleskan gemuk(Shell
(Shell ALVANIA
ALVANIA R3 R3 atau
or IDEMITSU
AUTOREX B or equivalent) to a new needle bearing.bearing ATTACHMENT DRIVER
AUTOREX B atau sejenisnya) pada needle
baru.
The sealed side of Press the needle bearing into the driven face squarely as
Sisi tertutup
needledari needle
bearing shown. needle bearing secara tegaklurus ke dalam
is Dorong 1.0 mm (0.04 in)
bearing menghadap ke
facing the special driven face seperti diperlihatkan.
special tools.
tools. TOOLS:
TOOLS:
Driver 07749-0010000
Driver
Attachment, 28 x 30 mm 07749-0010000
07946-1870100
Attachment,
Pilot, 20 mm 28 x 30 mm 07946-1870100
07746-0040500 PILOT
Pilot, 20 mm 07746-0040500
NEEDLE BEARING
8-24
9. FINAL REDUCTION
LOKASI KOMPONEN-KOMPONEN......9-2
COMPONENT LOCATION ····························9-2PERAKITAN FINAL REDUCTION
FINAL REDUCTION CASE .........9-7
CASE ASSEMBLY ·····9-7

SERVICE INFORMATION ·····························9-3PEMERIKSAAN FINAL REDUCTION
FINAL REDUCTION CASE ...9-8
INSPECTION··············9-8
9
TROUBLESHOOTING ····································9-5
PENGGANTIAN FINAL REDUCTION ..............
FINAL REDUCTION BEARING
BEARING ..........................................................9-10
REPLACEMENT·································· ··········· 9-10
PEMBELAHAN FINAL
FINAL REDUCTION CASE
REDUCTION CASE
SEPARATION ...............................9-6 9-6
···················································
9-1
FINAL REDUCTION
COMPONENT LOCATION
FINALREDUCTION
9-2
FINAL REDUCTION
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
• The final reduction can be serviced with the engine installed in the frame.
Final
•• When reduction
installing the dapat diservis
driveshaft, dengan
be sure to usemesin terpasang
the special pada rangka.
tools; position the special tools on the bearing inner race
• and pull the
Ketika driveshaft into
memasang the bearing
driveshaft, until it is
pastikan fullymemakai
untuk seated. special tools; tempatkan special tools pada bearing inner race dan
tarik driveshaft ke dalam bearing sampai ia telah duduk sepenuhnya.
SPECIFICATIONS
SPESIFIKASI Unit: mm (in)
ITEM STANDARD
SPESIFIKASI
Final reduction oil capacity BAGIANAfter draining 0.10 liter (0.11 US qt, 0.09 lmp qt)
Kapasitas oli final Pada After
penggantian periodik
disassembly 0,10(0.13
0.12 liter liter US qt, 0.11 lmp qt)
reduction Setelah pembongkaran 0,12 liter
Recommended final reduction oil Honda "4-stroke motorcycle oil" or equivalent motor oil
Oli final reduction yang dianjurkan Federalclassification:
API service Oil SupremeSG Flick
or dengan klasifikasi
higher (except oilsAPI Service
labeled as
SG., Viskositas: SAE 10W-30 JASO MB
energy conserving on the circular API service label)
JASO T 903 standard: MB
NILAI TORSI
Final reduction oil check bolt 13 N.m (1,3 kgf.m; 10 lbf.ft)
TORQUE VALUE
Final reduction oil drain bolt 13 N.m (1,3 kgf.m; 10 lbf.ft)
Final reduction oil check bolt 13 N·m (1.3 kgf·m, 10 lbf·ft)

Final reduction oil drain bolt 13 N·m (1.3 kgf·m, 10 lbf·ft)
TOOLS
TOOLS
Case puller Remover weight Bearing remover shaft, 10 mm

07SMC-0010001 07741-0010201 07936-GE00100
Bearing remover head, 10 mm Bearing remover shaft, 12 mm Bearing remover head, 12 mm

07936-GE00200 07936-1660120 07936-1660110
9-3
FINAL REDUCTION
Bearing remover shaft, 15 mm Bearing remover head, 15 mm Driver

07936-KC10100 07936-KC10200 07749-0010000
Attachment, 32 x 35 mm Attachment, 37 x 40 mm Attachment, 40 x 42 mm

07746-0010100 07746-0010200 07746-0010900
Attachment, 42 x 47 mm Pilot, 10 mm Pilot, 12 mm

07746-0010300 07746-0040100 07746-0040200
Pilot, 15 mm Pilot, 20 mm Pilot, 22 mm

07746-0040300 07746-0040500 07746-0041000
9-4
FINAL REDUCTION
Assembly collar Assembly shaft Assembly collar attachment

07965-GM00100 07965-1660200 07965-GM00200
TROUBLESHOOTING
TROUBLESHOOTING
Mesin bisa hidup tetapi skuter tidak mau bergerak
Engine does start but scooter won’t move
• Final reduction
• Damaged rusak
final reduction
• Final reduction
• Seized macet
final reduction
• Drivedrive
• Faulty pulley dan driven
pulley pulley/clutch
and driven rusak
pulley/clutch
Abnormal noise
Suara tidak normal
• Worn, seized or chipped gears
• Gears aus, macet atau sumbing
• Worn or damaged final reduction bearing
• Final reduction bearing aus atau rusak
Oil leak
• Oil level too
Kebocoran oli high
•
•
Worn or damaged
Tinggi permukaan oil oli
sealterlalu tinggi
•
•
Cracked
Oil seal aus atau rusak final reduction case
crankcase and/or
• Crankcase dan/atau final reduction case retak
9-5
FINAL REDUCTION
FINAL REDUCTION
PEMBELAHAN FINALCASE
REDUCTION CASE
SEPARATION
PELEPASAN
REMOVAL
• Final
• The reduction
final dapat
reduction candiservis dengan
be serviced mesin
with the ter -
engine
pasang pada rangka. BREATHER HOSE
installed in the frame.
Drain the final
Keluarkan reduction
oli final oil (page
reduction 3-13).
(hal. 3-13).
Remove thesebagai
Lepaskan following:berikut:
– Clutch/drivenpulley
- Clutch/driven pulley (hal.
(page8-15)
8-16)
– Rear wheel (page 12-4)
- Roda belakang (hal. 12-4)
– Rear brake shoes (page 13-5)
- Rear brake shoes (hal. 13-5)
Disconnect the final reduction case breather hose from the
Lepaskan final reduction case breather hose dari final
final reduction case hose joint.
reduction case hose joint.
Remove thebolts
Lepaskan boltsdan
and final reduction
reductioncase.
case. FINAL
REDUCTION CASE
BOLTS
Lepaskan
Remove thedowel pins dan
dowelpins gasket.
and gasket.
DOWEL PINS
GASKET
9-6
FINAL REDUCTION
Remove the
Lepaskan following:
sebagai berikut:
- –Counter
Countergear
gear COUNTER GEAR
- –Final
Final gearshaft
gear shaft
- –Countershaft
Countershaft
COUNTERSHAFT
FINAL GEAR SHAFT
FINAL REDUCTION CASE ASSEMBLY

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

SHAFT GEAR
9-7
FINAL REDUCTION
Install the
Pasang dowel
dowel pinsdan
pins andgasket
a new gasket.
baru.
DOWEL PINS
GASKET
Pasang final
Install the reduction
final reductioncase
case dan kencangkan
and tighten bolts.
the bolts.
FINAL
REDUCTION CASE
BOLTS
Sambungkan breather
Connect the breather hose
hose to pada finalreduction
the final reductioncase
casehose
BREATHER HOSE
hose
joint.joint.
– Rear brake shoes (page 13-5)
- –Rear
Rearbrake
wheelshoes
(page (sepatu
12-4) rem belakang) (hal. 13-5)
- –Roda belakang (hal. 12-4)
Clutch/driven pulley (page 8-17)
- Clutch/driven pulley (hal. 8-16)
Fill the final reduction case with the recommended oil (page
Isi final reduction case dengan oli yang dianjurkan (hal.
3-13).
3-13).
PEMERIKSAAN FINAL REDUCTION

BEARING
FINAL REDUCTION INSPECTION
LEFT CRANKCASE
BEARING
Periksa masing-masing bearing terhadap keausan atau
LEFT CRANKCASE
kerusakan.
Putar
Checkinner race dari
each bearing countershaft
for wear or damage. dan final gear shaft
bearings (lingkaran dalam dari bantalan countershaft FINAL GEAR DRIVESHAFT
Turnfinal
the inner SHAFT BEARING BEARING
dan gearrace of the
shaft) countershaft
dengan and Bearing
jari-jari. final gearharus
shaft
bearings with your finger. The bearing should
berputar dengan halus dan tanpa suara. Juga periksa turn smoothly
and quietly. Also check that the bearing outer race fits tightly
bahwa bearing outer race duduk dengan erat pada
in the crankcase.
crankcase.
Replace the bearings if they do not turn smoothly, quietly, or
Ganti bearings jika mereka tidak berputar dengan halus,
if they fit loosely on the crankcase.
Turn crankcase.
pada the driveshaft with your hand. The bearing should turn
smoothly and quietly. Also check that the bearing outer race
fits tightly
Putar in thedengan
driveshaft crankcase and the
tangan. bearingharus
Bearing inner berputar
race fits
tightly on the driveshaft.
dengan halus dan tanpa suara. Juga periksa bahwa
Replace the
bearing bearings
outer raceif they do not
duduk turn smoothly,
dengan erat diquietly,
dalamor
if they fit loosely on the crankcase and driveshaft.
crankcase dan bearing inner race duduk dengan erat COUNTERSHAFT BEARING
pada driveshaft.
Ganti bearings jika mereka tidak berputar dengan halus,
pada crankcase dan driveshaft.
9-8
FINAL REDUCTION
FINAL
FINALREDUCTION
REDUCTIONCASE
CASE
Check the
Periksa finalreduction
final reduction case
case bearings
bearingsanddan
finalfinal
gear gear
shaft
COUNTERSHAFT BEARING FINAL GEAR
oil seal for wear or damage.
shaft oil seal terhadap keausan atau kerusakan.
SHAFT
Turn each bearing inner race with your finger. BEARING
Putar masing-masing
The bearing should turnbearing inner
smoothly racefriction.
without dengan jari-jari.
Bearing harus berputar dengan halus tanpa
Check that there is no clearance between the outergesekan.
race and
Periksa
the final bahwa
reductiontidak
case. ada kerenggangan antara outer
race dan final reduction case.
FINAL GEAR
SHAFT OIL SEAL
LEFT
LEFTCRANKCASE
CRANKCASECOVER COVER
Lepaskan leftleft
crankcasecover
cover (hal.
(page8-5).
8-5).
DRIVESHAFT BEARING
Putar
Turn theinner race
inner racedari driveshaft
of the driveshaftbearing
bearingdengan jari-jari.
with your finger.
Bearing
The bearingharus berputar
should turn dengan
smoothlyhalus dan tanpa
and quietly. Alsosuara.
check
Juga periksa
that the bearing bahwa bearing
outer race outerinrace
fits tightly duduk dengan
the crankcase cover.
erat padathe
Replace crankcase
bearing if cover.
it does not turn smoothly, quietly, or if
it fits loosely on the crankcase
Ganti bearing jika ia tidak berputar cover. dengan halus, tanpa
suara, atau jika ia duduk dengan longgar pada
crankcase cover.
GEAR/SHAFT
GEAR/SHAFT
DRIVESHAFT
DRIVESHAFT
Periksa
Check thedriveshaft terhadap
driveshaft for tekukan,
bend, wear keausan atau
or damage.
DRIVESHAFT
kerusakan.
9-9
FINAL REDUCTION
COUNTER GEAR/COUNTERSHAFT/FINALGEAR
COUNTER GEAR/COUNTERSHAFT/FINAL GEAR
SHAFT
SHAFT
Check the countershaft, counter gear and final gear shaft for
Periksa countershaft, counter gear dan final gear shaft FINAL GEAR SHAFT
wear or damage.
terhadap keausan atau kerusakan.
COUNTER GEAR COUNTERSHAFT
FINAL REDUCTION BEARING

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

BEARING (6022 UU)
LEFT CRANKCASE
COVER
OIL SEAL
20 x 32 x 6
COUNTERSHAFT
BEARING (6301)
FINAL GEAR SHAFT

BEARING (6302) FINAL REDUCTION
OIL SEAL
CASE
29 x 44 x 7
9-10
FINAL REDUCTION
LEFTCRANKCASE
COVER
Remove the
Lepaskan left
left crankcasecover
crankcase cover (page 8-5).
(hal. 8-5). SNAP RING
Remove the snap ring from the left crankcase cover groove.
Lepaskan snap ring dari alur left crankcase cover.
Lepaskan driveshaftbearing/bushing
Remove the driveshaft bearing/bushing
using the dengan
special
menggunakan
tools. special tools.
TOOLS:
Bearing
TOOLS:remover head, 10 mm 07936-GE00200
Bearing remover shaft, 10
Bearing remover head, 10 mm mm 07936-GE00100
07936-GE00200
Remover weight
Bearing remover shaft, 10 mm 07741-0010201
07936-GE00100
- Jika bearing tertinggal pada left07741-0010201
Remover weight crankcase cover,
lepaskan denganremains
– If the bearing menggunakan
in the lefttools sebagai
crankcase berikut:
cover, remove
TOOLS:
it using the following tools:
Bearing remover head, 15 mm 07936-KC10200
TOOLS:remover shaft, 15 mm
Bearing 07936-KC10100
Bearing remover
Remover weighthead, 15 mm 07936-KC10200
07741-0010201
Bearing remover shaft, 15 mm 07936-KC10100 DRIVESHAFT
Remover weight 07741-0010201 BEARING/BUSHING
Jika bearing tertinggal di

dalam left crankcase cover:
DRIVESHAFT BEARING
Apply engineoli
Semprotkan oilmesin
to the bearing cavity.bearing.
pada rongga
DRIVER
Drive a new
Dorong driveshaft
masuk sebuahbearing into the
driveshaft left crankcase
bearing cover
baru secara
squarely until
tegaklurus keit dalam
is fully seated, using the special
left crankcase cover tools.
sampai ia
telah duduk sepenuhnya, dengan menggunakan special
tools.
TOOLS:
Driver 07749-0010000 ATTACHMENT
TOOLS:
Attachment, 32 x 35 mm 07746-0010100
Driver 07749-0010000
Pilot, 10 mm 07746-0040100
Attachment, 32 x 35 mm 07746-0010100
Pilot, 10 mm 07746-0040100
DRIVESHAFT
BEARING PILOT
9-11
FINAL REDUCTION
Install Install the
ring Pasang
the snap ring
Pasang snapring
snap ringpada
to thealur
left left
crankcase covercover.
crankcase groove.
dengan
SNAP RING
with theujung yang
chamfered
dipotong
edge menghadap
facing the
ke bearing.
bearing.
LEFT
LEFTCRANKCASE
CRANKCASE
Belah final
Separate thereduction case case
final reduction (hal.(page
9-6). 9-6).
SET PLATE
Remove the
Lepaskan two bolts
kedua boltsand
dansetset
plate.
plate.
BOLTS
Hati-hati agar not

Be careful tidakto Lepaskan
Remove thecountershaft danfinal
countershaft and finalgear
gear
shaftshaft bearings
bearings using
merusak permukaan
damage the final dengan menggunakan
the special tools. special tools.
penyatuan
reduction final
case mating
reduction case. TOOLS:
surface. TOOLS:
Countershaft bearing:
Bearing removerhead,
Bearing remover head,1212
mmmm 07936-1660110
07936-1660110
Bearing removershaft,
Bearing remover shaft,
1212
mmmm 07936-1660120
07936-1660120
Remover weight
Remover weight 07741-0010201
07741-0010201
Final
Finalgear
gear shaft bearing:
shaft bearing:
Bearing remover head,
Bearing remover head, 1515
mmmm 07936-KC10200
07936-KC10200
Bearing remover shaft, 15
Bearing remover shaft, 15 mmmm 07936-KC10100
07936-KC10100
Remover weight
Remover weight 07741-0010201
07741-0010201
FINAL GEAR COUNTERSHAFT
SHAFT BEARING BEARING
9-12
FINAL REDUCTION
Apply engine
Oleskan oil topada
oli mesin each bearing cavity. rongga bearing.
masing-masing
Drive each new bearing into the left crankcase baru
Sisi yang
Dorong masuk masing-masing bearing squarely until
secara
The bertanda dariof
marked side it is fully seated, using the special tools.
masing-masing bearing tegaklurus ke dalam left crankcase sampai ia duduk COUNTERSHAFT
each bearing is facing
menghadap ke special sepenuhnya,
TOOLS: dengan menggunakan special tools. BEARING
the special tools.
tools. Countershaft bearing:
TOOLS:
Driver 07749-0010000
Attachment, 37 x 40 mm 07746-0010200
Driver 07749-0010000
Pilot, 12 mm 07746-0040200
Attachment, 37 x 40 mm 07746-0010200
Final gear shaft bearing:
Pilot, 12 mm 07746-0040200
FinalDriver
gear shaft bearing: 07749-0010000
Attachment,
Driver 42 x 47 mm 07746-0010300
07749-0010000
Pilot, 15 mm 42 x 47 mm
Attachment, 07746-0040300
07746-0010300 FINAL GEAR
Pilot, 15 mm 07746-0040300 SHAFT BEARING
DRIVER
ATTACHMENT
BEARING PILOT
Bersihkan dan oleskan

Clean and apply cairanto pengunci
locking agent pada
the set plate bolt ulir set
threads
SET PLATE
from bolt
plate its tip to 6.5
dari ± 1.0 mm
ujungnya (0.26 ±
sampai 0.04
6,5 in) mm
± 1,0 down.
ke bawah.
Install the set plate with its "OUT" mark facing out. TANDA"OUT"
Pasang set plate dengan tanda "OUT" padanya
Install and tighten
menghadap the set plate bolts.
ke luar.
Pasang dan kencangkan set plate bolts.
6.5 ± 0.1 mm
(0.26 ± 0.04 in)
BOLTS
DRIVESHAFT
DRIVESHAFT
Remove the two bolts and set plate.
SET PLATE
Lepaskan kedua bolts dan set plate.
BOLTS
9-13
FINAL REDUCTION
Lepaskan driveshaft
Remove the driveshaftdengan menggunakan
using the special tool. special tool.
DRIVESHAFT
TOOL:
TOOL:
Case puller 07SMC-0010001
CASE PULLER
CASE PULLER
DRIVESHAFT
Remove the
Lepaskan snapring
snap ringdari
from thedriveshaft.
alur driveshaft groove.
SNAP RING
Remove thedriveshaft
Lepaskan driveshaft bearing
bearingusing a hydraulic
dengan press.
menggunakan BEARING
hydraulic press.
DRIVESHAFT
9-14
FINAL REDUCTION
Lepaskan driveshaft
Remove the driveshaftoiloilseal.
seal.
DRIVESHAFT OIL SEAL
Sisi yang bertanda dari Semprotkan to the pada
bearing cavity.bearing.
rongga
Drive a new driveshaft bearing into the left crankcase DRIVESHAFT BEARING DRIVER
masing-masing bearing
The marked
menghadap ke special squarely until
side of Dorong masuk it is fully seated,driveshaft
sebuah using the special tools.secara
bearing
each bearing is tools.
facing tegaklurus ke dalam left crankcase sampai ia duduk
TOOLS:
the special tools. sepenuhnya, dengan menggunakan special tools.
Driver 07749-0010000 ATTACHMENT
TOOLS: 07746-0010300
Pilot, 20 mm
Driver 07746-0040500
07749-0010000
Attachment, 42 x 47 mm 07746-0010300
Pilot, 20 mm 07746-0040500
DRIVESHAFT BEARING PILOT
Install the
Pasang driveshaftkeinto
driveshaft the bearing.
dalam bearing. DRIVESHAFT ASSEMBLY
Position the assembly
Tempatkan assembly collar collar on pada
the driveshaft bearing
driveshaft inner
bearing BEARING COLLAR
race and pull the drive shaft into the bearing until
inner race dan tarik keluar drive shaft ke dalam bearing it is fully
seated.
sampai ia duduk sepenuhnya. ASSEMBLY
SHAFT
TOOLS:
TOOLS:
Assembly shaft
Assembly shaft 07965-1660200
07965-1660200
Assembly collar
Assembly collar 07965-GM00100
07965-GM00100
Assembly collarattachment
Assembly collar attachment 07965-GM00200
07965-GM00200
ASSEMBLY COLLAR
ATTACHMENT
ASSEMBLY
COLLAR
DRIVESHAFT ATTACHMENT
BEARING
ASSEMBLY
ASSEMBLY COLLAR SHAFT
9-15
FINAL REDUCTION
Pasang
Install thesnap
snapring Install the
ring Pasang snapring
snap ringpada
to thealur
driveshaft groove.
driveshaft.
dengan ujungnya yang
with the chamfered SNAP RING
dipotong edge
menghadap ke
facing the
bearing.
bearing.
Semprotkan
Apply engineoli
oilmesin pada
to a new bibir driveshaft
driveshaft oil seal lip.oil seal baru.
DRIVESHAFT ASSEMBLY COLLAR
Jangan
Do notmasukkan
insert theoil
oil Pasang driveshaft
Install the driveshaftoiloilseal
seal sampai
until it isia flush
rata with
dengan left
the left OIL SEAL
seal terlalu dalam
seal too far . crankcase.
crankcase.
TOOLS:
TOOLS:
Assembly shaft
Assembly shaft 07965-1660200
07965-1660200 ASSEMBLY
Assembly collar 07965-GM00100
Assembly collar 07965-GM00100 SHAFT
ASSEMBLY COLLAR ATTACHMENT
ASSEMBLY COLLAR
ATTACHMENT
ASSEMBLY
COLLAR
DRIVESHAFT ASSEMBLY
OIL SEAL SHAFT
Bersihkan dan locking

Clean and apply oleskanagent
cairan pengunci
to the pada ulir set
set plate bolt
SET PLATE
plate bolt
threads dariitsujungnya
from tip to 6.5 sampai
± 1.0 mm 6,5 ± 1,0
(0.26 mm in)
± 0.04 ke down.
bawah.
Install the set plate with its "OUT" mark facing out. TANDA"OUT"
Pasang set plate dengan tanda "OUT" menghadap
keluar.
Install and tighten the set plate bolts.
Pasang dan kencangkan set plate bolts.
6.5 ± 0.1 mm
(0.26 ± 0.04 in)
BOLTS
9-16
FINAL REDUCTION
FINAL
FINAL REDUCTION
REDUCTION CASE
CASE
Separate the final reduction case (page 9-6).
Belah final reduction case (hal. 9-6). COUNTERSHAFT FINAL GEAR
Be careful not to Remove the final gear shaft oil seal. BEARING SHAFT BEARING
Hati-hati agar tidak Lepaskan final gear shaft oil seal.
damage
merusak the final
permukaan Remove the final gear shaft bearing.
reduction final Lepaskan final gear shaft bearing.
case mating
penyatuan
cace Remove the countershaft bearing using the special tools.
surface.
reduction
Lepaskan countershaft bearing dengan menggunakan
special tools.
TOOLS:
TOOLS:
Bearing remover
Bearing remover head,
head,1212mm
mm 07936-1660110
07936- OIL SEAL
Bearing remover shaft, 12 mm
1660110 07936-1660120
Removerremover
Bearing weight shaft, 12 mm 07741-0010201
07936-
1660120
Remover weight 07741-
0010201
Semprotkan oli to mesin

Apply engine oil pada bearing
the countershaft ronggacavity.
countershaft
DRIVER
bearing.
The marked side of Drive a new final gear shaft bearing into the final reduction
Sisi yang di tandai dari Dorong masuk final gear shaft bearing baru secara
bearing is facing the case squarely until it is fully seated, using the special tools.
masing – masing tegaklurus ke dalam final reduction case sampai duduk
bantalan special tools.
menghadapi sepenuhnya, dengan menggunakan special tools.
special tools. TOOLS:
Driver
TOOLS: 07749-0010000
ATTACHMENT
Driver
Attachment, 32 x 35 mm 07749-
07746-0010100
0010000
Pilot, 12 mm 07746-0040200
0010100
Pilot, 12 mm 07746-
0040200
COUNTERSHAFT BEARING PILOT
Semprotkan oli tomesin

Apply engine oil the finalkegearrongga final cavity.
shaft bearing gear shaft
DRIVER
bearing.
The marked
Hati-hati agarside
tidakof Drive a new final gear shaft bearing into the final reduction
Dorong masuk final gear shaft bearing secara
bearing is facing the case squarely until it is fully seated, using the special tools.
merusak permukaan tegaklurus ke dalam final reduction case sampai ia
special tools.
penyatuan final
duduk sepenuhnya, dengan menggunakan special
reduction cace TOOLS:
tools.
Driver 07749-0010000
TOOLS:
Attachment, 40 x 42 mm 07746-0010900 ATTACHMENT
Driver
Pilot, 22 mm 07749-
07746-0041000
0010000
0010900
Pilot, 22 mm 07746- FINAL GEAR
0041000 SHAFT BEARING PILOT
Apply engineoli
Semprotkan oilmesin
to a new finalbibir
pada g earfinal
shaftgear
oil seal lip. oil sea
shaft DRIVER
baru.
Install the oil seal with the flat side facing the rear wheel side
so that the depth from the final reduction case surface is 1.0 ±
Pasang
0.4 mm oil seal
(0.04 dengan sisinya yang datar menghadap
± 0.02 in) using the special tools. ATTACHMENT
ke sisi roda belakang sehingga kedalamannya dari
permukaan final reduction case adalah 1,0 ± 0,4 mm
TOOLS:
dengan menggunakan special tools.
Driver 07749-0010000
TOOLS: 07746-0010300
Driver 07749-
0010000
Attachment, 42 x 47 mm 07746- 1.0 ± 0.4 mm
0010300 (0.04 ± 0.02 in)
FINAL GEAR SHAFT OIL SEAL
9-17
CATATAN
10. CRANKCASE/CRANKSHAFT
LOKASI KOMPONEN ............................10-2 PEMBELAHAN CRANKCASE...............10-5

COMPONENT LOCATION ·························· 10-2 CRANKCASE SEPARATION ·······················10-5
KETERANGAN SERVIS ........................10-3 PERAKITAN CRANKCASE ...................10-8

SERVICE INFORMATION ···························10-3 CRANKCASE ASSEMBLY ···························10-8
TROUBLESHOOTING ...........................10-4 PEMERIKSAAN CRANKSHAFT ........... 10-12

TROUBLESHOOTING ··································10-4 CRANKSHAFT INSPECTION····················10-12
10
10-1
COMPONENT LOCATION
10-2
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
• This section covers the crankcase separation to service the crankshaft.
?• TheBabfollowing parts pembelahan
ini meliputi must be removed before separating
crankcase the crankcase.
untuk menservis crankshaft.
• ? Engine (page 6-4)
Parts berikut ini harus dilepaskan sebelum membelah crankcase.
? Cylinder
- Mesin head
(hal. (page
6-4) 7-14)
? Cylinder (page
- Cylinder head 7-32)
(hal. 7-14)
? Piston (page 7-34)
- Cylinder (hal. 7-32)
? Starter
- Piston pinion
(hal.(page
7-34)16-10)
? Drive pulley (page
- Starter pinion (hal. 8-12)
16-10)
? Clutch/driven
- Drive pulley (hal. (page
pulley 8-11) 8-16)
? Starter motor (page
- Clutch/driven 16-6)(hal. 8-15)
pulley
? Flywheel/stator (page 14-7)
- Starter motor (hal. 16-6)
? In addition to the parts listed above, remove the following parts when the left crankcase must be replaced.
- Flywheel/stator (hal. 14-8)
? Final reduction (page 9-6)
• Selain parts yang disebut di a tas, lepaskan parts berikut ini jika left crankcase harus diganti.
? In addition to the parts listed above, remove the following parts when the right crankcase must be replaced.
- Final reduction
? Oil pump (page 4-4) (hal. 9-6)
?• BeSelain parts
careful not toyang
damage disebut di a tas, lepaskan parts
the crankcase berikut
mating surfaces when ini jika right
separating crankcasethe
and assembling harus diganti.
crankcase halves.
- Oil pump (hal. 4-4)
? Clean all disassembled parts with clean solvent and dry them using compressed air before inspection.
Hati-hati
?• When agarthe
installing tidak merusak
crankshaft, be permukaan penyatuan
sure to use the crankcase
special tools; sewaktu
position the specialmembelah
tools on thedan merakit
bearing innerbelahan
race and crankcase.
pull the crankshaft into
• theBersihkan semua
bearing until parts
it is fully yang dibongkar dengan cairan pelarut bersih dan keringkan dengan udara dari kompressor
seated.
sebelum pemeriksaan.
• Sewaktu memasang crankshaft, pastikan untuk memakai special tools; tempatkan special tools pada bearing inner race
SPECIFICATIONS
dan tarik crankshaft ke dalam bearing sampai ia duduk sepenuhnya.
Unit: mm (in)
SPESIFIKASI Satuan: mm SERVICE
ITEM
BAGIAN STANDARD STANDARD BATAS SERVIS LIMIT
Crankshaft
Crankshaft Jarak renggang
Connecting rod ke
sidesamping
clearanceconnecting rod 0.10
0,10 – 0,35
– 0.35 (0.004 – 0.014) 0,55 0.55 (0.022)
Jarak renggang
Connecting rod radial connecting rod
radial clearance 0 –00.012
– 0,012
(0 – 0.0005) 0,05 0.05 (0.002)
Keolengan
Runout - – 0,10 0.10 (0.004)
TOOLS
TOOLS
Case puller Assembly shaft Assembly collar

07SMC-0010001 07965-VM00200 07965-VM00100
Assembly shaft adaptor Assembly collar Attachment, 62 x 68 mm

07WMF-KFF0200 07931-KF00100 07746-0010500
10-3
Pilot, 35 mm Driver Oil seal driver

07746-0040800 07749-0010000 07965-KE80200
Fork seal driver attachment 41.2 mm Universal bearing puller Attachment, 24 x 26 mm

07947-KF00100 07631-0010000 07746-0010700
TROUBLESHOOTING
TROUBLESHOOTING
Abnormal
Suara noise
tidak normal
? Worn crankshaft bearing
• Crankshaft bearing aus
? Worn connecting rod big end bearing
• Connecting rod big end bearing (bantalan kepala
? Worn connecting rod small end (page 7-37)
besar connecting rod)
• Connecting rod small end (kepala kecil connecting
rod) aus (hal. 7-37)
10-4
CRANKCASE SEPARATION
PEMBELAHAN CRANKCASE
Refer keterangan
Lihat to service information (page
servis (hal. 10-3) for
10-3) untukthe parts mana
parts which
must be removed before separating the crankcase.
yang harus dilepaskan sebelum membelah crankcase.
Unhook the centerstand return spring.
Lepaskan kaitan dari centerstand return spring (pegas
pengembalian standard utama).
RETURN SPRING
Lepaskan cotter
Remove the cotterpin
pindan
and washer.
washer.
COTTER PIN
WASHER
Remove the
Lepaskan bolt
bolt andcollar
dan collardari pivot
from the pivot shaft.
shaft.
BOLT COLLAR
Pull out
Tarik the pivot shaft
keluar pivot shaftand
danremove the centerstand.
lepaskan centerstand.
PIVOT SHAFT CENTERSTAND
Lepaskan crankcase
Remove the crankcasebolts dari right
bolts from crankcase.
the right crankcase.
BOLTS
10-5
Be careful
Hati-hati agar not Place the crankcase
to Letakkan
tidak crankcasewith the left
dengan leftcrankcase facing
crankcase down and
menghadap RIGHT CRANKCASE
merusak permukaan
damage the ke separate
bawahthe leftpisahkan
dan and right left
crankcase.
dan right crankcase.
penyatuan crankcase.
crankcase mating
surface.
LEFT CRANKCASE
Lepaskan dowel
Remove the dowelpins
pinsdari
fromleft
thecrankcase.
left crankcase.
DOWEL PINS
Lepaskan oiloil
Remove the seal
sealdari
fromright
the crankcase.
right crankcase.
OIL SEAL
Release the cam

Lepaskan camchain from dari
chain the timing sprocket
timing on the crank-
sprocket pada
shaft using a screwdriver
crankshaft as shown.
dengan menggunakan obeng seperti SCREWDRIVER CAM CHAIN
diperlihatkan.
TIMING SPROCKET
10-6
Sewaktu melepaskan
When removing the Hold the cam
Pegang cam chain
chainoffterlepas
the timing sprocket
dari timingand remove dan
sprocket the
crankshaft, LEFT CRANKCASE
crankshaft, beberhati-
careful crankshaft from
keluarkan the left crankcase
crankshaft usingcrankcase
dari left the case puller.
dengan
nothatilah agar
to pinch thetidak
cam menggunakan CRANKSHAFT
menjepit cam chain Remove the camcase puller.
chain.
chain between timing
antara timing sprocket CASE PULLER
sprocket and left Lepaskan cam chain.
dan left crankcase. TOOL:
crankcase.
TOOL:
CAM CHAIN
(Jangan di jepit)
CASE PULLER
CRANKSHAFT
Remove snap
Lepaskan ringring
snap anddan
oil seal.
oil seal.
SNAP RING
OIL SEAL
10-7
Lepaskan
Remove theleft crankshaft
left crankshaft bearing dengan
bearing using the menggunakan
special tool.
special tool. BEARING CRANKSHAFT
TOOL:
Universal bearing puller
TOOL: 07631-0010000
Universal bearing puller 07631-0010000
? If the left crankshaft bearing remains in the crankcase,
remove it to the right side.
- Jika left crankshaft bearing tertinggal pada crankcase,
lepaskan ke sisi kanan.
BEARING PULLER
Jika left crankshaft bearing

tertinggal pada crankcase:
LEFT CRANKSHAFT BEARING
PERAKITAN CRANKCASE
CRANKCASE ASSEMBLY
Hati-hati agar not
Be careful tidak Clean the inside
to Bersihkan bagianand mating
dalam surface
dan of the crankcases.
permukaan penyatuan dari
merusak permukaan Check for cracks or other damage.
damage the crankcases. PERMUKAAN PENYATUAN
penyatuan crankcase.
crankcase mating Periksa terhadap retak-retak atau kerusakan lain.
Remove any roughness or irregularities with an oil stone.
surface.
Buanglah kekasaran atau ketidak-teraturan dengan batu
asah.
Apply 2 cc minimum
Semprotkan minimumof2engine
cc oli oil to a pada
mesin new left crankcase
sebuah left
bearing. bearing baru.
crankcase DRIVER
Drive the left crankcase bearing into the left crankcase

Dorong
squarelymasuk
until it left crankcase
is fully bearing
seated, using secaratool.
the special tegaklurus
ke dalam left crankcase sampai ia duduk sepenuhnya,
dengan menggunakan special tool.
TOOLS: ATTACHMENT
Driver
TOOLS: 07749-0010000
Attachment,
Driver 62 x 68 mm 07746-0010500
07749-0010000
07746-0010500
Pilot, 35 mm 07746-0040800
PILOT
LEFT CRANKCASE BEARING
10-8
Install the
Pasang crankshaftke
crankshaft into the left
dalam leftcrankcase
crankcasebearing.
bearing.
ASSEMBLY SHAFT ASSEMBLY COLLAR B
Install the
Pasang assemblyshaft
assembly shaftadaptor
adaptor to the left
pada left crankshaft.
crankshaft. ADAPTOR
Position the assembly
Tempatkan assemblycollar A on
collar A the left crankcase
pada bearing
left crankcase
inner race and set the assembly collar B to the
bearing inner race (lingkaran dalam bantalan crankcase assembly col-
lar A.
kiri) dan tempatkan assembly collar B pada assembly
collar
InstallA.the assembly shaft to the assembly collar B and screw
it onto the crankshaft while aligning the center of the assem-
Pasang
bly collarassembly
B and the shaft
assemblypada assembly collar B dan
shaft.
sekrupkan pada crankshaft sementara mentepatkan
Pull thetengah
When pulling the bagian crankshaft intoassembly
dari the bearingcollar
until itBis dan
fully seated.
assembly
Sewaktu menarik
crankshaft into the shaft.
crankshaft
bearing, ke
be dalam
careful TOOLS:
bearing, berhati-hatilah
not to damage the Tarik crankshaft ke dalam bearing sampai ia duduk
agar tidak merusak Assembly shaft adaptor 07WMF-KFF0200 ASSEMBLY COLLAR A ASSEMBLY SHAFT
connecting rod . sepenuhnya.
connecting rod. Assembly shaft 07965-VM00200
Assembly collar A 07965-VM00100 ASSEMBLY ASSEMBLY
TOOLS:
Assembly collar B 07931-KF00100 COLLAR A SHAFT
Assembly shaft adaptor 07WMF-KFF0200
Assembly shaft 07965-VM00200 CRANKSHAFT
Assembly collar A 07965-VM00100
Assembly collar B 07931-KF00100
ASSEMBLY SHAFT
ADAPTOR ASSEMBLY COLLAR B
Apply engine
Oleskan oil topada
oli mesin a newbibir
o il seal lip.
oil seal.
DRIVER
Install the
Pasang oiloil sealsecara
seal to the right crankcase
tegaklurus squarely
pada right as shown.
crankcase
seperti diperlihatkan. OIL SEAL
TOOLS: ATTACHMENT
TOOLS:
Driver 07749-0010000
Driver
Attachment, 24 x 26 mm 07749-0010000
07746-0010700 10.4-10.9 mm
(0.41-0.43 in)
Attachment, 24 x 26 mm 07746-0010700
OIL SEAL
Apply liquid
Oleskan sealant
liquid (Three
sealant Bond 1207B
(cairan or three
perapat) bondBond
(Three 1215
or equivalent)
1207B to the crankcase
atau Three Bond 1215 mating
atausurface.
sejenisnya) pada
permukaan penyatuan crankcase.
10-9
Apply 2 cc minimum
Semprotkan of engine
minimum 2 cc oilolito right
mesin crankshaft
pada bear-
right
ing.
crankshaft bearing.
Apply 3 cc minimum of engine oil to connecting rod big end.
Semprotkan minimum 3 cc oli mesin pada connecting
Install
rod big the dowel pins to the left crankcase.
end.
Pasang dowel pins pada left crankcase.
DOWEL PINS
Rakit left dan

Assemble the right crankcase.
left and right crankcase.
RIGHT CRANKCASE
LEFT CRANKCASE
Install the
Pasang crankcasebolts
crankcase bolts dan
and tighten them indalam
kencangkan a crisscross
pola
pattern in 2 -dalam
bersilangan 3 steps.2 – 3 langkah. BOLTS
Semprotkan
Apply engineolioil mesin padasprocket
to the timing timing and
sprocket dan cam
cam chain.
chain.
Install the cam chain to the timing sprocket.
CAM CHAIN
Pasang cam chain pada timing sprocket.
TIMING SPROCKET
10-10
Apply engine
Oleskan oil to apada
oli mesin new bibir
o il seal
oil lip.
seal baru. OIL SEAL DRIVER
Install theoiloil
Pasang sealsecara
seal to the left crankcase
tegaklurus squarely
pada until it is
left crankcase
fully seated,
sampai using the
ia duduk special tool. dengan menggunakan
sepenuhnya,
special tool.
FORK SEAL
TOOLS: DRIVER
TOOLS:
Oil seal driver 07965-KE80200 ATTACHMENT
Oil seal driver
Fork seal driver attachment, 07965-KE80200
Fork seal
41.2 mm driver attachment, 07947-KF00100
41.2 mm 07947-KF00100
OIL SEAL
Set the snap ring

Tempatkan snapinto thepada
ring left crankcase groove.
alur left crankcase.
SNAP RING
Oleskan lapisan
Apply thin coat tipisto the
of grease gemuk padapivot
centerstand permukaan
shaft sur- COLLAR 6.5 ± 0.1 mm
centerstand
face. pivot shaft (poros engsel standard utama).
(0.26 ± 0.04 in)
Install the centerstand and insert the pivot shaft from the left PIVOT SHAFT
Pasang
crankcasecenterstand
side. dan masukkan pivot shaft dari sisi
left crankcase.
Install the collar to the pivot shaft.
Pasang
Clean and collar
applypada pivot
pada pivotagent
locking shaft.
shaftto
. the pivot shaft mounting
bolt threadsdan
Bersihkan fromoleskan
its tip to locking
6.5 ± 1.0 mm (0.26
agent (cat ± 0.04 in)
pengunci)
down, then install and tighten it.
pada ulir pivot shaft mounting bolt (baut pemasangan
poros engsel) dari ujungnya sampai 6,5 ± 1,0 mm
kebawah, kemudian pasang dan kencangkan.
CENTERSTAND BOLT
Pasang washer
and cotter pin baru.
new cotter pin.
COTTER PIN
WASHER
10-11
Hook thecenterstand
Kaitkan centerstand return
returnspring.
spring (pegas pengembalian
standard utama).information (page 10-3)
Refer to service 10-3) for installation of
parts removed to perform crankcase
crankcase service.
Bacalah keterangan servis (hal. 10-3) untuk
pemasangan dari parts yang telah dilepaskan untuk
menjalankan servis crankcase.
RETURN SPRING
PEMERIKSAAN CRANKSHAFT
CRANKSHAFT INSPECTION
Remove the
Lepaskan crankshaft(hal.
crankshaft (page10-5).
10-5).
10-5).
RIGHT CRANKCASE BEARING
Turn the
Putar outerouter racedari
race of theright
rightcrankshaft
crankshaft bearing
bearingwith your
dengan
finger. The bearing should turn smoothly and
ari-jari. Bearing harus berputar dengan halus dan tanpa quietly. Also
check that
suara. Jugatheperiksa
bearingbahwa
inner race fits tightly
bearing on theduduk
inner race right
crankshaft.
dengan erat pada right crankshaft.
Replace
Ganti the bearings
bearings if they
apabila do not turn
mereka tidaksmoothly,
berputarquietly,
dengan or
if they fit loosely on the right crankshaft.
halus, tanpa suara, atau jika mereka duduk dengan
longgar pada right crankshaft.
Jika gigi timing sprocket

aus
If atau rusak,sprocket
periksa Check the
the timing Periksa oiloilpump
pump drive
drive gear
gearand
dantiming
gigi sprocket teeth for
timing sprocket
cam chain, tensioner
teeth are worndan
or wear or damage. OIL PUMP DRIVE GEAR
cam sprocket.
damaged, check the
cam chain, tensioner
and cam sprocket.
TIMING SPROCKET
Ukur jarakthe
Measure renggang ke rod
connecting samping connecting
big end rod big
side clearance end
with a
dengan feeler gauge.
feeler gauge. FEELER GAUGE

SERVICE
LIMIT: 0.55 mm (0.022 in)
10-12
Set the crankshaft
Tempatkan on V-blocks
crankshaft and measure
pada V-blocks dantheukur
connecting
jarak
rod big end radial clearance.
renggang radial connecting rod big end.

SERVICE
LIMIT: 0.05 mm (0.002 in)
Set the crankshaft on V-blocks and measure the runout using

a dial indicator.
Actual runoutcrankshaft
Tempatkan is 1/2 of total indicator reading. dan ukur
pada V-blocks
keolengan dengan menggunakan dial indicator.
Keolengan
SERVICE sebenarnya adalah ½ dari pembacaan total
indicator.
LIMIT: 0.10 mm (0.004 in)
65 mm 35 mm
(2.6 in) (1.4 in)
10-13
CATATAN
11. RODA DEPAN/SUSPENSI/KEMUDI
COMPONENT
COMPONENT LOCATION ················
·······················
··········
··· 11-2 FORK ................
.................................
FORK ·················
········ .............................11-11
··················
·················
···············............11-11
···············
·················
·············11-11
····11-11
KETERANGAN SERVIS
SERVICE INFORMATION
INFORMAT ....................
........................
ION ··············· ....11-3
······················· 11-3
············11-3
····11-3 HANDLEBAR.................
HANDLEBAR
HANDLEBAR .................................11-19
HANDLEBAR ················
······· ................11-19
················
···············
················
················
·········· 11-19
TROUBLESHOOTING
TROUBLESHOOTING................
TROUBLESHOOTING...........................11-6
················ ...........11-6
·························
··················11-6
·········11-6 STEERING STEM ................
..........................11-21
STEERING STEM········ ..........11-21
························· ········ 11-21
RODA DEPAN.................................
DEPAN.............
FRONT ...........................11-7
WHEEL····················· .......11-7
························· 11-7
11
11-1
COMPONENT LOCATION
FRONTWHEEL/SUSPENSION/STEERING
1 N·
N·m (0.1 kgf ·m, 0.7 lbf ·ft)
4.5 N·
N·m (0.5 kgf ·m, 3.3 lbf ·ft)
59 N·
N·m (6.0 kgf ·m, 44 lbf ·ft)
64 N·
N·m (6.5 kgf ·m, 47 lbf ·ft)
59 N·
N·m (6.0 kgf ·m, 44 lbf ·ft)
11-2
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
! PERINGATAN
Frequentmenghirup
Seringkali inhalation ofdebu
brakebrake
pad and
pad shoe
dandust, regardless
shoe, apapunofkomposisi
material composition
bahannya,could
dapatbemembahayakan
hazardous to your health.
kesehatan.
• Avoid breathing dust particles.
• Jangan menghirup partikel-partikel debu.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
• Jangan sekali-kali memakai slang udara atau sikat untuk membersihkan susunan rem. Pakailah alat penghisap debu yang
baik.
• This section covers the front wheel, fork, handlebar and steering stem.
• Bab ini
• When meliputi
servicing theroda
frontdepan, fork or
wheel, fork (garpu), handlebar
steering (stang
stem, support the stir) danusing
scooter steering
a jackstem (poros
or other kemudi).
support.
•• AKetika menservis roda depan, fork atau steering stem, dukung skuter dengan menggunakan
contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated dongkrakdiscatau alata pendukung
with high quality
lain.
brake degreasing agent.
• Brake
• After thedisc
frontatau pad yang terkontaminasi
wheel installation, check the brakemengurangi
operation bydaya pengereman.
applying Buanglah pads yang terkontaminasi dan bersihkan
the brake lever.
disc
• For yang
brake terkontaminasi
system dengan
service, refer to pagebahan
13-3. pembersih gemuk berkualitas tinggi untuk peralatan rem.
• Setelah pemasangan roda depan, periksa cara kerja rem dengan menarik brake lever (handel rem).
• Untuk servis sistem rem, lihat hal. 13-3.
SPECIFICATIONS
Unit: mm (in)
SPESIFIKASI
SERVICE
ITEM STANDARD Satuan: mm
LIMIT
BAGIAN STANDARD BATAS SERVIS
Minimum tire tread depth – To the indicator
Kedalaman minimum alur kembang ban - 2 Sampai ke indikator
Cold tire pressure Driver only 200 kPa (2.00 kgf/cm
2 , 29 psi) –
Tekanan udara ban Pengendara saja 200 kPa (2,00 kgf/cm , 29 2 psi) -
Driver and passenger 200 kPa (2.00 kgf/cm
2 , 29 psi) –
(dingin) Pengendara dan pembonceng 200 kPa (2,00 kgf/cm , 29 psi) -
Axle runout – 0.2 (0.01)
Keolengan poros roda - 0,2
Wheel rim runout Radial – 2.0 (0.08)
Keolengan pelek roda Radial - 2,0
Axial – 2.0 (0.08)
Aksial - 2,0
Fork Spring free length 311.3 (12.26) 305.1 (12.01)
Fork Panjang bebas pegas 311,3 305,1
Pipe runout – 0.2 (0.01)
Keolengan pipe - 0,20
Recommended fluid Fork fluid –
Fluida garpu yang dianjurkan Fluida garpu (minyak sokbreker) -
Fluid level 50 (2.0) –
Tinggi permukaan fluida 50 -
Fluid capacity 75 ± 1
3 cm (2.5 ± 0.03 US oz,
3
–
Kapasitas fluida 75 ± 1 cm -
2.6 ± 0.04 Imp oz)
NILAI TORSI
TORQUE
Front axle nutVALUES 59 N.m (6,0 kgf.; 44 lbf.ft) U-nut
Front brake disc socket bolt 42 N.m (4,3 kgf.m; 31 lbf.ft) ALOC bolt; ganti dengan yang baru
Front axlepost
Handlebar nut nut 59 N·m
59 N.m (6,0(6.0 kgf·m,
kgf.m; 4444 lbf·ft)
lbf.ft) U-nut
Front
Rear brakelever
brake disc pivot
socketbolt
bolt 42 N·m
1 N.m (0,1 (4.3 kgf·m,
kgf.m; 0,7 31 lbf·ft)
lbf.ft) ALOC bolt; replace with new ones
Handlebar post nut
Rear brake lever pivot nut 59 N·m (6.0 kgf·m, 44 lbf·ft)
4,5 N.m (0,5 kgf.m; 3,3 lbf.ft)
Rear brake
Bottom bridgelever pivot
pinch bolt
bolt 1 N·m (0.1 kgf·m, 0.7 lbf·ft)
64 N.m (6,5 kgf.m; 47 lbf.ft)
Rear
Fork brake bolt
socket lever pivot nut 4.5 N·m
20 N.m (2,0(0.5 kgf·m,
kgf.m; 15 3.3 lbf·ft)
lbf.ft) Oleskan locking agent pada ulir
Bottomstem
Steering bridgetop
pinch bolt
thread 64hal.
Lihat N·m11-22
(6.5 kgf·m, 47 lbf·ft)
Steering stem lock nut
Fork socket bolt Lihat
20hal.
N·m11-22
(2.0 kgf·m, 15 lbf·ft) Apply locking agent to the threads
Steering stem top thread See page 11-22
Steering stem lock nut See page 11-22
11-3
TOOLS
Bearing remover shaft Bearing remover head, 12 mm Driver

07746-0050100 07746-0050300 07749-0010000
Attachment, 32 x 35 mm Pilot, 12 mm Fork seal driver body

07746-0010100 07746-0040200 07747-0010100
Fork seal driver attachment, 27.2 mm Pin spanner Socket wrench

07747-0010300 07702-0020001 07916-KM10000
Steering stem socket Ball race remover shaft Ball race remover, 34.5 mm
07916-3710101 07GMD-KS40100 07948-4630100
11-4
Bearing driver attachment Oil seal driver, 53.5 mm Fork seal driver attachment, 35.2 mm
07946-3710701 07947-SB00200 07947-KA20200
Oil seal remover

07748-0010001
11-5
TROUBLESHOOTING
TROUBLESHOOTING
Hard steering
Kemudi berattire pressure
• Insufficient
• Tekanan
• Faulty tire udara ban kurang
Ban rusak
• Steering stem lock nut too tight
•
• Steering
• Faulty stem
steering lockbearing
head nut terlalu kencang
• Faulty
• steering
Steering head head bearing
bearing race
rusak
• Bent
• steering
Steering stembearing race rusak
head
• Steering
Steers to one sidestem orbengkok
does not track straight
• Bent front axle
Kemudi
• Wheelmenarik ke satu sisi atau tidak dapat berjalan lurus
installed incorrectly
Front axle bengkok
• Worn or damaged front wheel bearings
•
• Bent
• Rodafork
tidak terpasang dengan benar
• Worn
• or damaged
Bearings engineaus
roda depan mounting bushings
atau rusak
•
• Bent frame
Fork bengkok
• Faulty
• Enginesteering
mountinghead bushings
bearing aus atau rusak
Front
• Rangka bengkok
wheel wobbles
•
• Loose front
Steering head axle fasteners
bearing rusak
• Bent rim
• Worn
Roda or damaged
depan bergoyang front wheel bearings
•
Front wheel turns hard longgar
Pengikat front axle
• Pelek
• Front bengkok
brake drag
• Bearings
• Bent front axleroda depan aus atau rusak
• Faulty front wheel bearings
Roda depan berat perputarannya
Soft suspension
• Rem depan menyangkut
• Low tire pressure
• Front axle fork
• Deteriorated bengkok
fluid
• Bearings roda
• Incorrect fork fluid depan
weightrusak
• Insufficient fluid in fork
Suspensi
• Weak fork lunakspring
• Tekanan udara ban rendah
Hard suspension
• Fork fluid memburuk kondisinya
• High tire pressure
• Berat fork fluidintidak
• Too much fluid fork benar
• Tidak ada cukup
• Incorrect fork fluid weightfluid di dalam fork
• Fork spring
• Bent fork pipes lemah
• Clogged fork fluid passage
Suspensi Keras
Suspension noisy
• Tekanan udara ban tinggi
• Bent fork slider
• Terlalu banyak fluid di dalam fork
• Insufficient fluid in fork
• Beratfork
forkfasteners
fluid tidak benar
• Loose
• Fork pipes bengkok
• Jalan lintasan fork fluid tersumbat
Suspensi berisik
• Fork slider bengkok
• Fluid di dalam fork kurang
• Pengikat fork longgar
11-6
FRONTDEPAN
RODA WHEEL
Raise and support
Naikkan the scooter
dan dukung using dengan
skuter safety stand.
menggunakan
dongkrak.
Remove/install the following:
Lepaskan/pasang sebagai berikutnya:
– Speedometer cable
- Speedometer
– O-ring cable
- O-ring
– Axle nut
- Axle
– nuaxle
Front t
- Front axle
– Front wheel
- Roda
– Side depan
collar
- Side collar
– Speedometer gearbox
- Speedometer gearbox
CATATAN:
• Replace the speedometer cable O-ring with a new one.
• Ganti speedometer cable O-ring dengan yang baru.
• Apply grease to the O-ring, front axle and speedometer
• Periksaascara
gearbox kerja rem setelah pemasangan ini.
specified.
• Check the brake operation after installation.
Lepaskan tab sementara mendorongnya O-RING

ke dalam dan lepaskan sepeedometer FRONT AXLE
Tepatkan alur
speedometer gearbox
dengan boss paka kaki
SPEEDOMETER GEARBOX AXLE NUT

59 N·m (6.0 kgf ·m, 44 lbf ·ft)
SIDE COLLAR
Tepatkan speedometer tabs RODA DEPAN
dengan alur-alur wheel hub.
*: Shell BEARING GREASE HD atau sejenisnya.
11-7
Lepaskan/pasang sebagai berikut:
– Dustseals
- Dust seals
– Socket bolts
- Socket bolts
– Brake disc
- Brake disc
– Wheel bearings
- Wheel bearings
– Distance collar
- Distance collar
Refer to page 11-9 for wheel bearing replacement.
Lihat hal. 11-9 untuk penggantian wheel bearing.
• Apply grease to the bearings, dust seal lips and distance

collar as specified.
• Replace the brake disc socket bolts with new ones.
RIGHT WHEEL BEARING (6201U)
DUST SEAL
DUST SEAL
SOCKET BOLTS 42
N·m (4.3 kgf ·m, 31
lbf ·ft)
DISTANCE Kencangkan baut-baut

COLLAR dalam pola bersilangan
dalam 2 atau 3 langkah.
LEFT WHEEL BEARING (6201U)

BRAKE DISC
Pasang brake disc dengan sisi yang
bertanda menghadap ke atas.
11-8
BEARING REPLACEMENT
PENGGANTIAN BEARING (BANTALAN)
Install the
Pasang bearingremover
bearing removerheadhead into the bearing.
ke dalam bearing.
From the opposite side, install the bearing
Dari sisi berlawanan, pasang bearing remover removershaft
shaft dan
and REMOVER HEAD REMOVER SHAFT
drive the bearing out of the wheel
drive bearing keluar dari wheel hub. hub.
Remove thedistance
Lepaskan distance collar
collaranddandrive out the keluar
dorong other bearing.
bearing
yang lain.
TOOLS:
TOOLS:
Bearing remover head, 12 mm 07746-0050300
Bearing removershaft
Bearing remover head, 12 mm 07746-0050300
07746-0050100
Bearing remover shaft 07746-0050100
REMOVER
BEARING HEAD
BEARINGS
REMOVER SHAFT REMOVER HEAD
Pack
Isi all bearing
semua rongga cavities with
bearing grease.gemuk.
dengan
Drive in a new left bearing squarely with its sealed side fac- ATTACHMENT DRIVER
Jangan
Never sekali-kali
install the old Dorong masuk
ing up until sebuah
it is fully bearing kiri baru dengan sisinya
seated.
memasang kembali
bearings. Once the yang tertutup menghadap ke atas sampai ia duduk
bearings lama.
bearings haveSekali
been sepenuhnya.
TOOLS:
removed, bearings telah
the bearings
dilepaskan, bearings Driver 07749-0010000
must be replaced with TOOLS:
harus diganti dengan Attachment, 32 x 35 mm 07746-0010100
new ones. Driver 07749-0010000
yang baru. Pilot, 12 mm 07746-0040200
Attachment, 32 x 35 mm 07746-0010100
Pilot, 12 mm 07746-0040200
BEARING PILOT
Oleskan
Apply thinlapisan
coat of tipis
greasegemuk pada distance
to the distance collar andcollar
installdan
it.
pasang.
Drive in a new right bearing squarely with its sealed side fac-
ing up. DISTANCE BEARING
Dorong masuk bearing kanan baru secara tegaklurus COLLAR
dengan sisinya yang tertutup menghadap ke atas.
TOOLS:
Driver
TOOLS: 07749-0010000
Attachment,
Driver 32 x 35 mm 07746-0010100
07749-0010000
07746-0010100
Pilot, 12 mm 07746-0040200
11-9
INSPECTION
PEMERIKSAAN
AXLE(POROS)
AXLE
Place the axle
Letakkan on V-blocks
axle and measure
pada V-blocks dantheukur
runoutkeolengan
with a dial
indicator.
dengan dial indicator.
SERVICE
BATAS
LIMIT: SERVIS: 0.2
0,2 mm
mm(0.01 in)
Keolengan sebenarnya
Actual runout is 1/2 of theadalah ½ darireading.
total indicator pembacaan total
indicator.
WHEEL
WHEELBEARING
BEARING(BANTALAN RODA)
Putar inner
Turn the innerrace dari
race of masing-masing
each bearing with yourbearing dengan
finger, the bear-
ari-jari, bearing
ing should harus berputar
turn smoothly dengan halus dan tanpa
and quietly.
Also check that the bearing outer race fits tightly in the hub.
suara.
Juga periksa bahwa bearing outer race duduk dengan
Replace the bearings Remove and discard the bearings if the races do not turn
erat pada hub.
in pairs. smoothly, quietly, or if they fit loosely in the hub.
Keluarkan dan buanglah bearings jika races tidak
Ganti bantalan dalam berputar dengan halus, tanpa suara, atau jika mereka
pasangan. duduk dengan longgar pada hub.
WHEEL
WHEELRIM
RIM(PELEK RODA)
Periksa
Check thekeolengan
wheel rim wheel
runout rim dengan
by placing themeletakkan wheel
wheel on a turning
pada
stand. turning stand (alat pegangan roda untuk stel
pelek).
Spin the wheel by hand and read the runout using a dial indi-
Putar
cator. roda dengan tangan dan baca keolengan dengan
Actual runout isdial
menggunakan 1/2 indicator.
the total indicator reading.
Keolengan sebenarnya adalah ½ dari pembacaan total
indicator.
SERVICE LIMIT:
Axial: 2.0 mm (0.08 in)
BATAS SERVIS:
Radial: 2.0 mm (0.08 in)
Aksial: 2,0 mm
Radial: 2,0 mm
11-10
FORK (GARPU)
FORK
REMOVAL
PELEPASAN
Lepaskan
Remove the sebagai berikut:
following:
- –Front
Frontupper
uppercover
cover(hal.
(page2-4)
2-4)
- –Front fender (spakbor depan) (hal. 2-7) UPPER PINCH BOLT
Front fender (page 2-7)
- –Front
Frontwheel
wheel(roda
(pagedepan)
11-7) (hal. 11-7)
Remove the brake caliper (page 13-13).
Support
Dukung front Lepaskan brake caliper (hal. 13-13).
thebrake
front
Remove the bottom bridge upper pinch bolts.
caliper
brake dengan
caliper seutas
with a Lepaskan bottom bridge upper pinch bolts.
kawat
Loosen the bottom bridge lower pinch bolts and remove the
piecesehingga
of wire soiathat
tidakit
Longgarkan bottom bridge lower pinch bolts dan
bergantung fork legs.
does not pada
hang front
from lepaskan fork legs.
brake hose.
the front brake hose.
Jangan memlintir brake
Do not twist the brake
hose.
INSTALLATION
hose.
PEMASANGAN
Install the fork pipe into the steering stem.
Align the bolt hole with the groove of the fork pipe as shown.
Pasang fork pipe ke dalam steering stem.
Tepatkan
Install the lubang bolt dengan
bottom bridge alur bolts.
upper pinch dari fork pipe seperti
Tighten the
diperlihatkan. bottom bridge pinch bolts to the specified torque.
LOWER
TORQUE:64 PINCH BOLT
Pasang bottomN·m (6.5 upper
bridge kgf·m,pinch
47 lbf·ft)
bolts.
Kencangkan bottom
Install the following: bridge pinch bolts dengan torsi
yang ditentukan. GROOVE
– Front wheel (page 11-7)
– Front64
TORSI: fender
N.m(page 2-7)
(6,5 kgf.m; 47 lbf.ft)
– Front upper cover (page 2-4)
– Brake
Pasang caliper berikut:
sebagai (page 13-13)
- Front wheel (hal. 11-7)

- Front fender (hal. 2-7)
FORK
- Front upper cover (hal. 2-4)
- Brake caliper (hal. 13-13) BOLT HOLE
11-11
PEMBONGKARAN
DISASSEMBLY
Pegang
Hold the fork
fork slider
slider indalam
a vice catok dengan
with soft jaws orpenjepit lunak
a shop towel.
atau dengan kain lap. FORK SLIDER SOCKET BOLT
Loosen the fork socket bolt but do not remove yet.
Longgarkan fork socket bolt tetapi jangan lepaskan
dulu.
Tempatkan suitable
Put the suitable tool ontool (kunciseat.
the spring perkakas yang sesuai)
pada spring seat. SUITABLE TOOL
Press the spring seat into the fork pipe using a suitable tool
To prevent loss of
tension,
Untuk and hydraulic press, then remove the stopper ring using a
do not
mencegah SPRING SEAT
Tekan spring seat ke dalam fork pipe dengan
compress the
hilangnya tegangan, small screwdriver.
fork
menggunakan suitable tool dan hydraulic press,
spring more
jangan tekan fork spring than
Remove the
kemudian spring seat,
lepaskan O-ringring
stopper and spring
denganfrom the fork pipe.
menggunakan
necessary. The spring
lebih daripada yang
diperlukan. Sprint
seat
obeng kecil.
seat
is under
berada
springdi bawah
pressure.
tekanan Lepaskan spring seat, O-ring dan spring dari fork pipe.
Use carepegas.
when
Berhati-hatilah
removing the ketika
fork
melepaskan fork
STOPPER RING
assembly from the
assembly dari hydraulic
hydraulic press.
press.
SPRING O-RING
Tuangkan forkfork
Pour out the fluid (minyak
fluid sokbreker)
by pumping keluar
the fork pipedengan
several
times.
memompa fork pipe beberapa kali.
Remove thedust
Keluarkan dustseal.
seal.
DUST SEAL
11-12
Lepaskan oiloil
Remove the seal
sealstopper
stopper ring.
ring.
STOPPER RING
Lepaskan socket
Remove the socketbolt
boltdan
and sealing washer.
sealing washer.
SEALING WASHER
SOCKET BOLT
Remove the
Lepaskan fork
fork piston
piston danand rebound
rebound spring
spring from
dari forkthe fork
pipe.
pipe. FORK PISTON
REBOUND SPRING
Tarik fork
Pull the pipe
fork keluar
pipe dari the
out from fork slider.
fork slider.
FORK SLIDER
FORK PIPE
11-13
Remove theoil
Keluarkan oilseal
seal dengan
using themenggunakan
special tool. special tool.
OIL SEAL REMOVER
TOOL:
TOOL:
Oil seall remover 07748-0010001
atau sejenisnya
Oil seal remover 07748-0010001 or equivalent
OIL SEAL
ASSEMBLY
PERAKITAN
FORK PISTON FORK PISTON RING

FORK PIPE STOPPER RING
DUST SEAL
SPRING SEAT
STOPPER RING
OIL SEAL
FORK SLIDER
O-RING
FORK SPRING
SOCKET BOLT
SEALING WASHER REBOUND SPRING
20 N·m (2.0 kgf ·m, 15 lbf ·ft)
Sebelum perakitan,
Before assembly, washcucilah semua parts
all parts dengan
with high flash larutan
point or non-
pembersih dengan
flammable solvent titik
and wipeapithem
tinggi atau yang tidak dapat
dry. FORK SLIDER
terbakar dan seka kering.
Install the fork pipe into the fork slider.
Pasang fork pipe ke dalam fork slider.
FORK PIPE
11-14
Make sure
Pastikan bahwa Install therebound
the Pasang
thatfork rebound spring
spring and
danfork piston
fork intoke
piston thedalam
fork pipe.
for
piston fork
ringpiston
telah ring
duduk is pipe. FORK PISTON
seateddiindalam alur.
the groove.
REBOUND SPRING
Bersihkan ulir bolt

Clean the socket socket
threadsbolt dan locking
and apply oleskan
agent cairan
to the
penguncian
bolt threads. pada ulir bolt.
SEALING WASHER
Install and tighten the socket bolt with a new sealing washer
Pasang dan kencangkan socket bolt dengan sebuah
to the fork piston.
sealing washer baru pada fork piston.
SOCKET BOLT
Apply fork
Oleskan fluid
fork to pada
fluid the lipbibir
of a sebuah
new oil seal.
oil seal baru.
FORK SEAL
Pasang oil seal
Install the dengan
oil seal Dorong
Drive themasuk
oil sealoil
intoseal ke dalam
the fork forkthe
slider using slider dengan
special tools
sisinya yang bertanda
DRIVER
with its marked side menggunakan special tools sampai ia duduk
until it is fully seated.
menghadap ke atas.
facing up. sepenuhnya.
TOOLS:
TOOLS:
Fork seal driver body 07747-0010100
Fork seal driver body 07747-0010100
Fork seal driver attachment, 07747-0010300
Fork seal driver attachment,
27.2 mm
07747-0010300
27.2 mm
ATTACHMENT OIL SEAL
Pasang oiloilseal
Install the sealstopper ringinto
stopper ring ke the
dalam alurring
stopper stopper
groovering
on
pada fork
the fork slider.
slider.
STOPPER RING
11-15
Oleskan fork
Apply fork fluid
fluid to pada
a n ewbibir
dust dust seal baru.
seal lip.
Jangan
Do ketuk bibir
not tap dust Pasang
the dust dust
Install the seal
dust sealsampai
until it isiafully
duduk sepenuhnya.
seated.
seal terlalu keras.
seal lip too hard .
DUST SEAL
Tuangkan jumlah amount

Pour the specified fork fluid yang dianjurkan
of recommended dalam
fork fluid into
umlah
the forkyang
pipe.ditentukan ke dalam fork pipe.
FORK FLUID
KAPASITAS CAPACITY:
FORK FLUID:
33
75 ± 1
75 1 cmcm (2.5 ± 0.03 US oz, 2.6 ± 0.04 Imp oz)
Pump thefork
Pompa forkpipe
pipe several timeskali
beberapa to remove
untuk trapped air from
mengeluarkan
the lower portion of the fork pipe.
udara yang terperangkap dari bagian bawah dari for
pipe.
Pastikan bahwa
Be sure the is Tekan
tinggi
oil level Compressforkthe
legfork
sepenuhnya
leg fully anddan ukur the
measure tinggi permukaan
fluid level from
permukaan fluida di
same in the both fluid dariofbagian
the top the forkatas
pipe.dari fork pipe.
dalam kedua forks.
forks
adalah sama. FORK FLUID
TINGGI PERMUKAAN FORK FLUID: 50 mm
LEVEL: 50 mm (2.0 in)
50 mm (2.0 in)
Tarik forkfork
Pull the pipepipe
ke atas daninstall
up and pasangthe fork
fork spring
spring dengan
with its
sisinya
taperedyang meruncing
side facing down.menghadap ke bawah. FORK SPRING
FORK PIPE
Sisi yang meruncing
11-16
Coat aO-ring
Lapisi new O-ring
baru with fork fork
dengan fluid fluid
and install it into the
dan pasang ke
groove in the spring seat.
dalam alur pada spring seat. TOOL YANG SESUAI
Set the fork assembly, spring seat and stopper ring onto the
Tempatkan fork assembly, spring seat dan stopper ring
hydraulic press.
pada
Put the suitable press.
hydraulic tool on the spring seat. STOPPER
Letakkan suitable tool pada spring seat.
To prevent loss of Press the spring seat into the fork pipe until the stopper ring
RING
Untuk menghindari
tension,
hilangnya tegangan, groove ismasuk
do not Dorong visible.spring seat ke dalam fork pipe sampai
jangancompress
tekan forkthe
spring
fork alur stopper ring tampak. O-RING
lebih daripada
spring moreyang
than
diperlukan.
necessary.
SPRING SEAT
Install the
Pasang stopperring
stopper ringke
intodalam
the stopper ring groove
alur stopper ring on the
pada
forkpipe.
fork pipe.
STOPPER RING
Hold the
Tahan fork
fork sliderpada
slider in a vise
catokwith soft jaws
dengan or a shop
penjepit towel.
lunak atau
dengan kain lap. FORK SLIDER
Tighten the fork socket bolt to the specified torque.
Kencangkan fork socket bolt dengan torsi yang
ditentukan.
SOCKET BOLT
PEMERIKSAAN
INSPECTION
FORKSPRING
FORK SPRING
Measure
Ukur the fork
panjang spring
bebas free
fork length.
spring.
BATAS
SERVICESERVIS: 305,1 mm SPRING
LIMIT: 305.1 mm (12.01 in)
11-17
FORK
FORK PIPE/SLIDER/PISTON
PIPE/SLIDER/PISTON
Periksa
Check thefork pipe,
fork pipe,fork
forkslider
sliderdan
and fork
fork piston terhadap
piston for score
tanda-tanda gerusan,
mark, and excessive dan keausan
or abnormal wear. berlebihan atau FORK SLIDER
tidak normal.
Check the fork piston ring for wear or damage.
Check the rebound spring for fatigue or damage.
Periksa fork piston ring terhadap keausan atau
kerusakan.
Replace the components if necessary.
Periksa rebound spring terhadap keletihan atau
kerusakan.
Ganti komponen-komponen bila perlu. FORK PIPE
REBOUND FORK
SPRING PISTON
FORK PISTON
RING
Letakkan forkpipe
Place the fork pipeonpada V-block
V-block dan ukurthe
and measure keolengan.
runout.
Keolengan sebenarnya adalah ½ dari pembacaan total
Actual runout is 1/2 the total indicator reading.
indicator.
SERVICE
LIMIT: 0.2 mm (0.01 in)
11-18
HANDLEBAR
HANDLEBAR (STANG STIR)
Longgarkan rear
Loosen the rear brake
brake cable cable (kabel
by turning rem belakang)
the adjusting nut.
dengan memutar adjusting nut.
– Front handlebar cover (page 2-5)
- –Front handlebar cover (hal. 2-5)
Rear handlebar cover (page 2-5)
- –Rear handlebar cover
Front upper cover (hal.
(page 2-4)2-5)
- –Front upper cover (hal. 2-4)
Rear brake lever pivot bolt/nut
- –Rear
Rearbrake
brakelever pivot bolt/nut
cable/lever
- –Rear brake cable/lever
Master cylinder/holder/bolts
- –Master cylinder/holder/bolts
Screw/upper throttle housing/lower throttle housing
- –Screw/upper throttle housing/lower
Throttle cable/throttle pipe throttle housing
- –Throttle cable/throttle
Left handlebar grip pipe
- –Left handlebar grip
Nut/collars/bolt/handlebar post
- Nut/collars/bolt/handlebar post
ADJUSTING NUT
CATATAN:
• Refer to page 11-20 for handlebar post/handlebar grip/
• Lihat hal.
throttle 11-20
housing untuk pemasangan handlebar
installation.
• Route the wires/cables properlyhousing.
post/handlebar grip/throttle (page 1-14).
Alurkan
• • Adjust thekawat/kabel dengan
rear brake lever benar
free play (hal.
(page 1-14).
3-16).
• Setel jarak main bebas rear brake lever (hal. 3-16).
Kencangkan baut atas dulu,
Tepatkan ujung master kemudian baru baut bawah.
cylinder dengan tanda titik
pada handlebar.
SCREW
UPPER HOUSING Letakkan holder dengan tanda

THROTTLE PIPE "UP" menghadap ke atas.
HOLDER
BOLTS
PIVOT BOLT
1 N·m (0.1 kgf ·m, 0.7 lbf ·ft)
MASTER CYLINDER
THROTTLE CABLE
PIVOT NUT
4.5 N·m (0.5 kgf ·m,
COLLAR
COLLAR 3.3 lbf ·ft)
REAR BRAKE LEVER
BOLT
NUT REAR BRAKE CABLE
59 N·m (6.0 kgf ·m, 44 lbf ·ft)
11-19
PEMASANGAN HANDLEBAR
HANDLEBAR POST POST
INSTALLATION
Pasang handlebar
Install the handlebar post padathesteering
post onto steering stem sementara
stem while align-
ing the bolt holes.
mentepatkan lubang-lubang bolt.
BOLT REAR COLLAR
Rear
Rear collar
collar tinggi Install the front/rear collars, bolt and nut.
is taller
lebih
Pasang front/rear collars, bolt dan nut.
thandari
the front collar.
front collar.
Tighten the nut to the specified torque.
Kencangkan nut dengan torsi yang ditentukan.
TORSI: 59 N.m
TORQUE:59 (6,0
N·m (6.0kgf.m;
kgf·m,44
44lbf.ft)
lbf·ft)
FRONT COLLAR NUT
PEMASANGAN HANDLEBAR
HANDLEBAR GRIP GRIP
INSTALLATION
Jika
If thehandlebar gripswere
handlebar grips telah dilepaskan,
removed, oleskan
apply Honda Honda
Bond A or
Bond A atau
equivalent sejenisnya
to the pada
inside of the gripbagian dalam
and to the cleandari grip
surfaces HANDLEBAR GRIP
of the
dan left permukaan
pada handlebar. bersih dari left handlebar.
Wait 3 – 5 minutes and install the grip.
Tunggu 3 - 5 menit dan pasang grip.
Allow
iarkan the
lemadhesive to Rotate the grip for even application of the adhesive.
mengering Putar grip agar lem terbagi merata.
selama
dry for11jam
hoursebelum
before
memakainya.
using.
LEFT HANDLEBAR
PEMASANGAN THROTTLE HOUSING

THROTTLE HOUSING INSTALLATION
Pasang throttle pipe.
Install the throttle pipe.
Oleskan 0,1 – 0,2 g gemuk pada daerah luncur throttle
Apply 0.1 – 0.2 g of grease to the throttle cable sliding area
cable dan hubungkan dengan throttle pipe.
and connect it to the throttle pipe.
Install thelower
Pasang lower throttle
throttle housing
housing by dengan
aligning the hole on the
mentepatkan
handlebar with the locating pin of the lower
lubang pada handlebar dengan locating pin dari throttle housing.
lower
throttle housing.
Tepatkan
THROTTLE CABLE
Install the
Pasang upperhousing
upper housing by aligningmentepatkan
dengan the groove of the
alurupper
dari
SCREW UPPER HOUSING
housing
upper and tabdan
housing of the
tablower
dari housing.
lower housing.
Install the screw and tighten it.
Pasang screw dan kencangkan.
LOWER HOUSING
11-20
STEERING STEM
STEERING STEM
PELEPASAN
REMOVAL
Remove the
Lepaskan following:
sebagai berikut: SPEEDOMETER CABLE
- – Fork
Fork (page
(hal. 11-11)
11-11)
– Handlebar (page 11-19) BOLT
- Handlebar (hal. 11-19)
Remove the
Lepaskan boltdan
bolt andbrake
brake hose
hose clamp.
clamp.
Lepaskan speedometer cable darithe
Release the speedometer cable from cable
cable guide.
guide.
CABLE GUIDE HOSE CLAMP
Tahan
Hold thetoptopthread
thread dengan
using themenggunakan pinloosen
pin spanner and spanner
the
dan longgarkan steering stem lock nut dengan SOCKET
steering stem lock nut using the socket wrench.
WRENCH
menggunakan socket wrench.
TOOLS:
TOOLS:
Socket wrench 07916-KM10000 STEM LOCK NUT
Socket wrench
Pin spanner 07916-KM10000
07702-0020001
Pin spanner 07702-0020001
Remove the steering stem lock nut. PIN SPANNER
Lepaskan steering stem lock nut.
Hati-hati
Be agar
careful not drop Tahan
totidak steering
Hold the stem
steering stemdan
andlonggarkan topthread
loosen the top threadusing
dengan
the
menjatuhkan steering STEM
the steering stem. menggunakan
stem socket. stem socket.
stem. SOCKET
TOOL:
TOOL:
Steering stem socket 07916-3710101
TOP THREAD
Hati-hati
Be agar
careful not totidak Remove theupper
drop Lepaskan upper bearing
bearinginner racerace
inner and the
danupper steelsteel
upper balls
menjatuhkan steering
the steering stem (23 balls)
and balls while sementara
(23 balls) holding the steering
memegang stem.steering stem. UPPER INNER
stem dan upper
the upper steel
steel balls. RACE
balls.
STEEL
BALLS (23)
STEERING STEM
11-21
Be Hati-hati
careful not to tidak
agar Remove the
drop Lepaskan steeringstem
steering stem and
danlower
lowersteel
steelballs
balls(29(29
balls).
balls).
the steering stem
menjatuhkan and
steering
the lower
stem dan steel
lowerballs.
steel
balls. STEERING STEM
STEEL
BALLS (29)
INSTALLATION
PEMASANGAN
Lihat hal. 11-24
Refer to page untuk
11-24 for penggantian
steering stem bearingsteering stem
replacement.
bearing.
LOCK NUT
LOWER OUTER RACE TOP THREAD
LOWER BEARING (29)

UPPER BEARING (23) UPPER INNER RACE
LOWER INNER RACE
DUST SEAL
WASHER
UPPER OUTER RACE
gemuk dengan bahan tahan tekanan tinggi

BOLT (dianjurkan : EXCELIGHT EP2 yang di
buat oleh KYODO YUSHI, japan atau
FRONT BRAKE
STEERING STEM Shell ALVANIA EP2 atau sejenisnya)
HOSE CLAMP
Oleskan
Apply 3g3gofgemuk
grease dengan bahanpressure
with extreme tahan tekanan tinggi
agent (recom-
STEEL BALLS (29 balls)
mended: EXCELIGHT
(dianjurkan: EXCELIGHTEP2 EP2manufactured by KYODO
yang dibuat oleh
YUSHI, japan
YUSHI, Japan or Shell
atauALVANIA EP2 or equivalent)
Shell ALVANIA EP2 to the
atau
lower bearing
sejenisnya) races.
pada lower bearing races.
Attach new steel balls (29 balls) to the lower bearing outer
Letakkan
race.
steel balls baru (29 balls) pada lower bearing
outer race.
Be careful not to drop Insert the steering stem into the steering head pipe, being
Hati-hati
the steeringagar
stemtidak
and careful not to
Masukkan drop thestem
steering steel balls.
ke dalam steering head pipe,
menjatuhkanthe steering
lower dengan berhati-hati agar tidak menjatuhkan steel balls.
stem dan steel
lowerballs.
steel
balls.
STEERING STEM
11-22
Apply 3g3gofgemuk
Oleskan grease dengan
with extreme
bahanpressure agent (recom-
tahan tekanan tinggi UPPER INNER RACE
mended: EXCELIGHT EP2 manufactured
(dianjurkan: EXCELIGHT EP2 yang dibuat oleh by KYODO
YUSHI, japan
YUSHI, Japanor Shell
atauALVANIA EP2 or equivalent)
Shell ALVANIA EP2 to the
atau
upper bearing races.
sejenisnya) pada lower bearing races.
Install new steel balls (23 balls) onto the upper bearing outer
Hati-hati agar tidak Letakkan
race. steel balls baru (29 balls) pada lower bearing
menjatuhkan steering outer race. STEEL BALLS
stem
Be dan upper
careful not to steel
drop Install a new upper bearing inner race onto the stem.
balls.
(23 balls)
the steering stem and Masukkan steering stem ke dalam steering head pipe,
the upper dengan berhati-hati agar tidak menjatuhkan steel balls.
steel balls.
Pasang toptop
Install the thread.
thread.
Tahan
Hold the steering
steeringstem dantighten
stem and kencangkan
the stemstem top thread
top thread to the STEM SOCKET
dengan torsi awal
initial torque using dengan menggunakan
the special tool. special tool.
TOOL:
TOOL:
Steering stem
Steering stemsocket
socket 07916-3710101
07916-3710101
TOP THREAD
TORSI: 25 N.m
TORQUE:25 (2,5
N·m (2.5kgf.m;
kgf·m,18
18lbf.ft)
lbf·ft)
Putar steering
Turn the stem
steering stembeberapa kali
lock-to-lock dari times
several ujung-ke-ujung
to seat the
untuk mendudukkan bearing.
bearing.
Loosen the top

Longgarkan topthread,
thread,then retightenkencangkan
kemudian the top thread to the
kembali
specified
top threadtorque using thetorsi
dengan special tool. ditentukan dengan
yang STEM SOCKET
menggunakan special tool.
TOOL:
Steering stem socket
TOOL: 07916-3710101
TORQUE:2.5 N·m (0.3 kgf·m, 1.8 lbf·ft) TOP THREAD
TORSI:
Turn the 2,5 N.m
thread (0,3 kgf.m; 1,8about
counterclockwise lbf.ft)
15 degrees.
Recheck
Putar that the
thread steering stemarah
berlawanan moves smoothly without
perputaran jarum play
jam
or binding.
sebanyak 15 derajat.
Periksa kembali bahwa steering stem bergerak dengan

halus tanpa kelonggaran atau mengikat.
11-23
Install the
Pasang following:
sebagai berikut:
- –Fork
Fork (page
(hal. 11-11)
11-11) STEM LOCK NUT
– Front wheel
- Roda depan (hal. (page11-7)
11-7)
Hold the top thread using the pin spanner and tighten the
Tahan
steeringtop
stemthread dengan
lock nut menggunakan
to the specified torque. pin spanner
dan kencangkan steering stem lock nut dengan torsi
TOOLS:
yang ditentukan.
Socket wrench 07916-KM10000
TOOLS:
Pin spanner 07702-0020001
Socket wrench 07916-KM10000 SOCKET
Pin spanner N·m (7.5 kgf·m, 55 lbf·ft)
TORQUE:74 07702-0020001 WRENCH
TORSI:
Turn the 74 N.m stem
steering (7,5 kgf.m; 55 lbf.ft)
lock-to-lock several times.
Make sure the steering stem moves smoothly without play PIN SPANNER
Putar steering stem dari ujung-ke-ujung beberapa kali. or
binding.
Pastikan bahwa steering stem bergerak dengan halus
tanpa
Installkelonggaran
the brake hoseatau mengikat.
clamp and tighten the bolt.
SPEEDOMETER CABLE
Route the
Pasang speedometer
brake cabledan
hose clamp through the cable guide.
kencangkan bolt. BOLT
Install the handlebar (page 11-19).
Alurkan speedometer cable melalui cable guide.
Pasang handlebar (hal. 11-19).
CABLE GUIDE HOSE CLAMP
STEERING STEM BEARINGS

PENGGANTIAN STEERING STEM
REPLACEMENT
BEARINGS
• Always replace the steel balls and races as a set.
•Remove theganti
Selalu steering stem
steel (page
balls dan11-21).
racessabagai satu set.
Remove the upper bearing outer race using the following UPPER
Lepaskan
tool. steering stem (hal. 11-21). OUTER RACE
Lepaskan upper bearing outer race dengan
menggunakan tool sebagai berikut.
TOOL:
Ball race remover shaft
TOOL: 07GMD-KS40100
Ball race remover shaft 07GMD-KS40100
BALL RACE
REMOVER SHAFT
Keluarkan lower bearing

Remove the lower bearing
outer outer race
race using dengan
the following
menggunakan
tools. tools sebagai beirkut. BALL RACE
REMOVER SHAFT
TOOLS:
TOOLS:
Ballrace
Ball race remover,
remover,34.5 mm
34.5 mm 07948-4630100
07948-4630100
Ball
Ballrace removershaft
race remover shaft 07GMD-KS40100
07GMD-KS40100
BALL RACE
REMOVER
LOWER
OUTER RACE
11-24
Remove thedust
Lepaskan dustseal
seal from
dari the steering
steering stemlower
stem lower bearing
bearing
DUST SEAL LOWER
inner race.
inner race. INNER RACE
Remove the lower bearing inner race with a chisel or equiva-
Lepaskan lower
lent tool being bearing
careful not toinner race
damage thedengan
stem. pahat atau
tool sejenis, dengan berhati-hati agar tidak merusak
Remove the washer from the steering stem.
stem. STEERING STEM WASHER
Lepaskan washer dari steering stem.
Install the
Pasang washerpada steering
washer to the steering stem.
stem.
Install alower
new lower bearing LOWER INNER RACE
Pasang bearing innerinner
race race usingmenggunakan
dengan the following WASHER
toolberikut
tool and hydraulic
ini danpress.
hydraulic press.
TOOL:
TOOL:
Fork
Forkseal driver attachment,
seal driver attachment, 07947-KA20200
07947-KA20200
35.2
35.2 mm
mm
FORK SEAL DRIVER

ATTACHMENT
Apply 3g3gofgemuk
Oleskan grease dengan
with extreme
bahanpressure agent (recom-
tahan tekanan tinggi
mended: EXCELIGHT EP2 manufactured
(dianjurkan: EXCELIGHT EP2 yang dibuat oleh by KYODO
YUSHI, japan
YUSHI, Japan or Shell
atau ALVANIA
Shell ALVANIAEP2 or equivalent)
EP2 atau to a
new dust seal lip then install it to the lower
sejenisnya) pada bibir dust seal baru kemudian pasang bearing inner
race. lower bearing inner race.
pada
DUST SEAL
Dorong masuk
Drive a new upper
upper bearing
bearing outer outer race
race into theke dalam
head head
pipe using
pipe dengan menggunakan
the following tools. tools sebagai berikut. DRIVER/ATTACHMENT
TOOLS:
TOOLS:
Driver 07749-0010000
Driver driver attachment
Bearing 07749-0010000
07946-3710701
Bearing driver attachment 07946-3710701
UPPER OUTER RACE
11-25
Dorong masuk
Drive a new lowerlower bearing
bearing outerinto
outer race race
thebaru ke dalam
head pipe using
LOWER OUTER RACE
the following
head tools. menggunakan tools berikut ini.
pipe dengan
TOOL:
TOOL:
Oilseal
Oil seal driver
driver 53.5
53.5mm
mm 07947-SB00200
07749-SB00200
Install the
Pasang steeringstem
steering stem (hal.
(page11-22).
11-22).
OIL SEAL
DRIVER
11-26
12. RODA BELAKANG/SUSPENSI
LOKASI KOMPONEN-KOMPONEN... 12-2 RODA BELAKANG............................. 12-4

COMPONENT LOCATION ·························· 12-2 REAR WHEEL ················································12-4
KETERANGAN SERVIS ..................... 12-3 SHOCK ABSORBER BELAKANG ..... 12-5

SERVICE INFORMATION ···························12-3 REAR SHOCK ABSORBER ·························· 12-5
TROUBLESHOOTING ........................ 12-3 HANGER LINKAGE ............................ 12-6

TROUBLESHOOTING ··································12-3 HANGER LINKAGE ······································12-6
12
12-1
COMPONENT LOCATION
REAR WHEEL/SUSPENSION
118 N·m (12.0 kgf ·m, 87 lbf ·ft)
69 N·m (7.0 kgf ·m, 51 lbf ·ft)
12-2
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
! PERINGATAN
Frequentmenghirup
Seringkali inhalation ofdebu
brakebrake
shoe dust, regardless
pad dan shoe,of material
apapun composition
komposisi could be hazardous
bahannya, to your health. kesehatan.
dapat membahayakan
•
• Jangan
Avoid breathing dust particles.
menghirup partikel-partikel debu.
•
• Jangan
Never use an air hose
sekali-kali or brush slang
memakai to clean brake atau
udara assemblies. Use anmembersihkan
sikat untuk OSHA-approvedsusunan
vacuum cleaner.
rem. Pakailah alat penghisap debu yang
baik.
• Use genuine Honda replacement bolts and nut for all suspension pivots and mounting points.
• Pakailah bolts dan nut asli Honda untuk semua titik engsel dan penggantungan suspensi.
• For brake system service, refer to section 13.
• Untuk servis sistem rem, lihat Bab 13.
SPECIFICATIONS
SPESIFIKASI
Unit: mm (in)
Satuan: mm
ITEM STANDARD
LIMIT
Kedalaman minimum alur kembang ban - Sampai ke indikator
Minimum tire tread depth 2 – To the indicator
Tekanan udara ban Pengendara saja 225 kPa (2,25 kgf/cm , 332
psi) -
Cold tire pressure
(dingin) Driver only 225 kPa (2.25 kgf/cm
2 , 33 psi) –
Pengendara dan pembonceng 225 kPa (2,25 kgf/cm , 33 psi) -
Driver and passenger 225 kPa (2.25 kgf/cm2, 33 psi) –
Keolengan pelek roda Radial - 2,0
Wheel rim runout Radial – 2.0 (0.08)
Aksial - 2,0
Axial – 2.0 (0.08)
TORQUE
NILAI VALUES
TORSI
Rear axle
Rear axlenut
nut 118 N.m (12,0 kgf.m;
118 N·m (12.087kgf·m,
lbf.ft)87 lbf·ft) U-nut Oleskan
U-nut oli mesin pada ulir
Engine hanger link nut (sisi rangka) 69 N.m (7,0 kgf.m; 51 lbf.ft) Apply engine oil to the threads
Engine hanger link nut (Frame side) 69 N·m (7.0 kgf·m, 51 lbf·ft)
TROUBLESHOOTING
TROUBLESHOOTING
Roda belakang bergoyang
Rear wheel wobbles
• Pelek bengkok
• Bent rim
• Ban rusak
• Faulty tire
• Axle dan/atau enginemounting
• Axle nut and/or engine mounting bolt/nut
bolt/nut not(baut/mur penggantung mesin) tidak dikencangkan dengan benar
tightened properly
Final gear shaft bearing longgar atau
• Loose or worn final gear shaft bearing
• aus
Tekanan udara
• Insufficient
• ban kurang
tire pressure
Soft suspension
Suspensi lunak
• Weak rear shock absorber spring
• Rear
• Oil shock
leakage absorber
from damperspring
unit lemah
• Adatire
• Low kebocoran
pressure oli dari damper unit
• Tekanan udara ban rendah
Stiff suspension
• Bent damper
Suspensi Keras rod
• High tire pressure
• Damper rod bengkok
RearTekanan
• suspension noisy
udara ban tinggi
• Loose mounting
Suspensi belakang fasteners
berisik
• Faulty
•
shock
Pengikat absorber
penggantung longgar
• Weak
•
rear suspension
Shock absorber rusak bushings
• Rear suspension bushings lemah
12-3
REAR
RODA WHEEL
BELAKANG
REMOVAL
PELEPASAN
Support the
Letakkan scooter
skuter withstandard
pada its centerstand.
utamanya.
Remove the exhaust pipe/muffler
Lepaskan exhaust pipe/muffler (hal. (page2-14).
2-14).
Remove the rear axle nut, washer and rear wheel.
Lepaskan rear axle nut, washer dan roda belakang.
RODA BELAKANG
PEMASANGAN
INSTALLATION
Semprotkan oli mesin pada ulir rear axle nut dan
permukaan
Apply engine duduk.
oil to the rear axle nut threads and seating sur-
face.
Pasang roda
Install the rearbelakang
wheel ontopada finalgear
the final gear shaft,
shaft, dengan
aligning its
Be careful not to
Hati-hati agar tidak
mentepatkan
splines with the splines-nya
final gear shaft dengan
splines. final gear shaft
damage the splines. splines.
merusak Install the washer onto the final gear shaft.
Pasang washer
Install the pada
rear axle nut.final gear shaft.
Kencangkan
Tighten the rearrear axle
axle nutnut dengan
to the torsitorque.
specified yang ditentukan.
TORQUE:118
TORSI: N·m
118 N.m (12.0kgf.m;
(12,0 kgf·m, 87
87 lbf·ft)
lbf.ft)
Install the
Pasang exhaustpipe/muffler
exhaust pipe/muffler (hal.
(page2-14).
2-14).
Tepatkan (splines)
WASHER
AXLE NUT
PEMERIKSAAN
INSPECTION
Periksa keolengan
Check the wheel rimpelek
runoutroda dengan
using dial indicators.
dial indicators.
Keolengan sebenarnya
Actual runout adalah
is 1/2 the total ½ dari
indicator pembacaan total
readings.
indicator.
SERVICE LIMITS:
BATAS SERVIS:
Radial: 2.0 mm (0.08 in)
Radial: 2,0 mm
Axial: 2.0 mm (0.08 in)
Aksial: 2,0 mm
12-4
REAR SHOCK ABSORBER
ABSORBER
REMOVAL
PELEPASAN
Remove the
Lepaskan bodycover
body cover(hal.
(page2-9).
2-9).
Remove the bolts and rear shock absorber. SHOCK ABSORBER
To avoid
Untuk damage to Lepaskan bolts dan rear shock absorber.
menghindari
kerusakan pada ulirshock
the rear rear
shock absorber
absorber mounting
mounting bolt, slightly
bolt threads, angkat
rodalift the rear wheel. PEMASANGAN
belakang sedikit.
Pasang shock absorber belakang dan kencangkan

bolts.

BOLTS
INSTALLATION
Install the rear shock absorber and tighten the bolts.
PEMERIKSAAN
INSPECTION
Periksa
Check the damper
damper unitunit terhadap
for leakage or otherkebocoran
damage. atau BUSHING
kerusakan lain.
Check the shock absorber bushing for wear or damage.
Replaceshock
Periksa the shock absorber
absorber assembly
bushing if necessary.
terhadap keausan atau
kerusakan.
Ganti shock absorber assembly bila perlu.
SHOCK ABSORBER
Check the
Periksa rear
rear shockabsorber
shock absorber mount
mount bushing
bushingforterhadap
wear or
REAR SHOCK ABSORBER MOUNT BUSHING
damage. atau kerusakan.
keausan
12-5
LINKAGE
HANGER LINKAGE
(PENGHUBUNG PENGGANTUNG MESIN)
REMOVAL
Remove the engine (page 6-4).
PELEPASAN
Remove the nut and engine hanger link bolt.
Lepaskan mesin (hal. 6-4).
Remove the engine hanger link from the frame.
Lepaskan nut dan engine hanger link bolt.
Lepaskan engine hanger link dari rangka.
NUT
BOLT ENGINE HANGER LINK
PEMASANGAN
INSTALLATION
Pasang engine
Install the enginehanger
hanger link
link pada rangka.
onto the frame.
Pasang engine
Install the hanger
engine hangerlink bolt
link dari
bolt sisithe
from kirileft
dariside
rangka.
of the
frame.
Pasang engine hanger link nut dan washer dan
kencangkan nut dengan
Install the engine torsinut
hanger link yang
andditentukan.
tighten it to the speci-
fied torque.
Pasang mesin (hal. 6-6). NUT
Install the engine (page 6-6).
BOLT ENGINE HANGER LINK
PEMERIKSAAN
INSPECTION
Periksa
Check thehanger linkbushings
hanger link bushingsand dan stopper
stopper rubbers rubbers
for wear
or damage.
terhadap keausan atau kerusakan. HANGER LINK BUSHINGS
STOPPER RUBBERS
Periksa engine
Check the enginemount
mount bushings terhadap
bushings for wear or keausan
damage. atau
kerusakan.
ENGINE MOUNT BUSHINGS
12-6
13. SISTEM REM
LOKASI KOMPONEN-KOMPONEN... 13-2 PENGGANTIAN BRAKE FLUID/

COMPONENT LOCATION ·························· 13-2 BRAKE FLUID REPLACEMENT/AIR
AIR BLEEDING ................................... 13-6
BLEEDING····································· ·················· 13-6
KETERANGAN SERVIS ..................... 13-3
SERVICE INFORMATION ···························13-3
BRAKE PAD/DISC.............................. 13-8
BRAKE PAD/DISC·························· ················ 13-8
TROUBLESHOOTING ........................ 13-4
TROUBLESHOOTING ··································13-4
BRAKE MASTER CYLINDER............. 13-11
BRAKE MASTER CYLINDER ···················13-11
REAR DRUM BRAKE ......................... 13-5
REAR DRUM BRAKE····································13-5
BRAKE CALIPER ............................... 13-13
BRAKE CALIPER ········································13-13
13
13-1
SISTEM REM
COMPONENT LOCATION
BRAKESYSTEM
FRONT
REM BRAKE
DEPAN
2 N·m (0.2 kgf·m, 1.5 lbf·ft)
34 N·m (3.5 kgf·m, 25 lbf·ft)
34 N·m (3.5 kgf ·m, 25 lbf ·ft)
30 N·m (3.1 kgf ·m, 22 lbf ·ft)
REAR BRAKE
REM BELAKANG
13-2
SISTEM REM
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
! AWAS
Seringkali menghirup debu brake pad dan shoe, apapun komposisi bahannya, dapat membahayakan kesehatan.
• Jangan menghirup partikel-partikel debu.
Frequent inhalation of brake pad and shoe dust, regardless of material composition, could be hazardous to yo ur heal
• Jangan sekali-kali memakai slang udara atau sikat untuk membersihkan susunan rem. Pakailah alat penghisap debu yang
• Avoid breathing dust particles.
baik.
• Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner.
CATATAN
Minyak rem yang tertumpah akan membuat kerusakan parah pada lensa instrumen dan permukaan yang dicat. Ia juga b erbahaya
Spilled
bagi brake fluid
beberapa willdari
parts severely
karet.damage instrument lenses and painted surfaces. It is also harmful to some rubber parts.
Be careful whenever you remove
Berhati-hatilah setiap kali melepaskan the reservoir cap; make
reservoir sure the master
cap; pastikan bahwa cylinder
masterreservoir
cylinderisreservoir
horizontal first.posisi horisontal dulu.
pada
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality
• Brakedegreasing
brake disc atau pad
agent. yang terkontaminasi mengurangi daya pengereman. Buanglah pads yang terkontaminasi dan bersihkan
disc yang
• Check terkontaminasi
the brake denganthe
system by applying bahan
brakepembersih gemuk
lever after the berkualitas tinggi untuk peralatan rem.
air bleeding.
• Periksa
• Never sistem
allow rem dengan
contaminants (dirt,menjalankan
water, etc.) to handel
get into rem setelah
an open proses air bleeding (pembuangan udara palsu).
reservoir.
• • Once the hydraulic
Jagalah system has been
agar benda-benda asingopened,
(kotoran,or ifair,
thedsb.)
braketidak
feels masuk
spongy,kethedalam
systemreservoir
must be bled.
terbuka.
•
• Always use fresh DOT 3 or DOT 4 brake fluid from a sealed container when servicing
Sekali sistem hidraulik telah dibuka, atau jika rem terasa seperti sepons, buanglah udara palsu the system. Do not mixsistem.
dari different types of fluid, they
•
may not be compatible.
Selalu pakai minyak rem baru DOT 3 atau DOT 4 dari kemasan yang belum pernah dibuka ketika menservis sistem. Jangan
• Always check brake
mencampurkan operation before riding
bermacam-macam jenisthe scooter.
minyak rem, mereka mungkin tidak cocok satu sama lain.
• Selalu periksa cara kerja rem sebelum mengendarai skuter.
SPECIFICATIONS
SPESIFIKASI
Unit: mm
Satuan: mm(in)
ITEM STANDARD
LIMIT
Jarak main bebas brake lever (handel rem) 10 – 20 -
Rear brake lever free play 10 – 20 (0.4 – 0.8) –
D.D. rear brake drum 130,0 131,0
Rear
Minyak brake
remdrum
yangI.D.
ditentukan 130.0DOT
(5.12)
3 atau 4 - 131.0 (5.16)
Specified
Brake discbrake fluid Ketebalan DOT3,3 3 or–DOT
3,7 4 3,0 –
Brake disc Thickness bentuk melengkung
Perubahan 3.3 –- 3.7 (0.13 – 0.15) 0,10 3.0 (0.12)
Master cylinder Warpage
D.D. cylinder 11,000 – 11,043– 11,055 0.10 (0.004)
Master cylinder Cylinder
D.L. pistonI.D. 11.000 – 11.043
10,957 (0.4331 – 0.4348)10,945
– 10,984 11.055 (0.4352)
Caliper Piston O.D.
D.D. cylinder 10.957 – 10.984
32,030 (0.4314 – 0.4324)32,090
– 32,080 10.945 (0.4309)
Caliper Cylinder
D.L. pistonI.D. 32.030
31,948 – 31,998 – 1.2630)31,94
– 32.080 (1.2610 32.090 (1.2634)
Piston O.D. 31.948 – 31.998 (1.2578 – 1.2598) 31.94 (1.257)
NILAI TORSI
TORQUE VALUES
Rear
Rearbrake
brakearm
arm bolt
bolt 10 N.m (1,0
10 kgf.m; 7 lf.ft)
N·m (1.0 kgf·m, 7 lbf·ft) ALOC bolt;
ALOC ganti dengan
bolt; yang
replace withbaru
new one.
Brake
Brake caliperbleed
caliper bleed valve
valve 6 N.m (0,66 kgf.m; 4,4 lbf.ft)
Brake
Brake master cylinder reservoir
master cylinder capscrew
reservoir cap screw 2 N.m (0,2 kgf.m,
2 N·m 1,5
(0.2lbf.ft)
Brake pad pin 18 N.m (1,8 kgf.m; 13 lbf.ft)
Brake pad pin 18 N·m (1.8 kgf·m, 13 lbf·ft)
Front brake lever pivot bolt 1 N.m (0,1 kgf.m; 0,7 lbf.ft)
Front brake lever pivot bolt 1 N·m (0.1 kgf·m, 0.7 lbf·ft)
Front brake lever pivot nut 6 N.m (0,6 kgf.m; 4,4 lbf.ft)
Front brake lever pivot nut
Front brake light switch screw 1 N.m (0,16 kgf.m;
0,7 lbf.ft)
Fronthose
Brake brakeoillight
boltswitch screw 1 N·m (0.125
34 N.m (3,5 kgf.m; kgf·m,
lbf.ft)0.7 lbf·ft)
Brake hose oil bolt
Brake caliper mounting bolt 30 N.m (3,1 kgf.m; 22 lbf.ft) 25 lbf·ft) ALOC bolt; ganti dengan yang baru
34 N·m (3.5 kgf·m,
Brake caliper
Brake caliper pin mounting bolt 30 kgf.m;
18 N.m (1,8 N·m (3.1
13kgf·m,
lbf.ft) 22 lbf·ft) ALOC bolt; replace with new ones.
Brake caliper pin 18 N·m (1.8 kgf·m, 13 lbf·ft)
13-3
SISTEM REM
TOOL
TOOL
Snap ring pliers

07914-SA50001
TROUBLESHOOTING
TROUBLESHOOTING
Front brake lever (handel rem depan) t erasa lunak atau seperti sepons
Front brake lever soft or spongy
• Ada
• Air in udara
hydraulicdalam sistem hidraulik
system
• Leaking hydraulic systemsistem hidraulik
• Ada kebocoran pada
• Brake pad/disc
• Contaminated terkontaminasi
brake pad/disc
Caliper
• Worn
• piston
caliper seals
piston aus
seals
Master
• Worn
• cylinder
master piston
cylinder cups
piston aus
cups
• Worn
• brake pad/disc
Brake pad/disc aus
• Contaminated
•
caliper
Caliper terkontaminasi
• Contaminated
• Master cylinder master cylinder
terkontaminasi
• Caliper
•
not sliding properly
Caliper tidak meluncur dengan benar
• Low brake fluid level
• Tinggi permukaan minyak rem terlalu rendah
• Clogged fluid passage
• Jalan lintasan fluid tersumbat
• Warped/deformed brake disc
• Brake disc berubah
• Sticking/worn bentuk melengkung/berubah bentuk
caliper piston
• Caliper piston macet/aus
• Sticking/worn master cylinder piston
Master
• Bent
• brake lever piston macet/aus
cylinder
• Brake lever bengkok
Front brake lever hard
• Clogged/restricted brake system
Brake lever depan keras
• Sticking/worn caliper piston
• Sistemnot
• Caliper rem tersumbat/terbatasi
sliding properly
• Caliper piston
• Worn caliper piston macet/aus
seal
Caliper tidakmaster
• Sticking/worn
• meluncur dengan
cylinder benar
piston
Caliper
• Bent
• brakepiston
lever seal aus
• Master cylinder piston macet/aus
Front brake drags
• Brake lever bengkok
• Contaminated brake pad/disc
• Misaligned wheel
Rem depan
• Badly wornmenyangkut
brake pad/disc
• Warped/deformedterkontaminasi
• Brake pad/disc brake disc
• Roda salah
• Caliper pasang
not sliding properly
Brake pad/disc sangat
• Clogged/restricted
• aus
fluid passage
• Brake disc
• Sticking berubah
caliper piston bentuk melengkung/berubah bentuk
PoorCaliper
• tidakperformance
rear brake meluncur dengan benar
• Jalan lintasan
• Incorrect fluidoftersumbat/terbatasi
adjustment rear brake lever
Caliper piston
• Contaminated brake
• macetshoes
• Worn brake shoes
Unjuk
• Wornkerja
brakeremcambelakang buruk
• Worn
• Penyetelan
brake drumbrake lever belakang tidak benar
• Improperly
• Brake shoes installed brake arm
terkontaminasi
• Improperly
• Brake shoes engaged
aus brake arm serrations
• Brake cam aus
• Brake drum aus
• Brake arm tidak terpasang dengan benar
• Gerigi brake arm tidak berhubungan dengan baik
13-4
SISTEM REM
REAR DRUM
DRUM BRAKE
BRAKE
(REM TEROMOL BELAKANG)
BELAKANG)
• Alway
Alwayss replace
replace the brake shoes as a set.
• Mark all
all parts
parts during disass
disassembly
embly soso they can
can be placed
placed
• Selalu
back ganti
in the brakelocations.
original shoes sebagai satu set.
• Tandai semua parts selama pembongkaran
Remove the rear wheel (page 12-4).
sehingga mereka dapat diletakkan kembali pada
Remove the adjusting
posisinya semula. nut and brake cable from the joint pin.
Remove theroda
Lepaskan jointbelakang
pin and return
(hal.spring.
12-4).
Expand theadjusting
Lepaskan brake shoes and brake
nut dan removecable
the brake shoes/shoe
dari joint
dari joint pin.
springs from
Lepaskan joint
Lepaskan thepin
joint brake
danpanel.
return spring.
Renggangkan
– Brake arm boltbrake shoes dan lepaskan brake
shoes/shoe
– Brake arm/brake dari
springs cam
cam brake panel.
Lepaskan
– sebagai berikut:
Dust seals
- Brake arm bolt

- • Brake
Applyarm/brake
grease tocam
grease the dust seals,
the seals, brake
brake cam and
and brake
anchor
- Dust seals pin as specified.
• Repla
Replacece the dust seals
seals and
and brake arm bolt
bolt with new
new ones.
ones.
Pasang
Install the parts
removed yang
partstelah dilepaskan
in the reverse dalam
order of urutan
removal.
Adjust the rear brake lever free play (page 3-16).
Setel jarak main bebas rear brake lever (hal. 3-16).
*: Berikut 0.2 - 0.3 g gemuk.
DUST SEAL *
Tepatkan
ANCHOR PIN
BRAKE CAM
BRAKE SHOES
BRAKE ARM
Pasang shoe springs

dengan ujungnya yang
terbuka menghadap keluar .
BRAKE ARM BOLT

10 N·
N·m (1.0 kgf ·m, 7 lbf ·ft)
ADJUSTING NUT
SHOE SPRINGS
JOINT PIN
Letakkan ujung-ujung return spring ke

dalam lubang pada brake panel dan
pada pin pada brake arm.
RETURN SPRING
13-5
SISTEM REM
PEMERIKSAAN
INSPECTION
Measure
Ukur therear
D.D. rearbrake
brake drum
drum I.D.
(teromol rem belakang)
SERVICE
LIMIT: 131.0 mm (5.16 in)
PENGGANTIAN BRAKE FLUID (MINYAK

BRAKE
REM) FLUID
/AIR REPLACEMENT/AIR
BLEEDING (PEMBUANGAN
BLEEDING
UDARA PALSU)
BRAKE FLUID DRAINING
PENGELUARAN BRAKE FLUID
• Do not mixmix different
different types
types of fluid,
fluid, as they are
are not com-
com-
• patible
Jangan with each other.
each
mencampurkan bermacam-macam
bermacam-macam jenis
• Do notoleh
fluid, allowkarena
allow foreignmereka
foreign material tidak
material to enter
to the system
the
cocok syste
satumsama
when
filling
lain. the reservoir.
• Jangan membiarkan benda asing memasuki sistem
ketika mengisi reservoir.
Spilled fluid can damage painted, plastic or rubber parts.
CATATAN
Place a rag over these
these parts whenever
whenever the system is serviced.
Fluid yang tertumpah dapat merusak parts yang dicat,
Do not allow foreign Turn the handlebar until the reservoir is parallel to the ground
atau terbuat dari plastik atau karet. Letakkan kain lap SCREWS
material to enter the before removing the reservoir cap. RESERVOIR CAP
systemwhen filling the
menutupi parts ini ketika sistem diservis.
Remove the screws, reservoir cap, diaphragm plate and dia-
angan membiarkan
reservoir. Putar handlebar sampai reservoir parallel dengan tanah
phragm.
benda asing memasuki
sebelum melepaskan reservoir cap.
sistem ketika mengisi DIAPHRAGM
reservoir. PLATE
Lepaskan screws, reservoir cap, diaphragm plate dan
DIAPHRAGM
diaphragm.
Sambungkan
Connect a bleedbleed
hose tohose (slang
the caliper pembuangan)
bleed valve. pada
BLEED VALVE
caliper bleed valve.
Loosen the bleed valve and pump the brake lever until no
more fluid flows out of the bleed valve. BLEED HOSE
Longgarkan bleed valve dan pompa brake lever sampai
fluid tidak mengalir keluar lagi dari bleed valve.
13-6
SISTEM REM
BRAKE FLUID FILLING/AIR
PENGISIAN
BLEEDINGBRAKE FLUID/AIR BLEEDING
angan mencampurkan
Do not mix different Isi
Fillmaster cylinder
the master reservoir
cylinder reservoirdengan
with DOT brake
3 or fluid
DOT DOT
4 brake3
bermacam-macam jenis
types of fluid. They atau
fluid DOT 4 dari
from the sealedkemasan
containeryang
to the belum pernah dibuka
upper level.
fluida. Mereka tidak UPPER LEVEL
are not compatible. sampai ke upper level (tinggi permukaan teratas).
cocok satu sama lain. • Check thethe fluid
fluid level often
often while
while bleeding
bleeding the
the brake to
to
prevent air from being pumped into the system.
• Periksa tinggi permukaan fluid sering-sering
sewaktu membuang udara dari sistem rem untuk
mencegah dipompanya masuk udara ke dalam
sistem.
Hubungkan brake bleeder

Connect a commercially yang brake
available dapatbleeder
dibeli to
di the
pasaran
bleed
BLEED HOSE
pada
valve.bleed valve.
Operate the brake bleeder and loosen the bleed valve.
Jalankan brake bleeder dan longgarkan bleed valve.
If air enters the Perform the bleeding procedure until the system is com-
Jika udara memasuki
memasuki Jalankan prosedur bleeding sampai sistem sama sekali
bleeder from around
bleeder dari sekitar ulir
pletely flushed/bled.
the bleed
dibilas.
Close the bleed valve and operate the brake lever.
bleed valve, rapativalve
ulir Tutup bleed
threads,
dengan teflon seal the
tape. If it still feelsvalve dan
spongy, jalankan
bleed brakeagain.
the system lever.
threads with tinggi
teflon
Jika masih terasa seperti sepons, buanglah udara palsu
Periksa After bleeding
permukaan fluid sering- tape.
serin g-
sekali lagi dari the system completely, tighten the bleed v alve
sistem.
sering
Checksewaktu
the fluidmem-
level
bleeding
often whilesistem rem
bleeding
Setelah sistem telah di-bleeding di- bleeding sama sekali,
untuk menghindari
the brake to prevent kencangkan bleed valve dengan torsi yang ditentukan.
dipompanya
air fromudara
being
masuk pumped
ke dalam into the TORSI: 6 N.m (0,6 kgf.m;
sistem. kgf.m; 4,4 lbf.ft)
lbf.ft) BLEED VALVE
system.
Jika
If thebrake
brake bleeder
bleeder istidak tersedia,perform
not available, jalankan prosedur
the following
sebagai berikut.
procedure.
Pump up the system pressure with the brake lever until the
Pompa tekanan sistem dengan brake lever (handel rem)
lever resistance is felt.
sampai terasa ada tahanan pada lever.
Check Periksa
the fluidtinggi
level Hubungkan bleed
Connect a bleed hosehose pada
to the bleed
bleed valvevalve dan the
and bleed buanglah
system BLEED VALVE BLEED HOSE
permukaan fluidbleeding
often while sering-
sering- udara palsu dari sistem sebagai berikut:
as follows:
sering sewaktu
the brake mem-
to prevent
bleeding sistem rem 1. Squeeze
Squeeze the brake leverlever all
all the way and loosen
loosen the bleed
bleed
air from being valve
• Tekan brake lever seluruhnya dan longgarkan
1/2 of a turn. Wait several seconds and then close
untuk menghindari
pumped into the bleed
the bleedvalve
valve. ½ putaran. Tunggu beberapa detik
dipompanya udara
system. kemudian
masuk ke dalam sistem. 2. Rele ase the tutup
Release brake bleed
brake valve.
lever slowly
slowly and wait wait several
several seconds
seconds
Do not release the after
Lepaskan brake
angan melepaskan •
it reaches the endlever pelan-pelan dan tunggu
of its travel.
brakebrake
lever lever
sampaiuntil the
bleed beberapa
3. Repea
Repeat detik
t the steps
steps 1 andsetelah
2 until theiare are
until there mencapai
no air ujung
air bubbles
bubble s in
bleed valve has been
valve telah ditutup. perjalanannya.
the bleed hose.
closed.
• Ulangi langkah 1 dan 2 sampai tidak ada lagi
After bleeding the system completely, tighten the bleed v alve
gelembung-gelembung udara di dalam bleed hose.
Setelah mem-bleeding
mem-bleeding sistem sama sekali, kencangkan
TORQUE:6
bleed N·m (0.6
valve dengan kgf·m,
torsi 4.4ditentukan.
yang lbf·ft)
TORSI: 6 N.m (0,6 kgf.m;

kgf.m; 4,4 lbf.ft)
lbf.ft)
13-7
SISTEM REM
Do not
angan Fill
mix different Isi
mencampurkan the reservoir
reservoir to the
sampai upper permukaan
ke tinggi level with DOT 3 ordengan
teratas DOT 4
bermacam-macam brake fluid
jenis brake
types of fluid. They fluid from
DOTa sealed
sealed container.
3 atau DOT 4 dari kemasan yang UPPER LEVEL
brake fluid.
are not Mereka belum pernah dibuka sebelumnya.
compatible.
tidak cocok satu sama
lain.
Pasang diaphragm,
Install the diaphragm,diaphragm
diaphragmplate
platedan
and reservoir
reservoir cap,
cap,
kemudian
then tighten the screws to the specified torque. torsi yang
kencangkan screws dengan RESERVOIR CAP SCREWS
ditentukan.
TORQUE:2
TORSI: N·m
2 N.m (0.2
(0,2 kgf·m,
kgf.m;
kgf 1.5lbf.ft)
.m; 1,5 lbf·ft)
lb f.ft)
DIAPHRAGM
PLATE
DIAPHRAGM
BRAKE
BRAKE PAD/DISC
PAD/DISC
PENGGANTIAN BRAKE PAD
BRAKE PAD REPLACEMENT
Check Periksa
the braketinggi
fluid Dorong
Push the caliper pistons
caliper pistons seluruhnya
all the ke dalam
way in to allow untuk
installation of
permukaan brake
brake fluid
new brake pads. pemasangan brake pads baru.
level in the reservoir memungkinkan
di dalam reservoir
as this operation
sering-sering oleh
causes operasi
karena the levelini
to
menyebabkan naiknya rise.
tinggi permukaan brake
fluid.
BRAKE CALIPER
Remove the
Lepaskan pad
Lepaskan padpin
pad pinplug
plugdari
frombrake
the brake caliper.
caliper.
PAD PIN PLUG
13-8
SISTEM REM
Remove the padpin
Lepaskan pad
Lepaskan pad pinplug
fromdari
the brake
brakecaliper.
caliper.
PAD PIN
Lepaskan brake
Remove the brakepads
pads dari
frombrake caliper.
the brake caliper.
BRAKE
PADS
Selalu ganti
Always brake
replace Install new
the Pasang brake
brake padsbaru
pads so that they are set
sehingga on the ditempatkan
mereka brake caliper
pads
brake pads dalam
in pairs bracket
to pada and bracket
brake caliper pin.
pin.
bracket dan bracket pin. Tempatkan
pasangan
assure evenuntuk
disc BRACKET PIN
memastikan pressure.
tekanan
merata pada disc.
BRAKE
PADS
Pasang
Install the pad pinby pushing
pad pin dengan themendorong brakethepads
brake pads against pad
terhadap pad the
spring to align spring untuk
pad pin mentepatkan
holes lubang-lubang
o n the pads and caliper.
pad pin pada pads
pada pads dan caliper.
PAD PIN
13-9
SISTEM REM
Kencangkan pad
Kencangkan pad
Tighten the pad pinpin dengan
to the torsitorque.
specified yang ditentukan.
TORSI: 18 N.m (1,8 kgf.m;
kgf.m; 13 lbf.ft)
PAD PIN
Setelah penggantian
After
brake pad,the pad Pasang
brakecara
periksa dan
Install and kencangkan
kencangkan pad
tighten pad
the pad pin pin plug.
plug.
replacement, check
kerja rem dengan
the brake
menekan operation
brake lever.
by applying the brake
lever.
PAD PIN PLUG
PEMERIKSAAN BRAKE DISC

BRAKE DISC INSPECTION
Periksa
Visually brake
inspect disc secara
the brake disc visual terhadap
for damage kerusakan
or cracks.
atau retak-retak.
Measure the brake disc thickness at several points.
Ukur ketebalan brake disc pada beberapa titik.
SERVICE
BATAS
LIMIT: SERVIS: 3 3,0 mm
.0 mm (0.12 in)
Periksa
Check the brake disc
brake disc terhadap perubahan
for warpage. bentuk
melengkung.
SERVICE
LIMIT: SERVIS: 0
BATAS .10 m
0,10 m (0.004 in)
mm
If theperubahan
Jika warpage exceeds
bentukthe service limit,melampaui
melengkung check the wheel
batas
bearings
servis, for excessive
periksa wheel play.
play.
bearings (bantalan roda) terhadap
kelonggaran
For brake discberlebihan.
replacement, refer to page 11-8.
Untuk penggantian brake disc, lihat hal. 11-8.
13-10
SISTEM REM
BRAKE MASTER
BRAKE MASTER CYLINDER
CYLINDER
Drain the brake fluid (page 13-6).
Keluarkan
Remove the brake fluid (minyak
rear handlebar coverrem) (hal.
(page 2-5).13-6).
Lepaskan rear handlebar cover (hal. 2-5).
Disconnect the brake light switch connectors.
Lepaskan brake light switch connectors.
Remove the oil bolt, brake hose and sealing washers.
Lepaskan oil bolt, brake hose dan sealing washers.
Install the removed parts in the reverse order of removal.
• Replace the sealing washers with new ones.
Isi
Filldan
and air bleedthe
air bleed (buang udara
hydraulic palsu)
system (pagesistem
13-7). hidraulik
(hal. 13-7).
SCREW Tepatkan ujung master

2 N·m (0.2 kgf ·m, 1.5 lbf ·ft) BOLTS cylinder dengan tanda titik
HOLDER pada handlebar.
RESERVOIR CAP
Kencangkan baut atas
dulu, baru kemudian
baut bawah.
DIAPHRAGM PLATE
Letakkan holder
dengan tanda "UP"
menghadap keatas.
DIAPHRAGM
SEALING WASHERS
OIL BOLT
MASTER CYLINDER 34 N·m (3.5 kgf ·m, 25 lbf ·ft) Tepatkan brake
hose eyelet
CONNECTORS BRAKE HOSE terhadap stopper.
13-11
SISTEM REM
- – Brake
Brakelever
leverpivot
pivotnut,
nut,bolt
bolt dan
and brake
brakelever
lever
– Screw and brake light
- Screw dan brake light switchswitch
- – Boot
Boot
Remove/install the snap ring using the special tool.
TOOL:
Snap
TOOL:ring pliers 07914-SA50001
Snap ring washer,
Lepaskan pliers master piston dan07914-SA50001
spring.
•
Remove the washer,
Pertahankan master piston
piston, cups, and spring.
spring, snap ring dan
boot sebagai satu set; jangan mengganti parts
SNAP RING PLIERS
secara terpisah. SNAP RING
• Keep the piston, cups, spring, snap ring and boot as a set;
• Ketika memasang
do not substitute cups,parts.
individual jaga agar bibirnya tidak
berputar
• Apply terbalik
brake bagian
fluid to dalammaster
the spring, di luar.
piston and piston
• Pastikan
cups. bahwa snap ring telah duduk dengan erat
pada alurnya.
• When installing the cups, do not allow the lips to turn
inside out.
• Apply silicone grease to the brake lever pivot bolt sliding
surface and boot as specified.
• Be sure that snap ring is firmly seated in the groove.
* PIVOT BOLT
SPRING
WASHER 1 N·m (0.1 kgf ·m, 0.7 lbf ·ft)
BOOT
MASTER
PISTON CUPS CYLINDER BODY
SNAP RING
MASTER PISTON
BRAKE LIGHT
SWITCH
BRAKE LEVER
PIVOT NUT SCREW
*: Oleskan 0.1 g silicone grease 6 N·m (0.6 kgf ·m, 4.4 lbf ·ft) 1 N·m (0.1 kgf ·m, 0.7 lbf ·ft)
PEMERIKSAAN
INSPECTION
Periksa
Check the piston cupsforterhadap
piston cups keausan,orpemburukan
wear, deterioration damage.
Check the
kondisi master
atau cylinder inner surface and piston outer sur-
kerusakan.
face for scratches
Periksa or damage.
permukaan dalam master cylinder dan
permukaan luar cylinder
Measure the master piston I.D.terhadap goresan atau
kerusakan.
SERVICE
Ukur D.D. master cylinder.
LIMIT: 11.055 mm (0.4352 in)
MeasureSERVIS:
BATAS the master 11,055
piston O.D.
mm
SERVICE
Ukur D.L. master piston.
LIMIT: 10.945 mm (0.4309 in)
13-12
SISTEM REM
BRAKE CALIPER
BRAKE CALIPER
REMOVAL
PELEPASAN
Avoidagar
Jaga spilling fluidrem
minyak on Drain the brake fluid (page 13-6).
Keluarkan brake fluid (hal. 13-6).
painted, plastic,
tidak tertumpah atas or
rubber parts.
parts yang dicat, atau Lepaskan sebagai berikut:
Place
terbuatadari
shopplastik
towel – Oil bolt/sealing washers
atau karet.
- Oil bolt/sealing washers
over these parts – Pad spring
Letakkan
whenever thekain lap
system
- Pad spring
– Brake pads (page 13-8)
menutupi parts ini
is serviced.
- Brake
– padsbolts
Mounting (hal. 13-8)
setiap kali sistem - – Mounting
Brake caliper (baut pemasangan)
bolts
diservis. - Brake caliper
INSTALLATION
PEMASANGAN
Install the front brake caliper onto the left fork leg.
Pasang front
Install new brake caliper
mounting pada
bolts and kakithem
tighten kiri fork.
to the specified
Pasang
torque. mounting bolts baru dan kencangkan dengan
TORSI: 30 N.m
Connect the brake(3,1
hosekgf.m; 22 lbf.ft)
to the brake caliper with the oil bolt
and new sealing washers.
Sambungkan brake hose pada brake caliper dengan oil
Tighten the oil bolt
bolt danthe
Tighten sealing washers
oil bolt baru. torque.
to the specified
Kencangkan oil bolt
while pushing the Kencangkan oil bolt dengan torsi yang ditentukan.
sementara menekan TORQUE:34 N·m (3.5 kgf·m, 25 lbf·ft)
brake hose eyelet TORSI: 34 N.m (3,5 kgf.m; 25 lbf.ft)
brake hose eyelet joint
joint against
terhadap the
stopper. Install the brake pads (page 13-9).
stopper. Pasang brake pads (hal. 13-9).
Fill the brake fluid and bleed the hydraulic system (page 13-
Isi brake fluid dan bleed (buang udara palsu) dari sistem
7).
hidraulik (hal. 13-7).
BRAKE HOSE
OIL BOLT
34 N·m (3.5 kgf ·m, 25 lbf ·ft)
BRAKE CALIPER
SEALING WASHERS
BRAKE CALIPER MOUNTING BOLTS

30 N·m (3.1 kgf ·m, 22 lbf ·ft)
13-13
SISTEM REM
- –Caliper
Caliper bracket
bracket
– Pin boots
- Pin boots
– Pad spring
- Pad spring
Place a shop towel over the piston.
Letakkan kain lap di atas piston.
Jangan Do not useudara
memakai high Position the caliper body with the piston facing down and
Tempatkan caliper body dengan piston menghadap ke
pressure air
bertekanan or bring
tinggi atau apply small squirts of air pressure to the fluid inlet to remove
bawah dan jalankan semprotan-semprotan kecil udara
meletakkan nozzle
the nozzle too the piston.
terlalu dekat
bertekanan pada lubang masuk fluid untuk
close to the pada
inlet.
lubang. Remove the dust seal/piston seal.
mengeluarkan piston.
Keluarkan dust seal/piston seal.
• Replace
terbalik dari the piston seals and dust seals with new ones.
pelepasan.
• Apply brake fluid to the piston and piston seals.
• Apply silicone grease to the bracket pin boots and dust seals as specified.
DUST SEAL
*
BRACKET PIN BOOT
CALIPER BRACKET
Pasang caliper piston dengan
ujung yang terbuka
menghadap ke brake pads.
PISTON SEAL
*
BRACKET PIN BOOT
BLEED VALVE
6 N·m (0.6 kgf ·m, 4.4 lbf ·ft)
PAD SPRING
CALIPER BODY
CALIPER PISTON *: Oleskan minimum 0.4 g grease

PEMERIKSAAN
INSPECTION
Periksa caliper
Check the cylinder
caliper cylinderterhadap gerusan,
for scoring, goresan
scratches atau
or damage.
kerusakan.
Measure the caliper cylinder I.D.
Ukur D.D. caliper cylinder.
SERVICE
LIMIT: 32.090 mm (1.2634 in)
Check the
Periksa caliperpiston
caliper piston terhadap
for scoring,gerusan,
scratchesgoresan
or damage.
atau
kerusakan.
Measure the caliper piston O.D.
Ukur D.L. caliper piston.

SERVICE
LIMIT:SERVIS: 31,94
BATAS 31.94 mm
mm(1.257 in)
13-14
14. BATERAI/SISTEM PENGISIAN/ALTERNATOR
LOKASI SISTEM
SYSTEM ....................................14-2
LOCATION ····································14-2 FLYWHEEL / ALTERNATOR STATOR...
FLYWHEEL/ALTERNATOR 14-7
STATOR······14-7
DIAGRAM
SYSTEMSISTEM
DIAGRAM................................14-2
······································14-2 PEMERIKSAAN
ALTERNATORALTERNATOR.............. 14-11
INSPECTION···················· 14-12
COMPONENT LOCATION ·························· 14-3 BATERAI.................................................. 14-12
BATTERY ······················································14-12

SERVICE INFORMATION ···························14-4
SISTEM PENGISIAN................................ 14-13
CHARGING SYSTEM ························ ········· 14-13
TROUBLESHOOTING ··································14-6
REGULATOR / RECTIFIER ..................... 14-14
REGULATOR/RECTIFIER ························· 14-14
14
14-1
BATERAI/SISTEM PENGISIAN/ALTERNATOR
SYSTEMSISTEM
LOCATION
BATTERY/CHARGINGSYSTEM/ALTERNATOR
LOKASI
DIMMER SWITCH LIGHTING SWITCH
BATTERY
REGULATOR/RECTIFIER
ALTERNATOR
SYSTEM DIAGRAM
DIAGRAM SISTEM
Y
W
MAIN FUSE
3P
15A
R R Y W
G Y
W
4P G
R: Red
G G: Green
BATTERY REGULATOR/ Y: Yellow
RECTIFIER W: White
ALTERNATOR
14-2
COMPONENT LOCATION
6 N·
N·m (0.6 kgf ·m, 4.4 lbf ·ft)
39 N·
N·m (4.0 kgf ·m, 29 lbf ·ft)
10 N·
N·m (1.0 kgf ·m, 7 lbf ·ft)
14-3
KETERANGAN SERVIS
SERVICE INFORMATION
UMUM
GENERAL
! PERINGATAN
• Baterai mengeluarkan gas-gas eksplosif; eksplosif; jauhkan percikan bunga api, lidah api dan rokok. Sediakan ventilasi
• The battery gives off off explosive gases; keep sparks, flames and cigarettes away.away. Provide adequate ventilation
ventilation when charging.
charging.
memadai ketika mengisi muatan listrik.
• The battery contains
contains sulfuric acid (electrolyte).
(electrolyte). Contact
Contact with skin or eyes may cause severe burns.
burns. Wear
Wear protective clothing and a face
• Baterai mengandung
shield. mengandung asam sulfat (elektrolit). Kontak dengan kulit atau mata dapat menyebabkan luka bakar parah.
Pakailah
– If electrolytepakaian
gets onpelindung
gets your skin,dan
flushpelindung
with water.mata.
- Jika elektrolit
– If electrolyte gets mengenai kulit, bilas
withdengan
gets in your eyes, flush with air.
water for at least
least 15 minutes and call a physician
physician immediately.
immediately.
-
• Electr Jika
Electroly
olyteelektrolit
te is
is poiso mengenai
poisonou
nous.
s. mata, bilas dengan air selama sekurangnya
sekurangnya 15 menit dan mintalah
bantuan dokter
– If swallowed, drink dengan
large segera.
large quantities of
of water or milk and call
call your local Poison Control Center or a call
call a physician
physician immediately.
immediately.
• Electrolit beracun.
- Jika tertelan, minumlah sejumlah besar air atau susu dan hubungilah Pusat Penanganan
Keracunan dengan segera atau minta bantuan dokter dengan segera.
• Always turn turn off the ignition switch before
before disconnecting
disconnecting any electrical component.
• Some
CATATAN electri
electrical
cal components may be damaged if terminals or connectors are connected
connected or disconnected while the ignition
ignition switch is ON and
•
current is present.kunci kontak sebelum melepaskan komponen listrik.
Selalu matikan
• • Beberapa
For extended komponen
storage, removelistrik the
remove dapat rusak
battery, jika
give it aterminal
it full charge, atau and connector
store it in disambungkan
store space.atau
a cool, dry space. dilepaskan
For maximum sementara
servi
service kuncithe
ce life, charge thekonta
stored
pada posisi
battery pevery
osisi ONO N dan
two weeks.
weeks.arus listrik
listrik mengalir
mengalir..
• For a battery
battery remaining in in a stored scooter,
scooter, disconnect the negative battery cable cable from the battery terminal.
terminal.
• • The maintenanc
maintenance
Untuk penyimpanan e free batt
battery
ery must be replaced when it reaches the end of its service life.
penyimpanan jangka panjang, lepaskan baterai, berikan muatan penuh, dan simpan di tempat kering yang sejuk. Untuk
• The battery can
mendapatkan can be
umurdamaged
pemakaianif overcharged
if maksimum, or undercharged,
undercha rged, oryang
isilah baterai if leftdisimpan
to discharge for long
dengan period.listrik
muatan Thesesetiap
same conditions
same dua minggu. contribute to short-
contribute
•
ening the "life span" of the battery. Even under normal use, the performance of the
Untuk baterai yang tetap dipasang pada skuter yang disimpan, lepaskan kabel negatif baterai dari terminal baterai. battery deteriorates after 2-3 years.
• Battery voltage
voltage may recover after after battery charging, but under heavy load, load, battery voltage will drop quickly and eventually die out. out. For this
• Baterai maintenance free harus diganti jika ia mencapai akhir dari umur pemakaiannya.
reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in the battery itself, which may
• Baterai dapat rusak jika di-overchargedi-overcharge (diisi muatan listrik berlebihan) atau di- undercharge (kurang pengisian muatan listrik),
appear to be an overcharging symptom. If one o f the battery cells is shorted and battery voltage does not increase, the regulator/rectifier sup-
atau excess
plies bila iavoltage
dibiarkan
voltage to the berkurang sendiri
battery. Under
battery. muatannya
these conditions,untuk
conditions, jangka
the electrolyte
electrol ytewaktu lama.down
level goes Keadaan-keadaan
quickly.
quickly. sama ini ikut berperan dalam
memperpendek
• Before troubleshooting umur pemakaian
troubleshooting the charging system, checkbaterai. Bahkan pada pemakaian normal,
check for proper use and maintenance of the battery. Check unjuk kerja baterai
Check ifakan memburuk
the battery setelahunder
is frequently 2-3
tahun.
heavy load, such as having the headlight and taillight ON for long periods of time without riding the scooter.
Voltase
• • The battery baterai dapat membaik
membaik
will self-discharge
will whenkembali
kem
the bali setelah
scooter is notpengisian
in use. Formuatan listrik
this reason, baterai,
charge tetapi every
the battery di bawah beban
beba
two weeks
we eksntoberat,
preventvoltase
sulfation
sulfationbaterai
from
akan turun dengan cepat dan akhirnya mati. Karena itu, sistem pengisian seringkali diduga sebagai penyebab persoalannya.
occurring.
Battery
• When overcharge
checki
checking seringkali
ng the charging
charging system,diakibatkan
always follow olehthepersoalan
steps in thedi dalam baterai
troubleshooting flow sendiri, yang14-6).
chart (page mungkin
14-6) . tampak sebagai gejala
overcharging.
• For battery charging,Jika do salah satu sel
not exceed the baterai
chargingada currenthubungan time singkat
and time specifieddan on thevoltase
the battery.baterai etidak
Use of excessive
xcessivebertambah, regulator/rectifier
current or charging time may
may
memasok
damage the voltase
battery. berlebihan ke baterai. Di bawah kondisi ini, tinggi permukaan elektrolit akan menurun dengan cepat.
• •
The flywheel,
Sebelum alternator and
troubleshooting and ignition
sistem pulse generator services
pengisian, service
periksalahs can beapakah done with the engine
baterai installed in thedengan
installed
dipergunakan frame. baik dan bagaimana
• Refe
Referr to page 15
15-7
-7 for igni
ignition
tion pu
pulse
lse gen
generat
erator
or inspe
inspectio
ction. n.
perawatannya. Periksa apakah baterai seringkali di bawah beban berat, seperti jika lampu besar dan lampu belakang menyala
terus untuk jangka waktu lama tanpa mengendarai skuter.
• Baterai akan berkurang muatan listrik dengan sendirinya jika skuter tidak dipakai. Oleh karena itu, isilah baterai dengan dengan
BATTERY CHARGING
muatan listrik setiap dua minggu untuk mencegah terjadinya sulfasi.
• • Turn
Sewaktuthe power
the ON/OFF
ON/OFF
memeriksa at the pengisian,
at
sistem charger, notselalu
charger, at the battery
at bat tery
ikuti terminal.
termina
langkah-langkah l. pada peta aliran troubleshooting (hal. 14-6).
• • For
Padabattery
waktucharging,
pengisiando notmuatan
exceed the charging
listrik baterai, current
jangan and time
timelampaui
me specifiedarus on sthepengisian
aru battery. Using
danexcessive
dan waktu yang current or extending
ditentukan the charging
pada baterai.
baterai.
time may damage the battery.
Pemakaian arus atau waktu pengisian berlebihan dapat merusak baterai.
•
• Quic
Quick k charging
Pekerjaanchargin g should
servis only bealternator
only
flywheel, done in andan emerg
emergency;ency;pulse
ignition slow charging
slow charg ing is preferred.
generator pref erred.
dapat dijalankan dengan mesin terpasang pada rangka.
• Lihat hal. 15-7 untuk pemeriksaan ignition pulse generator.
BATTERY TESTING
PENGISIAN MUATAN LISTRIK BATERAI
•Refer to the instruction
Hidup/matikan o f the
daya Operation
listrik denganManual
saklar for the charger
pada recommended battery tester
(alat pengisian for details
muatan listrikabout battery
baterai), testing.
dan bukan pada terminal baterai.
•
The recommended
Sewaktu mengisi battery tester puts a "load" on
mengisi muatan listrik baterai, jangan jangan melampaui arus dan waktu pengisian seperti terterameasured.
the battery so that the actual battery condition of the load can be pada baterai. Pemakaian
arus listrik berlebihan atau memperpanjang waktu pengisian dapat merusak baterai.
•Reco
Recomm
mmen
Quick ende
dedd batt
batter
charging ery
y tes
testeter:
(pengisianr: muatan BM-2
BM-21010 ordengan
listrik BATT
BATTER ERYY MA
MATE
cepat) or equi
hanya eqboleh
uiva
vale
lent
nt
dilakukan dalam keadaan darurat, lebih diutamakan
pengisian muatan lsitrik dengan pelan).
PENGETESAN BATERAI
Bacalah petunjuk pemakaian di dalam Operation Manual untuk battery tester yang dianjurkan untuk detil-detil mengenai
pengetesan baterai.
Battery tester yang dianjurkan meletakkan "beban" pada baterai sehingga kondisi baterai sebenarnya dari beban dapat diukur.
Battery tester yang

yang dianjurkan: BM-210 atau BATTERY MATE atau sejenisnya
14-4
SPESIFIKASI
SPECIFICATIONS
BAGIAN SPESIFIKASI
Baterai Kapasitas ITEM 12 V –SP3,5
ECAh IFICATIONS
Battery Capacarus
Kebocoran ity maksimum V
1 2 – 3mA
0,5 .5 Ah
C
Voltase u r r en t leakage Terisi penuh Di atas 12,8 V max.
0 .5 m A
Voltage Fullydiisi
Perlu chalistrik
rged kembali Di bawahA12,3
bove V 12.8 V
Arus pengisian Needs charging
Normal 0,4 A / 5 Below
– 10 jam12.3 V
Charging current Normal
Cepat 0.4jam
3,0 A / 0,5 A/5 – 10 h
-1
Alternator Kapasitas Quick 0,140 kW 3/ .5.000
0 A00
5.0 /0.5menit
h (rpm)
-1
Alternator Capacity 0.111 kW/5,000 min (rpm)
NILAI TORSI
TORQUE VALUES
Cooling fan mounting bolt 10 N.m (1,0 kgf.m; 7 lbf.ft)
Flywheel nut 39N. (4,0 kgf.m; 29 lbf.ft)
Cooling fan mounting bolt 10 N·m (1.0 kgf·m, 7 lbf·ft)
Ignition pulse generator bolt 6 N.m (0,6 kgf.m; 4,4 lbf.ft)
Flywheel nut 39 N·m (4.0 kgf·m, 29 lbf·ft)
Ignition pulse generator bolt 6 N·m (0.6 kgf·m, 4.4 lbf·ft)
TOOLS
TOOLS
Holder P.D. 32-92 Flywheel puller

07NAB-HAC0100 07733-0010000
14-5
TROUBLESHOOTING
TROUBLESHOOTING
BATTERY IS DAMAGED OR WEAK
BATERAI RUSAK ATAU LEMAH
1. Ba
Batt
tter
ery
y Te
Test
st
• Test Baterai
Remove the battery (page 14-12).
14-12).
Lepaskan baterai (hal. 14-12).
Check the battery condition using the recommended battery tester.
Periksa kondisi baterai dengan menggunakan
RECOMMENDED BATTERY battery
TES-tester yang direkomendasikan.
TE
BATTERY TESTER R:
YANG BMatau
DIREKOMENDASIKAN: BM-210 -210 oBATTERY
r BATTERY MATatau
MATE E or esejenisnya.
quivalent
Is thekondisi
Apakah baterai dalam battery inbaik?
good condition?
YA - LANJUTKAN – GO
DE GO TO STEP
YES DENGAN
NGAN 2.
LANGKAH 2.
TIDAK rusak – Faulty battery
- Baterai NO
• Test Kebocoran2. Arus
Curren
Cur rentt Lea
Leakag
Listrik kagee Te
Test
st
Install
Pasang baterai (hal. the battery (page 14-12).
14-12). 14-12).
Periksa kebocoran Check the battery current leakage ( page

arus listrik baterai (hal. 14-13).( page 14-12).
14-12).
Is the current leakage below 0.5 mA? mA?
Apakah kebocoran arus listrik di bawah bawah 0,5 mA?
YES – GO GO TO STEP 4.
YA - LANJUTKAN DENGAN DENGAN LANGKAH 4.
NO – GO TO STEP 3.
TIDAK - LANJUTKAN DENGAN LANGKAH LANGKAH 3.
3. Curr
Current
ent Leakage
Leakage Test
Test Without
Without Regulator/
Regulator/rect
rectifie
ifierr
• Test Kebocoran Arus Listrik Tanpa Regulator/rectifier
Disconnect the regulator/rectifier connector and recheck the battery current leakage.
Lepaskan regulator/rectifier connector dan periksa kembali kebocoran arus listrik baterai.
Is the current leakage below 0.5 mA? mA?
Apakah kebocoran arus listrik di bawah bawah 0,5 mA?
YES – Faulty
Faulty regulator/rectifi
regulator/rectifier
er
YA - Regulator/rectifier rusak
NO – • Sh
Shor
orte
tedd wire
wire har
harne
ness
ss
TIDAK - • Ada hubungan •singkat Faul
Fa typada
ulty igniti
igni wire
tion
on swharness
swit
itch
ch
• Ignition switch (kunci kontak) rusak
4. Alter
Alternato
natorr Chargin
Charging g Coil
Coil Inspec
Inspection
tion
• Pemeriksaan Kumparan Pengisian Alternator
Check the alternator charging coil (page 14-11).
14-11).
Periksa kumparan Is
pengisian alternator
the alternator (hal.coil
charging 14-11).
resistance within 0.2
resistance 0.2 – 1.0 Ω (20
(20° C/68° F)?
Apakah tahanan kumparanGpengisian
O TO STEP alternator
YES – GO a5.lternator di antara 0,2 – 1,0 (20 C)?
YA - LANJUTKAN
NO DENGAN
DE NGANcharging
– Faulty LANGKAH
coil 5.
TIDAK - Kumparan
5. Chapengisian
Charg
rging rusak
ing Volta
Voltage
ge Inspec
Inspectio
tion
n
• Measure
Pemeriksaan Voltase and record the battery voltage using a digital multimeter (page 14-12).
Pengisian 14-12).
Startbaterai
Ukur dan catat voltase the engine.
dengan menggun akan digital multimeter (hal. 14-12).
Hidupkan mesin. Measure the charging voltage (page 14-12).
14-12).
Compare
Ukur voltase pengisian (hal.the measurements to result of the following calculation.
14-13).
STANDARD: Measured battery Voltage < Measured charging voltage < 15.5 V
Bandingkan hasil pengukuran dengan hasil dari perhitungan berikut ini.
STANDARD: Voltase Is the measured
baterai chadiukur
charging
yang rging voltage within
within
Voltase the standard
pengisian yangvoltdiukur
voltage?
age? 15,5 V
YES – Faulty
Faulty battery
Apakah voltase pengisian yang diukur diukur di dalam voltase standard?
YA - Baterai rusak
6. Regu
Regulato
lator/rec
r/rectifie
tifierr System
System Inspe
Inspectio
ction
n
TIDAK - LANJUTKAN DENGAN LANGKAH LANGKAH 6.
Check the voltage and resistance at the regulator/rectifier connectors (page 14-14).
14-14).
• Pemeriksaan Sistem Regulator/Rectifier
Are the results
results of checked voltage
voltage and resistance correct?
correct?
Periksa voltase dan tahanan pada regulator/rectifier connectors (hal. 14-14).
YES – Faulty
Faulty regulator/rectifi
regulator/rectifier er
Apakah hasil dari voltase dan tahanan yang diperiksa benar?
NO – • Ope
Open n circu
circuit
it in
in relate
related
d wire
wire
YA - Regulator/rectifier
• rusak
Loose or poor conta
contacts
cts of
of related
related termin
terminal
al
• Sh
Shor
orte
tedd wire
wire har
harne
ness
ss
TIDAK - • Rangkaian terbuka pada pada kawat yang bersangkutan
• Kontak longgar atau
atau buruk dari terminal yang bersangkutan
• Ada hubungan singkat pada wire harness
14-6
FLYWHEEL/ALTERNATOR
FLYWHEEL/A LTERNATOR
FLYWHEEL/ALTE RNATORSTATOR
FLYWHEEL/ALTERNATOR STATOR
PELEPASAN
REMOVAL
Lepaskan
Remove thecooling
coolingfan
fancover
cover(hal.
(page2-12).
2-12).
Lepaskan
Remove themounting bolts
mounting bolts and(baut
coolingpemasangan)
fan. dan BOLTS
cooling fan.
COOLING FAN
Lepaskan crankcase
Release the crankcase breather
breather drain
drain hose fromhose (slang
the clamp.
pembuangan pernapasan crankcase) dari clamp.
Remove the two air cleaner housing mounting bolts from the BOLTS
Lepaskan
left side. kedua air cleaner housing mounting bolts dari
sisi kiri. the bolt from the right side of air cleaner housing.
Remove
Lepaskan bolt dari sisi kanan dari air cleaner housing.
DRAIN
HOSE CLAMP BOLT
Be careful not to Angkat

Slightlyair
lift cleaner housing
the air cleaner sedikit
housing overditheatas air cleaner
air cleaner hous-
disconnect the air housing bolt boss.
ing bolt boss. AIR CLEANER HOUSING
cleaner housing
BOLT BOSS
Hold the flywheel with the special tool and loosen the fly-
connecting hose from Tahan flywheel dengan special tool dan longgarkan
wheel nut.
the carburetor. flywheel nut.
TOOL:
TOOL:
Holder
Holder P.D. 32-92
P.D. 32-92 07NAB-HAC0100
07NAB-HAC0100
Lepaskan flywheel
Remove the nut
flywheel nutdan
andwasher.
washer.
HOLDER P.D. 32-92 NUT/WASHER
Lepaskan flywheel
Remove the flywheeldengan menggunakan
using the special tool. special tool.
TOOL:
Flywheel
TOOL: puller 07733-0010000
Flywheel puller 07733-0010000
FLYWHEEL PULLER
14-7
Disconnect the
Lepaskan alternator/ignition pulse
alternator/ignition pulsegenerator 3P connec-
generator 3P
tor.
connector.
Release the alternator/ignition pulse generator wire band boss
Lepaskan alternator/ignition pulse generator wire band
from the frame.
boss dari rangka.
ALTERNATOR/IGNITION
PULSE GENERATOR 3P
CONNECTOR WIRE BAND BOSS
Lepaskan alternator/ignition
Release the alternator/ignitionpulse
pulsegenerator
generator wire
wire band
band
bosses dari intake
bosses from shroud
the intake dan
shroud rangka.
and frame.
WIRE BAND BOSS WIRE BAND BOSS
Lepaskan
Remove the bolt, wire
bolt, wireholder
holderdan
and lepaskan
release thewire
wire grommet
grommet
WIRE GROMMET
dari
fromright
the crankcase.
right crankcase.
WIRE HOLDER BOLT
Remove the
Lepaskan two bolts
kedua boltsand
dansetset
plate from
plate theignition
dari ignitionpulse
pulse
generator.
generator. BOLTS
Remove the two mounting bolts, stator and ignition pulse

Lepaskan kedua mounting bolts, stator dan ignition STATOR
generator from the right crankcase.
pulse generator dari right crankcase.
BOLTS
SET PLATE
IGNITION PULSE GENERATOR
14-8
Be careful
Hati-hati agar not Remove the
to Lepaskan
tidak woodruff
woodruff key.
key.
merusak
damagekey dan
the keyalur.
and WOODRUFF KEY
groove.
PEMASANGAN
Hati-hati agar tidak Pasang woodruff key ke dalam alur crankshaft key.
merusak key dan alur.
INSTALLATION
Be careful not to Install the woodruff key into the crankshaft key gro ove.
damage the key and
the groove.
Set the stator

Tempatkan and ignition
stator pulse generator
dan ignition onto the pada
pulse generator right
crankcase.
right crankcase. BOLTS
Install and
Pasang dantighten the statorstator
kencangkan mounting bolts. bolts.
mounting
STATOR
Install the
Pasang setsetplate
plate pada
onto the ignition
ignition pulsegenerator
pulse generator dan
and
tighten the mounting
kencangkan bolts tobolts
mounting the specified
dengantorque.
torsi yang
ditentukan.
TORSI: 6 N.m (0,6 kgf.m; 4,4 lbf.ft) BOLT
SET PLATE
IGNITION PULSE GENERATOR
Route thekawat
Alurkan wire properly
denganandbenar
set the dan
wire grommet intowire
tempatkan the
WIRE GROMMET
right crankcase groove.
grommet ke dalam alur right crankcase.
Set the wire holder and tighten the holder bolt.
Tempatkan wire holder dan kencangkan holder bolt.
WIRE HOLDER BOLTS
Alurkan
Route thealternator
alternator/ Set the alternator/ignition
Tempatkan pulse generator
alternator/ignition wire band
pulse generator bosses
wire to
band
ignition pulse generator
ignition pulse the intake shroud and frame.
bosses pada intake shroud dan rangka.
wire dengan
generator(hal.
benar wire
1-14).
properly (page 1-14).
WIRE BAND BOSS WIRE BAND BOSS
14-9
Set the alternator/ignition
Tempatkan pulsepulse
alternator/ignition generator wire band
generator wireboss to
band
the frame.
boss pada rangka.
Connect the alternator/ignition pulse generator 3P connector.
Sambungkan alternator/ignition pulse generator 3P
connector.
ALTERNATOR/IGNITION
PULSE GENERATOR 3P
CONNECTOR WIRE BAND BOSS
Pasang flywheel
Install the pada
flywheel ontocrankshaft dengan
the crankshaft mentepatkan
by aligning the key
WOODRUFF KEY
wayway
key on the(alur
flywheel
spie)with the key
pada on the dengan
flywheel crankshaft.
key pada
crankshaft.
KEY WAY
Tepatkan
Pasang washer
andflywheel
flywheel nut.
nut.
WASHER
NUT
Tahan flywheel
Hold the flywheeldengan special
with the specialtool
tooldan
and kencangkan
tighten the nutnut
to
dengan torsi torque.
the specified yang ditentukan.
TOOL:
TOOL:P.D. 32-92
Holder 07NAB-HAC0100
Holder P.D. 32-92 07NAB-HAC0100
HOLDER P.D. 32-92 FLYWHEEL NUT
14-10
Set the airair
Letakkan cleaner housing
cleaner in position.
housing pada tempatnya.
BOLTS
Install and tighten the bolt to the right side of air cleaner
Pasang
housing.dan kencangkan bolt pada sisi kanan dari air
cleaner housing.
Install and tighten the two bolts to the left side of air cleaner
housing.dan kencangkan kedua bolts pada sisi kiri dari
Pasang
air cleaner
Secure housing.drain hose with the clamp.
the breather
DRAIN
HOSE CLAMP BOLT
Pasang cooling
Install the coolingfan dan tighten
fan and kencangkan mounting
the mounting bolts
bolts to the
dengan
specifiedtorsi yang ditentukan.
torque. BOLTS
TORQUE:10
TORSI: N·m
10 N.m (1.0
(1,0 kgf·m,77lbf.ft)
kgf.m; lbf·ft)
Pasang cooling
Install the fan
cooling cover
fan cover(hal.
(page2-12).
2-12).
COOLING FAN
PEMERIKSAAN ALTERNATOR
ALTERNATOR INSPECTION
Remove the
Lepaskan centerbody
center bodycover
cover (hal.
(page2-8).
2-8).
Disconnectalternator
Lepaskan the alternator 3P connector.
3P connector.
Check the
Periksa resistance
tahanan between
antara the following
terminals berikut terminals.
ini.
STANDARD:
STANDARD:
Kumparan
Charging coilpengisian
(White – (Putih – massa):
ground):
0,2
0.2 –
– 1,0 (pada
1.0 Ω (at 20 C)
20 °C/68°F)
Kumparan
Lighting coilpenerangan (Kuning – massa):
(Yellow – ground):
0,1
0.1 –
– 0,8 (pada
0.8 Ω (at 20 C)
20 °C/68°F)
Replace
Ganti the alternator
alternator stator
stator jika if measuredyang
pembacaan readings arejauh
diukur far
beyond the standard.
di luar standard. ALTERNATOR 3P
CONNECTOR
CHARGING COIL: LIGHTING COIL:
14-11
BATTERY
BATERAI
CATATAN:
Selalu turn
• • Always putar
thekunci kontak
ignition switch ke posisi
"OFF" "OFF"
before dulu
removing
the battery.melepaskan baterai.
sebelum BATTERY/POSITIVE
BATTERY (+) TERMINAL
Remove the battery cover (page 2-13).
Lepaskan battery cover (hal. 2-13).
Remove the bolt and disconnect the negative (–) cable.
Keluarkan
Remove theboltboltdan
and lepaskan
disconnectkabel negatif(+)
the positive ( -cable.
).
Keluarkan bolt dan
Remove the battery. lepaskan kabel positif ( + ).
Keluarkan baterai.
Connect theterminal
Sambungkan positive Install the battery in the reverse order of removal.
terminal Pasang baterai dalam urutan terbalik dari pelepasan.
positif dulu and
first dan After installing the battery, coat the terminals with clean
then the negative Setelah
kemudian baru grease. memasang baterai, lapisi terminal-terminal
terminalterminal.
negatif. dengan gemuk bersih.
Reinstall the removed parts.
Pasang kembali parts yang dilepaskan. BATTERY/NEGATIVE
( – ) TERMINAL
VOLTAGE INSPECTION
PEMERIKSAAN VOLTASE
Measure the battery voltage using a commercially available
digital multimeter.
Ukur voltase baterai dengan menggunakan digital
multimeter yang dapat dibeli di pasaran.
VOLTAGE (20⋅C/68⋅F):
Fully charged:
VOLTASE (20 C): Above 12.8 V
Under charged:
Bermuatan penuh:Below 12.3 V 12,8 V
Di atas
Muatan kurang: Di bawah 12,3 V
CHARGING SYST
CHARGING VOLTAGE INSPECTION
•
14-12
SISTEM PENGISIAN
TEST KEBOCORAN ARUS LISTRIK
( – ) JARUM (+) JARUM
Buka battery cover (hal. 2-13).
Putar kunci kontak ke OFF dan lepaskan kabel negatif (
- ) dari baterai.
Hubungkan jarum pemeriksaan ( + ) ammeter ke kabel
negatif ( - ) dan jarum pemeriksaan ( - ) ammeter ke
terminal ( - ) baterai.
Dengan kunci kontak pada posisi OFF, periksa terhadap
kebocoran arus listrik.
CATATAN:
• Ketika mengukur arus listrik dengan menggunakan
tester, letakkan pada daerah jangkauan tinggi dulu,
( – ) KABEL
kemudian turunkan daerah jangkauan ke tingkat
yang sesuai. Aliran arus listrik yang lebih tinggi dari
daerah jangkauan yang dipilih dapat memutuskan
sekring di dalam tester.
• Sewaktu mengukur arus listrik, jangan putar arus
kunci kontak ke ON. Lonjakan arus listrik dengan
mendadak dapat memutuskan sekring di dalam
tester.
KETENTUAN KEBOCORAN ARUS LISTRIK:

maksimum 0,5 mA.
Make sure the battery is in good condition before per-
Jika forming this test.
kebocoran arus listrik melampaui nilai yang
• Do not disconnect
ditentukan, kemungkinan the battery or any cable
ada hubungan in the charging
singkat.
system
Carilah without
lokasi first switching
hubungan singkatthe dengan
ignition switch to OFF.
melepaskan
hubungan satu demi satu dan mengukur arus listrik. or
Failure to follow this precaution can damage the tester
electrical components.
Warm up the engine to normal operating temperature.
PEMERIKSAAN
Stop the engine.
VOLTASE PENGISIAN
Remove the battery cover (page 2-13) and connect the multi-
To prevent a short, CATATAN:
meter as shown.
make absolutely • Pastikan bahwa baterai dalam kondisi baik sebelum
Connect a tachometer.
menjalankan test ini.
certain which are the
positive and negative • WithJangan melepaskan baterai
the headlight on high beam, atauthe
restart kabel apapun di
engine.
terminals or cables. dalam
Measure sistem onpengisian
the voltage tanpa
the multimeter when terlebih
the engine dulu
runs
mematikan
at 5,000 kunci kontak ke OFF. Kegagalan untuk
min-1 (rpm).
mengikuti tindakan pencegahan ini dapat merusak
tester atau komponen-komponen listrik.
STANDARD:
Measured battery voltage (page 14-12)
Panaskan mesin ke suhu operasi normal.
< Measured charging voltage (page 14-12)
Matikan mesin.
< 15.5 V at 5,000 min -1 (rpm)
Untuk menghindari Lepaskan battery cover (hal. 2-13) dan hubungkan
REGULATOR/RECTIFIER
hubungan singkat, multimeter seperti diperlihatkan.
pastikan dengan benar
manalah terminal atau Hubungkan tachometer.
kabel positif dan negatif.
Remo lampu besar pada sinar lampu jauh, hidupkan
Dengan
mesin kembali.
Ukur voltase pada multimeter sewaktu mesin berputar
-1
pada 5.000 menit (rpm).
STANDARD:
Ukur voltase baterai (hal. 14-12)
Voltase pengisian yang diukur (hal. 14-13)
-1
15,5 V pada 5.000 menit (rpm)
14-13
REGULATOR/RECTIFIER e the body cover
(page 2-9). REGULATOR/
BOLT RECTIFIER
PELEPASAN/PEMASANGAN Turn the ignition
switch to OFF.
Disconnect the regulator/rectifier 4P connector.
Putar kunci kontak ke OFF.
Remove the bolt and the regulator/rectifier.
Lepaskan regulator/rectifier 4P connector.
Lepaskan bolt dan regulator/rectifier.

pelepasan.
4P CONNECTOR
SYSTEM INSPECTION
Disconnect the regulator/rectifier 4P connector and check it
for loose contact or corroded
PEMERIKSAAN terminals.
SISTEM
If the battery charging voltage reading (page 14-12) is out of
the specification, inspect the connector terminals (wire har-
ness side) asregulator/rectifier
Lepaskan follows: 4P connector dan periksa
terhadap kontak longgar atau terminal-terminal
Item Terminal Specification
berkarat.
Battery charging Red (+) and Battery voltage
line ground (–)
Jika pembacaan voltase pengisian baterai should(hal.
register
14-13)
Charging coil line White and 0.2 – 1.0 Ω
di luar spesifikasi, periksa terminal-terminal connector
(sisi wire harness) ground
sebagai berikut: (at 20°C/68°F) REGULATOR/RECTIFIER
Ground line Green and ground Continuity should
4P CONNECTOR
Bagian Terminal exist
Spesifikasi
Saluran of the charging
omponents Merah (+)
systemdan are normal
Harusandada
there
pengisian massa ( - ) voltase
are no loose connections, replace the regulator/rectifier
baterai
unit. baterai
Saluran Putih dan 0,2 – 1,0 Ω
kumparan massa (pada 20°C)
pengisian
Saluran massa Hijau dan Harus ada
massa kontinuitas
Jika semua komponen sistem pengisian adalah normal

dan tidak ada sambungan longgar, gantilah
regulator/rectifier unit.
REGULATOR/
RECTIFIER 4P CONNECTOR
REGULATOR/
RECTIFIER 4P CONNECTOR
REGULATOR/RECTIFIER 4P
REGULATOR/
CONNECTOR
RECTIFIER
14-14
If thepembacaan
Jika lighting voltage reading
voltase is out of the
penerangan specification.
(hal. 14-15) di luar
Disconnect the tail/brake light/rear turn signal
spesifikasi, lepaskan tail/brake light/rear turn light 6P con-
signal 6P
nector (page 2-9), then check the connector
connector (hal. 2-9), kemudian periksa connector terminals (wire
harness
terminalsside) as wire
(sisi follows:
harness) sebagai berikut:
Terminal Specification
Bagian Terminal Spesifikasi
Yellow and 0.2 – 1.8 Ω
Saluran kumparan (at 20
ground Kuning
°C/68°F)
0,2 – 1,8 Ω
penerangan
Green and ground Continuitydan (pada 20°C)
massa
should exist
Saluran massa Hijau dan Harus ada
massa are normal
If all components of the system kontinuitas
and there are no
loose connections at the regulator/rectifier connectors, REGULATOR/RECTIFIER
replace the regulator/rectifier
Jika semua komponen dariunit.sistem adalah normal dan 4P CONNECTOR
tidak ada sambungan longgar pada regulator/rectifier
connectors, gantilah regulator/rectifier unit.
REGULATOR/RECTIFIER
4P CONNECTOR
14-15
CATATAN
15. SISTEM PENGAPIAN
LOKASI SISTEM...................................... 15-2

SYSTEM LOCATION ···································· 15-2
IGNITION COIL ......................................15-8
IGNITION COIL ············································· 15-8
DIAGRAM SISTEM .................................. 15-2 IGNITION SWITCH.................................15-8

SYSTEM DIAGRAM ······································ 15-2 IGNITION SWITCH·······································15-8
KETERANGAN SERVIS .......................... 15-3 SIDESTAND SWITCH............................15-9

SERVICE INFORMATION ··························· 15-3 SIDESTAND SWITCH ··································· 15-9
TROUBLESHOOTING ............................. 15-4 IGNITION CONTROL MODULE (ICM)...15-11

TROUBLESHOOTING ·································· 15-4 IGNITION CONTROL MODULE (ICM) ·· 15-11
PEMERIKSAAN SISTEM PENGAPIAN... 15-5 IGNITION TIMING ..................................15-12

IGNITION SYSTEM INSPECTION·············15-5 IGNITION TIMING······································15-12
15
15-1
SISTEM PENGAPIAN
SYSTEM LOCATION
IGNITIONSYSTEM
LOKASI SISTEM
MAIN FUSE 15A IGNITION SWITCH
BATTERY
IGNITION CONTROL MODULE (ICM)
SIDESTAND SWITCH
IGNITION COIL IGNITION PULSE GENERATOR
SYSTEM DIAGRAM
DIAGRAM SISTEM
MAIN FUSE G
15A
l Y
/ l Y
R R B
/ G W
/ u W
/ G B
/ /
l
R G B G R B IGNITION
COIL
Br
2P G 3P 3P 6P 4P
l Y
B W / G
G R / G / u
R G B
IGNITION CONTROL SPARK
BATTERY MODULE (ICM) PLUG
IGNITION SIDE STAND IGNITION

SWITCH SWITCH PULSE
GENELATOR
15-2
SISTEM PENGAPIAN
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
! PERINGATAN
If the
Jika engineharus
mesin must be run ning
dalam to do some
keadaan woruntuk
hidup k, make sure the area
melakukan is well ventilated.
sesuatu pekerjaan, Never run thebahwa
pastikan engine tempat
in an enclosed
kerja area. The exhaust
berventilasi baik.
contains poisonous carbon monoxide gas that may cause loss of consciousness and may
Jangan sekali-kali menjalankan mesin di dalam tempat tertutup. Gas pembuangan mengandung gas karbon monoksida beracun
lead dapat
yang to death.
mengakibatkan hilangnya kesadaran dan akhirnya dapat membawa kematian.
CATATAN
• Beberapa komponen listrik dapat rusak jika terminal-terminal atau connector-connector disambungkan atau dilepaskan
• Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and
sementara
current kunci kontak pada posisi ON dan ada arus listrik yang mengalir.
is present.
• Sewaktu menservis sistem pengapian, selalu ikuti langkah-langkah pada urutan troubleshooting pada hal. 15-4.
•• When servicing
Ignition timingthe(waktu
ignition system, always
pengapian) tidakfollow
perluthe stepsoleh
disetel in thekarena
troubleshooting sequence
Ignition Control on page(ICM)
Module 15-4. telah disetel awal di pabrik.
•• The ignition timing does not normally need to be adjusted since the Ignition Control
Ignition Control Module (ICM) dapat rusak jika dijatuhkan. Juga jika connector dilepaskan Module (ICM) is factory preset. arus listrik sedang
sewaktu
• The Ignition Control Module (ICM) may be damaged if dropped. Also if the connector is disconnected when current is flowing, the excessive
mengalir, voltase berlebihan dapat merusak module. Selalu matikan kunci kontak sebelum menservis.
voltage may damage the module. Always turn off the ignition switch before servicing.
• Sistem pengapian yang tidak bekerja dengan baik seringkali disebabkan oleh sambungan buruk. Selalu periksa
• A faulty ignition system is often related to poor connections. Check those connections before proceeding. Make sure the battery is adequately
sambungan ini sebelum melanjutkan. Pastikan bahwa baterai bermuatan listrik cukup. Menggunakan starter motor dengan
charged. Using the starter motor with a weak battery results in a slower engine cranking speed as well as no spark at the spark plug.
• Usebaterai lemah
spark plug of menghasilkan
the correct heat kecepatan
range. Usingperputaran mesin
spark plug with an yang lebih
incorrect rendah
heat maupun
range can tidak
damage the adanya
engine. percikan bunga api pada
busi.
• Pakailah busi dengan derajat panas yang tepat. Pemakaian busi dengan derajat panas yang tidak tepat dapat merusak
mesin.
SPECIFICATIONS
SPESIFIKASI ITEM SPECIFICATIONS
Spark plug Standard CPR8EA-9 (NGK) / U24EPR9 (DENSO)
BAGIAN For extended high speed riding SPESIFIKASI CPR9EA-9 (NGK)
Busi
Spark plugStandard
gap CPR 8EA -0.80
9 (NGK),
– 0.90U24EPR9
mm (0.031 (DENSO)
– 0.035 in)
Ignition coil peakpengendaraan
Untuk voltage lama pada kecepatan tinggi CPR 9EA – 9 (NGK) 100 V minimum
Jarak renggang busi
Ignition pulse generator peak voltage 0,80 – 0,90 mm 0.7 V minimum
Peak voltage
Ignition timing(voltase puncak) ignition coil minimum 100 V14° BTDC at idle speed
Peak voltage ignition pulse generator minimum 0,7 V
Ignition timing (pengaturan waktu pengapian) 14° sebelum TMA pada putaran stasioner
TORQUE VALUE
NILAI TORSI
Key shutter socket bolt 10 N·m (1.0 kgf·m, 7 lbf·ft.)
Key shutter socket bolt 10 N.m (1,0 kgf.m; 7 lbf.ft.)

TOOL
TOOL
Imrie diagnostic tester (model 625)

atau Peak voltage adaptor
07HGJ-0020100
Dengandigital
Dengan digitalmultimeter
multimeter (indeped-
(indepedansi
ansi minimum
minimum 10 MΩ10 WM/DCv)yang
/DCV )yang dapatdapat
di beli
didipasaran.
beli di pasaran.
15-3
SISTEM PENGAPIAN
TROUBLESHOOTING
TROUBLESHOOTING
• Inspect the following before diagnosing the system.
Periksa
• – Faulty sebagai
spark plug berikut ini sebelum mendiagnosa sistem.
- Spark
– Loose plug
spark (busi)
plug rusak.
cap or spark plug wire connection
- Spark plug cap (topi busi)
– Water got into the spark plug capatau sambungan
(Leaking kabel
the ignition busi
coil longgarvoltage)
secondary
- Air memasuki spark plug cap (Voltase sekunder ignition coil bocor)
No spark at spark plug
Tidak ada percikan bunga apicondition
Unusual pada busi. Probable cause (Check in numerical order)
Ignition coil Low peak voltage. 1. The multimeter impedance is too low; below 10 MΩ/ DCV.
primary voltage
Kejadian luar biasa 2. Cranking
Kemungkinanspeed is penyebab
too slow. (Battery is undercharged or operat-
ing force
(periksa of the kickstarter
menurut is weak)
urutan angka)
Voltase Peak voltage 1. Impedansi multimeter terlalu rendah; di bawah 10and
3. The sampling time of the tester MΩmeasured
/DCV. pulse were not
primer (voltase puncak) rendah synchronized. (System is normal
2. Putaran start mesin terlalu rendah (Baterai lemah atau gaya dorongif measured voltagepada
is over the
ignition kickstarter lemah) standard voltage at least once.)
coil 3. Waktu pengambilan 4. contoh
Poorly connected
tester danconnectors
pulsa yang or d
aniukur
opentidak
circuit in the ignition
sinkron
system.
(Sistem adalah normal bila voltase yang diukur adalah sekurangnya sekali
di atas voltase standard.)
5. Faulty ignition coil.
4. Connectors tersambung6. Faultydengan
ignitionburuk
controlatau ada rangkaian
module terbuka
(ICM) (in case whenpada
above No. 1
ignition system (sistem
– 5pengapian).
are normal).
No peak voltage. 5. Ignition coil tidak bekerja dengan
1. Incorrect peakbaik.
voltage adaptor connections.
6. Ignition control module (ICM) tidak switch.
2. Faulty ignition bekerja dengan baik (dalam hal bila No.
1-5 di atas adalah3.normal).
Loose or poorly connected ICM connectors.
Tidak ada peak voltage 1. Sambungan peak4.voltage circuit ortidak
Open adapter poor benar.
connection in the Red/Black wire of the
2. Ignition switch (kunciICM.kontak) tidak bekerja dengan baik.
5. Open
3. ICM connectors longgar circuit
atau or poor
buruk connection in the Green wire of the ICM.
sambungannya.
4. Rangkaian terbuka 6. atau
Open circuit in theburuk
sambungan Green/White
pada kawatwire or Green wire ofdari
Merah/Hitam the side-
ICM. stand switch.
5. Rangkaian terbuka 7. atau
Faulty sidestand switch.
sambungan buruk pada kawat Hijau dari ICM.
8. Faulty peak
6. Rangkaian terbuka pada kawat Hijau/Putihvoltage adaptor
atau(page
kawat15-5).
Hijau dari sidestand
switch. 9. Faulty ignition pulse generator. (Measure the peak voltage.)
10. Faulty ICM (in
7. Sidestand switch tidak bekerja dengan baik. case when above No.1 – 9 are normal).
Peak voltage is normal, but no spark jumps 1. Faulty spark plug or leaking
8. Peak voltage adapter (hal. 15-5) tidak bekerja dengan baik. ignition coil secondary current.
at the plug. 2. Faulty ignition coil.
9. Ignition pulse generator tidak bekerja dengan baik (Ukur peak voltage).
Ignition pulse Low peak voltage. 10. ICM tidak bekerja1. The multimeter
dengan baik (dalam impedance
hal bilaisNo.
too1-9
low.di atas adalah
generator normal). 2. Cranking speed is too slow. (Operating force of the kickstarter is
Peak voltage normal, weak)
1. Busi tidak bekerja dengan baik atau ada kebocoran pada arus sekunder
tetapi tidak ada ignition coil. 3. The sampling time of the tester and measured pulse were not
percikan bunga api synchronized.
2. Ignition coil tidak bekerja (System is normal if measured voltage is over the
dengan baik.
pada busi standard voltage at least once.)
4. Faulty ignition pulse generator (in case when above No.1 – 3 are
Ignition Peak voltage rendah 1. Impedansi multimeter terlalu rendah.
normal).
pulse 2. Putaran start mesin terlalu rendah (Gaya dorong pada kickstarter lemah).
No peak voltage. 1. Faulty peak voltage adapter (page 15-5).
generator 3. Waktu pengambilan contoh dari tester dan pulsa yang diukur tidak sinkron
2. Faulty ignition pulse generator.
(Sistem adalah normal bila voltase yang diukur adalah sekurangnya sekali
di atas voltase standard.)
4. Ignition pulse generator tidak bekerja dengan baik (dalam hal bila No. 1-3
di atas adalah normal).
Tidak ada peak voltage. 1. Peak voltage adapter tidak bekerja dengan baik (hal. 15-5).
2. Ignition pulse generator tidak bekerja dengan baik.
15-4
SISTEM PENGAPIAN
IGNITION SYSTEM
PEMERIKSAAN INSPECTION
SISTEM PENGAPIAN
CATATAN:
• • If theretidak
Jika is no spark
ada at plug, check
percikan all connections
bunga api pada for busi,
loose
DIGITAL MULTIMETER
or poor contact before measuring
periksa semua sambungan terhadap kontakpeak voltage.
• Use commercially
longgar available
atau buruk digital multimeter
sebelum mengukurwith peaan
impedance of 10 M Ω
voltage (voltase puncak)./DCV minimum.
• The display value differs depending upon the internal
• Pakailah digital multimeter dengan impedansi
impedance of the multimeter.
minimum 10 MΩ/DCV yang dapat dibeli di pasaran.
• If using Imrie diagnostic tester (model 625), follow the
• Nilai yang ditayangkan
manufacturer’s instructions.berbeda tergantung pada
impedansi internal dari multimeter.
Connect the peak voltage adaptor to the digital multimeter, or
•use Jika Imrie
the Imrie diagnostic
diagnostic tester. tester (model 625) yang
dipakai, ikutilah petunjuk pabrik pembuatnya.
TOOLS:
Hubungkan
Imrie diagnostic peak
testervoltage
(model 625) adaptor
or pada digital
multimeter,
Peak voltage atau pakailah Imrie diagnostic
adaptor tester.
07HGJ-0020100 PEAK VOLTAGE ADAPTOR
with Commercially available digital multimeter (imped-
TOOLS:
ance 10 MΩ/DCV minimum)
Imrie diagnostic tester (model 625) atauPeak voltage
adaptor 07HGJ-0020100
PEAK VOLTAGE ADAPTORdapat dibeli di
dengan digital multimeter yang
pasaran
INSPECTION (dengan impedansi minimum 10 M /DCV)
When
PEMERIKSAAN PEAK VOLTAGE
ADAPTOR
Sewaktu mengetes
testing the tegangan
high tension tinggi pada
on the ignition sisi sekunder
coil secondary side
ignition
using the coil denganadaptor,
peak voltage menggunakan peak
the inner diode may bevoltage
dam- PEAK VOLTAGE ADAPTOR
adaptor,
aged. As adiode
damageddi adaptor
sebelahwilldalam dapat rusak.
cause incorrect Oleh
peak voltage
karena sebuah
readings, alwaysadaptor
consideryang rusak adaptor
a defective akan mengakibatkan
if the peak vo lt-
age readings are
pembacaan all abnormal.
peak voltage yang tidak benar, selalu
The adaptor diode
pertimbangkan can be easilyadaptor
kemungkinan checkedyang
by therusak
following
jika
procedure. Therefore, be sure to check
pembacaan peak voltage semuanya tidak normal. the adaptor before
replacing
Diode the parts
adaptor that display
dapat an abnormal
diperiksa testing value.
dengan mudah dengan
Set the multimeter to the AC voltage range and measure the
prosedur sebagai
If you touch the local line voltage.
berikut. Oleh karena itu, pastikan
untuk memeriksa adaptor sebelum mengganti parts
adaptor jack Then, connect the peak voltage adaptor to the multimeter,
immediately after yang memperlihatkan
measure the same AC nilai pengetesan
voltage with DC tidak
voltage normal.
range and
disconnecting the compare it to AC voltage measured previously.
ika adaptor
adaptor, you may get Pasang multimeter pada daerah jangkauan voltase AC
jack
disentuh segera setelah dan • The
ukuradaptor
voltaseissaluran
normal if the DC voltage measured via the
lokal.
electrical shock.
melepaskan adaptor, Kemudian adaptor ishubungkan
1.4 times of AC voltage.
peak voltage adaptor ke
Be sure to disconnect
anda mungkin terkena • The adaptor
multimeter, ukur is defective
voltase AC if the DC
yang voltage
sama measured
dengan via
daerah
the adaptor
kejutan after
listrik. the adaptor is 0 V.
angkauan voltase DC dan bandingkan dengan voltase
allowing the voltage
Pastikan untuk
melepaskan to decrease
adaptor AC yang diukur sebelumnya.
sufficiently. • Adaptor adalah normal jika voltase DC yang diukur
setelah membiarkan
voltase turun sendiri melalui adaptor adalah 1,4 kali voltase AC (sekitar
dengan cukup. 300V).
• Adaptor adalah rusak jika voltase DC yang diukur
melalui adaptor adalah 0 V.
15-5
SISTEM PENGAPIAN
IGNITION
IGNITION COIL
COIL PRIMARY
PRIMARY PEAKPEAK
VOLTAGE
VOLTAGE
(VOLTAGE PUNCAK PRIMER COIL
PENGAPIAN)
CATATAN:
• Check all system connections before inspection. If the
system is disconnected,
• Periksa semua sambunganincorrect peak voltage sebelum
sistem might be
measured. Jika sistem terlepas, peak voltage yang
pemeriksaan.
• diukur
Checkmungkin
cylinder tidak
compression
benar. and check that the spark plug
is installed correctly.
• Periksa kompressi cylinder dan periksa bahwa busi
telahthe
Place dipasang dengan
scooter with benar. on a level surface.
its centerstand
Remove the skuter
Letakkan body cover (page 2-9).
dengan standard utama pada
permukaan mendatar.
Release the spark plug wire clamp boss from the intake
shroud.
Lepaskan spark plug wire clamp boss dari intake WIRE CLAMP
shroud.
Lepaskan
Disconnectspark plug
the spark cap
plug cap (topi busi)
from the dari
spark spark plug
plug.
(busi).
Connect a known-good spark plug to the spark plug cap and
ground the spark plug to the cylinder as done in a spark test.
Sambungkan busi yang diketahui dalam keadaan baik
pada spark plug cap dan hubungkan busi dengan
massa pada cylinder seperti dilakukan pada test
percikan api busi.
BUSI BAGUS
Dengan ignitioncoilcoil
With the ignition primary
primary wire tersambung,
wire connected, connect the
peak voltage peak
hubungkan adaptorvoltage
or tester adaptor
probes to the ignition
atau coil pri-
jarum-jarum
mary wire terminal
pemeriksaan andpada
tester ground.ignition coil primary wire
terminal dan massa.
TOOLS:
Imrie diagnostic tester (model 625) or
TOOLS:
Peak diagnostic
Imrie voltage adaptor
tester (model 625)07HGJ-0020100
atau
Peak withvoltage adaptor
commercially available digital07HGJ-0020100
multimeter (imped-
ance 10 M
dengan Ω/DCV
digital minimum)(impedansi minimum 10
multimeter
M /DCV)
CONNECTION:
Black/Yellow (–) – Body ground (+)
HUBUNGAN:
Hitam/Kuning ( - ) - Massa badan ( + ) IGNITION COIL PRIMARY
Retract the sidestand.
WIRE TERMINAL (Bl/Y)
Turn the ignition switch "ON" then squeeze the brake lever
Tarik sidestand ke atas.
fully.
Putar kunci kontak ke "ON" kemudian tekan handel rem JARUM IGNITION COIL
Crank the engine with the starter motor and measure the igni- PEMERIKSAAN( – )
Avoid touching the sepenuhnya.
tester
angan probes to tion coil primary peak voltage.
menyentuh
prevent electric Putar mesin dengan starter motor dan ukur ignition coil
jarum pemeriksaan
PEAK VOLT-
shock. primary peak voltage (voltase puncak primer coil
tester untuk menghindari
AGE: 100 V minimum
kejutan listrik. pengapian). BI/Y G
If the peak voltage is abnormal, check each item following

PEAK VOLTAGE (VOLTASE
the troubleshooting PUNCAK):
chart (page 15-4).
minimum 100 V
Connect the spark plug cap to the spark plug. Dari ICM
Jika peak voltage tidak normal, periksa masing-masing
Set the spark plug wire clamp boss to the intake shroud. BUSI BAGUS
bagian mengikukti peta troubleshooting (hal. 15-4)
Sambungkan spark plug cap pada spark plug. JARUM
PEMERIKSAAN(+)
Tempatkan spark plug wire clamp boss pada intake
shroud.
15-6
SISTEM PENGAPIAN
IGNITION
IGNITION PULSE
PULSE GENERATOR
GENERATOR PEAK PEAK
VOLTASE
VOLTAGE
(VOLTASE PUNCAK IGNITION PULSE
GENERATOR)
• Check cylinder compression and make sure the spark plug
CATATAN:
is installed correctly.
Periksa
• • Check kompressi
all system cylinder
connection dan
before pastikanIf bahwa
inspection. the sys-
spark
tem plug terpasang
is disconnected, dengan
incorrect benar.
peak voltage might be mea-
• sured.
Periksa semua sambungan sistem sebelum
Turnpemeriksaan. Jika to
the ignition switch sistem
"OFF".terlepas sambungannya,
maka voltase puncak yang salah yang akan
terukur.
Disconnect the ICM 6P connector.
Putar kunci kontak ke "OFF".
Connect the peak voltage adaptor or tester probes to the ICM
Lepaskan battery cover (hal. 2-13).
6P connector.
Lepaskan
TOOLS: ICM 6P connector.
Imrie diagnostic
Hubungkan peaktester (model
voltage 625) or atau jarum-jarum
adaptor
IGNITION CONTROL
tester
Peak ke ICM adaptor
voltage 6P connector. 07HGJ-0020100
MODULE (ICM) 6P CONNECTOR
TOOLS:
with commercially available digital multimeter (imped-
Imrie
ancediagnostic
10 MΩ/DCV tester (model 625) atau
minimum)
Peak voltage adaptor 07HGJ-0020100
CONNECTION:Blue/yellow
dengan digital multimeter (+) – Body ground
(impedansi (–)
minimum 10
M /DCV) yang dapat dibeli di pasaran
Turn the ignition switch "ON" and squeeze the brake lever
fully.
HUBUNGAN: Biru/kuning ( + ) - Massa badan ( - ) Bu/ Y
angantouching
menyentuh Crank kunci
the engine withke
the "ON"
kickstarter
Avoid
jarum-jarum
the Putar kontak dan and measure
tekan the igni-
handel rem
tester probes to tion pulse generator peak voltage.
emeriksaan testerelectric
untuk sepenuhnya.
prevent Bu/ Y
menghindari kejutan PEAK VOLT-
shock . ICM 6P CONNECTOR
listrik. Putar
AGE:mesin dengan 0.7kickstarter
V minimumdan ukur ignition pulse
generator peak voltage.
If the peak
PEAK voltage minimum 0,7 V
VOLTAGE:
IGNITION PULSE
Jika peak voltage yang diukur pada ICM connector GENERATOR
adalah tidak
measured normal,
at the ukur peak
ICM connector voltage measuthe
is abnormal, pada ignition
igni-
pulse generator
tin pulse generator3P3P
connector.
connector.
Remove the
Lepaskan centerbody
center bodycover
cover (hal.
(page2-8).
2-8).
Connect the peak voltage tester or adaptor probes to the 3P
Hubungkan peak voltage tester atau jarum-jarum
connector terminal of the ignition pulse generator side.
pemeriksaan adaptor pada 3P connector terminal dari
In the
sisi samepulse
ignition manner as at the ICM connector, measure the
generator.
peak voltage and compare it to the v oltage measured at the
ICM connector.
Dengan cara sama seperti pada ICM connector, ukurlah
peak voltage dan bandingkan
• If the peak voltage dengan
measured at the ICM isvoltase
abnormal yang
and
diukur pada ICM connector.
the one measured at the ignition pulse generator is nor-
mal, the wire harness has an open or short circuit, or loose
• Jika peak voltage yang diukur pada ICM tidak
connection.
normal
• If both peakdanvoltages
yang measure
diukur are
pada ignition
abnormal, checkpulse
each
generator
item adalah normal,
in the troubleshooting maka
chart (pagewire harness ada
15-4). IGNITION PULSE GENERATOR
rangkaian
If all items terbuka atauthe
are normal, adaignition
hubunganpulsesingkat, atau
generator is 3P CONNECTOR
hubungan
faulty. longgar.
See page 14-7 for ignition pulse generator replace-
• Jika kedua peak voltages yang diukur tidak normal,
ment.
periksalah masing-masing bagian pada peta 3P CONNECTOR
troubleshooting (hal. 15-4).
Jika semua bagian adalah normal, maka ignition
pulse generator rusak. Lihat hal. 14-7 untuk
penggantian ignition pulse generator.

IGNITION PULSE
GENERATOR
15-7
SISTEM PENGAPIAN
IGNITIONCOIL
IGNITION COIL(COIL PENGAPIAN)
Remove the
Lepaskan bodycover
body cover(hal.
(page2-9).
2-9).
Disconnectspark
Lepaskan the spark
plug plug
cap cap
dan and releasespark
lepaskan spark plug
plug wire
clamp from the intake shroud.
clamp dari intake shroud.
CLAMP SPARK PLUG CAP
Disconnectignition
Lepaskan the ignition coil primary
coil primary wirewire connectors.
connectors. PRIMARY WIRE CONNECTORS
Release thespark
Lepaskan sparkplug
plugwire
wire clamp
clamp from the frame.
dari rangka. IGNITION COIL
Remove the
Lepaskan two mounting
kedua mountingbolts
boltsand ignition
dan coil.
ignition coil.
Route
lurkan Installation is in adalah
the wire Pemasangan
wire harness the reversedalam
order of urutan
removal. terbalik dari CLAMP
dengan benar
harness (hal. pelepasan.
properly
(page 1-14).
1-14).
BOLTS
IGNITION
IGNITIONSWITCH
SWITCH(KUNCI KONTAK)
Lepaskan steering
Remove the steeringstem
stem (hal.
(page11-21).
11-21).
BOLT IGNITION
Disconnectignition
Lepaskan the ignition switch
switch 2P connector.
2P connector. SWITCH
Remove the socketbolt
boltdan
and key
key shutter.
shutter. SCREWS
Lepaskan socket
Remove the
Lepaskan screwsdan
screws and ignition
ignition switch.
switch.
Installation is in adalah
Pemasangan the reversedalam
order of urutan
removal. terbalik dari
pelepasan.
TORQUE:
TORSI:
Key shutter socket bolt: 10 N·m (1.0 kgf·m, 7 lbf·ft)
Key shutter socket bolt: 10 N.m (1,0 kgf.m; 7 lbf.ft)
KEY
2P CONNECTOR SHUTTER
15-8
SISTEM PENGAPIAN
INSPECTION
PEMERIKSAAN
Remove the
Lepaskan front
front uppercover
upper cover(hal.
(page2-4).
2-4).
Disconnect the ignition switch 2P connector.
Lepaskan ignition switch 2P connector.
IGNITION SWITCH
2P CONNECTOR
Periksa
Check theignition switchforterhadap
ignition switch continuitykontinuitas antara
between the connec-
connector terminals
tor terminals pada setiap
in each switch posisi switch.
position.
IGNITION SWITCH
IGNITION SWITCH
B AT 1 B AT
ON
OFF
LOCK
COLOR R/Bl R
SIDESTAND SWITCH
SIDESTAND
(SAKLAR SWITCH
STANDARD SAMPING)
Lepaskan center
Remove the centerbody
bodycover
cover (hal.
(page2-8).
2-8).
Disconnectsidestand
Lepaskan the sidestand switch
switch 3P3P connector.
connector.
SIDESTAND SWITCH
3P CONNECTOR
15-9
SISTEM PENGAPIAN
Lepaskan
Release thekawat sidestand
sidestand switch switch dari
wire from theframe
frameclamps.
clamps.
SIDESTAND SWITCH WIRE
CLAMPS
Lepaskan bolt
Remove the dan
bolt andsidestand
sidestand switch.
switch.
BOLT SPRING PIN
Pasang
Install thesidestand switch
sidestand switch whilesementara mentepatkan
aligning its groove with the
spring pin,
alurnya making
dengan sure that
spring pin,the tabs arememastikan
dengan positioned as bahwa
shown. GROOVE
tabs telah ditempatkan seperti diperlihatkan.
Install and tighten the sidestand switch bo lt.
lurkan wire harness
Route the wire Pasang
Connectdan kencangkan
the sidestand sidestand
switch switch bolt.
3P connector.
dengan benar
harness (hal.
properly
1-14). Sambungkan sidestand
Install the center switch
body cover 3P2-8).
(page connector.
(page 1-14).
Pasang center body cover (hal. 2-8).
• Do not reuse the broken sidestand switch.
CATATAN:
•
• Remove
Jangan the sidestandkembali
memakai switch before retightening
sidestand switchtheyang
side-
stand pivot nut.
patah.
SIDESTAND SWITCH TABS
• Lepaskan sidestand switch sebelum
mengencangkan kembali sidestand pivot nut.
INSPECTION
PEMERIKSAAN
IGNITION CONTROL
Turn the ignition
Lepaskan batteryswitch
cover"OFF".
(hal. 2-13). MODULE (ICM)
Disconnect
Putar theswitch
ignition ICM 6Pkeconnector.
"OFF".
Lepaskan ICM 6P connector.
6P CONNECTOR
15-10
SISTEM PENGAPIAN
Periksa
Check forterhadap kontinuitas
continuity antara
between the ICM ICM 6P connector
6P connector of the
dari
wiresisi wire side
harness harness dan massa.
and ground.
CONNECTION:Green/White
HUBUNGAN: – Body badan
Hijau/Putih – Massa ground
There should
Harus be continuitydengan
ada kontinuitas with thesidestand
sidestand retracted, and
ditarik, dan
there should
tidak bolehbe no continuity
ada with the sidestand
kontinuitas dengan applied.
sidestand
diturunkan.
If there is no continuity with the sidestand retracted, the wire
harness is broken or the sidestand switch is faulty.
Jika tidak ada kontinuitas dengan sidestand ditarik ke
atas, wire harness patah atau sidestand switch rusak. SIDESTAND
Kontinuitas (Sidestand Tidak ada Kontinuitas

ditarik): (Sidestand diturunkan):
ICM 6P CONNECTOR ICM 6P CONNECTOR
G/W G/W
G G
UP UP
SIDESTAND SIDESTAND
SWITCH SWITCH
IGNITION
IGNITIONCONTROL
CONTROLMODULE
MODULE(ICM)
(ICM)
Lepaskan battery
Remove the batterycover
cover(hal.
(page2-13).
2-13).
IGNITION CONTROL
Putar ignition
Turn the switch
ignition ke"OFF".
switch "OFF". MODULE (ICM)
Lepaskan
DisconnectICM 4P/6P
the ICM connectors.
4P/6P connectors.
Installation is in the
Pemasangan reverse
dalah order ofurutan
dalam removal. terbalik dari
pelepasan.
4P/6P CONNECTORS
15-11
SISTEM PENGAPIAN
POWER/GROUND
PEMERIKSAAN LINE INSPECTION
POWER/GROUND LINE
(SALURAN
POWER LINEDAYA/MASSA)
Remove the
Lepaskan batterycover
battery cover(hal.
(page2-13).
2-13).
IGNITION CONTROL
Disconnect
POWER the ICM
LINE 4P connector.
(SALURAN DAYA) MODULE (ICM)
Turn the ignition
Lepaskan ICM 4P switch "ON".
connector.
Measure the battery voltage between the ICM 4P connector
Putar ignition switch ke "ON".
of the wire harness side and ground.
Ukur voltase baterai antara ICM 4P connector dari sisi
CONNECTION:Red/Black
wire harness dan massa. (+) – Body ground (–)
There should be battery voltage with the ignition switch
HUBUNGAN:
"ON". Merah/Hitam ( + ) - Massa badan ( - )
Harus
If thereada
is novoltase
voltage baterai
with the dengan ignition
ignition switch switch
"ON", pada
check the
"ON".
following:
Jika tidak ada voltase dengan ignition switch pada "ON", 4P CONNECTORS
– Wire harness between the battery and ICM
periksa sebagai berikut:
– Ignition switch
- Wire harness antara baterai dan ICM POWER LINE: GROUND LINE:
– Fuse
- Ignition switch ICM 4P
- GROUND
Sekring LINE CONNECTOR ICM 4P
Turn the ignition
GROUND switch "OFF".MASSA)
LINE (SALURAN CONNECTOR
Disconnect
Putar theswitch
ignition ICM 4Pkeconnector.
"OFF".
Check for ICM
Lepaskan continuity between the ICM 4P connector of the
4P connector.
wire harness side and ground. R/Bl
Periksa terhadap kontinuitas antara ICM 4P connector
CONNECTION:Green
dari sisi wire harness dan – Body
massa. ground IGNITION
HUBUNGAN: SWITCH
There should beHijau – Massa
continuity badan
at all time. G
Harus ada kontinuitas setiap waktu.

lurkan
Route the wire If there is no continuity, check the open circuit in green wire.
wire harness FUSE 15A
dengan benar
harness (hal. Jika tidak ada kontinuitas, periksa rangkaian terbuka
properly
(page 1-14).
1-14). pada kawat hijau.
IGNITION
IGNITIONTIMING
TIMING(WAKTU PENGAPIAN)
CATATAN:
Ignition
• • The timing
ignition telah
timing disetelpreset
is factory awaland
di need
pabrik dan
only be
hanya perlu diperiksa jika sebuah komponen
checked when an electrical system component is replaced.dari
sistem
• Read thelistrik telah diganti.
instructions for timing light operation.
• Bacalah petunjuk pemakaian timing light.
Remove the cooling fan cover (page 2-12).
NOTCH
Lepaskan cooling fan cover (hal. 2-12).
Connect the timing light to the spark plug wire.
Hubungkan timing
Turn the ignition light "ON".
switch pada kabel lbusi.
Putar ignition
Start the and letkeit "ON".
switch
engine idle.
Hidupkan
ENGINE mesin dan biarkan berputar
IDLE SPEED:1,700 stasioner.
-1
± 100 min (rpm)
-1
PUTARAN STASIONER MESIN: 1.700 100 menit TANDA "F"
The ignition timing is correct if the index notch on the right
(rpm)
crankcase aligns with the "F" mark on the flywheel as shown.
If the ignition
Ignition timingtiming
adalahis incorrect, inspect
tepat jika the ignition
index pulse
notch (takik
generator (page
penunjuk) pada15-7).
right crankcase bertepatan dengan
tanda "F" pada flywheel seperti diperlihatkan.
TIMING LIGHT
Jika ignition timing tidak tepat, periksa ignition pulse
generator (hal. 15-7).
15-12
16. SISTEM STARTER LISTRIK
LOKASI SISTEM ....................................16-2 STARTER PINION .................................16-10

SYSTEM LOCATION ····································16-2 STARTER PINION ·······································16-10
DIAGRAM SISTEM ................................16-2 STARTER RELAY..................................16-11

SYSTEM DIAGRAM ······································16-2 STARTER RELAY········································16-11
KETERANGAN SERVIS ........................16-3 STARTER SWITCH................................16-14

SERVICE INFORMATION ···························16-3 STARTER SWITCH ·····································16-14
TROUBLESHOOTING ...........................16-4 BRAKE LIGHT SWITCH ........................16-14

TROUBLESHOOTING ··································16-4 BRAKE LIGHT SWITCH····························16-14
STARTER MOTOR ................................16-6

STARTER MOTOR ········································ 16-6
16
16-1
SISTEM STARTER LISTRIK
SYSTEMSISTEM
LOCATION
ELECTRICSTARTERSYSTEM
LOKASI
REAR BRAKE LIGHT SWITCH
STARTER SWITCH
MAIN FUSE 15A

FRONT BRAKE
SUB FUSE 10A LIGHT SWITCH
IGNITION CONTROL MODULE (ICM)
BATTERY
IGNITION SWITCH
STARTER MOTOR STARTER RELAY
DIAGRAM SISTEM
SYSTEM DIAGRAM
MAIN FUSE
15A
R
R/Bl
STARTER
RELAY
SUB FUSE
l 10A l
R B B
/ R
R
BATTERY 5P
4P 6P 2P
l l
W
/ R W R B
/ / / B
R R Y R
2P
l Y Y l Y l l

W
/ B
/ G G
/ G G
/ / / / B
/ R
R R Y Y G G B G B R
Br
4P 6P Bl
W
/
G
BRAKE LIGHT
IGNITION CONTROL SWITCHES
MODULE (ICM)
STARTER STARTER IGNITION
MOTOR SWITCH SWITCH
16-2
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
• Always turn the ignition switch "OFF" before servicing the starter motor. The motor could suddenly start, causing serious injury.
•
• A Selalu putarmay
weak battery ignition switch
be unable ke the
to turn "OFF" sebelum
starter menservis
motor quickly starter
enough, motor.
or supply Motorignition
adequate dapatcurrent.
dihidupkan dengan tiba-tiba, dan
• menyebabkan luka-luka parah.
The starter motor can be serviced with the engine in the frame.
•
• Baterai
When lemah
checking themungkin tidak always
starter system, sanggup memutar
follow the stepsstarter motor dengan (page
in the troubleshooting cukup16-4).
cepat, atau memasok arus pengapian yang
• If mencukupi.
the current is kept flowing through the starter motor to turn it while the engine is not cranking over, the starter motor may be damaged.
•
• Refer to the
Starter following
motor dapatcomponent information.
diservis dengan mesin terpasang pada rangka.
•
– Ketika
Ignitionmemeriksa
switch (pagesistem
15-8) starter, selalu ikuti langkah-langkah pada troubleshooting (hal. 16-4).
• Jika arus listrik dibiarkan mengalir melalui starter motor untuk memutarnya sementara mesin tidak berputar, starter motor
dapat rusak.
SPECIFICATION
• Bacalah informasi komponen berikut ini.
- Ignition switch (hal. 15-8) Unit: mm (in)
SERVICE
ITEM STANDARD
LIMIT
SPESIFIKASI
Starter motor brush length 7.0 (0.28) 3.5 (0.14)
Satuan: mm
BAGIAN STANDARD BATAS SERVIS
TORQUE
Panjang sikat VALUE
starter motor 7,0 3,5
Starter motor case screw 2 N·m (0.2 kgf·m, 1.5 lbf·ft)

NILAI TORSI
Starter motor case screw 2 N.m (0,2 kgf.m; 1,5 lbf.ft)
16-3
TROUBLESHOOTING
TROUBLESHOOTING
Starter motordoes
Starter motor tidak berputar
not turn
1. Standard
1. Inspection
Pemeriksaan Standard
Check forterhadap
Periksa following:berikutnya:
–- Kondisi
Battery condition
baterai
–- Sekring
Burned fuse
putus terbakar
Are the above
Apakah itemsdiinatas
hal-hal gooddalam
condition?
kondisi baik?
YES – GO TO STEP 2.
YA - LANJUTKAN DENGAN LANGKAH 2.
NO – Replace or repair the malfunction part(s).
TIDAK - Ganti atau perbaiki parts yang tidak bekerja dengan baik.
2. Starter Relay Operation
2. Cara Kerja Starter Relay
Turn the ignition switch "ON".
Putar kunci
Squeeze kontak
the brake kefully
lever "ON". and push the starter switch.
You should hear the relay "CLICK"dan
Tekan handel rem sepenuhnya tekan
when starter
the starter switch.
switch is depressed.
Harus terdengar bunyi "KLIK" dari relay ketika starter switch ditekan.
Is the "CLICK" heard?
Apakah bunyi "KLIK" terdengar?
TIDAK - LANJUTKAN DENGAN LANGKAH 5.
3. Starter Motor Cable Inspection
3. Pemeriksaan Starter Motor Cable
Turn the ignition switch "OFF".
Putar for
Check kunci
openkontak
circuitkein "OFF".
starter motor cable and starter motor ground cable.
Periksa terhadap rangkaian terbuka pada starter motor cable dan starter motor ground cable (kabel massa
Are the above cables in good condition?
starter motor).
Apakah kabel-kabel di atas dalam kondisi baik?
NO – • Loose or poorly connected starter motor cable.
YA •- LANJUTKAN
Open circuit inDENGAN LANGKAH
starter motor 4. (Green) and battery negative terminal.
ground cable
• Open circuit in starter motor Red/White cable between the starter relay and starter motor.
TIDAK - • Starter motor cable longgar atau tersambung dengan buruk.
4. Starter Motor Inspection
• Rangkaian terbuka pada starter motor ground cable (Hijau) dan terminal negatif baterai.
Rangkaian
Apply battery voltage
• terbuka
to the starter pada
motor kabel and
directly Merah/Putih starter motor antara starter relay dan starter
check the operation.
motor.
Does the starter motor turn?
4. Pemeriksaan Starter Motor
YES – • Open circuit in Red wire between the starter relay and battery.
Hubungkan voltase
• Faulty baterai
starter langsung ke starter motor dan periksa cara kerja.
relay.
Apakah
NO starterstarter
– Faulty motor berputar?
motor.
5. YA
Starter Relay
- Coil• Circuit Inspection
Rangkaian terbuka pada kawat Merah antara starter relay dan baterai.
Starter
• relay rusak.
Turn
TIDAKthe ignition switch
- Starter "ON".
motor tidak bekerja dengan baik.
Measure the battery voltage between the ICM connector of the wire harness side and ground.
5. Pemeriksaan Rangkaian Starter Relay Coil
CONNECTION:Yellow/Red
Lepaskan ICM 4P connector. (+) – Ground (–)
Putarthe
Does kunci kontak
battery ke "ON".
voltage exist?
Ukur voltase baterai antara ICM connector dari sisi wire harness dan massa.
HUBUNGAN: Kuning/Merah ( + ) - Massa ( - )
NO – • Loose or poorly connected connector.
Apakah • adaOpen
voltase baterai?
circuit in battery cable between the battery and ignition switch.
YA • Open circuit in
- LANJUTKAN DENGAN starter relayLANGKAH
Red/Black 6.
wire between the ignition switch and starter relay.
• Open circuit in starter relay Yellow/Red wire between the ICM and starter relay.
TIDAK •- Faulty
• Connector
ignitionyang tersambung
switch (page 15-8).dengan buruk.
• Faulty
• starter relay coil.
Rangkaian terbuka pada kabel baterai antara baterai dan kunci kontak.
• Rangkaian terbuka pada kawat Merah/Hitam starter relay antara kunci kontak dan starter
relay.
• Rangkaian terbuka pada kawat Kuning/Merah starter relay antara ICM dan starter relay.
• Kunci kontak tidak bekerja dengan baik (hal. 15-8).
• Starter relay coil tidak bekerja dengan baik.
16-4
6.6. Pemeriksaan
Brake Light Switch/Starter SwitchLight
Rangkaian Brake Circuit Inspection
Switch/Starter Switch
Turn the
Putar ignition
kunci switch
kontak "ON".
ke "ON".
Squeeze
Tekan the brake
handel remlever fully and push
sepenuhnya dan the starter
tekan switch.
starter switch.
Measure the battery voltage between the ICM connector
Ukur voltase baterai antara ICM connector dari sisi wire of theharness
wire harness side and ground.
dan massa.
HUBUNGAN: Kuning/Hijau ((+)
CONNECTION:Yellow/Green + )– -Ground
Massa(–)
(- )
Apakah
Does the ada voltase
battery voltagebaterai?
exist?
YA
YES – -GO LANJUTKAN
TO STEP 7. DENGAN LANGKAH 7.
TIDAK
NO – - • • Connector
Loose longgar
or poorly atau connector.
connected tersambung dengan buruk.
• • Brakebrake
Faulty light switch tidak bekerja dengan baik.
light switch.
• • Open circuit in
Rangkaian Black wire
terbuka padabetween
kawat the sub antara
Hitam fuse andsekring
brake light switch. dan brake light switch.
tambahan
• • Open circuit in Green/Yellow wire between
Starter switch tidak bekerja dengan baik. the brake light switch and starter switch.
• •
Faulty starter switch.
Rangkaian terbuka pada kawat Kuning/Hijau antara ICM dan starter switch.
• Open circuit in Yellow/Green wire between the ICM and starter switch.
7. Starter Relay Continuity Inspection
7. Check the starterKontinuitas

Pemeriksaan relay for continuity
Starter(page 16-13).
Relay
Is there continuity?
Periksa starter relay terhadap kontinuitas (hal. 16-13)
YES – • Open circuit in ICM Red/Black wire.
Apakah ada kontinuitas?
• Open circuit in ICM Green wire.
YA - • Faulty
• ICM. terbuka pada kawat Merah/Hitam ICM.
Rangkaian
NO •
– FaultyRangkaian terbuka pada kawat Hijau ICM.
starter relay.
• ICM tidak bekerja dengan baik.
Starter motor turns engine slowly
TIDAK
• Low battery- Starter
voltage.relay tidak bekerja dengan baik.
• Poorly connected battery terminal cable.
• Poorly connected starter motor cable.
Starter
• Faulty motor memutar
starter motor. mesin dengan pelan
• •Voltase
Poorlybaterai
connected battery ground cable.
rendah.
•
Starter motor turns, but tersambung
Battery terminal cable dengan
engine does not turn buruk.
•
•Starter
Startermotor
motorcable tersambung
is running dengan buruk.
backwards.
• Starter
– Case motor tidak bekerja
assembled dengan baik.
improperly.
• Battery groundconnected
– Terminals cable tidak tersambung dengan baik.
improperly.
• Faulty starter pinion.
Starter motor berputar, tetapi mesin tidak berputar
Starter relay "CLICK", but engine does not turn
•
•Starter motordoes
Crankshaft berputar terbalik.
not turn due to engine problems.
- Case telah dirakit
• Faulty starter pinion. dengan salah.
- Terminals disambung dengan salah.
• Starter pinion tidak bekerja dengan baik.
Starter relay berbunyi "KLIK", tetapi mesin tidak berputar

• Crankshaft tidak berputar disebabkan persoalan di dalam mesin.
• Starter pinion tidak bekerja dengan baik.
16-5
STARTER MOTOR
MOTOR
PELEPASAN
REMOVAL
Lepaskan airair
Remove the cleaner
cleanerhousing
housing (hal.
(page5-6).
5-6).
SCREW/STARTER MOUNT BOLT
Tarik lepas
Pull off dustcover.
the dust cover. MOTOR CABLE
Lepaskan
Remove the screw
screwdan startermotor
and starter motorcable
cable dari
from the starter
starter
motor.
motor.
Remove the mounting bolts, ground cable and starter motor.
Lepaskan mounting bolts, ground cable dan starter
Remove the starter motor case screw and ground cable.
motor.
Lepaskan starter motor case screw dan ground cable. DUST COVER
MOUNT BOLT/
GROUND CABLE SCREW/GROUND CABLE
Lepaskan O-ring
Remove the dari
O-ring starter
from motor.
the starter motor.
STARTER
PEMASANGAN MOTOR
Lapisi sebuah O-ring baru dengan oli mesin dan pasang

ke dalam alur starter motor.
O-RING
Route
lurkan the starter
starter motor Set the ground
Tempatkan cable cable
ground and tighten the starter motor
dan kencangkan case motor
starter screw
SCREW/STARTER MOUNT BOLT
cable dan ground
motor cablecable
and to thescrew
case specified torque.
dengan torsi yang ditentukan.
dengan benarcable
ground (hal. MOTOR CABLE
1-14).
properly TORQUE:2
TORSI: N·m
2 N.m (0.2
(0,2 kgf·m,1,5
kgf.m; 1.5lbf.ft)
lbf·ft)
(page 1-14).
Install the
Pasang startermotor
starter motorpada
to themesin.
engine.
Set the groundground
Tempatkan cable andcable
tightendan
the starter mounting bolts.
kencangkan starter
mounting bolts.
Install the starter motor cable and tighten the screw.
Put the dust cover back in the appropriate position.
Pasang starter motor cable dan kencangkan screw. DUST COVER
Install the air cleaner housing (page 5-7).
Letakkan dust cover kembali pada posisi yang sesuai.
Pasang air cleaner housing (hal. 5-7).
MOUNT BOLT/
GROUND CABLE SCREW/GROUND CABLE
16-6
DISASSEMBLY
PEMBONGKARAN
Remove the
Lepaskan screwsdan
screws andstarter
starter motor
motor case.
case.
Remove the
Lepaskan following:
sebagai berikut:
- – Armature
Armature
– Bracket
- Bracket
– Springs
- Springs
- –Gasket
Gasket
MOTOR CASE
ARMATURE
SPRING
SCREW
GASKET
BRACKET
PERAKITAN
ASSEMBLY
Pasang springs
Install the diindalam
springs brush
the brush holders.
holders.
BRUSH HOLDERS
SPRINGS
16-7
Pasang
Install thearmature ke the
armature into dalam bracket
bracket sementara
while holding the
menahan
brushes. brushes. ARMATURE
BRUSHES
Install agasket
Coil dapat rusak jika Pasang new gasket
baruonto thebracket.
pada bracket.
BRACKET MOTOR CASE
magnet
The coilmenarik Install thebracket
may be Pasang bracket and
danarmature to the motor
armature pada case while case
motor hold-
armature terhadap
damaged case. ing the bracket
if the sementara side armature shaft tightly.
memegang armature shaft dari sisi bracket
magnet pulls the dengan erat.
armature against the
case.
ARMATURE
GASKET
Pasang motor
Install the motorcase screwsand
case screws dan kencangkan
tighten dengan
them to the speci-
fied torque. SCREWS
PEMERIKSAAN
INSPECTION
BRUSH
BRUSH
Periksa brushes
Inspect the terhadap
brushes kerusakan
for damage danthe
and measure ukur panjang
brush length.
brush.
SERVICE
LIMIT: 3.5 mm (0.14 in)
16-8
ARMATURE
ARMATURE
Jangan menggunakan
Do not use emery or Periksa commutator
Inspect the commutator bars
bars ofdari armaturefor terhadap
the armature discolor-
kertas amplas pada
paper on the perubahan
sand commutator. ation. warna. COMMUTATOR BARS
commutator.
Bars discolored in pairs indicate shorted coils.
Bars yang berubah warna dalam pasangan
menunjukkan coils yang ada hubungan singkat.
Periksa
Check forterhadap
continuity kontinuitas
between each antara masing-masing
pair of commutator bars.
KONTINUITAS:
pasangan commutator bars.
There should be continuity.
Tidak boleh ada kontinuitas.
Periksa
Check forterhadap
continuitykontinuitas
between eachantara masing-masing
commutator bar and the
armature shaft. TIDAK ADA KONTINUITAS:
commutator bar dan armature shaft.
Thereboleh
Tidak shouldada
be no continuity.
kontinuitas.
16-9
STARTER
STARTER PINION
PINION
PELEPASAN
REMOVAL
Lepaskan leftleft
crankcasecover (hal. 8-5).
cover (page 8-5).
STARTER PINION HOLDER
Lepaskan starter
Remove the starterpinion
pinionholder.
holder.
Remove the
Lepaskan starterpiniion.
starter pinion.
STARTER PINION
PEMASANGAN
INSTALLATION
Oleskan
Apply 0.1 0,1– –0.3
0,3gg ofgemuk
grease(Shell
(ShellALVANIA
ALVANIA R3R3atau
or
STARTER PINION
IDEMITSU
IDEMITSUAUTOREX
AUTOREX BB atau sejenisnya)
or equivalent) pada
to the endsujung-
of the
starterstarter
ujung pinion.pinion.
Install the starter pinion into the left crankcase.
Pasang starter pinion ke dalam left crankcase.
Pasang starter
Install the starterpinion
pinionholder
holder ke dalam
into left
the left crankcase.
crankcase.
STARTER PINION HOLDER
Pasang leftleft
crankcasecover
cover (hal.
(page8-5).
8-5).
16-10
PEMERIKSAAN
INSPECTION
Check that
Periksa the starter
bahwa starterpinion operates
pinion bekerjasmoothly.
dengan halus. DRIVEN GEAR
Check the
Periksa pinion
gigi geargear
pinion teeth and
danshaft
shaftforterhadap
wear or damage.
keausan
atau kerusakan.
Check the starter driven gear teeth of the drive pulley face for
wear or damage.
Periksa gigi starter driven gear dari muka drive pulley
PINION GEAR
STARTER
STARTER RELAY
RELAY
Lepaskan battery
cover(hal.
(page2-13).
2-13).
5P CONNECTOR
Lepaskan starter
Remove the starterrelay
relaydari
frombattery holder
the battery stay.
holder stay.
Lepaskan
Disconnectstarter relay
the starter 5P connector.
relay 5P connector.
Pemasangan
the reversedalam
order of urutan
pelepasan.
STARTER RELAY
PEMERIKSAAN CARA KERJA

OPERATION INSPECTION
Remove the
battery cover(hal.
(page2-13).
2-13).
Turn the
Putar ignition
kunci kontakswitch "ON".
ke "ON".
Squeeze the brake lever
Tekan handel rem sepenuhnya fully and push the starter
dan tekan switch.
starter switch.
The system is normal if the starter relay clicks.
Sistem adalah normal jika starter relay berbunyi klik.
If yourelay
Jika don’t hear
tidaktheberbunyi
relay "CLICK", inspect
"KLIK", the
periksa sebagai
following:
berikut:
- –Rangkaian starter
Starter relay relay coil
coil circuit (page(hal. 16-12)
16-12)
- –Rangkaian
Brake lightbrake light switch/starter
switch/starter switch
switch circuit (page(hal.16-12)
16-12)
- –Rangkaian ICM power/ground
ICM power/ground circuit (page(hal. 15-12)
15-12)
Jika terdengar
If you hear the suara "KLIK" dari
relay "CLICK", relay, does
but starter tetapinotstarter
turn,
inspect
tidak the starter
berputar, relay continuity
periksa (page
starter relay 16-13). kontinuitas
terhadap
(hal. 16-13).
STARTER RELAY
16-11
PEMERIKSAAN RANGKAIAN
STARTER RELAY COIL CIRCUIT
STARTER RELAY COIL
INSPECTION
Remove the
battery cover(hal.
(page2-13).
2-13).
DisconnectICM
Lepaskan the ICM 4P connector.
4P connector.
Turn the
Putar ignition
kunci kontakswitch "ON".
ke "ON".
Measure
Ukur the voltage
voltase antarabetween
ICM the ICM connector
connector dari of the wire
sisi wire
harness side and
harness dan massa. ground.
CONNECTION:Yellow/Red (+) – Ground (–)
HUBUNGAN: Kuning/Merah ( + ) - Massa ( - )
If the battery voltage appears only when the ignition switch is
Jika
"ON",voltase baterai
the circuit hanya tampak sewaktu kunci kontak
is normal.
pada posisi "ON", rangkaian adalah normal.
IGNITION CONTROL MODULE

(ICM) 4P CONNECTOR
ICM 4P CONNECTOR
Dari
BATTERY
R/Bl
Y/R IGNITION
SWITCH
STARTER
RELAY
PEMERIKSAAN RANGKAIAN
BRAKE LIGHT SWITCH/STARTER
BRAKE LIGHT SWITCH/STARTER SWITCH
SWITCH CIRCUIT INSPECTION
Lepaskan battery
cover(hal.
(page2-13).
2-13).
Lepaskan ICM 6P connector.
Putar kunci
Turn the kontak
ignition ke "ON".
switch "ON".
Tekan handel
Squeeze remlever
the brake sepenuhnya dan tekan
fully and push starter
the starter switch.
switch.
Ukur voltase
Measure antara
the voltage ICM the
between connector dari of
ICM connector sisi
the wire
harness dan and
harness side massa.
ground.
CONNECTION:Yellow/Green
HUBUNGAN: Kuning/Hijau ( (+)
- ) –- Ground
Massa ((–)
-)
If thevoltase
Jika battery voltage
baterai appears
hanya only whenketika
tampak the ignition
kunciswitch
kontak is
"ON", the brake lever is fully squeezed and the
pada posisi "ON", handel rem telah ditekan sepenuhnya starter switch
is pushed,
dan starterthe circuit
switch is normal.
ditekan, rangkaian adalah normal. IGNITION CONTROL MODULE
(ICM) 6P CONNECTOR
ICM 6P CONNECTOR
Dari BATTERY
FRONT BRAKE
Y/G
LIGHT SWITCH
G/Y Bl
STARTER REAR BRAKE

SWITCH G/Y LIGHT SWITCH
Bl
16-12
PEMERIKSAAN KONTINUITAS
STARTER RELAY CONTINUITY
STARTER RELAY
INSPECTION
Remove the
Lepaskan starterrelay
starter relay(hal.
(page16-11).
16-11).
Connect a fully
Hubungkan charged
kawat positif12 V battery
baterai 12 Vpositive
bermuatanwire penuh
to the
relay switch terminal A and negative wire to the
pada terminal A relay switch dan kawat negatif padaterminal B.
terminal B.continuity at the terminal C and terminal D.
Check for
There should
Periksa be continuity
terhadap between
kontinuitas the C
pada and D terminals
terminal C dan
while the
terminal D. battery is connected, and no continuity when the
battery is disconnected.
Harus ada kontinuitas antara terminal C dan D sewaktu
A C
baterai dihubungkan, dan tidak ada kontinuitas ketika
baterai dilepaskan.
B D
STARTER RELAY
A B C D
16-13
STARTER
STARTER SWITCH
SWITCH
PEMERIKSAAN
INSPECTION
Lepaskan front
Remove the handlebar
front handlebarcover (hal. 2-5).
cover (page 2-5).
Turn the
Putar ignition
kunci kontakswitch "OFF".
ke "OFF".
Disconnect the starter switch connector.
Lepaskan starter switch connector.
Check for
Periksa continuity
terhadap between the
kontinuitas connector
antara terminals
connector in each
terminals
switch position.
pada masing-masing posisi switch.
Continuity should exist between the color coded wire termi-
Harus
nals as ada kontinuitas antara terminal-terminal kawat
follows:
dengan kode warna sebagai berikut:
STARTER SWITCH
STARTER SWITCH
CONNECTOR
STARTER SWITCH
ST ICM
FREE
PUSH
COLOR G/Y Y/G
BRAKE
BRAKE LIGHT
LIGHTSWITCH
SWITCH
PEMERIKSAAN
INSPECTION
Lepaskan front
cover (page 2-5).
DEPAN: BELAKANG:
Lepaskan
Disconnect thebrake
brake light switch
switchwire wire connectors
connectors (Green/
Yellow and Black) and check for continuity
(Hijau/Kuning dan Hitam) dan periksa terhadap between the
switch side antara
kontinuitas terminals.
terminal-terminal pada sisi switch.
There should be continuity with the brake lever squeezed,
Harus ada kontinuitas dengan handel rem ditekan, dan
and there should be no continuity with the brake lever
tidak boleh ada kontinuitas sewaktu handel rem
released.
dilepaskan.
BRAKE LIGHT SWITCH BRAKE LIGHT SWITCH

CONNECTORS WIRE CONNECTORS
16-14
17. LAMPU/METER/SAKLAR-SAKLAR
LOKASI SISTEM............................................ 17-2 RELAY LAMPU SEIN ...................... 17-10

SYSTEM LOCATION ····································17-2 TURN SIGNAL RELAY ·······························17-10
KETERANGAN SERVIS ................................17-3 LAMPU REM/BELAKANG............... 17-11

SERVICE INFORMATION ···························17-3 TAIL/BRAKE LIGHT ·································· 17-10
PEMERIKSAAN SISTEM PENERANGAN ....17-4 FUEL LEVEL SENSOR.................... 17-13

LIGHTING SYSTEM INSPECTION············ 17-4 SPEEDOMETER ···········································17-11
LAMPU BESAR ............................................. 17-6 FUEL METER................................... 17-14

HEADLIGHT ··················································· 17-6 FUEL LEVEL SENSOR ·······························17-13
LAMPU SENJA .............................................. 17-7 KLAKSON ........................................ 17-15

POSITION LIGHT··········································17-7 FUEL METER ···············································17-14
LAMPU SEIN .................................................17-8

TURN SIGNAL LIGHT··································17-8 HORN····························· ·························· ······· 17-15
SAKLAR LAMPU SEIN..................................17-9

TURN SIGNAL SWITCH······························· 17-9
17
17-1
LAMPU/METER/SAKLAR-SAKLAR
SYSTEMSISTEM
LOKASI LOCATION
DIMMER SWITCH
SPEEDOMETER
TURN SIGNAL SWITCH
HORN SWITCH TURN SIGNAL RELAY
FUEL LEVEL SENSOR
LIGHTING
SWITCH
HORN
17-2
SERVICE INFORMATION
KETERANGAN SERVIS
GENERAL
UMUM
• Check the battery condition before performing any inspection that requires proper battery voltage.
Periksa
•• Route kondisi
the wires and baterai sebelum
cables properly menjalankan
after sesuatu
servicing each pemeriksaan
component yang memerlukan voltase baterai yang memadai.
(page 1-14).
Alurkan
•• The kawat-kawat
following color codesdan kabel-kabel
are used throughoutdengan benar setelah menservis masing-masing komponen (hal. 1-14).
this section.
• Kode warna berikut ini dipakai sepanjang bab ini.
BuBu==Blue
Blue (biru) G = Gr
Green
= Gray (abu-abu)Lg = Light green W (merah)
R = Red = White
Bl = Black
Bl = Black (hitam) Gr =Lb
Gray O =muda)
= Light blue (biru Orange W = White Yellow
Y = (putih)
BrBr==Brown
Brown (coklat) Lb =Lg
Light blue R = Red
= Light green (hijau muda) Y = Yellow (kuning)
G = Green (hijau) O = Orange (jingga)
SPECIFICATIONS
SPESIFIKASI
ITEM SPECIFICATIONS
Bulbs Headlight BAGIAN SPESIFIKASI
12 V – 32/32 W
Bola lampu Lampu besar
Position light 12 V 12–V32/32
– 3.4 W
W
Lampu senja light
Tail/brake 12 V – 3,4 W
12 V – 5/18 W
Lampu rem/belakang
Front turn signal light 1212VV– –5/18
10 WWx 2
Lampu sein
Rear depan
turn signal light 1212VV –– 1010WWx x22
Lampu sein belakang
Instrument light 1212VV – –10
1.7WWx x2 2
Lampu instrumen
High beam indicator 12 V12– V1,7 W xW2
– 1.7
Lampu indikator sinar jauh 12 V – 1,7 W
Turn signal indicator 12 V – 3.4 W
Lampu indikator lampu sein 12 V – 3,4 W
Fuse Main fuse 15 A x 1
Sekering Sekering utama 15 A x 1
Sub fuse 10 A x 1
Sekering tambahan 10 A x 1
17-3
LIGHTING SYSTEM
PEMERIKSAAN INSPECTION
SISTEM PENERANGAN
LAMPU BESARDOES
HEADLIGHT TIDAKNOT
MENYALA
COME ON OR
IS WEAK
ATAU REDUP NYALANYA
Standard Inspection
Pemeriksaan Standard
Check the
Periksa following
sebagai berikut
- – Bola
Burned out bulb
lampu putusor terbakar
bulb with atau
unspecified wattagedengan
bola lampu
– Loose connector
watt yang tidak sesuai
– Lighting switch
- Connector longgar
– Dimmer switch
- Lighting switch (saklar lampu)
- IfDimmer switch
the above items (saklar dim)check as follows:
are normal,
Jika hal-hal
Lighting di atas
Circuit adalah normal, periksa sebagai
Inspection
berikut:
Remove the followings:
Pemeriksaan Rangkaian Penerangan HEADLIGHT 6P
– Front upper cover (page 2-4) CONNECTOR
Lepaskan
– Centersebagai berikut:
- Front upper cover (hal. 2-4)
- Center body cover (hal. 2-8)
Lepaskan alternator/ignition
Disconnect the pulse
alternator/ignition pulse generator
generator 3P
3P connec-
tor.
connector.
ALTERNATOR/IGNITION
PULSE GENERATOR 3P
CONNECTOR
Putar lighting
Turn the switch
lighting ketoposisi
switch H andHdimmer
dan dimmer switch
switch to ke
Hi posi-
Hi.
tion. HEADLIGHT 6P
CONNECTOR
Check the continuity between the Blue terminal of the head-
Periksa kontinuitas antara terminal Biru dari headlight
light 6P connector and yellow terminal of the alternator/igni-
6P connector dan terminal Kuning dari alternator/ignition
tion pulse generator 3P connector.
pulse generator 3P connector.
If there is continuity, check the following:
Jika ada kontinuitas, periksa sebagai berikut:
Bu
Bu/W Y
DIMMER
SWITCH
ALTERNATOR/IGNITION
LIGHTING
PULSE GENERATOR 3P
SWITCH
CONNECTOR
17-4
Lepaskan body
Remove the cover
body cover(hal.
(page2-9).
2-9).
Lepaskan
Disconnectregulator/rectifier 4P connector.
the regulator/rectifier 4P connector.
REGULATOR/RECTIFIER
4P CONNECTOR
Check thekontinuitas
Periksa continuity between
antara theterminal
Yellow terminals
Kuning ofdari
the
REGULATOR/RECTIFIER 4P CONNECTOR
regulator/rectifier 4P
regulator/rectifier 4Pconnector
connectorand dan
alternator/ignition pulse
alternator/ignition
generator
pulse 3P connector.
generator 3P connector.
If there is continuity, check the following:
Jika ada kontinuitas, periksa sebagai berikut:
Y
ALTERNATOR/IGNITION
PULSE GENERATOR 3P
CONNECTOR
Pemeriksaan Massa
Ground Inspection
Check the
Periksa continuity antara
kontinuitas betweenterminal
the GreenHijau
terminal
dariofheadlight
the head-
light 6P connector HEADLIGHT 6P
6P connector dan and ground.
ground (massa).
CONNECTOR
If there is continuity, check the lighting coil (page 14-12).
Jika ada kontinuitas, periksa lighting coil (kumparan
If the lighting
penerangan) coil
(hal. is normal, check the regulator/recti-
14-11).
fier(page 14-14).
Jika lighting coil adalah normal, periksa
regulator/rectifier (hal. 14-14).
17-5
HEADLIGHT
HEADLIGHT(LAMPU BESAR)
PENGGANTIAN BULB (BOLA LAMPU)
BULB REPLACEMENT
Lepaskan front
Remove the upper
front uppercover
cover(hal.
(page2-4).
2-4).
HEADLIGHT BULB
Lepaskan
Remove thedust
dustcover.
cover.
Slightly headlight
Tekan push the headlight
bulb bulb socket
socket and turn
sedikit it counter-
dan putar
clockwise.
berlawanan arah jarum jam.
Remove the
Lepaskan headlightbulb
headlight bulbdan
and ganti
replace it with yang
dengan a new baru.
one.
TANDA
Install a new headlight bulb by aligning the tab on the head- "TOP"
Pasang headlight bulb baru dengan mentepatkan tab
light bulb with the groove on the headlight unit.
pada
Installheadlight bulb dengan
the bulb socket alurthe
by aligning pada
tabsheadlight unit.
on the bulb socket
Pasang bulb socket dengan mentepatkan
with the slots on the headlight unit. tabs pada
bulb socket dengan slots pada headlight
Push the bulb socket in, turn it clockwise. unit.
Tekan bulb socket ke dalam, putar searah jarum jam.
Install cover Install the dust cover tightly on the headlight unit.
the dust cover
Pasang
dengan
with itstanda
"TOP" "TOP"
mark
Pasang dust cover dengan erat pada headlight unit.
Install the front upper cover (page 2-4).
menghadap ke atas.
facing up. Pasang front upper cover (hal. 2-4). BULB SOCKET DUST COVER
LIGHTING SWITCH INSPECTION

PEMERIKSAAN LIGHTING SWITCH
Lepaskan front
cover (page 2-5).
LIGHTING SWITCH
Putar kunci
Turn the kontak
ignition ke "OFF".
switch "OFF".
Disconnectlighting
Lepaskan the lighting switch
switch connector.
connector.
Check for
Periksa continuity
antara terminals
connector in each
terminals
switch
pada position.
masing-masing posisi switch.
Continuity
Harus ada should exist between
kontinuitas antara the color coded
terminal wire
kawat termi-
dengan
nals as follows:
kode warna sebagai berikut:
LIGHTING SWITCH
CONNECTORS
LIGHTING SWITCH
HL C1 TL
(N)
(N)
COLOR Bu/W Y Br
17-6
PEMERIKSAAN DIMMER
DIMMER SWITCH SWITCH
INSPECTION
Remove the
Lepaskan front
front handlebarcover
handlebar cover (page 2-5).
(hal. 2-5).
DIMMER SWITCH
Turn the
Putar ignition
ke "OFF".
Disconnectdimmer
Lepaskan the dimmer switch
switch connector.
connector.
Check for
Periksa continuity
antara terminals
connector in each
terminals
switch
pada position.
masing-masing posisi switch.
Continuity
Harus ada should exist between
kontinuitas antara the color coded wire kawat
terminal-terminal termi-
nals as follows:
dengan kode warna sebagai berikut:
DIMMER SWITCH
CONNECTOR
DIMMER SWITCH
Hi Lo HL
HI
(N)
LO
COLOR Bu W Bu/W
POSITION
POSITIONLIGHT
LIGHT(LAMPU SENJA)
PENGGANTIAN BOLA LAMPU
BULB REPLACEMENT
Lepaskan
Remove the front upper
front uppercover
cover (hal.
(page2-4).
2-4). BULB SOCKET POSITION
Tarik keluar position
Pull out lightbulb
the position light bulb socket
socket dari
from theheadlight
headlightunit.
unit. LIGHT BULB
Keluarkan
Remove the position light bulb and replace it with a newyang
position light bulb dan ganti dengan one.
baru.
Install the position light bulb socket in the reverse order of
removal.
Pasang position light bulb socket dalam urutan terbalik
dari pelepasan.
17-7
TURN SIGNAL
SIGNAL LIGHT
LIGHT(LAMPU SEIN)
PENGGANTIAN BULB (BOLA LAMPU)
BULB REPLACEMENT
DEPAN
FRONT
Remove the
Lepaskan front
front uppercover
upper cover (hal.
(page2-4).
2-4).
Turn the
Putar front
front turnturn signal
signal light
light bulbbulb socketberlawanan
socket counterclockwise
arah
and remove
arum jam dan it from the light
lepaskan unit.
dari light unit.
Remove the
Keluarkan bulb
bulb from
dari the socket
socket and replace
dan ganti denganityang
with abaru.
new
one.
Pasang turn signal light bulb socket dalam urutan
Install the
terbalik turn
dari signal light bulb socket in the reverse order of
pelepasan.
removal.
FRONT TURN SIGNAL

LIGHT BULB BULB SOCKET
BELAKANG
REAR
Lepaskan tail/brake
Remove the tail/brakelight
lightlens
lens (hal.
(page17-10).
17-10).
REAR TURN SIGNAL
Be careful
Hati-hati agarnot to Lepaskan
tidak rear
Remove the rearturn
turnsignal
signallight
light lens.
lens. LIGHT LENS
menggores permukaan
scratch the reflector
reflector.
surface.
Hati-hati agarnot
Be careful tidak
to
merusak
damage lens.
the lens.
Remove therear
Lepaskan rearturn
turn signal
signal light
lightbulb
bulbfrom
darithesocket
socket dan
and
Installation is in the reverse order of removal. REAR TURN SIGNAL
replace it with a new
ganti dengan yang baru. one.
LIGHT BULB

pelepasan.
17-8
TURN SIGNAL SWITCH TURN

(SAKLAR LAMPU SEIN) SIGNAL
PEMERIKSAAN
SWITCH
INSPECTION
Lepaskan front handlebar cover (hal. 2-5).
Remove the front handlebar cover (page 2-5).
Putar kunci kontak ke "OFF".
Turn the ignition
Lepaskan switch
turn signal "OFF".
switch connector.
Disconnect the turn signal switch connector.
Periksa terhadap kontinuitas antara connector terminals
Check
pada for continuity between
masing-masing the connector terminals in each
posisi switch.
switch position.
Harus ada kontinuitas antara terminal kawat dengan
Continuity
kode warnashould exist
sebagai between the color coded wire termi-
berikut:
nals as follows:
TURN SIGNAL SWITCH
TURN SIGNAL SWITCH

CONNECTOR
TURN SIGNAL SWITCH
R W L
COLOR Lb Gr O
17-9
TURN
TURN SIGNAL
SIGNALRELAY
RELAY
PEMERIKSAAN
INSPECTION
Lepaskan front
cover (hal.
(page2-5).
2-5).
Check the
Periksa following:
sebagai berikut:
- –Kondisi
Batterybaterai
condition
- –BolaBurned
lampuout bulb
putusor terbakar
non-specified
atauwattage
dengan watt yang
– tidak
Burned
sesuaifuse
- –Sekring
Ignition switch
putus and turn signal switch function
terbakar
– Loose connector
- Fungsi ignition switch dan turn signal switch
- IfConnector longgar
the above items are normal, check as follows:
Jika hal-halthediturn
Disconnect atas adalah
signal normal,
relay 2P periksa
connector sebagai
from the relay.
berikut:
Short the turn signal relay connector terminals of the wire
harness side
Lepaskan with
turn a jumper
signal relaywire.
2P connector dari relay.
CONNECTION:Black TURN SIGNAL RELAY
Hubungkan singkat turn–signal
Gray relay connector terminals
dari sisithe
Check wire harness
turn dengan
signal light kawatthe
by turning penghubung.
switch ON. TURN SIGNAL RELAY
KAWAT PENGHUBUNG
2P CONNECTOR
If the light comes
HUBUNGAN: on, the– turn
Hitam signal relay is faulty or the con-
Abu-abu
nector has poor connection.
Periksa lampu sein dengan memutar switch ke ON.
If the light does not come on, the wire harness is broken.
Jika lampu sein menyala, maka turn signal relay rusak IGNITION
atau connector sambungannya buruk. Dari SWITCH Bl Gr
O
MAIN Lb
Jika lampu sein tidak menyala, maka wire harness FUSE

putus. TURN SIGNAL G
SWITCH
TURN SIGNAL
TAIL/BRAKE LIGHT (LAMPU LIGHT
BELAKANG/REM)
TAIL/BRAKE LIGHT
PENGGANTIAN BULB
BULB REPLACEMENT
Tekan bagian atas dari
Slightly
rear fenderpress down
sedikit
Lepaskan screws dan tail/brake light lens.
ke Remove the screws and tail/brake light lens.
the upperbawah
side ofuntuk
rear SCREWS
mempermudah
fender to ease
pelepasan.
removal.
Hati-hati agarnot
Be careful tidak
to
merusak
damagelens
the dan
lensrear
and
ender.
rear fender.
TAIL/BRAKE LIGHT LENS
Tekan
Slightlybulb
presssedikit
the bulbdanandputar
turndalam arah berlawanan
it counterclockwise, then
arum
removejam, dan the
it from lepaskan dari light unit.
light unit. TAIL/BRAKE LIGHT BULB
Ganti tail/brake
Replace light bulb
the tail/brake lightdengan
bulb withyang
a newbaru.
one.
Make sure that the Pemasangan
the reversedalam
order of urutan
lens packing is in pelepasan.
place.
17-10
SPEEDOMETER
SPEEDOMETER
PENGGANTIAN BULB
BULB REPLACEMENT
Lepaskan front
cover (hal.
(page2-5).
2-5).
Tarik keluar
Pull out bulbsocket
the bulb socketfrom
darithe
speedometer
speedometerunit.
unit. BULB
Lepaskan
Remove the bulb
bulbdari socket
from dan ganti
the socket and dengan
replace ityang
with baru.
a new
one.
pelepasan.
BULB SOCKET
Lepaskan rear
Remove the rearhandlebar
handlebar cover (hal. 2-5).
cover (page 2-5).
CONNECTORS
Lepaskan
Disconnectsebagai berikut:
the following:
- –Starter switch
Starter switchconnector
connector
- –Lighting
Lightingswitch connectors
switch connectors
- –Dimmer switch connector
Dimmer switch connector
- –Turn signal
Turn switch
signal switchconnector
connector
- –Horn switch connector
Horn switch connector
Lepaskan ketiga
Remove the three screws dan speedometer
screws and speedometer unit.
unit.
order of urutan
pelepasan.
SCREWS
SPEEDOMETER
17-11
Remove thesebagai
Lepaskan following:
berikut:
– Turnsignal
- Turn signalrelay
relay
– Meterlens
- Meter lens
– Four bulb
- Empat bulbsockets
sockets
– Three terminal screwsdan
- Tiga terminal screws and wire
wire terminals
terminals
– Two screws and speedometer/fuel
- Dua screws dan speedometer/fuel meter
meterunitunit
– Meter case
- Meter case
Assembly is inadalah
Perakitan the reverse order of urutan
dalam disassembly.
terbalik dari
pembongkaran.
TERMINAL
TURN SIGNAL SCREWS SCREWS
RELAY
SPEEDOMETER/
HANDLEBAR
SWITCH WIRE
METER CASE
SPEEDOMETER/
FUEL METER UNIT
METER LENS
INSTRUMENT LIGHT
(BI and G)
TURN SIGNAL
INDICATOR HI BEAM INDICATOR
(O and Lb) (Bu and G)
INSTRUMENT LIGHT
(BI and G)
TERMINAL (BI) TERMINAL (Bu/W)

TERMINAL (Y/W)
17-12
FUEL
FUEL LEVEL
LEVELSENSOR
SENSOR
PELEPASAN
REMOVAL
Unlockkunci
Buka and open the seat
tempat usingdan
duduk the ignition
naikkankey.
tempat duduk
Disconnect
dengan the fuel unit 3P
menggunakan connector.
anak kunci kontak.
Lepaskan fuel
Turn the fuel unitsensor
level 3P connector.
holder plate counterclockwise with
a pair offuel
Putar needle nose pliers
level sensor andholder
align theplate
tabs ofdalam
the fuel arah
tank
and grooves of
berlawanan the fuel
jarum jamlevel sensortang
dengan holder plate.
lancip dan tepatkan
tabs dari fuel tank dan alur-alur pada
Remove the fuel level sensor holder plate. fuel level sensor
Removeplate.
holder the fuel level sensor and the O-ring.
Be careful not to
Hati-hati agar tidak Lepaskan fuel level sensor holder plate.
damage the float arm.
merusak float arm. Lepaskan fuel level sensor dan O-ring.
INSTALLATION
PEMASANGAN
Install the new O-ring to the fuel tank.
Install theO-ring
Pasang fuel level
barusensor
padatofuel
thetank.
fuel tank.
Hati-hati agar not
Be careful tidak
to
Set the holder plate by aligning the tabs of the fuel tank and
merusak
damage the float arm. Pasang fuel level sensor pada fuel tank.
float arm.
grooves of the holder plate.
Tempatkan holder
Turn the holder plateplate dengan
clockwise untilmentepatkan tabs
the arrow marks on dari
the
fuel tank dan alur-alur dari holder plate.
holder plate and the fuel tank are aligned.
Puter holder plate searah jarum jam sampai tanda-
tanda panah pada holder plate dan fuel tank telah
ditepatkan.
Pelepasan: Tepatkan
HOLDER HOLDER
PLATE PLATE
HOLDER PLATE
Pemasangan:
FUEL LEVEL
SENSOR Tepatkan
FUEL LEVEL SENSOR TANDA PANAH
HOLDER PLATE
O-RING
Tepatkan
17-13
PEMERIKSAAN
INSPECTION
Ukur
Measuretahanan antara
the resistance terminal-terminal
between connector
the connector terminals with
dengan
the floatfloat (pelampung)
at upper pada(empty)
(full) and lower posisi positions.
teratas (penuh)
dan paling bawah (kosong). Y/W FUEL LEVEL
(20°C/68°F) G Bu/W SENSOR
CONNECTION FLOAT POSITION
(20° C)
FULL EMPTY
HUBUNGAN POSISI PELAMPUNG
Blue/White - Green 25 – 45 Ω 400 – 700 Ω
PENUH KOSONG
Yellow/White – Green 400 – 700 Ω 25 – 45 Ω
Biru/Putih – Hijau 25 – 45 Ω 400 – 700 Ω
Yellow/White – Blue/ 450 – 750 Ω 450 – 750 Ω
Kuning/Putih
White
– 400 – 700 Ω 25 – 45 Ω
Hijau
Kuning/Putih
Replace the fuel– level sensor
450if it– is750
outΩ 450 – 750 Ω
of specification.
Biru/Putih
FUEL METER
METER CIRCUIT INSPECTION
FUEL METER DOES NOT MOVE
• Before performing the system inspection, make sure that
the following items are normal.
FUEL METER – Battery condition
– Fuse
PEMERIKSAAN RANGKAIAN METER
– Meter indicators
• Sebelum
Unlock and open menjalankan
the seat using the pemeriksaan
ignition key. sistem,
pastikan bahwa bagian-bagian berikut ini adalah FUEL LEVEL SENSOR
Disconnect
normal. the fuel level sensor 3P connector. 3P CONNECTOR
Short the fuel level sensor connector terminals of the wire
Jangan
Do nottinggalkan
- Kondisi baterai
harness side with
leave the the jumper wire.
terminal-terminal
terminals connected - Sekring
tersambung CONNECTION:Blue/White
dengan - Meter indicators – Green
with the jumper wire
kawat listrik untuk
for a long time, waktu
as it Turn the
lama, oleh karena FUEL METER TIDAK
ignition switchBERGERAK
"ON" and check the fuel meter.
causes damage to the
menyebabkan kerusakan Buka kunci
fuel meter. If the fuel tempat
meter gaugeduduk
moves dan
to thenaikkan
"F", it is tempat
normal. duduk
pada fuel meter.
dengan anak kunci kontak.
• If the above inspection is normal, check the fuel level sen-
sor (see page 17-14).
Lepaskan fuel level
• If the meter sensor
gauge moves3Pto connector.
"E" with connector shorted,
check the following:
Hubungkan singkat fuel level sensor connector
– Fuel level
terminals dari sensor
sisi wire
wirefor open circuitdengan kawat
harness
– Fuel
penghubung. meter Black wire for open circuit
If the wire harness is normal, replace the speedometer/ fuel
HUBUNGAN:
meter unit with aBiru/Putih – Hijau
new one, and recheck. FUEL METER
Putar kunci kontak ke "ON" dan periksa fuel meter. FUEL LEVEL
SENSOR 3P
Jika fuel meter gauge bergerak ke "F", ia adalah normal. CONNECTOR
• Jika pemeriksaan di atas adalah normal, periksa IGNITION
fuel level sensor (lihat hal. 17-14). SWITCH
• Jika meter gauge bergerak ke "E" dengan Dari BI
Bu/ W
connector dihubungkan singakt, periksa sebagai MAIN Y/ W
berikut: FUSE G
- Rangkaian terbuka pada kawat fuel level sensor

- Rangkaian terbuka pada kawat Hitam fuel meter
KAWAT PENGHUBUNG
Jika wire harness adalah normal, ganti
speedometer/fuel meter unit dengan yang baru, dan
periksa kembali.
17-14
FUEL
FUELMETER
METERTETAP
STAYSPADA "F"
AT "F"
Lepaskan
Remove the rear handlebar
rear handlebar covercover (hal.
(page 2-5) 2-5) dan
and connect the
sambungkan handlebar switch/speedometer
handlebar switch/speedometer 4P/6P connectors. 4P/6P
connectors.
Turn the ignition switch "OFF".
Putar kunci the
Disconnect kontak
fuel ke "OFF".
level sensor 3P connector (page 17-14).
Check for fuel
Lepaskan continuity between3P
level sensor theconnector
fuel level sensor connector
(hal. 17-14).
of the wire harness side and meter terminal.
Periksa terhadap kontinuitas antara fuel level sensor
connector dari sisi wire harness– dan
CONNECTION:Yellow/White meter terminal.
Yellow/White
• If there is no
HUBUNGAN: continuity, there
Kuning/Putih is open circuit in Yellow/
– Kuning/Putih
White wire.
Jika
• • If tidak
there ada kontinuitas,
is continuity, ada level
check the fuel rangkaian terbuka
sensor (page 17-
14).
pada kawat Kuning/Putih. FUEL METER Y/W TERMINAL
• Jika
If the ada
fuel kontinuitas,
level sensor isperiksa
normal,fuel levelthe
replace sensor (hal.
speedome-
17-14).
ter/fuel meter unit with a new one (page 17-12) and
Jika fuel level sensor adalah normal, ganti
recheck.
speedometer/fuel meter unit dengan yang baru FUEL METER
(hal. 17-12) dan periksa kembali.
IGNITION
Dari SWITCH
MAIN Bu/ W
Y/W
FUSE
G
FUEL LEVEL SENSOR 3P

CONNECTOR
HORN
HORN (KLAKSON)
Lepaskan front
Remove the upper
front uppercover
cover(hal.
(page2-4).
2-4).
HORN CONNECTORS
Disconnecthorn
Lepaskan the horn connectors
connectors darifrom the horn.
horn.
Remove the
Lepaskan bolt,
bolt, washer,rubber
washer, rubber dan
and horn.
horn.
order of urutan
pelepasan.
BOLT/WASHER/RUBBER
PEMERIKSAAN HORN
HORN INSPECTION
Remove the
Lepaskan front
front uppercover
upper cover(hal.
(page2-4).
2-4).
Disconnecthorn
Lepaskan the horn connectors
connectors darifrom the horn.
horn.
Connect a 12V
Hubungkan battery
baterai 12Vto the
padahorn terminals.
horn terminals.
The horn is normal if it sounds when
Horn adalah normal jika berbunyi sewaktu the 12V battery
bateraiis 12V
con-
nected to the horn terminals.
dihubungkan ke horn terminals.
17-15
PEMERIKSAAN
HORN SWITCH HORN SWITCH
INSPECTION
Remove the
Lepaskan front
handlebar cover (page 2-5).
(hal. 2-5).
Turn the
Putar ignition
ke "OFF".
Disconnect the horn switch connector.
Lepaskan horn switch connector.
Check for
Periksa continuity
antara terminals
connector in each
terminals
switch position.
pada masing-masing posisi switch.
Continuity
Harus adashould exist between
kontinuitas antarathe colorterminals
wire coded wire termi-
dengan
nals as follows:
kode warna sebagai berikut:
HORN SWITCH
HORN SWITCH CONNECTOR
HORN SWITCH
BAT HO
FREE
PUSH
COLOR Bl Lg
17-16
18. DIAGRAM LISTRIK
WIRING DIAGRAM·······························
DIAGRAM LISTRIK.......................... ········
18-218-2
18
18-1
DIAGRAM LISTRIK
WIRING
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18-2
19. TROUBLESHOOTING
MESIN TIDAK MAU HIDUP ATAU UNJUK KERJA

ENGINE BURUK
LACKS PADA
POWER19-3
SULIT DIHIDUPKAN..............................19-2 KECEPATAN TINGGI ............................19-6
POOR PERFORMANCE AT LOW
MESIN KEKURANGAN TENAGA .........19-3 PENGENDALIAN BURUK .....................19-6
AND IDLE SPEED19-5
UNJUK KERJA BURUK PADA GIGI POOR PERFORMANCE AT

SATU DAN PUTARAN STASIONER.....19-5 HIGH SPEED19-6
POOR HANDLING19-6
ENGINE DOES NOT START
OR IS HARD TO START ·······························19-2
19
19-1
TROUBLESHOOTING
ENGINE DOESMAU
NOTHIDUP
STARTATAU
OR ISSULIT
HARDDIHIDUPKAN
TO START
TROUBLESHOOTING
MESIN TIDAK
1. Spark
1. Plug Inspection
Pemeriksaan Busi
Remove and inspect spark plug.
Lepaskan dan periksa busi.
Is the spark plug wet?
Apakah busi basah?
YES – • Flooded carburetor
YA •- Faulty
• Karburator banjir
starting enrichment (SE) thermal valve
• Throttle
• Startingvalve open (SE) thermal valve tidak bekerja dengan baik
enrichment
• Dirty
•
air cleaner
Throttle valve terbuka
• Improperly adjusted pilot screw
• Air cleaner kotor
NO – GO TO
•
STEP
Pilot 2. tidak disetel dengan baik
screw
2. Spark
TIDAKTest
- LANJUTKAN DENGAN LANGKAH 2.
2. Perform spark test.
Test Percikan Bunga Api Busi
Is there weak or no spark?
Jalankan test percikan bunga api busi.
YES – • Faulty spark plug
Apakah percikan
• Fouledbunga api lemah atau tidak ada?
spark plug
YA •
- Loose or disconnected
Busi tidak bekerja dengan
•
ignition system wires
baik
• Broken or shorted spark plug wire
Busi kotor
•
• Faulty ignition coil
Kabel-kabel
• Faulty
• igniting sistem pengapian longgar atau terlepas
pulse generator
• Faulty ignition switch
Kabel busi putus atau ada hubungan singkat
•
• Faulty ignition
Ignition
•
control
coil tidak module
bekerja (ICM)baik
dengan
• Faulty sidestand switch
Ignition
•
• Broken pulse generator
sidestand tidak bekerja dengan baik
switch wire
Ignition switch tidak bekerja dengan baik
•
Ignition control module (ICM) tidak bekerja dengan baik
•
3. Carburetor Inspection
Sidestand switch tidak bekerja dengan baik
•

Check carburetorKawat
•
for sidestand
clogging. switch putus
TIDAK
Is - LANJUTKAN
the carburetor clogged? DENGAN LANGKAH 3.
3. Pemeriksaan
YES Karburator
– Carburetor not serviced frequently enough
NO GO TO STEP
Periksa– karburator 4.
terhadap sumbatan.
4. Apakah
Fuel Linekarburator
Inspection tersumbat?
Disconnect
YA - the fuel hose
Karburator at carburetor
kurang and apply
mendapatkan vacuum teratur
perawatan pressure to the fuel auto valve.
Does fuel flow freely?
4. Pemeriksaan Saluran Bahan Bakar
NO – • Clogged fuel line
Lepaskan •fuel hose (slang
Clogged bahan
fuel auto bakar) pada karburator dan terapkan tekanan vakuum pada fuel auto
valve
valve. • Clogged fuel tank breather
• Clogged fuel strainer
Apakah bahan bakar mengalir dengan bebas?
5. Cylinder Compression Inspection
Check the cylinder compression.
TIDAK
Is - Fuelwithin
•
the compression line (saluran bahan bakar) tersumbat
specification?
Fuel auto valve tersumbat
•
Fuel tank breather tersumbat
•
NO – • Valve
Fuel stuck
• open
strainer tersumbat
• Worn cylinder and piston rings
5. Pemeriksaan Kompressi
• Damaged Cylinder
cylinder head gasket
• Seized valve
Periksa kompressi cylinder
• Incorrect valve.seat contact
• Improper
Apakah kompressi sesuai valve timing
dengan spesifikasi?
TIDAK - • Valve macet terbuka
• Cylinder dan piston rings aus
• Cylinder head gasket rusak
• Valve macet
Kontak valve seat tidak benar
•
• Valve timing tidak sesuai
19-2
TROUBLESHOOTING
6 Kondisi
6. Engine Start Mesin
Starting Condition
Start by following
Hidupkan mesin normal
denganprocedure.
mengikuti prosedur normal.
Apakah mesin hidup kemudian
Does the engine start then stops? mati lagi?
YA
YES – •- SE thermal
Faulty
• valvevalve
SE thermal tidak bekerja dengan baik
• Leaking
• inletbocor
Inlet pipe pipe
• Incorrectly
• Karburator adjusted carburetor
tidak disetel dengan benar
• Clogged carburetor
• • Karburator tersumbat
Improper ignition timing (Faulty ICM or ignition pulse generator)
• Ignition timing
Contaminated
• tidak benar (ICM atau ignition pulse generator rusak)
fuel
• Bahan bakar terkontaminasi
ENGINE
MESIN LACKS POWER
KEKURANGAN TENAGA
1. Engine
1. Oil Inspection
Pemeriksaan Oli Mesin
Periksa tinggi permukaan oli dan kondisinya.
Apakah tinggi permukaan oli benar dan oli berada dalam kondisi baik?
Check
YA the -oilLANJUTKAN
level and condition.
DENGAN LANGKAH 2.
IsTIDAK
the oil level
- correct
• Tinggiand the oil in oli
permukaan good condition?
terlalu tinggi/rendah
Oli
• terkontaminasi
2. NOPemeriksaan
– • Oil Peralatan Penggerak
level too high/low
• Contaminated oil
Naikkan roda lepas tanah dan putar dengan tangan.
2. Drive Train Inspection
Apakah roda berputar dengan bebas?
Raise the wheel off the ground and spin it by hand.
Does the wheel spin freely?
TIDAK - Rem menyangkut
•
Final reduction dan driven pulley bearings aus atau rusak
•
NO – • Brake
Finaldragging
• shaft bengkok
• Worn or damaged final reduction and driven pulley bearings
3. Pemeriksaan • Bent final shaft
Tekanan Udara Ban
3. Tire Pressure
Periksa Inspection
tekanan udara ban depan dan belakang.
Check front and rear
Apakah tekanan udara tire pressure.
ban rendah?
Is the tire pressure low?
YA - • Tire valve tidak bekerja dengan baik
YES – • Faulty •
tire valve
Ban bocor
• Punctured tire
4. Pemeriksaan Busi
4. Spark Plug Inspection
Lepaskan
Remove and dan periksa
inspect thebusi.
spark plug.
Apakah
Is busi
the spark plugdalam
in goodkondisi baik?
condition?
YA
YES – G-OLANJUTKAN
TO STEP 5. DENGAN LANGKAH 5.
TIDAK– •- Plug
NO • Busi
notkurang mendapatkan
serviced perawatan teratur
frequently enough
• Incorrect
• Derajatspark
panasplug
busiheat range
tidak sesuai
• Faulty
• Busi spark plug
tidak bekerja dengan baik
5. Carburetor Inspection
5. Pemeriksaan Karburator
Check carburetor for clogging.
Periksa karburator terhadap sumbatan.
Is the carburetor clogged?
Apakah karburator tersumbat?
YES – Carburetor not serviced frequently enough
YA - Karburator kurang mendapatkan perawatan teratur
6. Ignition Timing Inspection
6. Pemeriksaan Ignition Timing
Check the ignition timing.
IsPeriksa ignition
the ignition timing.
timing correct?
Apakah
YES ignition
– G timing
O TO STEP 7. benar?
YA
NO – •- LANJUTKAN
Faulty ignitionDENGAN LANGKAH
control module (ICM) 7.
• Faulty ignition pulse generator
TIDAK - Ignition control module (ICM) tidak bekerja dengan baik
•
Ignition pulse generator tidak bekerja dengan baik

•
19-3
TROUBLESHOOTING
7. Cylinder
7. compression
Pemeriksaan Inspection
Kompressi Cylinder
Test the cylinder compression.
Test kompressi cylinder .
Is the compression within specification?
Apakah kompressi sesuai dengan spesifikasi?
NO – • Valve stuck open
TIDAK • - Worn
• Valve macet and
cylinder terbuka
piston rings
Cylinder dan piston
• Damaged
• rings
cylinder head aus
gasket
• Seized
•
valve
Cylinder head gasket rusak
• Incorrect valve seat contact
• Valve macet
• Improper valve timing
• Kontak valve seat tidak benar
8. Overheating Inspection
• Valve timing tidak tepat
Check for engine overheating.
8. Pemeriksaan Overheating
Is the engine overheating?
Periksa terhadap engine overheating.
YES – • Excessive carbon build-up in combustion chamber
Apakah mesin
• Useoverheating?
of poor quality fuel
• Lean fuel mixture
YA -• Pembentukan karbon secara berlebihan di ruang pembakaran
NO – GO TO
•
STEP 9. bahan bakar berkualitas rendah
Pemakaian
9. Engine Knocking
• Campuran bahan bakar miskin
Inspection
TIDAK - or
Accelerate LANJUTKAN DENGAN LANGKAH 9.
run at high speed.
9. Is the engine knocking?
Pemeriksaan Engine Knocking (mesin mengelitik)
YES – • Wornatau
Berakselerasilah piston andpada
jalan cylinder
kecepatan tinggi.
• Wrong type of fuel
Apakah mesin knocking?
• Excessive carbon build-up in combustion chamber
• Ignition timing too advanced (faulty ICM)
YA •- Lean
•Piston
fueldan cylinder aus
mixture
•Jenis bahan bakar tidak sesuai
•Pembentukan karbon secara berlebihan di ruang pembakaran
10. Valve Timing Inspection
•Ignition timing terlalu maju (ICM tidak bekerja dengan baik)
Check the valve timing. bahan bakar miskin
•Campuran
TIDAK
Is - timing
the valve LANJUTKAN
correct?DENGAN LANGKAH 10.
10. YES – GO TO
Pemeriksaan STEPTiming
Valve 11.
NO Cam timing
Periksa– valve sprocket not buka
(tertib installed properly
klep).
11. Apakah
Drive Train Inspection
valve timing benar?
Check thedrive
YA train.
LANJUTKAN DENGAN LANGKAH 11.
Is the drive train normal?
TIDAK - Cam sprocket tidak terpasang dengan benar
NO – • Fouled or faulty drive belt
11. Pemeriksaan DriveorTrain
• Fouled faulty(Peralatan
drive pulleypenggerak)
• Fouled
Periksa drive train. or faulty driven pulley
• Worn clutch shoes
Apakah drive train normal?
TIDAK - • Drive belt kotor atau tidak bekerja dengan baik
• Drive pulley kotor atau tidak bekerja dengan baik
• Driven pulley kotor atau tidak bekerja dengan baik
• Clutch shoes aus
19-4
TROUBLESHOOTING
UNJUK KERJA BURUK PADA
POOR PERFORMANCE AT LOWGIGI
ANDSATU DAN
IDLE PUTARAN
SPEED
STASIONER
1. Idle Adjustment Inspection
Check the idle speed.
1. Pemeriksaan Penyetelan Putaran Stasioner
Is the idle speed correct?
Periksa putaran stasioner.
Apakah
NO
putaran stasioner benar?
– Adjust the idle speed
2. YA
Spark Test- LANJUTKAN DENGAN LANGKAH 2.
TIDAK spark
Perform - Setel putaran stasioner
test.
2. Is
Test Percikan
there weak or Bunga Api spark?
intermittent Busi
Jalankan
YES – test percikan
• Faulty sparkbunga
plug api busi.
• Fouled spark plug
Apakah percikan
• Faulty bunga
ignitionapi
coillemah atau tidak teratur?
• Faulty ignition control module (ICM)
YA - • Busi tidak bekerja dengan baik
NO – GO TO
•
STEP
Busi kotor3.
3. Intake Air Leaking
• Ignition coil tidak bekerja dengan baik
Inspection
• Ignition control module (ICM) tidak bekerja dengan baik
Check for air leaks at the inlet pipe.
TIDAK
Is there air- leaking?
LANJUTKAN DENGAN LANGKAH 3.
3. Pemeriksaan
YES Kebocoran
– • Loose inlet pipeUdara Pemasukan
• Damaged
Periksa terhadap inlet pipe
kebocoran udara pada inlet pipe.
• Damaged inlet pipe gasket
Apakah
NO – ada kebocoran
GO TO STEP 4. udara pemasukan?
4. YA -• Inlet pipe
Starting Enrichment (SE)longgar
Thermal Valve Inspection
• Inlet pipe rusak
Check the SE thermal valve (page 5-18).
• Inlet pipe gasket rusak
Is the SE Thermal valve OK?
4. Pemeriksaan Starting Enrichment (SE) Thermal Valve
NO – Faulty SE thermal valve
Periksa SE thermal valve (hal. 5-18).
5. Ignition Timing Inspection
Apakah SE thermal valve OK?
Check the ignition timing.
Is the ignition timing correct?
TIDAK - SE thermal valve tidak bekerja dengan baik.
YES – Improper valve timing
5. NOPemeriksaan Ignition
– • Faulty Timing
ignition control module (ICM)
• Faulty ignition
Periksa ignition timing (waktu pulse generato
pengapian).
Apakah ignition timing benar?
YA - Valve timing tidak benar
TIDAK - • Ignition control module (ICM) tidak bekerja dengan baik
• Ignition pulse generator tidak bekerja dengan baik.
19-5

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DAFTAR ISI

CARA MEMAKAI BUKU INI

SPESIFIKASI RODA BELAKANG/

NOMOR SERI MESIN

SPESIFIKASI SISTEM BAHAN BAKAR

SPESIFIKASI CYLINDER HEAD/VALVES Satuan: mm

KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH

FINAL REDUCTION SPECIFICATIONS

SPESIFIKASI CRANKCASE/CRANKSHAFT Satuan: mm

Kapasitas minyak 75 ± 1 cm

REAR WHEEL/SUSPENSION SPECIFICATIONS

BRAKE SYSTEM SPECIFICATIONS

SPESIFIKASI LAMPU2 / METER2 / SAKELAR2

TORSI PENGENCANGAN MESIN & RANGKA

MAINTENANCE JUM- DIAMETER TORSI

Oil pump plate screw 1 4 3 (0.3, 2.2)

FRONT BRAKE HOSE

REAR BRAKE CABLE

REAR BRAKE LIGHT

THROTTLE REAR BRAKE

REAR BRAKE CABLE

REAR BRAKE CABLE

FRONT BRAKE HOSE

FRONT BRAKE HOSE

Jepit daerah dengan pita putih:

REAR BRAKE CABLE

BATTERY NEGATIVE BATTERY POSITIVE

FUSE BOX WIRE STARTER RELAY WIRE

PULSE SECONDARY CRANKCASE

° SISI ATAS CARBURETOR VACUUM

CRANKCASE BREATHER HOSE

INLET PIPE BAND

AIR SUPPLY PIPE

PULSE SECONDARY STARTING ENRICHMENT (SE)

SISI AIR SUPPLY HOSE SPARK PLUG WIRE

STARTER MOTOR CABLE GROUND CABLE

IGNITION PULSE GENERATOR WIRE

CRANKCASE BREATHER FINAL REDUCTION CASE

Sewaktu memasang pedal kikstarter

REAR BRAKE CABLE

POSITION LIGHT WIRE

LEFT FRONT TURN RIGHT FRONT TURN

HEAD LIGHT WIRE

RIGHT REAR TURN

TAIL/BRAKE LIGHT WIRE

TAIL/BRAKE LIGHT/REAR LEFT REAR TURN SIGNAL

Tepatkan daerah yang

PAIR CONTROL VALVE CHECK VALVE PAIR AIR CLEANER

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

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

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

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

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

BODY PANEL REMOVAL CHART

CUSHION RUBBERS SCREW

Lepaskan headlight/front turn signal light 6P connector

Lepaskan kedua cushion rubbers.

SCREWS 4P/6P CONNECTORS

Pemasangan adalah dalam urutan terbalik dari

FRONT LOWER COVER

LUGGAGE BOX (KOTAK BAGASI)

Pemasangan adalah dalam urutan terbalik dari

UNDER COVER SCREWS