Buku Pedoman Reparasi BEAT

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

LIGHTS/METERS/SWITCHES
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
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
RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS
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.
Remove the body cover (page 2-9).
Lepaskan crankcase breather drain hose plug
(penyumbat slang pembuangan pernapasan bak mesin) DRAIN HOSE HOSE PLUG
dari ujung hose dan keluarkan endapan ke dalam
penampung yang sesuai.
Pasang crankcase breather drain hose plug dan

tempatkan crankcase breather hose pada hose clamp.
Check the crankcase breather hose for deterioration, damage
or leakage.
Replace the crankcase breather hose if n ecessary.
Also check the crankcase breather hose fittings for leakage.
Install the body cover (page 2-9).
3-6
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
PENURUNAN / PEMASANGAN MESIN
PEMASANGAN MESIN
ENGINE INSTALLATION
Maneuver mesin
Gerakkan the engine into therangka
ke dalam frame from
dari the
sisi right
kanansidedari
of
the vehicle.
kendaraan.
Set the engine
Tempatkan mesinstraight
lurus with
denganthe frame
rangkaand danpush the
dorong
engine forward so that the bolt holes are aligned.
mesin ke depan sehingga lubang-lubang bolt telah
Install the engine hanger link bolt from the left side of the
disejajarkan.
scooter.
Install and
Pasang tightenhanger
engine the nut to thebolt
link specified
(bauttorque.
penyambung
penggantung mesin) dari sisi
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
PENURUNAN / PEMASANGAN MESIN
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).
Install the following:
Setel jarak main bebas rear brake lever (hal. 3-16).
– Under cover (page 2-10)
Pasang
– Centersebagai berikut:
body cover (page 2-8)
Luggage
- – Under coverbox (page
(hal. 2-7)
2-10)
- Center body cover (hal. 2-8)
- Luggage box (hal. 2-7)
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
KETERANGAN SERVIS ........................7-3

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
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)
PELEPASAN/PEMASANGAN
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)
- Luggage box (hal. 2-7)
– 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
Remove thesebagai berikut:
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
and that sprocket camshaft
on the cam sprocketkemudian
sprocke t is facing
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
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 TORQUE:8 N·m (0.8 kgf·m, 5.9 lbf·ft)
jatuhnya cam sprocket
sprocket
boltthe
ke cam sprocket
dalam bolt TORSI: 8 N.m (0,8 kgf.m;
crankcase.
kgf.m; 5,9 lbf.ft)
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.
TORQUE:4 N·m (0.4 kgf·m, 3.0 lbf·ft)
TORSI:
Install the4following:
N.m (0,4 kgf.m;
kgf.m; 3,0 lbf.ft)
lbf.ft)
Pasang sebagai berikut:
– Intake/exhaust shroud (page 7-9)
– Cooling
- Intake/exhaustfan 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
Remove the following:
Lepaskan sebagai berikut:
– 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)
TORSI: 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
VALVE GUIDEVALVE
PENGGANTIAN REPLACEMENT
GUIDE
Disassemble
Bongkar the cylinder
cylinder head 7-18).
head (hal. (page 7-18).
VALVE GUIDE DRIVER
Chill new valve
Dinginkan valveguides in abaru
guides freezer for about
dalam 1 hour.
bagian freezer dari
lemari es selama kira-kira 1 jam.
CATATAN:
• Be sure to wear heavy gloves to avoid burns when han-
• 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
Bongkar the cylinder
cylinder head7-18).
head (hal. (page 7-18).
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.
TORQUE:10 N·m (1.0 kgf·m, 7 lbf·ft)
Install the following:
– 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
Apply engineolioilmesin
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)
BATAS SERVIS: 0,05 mm
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
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.
terhadap keausan atau kerusakan.
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
LOKASI KOMPONEN-KOMPONEN......11-2
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 padshoe
dandust, regardless
shoe, apapunofkomposisi
material composition
compositi on could
bahannya, dapatbemembahayakan
hazardous to your health.
kesehatan.
• Avoid breathing
breathing dust particles
particles..
• Jangan menghirup partikel-partikel debu.
• Never use an air hose or brush to clean brake assemblies.
assemblies. Use an OSHA-approved vacuum cleaner cleaner..
• Jangan sekali-kali
sekali-kali memakai
memakai slang udara atau sikat sikat untuk membersihkan susunan rem. rem. Pakailah alat penghisap debu yang
baik.
• This section
section covers
covers the front
front wheel,
wheel, fork, handleba
handlebarr and steering
steering stem.
stem.
• Bab ini
• When meliputi
servicing theroda
frontdepan, fork (garpu),
wheel, fork handlebar
or 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
contaminated brake disc or pad reduces stopping power. Discard contaminated
contaminated skuter dengan menggunakan
contaminated pads and clean dongkrak
clean a contaminated
contamina atau
ted disc alata pendukung
with high quality
lain.
brake degreasing agent.
agent.
• Brake
• After thedisc
frontatau pad
atau pad
wheel yang terkontaminasi
installation, check the brakemengurangi
operation bydaya
operation pengereman.
applyi
applying Buanglah pads yang terkontaminasi dan bersihkan
ng the brake lever.
disc
• For yang
brake
brake terkontaminasi
system
system service,
servi dengan
ce, refer
refer pagebahan
to page 13-3. pembersih gemuk berkualitas tinggi untuk peralatan rem.
13-3.
• 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 - Sampai ke indikator
Cold tire pressure Driver only 200 kPa (2.00 kgf2/cm2, 29 psi) –
Tekanan udara ban Pengendara saja 200 kPa (2,00 kgf/cm , 29 psi) -
Driver and passenger 200 kPa (2.00 kgf2/cm2, 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(6,0
59 N.m ·m (6kgf.m;
.0 kgf·m 44, 4lbf.ft)
4 lbf·ft) U-nut
Fron
Rear t brakelever
brake disc pivot
sockebolt
t bolt 42 N
1 N.m ·m (kgf.m;
(0,1 4.3 kgf0,7 ·m, 3 1 lbf·ft)
lbf.ft) ALOC bolt; replace with new ones
H an d le b ar p os t n
Rear brake lever pivot nutu t 4,5 N.m (0,5 kgf.m; 3,34lbf.ft)
5 9 N ·m ( 6 .0 kg f · m , 4 lbf·ft)
Rear bbridge
Bottom rake levpinch
er pivo t bolt
bolt 1 N ·m (0 .1 kg f ·m
64 N.m (6,5 kgf.m; 47 lbf.ft) , 0 .7 lb f·ft)
Reasocket
Fork r brake bolt
lever pivot nut 4.5 N(2,0
20 N.m ·m (0kgf.m;
.5 kgf·15 m, 3lbf.ft)
.3 lbf·ft) Oleskan locking agent pada ulir
Bottomstem
Steering bridgetop pinthread
ch bolt 64hal.
Lihat N·m11-22
(6.5 kgf·m, 47 lbf·ft)
Steering stem lock nut
Fo rk s o ck et b o lt 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
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
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.
Pasang body cover (hal. 2-9).

BOLTS
INSTALLATION
Install the rear shock absorber and tighten the bolts.
Install the body cover (page 2-9).
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)
BAGIAN STANDARD BATAS SERVIS SERVICE
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)
kgf·m, 1.5 lbf·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
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.
to the specified torque.
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.
to the specified torque.
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.
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
REMOVAL/INSTALLATION
Drain the brake fluid (page 13-6).
13-6).
Keluarkan
Remove the brake fluid (minyak
rear handlebar coverrem)
(page(hal.
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.
Pasang parts yang telah dilepaskan dalam urutan
terbalik dari pelepasan.
• Repla
Replace
ce the
the sealing
sealing washe
washers
rs with
with new ones.
ones.
Isi
Fill and air bleed the hydraulic system (pagesistem
dan air bleed (buang udara palsu) 13-7). hidraulik
13-7).
(hal. 13-7).
SCREW Tepatkan ujung master

2 N·
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·
N·m (3.5 kgf ·m, 25 lbf ·ft) Tepatkan brake
hose eyelet
CONNECTORS BRAKE HOSE terhadap stopper.
13-11
SISTEM REM
DISASSEMBLY/ASSEMBLY
PEMBONGKARAN/PERAKITAN
Remove/install the following:
Lepaskan/pasang sebagai berikut:
- – 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
Remove the following:
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 yang ditentukan.
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
DISASSEMBLY/ASSEMBLY
PEMBONGKARAN/PERAKITAN
Remove/install the following:
Lepaskan/pasang sebagai berikut:
- –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.
Install the removed parts in the reverse order of removal.
Keluarkan dust seal/piston seal.
Pasang parts yang telah dilepaskan dalam urutan
• 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
BATERAI/SISTEM PENGISIAN/ALTERNATOR
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.
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
ion generator
alternator/ignition
alternator/ignit 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).
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
Install the washerdan
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
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
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
Remove the battery cover (page 2-13).
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
LAMPU/METER/SAKLAR-SAKLAR
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.
Installation is in adalah
Pemasangan the reversedalam
order of urutan
removal. terbalik dari
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
LAMPU/METER/SAKLAR-SAKLAR
PEMERIKSAAN
HORN SWITCH HORN SWITCH
INSPECTION
Remove the
Lepaskan front
front handlebarcover
handlebar cover (page 2-5).
(hal. 2-5).
Turn the
Putar ignition
kunci kontakswitch "OFF".
ke "OFF".
Disconnect the horn switch connector.
Lepaskan horn 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
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
DIAGRAMDIAGRAM
LISTRIK
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6
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A
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R V L
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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?
TIDAK - LANJUTKAN DENGAN LANGKAH 4.
YES – GO TO STEP 5.
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
YA - LANJUTKAN DENGAN LANGKAH 5.
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 the- drive
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
TROUBLESHOOTING
UNJUK KERJA BURUK PADA KECEPATAN TINGGI

1. Pemeriksaan Ignition Timing
Periksa ignition timing.
Apakah ignition timing benar?
TIDAK - • Ignition control module (ICM) tidak bekerja dengan baik
• Ignition pulse generator tidak bekerja dengan baik
2. Pemeriksaan Karburator
Periksa karburator terhadap sumbatan.
Apakah karburator tersumbat?
YA - Karburator kurang mendapatkan perawatan teratur
3. Pemeriksaan Saluran Bahan Bakar
Lepaskan fuel hose pada karburator dan terapkan tekanan vacuum pada fuel auto valve.
Apakah bahan bakar mengalir bebas?
TIDAK - • Fuel line tersumbat.
• Fuel tank breather tersumbat.
• Fuel auto valve tidak bekerja dengan baik
• Fuel strainer tersumbat
4. Pemeriksaan Valve Timing
Periksalah valve timing (tertib waktu buka klep).
Apakah valve timing benar?
TIDAK - Cam sprocket tidak terpasang dengan benar
5. Pemeriksaan Valve Spring
Periksalah valve springs.
Apakah valve springs lemah?
YA - Valve spring tidak bekerja dengan baik
PENGENDALIAN BURUK
Pengemudian terasa berat
• Steering top thread/lock nut terlalu kencang
• Steering head bearings rusak
• Tekanan udara ban rendah
Roda bergoyang
•Ada kerenggangan berlebihan pada wheel bearing
•Ban kondisinya tidak baik
•Pelek bengkok
•Engine mounting bushings aus secara berlebihan
•Rangka bengkok
Skuter menarik ke satu sisi

• Roda depan dan belakang tidak sebidang
• Fork bengkok
• Shock absorber tidak bekerja dengan baik
• Axle bengkok
• Rangka bengkok
19-6

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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

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

CARA KERJA OPERATION

SECONDARY AIR SUPPLY SYSTEM....3-12

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

Valve adjusting wrench

Pasang body cover (hal. 2-9)

Sementara mesin berputar stasioner, putar handlebar

Pasang crankcase breather drain hose plug dan

Jika ada dugaan adaya kondisi-kondisi tidak normal,

Hold the scooter

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

DIAGRAM SISTEM PELUMASAN

ROCKER ARM SHAFT

OIL STRAINER SCREEN

OIL PUMP ASSEMBLY O-RING

OIL PUMP COVER

Lepaskan oil pump cover dengan

Pasang dan kencangkan nut dengan torsi yang

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

STARTER MOTOR WIRE

CABLE CLAMP/ BOLT CABLE HOLDER

KETERANGAN SERVIS ........................7-3

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,

8 N·m (0.8 kgf ·m, 5.9 lbf ·ft)

12 N·m (1.2 kgf ·m, 9 lbf ·ft)

CYLINDER HEAD COVER

Oleskan oli mesin