Buku Pedoman Reparasi Beat [PDF]

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DAFTAR ISI



CARA MEMAKAI BUKU INI



1



Buku Pedoman Reparasi ini menguraikan prosedur servis untuk skuter HONDA BEAT.



RANGKA / BODY PANELS / SISTEM PEMBUANGAN GAS



2



Ikuti petunjuk pada Jadwal Perawatan (Bab 3) untuk mempertahankan skuter pada kondisi operasional puncak.



PERAWATAN



3



SISTEM PELUMASAN



4



SISTEM BAHAN BAKAR



5



PENURUNAN / PEMASANGAN MESIN



6



CYLINDER HEAD/VALVES/CYLINDER/PISTON



7



KICKSTARTER / DRIVE PULLEY / DRIVEN PULLEY / CLUTCH



8



FINAL REDUCTION



9



Bab 2 menggambarkan prosedur untuk pelepasan/pemasangan komponen yang mungkin diperlukan untuk menjalankan servis yang diuraikan pada bab-bab berikutnya. Bab 4 sampai dengan 17 menguraikan bagian-bagian skuter yang dikelompokkan menurut lokasi. Carilah bab yang Anda inginkan pada halaman ini, kemudian bacalah daftar isi pada halaman pertama dari bab itu. Kebanyakan bab dimulai dengan gambar susunan atau gambar sistem, keterangan servis dan cara mencari penyebab kesukaran untuk bab itu. Halaman-halaman berikutnya memberikan prosedur servis secara mendetil. Jika Anda tidak mengetahui sumber penyebab kesukaran, bacalah bab 19, TROUBLESHOOTING.



Semua keterangan, gambar, petunjuk dan spesifikasi di dalam publikasi ini berdasarkan data-data produk terakhir yang tersedia pada waktu persiapan untuk pencetakan. PT Astra Honda Motor berhak membuat perubahan pada setiap waktu tanpa pemberitahuan dan tanpa ikatan apapun. Dilarang mengutip atau mencetak ulang bagian dari penerbitan ini tanpa ijin tertulis penerbit. Buku Pedoman ini ditulis untuk orang yang telah memiliki pengetahuan dasar perawatan skuter Honda. PT ASTRA HONDA MOTOR



RANGKA



Bab 1 dan 3 berlaku untuk skuter secara keseluruhan.



KELISTRIKAN



Adalah sangat penting untuk menjalankan perawatan berkala 1 dan 2 pada waktunya. Servis ini mengadakan penyesuaian terhadap keausan awal yang terjadi dalam masa pemakaian mula.



MESIN & PERALATAN PENGGERAK



KETERANGAN UMUM



CRANKCASE / CRANKSHAFT



10



RODA DEPAN / SUSPENSI / KEMUDI



11



RODA BELAKANG / SUSPENSI



12



SISTEM REM



13



BATERAI / SISTEM PENGISIAN / ALTERNATOR



14



SISTEM PENGAPIAN



15



SISTEM STARTER LISTRIK



16



LAMPU / METER / SAKLAR-SAKLAR



17



DIAGRAM LISTRIK



18



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. Adalah penting untuk mengetahui bahwa buku ini hanya memuat beberapa peringatan terhadap cara-cara servis tertentu yang dapat menimbulkan KECELAKAAN BADANIAH kepada mekanik atau dapat merusak kendaraan atau menyebabkannya tidak aman untuk dikendarai. Harap dimengerti bahwa peringatan-peringatan ini tidak dapat meliputi semua cara-cara pelaksanaan servis, baik yang dianjurkan oleh Honda maupun yang tidak, ataupun akibat-akibat yang mungkin berbahaya yang timbul dari setiap cara pelaksanaan servis, juga bahwa Honda tidak dapat menyelidiki semua cara - cara tersebut. Setiap orang yang menggunakan prosedur kerja ataupun tool, balk yang dianjurkan oleh Honda maupun tidak, harus meyakinkan dirinya sendiri dengan pasti bahwa keamanan pribadi maupun keamanan kendaraan tidak terancam oleh cara pelaksanaan servis ataupun tool yang dipilih.



1. KETERANGAN UMUM 1



SPESIFIKASI RODA BELAKANG/



PERATURAN SERVIS ................................... SERVICE RULES ?????????????????????? 1-21-2 IDENTIFIKASI MODEL .................................. MODEL IDENTIFICATION ????????????? 1-21-2 SPESIFIKASI UMUM ..................................... GENERAL SPECIFICATIONS??????????? 1-41-4



SUSPENSI .................................................. 1-7 REAR WHEEL/SUSPENSION SPECIFICATIONS ????????????????????? 1-7 SPESIFIKASI SISTEM REM ....................... 1-7 BRAKE SYSTEM SPECIFICATIONS ????? 1-7



SPESIFIKASI BATERAI/SISTEM



SPESIFIKASI SISTEM PELUMASAN ........... 1-5 LUBRICATION SYSTEM



BATTERY/CHARGING SYSTEM/ PENGISIAN/ALTERNATOR ....................... 1-8 ALTERNATOR SPECIFICATIONS ?????? 1-8



SPESIFIKASI SISTEM BAHAN BAKAR ....... 1-5



IGNITION SYSTEM SPECIFICATIONS ?? 1-8



SPECIFICATIONS ????????????????????? 1-5 FUEL SYSTEM SPECIFICATIONS??????? 1-5



SPESIFIKASI CYLINDER HEAD/VALVES.... 1-5 CYLINDER HEAD/VALVES



SPECIFICATIONS ????????????????????? 1-51-6 SPESIFIKASI CYLINDER/PISTON................ CYLINDER/PISTON SPECIFICATIONS ?? 1-6 SPESIFIKASI KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH ............ 1-6 KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH ??? 1-61-6 SPESIFIKASI FINAL SPECIFICATIONS REDUCTION................



SPESIFIKASI SISTEM PENGAPIAN.......... 1-8 SPESIFIKASI SISTEM STARTER ELECTRIC STARTER SYSTEM LISTRIK....................................................... 1-8 SPECIFICATION ?????????????????????? 1-8



SPESIFIKASI LAMPU/METER/



LIGHTS/METERS/SWITCHES SAKLAR...................................................... 1-8 SPECIFICATION ?????????????????????? 1-8



NILAI TORSI STANDARD .......................... 1-9



STANDARD TORQUE VALUES ????????? 1-9



NILAI TORSI MESIN & RANGKA............... 1-9



ENGINE & FRAME TORQUE VALUES ?? 1-9



TITIK-TITIK PELUMASAN &



FINAL REDUCTION SPECIFICATIONS?? 1-6 SPESIFIKASI CRANKCASE/ CRANKSHAFT............................................... 1-6



LUBRICATION & SEAL POINTS ??????? 1-121-12 PERAPATAN ............................................



CRANKCASE/CRANKSHAFT SPECIFICATIONS 1-6 SPESIFIKASI RODA????????????????????? DEPAN/



CABLE & HARNESS ROUTING ???????? 1-141-14 PERLETAKAN KABEL & HARNESS.......



SUSPENSI/ KEMUDI ..................................... 1-7 FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS ????????????????????? 1-7



EMISSION CONTROL SYSTEMS??????? 1-241-24 SISTEM-SISTEM PENGATURAN EMISI..



1-1



KETERANGAN UMUM



SERVICE RULES PERATURAN SERVIS GENERAL INFORMATION



1. 1. 2. 3. 2. 4. 3. 5. 4. 6. 5. 7. 8. 6. 7. 8.



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



MODEL IDENTIFICATION



IDENTIFIKASI MODEL



1-2



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



NOMOR SERI RANGKA



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



NOMOR SERI MESIN



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



NOMOR IDENTIFIKASI KARBURATOR



1-3



KETERANGAN UMUM



GENERAL SPECIFICATIONS SPESIFIKASI UMUM DIMENSI DIMENSIONS



RANGKA FRAME



MESIN



ENGINE



KARBURATOR PERALATAN CARBURETOR PENGGERAK DRIVE TRAIN KELISTRIKAN



ELECTRICAL



1-4



BAGIAN SPESIFIKASI ITEM SPECIFICATIONS Panjang menyeluruh 1.859 mm Overall length 1,850 mm (72.8 in) 676 mm Lebar menyeluruh Overall width 676 mm (26.6 in) 1.053 mm Tinggi menyeluruh Overall heightroda 1.240 mm 1,040 mm (40.9 in) Jarak sumbu Wheelbase 1,240 mm (48.8 in) 737 mm Tinggi tempat duduk Seat height 737 mm (29.0 in) 260 mm Tinggi pijakan kaki Footpeg height ke tanah 260 mm (10.2 in) 135 mm Jarak terendah Ground clearance 135 mm (5.3 in) 89,2 kg Berat motor siap pakai Curb weight 89.2 (tulang kg (196.7 lbs) Jenis rangka Jenis under bone bawah) Frame typedepan Under bone type Suspensi Garpu teleskopik Jarak 80,5 mm Front pergerakan suspension poros depan Telescopic fork Suspensi Unit swing (unit berayun) Front axlebelakang travel 80.5 mm (3.17 in) Jarak pergerakan poros belakang 75,0 mm Rear suspension Unit swing Ukuran ban depan 80/90-14M/C 40 Rear axle travel 75.0 mm (2.95 in) Ukuran ban belakang 90/90-14M/C 46P Front tire size 80/90 - 14M/C40P Merek ban SRI FT235 90/90 - 14M/C46P Rear tire size (Depan/Belakang) Rem depan Rem cakram hidraulik Tire brand SRI (Front/Rear) FT235 Rem belakang Mekanis, mendahului-mengikuti Front brake Hydraulic disc brake Sudut caster 26° 30′ Rear brake Mechanical leading trailing Panjang trail 79,0 mm Caster angle 26°30’ Kapasitas tangki bahan bakar 3,3 liter Trail length 79.0 mm (3.11 in) Diameter dan langkah 50,0 x 55,0 mm 3 Fuel tank capacity 3.3 liter (0.87 US gal, 0.73 lmp gal) Volume langkah 108,0 cm Bore and strokekompressi 50.0 x 55.0 mm (1.97 x 2.17 in) Perbandingan 9,2 : 1 cu-in) Displacement cm3 (6.59 Peralatan penggerak klep 2 klep, SOHC108.0 digerakkan rantai tunggal Compression ratio 9.5 : 1 Klep masuk membuka ] pada peng10° BTDC (sebelum TMA) Valve train menutup ] angkatan 2 valve, single chain driven SOHC 35° ABDC (setelah TMB) Intake valve membukaopens at 1 mm (0.04 in) 10° BTDC Klep buang ] 1 mm 25°lift BBDC (sebelum TMB) at 1 mm (0.04 in) 35° ABDC menutup closes ] 0° lift ATDC (setelah TMA) Sistem Exhaustpelumasan valve opens at 1 mm (0.04 in) lift 25° Di bawah tekananBBDC paksaan dgn bak oli basah Jenis pompa oli closes at 1 mm (0.04 in) lift 0° ATDC Trochoid Sistem pendinginan Lubrication system Forceddengan pressurepaksaan and wet sump Pendinginan udara Saringan Oil pump udara type Trochoid Saringan kertas Berat kosong 24,9 kg Cooling systemmesin Forced air cooled Jenis karburator CV (constant velocity) Air filtration Viscous paper element Diameter 22 mm atau ekuivalennya Engine drythrottle weight 24.9 kg (54.9 lbs) Sistem kopeling Kopeling kering, sentrifugal otomatis Carburetor type CVjenis (constant velocity) 2,68 : 1 - 0,85 1 (0.9 in) or equivalent Throttle bore 22: mm Perbandingan Clutch system drive belt (sabuk penggerak) Dry, automatic centrifugal clutch 10,625 (51/182.68 x 45/12) Reduksi Drive beltakhir ratio : 1 - 0.85 : 1 Sistem pengapian DC – CDI Final reduction 10.625 (51/18 x 45/12) Sistem Kickstarter dan motor starter listrik Ignitionstarter system DC-CDI Sistem pengisian Alternator dengan output fase tunggal Starting system Kickstarter with electric starter motor Regulator/rectifier Fase tunggal/dibuka oleh SCR, pembetulan setengah Charging system Single phase output alternator gelombang Regulator/rectifier SCR shorted/single phase, half wave rectification Sistem penerangan Alternator Lighting system Alternator



KETERANGAN UMUM



LUBRICATION SYSTEM SPECIFICATIONS SPESIFIKASI SISTEM PELUMASAN



Satuan: mm STANDARD BATAS SERVIS Unit: mm (in) BAGIAN Kapasitas oli Pada penggantian oli 0,7 liter SERVICE ITEM STANDARD mesin Pada pembongkaran mesin 0,8 liter LIMIT Oli mesin dianjurkan Supreme atau Engine oil yang capacity After drainingFederal Oil0.7 liter (0.7Flick US qt, 0.6oli lmp qt) – mesin 4 tak0.8 sejenis dengan After disassembly liter (0.8 US qt,klasifikasi 0.7 lmp qt) – API serviceHonda SG, "4-stroke motorcycle oil" or equivalent Recommended engine oil Viskositas: motor SAE 10W-30 JASO MB oil 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 rotor pompa Oil pump rotor 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 Nomor identifikasi karburator Main jet ITEM Slow jet identification number Carburetor Tahanan Main jet listrik SE thermal valve Float level (tinggi permukaan pelampung) Slow jet Pembukaan awalresistance pilot screw SE thermal valve Putaran stasioner Float level Vakuum yang ditentukan Pilot screw initial opening untuk PAIR control valve Jarak main bebas Engine idle speed putaran gas tangan PAIR control valve specified vacuum Throttle grip free play



SPESIFIKASI AVK2CH # 100 SPECIFICATIONS # 35 AVK2CH 3,2 – 5,6 #100 Ω (20°C) 13,0 #35 mm Lihat 5-20 3.2 – halaman 5.6 Ω (25°C/77°F) –1 1.700 ±13.0 100mm menit (rpm) (0.51 in) 60 kPa (450 mmHg) See page 5-20 –6 mm 100 min-1 (rpm) 1,7002 ± 60 kPa (450 mmHg) 2 – 6 mm (0.1 – 0.2 in)



SPESIFIKASI CYLINDER HEAD/VALVES BAGIAN STANDARD CYLINDER HEAD/VALVES SPECIFICATIONS IN/EX (masuk/ buang) IN/EX IN/EX IN/EX IN/EX IN IN/EX EX IN IN EXEX IN IN EX EX IN IN/EX EX IN/EX IN IN EX EX IN/EX IN/EX



1314 kPa (13,4 kgf/cm2, 191 psi) pada 520 min-1(rpm) 0,05 STANDARD 10,000 – 10,015 2 10,04 1314 kPa (13.4 kgf/cm , 191 psi) at 520 min-1 (rpm) – 9,972 – 9,987 9,91 10.000 – 10.015 (0.3937 – 0.3943) 0,013 – 0,043 0,08 9.972 – 9.987 32,4006 – (0.3926 32,6406– 0.3932) 32,37 0.013 – 0.043 32,0064 – (0.0005 32,2464– 0.0017) 31,97 32.4006 – 32.6406 (1.27561 – 1.28506) 0,14 ± 0,02 32.0064 – 32.2464 (1.26009 – 1.26954) 0,14 ± 0,02 0.14 ± 0.02 (0.006 ± 0.001) 4,975 – 4,990 4,90 0.14 ± 0.02 (0.006 ± 0.001) 4,955 – 4,970 4,90 4.975 – 4.990 (0.1959 – 0.1965) 5,000 – 5,012 5,03 4.955 – 4.970 (0.1951 – 0.1957) 5.000 – 5.012 (0.1969 – 0.1973) 0,010 – 0,037 0,08 0.010 – 0.037 (0.0004 – 0.0015) 0,030 – 0,057 0,10 0.030 – 0.057 (0.0012 – 0.0022) 9,1 – 9,3 9.1 – 9.3 (0.36 – 0.37)



IN/EX IN/EX IN/EX IN/EX



1,0 1.0 (0.04) 29,78 29.78 (1.172)



Kompressi cylinder



Perubahan bentuk melengkung ITEMpada cylinder head Rocker arm D.D. rocker arm Cylinder compression



Cylinder head warpage D.L. rocker arm shaft Rocker arm Rocker arm I.D. Jarak renggang arm ke shaft Rocker arm shaft O.D. Camshaft Tinggi cam lobe (bubungan) Arm to shaft clearance Camshaft lobe height Valve, ValveCam clearance (jarak renggang valve guide Valve, valve guide



klep) Valve clearance D.L. valve stem



Valve stem O.D. D.D. valve guide Valve guide I.D. Jarak renggang stem-ke-guide Stem-to-guide clearance Proyeksi valve guide di atas Valve guide projection above cylinder head cylinder head Lebar valve seat Valve seat width Panjang bebas valve spring Valve spring free length



Satuan: mm BAGIAN Unit: mm (in) SERVICE LIMIT



1,5 29,11



– 0.05 (0.002) 10.04 (0.395) 9.91 (0.390) 0.08 (0.003) 32.37 (1.274) 31.97 (1.259) – – 4.90 (0.193) 4.90 (0.193) 5.03 (0.198) 0.08 (0.003) 0.10 (0.004) – 1.5 (0.06) 29.11 (1.146)



1-5



KETERANGAN UMUM



CYLINDER/PISTON SPECIFICATIONS SPESIFIKASI CYLINDER/PISTON BAGIAN Cylinder



D.D. ITEM Kelonjongan Cylinder I.D. Ketirusan Out-of-round Perubahan bentuk melengkung Taper Piston, piston D.L. piston Warpage rings, piston pin Piston, piston Piston O.D. Titik pengukuran D.L. piston rings, piston pin Piston O.D. measurement point Piston pin bore I.D.pin D.D. lubang piston Piston pin pin O.D. D.L. piston Piston-to-piston pin clearance Jarak renggang antara Piston ring-to-ring Top piston-ke-piston pin groove clearance Second Jarak renggang Ring paling atas piston ring-ke-alurnya Ring Piston ring end gap Top kedua Celah pada ujung Ring paling atas Second piston ring Ring kedua Oil (side rail) Ring oli (side Cylinder-to-piston clearance rail) Connecting rod small end I.D. Jarak renggang antara cylinder-ke-piston Connecting rod-to-piston pin clearance D.D. kepala kecil connecting rod Jarak renggang antara connecting rod-ke-piston pin



STANDARD 50,000 – 50,015 50,10 STANDARD 0,05 50.005 – 50.015 - (1.9687 – 1.9691) 0,05 – 0,05 – 49,970 – 49,990 49,90 – 49.970 49.990 (1.9673 – 1.9681) 6,0 mm– dari bagian 6.0 (0.24) from bottom of skirt bawah piston 13.002 (0.5119 – 0.5121) 13,002––13.008 13,008 13,04 12.994 (0.5116 – 0.5118) 12,994––13.000 13,000 12,96 0.002 0,002––0.014 0,014(0.0001 – 0.0006) 0,02 0.015 – 0.050 (0.0006 – 0.0020) 0.015 0,015––0.050 0,050(0.0006 – 0.0020) 0,08 0,015 – 0,050 0.10 – 0.25 (0.004 – 0.0020) 0,08 0,10––0.25 0,25(0.004 – 0.0020) 0,45 0.10 0,10––0.70 0,25(0.008 – 0.028) 0,45 0.20 0,20 –– 0,70 0.015 0.045 (0.0006 – 0.0018) 13.010 – 13.028 (0.5122 – 0.5129) 0,015––0.034 0,045(0.0004 – 0.0013) 0,09 0.010 13,010 – 13,028 13,05 0,010 – 0,034 0,05



Satuan: mm BATAS SERVISUnit: mm (in) SERVICE LIMIT 50.10 (1.972) 0.05 (0.002) 0.05 (0.002) 0.05 (0.002) - 49.95 (1.967) – 13.04 (0.513) 12.96 (0.510) 0.02 (0.001) 0.08 (0.003) 0.08 (0.003) 0.45 (0.018) 0.45 (0.018) – - 0.09 (0.004) 13.05 (0.514) 0.05 (0.002)



KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH SPECIFICATIONS SPESIFIKASI KICKSTARTER/DRIVE PULLEY/ Unit: mm (in) SERVICE ITEM STANDARD DRIVEN PULLEY/CLUTCH Satuan: LIMIT mm Drive belt width Lebar drive belt Movable drive face Movable drive face Clutch Clutch Driven pulley Driven pulley



BAGIAN Bushing I.D. D.D.O.D. bushing Boss D.L. boss Weight roller O.D. D.L. weight roller Lining thickness Ketebalan lapisan kanvas Clutch outer I.D. D.D.spring clutch outer Face free length Panjang bebas Driven face O.D. face spring D.L. driven face Movable driven face I.D. D.D. movable driven face



STANDARD 18.5 (0.73) 18,5 22.035 – 22.085 (0.8675 17,5 – 0.8695) 22,035 22.010– –22,085 22.025 (0.8665 22,11 – 0.8671) 22,010 21,98 15.92 –– 22,025 16.08 (0.627 – 0.633) 15,92 – 16,08 – 15,3 2,0 112.0 – 112.2 (4.41 – 4.42) 112,0 112,2 112,5 124.2– (4.89) 124,2 33.965 – 33.985 (1.3372 121,4 – 1.3380) 33,965 34.000– –33,985 34.025 (1.3386 33,94 – 1.3396) 34,000 – 34,025 34,06



BATAS SERVIS 17.5 (0.69) 22.11 (0.871) 21.98 (0.865) 15.3 (0.60) 2.0 (0.08) 112.5 (4.43) 121.4 (4.78) 33.94 (1.336) 34.06 (1.341)



FINAL REDUCTION SPECIFICATIONS SPESIFIKASI FINAL REDUCTION ITEM BAGIAN Final reduction oil capacity After draining Kapasitas oli final Pada penggantian periodik After disassembly reduction Setelah pembongkaran Recommended final reduction oil Oli final reduction yang dianjurkan



Unit: mm (in) SPECIFICATIONS SPESIFIKASI 0.10 liter (0.11 US qt, 0.09 lmp qt) 0,10 liter 0.12 liter (0.13 US qt, 0.11 lmp qt) 0,12 liter Honda Oil "4-stroke motorcycle oil"oli or mesin equivalent motor oil dengan Federal Supreme Flick atau 4 tak sejenis API service classification: SG or higher (except oils labeled as energy klasifikasi API service SG, Viskositas: SAE 10W-30 JASO MB conserving on the circular API service label) JASO T 903 standard: MB Viscosity: SAE 10W-30



SPESIFIKASI CRANKCASE/CRANKSHAFT STANDARD BAGIAN CRANKCASE/CRANKSHAFT SPECIFICATIONS Crankshaft



Crankshaft



1-6



Jarak renggang ke samping connecting rod Jarak renggang ITEMradial connecting rod Keolengan Connecting rod side clearance Connecting rod radial clearance Runout



0,10 - 0,35 0 – 0,012



0,55



0,05 STANDARD 0,10 0.10 – 0.35 (0.004 – 0.014) 0 – 0.012 (0 – 0.0005) –



Satuan: mm BATAS SERVIS



Unit: mm (in) SERVICE LIMIT 0.55 (0.022) 0.05 (0.022) 0.10 (0.004)



KETERANGAN UMUM



FRONT WHEEL/SUSPENSION/STEERING SPECIFICATIONS SPESIFIKASI RODA DEPAN/SUSPENSI/KEMUDI Satuan: mm BAGIAN Kedalaman minimum alur telapak ban ITEM Tekanan udara Pengendara saja ban (dingin) Pengendara dan Minimum tire tread depth pembonceng Cold tire pressure Driver only Keolengan axle (poros roda) Driver and passenger Keolengan Radial Axle runout pelek roda AksialRadial Wheel rim runout Fork (garpu) Panjang Axialbebas pegas Keolengan Fork Spring tabung free length Minyak garpu yang Pipe runout dianjurkan Recommended fluid Tinggi permukaan Fluid level minyak Fluid capacity Kapasitas minyak



STANDARD BATAS SERVIS Unit: mm (in) Sampai ke indikator SERVICE STANDARD 2 LIMIT 200 kPa (2,00 kgf/cm , 29 psi) 2 200 kPa (2,00 kgf/cm , 29 psi) – To the indicator 200 kPa (2.00 kgf/cm2, 29 psi) – - kPa (2.00 kgf/cm2, 290,20 psi) – 200 – 2,0 0.2 (0.01) – 2,0 2.0 (0.08) 311,3 – 305,1 2.0 (0.08) - (12.26) 0,20 311.3 305.1 (12.01) Minyak sokbreker – 0.2 (0.01) Fork fluid – 50 50 (2.0) – 75 ± 1 cm3 3 – 75 ± 1 cm (2.5 ± 0.03 US oz, 2.6 ± 0.04 Imp oz)



REAR WHEEL/SUSPENSION SPECIFICATIONS SPESIFIKASI RODA BELAKANG/SUSPENSI BAGIAN Kedalaman minimum alur ITEM telapak ban Tekanan Pengendara saja Minimumudara tire tread depth ban Pengendara dan Colddingin tire pressure Driver only pembonceng Driver and passenger Keolengan pelek Radial Wheel rim runout Radial roda AksialAxial



Satuan: mmmm (in) Unit: STANDARD BATAS SERVIS SERVICE STANDARD Sampai ke indikator LIMIT 2 225 kPa (2,25 kg/cm , 33 psi) – To the indicator 2 225 kPa (2,25 kg/cm , 33 psi)kgf/cm2, 33 psi) 225 kPa (2.25 – 225 kPa (2.25 kgf/cm2, 33 psi) – – 2,0 2.0 (0.08) – 2,0 2.0 (0.08)



BRAKE SYSTEM SPECIFICATIONS SPESIFIKASI SISTEM REM BAGIAN ITEM Jarak main bebas rear brake lever (handel rem blk.) Rear brake lever free play D.D. rear brake drum (tromol rem belakang) Rear brake drum I.D. Minyak rem yang dianjurkan Specified brake fluid Brake disc Ketebalan Brake disc Thickness (cakram rem) Perubahan bentuk melengkung Warpage Master cylinder D.D. Cylinder Master cylinder Cylinder I.D. D.L. Piston Piston O.D. Caliper D.D. Cylinder Caliper Cylinder I.D. D.L. Piston Piston O.D.



Satuan:Unit: mm mm (in) SERVICE STANDARDSTANDARD BATAS SERVIS LIMIT 10 - 20 10 – 20 (0.4 – 0.8) – 130,0 131,0 130.0 (5.12) 131.0 (5.16) DOT 3 atau 4 DOT 3 or 4 – 3,3 – 3,7 3,0 3.3 – 3.7 (0.13 – 0.15) 3.0 (0.12) 0,10 – 0.10 (0.004) 11,000 – 11,043 11,055 11.000 – 11.043 (0.4331 – 0.4348) 11.055 (0.4352) 10,957 – 10,984 10,945 10.957 – 10.984 (0.4314 – 0.4324) 10.945 (0.4309) 32,030 – 32,080 32,090 32.030 – 32.080 (1.2610 – 1.2630) 32.090 (1.2634) 31,948 – 31,998 31,94 31.948 – 31.998 (1.2578 – 1.2598) 31.94 (1.257)



1-7



KETERANGAN UMUM



BATTERY/CHARGING SYSTEM/ALTERNATOR SPECIFICATIONS SPESIFIKASI BATERAI/SISTEM PENGISIAN/ALTERNATOR Baterai Battery



Alternator Alternator



BAGIAN ITEM Kapasitas Capacity Kebocoran arus listrik Current leakage Voltase Bermuatan penuh Voltage Fully charged Perlu diisi listrik kembali Needs charging Arus pengisian Normal Charging current Normal Cepat Quick Kapasitas Capacity



SPESIFIKASI SPECIFICATIONS 12– V3.5 – Ah 3,5 Ah 12 V maksimum 0,5 mA 0.5 mA max. Di atas 12,8 V Above 12.8 V Di bawah 12,3 V Below 12.3 V 0,4 A / 5-10 jam 0.4 A/5 – 10 h 3,0 A / 0,5 jam 3.0 A/0.5 h -1 0,140 kW / 5.000 menit (rpm) 0.140 kW/5,000 min-1 (rpm)



SPESIFIKASI SISTEM PENGAPIAN IGNITION SYSTEM SPECIFICATIONS BAGIAN



SPESIFIKASI CPR 8EA - 9 (NGK), U24EPR9 (DENSO) SPECIFICATIONS CPR CPR 9EA 8EA – 9 (NGK) – 9 (NGK)



Busi



StandardITEM Untuk pengendaraan lama pada Spark plug Standard kecepatan tinggi For extended high speed riding Jarak renggang busi Spark plug gap Voltase puncak ignition coil Ignition coil peak voltage Voltase puncak ignition pulse generator Ignition pulse generator peak voltage Ignition timing (pengaturan waktu pengapian) Ignition timing



CPR 9EA – 9 (NGK) 0,80 – 0,90 mm 0.80 – 0.90 mm (0.031 – 0.035 in) minimum 100 V 100 V minimum minimum 0,7 V 0.7 V minimum 14° sebelum TMA pada putaran stasioner 14° BTDC at idle speed



ELECTRIC STARTER SYSTEM SPECIFICATION SPESIFIKASI STARTER LISTRIK BAGIAN Panjang sikat starter motor ITEM



Starter motor brush length



STANDARD 7,0



3,5 STANDARD



7.0 (0.28)



Satuan: mm BATAS SERVIS Unit: mm (in) SERVICE LIMIT 3.5 (0.14)



SPESIFIKASI LAMPU2 / METER2 / SAKELAR2 BAGIAN SPESIFIKASI LIGHTS/METERS/SWITCHES SPECIFICATION Bola lampu



Bulbs



Sekring



Fuse



1-8



Lampu besar Lampu senja ITEM Lampu belakang/rem Headlight Lampu seinlight depan Position Lampu sein belakang Tail/brake light Lampu instrumen Frontpenerangan turn signal light Indikator lampu jauh Rear turn signal light Indikator lampu sein Instrument light Sekring utama High beam indicator Sekring Turn tambahan signal indicator Main fuse Sub fuse



12 V – 32/32 W 12SPECIFICATIONS V – 3,4 W 12 V12 –V 5/18 W W – 32/32 12 V –12 10VW– 3.4 x 2W 12 V –1210 x2 W VW – 5/18 12 V 12 – 1,7 2 x2 V –W10xW 12 V WW x 2 12–V1,7 – 10 12 12 V –V3,4 WW x 2 – 1.7 15 12 AX 1 V – 1.7 W 10 12 AX V 1– 3.4 W 15 A x 1 10 A x 1



KETERANGAN UMUM



STANDARD VALUES NILAI TORSITORQUE STANDARD JENIS PENGIKAT TYPE FASTENER Baut dan mur hex 5 mm 5 mmdan hex mur bolt and Baut hexnut 6 mm 6 mm hex bolt nut SH) (termasuk bautand flens (Include flange Baut danSH mur hex bolt) 8 mm 8 mmdan hex mur bolt and Baut hexnut 10 mm 10 mm hexmur bolthex and12 nutmm Baut dan 12 mm hex bolt and nut



TORSI JENIS TORQUE PENGIKATFASTENER TYPE N.m (kgf.m; lbf.ft) N·m (kgf·m, lbf·ft) 5,2 (0,5; 3,8) Sekrup 5 mm 5 mm screw 10 (1,0; 5.2 7) (0.5, 3.8) Sekrup 6 mm 10 (1.0, Baut 7) mm screw flens 66mm 6 mm flange bolt 22 (2,2; 16) (termasuk NSHF) dan mur 22 (2.2, 16) 34 (3,5; 25) Baut flens 8(Include mm danNSHF) mur and nut 34 (3.5, 25) 8 mm bolt and nut 54 (5,5; 40) Baut flens 10 mmflange dan mur 10 mm flange bolt and nut 54 (5.5, 40)



TORSI TORQUE N.m (kgf.m; lbf.ft) N·m (kgf·m, lbf·ft) 4,2 (0,4; 3,1) 9,0 (0,9; 6,6)4.2 (0.4, 3.1) 12 (1,2; 9) 9.0 (0.9, 6.6) 12 (1.2, 9) 27 (2,8; 20) 39 (4,0; 29) 27 (2.8, 20) 39 (4.0, 29)



TORSI PENGENCANGAN MESIN & RANGKA ENGINE & FRAME VALUES • Spesifikasi torsi yang terdaftar diTORQUE bawah adalah untuk pengikat tertentu.



Pengikat lain harus dikencangkan dengan torsi pengencangan standard yang terdaftar di atas. •• Torque specifications listed below are for specified fasteners. •RANGKA/BODY Others should bePANELS/SISTEM tightened to standardPEMBUANGAN torque values listed above. GAS DIAMETER TORSI FRAME/BODY PANELS/EXHAUST SYSTEMJUMBAGIAN LAH ULIR (mm) N.m (kgf.m; lbf.ft) THREAD TORQUE Cooling fan cover ITEM screw 2 Q'TY 5 0,8 (0,1; 0,6) 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 mounting bolt 2 10 59 (6.0, 44) PERAWATAN



MAINTENANCE



BAGIAN Spark plug (busi) ITEM Valve adjusting screw lock nut Spark plug Engine oil drain bolt Valve adjusting screw lock nut Engine oil strainer screen cap Engine oil drain oil boltcheck bolt Final reduction Engine oil strainer Final reduction oilscreen drain cap bolt Final reduction oil check boltscrew Air cleaner housing cover Final reduction oil drain bolt SISTEM PELUMASAN Air cleaner housing cover screw



LUBRICATION SYSTEM BAGIAN Oil pump plate screw Oil pump mountingITEM bolt Oil pump plate screw Oil pump mounting bolt SISTEM BAHAN BAKAR FUEL SYSTEM



BAGIAN Inlet pipe band screw ITEM SE thermal valve body screw Inletthermal pipe band screw SE valve setting plate screw SE thermal valve body screw Vacuum chamber cover screw SE thermal Slow jet valve setting plate screw Main jet chamber cover screw Vacuum Needle Slow jetjet holder Float screw Main chamber jet Float Needlechamber jet holderdrain screw PAIR check valve Float chamber screwcover screw Fuel valve lockscrew nut Floatauto chamber drain PAIR check valve cover screw Fuel auto valve lock nut PELEPASAN/PEMASANGAN MESIN



ENGINE REMOVAL/INSTALLATION BAGIAN Engine hanger link nut (sisi mesin) ITEM



Engine hanger link nut (Engine side)



CATATAN REMARKS



JUMDIAMETER TORSI CATATAN LAH ULIR (mm) N.m (kgf.m; lbf.ft) THREAD 1 Q'TY 10 16 (1,6;TORQUE 12) REMARKS DIA. (mm) lbf·ft) 2 5 10N·m (1,0;(kgf·m, 7) Oleskan oli pd. ulir (1.6, 12) 1 1 12 10 24 (2,4;1618) (1.0, 7) Apply oil to the threads 1 2 30 5 20 (2,0;10 15) (2.4, 18) 1 1 8 12 13 (1,3;2410) (2.0, 15) 1 1 8 30 13 (1,3;2010) 8 (1.3, 10) 4 1 5 1,1 (0,1;130,8) 1 8 13 (1.3, 10) 4 5 1.1 (0.1, 0.8) JUMDIAMETER TORSI CATATAN LAH ULIR (mm) N.m (kgf.m; lbf.ft) 1 4THREAD 3 (0,3; TORQUE 2,2) REMARKS 2 Q'TY 6 10N·m (1,0;(kgf·m, 7) DIA. (mm) lbf·ft) 1 4 3 (0.3, 2.2) 2 6 10 (1.0, 7) JUMDIAMETER TORSI LAH ULIR (mm) N.m (kgf.m; lbf.ft) 2 Q'TY 5THREAD 2 (0,2; TORQUE 1,5) DIA. (mm) 3,4 N·m 2 5 (0,4; (kgf·m, 2,5) lbf·ft) 5 (0.2, 1.5) 1 2 4 2,1 (0,2;2 1,5) 5 3.41,5) (0.4, 2.5) 2 2 4 2,1 (0,2; 4 2.11,1) (0.2, 1.5) 1 1 1,5 (0,2; 1 2 2,1 (0,2; 4 2.11,5) (0.2, 1.5) 1 1 2,5 (0,3; – 1.51,8) (0.2, 1.1) 3 1 4 2,1 (0,2; – 2.11,5) (0.2, 1.5) 1 1 1,5 (0,2; – 2.51,1) (0.3, 1.8) 2 3 4 2,1 (0,2; 4 2.11,5) (0.2, 1.5) 1 1 16 – 22,5 (2,3; 1.5 17) (0.2, 1.1) 2 4 2.1 (0.2, 1.5) 1 16 22.5 (2.3, 17) JUMDIAMETER TORSI LAH ULIR (mm) N.m (kgf.m; lbf.ft) THREAD 1 10 49 (5,0;TORQUE 36) Q'TY DIA. (mm) N·m (kgf·m, lbf·ft) 1 10 49 (5.0, 36)



CATATAN



REMARKS



CATATAN



REMARKS



1-9



KETERANGAN UMUM CYLINDER CYLINDER HEAD/VALVES/CYLINDER/PISTON HEAD/VALVES/CYLINDER/PISTON JUMDIAMETER TORSI THREAD TORQUE ITEM Q'TY ULIR (mm) REMARKS BAGIAN CATATAN LAH lbf.ft) lbf·ft) DIA. (mm)N.m (kgf.m; N·m (kgf·m, Intake shroud mounting screw 3 5 0,8 (0,1; 0,6) Intake shroud mounting screw 3 5 0.8 (0.1, 0.6) Exhaust shroudmounting mounting bolt 1 1 6 7 (0,7; 75,1) Exhaust shroud bolt 6 (0.7, 5.1) Cylinder headnut nut 4 4 7 18 (1,8;1813) pd. uliroil to the threads Cylinder head 7 (1.8, 13) Oleskan oliApply Oleskan oli pd. ulir Cylinder head bolt 2 6 12 (1,2; 9) Cylinder head bolt 2 6 12 (1.2, 9) Apply oil to the threads Oleskan oli pd. ulir Cam sprocket bolt 2 5 8 (0,8; 5,9) 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 6 Cam chain tensioner sliderbolt pivot pin bolt 1 2 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 PULLEY/CLUTCH KICKSTARTER/DRIVE PULLEY/DRIVEN JUMDIAMETER TORSI THREAD TORQUE ITEM Q'TY ULIR (mm) REMARKS BAGIAN CATATAN LAH lbf.ft) lbf·ft) DIA. (mm)N.m (kgf.m; N·m (kgf·m, Left crankcase cover plate screw 5 4 3 (0,3; 2,2) Left crankcase cover plate screw 5 4 3 (0.3, 2.2) Drive facenut nut 1 1 14 14 108 (11,0; 80) 80) Oleskan oliApply pd. uliroil to the threads Drive pulley pulley face 108 (11.0, Clutch/driven pulleynut nut 1 1 28 28 54 (5,5;5440) Clutch/driven pulley (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 ITEM BAGIAN Front axlenut nut Front axle Front brakedisc discsocket socket bolt Front brake bolt Handlebar post nut Rear brakepost lever Handlebar nutpivot bolt Rear brakelever leverpivot pivotbolt nut Rear brake Bottom bridge Rear brake leverpinch pivot bolt nut Fork socket Bottom bridgebolt pinch bolt Steering stem Fork socket bolttop thread Steering stem lock nut Steering stem top thread Steering stem lock nut RODA BELAKANG/SUSPENSI REAR WHEEL/SUSPENSION BAGIAN ITEM Rear axle nut Engine hanger Rear axle nut link nut (sisi rangka)



Engine hanger link nut (Frame side) SISTEM REM BRAKE SYSTEM BAGIAN Rear brake arm bolt ITEM Brake caliper bleed valve Rear brake armcylinder bolt Brake master reservoir cap screw Brake caliper Brake pad pinbleed valve Brake master cylinder reservoir Front brake lever pivot bolt cap screw Brake brake pad pinlever pivot nut Front Front brake bolt Front brakelever light pivot switch screw Front brake pivot nut Brake hoselever oil bolt Front brake light switch screw Brake caliper mounting bolt Brake caliper Brake hose oil pin bolt Brake caliper mounting bolt Brake caliper pin



1-10



THREAD TORQUE JUMDIAMETER TORSI Q'TY REMARKS CATATAN LAH ULIRDIA. (mm)(mm)N.m (kgf.m; lbf.ft) lbf·ft) N·m (kgf·m, 1 1 12 12 59 (6,0;5944) (6.0, 44) U-nut U-nut 4 4 8 42 (4,3;4231) 8 (4.3, 31) ALOC bolt: ALOC bolt: 1 10 59 (6,0; 44) ganti dgn. replace yg. baru with new ones 1 1 5 10 1 (0,1;59 0,7) (6.0, 44) 1 1 5 4,5 (0,5;1 3,3) 5 (0.1, 0.7) 4 1 10 5 64 (6,5; 4.547) (0.5, 3.3) 2 4 8 10 20 (2,0;6415) (6.5, 47) pengunci 1 2 26 8 Lihat hal.2011-22 (2.0, 15) Oleskan cairan Apply locking agent 1 26 Lihat hal. 11-22 1 26 See page 11-22 1 26 See page 11-22 JUMDIAMETER TORSI CATATAN TORQUE LAH ULIR THREAD (mm) N.m (kgf.m; lbf.ft) Q'TY REMARKS DIA. (mm) 118 N·m (kgf·m, 1 16 (12,0; 87) lbf·ft) U-nut, Oleskan oli pd. ulir 1 1 10 16 69 (7,0; 11851) (12.0, 87) U-nut, Apply oil to the threads 1 10 69 (7.0, 51) JUMDIAMETER TORSI CATATAN LAH ULIR (mm) N.m (kgf.m; lbf.ft) THREAD TORQUE 1Q'TY 6 10 (1,0; 7) ALOC bolt: ganti dengan yang baru REMARKS DIA. (mm) N·m (kgf·m, lbf·ft) 1 8 6 (0,6; 4,4) 6 (1.0, 7) ALOC bolt: replace with a 2 1 4 2 (0,2; 10 1,5) new one (0.6, 4.4) 1 1 10 8 18 (1,8;6 13) 4 (0.2, 1.5) 1 2 6 1 (0,1; 20,7) (1.8, 13) 1 1 6 10 6 (0,6;18 4,4) 6 (0.1, 0.7) 1 1 4 1 (0,1; 10,7) (0.6, 4.4) 2 1 10 6 34 (3,5;6 25) 4 (0.1, 0.7) ALOC bolt: ganti dengan yang baru 2 1 8 30 (3,1;1 22) 1 2 8 10 18 (1,8;3413) (3.5, 25) 2 8 30 (3.1, 22) ALOC bolt: replace with new ones 1 8 18 (1.8, 13)



KETERANGAN UMUM BATTERY/CHARGING SYSTEM/ALTERNATOR BATTERY/SISTEM PENGISIAN/ALTERNATOR JUMDIAMETER TORSI THREAD TORQUE ITEM Q'TY ULIR (mm) BAGIAN LAH N.m (kgf.m; lbf.ft) lbf·ft) DIA. (mm) N·m (kgf·m, Cooling fan mounting mountingbolt bolt 3 3 6 10 (1,0;107)(1.0, 7) Cooling fan 6 Flywheel nut 1 1 10 10 39 (4,0;3929) Flywheel nut (4.0, 29) Ignition pulse generator 2 5 6 (0,6; 64,4) lgnition pulse generator 2 5 (0.6, 4.4) IGNITION SYSTEM SISTEM PENGAPIAN ITEM BAGIAN Key shutter shutter socket Key socketbolt bolt ELECTRIC STARTER SYSTEM SISTEM STARTER LISTRIK ITEM BAGIAN Starter motor case screw Starter motor case screw OTHERS LAIN-LAIN



ITEM



BAGIAN Carburetor throttle cable holder mounting screw Carburetor throttle cable holder Brake shoescrew anchor pin nut mounting Brake (when shoe using anchor the stakepin nut)nut (sewaktu memakai stake (when using the normal nut)nut) (sewaktu memakai normalbolt nut) Muffler protector mounting Muffler protector Sidestand pivot nutmounting bolt Sidestand pivotbolt nut Sidestand pivot Sidestand pivot bolt



REMARKS CATATAN



THREAD TORQUE JUMTORSI Q'TY DIAMETER N·m (kgf·m, LAH ULIRDIA. (mm)(mm)N.m (kgf.m; lbf.ft) lbf·ft) 6 1 1 6 10 (1,0;107)(1.0, 7)



REMARKS CATATAN



THREAD TORQUE Q'TY DIAMETER JUMTORSI DIA. (mm) N·m (kgf·m, lbf·ft) LAH ULIR (mm) N.m (kgf.m; lbf.ft) 3 4 2 (0.2, 1.5) 3 4 2 (0,2; 1,5)



REMARKS CATATAN



THREAD TORQUE Q'TY DIA. (mm) N·m (kgf·m, lbf·ft) JUMDIAMETER TORSI 5 3.4 lbf.ft) (0.4, 2.5) LAH 2 ULIR (mm) N.m (kgf.m; 2 5 3,4 (0,4; 2,5) 1 8 1 8 20 (2.0, 15) 20 (2,0;1815) (1.8, 13) 18 (1,8;10 13) 2 6 (1.0, 7) 2 1 6 10 10 (1,0; 297) (3.0, 21) 1 1 10 10 29 (3,0; 1021) (1.0, 0.7) 1 10 10 (1,0; 0,7)



REMARKS CATATAN



1-11



KETERANGAN UMUM



LUBRICATION & SEAL POINTS TITIK-TITIK PELUMASAN & PERAPATAN ENGINE MESIN



MATERIAL BAHAN Liquid sealant Liquid sealant(recommended: (dianjurkan: Three Bond 1207B or Three Three Bond 1207B atau Three Bond 1215 or equivalent) Bond 1215 atau sejenisnya) Liquid sealant (recommended: Liquid sealant (dianjurkan: Three Bond 5211C or SHIThree Bond 5211C atau NETSU-SILICONE KE45T or SHINETSU-SILICONE KE45T Three Bond 1215 or equivaatau lent) Three Bond 1215 atau sejenisnya) Adhesive (recommended: Adhesive (dianjurkan: CEMEDINE 575 or Three CEMEDINE atau Three Bond 1194 or575 equivalent) Bond 1194 atau sejenisnya) Locking agent (recommended: Locking agent (dianjurkan: Three Bond 2415 or 1322N or Three Bond 2415 1322N LOCKTITE 200 or atau equivalent) atau LOCKTITE 200 atau Molybdenum oil solution (a sejenisnya) mixture of 1/2 engine oil and 1/ Molybdenum solution 2 molybdenumoil disulfide (campuran dari ½ oli mesin grease) dan ½ molybdenum Molybdenum disulfidedisulfide paste grease) Molybdenum disulfide paste



Multi-purpose grease Grease Multi-purpose grease (Shell ALVANIA R3 or Grease (gemuk) IDEMITSU AUTOREX B or (Shell ALVANIA R3 atau equivalent) IDEMITSU AUTOREX B atau Engine oil sejenisnya) (Without molybdenum additives) Oli mesin (Tanpa molybdenum additives)



Degrease Bersihkan dari gemuk



1-12



LOCATION LOKASI Right crankcase mating surface Permukaan penyatuan right crankcase



REMARKS CATATAN See page 10-9 Lihat hal. 10-9



Cylinder head mating surface (semicircular area) Permukaan penyatuan cylinder head (daerah setengah lingkaran)



See page 7-8 Lihat hal. 7-8



Cylinder head cover and seal rubber mating surface (hatched See page 7-7 Cylinder head cover dan permukaan penyatuan Lihat hal. 7-7 area) seal rubber (daerah penutupan) Driveshaft bearing set plate bolt threads Ulir supply driveshaft bolt Air pipe bearing mountingset boltplate threads Ulir air supply pipe mounting bolt



See page 9-16 Lihat hal.See 9-16 page 5-25 Lihat hal. 5-25



Camshaft cam lobes Camshaft cam lobes (bubungan camshaft)



Kickstarter spindle sliding surface Kickstarter driven gear shaft Permukaandriven luncur kickstarter spindle Kickstarter gear friction spring sliding area Kickstarter driven gear shaft Kickstarter spindle dust seal lip Daerah luncur kickstarter driven gear friction spring Driven face inner surface Bibir kickstarter spindle dust seal Movable driven face cam groove Permukaan driven face Starter piniondalam gear shaft (both end) Alur movable driven face cam Driven face ball bearing and needle bearing Starter pinion gear shaft (kedua ujungnya) Oil pump drive gear teeth Driven face ball bearing dan needle bearing Oil pump rotor whole surface Oil pump oil shaft and pump cover sliding area Gigi-gigi pump drive gear Oil pump driven gear teeth Seluruh permukaan oil pump rotor Rocker shaftoilsliding Daeraharm luncur pumpsurface shaft dan pump cover Rocker arm Gigi-gigi oilroller pumpsliding drivenarea gear Camshaft decompressor rotating Permukaan luncur rocker arm surface shaft Camshaft bearing Daerah luncur rocker arm roller Cam sprocketberputar teeth Permukaan camshaft decompressor Camshaft bearing Cam chain whole surface Gigi-gigi cam sprocket Timing sprocket teeth Seluruh cam surfaces chain Piston andpermukaan cylinder sliding Gigi-gigi sprocket Piston pintiming hole sliding area Permukaan luncur piston dan Piston ring whole surface and ringcylinder grooves Daerah lubang piston pin Piston pinluncur outer surface Seluruh permukaan piston ring dan alur ring Connecting rod small end inner surface Permukaan luar piston pin Crankshaft bearings Permukaan dalam connecting rod small end Connecting rod big end bearing (kepala kecil connecting rod) Valve stem (valve guide sliding area) Crankshaft bearings Valve stem seal inner surface Connecting rod big end bearing (bantalan kepala Bearing area of drive, counter and final shaft besar connecting rod) Drive, and final gear teeth Valve counter stem (daerah luncur valve guide) Cam set plunger whole surface Permukaan dalam valve stem seal Ball/needle bearing sliding area Daerah bearing dari drive, counter dan final shaft Each O-ring whole surfacedan final gear Gigi-gigi drive, counter Seluruh permukaan set plunger Oil seal lips and outer cam surfaces Daerah luncur ball/needle Right crankshaft tapered areabearing Seluruh permukaan masing-masing Drive/driven pulley face and drive belt O-ring Bibircrankcase dan permukaan luar oil seal inner surface Left cover bearing bushing Daerah meruncing dari right crankshaft Muka drive/driven pulley dan drive belt Permukaan dalam left crankcase cover bearing bushing



0.1 – 0.3 g 0.2 – 0.3 g 0,1 –0,3 g 0,2 – 0,3 g 7.0 – 8.0 g 2.0 – 2.5 g 7,0 – 8,00.1 g – 0.3 g 2,0 – 2,5 g 0,1 – 0,3 g



0.5 – 1.0 cc 0,5 – 1,0 cc



Fill up 2 cc minimum Fill up 3 cc minimum Isi dengan minimum 2 cc Isi dengan minimum 3 cc



KETERANGAN UMUM RANGKA FRAME



BAHAN MATERIAL Multi-purpose grease dengan Multi-purpose grease with tekanan sangat tinggi extreme pressure (recom(dianjurkan: EXCELIGHT EP2 mended: EXCELIGHT EP2 buatan KYODO YUSHI, manufactured by KYODO Japan, atau Shell ALVANIA YUSHI, japan. or Shell ALVAEP2 atau sejenisnya) NIA EP2 or equivalent) Grease (Shell BEARING Grease GREASE HD atau sejenisnya) (Shell BEARING GREASE Multi-purpose grease HD or equivalent)



Multi-purpose grease



Silicone grease Silicone grease



Brake fluid (minyak rem) Brake 3fluid (DOT atau DOT 4) (DOT 3 or DOT 4) Fork fluid (minyak sokbreker) Fork fluid Adhesive (Honda bond A atau Adhesive sejenisnya) (Honda bond A or equivalent)



Locking agent (recommended: Locking agent (dianjurkan: Three Bond 2415 or 1322 N or LOCKTITE or atau equivalent) Three Bond 200 2415 1322 N atau LOCKTITE 200 atau sejenisnya)



LOKASI LOCATION Steering bearing race Steering bearingstem race dust seal Bibir steering Steering stem dust seal lip



CATATAN REMARKS Isi dengan minimum 3 g Fill up 3 g minimum



Bagian dalam speedometer gear box Speedometer gear box inside Bibir front wheel dust seal Permukaan luncur Front wheel dust sealfront lip wheel axle Seluruh permukaan front wheel distance collar Front wheel axle sliding surface Daerah luncur front wheel bearing Front wheel distance collar whole surface Bibir speedometer gear box seal Front wheel sliding Rear brake bearing cam dan shaftarea Oleskan masing-masing Speedometer gear box seal lip 0,2 – 0,3 g Rear brake and shaft eachg0.2 - 0.3 g Rear brakecam anchor pin shaft Oleskan Apply 0,2 – 0,3 Rear brake anchordust pin shaft Apply 0.2 - 0.3 g Bibir rear brake seal Rear brake dust seal lip Permukaan luncur rear brake lever pivot bolt Rear brake leverthrottle pivot bolt sliding surface drum Daerah luncur cable-ke-throttle Oleskan 0,1 – 0,2 g Throttle cable-to-throttle drum sliding area Apply 0.1 - 0.2 g Daerah kontak seat catch (penahan tempat duduk) Daerah centerstand Seat catch contact areapivot Daerah sidestand pivot Centerstand pivot area Sidestand pivot area Bagian dalam cable cap boot Rear brake cablerear cap brake boot inside Daerah kontak front brakepiston lever-ke-master piston Oleskan Apply 0,1 g 0.1 g Front brake lever-to-master contacting area Daerah luncur front brake lever pivot Front brake lever pivot sliding area Daerah luncur caliper Oleskan Apply minimum g Brake caliper pinbrake sliding area pin 0.4 g0,4 minimum Seluruh permukaan brake caliper dust seal Brake caliper dust seal whole surface 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 Bagian dalam dan daerah luncur master cylinder Master cylinder insidebrake and sliding area Seluruh permukaan caliper piston seal Brake caliper piston seal whole surface Seluruh permukaan brake caliper piston Brake caliper piston whole surface Master cylinder piston cup Master cylinder piston cupoil seal Bibir fork dust seal dan Fork dustpermukaan seal and oil seal Seluruh fork lips spring seat O-ring Fork spring seathandlebar O-ring whole Bagian dalam gripsurface rubber Handlebar grip rubberPAIR insidecontrol valve rubber Daerah penyatuan PAIR control valve rubber-to-air cleaner housing mating area -ke-air cleaner housing Daerah penyatuan airhose-to-housing cleaner connecting Air cleaner connecting matinghose-kearea housing Centerstand shaft bolt threads See page 10-11 Ulir centerstand shaft bolt Lihat hal. 10-11



1-13



KETERANGAN UMUM



CABLE & HARNESS ROUTING PERLETAKAN KABEL & 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 WIRE



LEFT HANDLEBAR SWITCH WIRE



HORN SWITCH WIRE



REAR BRAKE CABLE



REAR BRAKE LIGHT SWITCH WIRE THROTTLE



REAR BRAKE CABLE



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



HANDLEBAR SWITCH/ SPEEDOMETER WIRE



SPEEDOMETER CABLE FRONT BRAKE HOSE THROTTLE CABLE



SPEEDOMETER CABLE



REAR BRAKE CABLE



THROTTLE CABLE IGNITION SWITCH WIRE



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



1-14



SPEEDOMETER



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 (–) CABLE



FUSE BOX WIRE



1-16



BATTERY POSITIVE (+) CABLE



STARTER RELAY WIRE



KETERANGAN UMUM



STARTER ENRICHMENT (SE) THERMAL VALVE WIRE



PULSE SECONDARY AIR INJECTION (PAIR) CONTROL VALVE VACUUM HOSE



CRANKCASE BREATHER HOSE CARBURETOR AIR VENT HOSE FUEL VALVE VACUUM HOSE THROTTLE CABLE



ALTERNATOR/IGNITION PULSE GENERATOR WIRE



STARTER MOTOR/ GROUND CABLE



SIDESTAND SWITCH WIRE



CARBURETOR DRAIN HOSE 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



° 75



SISI ATAS



CARBURETOR VACUUM 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



REGULATOR/ RECTIFIER WIRE



SPARK PLUG WIRE



GROUND CABLE (KECIL)



BOLT



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



AIR SUPPLY PIPE



PULSE SECONDARY AIR INJECTION (PAIR) CONTROL VALVE VACUUM HOSE



AIR SUPPLY HOSE



STARTING ENRICHMENT (SE) THERMAL VALVE WIRE



AIR SUPPLY HOSE



Terpasang



SISI ATAS



AIR SUPPLY HOSE



HOSE BAND



ALTERNATOR/ IGNITION PULSE GENERATOR WIRE



SPARK PLUG WIRE STARTER MOTOR/ GROUND CABLE



1-19



KETERANGAN UMUM



CARBURETOR VACUUM PISTON HOSE THROTTLE CABLE FUEL HOSE FUEL VALVE VACUUM HOSE



FUEL HOSE



PULSE SECONDARY AIR INJECTION (PAIR) CONTROL VALVE VACUUM HOSE



FUEL VALVE VACUUM HOSE FUEL VALVE VACUUM HOSE THROTTLE CABLE



CRANKCASE BREATHER HOSE



CARBURETOR DRAIN HOSE



CARBURETOR AIR VENT HOSE



1-20



KETERANGAN UMUM GROUND CABLE



STARTER MOTOR CABLE



GROUND CABLE ALTERNATOR/IGNITION PULSE GENERATOR WIRE



IGNITION PULSE GENERATOR WIRE



1-21



KETERANGAN UMUM



CRANKCASE BREATHER DRAIN HOSE



FINAL REDUCTION CASE BREATHER HOSE Sewaktu memasang pedal kikstarter pada posisi standard:



SEJAJAR



Waktu memasang standard samping pada posisi standard:



1-22



REAR BRAKE CABLE



CARBURETOR DRAIN Waktu memasang standard utama pada posisi standard:



KETERANGAN UMUM



POSITION LIGHT WIRE



LEFT FRONT TURN SIGNAL LIGHT WIRE



RIGHT FRONT TURN SIGNAL LIGHT WIRE HEAD LIGHT WIRE RIGHT REAR TURN SIGNAL LIGHT WIRE TAIL/BRAKE LIGHT WIRE



TAIL/BRAKE LIGHT/REAR TURN SIGNAL LIGHT WIRE



LEFT REAR TURN SIGNAL LIGHT WIRE Tepatkan daerah yang berpita putih dengan tab



TAIL/BRAKE LIGHT/REAR TURN SIGNAL LIGHT WIRE



1-23



KETERANGAN UMUM



EMISSION CONTROL SYSTEMSEMISSI SISTEM-SISTEM PENGATURAN SOURCEEMISSI OF EMISSIONS SUMBER The combustion process produces carbon monoxide and hydrocarbons. Controlling hydrocarbon emission is very important because, under Proses pembakaran karbon monoksida dan hidrokarbon. Pengaturan hidrokarbon adalah sangat certain conditions, theymenghasilkan react to form photochemical smog when subjected to sunlight. Carbonemissi monoxide does not react in the same penting way, butoleh it is karena, pada kondisi tertentu, mereka bereaksi membentuk photochemical smog ketika terkena cahaya matahari. Karbon toxic. monoksida tidak bereaksi dengan cara yang sama, tetapi ia beracun. Honda Motor Co., Ltd. utilizes lean carburetor settings as well as other systems, to reduce carbon monoxide, oxides of nitrogen and hydrocarbons. Honda Motor Co., Ltd. menggunakan penyetelan karburator yang miskin maupun sistem lain, untuk mengurangi karbon monoksida, oksida dari nitrogen dan hidrokarbon.



CRANKCASE EMISSION CONTROL SYSTEM



The engine is equipped with a closed crankcase system to prevent discharging crankcase emissions into the atmosphere. Blow-by gas is returned



to the combustion chamber through the air cleaner and carburetor. SISTEM PENGATURAN EMISSI CRANKCASE



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



CARBURETOR



AIR CLEANER



UDARA BLOW-BY GAS



1-24



KETERANGAN UMUM EXHAUST EMISSION CONTROL SYSTEM (PULSE SECONDARY AIR INJECTION SYSTEM) SISTEM PENGATURAN EMISSI GAS PEMBUANGAN The exhaust emission control system consists of a secondarySYSTEM) air supply system which introduces filtered air into the exhaust gas in the exhaust (PULSE SECONDARY AIR INJECTION



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



PAIR CONTROL VALVE



CHECK VALVE



PAIR AIR CLEANER



UDARA SEGAR UDARA VAKUM



EXHAUST PORT



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



1-25



CATATAN



2. RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS



2



BODY PANEL LOCATIONS????????????? LOKASI BODY PANEL.......................... 2-22-2



SEAT ????????????????????????????????? TEMPAT DUDUK ........................................2-8 2-8



PETA PELEPASAN BODY CHART PANEL....... 2-22-2 BODY PANEL REMOVAL ??????



GRAB RAIL................................................. 2-8 GRAB RAIL ??????????????????????????? 2-8



KETERANGAN SERVIS ........................ 2-32-3 SERVICE INFORMATION ??????????????



BODY COVER............................................. 2-9 BODY COVER????????????????????????? 2-9



TROUBLESHOOTING 2-32-3 TROUBLESHOOTING........................... ?????????????????



UNDER COVER 2-10 UNDER COVER........................................ ?????????????????????? 2-10



FRONT UPPER 2-42-4 FRONT UPPERCOVER COVER........................ ????????????????



FLOOR PANEL/FRONT 2-11 FLOOR PANEL/FRONTINNER INNER COVER.. COVER 2-11



FRONT HANDLEBAR 2-52-5 FRONT HANDLEBARCOVER.............. COVER ??????????



REAR FENDER......................................... 2-11 REAR FENDER ??????????????????????? 2-11



REAR HANDLEBAR 2-52-5 REAR HANDLEBARCOVER COVER ................ ???????????



LEFT CRANKCASE .........2-12 2-12 LEFT CRANKCASECOVER COVER DUCT DUCT ?????



FRONT LOWER 2-62-6 FRONT LOWERCOVER COVER....................... ???????????????



COOLING FAN 2-12 COOLING FANCOVER............................ COVER ??????????????? 2-12



FRONT INNER 2-62-6 FRONT INNERUPPER UPPERCOVER COVER ............ ?????????



TRIM CLIPS .............................................. 2-13 TRIM CLIPS ????????????????????????? 2-13



FRONT FENDER.................................... 2-72-7 FRONT FENDER ??????????????????????



BATTERY COVER .................................... 2-13 BATTERY COVER ???????????????????? 2-13



LUGGAGE BOX..................................... 2-72-7 LUGGAGE BOX ???????????????????????



EXHAUST PIPE/MUFFLER 2-14 EXHAUST PIPE/MUFFLER...................... ???????????? 2-14



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



2-1



RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS



LOKASI BODYLOCATIONS PANEL BODY PANEL FRAME/BODY PANELS/EXHAUST SYSTEM



(8) (1) (10)



(9)



(2) (11) (3)



(6)



(14) (5)



(17) (13)



(15) (12) (7)



(16)



(4) (1) Front handlebar cover (hal. 2-5) (1) Front handlebar cover (page 2-5) (2) Rear handlebar cover (hal. 2-5) (2) Front Rear handlebar cover(hal. (page 2-5) (3) upper cover 2-4) (3) Front upper cover (page 2-4) (4) Front lower cover (hal. 2-6) (4) Front Front lower (5) fendercover (hal.(page 2-7) 2-6) (5) Front fender (page 2-7) (6) Front inner upper cover (hal. 2-6) (6) Center Front inner upper cover (page (7) body cover (hal. 2-8)2-6) (7) Seat Center(hal. body2-8) cover (page 2-8) (8) (8) Seat (page 2-8)



(9) Luggage box (hal. 2-7) (9) Luggage box (page 2-7) (10) Grab rail (hal. 2-8) (10) Grab railcover (page(hal. 2-8) 2-9) (11) Body (11) Body cover (page 2-9)2-10) (12) Under cover (hal. (12) Under (page 2-10) (13) Floorcover panel/Front inner cover (hal. 2-11) (13) Floor inner cover (page 2-11) (14) Rearpanel/Front fender (hal. 2-11) (14) Rear (page cover 2-11) duct (hal. 2-12) (15) Leftfender crankcase (15) Left crankcase cover duct (16) Cooling fan cover (hal.(page 2-12)2-12) (16) Cooling cover(hal. (page 2-12) (17) Batteryfan cover 2-13) (17) Battery cover (page 2-13)



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



(3) Front upper cover



(1) Front handlebar cover



(9) Luggage box



(4) Front lower cover



(2) Rear handlebar cover



(15) Left crankcase cover duct



(6) Front inner upper cover



(16) Cooling fan cover



(12) Under cover



(17) Battery cover



2-2



(7) Center body cover



(8) Seat



(13) Floor panel/Front inner cover



(10) Grab rail



(11) Body cover



(14) Rear fender



RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS



SERVICE INFORMATION KETERANGAN SERVIS UMUM GENERAL coverspelepasan removal anddan installation of the body exhaust system. •• This Babsection ini meliputi pemasangan bodypanels panelsand dan sistem pembuangan gas. the exhaust pipe gasketsetelah after removing the exhaust pipepipe from(pipa the engine. •• Always Selalureplace ganti exhaust pipe gasket melepaskan exhaust pembuangan gas) dari mesin. installing the exhaust loosely install of the exhaust pipepengikat fasteners.exhaust Always pipe tighten the exhaust joint Selalu first, then tighten the dengan longgar. kencangkan •• When Ketika memasang sistemsystem, pembuangan gas, all pasanglah semua mounting fasteners. If you tighten the mounting fasteners first, the exhaust pipe may not seat properly. exhaust joint (penyambung pipa pembuangan gas) dulu, kemudian kencangkan mounting fasteners (pengikat pemasangan). • Always inspect the exhaust system for leaks dulu, after installation. Jika mounting fasteners dikencangkan exhaust pipe mungkin tidak akan duduk dengan benar. • Setelah pemasangan, selalu periksa sistem pembuangan gas terhadap kebocoran.



TORQUE VALUES NILAI TORSI Cooling Cooling fan fancover coverscrew screw Cooling Cooling fan fancover coverbolt bolt Muffler mounting mountingbolt bolt



0.8 N·m kgf·m, 0.6 lbf·ft) 0,8 N.m (0,1 (0.1 kgf.m; 0,6 lbf.ft) N·m kgf.m; (0.9 kgf·m, 6.6 lbf·ft) 9 N.m9 (0,9 6,6 lbf.ft) 5.9 N·m kgf·m, 4.4 lbf·ft) 5,9 N.m (0,6 (0.6 kgf.m; 4,4 lbf.ft)



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



2-3



RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS



FRONT UPPER COVER REMOVAL/INSTALLATION PELEPASAN/PEMASANGAN Remove thesebagai following: Lepaskan berikut:



Be careful to Hati-hati agarnot tidak damage tabs, merusak tabs,the stoppers danslots. slots. stoppers and



Two boltsbulb and license -– Headlight socket plate (hal. holder 17-6) from the front side Two screws lower(hal. front17-6) side -– Position light from bulb the socket Six screws from the side -– Front turn signal lightrear bulb sockets (hal. 17-8) -Remove Enam the screws front upper cover by releasing the following: - Front turn signal units kanan/kiri Tabs on the lower front -– Headlight adjusting boltside of the front upper cover from the slots on the front lower cover - Headlight retainers Stoppers unit around the rear side of the front upper cover -– Headlight from the front inner upper cover and front inner cover Perakitan adalah dalam urutan terbalik dari Disconnect the headlight/front turn signal light 6P connector. pembongkaran. Remove the two cushion rubbers. Setel arah sinar headlight (hal. 3-18) setelah Installation is in the reverse order of removal. pemasangan front upper cover.



LICENSE PLATE HOLDER FRONT UPPER COVER 6P CONNECTOR BOLTS



TABS STOPPERS CUSHION RUBBERS



SCREW



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



FRONT TURN SIGNAL UNITS FRONT UPPER COVER



SCREWS



Lepaskan headlight/front turn signal light 6P connector (connector 6P lampu besar/lampu sein). Lepaskan kedua cushion rubbers. Pemasangan pelepasan.



adalah



dalam



urutan



terbalik



dari



BOLT



RETAINERS HEADLIGHT UNIT



2-4



RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS



FRONT HANDLEBAR HANDLEBAR COVER COVER FRONT PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Longgarkan rear view mirror lock nuts (mur pengunci Loosen the rearview mirror lock nuts. kaca spion). Remove the rearview mirrors by turning them counterclockwise. Lepaskan rear view mirrors (kaca spion) dengan memutar mereka berlawanan arah jarum jam. Remove the following:



– Two screws fromberikut: the front side Lepaskan sebagai – Two screws from the rear side - Dua screws dari sisi depan Hati-hati agarnot tidak the front handlebar cover by releasing the following: Be careful to -Remove Dua screws dari sisi belakang



REAR VIEW MIRRORS FRONT HANDLEBAR COVER STOPPER BOSSES



merusak tabs, damagebosses, the bosses, – Four bosses on the upper side of the front handlebar cover stoppers dan slots. tabs, stoppers and Lepaskan front handlebar cover dengan melepaskan from berikut: the hole on the rear handlebar cover sebagai slots.



– Two slots on the upper side of the front handlebar cover from thebosses tabs on the rearsisi handlebar coverfront handlebar - Empat pada atas dari – cover Two dari stoppers on the front handlebar cover from the slots lubang pada rear handlebar cover. on the combination meter - Dua slots pada sisi atas dari front handlebar cover – dari Hole on pada the front from the front brake tabs rearhandlebar handlebarcover cover. master cylinder - Dua stoppers pada front handlebar cover dari slots pada combination meter.order of removal. Installation is in the reverse - Lubang pada front handlebar cover dari front brake master cylinder



HOLES SLOT



TAB Pemasangan pelepasan.



adalah



dalam



urutan



terbalik



dari



SCREW



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



FRONT BRAKE LIGHT SWITCH CONNECTORS



REAR HANDLEBAR COVER REAR BRAKE LIGHT SWITCH CONNECTORS



SPEEDOMETER CABLE



WIRE BOSS



WIRE GUIDE SCREWS



HORN CONNECTORS



4P/6P CONNECTORS



2-5



RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS



FRONT FRONT LOWER LOWER COVER COVER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan berikut: Remove thesebagai following: -– Front Frontupper uppercover cover (hal. (page2-4) 2-4) Two screws -– Empat screwsfrom dariboth sisi sides depan Two screws fromhook the lower side -– Bolt dan luggage dari front sisi belakang



Be careful not to Hati-hati agar tidak damage the hooks. merusak hooks.



Remove thewire frontboss lowerdari cover by releasing the inner hooks upper on its Lepaskan lubang dari front lower side from the under cover. cover. Tarik frontis inner cover order sedikit ke belakang untuk Installation in the reverse of removal. membuat ruangan bagi pelepasan front inner upper cover. Lepaskan bagian atas dari front inner upper cover dari rear handlebar cover, kemudian tarik ke atas dan keluarkan. Pemasangan pelepasan.



adalah



dalam



urutan



terbalik



dari



SCREWS



FRONT LOWER COVER HOOKS



FRONT FRONT INNER INNER UPPER UPPER COVER COVER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan berikut: Remove thesebagai following:



FRONT INNER UPPER COVER



-– Front Frontupper uppercover cover (hal. (page2-4) 2-4) -– Dua screws sisiside Four screwsdari fromkedua the front -– Dua dari sisi depan Boltscrews and luggage hook from bawah the rear side



Hati-hati agarnot tidak Be careful to merusak damagefront the inner front covercover dan front inner and inner front upper cover. cover. inner upper



Lepaskan cover melepaskan Release thefront wire lower boss from thedengan hole of the front inner hooks upper cover.sisinya yang bawah dari under cover. pada Slightly pull the front inner cover backward to make space for front inner upper cover removal. Pemasangan adalah dalam urutan terbalik dari Release the upper side of the front inner upper cover from the pelepasan. rear handlebar cover, then pull it upward and remove it.



HOLE BOLT WIRE BOSS



Installation is in the reverse order of removal.



LUGGAGE HOOK SCREWS



2-6



RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS



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



FRONT FENDER dari



BOLTS



LUGGAGE BOX (KOTAK BAGASI) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan berikut: Remove thesebagai following:



WIRE HARNESS COVER



-– Baterai 14-12) Battery(hal. (page 14-12) -– ICM (hal. 15-11) ICM (page 15-11) -– Screw atas side Screwdari fromsisi thedepan front upper -– Dua sisi Twoscrews screwsdari fromkedua both sides Twobolts boltsdan andcollars collars dari fromsisi the belakang upper rear atas side -– Dua Twobolts boltsdari from thedepan inner front side -– Dua sisi dalam Wireharness harness cover cover -– Wire



BOLTS



COLLARS



Remove the luggage box upward while pulling the wire harAlurkan wire harness Lepaskan luggage box ke atas sementara menarik wire ness out of its hole. keluar dari lubangnya. dengan benar (hal. harness 1-14) Route the wire Installation is in the reverse order of removal. harness properly Pemasangan adalah dalam urutan terbalik (page 1-14) pelepasan.



dari



SCREWS



LUGGAGE BOX WIRE HARNESS



2-7



RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS



CENTER CENTER BODY BODY COVER COVER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan kunci duduk Unlock the seat withtempat the ignition key. dengan anak kunci kontak. Open the seat. Buka tempat duduk. Remove the following: Lepaskan sebagai ? Screw from frontberikut: upper side



Hati-hati agarnot tidak Be careful to merusak hooks dan damage the hooks slots. and slots.



HOOK



SCREWS



Two screws from frontatas. lower side -– Screw dari sisi depan Two screwsdari fromsisi both sides bawah -– Dua screws depan -Push Duathe screws sisithe center body cover upward upperdari frontkedua side of and release fromsisi the depan floor panel. Dorong ke itatas atas dari center body cover dan lepaskan dari panel lantai. Remove the center body cover while releasing its hooks from the slots on the body cover by sliding it forward. Lepaskan center body cover sementara melepaskan Installation isdari in the reverse order of body removal.cover dengan hooks-nya slots pada menggesernya ke depan. Pemasangan pelepasan.



adalah



dalam



urutan



terbalik



dari



SLOT



CENTER BODY COVER



TEMPAT DUDUK SEAT PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan (hal. 2-8). Remove thecenter centerbody body cover cover (page 2-8)



LUGGAGE BOX LID



luggage boxit. lid (tutup kotak Lepaskan Unhook the kaitan luggage dari box lid and remove bagasi) Slide thedan pin lepaskan. out and remove the seat. Geser pin keluar dan lepaskan tempat duduk. Installation is in the reverse order of removal. Pemasangan adalah dalam urutan terbalik dari pelepasan.



TEMPAT DUDUK PIN



GRAB GRAB RAIL RAIL (PEGANGAN TANGAN) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan kunci duduk Unlock the seat withtempat the ignition key. dengan anak kunci Open the seat. kontak. Buka tempat duduk. Remove the following: Lepaskan sebagai berikut: ? Four bolts



Grab rail -– Empat bolts -Installation Grab rail is in the reverse order of removal. Pemasangan pelepasan.



2-8



adalah



dalam



urutan



GRAB RAIL



BOLTS terbalik



dari



RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS



BODY COVER COVER BODY PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan berikut: Remove thesebagai following: -– Center Centerbody bodycover cover (hal. (page2-8) 2-8) Grabrail rail(hal. (page 2-8) -– Grab 2-8) Two screwsdari fromsisi thebawah lower side -– Dua screws Specialbolt boltdari fromsisi thekiri lower left side -– Special bawah Two boltsdari from theatas upper side -– Dua bolts sisi Hati-hati agarnot tidak Remove the body by releasing the following tabs/ Be careful to Lepaskan dengan melepaskan body covercover merusak dan tabs/bosses/hooks bosses/hooks: damage hooks the hooks berikut ini: tabs. and tabs. - Rear shock absorber cover tab dengan agak – Rear shock absorber cover tab by slightly bending it



– membengkokkannya Grab rail mounting bosses by slightly pulling the body - Grab mounting bosses dengan sedikit menarik coverrail upward body cover ke atas – Hooks on the front side of the body cover by pulling it - Hooks pada sisi depan dari body cover dengan backward menariknya ke belakang Disconnect the tail/brake light/rear turn signal light 6P connector. tail/brake light/rear turn signal light 6P Lepaskan



AlurkanRoute wire the harness Installation is in the reverse order of removal. wire connector. dengan benar (hal. Pemasangan adalah dalam urutan terbalik harness properly 1-14). pelepasan. (page 1-14).



BOLTS



dari



SCREWS



BODY COVER



HOOKS/TABS



REAR SHOCK ABSORBER COVER TAB



SPECIAL BOLT GRAB RAIL MOUNTING BOSSES



TAIL/BRAKE LIGHT/REAR TURN SIGNAL LIGHT 6P CONNECTOR



2-9



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



SCREWS



TAIL/BRAKE LIGHT/REAR TURN SIGNAL LIGHT UNIT



SCREWS



BODY COVER REAR SHOCK ABSORBER COVER



UNDER UNDER COVER COVER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan sebagai berikut: Remove the following: - –Dua screws sisi Two screwsdari from thedepan front side - –Empat screwsfrom dari both kedua sisi Four screws sides - –Dua screws sisi belakang Two screwsdari from rear side



HOOKS



Lepaskan coverbydengan Remove theunder under cover releasing melepaskan the following: sebagai berikut: – Hooks on the front side from the slots on front lower - Hooks pada sisi depan dari slots pada front lower cover cover – Tabs on both sides from the floor step - Tabs pada kedua sisi dari floor step Installation is in the reverse order of removal. Pemasangan adalah dalam urutan terbalik dari pelepasan.



TABS UNDER COVER



2-10



SCREWS



SCREWS



RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS



FLOOR PANEL/FRONT PANEL/FRONT INNER INNERCOVER COVER FLOOR REMOVAL/INSTALLATION PELEPASAN/PEMASANGAN Lepaskan sebagai berikut: Remove the following:



FLOOR PANEL/FRONT INNER COVER



- –Front Frontlower lowercover cover(hal. (page2-6) 2-6) - –Front (hal. 2-6) Frontinner innerupper uppercover cover (page 2-6) - –Body cover 2-9) Body cover(hal. (page 2-9) - –Under Undercover cover(hal. (page2-10) 2-10)



Remove the floorpanel/front panel/frontinner inner cover cover assembly pulling Lepaskan floor assemblybydengan it upward while the screwmelepaskan tabs from thescrew frame. tabs menariknya ke releasing atas sementara dari rangka.is in the reverse order of removal. Installation Pemasangan pelepasan.



adalah



dalam



urutan



terbalik



dari



SCREW TABS



REAR FENDER FENDER (SPAKBOR BELAKANG) REAR PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan sebagai berikut: Remove the following:



BOSSES



- –Body cover 2-9) Body cover(hal. (page 2-9) - –Fuel 5-26) Fueltank tank(hal. (page 5-26)



HOOKS BOLTS



Lepaskan ketiga Remove the three bolts. bolts.



Remove therear rear fender fender while releasingmelepaskan the bosses andbosses hooks Lepaskan sementara by pulling straight back and remove it. ke belakang dan dan hooksitdengan menariknya lurus melepaskannya. Installation is in the reverse order of removal. Pemasangan pelepasan.



adalah



dalam



urutan



terbalik



dari



REAR FENDER



2-11



RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS



LEFT CRANKCASE CRANKCASE COVER COVER DUCT DUCT LEFT REMOVAL/INSTALLATION PELEPASAN/PEMASANGAN Lepaskan berikut: Remove thesebagai following: -– Dua bolts Two bolts -– Left crankcase duct Left crankcase cover cover duct – Packing Packing is in the reverse order of removal. -Installation



Pastikan bahwa Make sure the Pemasangan packing berada packing is indalam good pelepasan. kondisi baik dan ganti condition and replace bila perlu. it if necessary.



adalah



dalam



urutan



LEFT CRANKCASE COVER DUCT terbalik



dari



PACKING BOLTS



COOLING COOLING FAN FAN COVER COVER PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan kedua screws dan kedua bolts. Remove the two screws and two bolts. Lepaskan starting enrichment (SE) thermal valve wire Release the starting enrichment (SE)guide thermal valve wire and dan starter motor wire dari wire dari cooling fan starter motor wire from the wire guide of the cooling fan cover. cover. Lepaskan Remove thecooling coolingfan fancover. cover. Alurkan wire Route the wire harness dengan baik harness properly (hal.1-14). 1-14) (page



Pemasangan adalah Installation is in the reversedalam order of urutan removal. terbalik pelepasan. TORQUE: Cooling fan cover screw: TORSI: Cooling fan (0.1 cover screw: 0.8 N·m kgf·m, 0.6 lbf·ft) 0,8fan N.m (0,1bolt: kgf.m; 0,6 lbf.ft) Cooling cover Cooling fan cover bolt: 9 N·m (0.9 kgf·m, 6.6 lbf·ft) 9 N.m (0,9 kgf.m; 6,6 lbf.ft)



SE THERMAL VALVE/STARTER MOTOR WIRE



dari



SCREW



JOINT NUTS



COOLING FAN COVER BOLTS



2-12



RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS



TRIM CLIPS



REMOVAL PELEPASAN



Push the centerpin pindari of the trim clip. Tekan center trim clip. Remove thetrim trimclip. clip. Lepaskan



CENTER PIN



TRIM CLIP



PEMASANGAN INSTALLATION Naikkan centerpinpin denganthe menekan retaining Raise the center by pushing retaining tabs back. tabs kembali. Install the trim clip.



RETAINING TABS CENTER PIN



Push the trim center pin until the pin is flush with the outer casing. Pasang clip. Tekan center pin sampai pin rata dengan outer casing.



TRIM CLIP



TRIM CLIP



CENTER PIN



BATTERY COVER BATTERY COVER REMOVAL/INSTALLATION PELEPASAN/PEMASANGAN



Unlock the ignition key. Open penguncian the seat. Buka dengan anak kunci kontak. Naikkan tempat duduk. Remove the trim clip (see page 2-13). Remove thetrim battery Lepaskan clip cover. (lihat hal. 2-13). Lepaskan battery cover. Installation is in the reverse order of removal. Pemasangan pelepasan.



adalah



dalam



urutan



terbalik



BATTERY COVER



dari



TRIM CLIP



2-13



RANGKA / BODY PANEL / SISTEM PEMBUANGAN GAS



EXHAUST PIPE/MUFFLER PIPE/MUFFLER (KNALPOT) PELEPASAN REMOVAL Remove thesebagai following: Lepaskan berikut: Two jointnuts nuts -– Dua joint Two mufflermounting mountingbolts bolts -– Dua muffler Exhaustpipe/muffler pipe/muffler -– Exhaust Gasket -– Gasket



GASKET



JOINT NUTS



PEMASANGAN INSTALLATION Ganti exhaust gasket dengan Replace the exhaust gasket with yang a newbaru. one. exhaust pipe flange pada stud Tempatkan Set the exhaust pipe flange onto the stud bolts andbolts installdan the pasang joint nuts, tetapi jangan kencangkan joint nuts, but do not tighten them yet. Install the mereka muffler dulu. mounting bolts, but do not tighten them yet. Pasang muffler mounting bolts, tetapi jangan Tighten the joint nuts first, kencangkan mereka dulu.then tighten the muffler mounting bolts to the specified torque. Kencangkan joint (6.0 nuts dulu, kemudian kencangkan TORQUE:59 N·m kgf·m, 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 pembuangan gas tidak bocor.



bahwa



sistem



BOLTS EXHAUST PIPE/MUFFLER



2-14



3. PERAWATAN



3



KETERANGAN SERVIS ...........................3-2 SERVICE INFORMATION ?????????????? 3-2



OLI FINAL DRIVE ..................................... 3-13 FINAL DRIVE OIL ???????????????????? 3-13



JADWAL PERAWATAN ...........................3-4 MAINTENANCE SCHEDULE ??????????? 3-4



MINYAK 3-14 BRAKEREM............................................ FLUID ??????????????????????? 3-14



SALURAN BAHAN BAKAR .....................3-5 FUEL LINE ??????????????????????????? 3-5



KEAUSAN BRAKE SHOES/PADS........... 3-15 BRAKE SHOES/PADS WEAR ?????????? 3-15



CARA KERJA OPERATION THROTTLE .......................3-5 THROTTLE ?????????????? 3-5



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



AIRAIR CLEANER ..........................................3-6 CLEANER ???????????????????????? 3-6



BRAKE 3-17 BRAKELIGHT LIGHTSWITCH SWITCH........................... ?????????????? 3-17



CRANKCASE BREATHER.......................3-6 CRANKCASE BREATHER?????????????? 3-6



CARA KERJA LOCK??????????? ..................3-17 3-17 BRAKE LOCKBRAKE OPERATION



SPARK PLUG ...............................3-7 SPARK PLUG(BUSI) ????????????????????????? 3-7



PENYETELAN ARAH LAMPU BESAR ....3-18 3-18 HEADLIGHT AIM ????????????????????



JARAK RENGGANG KLEP......................3-8 VALVE CLEARANCE ?????????????????? 3-8



KEAUSAN CLUTCH SHOES....................3-18 3-18 CLUTCH SHOES WEAR???????????????



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



SIDESTAND ..............................................3-18 3-18 SIDESTAND??????????????????????????



ENGINE OIL STRAINER ENGINE OIL STRAINERSCREEN.........3-11 SCREEN?????? 3-11



SUSPENSI ................................................3-19 3-19 SUSPENSION?????????????????????????



PUTARAN MESIN .............3-11 ENGINE STASIONER IDLE SPEED ????????????????? 3-11



MUR, BAUT, PENGIKAT .......................... 3-20 NUTS, BOLTS, FASTENERS ??????????? 3-20



SECONDARY AIR SECONDARY AIRSUPPLY SUPPLY SYSTEM....3-12 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 KETERANGAN SERVIS MAINTENANCE



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



SPESIFIKASI



ITEM Throttle grip freeplay BAGIAN Spark plug Standard Jarak main bebas throttle For gripextended high speed riding Busi Standard Spark plug gap Untuk pengendaraan lama Valve clearance IN kecepatan tinggi EX Jarak renggangengine busi oil Recommended Jarak renggang klep IN (Masuk) EX (Buang) Oli mesin yang dianjurkan



SPECIFICATIONS 2 – 6 mm (0.1 – 0.2 in) SPESIFIKASI CPR8EA-9 (NGK) 2 – 6 mm(NGK) CPR9EA-9 CPR8EA-9 0.80 – 0.90 mm(NGK), (0.031 U24EPR9 – 0.035 in) (DENSO) pada 0.14 CPR9EA-9 ± 0.02 mm(NGK) (0.006 ± 0.001 in) 0.14 ± 0.02 mm (0.006 ± 0.001 in) 0,80 "4-stroke – 0,90 mm Honda motorcycle oil" or an equivalent motor oil API service 0,14 ± 0,02SG mm classification: or higher (except oils labeled as energy conserving on the0,14 circular APImm service label) ± 0,02 JASO T 903Oil standard: MB Flick atau oli mesin 4 tak sejenis Federal Supreme Viscosity: 10W-30 dengan SAE klasifikasi API service SG, Engine oil capacity After draining 0.7Viskositas: liter (0.7 US qt, 0.6 Imp qt) SAE 10W-30 JASO MB After penggantian disassembly periodik 0.80,7 liter (0.8 US qt, 0.7 Imp qt) Kapasitas oli mesin Pada liter Engine idle speed 1,700 100 min-1 (rpm) Pada pembongkaran mesin 0,8 ± liter Drive belt width mesin Service limit: mm-1 (0.69 Putaran stasioner 1.700 ± 10017.5 menit (rpm)in) Recommended Honda "4-stroke Lebar drive beltfinal reduction oil Batas servis: motorcycle 17,5 mm oil" or an equivalent motor oil API service classification: or higher (except oils labeled as energy conserving Oli final reduction yang dianjurkan Federal OilSGSupreme Flick atau oli mesin 4 tak sejenison thedengan circularklasifikasi API serviceAPI label) service SG, JASO T 903 standard: MB JASO MB Viskositas: SAE 10W-30 Viscosity: Kapasitas oli final Pada penggantian periodik 0,10 literSAE 10W-30 Final reduction oil After pembongkaran draining 0.10 liter (0.11 US qt, 0.09 Imp qt) reduction Pada 0,12 liter capacity disassembly 0.12 Jarak main bebas handel After rem belakang 10 liter – 20(0.13 mm US qt, 0.11 Imp qt) Rear brakeclutch lever free play(kanvas kopeling) 10Batas – 20 mm (0.4 2,0 – 0.8mm in) Ketebalan lining servis: 2 in) Clutch lining thickness Service limit: 2.0 mm (0.08 Tekanan udara ban Pengendara Depan 200 kPa (2,00 kgf/cm , 29 psi) 2 , 292,psi) Cold tire pressure Driver only Front 200 kPakPa (2.00 kgf/cm dingin saja Belakang 225 (2,25 kgf/cm 33 psi) 2 225 kPakPa (2.25 kgf/cm , 332,psi) Pengendara dan Depan Rear 200 (2,00 kgf/cm 29 psi) 2 Driver and passenger Front 200 kPa (2.00 kgf/cm , 292,psi) pembonceng Belakang 225 kPa (2,25 kgf/cm 33 psi) 225 kPa (2.25 kgf/cm2, 33 psi) Ukuran ban Depan Rear 80/90 – 14M/C40P Tire size Front 80/90 – 14M/C40P Belakang 90/90 – 14M/C46P 90/90 – 14M/C46P Merek ban SRI Depan Rear FT235 Tire brand SRI Front FT235 Belakang FT235 FT235 Kedalaman minimum alur telapak ban Depan Rear Sampai ke indikator Minimum tire tread depth Front ToSampai the indicator Belakang ke indikator Rear To the indicator



3-2



PERAWATAN TORQUE VALUES NILAI TORSI Spark plug Spark plug(busi) AirAir cleaner housing cleaner housingcover cover screw screw Valve adjusting screw Valve adjusting screw lock lock nut nut Engine oiloil drain Engine drainbolt bolt Engine oil strainer Engine oil strainerscreen screen cap cap Final reduction Final reductionoiloilcheck checkbolt bolt Final reduction oil drain bolt Final reduction oil drain bolt



16 N.m (1,6 kgf.m; 12 lbf.ft) 16 N·m (1.6 kgf·m, 12 lbf·ft) 1,1 N.m (0,1 kgf.m; 0,8 lbf.ft) 1.1 N·m (0.1 kgf·m, 0.8 lbf·ft) 10 N.m (1,0 kgf.m; 7 10 N·m (1.0 kgf·m, 7 lbf·ft) lbf.ft) ApplySemprotkan engine oil to oli themesin threadspada and ulir dan seatingpermukaan surface. duduk 24 N.m (2,4 kgf.m; 18 lbf.ft) 24 N·m (2.4 kgf·m, 18 lbf·ft) 20 N.m (2,0 kgf.m; 15 20 N·m (2.0 kgf·m, 15 lbf·ft) lbf.ft) 13 N.m (1,3 kgf.m; 10 lbf.ft) 13 N·m (1.3 kgf·m, 10 lbf·ft) 13 N.m (1,3 kgf.m; 10 lbf.ft) 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 Lubricate or Replace if Lumasi necessary. C: Clean. R: Replace. A:Bersihkan. Adjust. L: Lubricate. P: Periksa Bersihkan, Setel, atau Ganti bila perlu. B: G: Ganti. L: Lumasi. PB: Perawatan Berkala. Bagian-bagian berikut memerlukan pengetahuan mekanis tertentu. Beberapa bagian yang ditandai * dan infor**) The following items require some mechanical knowledge. Certain items (particularly those marked * and(terutama **) may require more technical mation tools. Consult anbanyak authorized Honda dealer. dapat and memerlukan lebih 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 X1,000 km 1 4 8 12 PB 1 PB 2 X1,000 PB mi 3 ↓ 0.6 2.5 5 7.5 BAGIAN YANG DISERVIS 500 2.000 Months 4.000 8.000 12.000 ITEMS 6 12 18 SALURAN BAHAN BAKAR P P P P PI ** FUEL LINE I I CARA KERJAOPERATION GAS TANGAN P P P P PI ** THROTTLE I I AIR CLEANER Catatan 2 NOTE2 SETIAPEVERY 16.000 km: G km (10,000 mi) R ** AIR CLEANER 16,000 CRANKCASE BREATHER Catatan 4 NOTE4 B B B B B CRANKCASE BREATHER C C C BUSI P P P G P SPARK PLUG I R I JARAK RENGGANG KLEP P P P PI PI ** VALVE CLEARANCE I I OLI MESINOIL G G SETIAP 4.000 ENGINE R R km: GR R ENGINE OIL SCREEN B ** ENGINE OILSTRAINER STRAINER SCREEN C PUTARANIDLE STASIONER P P P PI PI ** ENGINE SPEEDMESIN I I SECONDARY AIR SUPPLY SYSTEM P P ** SECONDARY AIR SUPPLY SYSTEM I * DRIVE BELT SETIAP 8.000 km: P * DRIVE BELT EVERY 8,000 km (5,000 mi) I, SETIAP 24.000 km: Gkm (15,000 mi) R EVERY 24,000 * OLI FINAL DRIVE Catatan 3 * FINAL DRIVE OIL NOTE3 MINYAK REM Catatan 3 P P P P P BRAKE FLUID NOTE3 I I I KEAUSAN BRAKE SHOES/PADS P P P P P BRAKE SHOES /PADS WEAR I I I SISTEM REM P P P P P BRAKE SYSTEM I I I I * SAKELAR LAMPU REM P P P P P * BRAKE LIGHT SWITCH I I I * CARA KERJA BRAKE LOCK P P P P P * BRAKE LOCK OPERATION I I I I * ARAH SINAR LAMPU BESAR P P P P P * HEADLIGHT AIM I I I ** KEAUSAN CLUTCH SHOES P ** CLUTCH SHOES WEAR I STANDARD SAMPING P P P P P SIDESTAND I I I * SUSPENSI P P P P P * SUSPENSION I I I * MUR, BAUT, PENGENCANG P P P P P *** NUTS, BOLTS, FASTENERS I I RODA/BAN Catatan 3 P P P P P ** I I ** WHEELS/TIRES BANTALAN KEPALA KEMUDI P PI -I ** STEERING HEAD BEARINGS I I



LIHAT REFER TO HALAMAN PAGE 3-5 3-5 3-5 3-5 3-6 3-6 3-6 3-6 3-7 3-7 3-8 3-8 3-9 3-9 3-11 3-11 3-11 3-11 3-12 3-12 3-13 3-13 3-13 3-13 3-14 3-14 3-15 3-15 3-15 3-15 3-17 3-17 3-17 3-17 3-18 3-18 3-18 3-18 3-18 3-18 3-19 3-19 3-20 3-20 3-20 3-20 3-21 3-21



HARUS DISERVIS OLEH AHASS, KECUALI BILA PEMILIK MEMPUNYAI TOOLS YANG TEPAT DAN DATA * SERVIS SHOULD SERVICEDDAN BY AN AUTHORIZED Honda MEKANIS DEALER,UNTUK UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE YANGBE DIPERLUKAN, MEMPUNYAI KETRAMPILAN MENGERJAKANNYA. DATA AND IS MECHANICALLY QUALIFIED. ** DEMI KEAMANAN, KAMI MENGANJURKAN AGAR PEKERJAAN-PEKERJAAN INI HANYA DILAKUKAN OLEH ** AHASS. IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED Honda DEALER. *



CATATAN: NOTES: 1. Pada pembacaan odometer lebih tinggi, ulangilah pada interval frekuensi yang ditentukan di atas. 1.2. AtServis higher lebih odometer readings, repeat at the interval here. sering jika dikendarai di frequency daerah yang luarestablished biasa basah atau berdebu. 2.3. Service more frequently when riding in unusually wet or dusty areas. Ganti setiap 2 tahun. Penggantian memerlukan ketrampilan mekanis. 3. Replace every 2 years. Replacement requires mechanical skill. 4. Servis lebih sering jika dikendarai dalam hujan atau dengan gas penuh. 4. Service more frequently when riding in rain or at full throttle.



3-4



PERAWATAN



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



FUEL HOSE



CARA KERJA THROTTLE (GAS TANGAN) THROTTLE OPERATION CATATAN: • ? Reusing Pemakaian kembali cable gas)throttle yang a damaged or throttle abnormally bent(kabel or kinked rusak,can tertekuk secara tidak and normal cable prevent atau properbengkok throttle slide operation may dapat kerja lead to amengganggu loss of throttle cara 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 posiPeriksa terhadap pemburukan kondisi atau kerusakan tions. pada throttle cable. Periksa throttle grip (putaran gas If the throttle gripkelancaran does not return properly, lubricate the tangan) terhadap cara kerja. Periksa bahwa throttlemembuka cable. throttle dan secara otomatis menutup kembali For cable lubrication, disconnect the throttle cable at their pada semua posisi kemudi. pivot points and apply commercially available cable lubricant or light weightgrip oil. tidak kembali dengan benar, lumasi Jika throttle throttle cable. If the throttle grip still does not return properly, replace the Untuk melumasi throttle cable. cable, lepaskan throttle cable pada titiktitik perputarannya dan oleskan dengan pelumas kabel With dapat the engine idling, the handlebar the way berat to the yang dibeli di turn pasaran atau olialldengan 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 cable routing. Jika 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.



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



2 – 6 mm (0.1 – 0.2 in)



3-5



PERAWATAN Throttle grip free playthrottle can be adjusted by turning the adjuster. Jarak main bebas grip dapat disetel dengan memutar adjuster (penyetel). Remove the body cover (page 2-9).



ADJUSTER



Loosen thebody lock nut and(hal. turn 2-9). the adjusting nut as required. Lepaskan cover Tighten the lock Longgarkan locknut. nut (mur pengunci) dan putar adjusting nut (mur penyetel) Recheck the throttlesebanyak operation. diperlukan. Install the body cover Kencangkan lock nut.(page 2-9). Periksa kembali cara kerja throttle. Pasang body cover (hal. 2-9).



LOCK NUT



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



COVER



ELEMENT



SCREWS



CRANKCASE BREATHER CRANKCASE BREATHER



? Service more frequently when ridden in rain, at full throtCATATAN: tle, or after the scooter is washed or overturned. Service if • Servis lebih sering jika dikendarai dalam hujan, 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 breather drain hose dalam from the hose permukaan endapan dapat terlihat bagian clamp. tembus pandang dari drain hose (slang pembuangan). Remove the crankcase breather drain hose plug from the hose



HOSE CLAMP



end and drain deposits into a suitable container. Lepaskan crankcase breather drain hose (slang Install the crankcase breather hosedari plughose and set the pembuangan pernapasan bakdrain mesin) clamp crankcase breather hose to the hose clamp. (klem slang). Remove the body cover (page 2-9). Lepaskan crankcase breather drain hose plug (penyumbat slang pembuangan pernapasan bak mesin) dari ujung hose dan keluarkan endapan ke dalam penampung yang sesuai. Pasang crankcase breather drain hose plug dan tempatkan crankcase breather hose pada hose clamp. Check the crankcase breather hose for deterioration, damage or leakage.



Replace the crankcase breather hose if necessary. Also check the crankcase breather hose fittings for leakage. Install the body cover (page 2-9).



3-6



DRAIN HOSE



HOSE PLUG



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



?



SPARK PLUG (BUSI) ? allowed to enter the combustion chamber.



BREATHER HOSE



CATATAN: Remove the center body cover (page 2-8). • Bersihkan disekitar dasar busi dengan udara dari Disconnect the spark plug cap and clean around the spark kompressor sebelum melepaskan busi, dan plug base. pastikan bahwa kotoran tidak memasuki ruang Remove the spark plug. pembakaran. Lepaskan center body cover (hal. 2-8). Lepaskan spark plug cap (topi busi) dan bersihkan daerah di sekitar dasar busi. Lepaskan spark plug.



SPARK PLUG CAP Inspect or replace as described in the maintenance Periksa atau ganti seperti diuraikan di dalamschedule jadwal (page 3-4). (hal. 3-4). perawatan Periksa sebagai berikutnya danifganti bila perlu. Check the following and replace necessary. •? •? •?



SPARK PLUG CENTER ELECTRODE



Insulatorfor terhadap Insulator damage kerusakan Electrodesfor(kutub-kutub busi) terhadap keausan Electrodes wear Kondisi condition, terbakar, coloration; perubahan warna; Burning



-? – ?



Coklat sampai muda kondisii Dark totua light browncoklat indicates goodmenunjukkan condition. baik. Excessive lightness indicates malfunctioning ignition Warnaormuda yang berlebihan menunjukkan sistem system lean mixture. Wet or blackyang sootytidak deposit indicates over-rich mixture. pengapian bekerja dengan baik atau campuran bahan with bakarcarbon yang deposits, miskin. clean If the electrode is contaminated atau hitam arang menunjukkan - theEndapan yang basah electrode using a spark plug cleaner. campuran bahan bakar yang terlalu Always kaya.use the specified spark plug on this scooter.



INSULATOR



SIDE ELECTRODE



SPECIFIED SPARK PLUG: Jika elektroda terkontaminasi dengan endapan karbon, Standard: bersihkan electrode dengan menggunakan spark plug cleaner. Selalu pakai spark plug yang ditentukan pada skuter ini. CPR8EA-9 (NGK) For extended high speed riding: CPR9EA-9 (NGK) BUSI YANG DITENTUKAN: Standard: CPR8EA-9 (NGK), U24EPR9 (DENSO) Untuk pengendaraan lama pada kecepatan tinggi: CPR9EA-9 (NGK)



3-7



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



0.80 – 0.90 mm (0.031 – 0.035 in)



Install and handplug tighten the dengan spark plug to thepada cylinder cylinder head, spark (busi) tangan Domengencangkan not overtighten Pasang Jangan then tighten the spark plug to the specified torque.torsi yang theberlebihan. spark plug. head, kemudian kencangkan busi dengan busi secara ditentukan. TORQUE:16 N·m (1.6 kgf·m, 12 lbf·ft) TORSI: Connect 16 the N.m spark(1,6 plugkgf.m; cap. 12 lbf.ft) Pasang spark plug cap (topi(page busi). Install the center body cover 2-8). Pasang center body cover (hal. 2-8).



SPARK PLUG CAP



JARAK VALVE RENGGANG CLEARANCEKLEP PEMERIKSAAN INSPECTION CATATAN: • ? Inspect Periksaand dan setel klep the sementara adjust thejarak valve renggang clearance while engine is mesin dalam keadaan dingin (di bawah 35° C). cold (below 35°C/95°F).



Remove the following: Lepaskan sebagai berikut: ? Cylinder headcover cover (hal. (page7-7) 7-7) - Cylinder head ? Cooling fan cover (page 2-12) - Cooling fan cover (hal. 2-12) Rotate the crankshaft clockwise by rotating the cooling fan Putar crankshaft (poros engkol) searah jarum jam slowly and align the "T mark" on the flywheel with the index dengan memutar cooling fan dengan pelan dan notch on the right crankcase. mentepatkan "tanda T" pada flywheel dengan index Make (takik sure the piston ispada at TDC (Top Dead Center) on the notch penunjuk) right crankcase (bak mesin compression stroke. kanan). This position can be confirmed by checking that there is slack in the rocker arm. piston berada pada TDC (Top Dead Pastikan bahwa If there [TMA is no slack, is because piston is moving through Center) (TitikitMati Atas)] the pada langkah kompressi. the exhaust stroke dipastikan to TDC. Posisi ini dapat dengan memeriksa bahwa Rotate the crankshaftpada one full turnarm. by rotating the cooling fan ada kerenggangan rocker slowly and match up the "T" mark again. Jika tidak ada kerenggangan, berarti bahwa piston sedang bergerak melalui langkah pembuangan ke TDC. Putar crankshaft satu putaran penuh dengan memutar cooling fan dengan pelan dan mentepatkan "tanda T" sekali lagi.



3-8



PENUNJUK



TANDA "T"



SPARK PLUG



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



Jika tidak sesuai, valve If thejarak valverenggang clearance klep is incorrect, loosen longgarkan the valve adjusting adjusting lock nut the danvalve setelclearance jarak renggang screw lockscrew nut and adjust by turningklep the dengan adjusting sampai tahanan adjustingmemutar screw until there is a screw slight drag on theada feeler gauge. Apply pada enginefeeler oil to the valve adjusting screw lock nut threads sedikit gauge. and seating surface. Semprotkan oli mesin pada ulir valve adjusting screw Holdnut thedan adjusting screw and tighten the lock nut. lock permukaan duduk. Tahan adjusting screw dan kencangkan lock nut. TOOL: Valve adjusting wrench 07908-KE90000 TOOL:



FEELER GAUGE



ADJUSTING SCREW



LOCK NUT



Valve adjusting wrench 07908-KE90000 TORQUE:10 N·m (1.0 kgf·m, 7 lbf·ft) TORSI: kgf.m; 7 lbf.ft) Recheck 10 theN.m valve(1,0 clearance.



Install the following: Periksa kembali jarak renggang klep. Pasang sebagai ? Cylinder headberikut: cover (page 7-7) Coolinghead fan cover - ? Cylinder cover(page (hal.2-12) 7-7) - Cooling fan cover (hal. 2-12)



VALVE ADJUSTING WRENCH



OLI MESIN ENGINE OIL PEMERIKSAAN TINGGI PERMUKAAN OLI OIL LEVEL CHECK Letakkan atas standard on utamanya di atas Support theskuter scooterdiwith its centerstand a level surface. tanah mendatar. Start the engine letbiarkan it idle forberputar 3 - 5 minutes. Hidupkan mesinand dan stasioner selama Stop the engine and wait for 2 3 minutes. 3-5 menit. Matikan selama 2-3 menit. Removemesin the oildan fillertunggu cap/dipstick and wipe off the oil from the dipstick with a clean cloth. Lepaskan oil filler cap/dipstick (tutup pengisian Insert the oil filler cap/dipstick without it in, oli/tangkai pengukur) dan sekalah oli screwing dari dipstick remove kain it andbersih. check the oil level. dengan



The level should be between the "UPPER" and "LOWER" Masukkan oil filler cap/dipstick tanpa menyekrupkannya level lines of the oil filler cap/dipstick. ke dalam, lepaskan dan periksa tinggi permukaan oli.



FILLER CAP/DIPSTICK



UPPER



LOWER



Tinggi permukaan harus antara garis tinggi permukaan "UPPER" (TERATAS) dan "LOWER" (TERBAWAH) dari oil filler cap/dipstick. Viskositas lain yang Other viscosities diperlihatkan pada peta shown in the dapat dipakai jikachart suhu may be used di when the rata-rata daerah average temperature pengendaraan anda in your riding daerah area is berada di dalam within the indicated jangkauan yang diperlihatkan. range.



Jika permukaan berada di bawah dekat If thetinggi oil level is below oroli near the lower level lineatau on the dipgaris tinggi permukaanoil terbawah dari dipstick, stick, add the recommended to the upper level. tambahkan oli yang dianjurkan sampai ke tinggi RECOMMENDED permukaan teratas. ENGINE OIL: Honda "4-stroke motorcycle oil" or equivalent motor oil classification: SG or higher OLIAPI MESIN YANG DIANJURKAN: (exceptOil oils Supreme labeled as energy the circular Federal Flick conserving atau oli on mesin 4 tak API service label) sejenis dengan klasifikasi API service SG, JASO T 903 standard: Viskositas: SAE 10W-30MB JASO MB Viscosity: SAE 10W-30



3-9



PERAWATAN Pastikan O-ring dalam kondisi baik it dan Make surebahwa the O-ring is inberada good condition and replace if ganti bila perlu. necessary.



O-RING



Coat the O-ring with engine oil and install the oil filler cap/ Lapisi O-ring dengan oli mesin dan pasang oil filler dipstick. cap/dipstick. For engine oil change, see page 3-10. Untuk penggantian oli mesin, lihat hal. 3-10.



FILLER CAP/DIPSTICK



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



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



3-10



WASHER/DRAIN BOLT



PERAWATAN



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



OIL STRAINER SCREEN



SPRING



OIL STRAINER SCREEN CAP



O-RING



Isi crankcase yang oli mesin yang dianjurkan dan periksa tinggi permukaan oli mesin (hal. 3-9). Pastikan bahwa tidak ada kebocoran oli.



PUTARAN STASIONER ENGINE IDLE SPEED MESIN CATATAN: Periksaand danadjust setelthe putaran stasioner setelah • ? Inspect idle speed after all other semua engine bagian perawatan mesin lain telah maintenance items have beenyang performed and dijalankan are within dan adalah sesuai dengan spesifikasi. specifications. engineharus must bedalam warm forkeadaan accurate idle speed inspecMesin panas untuk • ? The tion and adjustment. minutes of stop-and-go riding is pemeriksaan danTen penyetelan putaran stasioner sufficient. yang akurat. Sepuluh menit pengendaraan jalandan-berhenti Support the scooteradalah with itscukup. centerstand.



ADJUSTING HOLE CAP



Warm up the engine about ten minutes. Letakkan skuter pada standard utamanya. Connect a tachometer and check the sepuluh idle speed. Panaskan mesin selama kira-kira menit. -1 IDLE SPEED: 1,700 ± 100 (rpm) Hubungkan tachometer danmin periksa putaran stasioner.



-1



PUTARAN 1.700 ± 100 menit (rpm) If the engineSTASIONER: idle speed is out of specification, adjust as follows: Jika putaran stasioner mesin tidak sesuai dengan Unlock the seat with ignition key. spesifikasi, setel sebagai berikut: Open the seat. Buka penguncian tempat duduk Remove the adjusting hole cap and dengan turn the anak throttlekunci stop kontak. screw as required to obtain the specified idle speed. Naikkan tempat duduk. Lightly open the throttle 2 –dan 3 times, checkstop the Lepaskan adjusting holeforcap putarthen throttle enginesebanyak idle speed again. screw diperlukan untuk mendapatkan putaran stasioner ditentukan. Install the yang removed parts in the reverse order of removal.



THROTTLE STOP SCREW



Bukalah throttle 2 - 3 kali dengan ringan, kemudian periksa putaran stasioner mesin sekali lagi. Pasang parts yang telah dilepaskan dalam urutan terbalik dari pelepasan.



3-11



PERAWATAN



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



ELEMENT



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



Peras larutan pembersih sepenuhnya



Cucilah dalam larutan pembersih



Penuhi element dengan oli



Oleskan 1,0 - 1,5 g oli mesin bersih



Install the element. Pasang element. Install the cleanerhousing housing cover cover (page 3-6). Pasang airair cleaner (hal. 3-6). Remove thebody bodycover cover(hal. (page2-9). 2-9). Lepaskan



Jika joint If thememperlihatkan joint show any tanda-tanda signs of heat damage, kerusakan inspect theakibat PAIR panas, check valveperiksalah (page 5PAIR check valve. 24).



Check theairairsuction suction joint cleaner housing housing Periksa joint between antara the air air cleaner and PAIRsaringan control valve for cracks, damage or (rumah udara) dan deterioration, PAIR control valve loose connections. terhadap retak-retak, pemburukan kondisi, kerusakan atau sambungan longgar. Check the air supply hose between the PAIR control valve and air supply pipe for cracks, deterioration, damage or loose Periksa air supply hose antara PAIR control valve dan connections. air supply pipe terhadap retak-retak, pemburukan Check the air supplyatau pipesambungan between thelonggar. air supply hose and kondisi, kerusakan cylinder head for damage or loose fasteners. Periksa supply pipe antara air supply hose dan Check theair vacuum hose between the intake manifold vacuum cylinder head terhadap kerusakan atau pengikat joint and PAIR control valve for deterioration, damage or longgar. loose connections.



VACUUM HOSE



Also check that hose is notantara kinkedintake or pinched. Periksa vacuum hose manifold vacuum joint dan PAIR control valve terhadap Install the removed parts in the reverse order of pemburukan removal. kondisi, kerusakan atau sambungan longgar. Juga periksa bahwa hose (slang) tidak tertekuk atau terjepit. Pasang parts yang telah dilepaskan dalam urutan terbalik dari pelepasan.



3-12



AIR SUPPLY HOSE/PIPE



AIR SUCTION JOINT



PERAWATAN



DRIVE BELT BELT DRIVE Lepaskan Remove theleft leftcrankcase crankcase cover cover (page (hal. 8-5). 8-5).



Check the drive for cracks, separationpemisahan or abnormal or atau Periksa drive beltbelt terhadap retak-retak, excessive wear replaceatau it if necessary (page keausan tidak and normal berlebihan dan8-12). ganti bila perlu (hal. 8-11).



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



DRIVE BELT



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



DRIVE BELT



FINAL FINAL DRIVE DRIVEOIL OIL PEMERIKSAAN TINGGI PERMUKAAN OLI OIL LEVEL CHECK Make sure bahwa that the final case has no oli oil leaks. Pastikan tidakreduction ada kebocoran pada final reduction case. Support the scooter with its centerstand.



SEALING WASHER



Remove the oil check Letakkan skuter padabolt. standard utamanya. Check whether the oilbolt. flows out from the check bolt hole. Lepaskan oil check If the level is lowoli(oil does notkeluar flow out), the recomcheck Periksa apakah mengalir dari add lubang mended oil as described below. bolt. Jika tinggi permukaan rendah (oli tidak mengalir RECOMMENDED FINAL REDUCTION OIL: keluar), tambahkan oli yang dianjurkan diuraikan di Honda "4-stroke motorcycle oil" orseperti equivalent motor oil bawah. API classification: SG or higher (except oils labeled as energy conserving on the circular FINAL REDUCTION API service label) OIL YANG DIANJURKAN: Federal Flick atau oli mesin 4 tak JASO TOil 903Supreme standard: MB sejenis dengan API service SG, Viscosity: SAE klasifikasi 10W-30 Viskositas: SAE 10W-30 JASO MB Install the oil check bolt with a new sealing washer and Pasang check bolt torque. dengan sebuah sealing washer tighten it oil to the specified baru dan kencangkan dengan torsi yang ditentukan. TORQUE:13 N·m (1.3 kgf·m, 10 lbf·ft) TORSI: 13 N.m (1,3 kgf.m; 10 lbf.ft)



CHECK BOLT



LOWER LEVEL



3-13



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



DRAIN BOLT



CHECK BOLT



SEALING WASHER



SEALING WASHER



TORSI: 13 N.m (1,3 TORQUE:13 N·m (1.3kgf.m; kgf·m,10 10 lbf.ft) lbf·ft)



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



3-14



TANDA TINGGI PERMUKAAN TERENDAH



PERAWATAN



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



REAR DRUM BRAKE SHOES (SEPATU REM TEROMOL BELAKANG) REAR DRUM BRAKE SHOES Periksa posisi keausan ketika handel rem Check the wear indikator indicator position when the brake lever is ditekan. applied.



ALUR-ALUR BATAS KEAUSAN



BELAKANG:



TANDA " "



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



BRAKE SYSTEM (SISTEM REM) BRAKE SYSTEM FRONT DISC BRAKE



INDIKATOR KEAUSAN



(REM CAKRAM DEPAN) FRONT DISC BRAKE Tekan rem dengan kuatcheck dan periksa bahwa tidak Firmlyhandel apply the brake lever and that no air has entered the system. ada udara yang telah memasuki sistem. If thehandel lever feels soft or spongy when operated, bleed the air Jika terasa lunak atau seperti sepons ketika from the system. dijalankan, buanglah udara palsu dari sistem.



For air bleeding procedures (page 13-7). Untuk prosedur pembuangan udara palsu (hal. 13-7).



3-15



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



BRAKE HOSE



REAR DRUM BRAKE (REM BELAKANG) REARTEROMOL DRUM BRAKE Periksa brake rem)lever danfor brake (handel Check the brakecable cable(kabel and brake looselever connections, excessive play orsambungan other damage.longgar, jarak main bebas rem) terhadap Replace or repair atau if necessary. yang berlebihan kerusakan lain. Ganti atau bilalever perlu. Measure theperbaiki rear brake free play at the end of the lever.



10 – 20 mm (0.4 – 0.8 in)



Ukur jarak main bebas rear brake lever (handel rem FREE PLAY: 10 – 20 mm (0.4 – 0.8 in) belakang) pada ujung lever. JARAK MAIN BEBAS: 10 – 20 mm



Pastikan bahwa Make sure the cut-out potongannut pada of the adjusting is adjusting nut telah seated on the joint duduk pada joint pin. pin.



Setel bebas brake dengan Adjust jarak the rearmain brake lever freerear play by turninglever the rear brake memutar rearnut. brake arm adjusting nut (mur penyetelan arm adjusting lengan rem belakang).



ADJUSTING NUT



3-16



PERAWATAN



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



REAR BRAKE LIGHT SWITCH



FRONT BRAKE LIGHT SWITCH



BRAKE LOCK OPERATION BRAKE LOCK OPERATION (CARA KERJA KUNCI REM) CATATAN: • ? Check Periksa brake lock the cara brakekerja lock operation aftersetelah the rear jarak brake main lever bebas brake and lever telah (page diperiksa free playrear is checked adjusted 3-16).dan disetel (hal. 3-16). Squeeze the rear brake lever and set the lock lever.



LOCK LEVER



Tekan rearthe brake lever dan completely. tempatkan lock lever Check that rear wheel is locked (handel kunci). Periksa bahwa roda belakang telah dikunci sama sekali.



BRAKE LEVER



3-17



PERAWATAN



HEADLIGHT AIM PENYETELAN ARAH SINAR LAMPU BESAR



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



HEADLIGHT AIM ADJUSTING BOLT



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



CLUTCH SHOE



SIDESTAND SIDESTAND (STANDARD SAMPING) Letakkan skuter pada utamanya. Support the scooter withstandard its centerstand. Periksa sidestand terhadap kerusakan Check thepegas sidestand spring for damage or loss of tension.atau kehilangan tegangan. Check the sidestand assembly for freedom of movement and lubricate the sidestand pivot if necessary. Periksa sidestand assembly terhadap kebebasan Check the sidestand ignition cut-off system: bila perlu. pergerakan dan lumasi engsel sidestand



1. Retract the sidestand. Periksa sistem sidestand ignition cut-off (sistem 2. Start the engine. pematian pengapian samping): 3. Move the sidestanddari full standard down. 1. Tarik sidestand ke atas. 4. The engine should stop as the sidestand is lowered. 2. Hidupkan mesin. If there is a problem withsepenuhnya the system, check the sidestand 3. Gerakkan sidestand ke bawah. switch (pageharus 15-9). berhenti berputar sewaktu sidestand 4. Mesin diturunkan. Jika ada persoalan dengan sistem, periksa sidestand switch (saklar standard samping) (hal. 15-9).



3-18



SIDESTAND



PERAWATAN



SUSPENSI SUSPENSION Bagian suspensi yang Loose, aus worn or longgar, atau damaged suspension rusak mempengarui parts impair scooter kestabilan dan stability and control. pengendalian skuter.



DEPAN FRONT Periksa Check thecara action kerja of the forks forks(garpu) by operating dengan the front menjalankan brake and compressing the front suspension several times.beberapa kali rem depan dan menekan suspensi depan Check the entire assembly for signs of leaks, damage or loose ke bawah. fasteners. keseluruhan susunan terhadap tanda-tanda Periksa kebocoran, kerusakan atau pengikat longgar. Replace damaged components which cannot be repaired.



Tightenkomponen-komponen all nuts and bolts. Ganti rusak yang tidak dapat diperbaiki. For fork service (page 11-11). Kencangkan semua baut dan mur. Untuk service fork (hal. 11-11).



FRONT FORK



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



Dukung skuter kokoh naikkan Support the scooterdengan securely and raise dan the rear wheel offroda the belakang ground. lepas tanah.



REAR SHOCK ABSORBER ENGINE MOUNTING BUSHINGS



Check for worn engine mounting bushings by grabbing the Periksa terhadap engine mounting bushings (bos-bos engine and attempting to move the wheel side to side. pemasangan mesin) yang aus dengan memegang For engine service (page 12-6). mesin dan bushing mencoba untuk menggerakkan roda dari sisi ke sisi. Untuk servis engine bushing (hal. 12-6).



3-19



PERAWATAN



NUTS,BAUT, BOLTS, FASTENERS MUR, PENGIKAT Check thatbahwa all chassis nuts and boltsdan are tightened to theirtelah corPeriksa semua baut mur rangka rect torque values (page 1-9). dikencangkan dengan nilai torsi mereka yang benar Check that all cotter pins, safety clips, hose clamps and cable (hal. 1-9). stays are bahwa in place and properly secured. Periksa semua cotter pins, safety clips, hose clamps dan cable stays berada pada tempatnya dan telah dipasang dengan erat.



WHEELS/TIRES RODA/BAN



Support the scooter centerstand. Letakkan skuter di with atas its standard utamanya. Making sure that fork the fork not allowed to move, raiseroda the Pastikan bahwa tidakisdapat bergerak, naikkan front wheel and check for play.kelonggaran. depan dan periksa terhadap Check forterhadap worn front wheel bearings by grabbing the front Periksa front wheel bearings (bantalan roda wheel and attempting to movememegang the wheel side to side. depan) yang aus dengan roda depan dan Replace the frontmenggerakkan wheel bearings ifroda any dari looseness is sisi. noted. mencoba untuk sisi ke jika diketahui Ganti front wheel bearings Turn the wheel and check that it rotates smoothly withada no kelonggaran. unusual noises.



WHEEL BEARINGS



If anyroda abnormal conditions are suspected, inspect the halus front Putar dan periksa bahwa ia berputar dengan wheel bearings (page 11-10). tanpa adanya suara-suara tidak normal. Jika ada dugaan adaya kondisi-kondisi tidak normal, periksa front wheel bearings (hal. 11-10).



Support theskuter scooter dengan securely and raise the wheel. roda Dukung kokoh danrearnaikkan 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 gear shaft bearings if anyroda looseness is belakang danfinal mencoba untuk menggerak dari sisi noted. ke sisi. Turn the wheel and check that it rotates smoothly with no Ganti gear shaft bearings bila diketahui ada unusualfinal noises. kelonggaran. If anyroda abnormal conditions are ia suspected, the halus final Putar dan periksa bahwa berputarcheck dengan reduction (pagesuara-suara 9-8). tanpa adanya tidak normal. Jika ada dugaan adanya kondisi-kondisi tidak normal, periksa final reduction (hal. 9-8).



FINAL GEAR SHAFT BEARINGS



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



PRESSURE GAUGE



3-20



PERAWATAN Check the ban tires for cuts, embedded other damage. Periksa terhadap sayatan,nails, pakuor yang tertancap, Check the front wheel atau kerusakan lain.and rear wheel for trueness. Periksa apakah TIRE roda SIZE depan dan roda belakang RECOMMENDED AND TIRE BRAND: berjalan lurus dalam satu bidang. UKURAN BAN DAN MEREK BAN FRONT REARYANG DIANJURKAN: Tire size 80/90-14M/C40P 90/90-14M/C46P Tire brand SRI FT235 FT235 DEPAN BELAKANG Measure theban tread depth at the center of the tires. Ukuran 80/9090/90Replace the tires when the tread depth reaches the following 14M/C40P 14M/C46P limits. Merek SRI FT235 FT235 ban MINIMUM TIRE TREAD DEPTH: Ukur kedalaman alur telapak ban pada tengah-tengah FRONT/REAR: To the indicator ban. Ganti ban jika kedalaman telapak ban mencapai batas sebagai berikut. KEDALAMAN ALUR TELAPAK BAN MINIMUM: DEPAN/BELAKANG: Sampai ke indikator



INDICATOR



STEERING HEAD HEAD BEARINGS BEARINGS STEERING (BANTALAN KEPALA KEMUDI)



? Check that the control cables do not interfere with handleCATATAN: bar rotation. • Periksa bahwa kabel-kabel pengontrol tidak Support the scooterperputaran with its centerstand and raise the front mengganggu handlebar. wheel off the ground. Letakkan pada standard utamanya dan naikkan Check thatskuter the handlebar moves freely from side-to-side. If roda depan lepas tanah. the handlebar moves unevenly or binds, inspect the steering Periksa bahwa handlebar head bearings (page 11-21). bergerak dengan bebas dari sisi-ke-sisi. Jika handlebar bergerak secara tidak merata atau mengikat, periksa steering head bearings (hal. 1121).



Hold the scooter check the steering bearings for Peganglah skuterand dan periksa steeringhead head bearings wear by moving thedengan fork forward and backward. terhadap keausan menggerakkan fork ke depan dan belakang. If the steering stem has vertical movement, inspect the steer-



STEM BEARINGS



STEM BEARINGS



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



4



DIAGRAM SISTEM PELUMASAN......... 4-2 LUBRICATION SYSTEM DIAGRAM????? 4-2



TROUBLESHOOTING ........................... 4-3 TROUBLESHOOTING ????????????????? 4-3



KETERANGAN SERVIS ........................ SERVICE INFORMATION ?????????????? 4-3 4-3



OIL PUMP .............................................. 4-4 PUMP ???????????????????????????? 4-4



4-1



SISTEM PELUMASAN



LUBRICATION SYSTEM DIAGRAM DIAGRAM SISTEM PELUMASAN LUBRICATION SYSTEM



ROCKER ARM SHAFT



CAM SHAFT



PISTON



CRANKSHAFT



OIL PUMP



OIL STRAINER SCREEN



4-2



SISTEM PELUMASAN



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



Oil oil pump (pompa dapat diservis mesin terpasang pada rangka. The pump can beoli) serviced with the dengan engine installed in the frame. The service procedures in this sectionbab must performed withdengan the engine oil drained. Prosedur-prosedur servis di dalam ini be harus dijalankan oli mesin dikeluarkan. When and installing the oil pump, use berhati-hatilah care not to allow dustdebu or dirt to enter thetidak engine. Ketikaremoving melepaskan dan memasang oil pump, agar atau kotoran memasuki mesin. If any portion of the oil pump is worn beyond the specified service limits, replace the oil pump as an assembly. Jika ada bagian dari oil pump yang aus melampui batas servis yang ditentukan, gantilah oil pump sebagai sebuah susunan. After the oil pump has been installed, check that there are no oil leaks. Setelah oil pump telah dipasang, periksa bahwa tidak ada kebocoran oli.



SPECIFICATIONS



SPESIFIKASI



Unit: mmmm (in) Satuan: SERVICE STANDARD BATAS SERVIS BAGIAN 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 Honda "4-stroke motorcycle oil" or equivamesin lent motor oil Oli mesin yang dianjurkan Federal Oil Supreme Flick atau mesin 4 tak API classification: SGoli or higher sejenis dengan(except klasifikasi API service SG, conserving– oils labeled as energy Viskositas: SAE JASO on10W-30 the circular APIMB service label) JASO T 903 standard: MB Oil pump rotor Jarak renggang pada 0,15 0,20 Viscosity: SAE 10W-30 ujung rotor Oil pump rotor Tip clearance 0.20 (0.008) Jarak renggang antara 0,15 – 0,21 0.15 (0.006) 0,35 0.35 (0.014) Body clearance – 0.21 (0.006 – 0.008) 0.15 rotor dan rumah clearance 0.12 (0.005) Jarak renggang Sideke 0,05 – 0,10 0.05 – 0.10 (0.002 – 0.004) 0,12 samping rotor pompa



TORQUE VALUES NILAI TORSI Oil pump plate screw Oil pump mounting bolt Oil pump plate screw Oil pump mounting bolt



3 N·m (0.3 kgf·m, 2.2 lbf·ft) 10 N·m (1.0 kgf·m, 7 lbf·ft) 3 N.m (0,3 kgf.m; 2,2 lbf.ft) 10 N.m (1,0 kgf.m; 7 lbf.ft)



TROUBLESHOOTING Engine oil level too low, high oil consumption TROUBLESHOOTING



• External oil leak • Worn piston ringsoli or mesin incorrect pistonrendah, ring installation (pageoli7-35) Tinggi permukaan terlalu pemakaian tinggi • Worn cylinder (page 7-33) • Ada kebocoran oli di luar • Worn valve guide or seal (page 7-24) • Piston rings aus atau pemasangan piston ring tidak benar (hal. 7-34) •Oil contamination Cylinder aus (hal. 7-32) not changed often •• Oil Valve guide atau 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 the oiloil pump, do not allow dust dirt • • When Ketikaremoving melepaskan pump, jagalah atar or debu to enter the engine. atau kotoran tidak memasuki mesin. Drain the engine oil (page 3-10). Keluarkan ollialternator mesin (hal. 3-10). Remove the (page 14-7).



Lepaskan alternator (hal. 14-8). Remove the following: – Oil pump coverberikut: bolts Lepaskan sebagai – Oil pump cover - –OilO-ring pump cover bolts - –OilOil pump cover pump driven gear Oil pump bolts - –O-ring pump assembly - –OilOil pump driven gear - Oil pump bolts - Oil pump assembly



OIL PUMP ASSEMBLY



O-RING OIL PUMP DRIVEN GEAR



OIL PUMP COVER



Lepaskan oil pump cover dengan menggunakan baut-baut 5 mm. OIL PUMP BOLTS



5 mm BOLTS



OIL PUMP COVER BOLTS



4-4



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



OIL PUMP



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



BOLTS



oil Semprotkan oil pump gearoildan Apply engineolioilmesin to the pada oil pump drivendriven gear and pump pump shaft. shaft.



DRIVEN GEAR



Tepatkan



Install the oil pump driven gear to the oil pump by alignPasang oil pump pada oilcut-out. pump dengan ing the driven gear driven cut-out gear with oil pump mentepatkan potongan pada driven gear dengan potongan pada oil pump.



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



O-RING



Pasang oil pump cover pada right crankcase.



OIL PUMP COVER



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



BOLTS



4-5



SISTEM PELUMASAN PEMBONGKARAN/PERAKITAN DISASSEMBLY/ASSEMBLY Remove the following: Lepaskan sebagai berikut: – Dowel pins - Dowel pins – Screw -– Screw Pump plate -– Pump Outerplate rotor -– Outer Innerrotor rotor - •Inner rotor Apply engine oil to the inner rotor and outer rotor. Assembly is in theolireverse disassembly. • Semprotkan mesinorder padaofinner rotor dan outer rotor. TORQUE:OIL PUMP PLATE SCREW



3 N·m (0.3 kgf·m, 2.2 lbf·ft) Perakitan adalah dalam urutan pembongkaran.



terbalik



dari



TORSI: OIL PUMP PLATE SCREW 3 N.m (0,3 kgf.m; 2,2 lbf.ft) PUMP PLATE



DOWEL PINS



OUTER ROTOR



PUMP BODY



INNER ROTOR



4-6



SCREW 3 N·m (0.3 kgf·m, 2.2 lbf·t)



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



•



Kerenggangan pada ujung inner rotor :



BATAS SERVIS: 0,20 mm



Jarak renggang antara outer rotor dan badan Body clearance Ukur jarakthe renggang oil pump Measure clearanceantara between the oil body pump dan bodyouter and the outer rotor with gauge. a feeler gauge. rotor dengan feeler



SERVICE BATAS 0,35 mm mm(0.014 in) LIMIT: SERVIS: 0.35



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



Kerenggangan antara outer dan badan :



Kerenggangan ke samping:



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



4-7



CATATAN



5. SISTEM BAHAN BAKAR



5



LOKASI KOMPONEN .............................. COMPONENT LOCATION ?????????????5-2 5-2



PEMBERSIHAN KARBURATOR.............5-17 5-17 CARBURETOR CLEANING????????????



DIAGRAM SISTEM .................................. SYSTEM DIAGRAM ???????????????????5-3 5-3



PEMERIKSAAN KARBURATOR............. 5-18 CARBURETOR INSPECTION ?????????? 5-18



KETERANGAN SERVIS .......................... SERVICE INFORMATION ??????????????5-4 5-4



PENYETELAN SCREW................ 5-20 PILOT SCREWPILOT ADJUSTMENT ????????? 5-20



TROUBLESHOOTING TROUBLESHOOTING............................. ?????????????????5-5 5-5



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



AIR CLEANER AIR CLEANERHOUSING HOUSING....................... ??????????????5-6 5-6



SECONDARY AIR SUPPLY SUPPLYSYSTEM SYSTEM..... 5-23 SECONDARY AIR ??? 5-23



PELEPASAN KARBURATOR ................. 5-8 CARBURETOR REMOVAL ????????????? 5-8



TANGKI BAHAN BAKAR ........................5-26 5-26 FUEL TANK ?????????????????????????



PEMASANGAN 5-10 CARBURETORKARBURATOR INSTALLATION............. ??????? 5-10



FUEL 5-27 FUELAUTO AUTO VALVE VALVE ................................ ?????????????????? 5-27



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



5-1



SISTEM BAHAN BAKAR



COMPONENT LOCATION LOKASI KOMPONEN FUEL SYSTEM



5-2



SISTEM BAHAN BAKAR



SYSTEM DIAGRAM DIAGRAM SISTEM MAIN FUSE 15A



SUB FUSE 10A



Bl Br



3P



Bl



Bl



6P



G



R/Bl



R



4P



G/O



2P



G



G/O



R/Bl



R/Bl



R



R



R/Bl



IGNITION CONTROL MODULE (ICM)



BATTERY



IGNITION SWITCH



STARTER ENRICHMENT (SE) THERMAL VALVE



5-3



SISTEM BAHAN BAKAR



SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM •? ? • ? •?



Bending or atau twisting the control cable will impair smooth operation and could causedan the dapat cable to stick or bind,bahwa resulting in loss of Menekuk memilin kabel pengontrol akan mengganggu kelancaran kerjanya menyebabkan kabel macet vehicle control. atau in mengikat, sehingga mengakibatkan hilangnya pengaturan atas Work a well ventilated area. Smoking or allowing flames or sparks in kendaraan. the work area or where gasoline is stored can cause a fire orBekerjalah explosion.di ruangan dengan ventilasi baik. Merokok atau membiarkan lidah api atau percikan bunga api di tempat kerja atau When disassembling fuel system parts, notemengakibatkan the locations of kebakaran the O-rings.atau Replace them with new ones on reassembly. di tempat di mana bensin disimpan dapat ledakan. Before disassembling the parts carburetor, a suitable carburetor hose.yang Loosen thepada drain waktu screw and drain Sewaktu membongkar sistemplace bahan bakar, container catatlah under lokasi the O-rings. Gantidrain dengan baru perakitan the carburetor. kembali. ? After removing the carburetor, wrap the intake port of the engine with a shop towel or cover it with pieces of tape to prevent any for• eign Sebelum membongkar karburator, letakkan penampung yang sesuai di bawah carburetor drain hose (slang pembuangan material from dropping into the engine. karburator). Longgarkan drain screw (sekrup pembuangan) dan kosongkan karburator. • Setelah melepaskan karburator, bungkuslah lubang pemasukan mesin dengan kain lap atau tutuplah dengan pita perekat SPECIFICATIONS untuk mencegah masuknya benda asing ke dalam mesin.



ITEM



SPESIFIKASI Carburetor identification number



Main jet BAGIAN Slow jet Nomor identifikasi karburator SE thermal valve resistance Main jet Float level Slow Pilot jet screw initial opening Tahanan listrik SE thermal valve Engine idle speed Tinggi pelampung PAIR control valve specified vacuum Throttle grip awal free play Pembukaan pilot screw Putaran stasioner mesin Vakuum PAIR control valve yang ditentukan TORQUE VALUES Jarak main bebas throttle grip Inlet pipe band screw



NILAI TORSI SE thermal valve body screw SE thermal valve setting plate screw Inlet pipe band screw cover screw SEVacuum thermal chamber valve body screw Slow jet SE thermal valve setting plate screw Main jet Vacuum chamber cover screw Needle Slow jet jet holder Float Main jet chamber screw Floatjet chamber Needle holder drain screw PAIR check valve Float chamber screwcover screw Float chamber drain screw Fuel auto valve lock nut PAIR check valve cover screw Fuel auto valve lock nut



TOOLS TOOLS



Pin driver 07744-0010100



5-4



SPECIFICATIONS AVK2CH #100 SPESIFIKASI #35 AVK2CH 3.2 – 5.6 Ω (25°C/77°F) # 100 13.0 mm (0.51 in) # 35 See page 5-20 3,2 – 5,6 Ω (20° C) 1,700 ± 100 min-1 (rpm) 13,0 mm 60 kPa (450 mmHg) Lihat halaman 5-20 2 – 6 mm (0.1 – 0.2 in) -1 1.700 ± 100 menit (rpm) 60 kPa (450 mmHg) 2 – 6 mm



2 N·m (0.2 kgf·m, 1.5 lbf·ft) 3.4 N·m (0.4 kgf·m, 2.5 lbf·ft) 2.1 N·m (0.2 kgf·m, 1.5 lbf·ft) 2 N.m (0-,2 kgf.m; 1,5 lbf.ft) 2.1 ·m (0.2 kgflbf.ft) ·m, 1.5 lbf·ft) 3,4 N.m (0,4 N kgf.m; 2,5 1.5 N · m (0.2 kgf ·m, 1.1 lbf·ft 2,1 N.m (0,2 kgf.m; 1,5 lbf.ft) 2.1 N ·m (0.2 kgflbf.ft) ·m, 1.5 lbf·ft) 2,1 N.m (0,2 kgf.m; 1,5 2.5 N ·m (0.3 kgflbf.ft) ·m, 1.8 lbf·ft) 1,5 N.m (0,2 kgf.m; 1,1 2.1 N ·m (0.2 kgflbf.ft) ·m, 1.5 lbf·ft) 2,1 N.m (0,2 kgf.m; 1,5 1.5 N ·m (0.2 kgflbf.ft) ·m, 1.1 lbf·ft) 2,5 N.m (0,3 kgf.m; 1,8 2.1kgf.m; N·m (0.2 ·m, 1.5 lbf·ft) 2,1 N.m (0,2 1,5 kgf lbf.ft) 1,5 N.m (0,2 1,1kgf lbf.ft) 22.5kgf.m; N·m (2.3 ·m, 17 lbf·ft) 2,1 N.m (0,2 kgf.m; 1,5 lbf.ft) 22,5 N.m (2,3 kgf.m; 17 lbf.ft)



Carburetor float level gauge 07401-0010000



SISTEM BAHAN BAKAR



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



5-5



SISTEM BAHAN BAKAR



AIR CLEANER CLEANER HOUSING HOUSING AIR REMOVAL PELEPASAN Remove the following: Lepaskan sebagai berikut: Luggagebox box(hal. (page 2-7) -? Luggage 2-7) Bodycover cover(hal. (page 2-9) -? Body 2-9) Leftcrankcase crankcasecover coverduct duct(hal. (page2-12) 2-12) -? Left



PAIR CONTROL VALVE



BOLTS



Remove the two PAIR valve mounting bolts bolts and Lepaskan kedua PAIRcontrol control valve mounting disconnect the valve from the air cleaner housing. (baut pemasangan PAIR control valve) dan lepaskan Disconnect the crankcase breather hose from the air valve dari air cleaner housing. cleaner housing. Lepaskan crankcase breather hose (slang pernapasan bak mesin) dari air cleaner housing.



CRANKCASE BREATHER HOSE Loosen the connecting band screw. Longgarkan connectinghose hose band screw (sekrup pita Disconnect the vacuum piston hose from the air cleaner slang penyambung). housing.



BAND SCREW



Lepaskan vacuum piston hose dari air cleaner housing.



VACUUM PISTON HOSE



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



BOLTS



BREATHER DRAIN HOSE



Be Hati-hati careful not to agar damage the air tidak merusak air cleaner cleanerconnecting connecting hose. hose.



BREATHER HOSE



CLAMP



Remove the from right side. Lepaskan boltbolt dari sisithe kanan. Disconnect the connecting hose from the carburetor by Lepaskan hose dari dengan holding the connecting carburetor and pulling thekarburator air cleaner housing memegang karburator dan menarik air cleaner housing backward. ke belakang. Remove the air cleaner housing from the right side of the frame. Lepaskan air cleaner housing dari sisi kanan dari rangka.



AIR CLEANER HOUSING BOLT



5-6



SISTEM BAHAN BAKAR PEMASANGAN INSTALLATION Install the cleaner housing the right of the Pasang air air cleaner housing darifrom sisi kanan dariside rangka. frame. dengan Sambungkan connectinghose hose Connect the connecting to ke the karburator carburetor by holdmemegang karburator dengan hati-hati ing the carburetor and dan carefully pushing the mendorong air cleaner air cleaner housing ke depan. housing forward.



BAND SCREW



CONNECTING HOSE



Be careful not to Hati-hati damage theagar air tidak merusak air cleaner connecting cleaner connecting Set the connecting hose band as shown. hose. hose.



Tempatkan seperti diperlihatkan. Tighten the connecting band screwhose until band the band seats on the collar Kencangkan band screw sampai band duduk pada as shown. collar seperti diperlihatkan.



75°



VACUUM PISTON HOSE



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



PAIR CONTROL VALVE



BOLTS



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



AIR CLEANER HOUSING BOLT Install and the two boltsbolts to the left sisi sidekiriofdari air pada Pasang dantighten kencangkan kedua cleaner housing. air cleaner housing. Set the crankcase breather drain hose to the clamp on Tempatkan crankcase breather drain hose pada clamp the air cleaner housing. pada cleaner Insertairthe final housing. reduction breather hose into the air Masukkan final reduction breather hose ke dalam air cleaner housing. cleaner housing. Install the following:



BOLTS



BREATHER HOSE



? Left crankcase cover duct (page 2-12) Pasang sebagai berikut: ? Body cover (page 2-9) Luggage box (page -? Left crankcase cover2-7) duct (hal. 2-12) - Body cover (hal. 2-9) - Luggage box (hal. 2-7) BREATHER DRAIN HOSE



CLAMP



5-7



SISTEM BAHAN BAKAR



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



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



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



FLOAT CHAMBER DRAIN SCREW CLAMP



CARBURETOR DRAIN HOSE



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



SE THERMAL VALVE 3P CONNECTOR



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



WIRE GUIDE



WIRE CLAMPS



5-8



SISTEM BAHAN BAKAR Release the crankcase breather from the Lepaskan crankcase breather draindrain hose hose dari clamp. clamp. Lepaskan kedua air cleaner housing mounting bolts dari Remove the two air cleaner housing mounting bolts from sisi the kiri. left side of air cleaner housing. Lepaskan boltbolt darifrom sisi the kanan dari air of cleaner housing. Remove the right side air cleaner housing.



Kanan



Kiri: BOLTS



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



LOCK NUT



CLAMP THROTTLE CABLE



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



BAND SCREWS



Longgarkan inlet pipe band screw dan lepaskan karburator dari inlet pipe.



FUEL HOSE



VACUUM PISTON HOSE



5-9



SISTEM BAHAN BAKAR



CARBURETOR INSTALLATION PEMASANGAN KARBURATOR Connect the carburetor to the inlet pipe while aligning the



Sambungkan karburator pada inlet pipe sementara agar BeHati-hati careful not to tab of the carburetor with the groove of the inlet pipe. mentepatkan tab dari karburator dengan alur dari inlet tidak merusak inlet damage the inlet pipe. pipe. pipe.



Be careful to Hati-hati agarnot tidak damage the air merusak air cleaner connecting hose. cleaner connecting hose.



Connect the airair cleaner connecting hose to hose the carburepada Sambungkan cleaner connecting tor while holding the carburetor carefullydan pushing the karburator sementara menahanand karburator dengan air cleaner housing forward. hati-hati mendorong air cleaner housing ke depan. Tighten the inlet pipe band screw to the specified torque.



Tepatkan



CARBURETOR



CONNECTING HOSE



TORQUE:2 N·m kgf·m, lbf·ft)dengan torsi yang Kencangkan inlet (0.2 pipe band1.5screw ditentukan. Set the air cleaner connecting hose band by the specified angle. Tighten 2 the connecting hose TORSI: N.m (0,2 kgf.m; 1,5band lbf.ft)screw until the band seats on the collar as shown.



Tempatkan air cleaner connecting hose band dengan sudut yang ditentukan. Kencangkan connecting hose band screw sampai band duduk pada collar seperti diperlihatkan.



BAND SCREWS INLET PIPE BAND SCREW



ATAS



75°



CONNECTING HOSE BAND SCREW



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



THROTTLE CABLE



Tempatkan carburetor air vent hose pada intake shroud seperti diperlihatkan.



AIR VENT HOSE



5-10



FUEL HOSE



VACUUM PISTON HOSE



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



Kanan



BOLTS



BOLT



Route the wire Alurkan wire harness properly harness (pagedengan 1-14). benar (hal. 1-14).



Secure thekedua two SE the Kokohkan SE thermal thermal valve valvewire wireclamps clampstopada frame. rangka. Set the SE thermal valve wirewire to the wirewire guide. Tempatkan SE thermal valve pada guide.



Kiri:



BREATHER DRAIN HOSE



CLAMP



WIRE GUIDE



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



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



CLAMP



CARBURETOR DRAIN HOSE



5-11



SISTEM BAHAN BAKAR



CARBURETOR DISASSEMBLY/ PEMBONGKARAN/PERAKITAN ASSEMBLY KARBURATOR



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



PIN DRIVER



FLOAT PIN



2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)



DIAPHRAGM/ VACUUM PISTON



VACUUM CHAMBER COVER



FLOAT VALVE



FLOAT FLOAT PIN SE THERMAL VALVE COVER



O-RING DRAIN SCREW 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)



FLOAT CHAMBER



SE THERMAL VALVE



O-RING



COMPRESSION SPRING



O-RING WASHER



NEEDLE HOLDER



SPRING



SPRING NEEDLE JET



JET NEEDLE



SLOW JET 1.5 N·m (0.2 kgf·m, 1.1 lbf·ft)



2.1 N·m (0.2 kgf·m, 1.5 lbf·ft) SETTING PLATE



PILOT SCREW O-RING NEEDLE JET HOLDER 2.5 N·m (0.3 kgf·m, 1.8 lbf·ft)



MAIN JET 2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)



5-12



2.1 N·m (0.2 kgf·m, 1.5 lbf·ft)



SE THERMAL VALVE BODY O-RING



3.4 N·m (0.4 kgf·m, 2.5 lbf·ft)



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



NEEDLE JET



WASHER MAIN JET PILOT SCREW



Kerusakan Damageakan to theterjadi pilot padaseat dudukan pilot screw will occur screw jika pilot screw if the pilot screw is dikencangkan terhadap tightened against the kedudukannya. seat.



Pasang O-ring, dan Install the O-ring,washer, washer,spring springdan and pilot pilot screw screw and kembalikan keoriginal tempatnya semula seperti telahremoval. dicatat return it to its position as noted during pada waktu prosedur penyetelan pilot Perform the pelepasan. pilot screw Jalan adjustment procedure if a new pilot screw is installed (page 5-20) . screw seperti bila sebuah pilot screw baru telah dipasang Install the(hal. float5-20). and float valve in the carburetor body, then install the float pin through the body and float. Pasang float dan float valve di dalam badan karburator, kemudian pasang float pin melalui badan dan float.



NEEDLE JET HOLDER



O-RING



SPRING



FLOAT PIN



SLOW JET FLOAT VALVE



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



TOOL: TOOL: Pin driver driver Pin



PIN DRIVER



07744-0010100 07744-0010100



0.15 – 0.55 mm (0.006 – 0.022 in)



FLOAT PIN Install a new O-ring into the float chamber. Pasang O-ring baru ke dalam float chamber Install thesebuah float chamber. (ruang pelampung). Pasang float chamber.



FLOAT CHAMBER



O-RING



5-13



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



SCREWS



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



VACUUM PISTON



JET NEEDLE SPRING



NEEDLE HOLDER



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



Be careful not to damage theagar jet Hati-hati needle. tidak merusak jet needle.



Install thediaphragm/vacuum diaphragm/vacuum piston piston into carburetor Pasang ke the dalam badan body aligning the diaphragm tab with the groove on the karburator dengan mentepatkan diaphragm tab dengan carburetor body. alur pada badan karburator. Hold the vacuum piston almost full open to prevent the diaphragm from being pinched by the chamber cover. Tahan vacuum piston hampir terbuka penuh untuk Install the compression spring into the piston. menghindari dijepitnya diaphragm olehvacuum chamber cover. Set the boss of the vacuum chamber cover to the compressioncompression spring and install the cover. piston. Pasang spring kechamber dalam vacuum



NEEDLE HOLDER



Tempatkan



VACUUM CHAMBER COVER SPRING Tepatkan



Tempatkan boss dari vacuum chamber cover pada compression spring dan pasang chamber cover. DIAPHRAGM/ VACUUM PISTON



5-14



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



SCREWS



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



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



SPRING



PISTON



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



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



SE THERMAL VALVE BODY



TORSI: 3,4 N.m (0,4 kgf.m; 2,5 lbf.ft)



SCREW



5-15



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



SE THERMAL VALVE



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



Install the setting Pasangplate setting withplate the dengan ujung yang edge telah chamfered dipotong menghadap ke facing up. atas.



Pasang setting plate pada Install the setting plate ontoalur the SE SE thermal thermal valve. valve groove. Install and tighten the setting plate screw to the specified Pasang dan kencangkan setting plate screw dengan torque. torsi yang ditentukan. TORQUE:2.1 N·m (0.2 kgf·m, 1.5 lbf·ft) TORSI: 2,1 N.m (0,2 kgf.m; 1,5 lbf.ft)



SETTING PLATE



Atur



SCREW



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



SE THERMAL VALVE COVER



5-16



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



AIR VENT HOSE



CARBURETOR DRAIN HOSE



CARBURETOR CLEANING PEMBERSIHAN KARBURATOR



Do not use a piece of wireJangan to cleanmemakai the air kawat untuk andseutas fuel passage as it membersihkan saluran could damage the lintasan bahan body. bakar carburetor oleh karena dapat merusak badan karburator.



Remove the following: Lepaskan sebagai berikut: ? SE thermal valve - SE thermal valve Diaphragm/vacuumpiston piston -? Diaphragm/vacuum ? Float/float valve -? Float/float valvejet/needle jet/needle jet holder Main jet/slow -Blow jet/slow jet/needle jet/needle jet in holder ? Main Pilot screw/spring/washer/O-ring open all air and fuel passages the carburetor -body Pilotwith screw/spring/washer/O-ring compressed air. Tiuplah semua lubang terbuka dan lintasan bahan bakar di dalam badan karburator dengan udara dari kompressor.



5-17



SISTEM BAHAN BAKAR



CARBURETOR INSPECTION PEMERIKSAAN KARBURATOR SE VALVE SE THERMAL THERMAL VALVE VALVE/NEEDLE INSPECTION PEMERIKSAAN VALVE/NEEDLE Lepaskan SESE thermal valve (hal. 5-12). Remove the thermal valve (page 5-12).



VALVE



Inspect valve the valve needle for stepped wearbertingkat or damterhadap keausan Periksa danand needle age. kerusakan. atau



SE THERMAL VALVE



PEMERIKSAAN VALVE THERMOWAX



Pemeriksaan tahanan SE The SE thermal valve thermal valve dapat resistance inspection dengan candilakukan be done with the karburator terpasang carburetor installed pada mesin. to the engine.



NEEDLE



VALVE THERMOWAX Measure the resistance atINSPECTION the connector terminals of the Ukur tahanan pada connector terminals dari sisi SE SE thermal valve side. thermal valve. CONNECTION: Black – Green/Orange HUBUNGAN: Hitam STANDARD: 3.2 – 5.6–ΩHijau/Jingga (at 25°C/77°F) STANDARD: 3,2 – 5,6 Ω (pada 25° C) If the resistance is abnormal, replace the SE thermal Jika tahanan tidak normal, gantilah SE thermal valve. valve.



PEMERIKSAAN CARA KERJA VALVE



Bl



G/O



Jika mesin telah dijalankan, biarkan mendingin (di bawah 35° C) selama 30 menit atau lebih. Lepaskan SE thermal valve body (hal. 5-12). Masukkan slang vinyl ke dalam fuel enrichment circuit (rangkaian pengkayaan bahan bakar) dan tiuplah ke VALVE OPERATION INSPECTION dalam hose. If the engine has been running, let it cool down (below °C (95 °F)) for ke 30 dalam minutes or more. Udara 35 harus mengalir rangkaian.



SE THERMAL VALVE 3P CONNECTOR



SE THERMAL VALVE



Remove the SE12thermal valve (page valve 5-12). 3P Hubungkan baterai V pada SEbody thermal connector terminals 5 menit. Insert a vinyl dan hosetunggu into the fuel enrichment circuit and Masukkan vinyl ke dalam fuel enrichment circuit blow slang into the hose. dan tiuplah ke dalam slang. Air should flow into the circuit. Connect the 12 V battery to the SE thermal valve 3P conUdara nector tidak boleh mengalir ke dalam rangkaian. terminals and wait 5 minutes. Insert a vinyl hose into the fuel enrichment Jika cara kerja tidak normal, ganti SE thermal valve.circuit and blow into the hose. Pasang thermal (hal.the 5-15). AirSE should not valve flow into circuit. If operation is abnormal, replace the SE thermal valve. Install the SE thermal valve (page 5-15).



5-18



FUEL ENRICHMENT CIRCUIT



SE THERMAL VALVE 3P CONNECTOR



SISTEM BAHAN BAKAR SYSTEM INSPECTION PEMERIKSAAN SISTEM performing the systempemeriksaan inspection, make sure • ? Before Sebelum menjalankan sistem, that the following is normal. yang berikut adalah normal. ?pastikan Battery bahwa condition Kondisi baterai ?- Fuse - Sekring Remove the center body cover (page 2-8).



Lepaskan center body covervalve (hal.3P 2-8). Disconnect the SE thermal connector. Turn If the engine has been Jika mesin telah Lepaskan SE thermal valve 3P connector.



running, letbiarkan it cool dijalankan, mendingin (di Putar kunci kontak ke "ON". down dulu (below bawah C)°F)) selama 30 Ukur voltase pada sisi wire harness dari SE thermal 35°35 C °(95 for 30 menit atau lebih. valve connector. minutes or more.



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



Black (+) – Green/Orange (–) periksa Jika ada voltase baterai pada setiap waktu, •CONNECTION: STANDARD: Battery voltage sebagai berikut: - Hubungan singkat pada kawat Hijau/Jingga dari ? If there is battery voltage at all time, check the following:SE thermal valve • ?Jika tidak ada involtase baterai valve pada Green/Orange setiap waktu, Short circuit SE thermal wire sebagai berikut: periksa ? If- there is no voltage all time, check the following: Rangkaian terbukaatpada kawat Hitam ?- Open circuit in Black wire Rangkaian terbuka pada kawat Hitam dari SE ? Open circuit in SE thermal valve Black wire and/or thermal valve dan/atau kawat-kawat Hijau/Jingga. Green/Orange wires • ? IfJika kawat-kawat adalah normal, gantilah ICM the wires are normal, replace the ICM with a new one, and yang recheck. dengan baru, dan periksa kembali.



SE THERMAL VALVE 3P CONNECTOR



TO MAIN FUSE R/Bl Bl R R/Bl



R/Bl



G/O



ICM R R/Bl



SE THERMAL VALVE 3P CONNECTOR



VACUUM CHAMBER (RUANGAN VAKUUM) Lepaskan vacuum chamber (hal. 5-12). Periksa sebagai berikut: -VACUUM Jet needle terhadap keausan bertingkat CHAMBER - Vacuum piston terhadap keausan atau kerusakan the vacuum chamber (page 5-12) terhadap lubang kecil,. pemburukan -Remove Diaphragm kondisi kerusakan Check theatau following:



IGNITION SWITCH



VACUUM PISTON



? Jet needle for stepped wear ? Vacuum piston for wear or damage ? Diaphragm for pin holes, deterioration or damage



JET NEEDLE



DIAPHRAGM



5-19



SISTEM BAHAN BAKAR FLOATCHAMBER CHAMBER FLOAT Remove the float (page 5-12).(hal. 5-12). Lepaskan float (pelampung) Check the float for damage. Periksa float terhadap kerusakan. Replace the float if there is fuel in the float. Ganti float jika ada bahan bakar di dalam float. Inspect the float valve seat for scores, scratches, clogs and damage. Periksa float valve seat (dudukan katub pelampung) Check the tip of the float valve where it contacts the terhadap goresan, sumbatan dan kerusakan. valve seatgerusan, for stepped wear or contamination. di tempat di mana ia Periksa ujung dari float valve Replace the valve if the tip is worn or contaminated. mengadakan kontak dengan valve seat terhadap Check the operation of the float valve. keausan bertingkat atau kontaminasi. Push valve the pin the floataus valve make sure that it Ganti bilaon ujungnya atauand terkontaminasi. returns smoothly. Periksa cara kerja dari float valve. Dorong pin pada float valve dan pastikan bahwa ia kembali dengan lancar.



PIN



FLOAT



FLOAT VALVE VALVE SEAT



(page 5-13). Install the float valve and float Pasang float valve dan float (hal. 5-13). Set the float level Letakkan float level gauge so that it is gauge sedemikian perpendicular to the sehingga ia tegaklurus float permukaan chamber face at pada float the highestpada pointtitik of chamber the float. tertinggi dari float.



With the float valve seated and the float arm just touchDengan float measure valve pada posisi duduk danspecial float arm ing the valve, the float level with the tool tepat menyentuh valve, ukur float level (tinggi as shown. pelampung) dengan special tool seperti diperlihatkan. FLOAT LEVEL: 13.0 mm (0.51 in)



FLOAT LEVEL: 13,0 mm TOOL: Carburetor float level gauge TOOL:



07401-0010000



Carburetor floatbe level gauge 07401-0010000 The float cannot adjusted. Replace the float assembly if the float level is out of Float tidak dapat disetel. specification. Ganti float assembly (susunan pelampung) bila float level tidak sesuai dengan spesifikasi.



FLOAT LEVEL GAUGE



PILOT PILOTSCREW/JETS SCREW/JETS Remove pilot jet (page 5-12) Lepaskan pilotscrew screwand daneach masing-masing jet. (hal. 5-12). Check the following: Periksa sebagai berikut: ? Pilot screw needle for wear or damage -? Pilot screw needle keausan atau kerusakan Pilot screw springterhadap for deterioration -? Pilot screw spring terhadap pemburukan kondisi Each jet for clogging -? Masing-masing Each passage jet forterhadap clogging penyumbatan - Masing-masing jalan lintasan terhadap penyumbatan



NEEDLE JET NEEDLE JET HOLDER MAIN JET



SPRING PILOT SCREW



PILOT SCREWPILOT ADJUSTMENT PENYETELAN SCREW



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



•



5-20



SLOW JET



SISTEM BAHAN BAKAR IDLEDROP DROP PROCEDURE IDLE PROCEDURE (PROSEDUR PENURUNAN PUTARAN STASIONER) 1. Remove the luggage box (page 2-7).



Damage to the pilot Kerusakan akan Turn the pilot screw clockwise until it seats lightly, and screw seat pada will occur terjadi pilot Lepaskan box (hal. 2-7). given. back itluggage out to the specification if the seat pilotjika screw is 1. then screw pilot This an initial to jam the sampai final pilot screw searahprior jarum ia duduk Putarispilot screwsetting tightened against the screw dikencangkan adjustment. dengan ringan, dan kemudian putar keluar sampai seat. terhadap dudukannya.



ke spesifikasi yang telah diberikan. INITIAL OPENING: @@@ turns out Ini merupakan penyetelan awal sebelum 2. Warm the engine to screw. operating temperature. penyetelan akhir up pilot 7 PEMBUKAAN AWAL: – /8 putaran keluar Stop-and-go riding for 101minutes is sufficient.



3. Stop the engine. 2. Panaskan mesin sampai suhu operasionil. Connect a tachometer according to the tachometer Pengendaraaninstructions. jalan-dan-berhenti selama 10 menit manufacturer’s adalah cukup.



3. Matikan mesin. 4. Disconnect vacuum hose from PAIR control valve sesuai dengan petunjuk Hubungkanthetachometer and connect the vacuum pump to the PAIR control pemakaian pabrik pembuatnya. valve vacuum hose joint. Plug the vacuum hose. 5. Apply the specified toPAIR the PAIR control dan 4. Lepaskan vacuum vacuum hose dari control valvevalve vacuum hose more than 60 kPa (450 mm Hg). hubungkan vacuum pump (pompa vakuum) ke PAIR control valve vacuum hose joint. Sumbat vacuum hose. 5.



Terapkan vakuum yang ditentukan pada PAIR control valve vacuum hose lebih dari 60 kPa (450 mm Hg).



6.



Hidupkan mesin dan setel putaran stasioner dengan throttle stop screw. -1 PUTARAN STASIONER: 1.700 ± 100 menit (rpm)



7.



Putar pilot screw masuk atau keluar dengan pelan untuk mendapatkan putaran mesin tertinggi.



6. Start the engine and adjust the idle speed with the 8. throttle Buka throttle 2 atau 3 kali dengan ringan, kemudian stop screw. setel putaran stasioner dengan throttle screw. IDLE SPEED: 1,700 ± 100 min-1 (rpm) -1 PUTARAN STASIONER: 1.700 ± 100 menit 7. Turn the pilot screw in or out slowly to obtain the high(rpm) est engine speed.



PILOT SCREW VACUUM PUMP



PAIR CONTROL VALVE



PLUG



THROTTLE STOP SCREW



8. Lightly throttle 2 or 3berangsur times then ke adjust the secara dalam 9. Putar open pilot the screw idle speed with the throttle stop screw -1 sampai putaran mesin turun -1dengan 100 menit IDLE SPEED: 1,700 ± 100 min (rpm) (rpm). 9. Turn the pilot screw in gradually until the engine keluar 10. speed Putar drops pilot by screw (rpm) ke pembukaan @@@ min-1 sampai akhir. 10.Turn the pilot screw outward½to putaran the final opening. PEMBUKAAN AKHIR: keluar dari



FINAL OPENING: @@@ turns out from posisi yang diperoleh pada langkah 9 the position obtained in step 9 11. Lepaskan plug (sumbat) dari vacuum hose, 11.Disconnect the plug vacuum from thepump vacuum hose, then kemudian lepaskan dan hubungkan remove the vacuum pump and connect the vacuum vacuum hose kecontrol PAIR valve control valve hose vacuum hose hose to the PAIR vacuum joint. joint. 12.Readjust the idle speed with the throttle stop screw.



PILOT SCREW



± 100stasioner min-1 (rpm) 12. IDLE Setel SPEED: kembali 1,700 putaran dengan throttle stop screw. Install the luggage box (page 2-7). PUTARAN STASIONER: (rpm)



-1



1.700 ± 100 menit



Pasang luggage box (hal. 2-7).



5-21



SISTEM BAHAN BAKAR



INLETPIPE PIPE(PIPA MASUK) INLET REMOVAL PELEPASAN Lepaskan sebagai berikut: Remove the following: -? Left crankcase 2-12) Left crankcasecover coverduct duct(hal. (page 2-12) Luggagebox box(hal. (page 2-7) -? Luggage 2-7)



Kanan



Kiri: BOLTS



Release the crankcase breather drain hose from the Lepaskan clamp. crankcase breather drain hose dari clamp. Lepaskan ketiga airaircleaner Remove the three cleanerhousing housingmounting mountingbolts. bolts.



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



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



Sambungkan inlet karburator dengan Connect the inlet pipepipe to thepada carburetor by aligning the tab of the carburetor the groove of the alur inlet dari pipe.inlet mentepatkan tab dariwith karburator dengan Install the inlet pipe mounting nuts and tighten them. pipe. Tighten inlet the inlet band screw to the specified torque. Pasang pipepipe mounting nuts dan kencangkan.



TORQUE:2 N·m (0.2 kgf·m, 1.5 lbf·ft) Kencangkan inlet pipe band screw dengan torsi yang ditentukan. Connect the fuel auto valve vacuum hose and PAIR control valve vacuum hose to the inlet pipe. TORSI: 2 N.m (0,2 kgf.m; 1,5 lbf.ft) Sambungkan fuel auto valve vacuum hose dan PAIR control valve vacuum hose pada inlet pipe.



5-22



CLAMP NUTS



BAND SCREW GASKET



PAIR CONTROL VALVE VACUUM HOSE



NUTS



Tepatkan FUEL AUTO VALVE VACUUM HOSE



BAND SCREW



SISTEM BAHAN BAKAR Set the air cleaner housing in housing position. pada Letakkan air cleaner tempat Install and tighten the three bolts. pemasangannya. Pasang ketiga bolts. Secure dan the kencangkan crankcase breather drain hose with the clamp. Kokohkan pemasangan crankcase breather drain hose Install the following: dengan clamp.



Kiri:



Kanan:



BOLTS



? Left crankcase cover duct (page 2-12) ? Luggage box berikut: (page 2-7) Pasang sebagai - Left crankcase cover duct (hal. 2-12) - Luggage box (hal. 2-7)



BOLT



BREATHER DRAIN HOSE



CLAMP



SECONDARY AIR AIR SUPPLY SUPPLY SYSTEM SECONDARY PEMERIKSAAN SISTEM SYSTEM INSPECTION Hidupkan mesin and dan warm panaskan sampai keoperating suhu operasi Start the engine it up to normal temperature and stop the engine. normal dan matikan mesin.



AIR INTAKE PORT



Remove the PAIR air cleaner element (page 3-12). Lepaskan PAIR air cleaner element (hal. 3-12). Check that the PAIR air intake port is clean and free of Periksa bahwa PAIR air intake port (lubang pemasukan carbon deposits. PAIR) adalah bersihfouled, dan bebas dari karbon. If the port is carbon check theendapan PAIR check valve.



Jika port kotor dengan karbon, periksa PAIR check valve.



Remove the two bolts bolts dan and lepaskan disconnectPAIR the PAIR controlcontrol valve Keluarkan kedua valve the air cleaner housing (see page 5-24). dari airfrom cleaner housing (lihat hal. 5-24). Disconnect the PAIR control valve vacuum hose and Lepaskan PAIR control valve vacuum hose dan sumbat plug the hose. hose. Connect the vacuum pump to the PAIR control valve vacuum hose joint. Hubungkan vacuum pump pada PAIR control valve Start the engine and open the throttle slightly to be cervacuum tain thathose air isjoint. sucked in through the joint of the PAIR control valve. Hidupkan mesin dan buka the throttle sedikit If the air is not drawn in, check joint and supply untuk hose for clogs. memastikan bahwa udara dihisap masuk melalui joint dari control running, valve. gradually apply vacuum to the WithPAIR the engine PAIRudara control valve. Jika tidak ditarik masuk, periksa joint dan slang Check that the joint of the PAIR control valve stops drawsaluran terhadap sumbatan. ing air, and that the vacuum does not bleed.



VACUUM PUMP



PAIR CONTROL VALVE



PLUG



Sementara mesin dalam keadaan hidup, secara SPECIFIED VACUUM: 60 kPa (450 mm Hg) berangsur terapkan vakuum pada PAIR control valve. If air is drawn or if dari the specified vacuum is notterhenti mainPeriksa bahwain,joint PAIR control valve tained, replace the PAIR control valve withbocor. a new one. menarik udara, dan bahwa vakuum tidak



VAKUUM YANG DITENTUKAN: 60 kPa (450 mm Hg) Jika udara dihisap masuk, atau jika vakuum yang ditentukan tidak dapat dipertahankan, gantilah PAIR control valve dengan yang baru.



5-23



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



adalah



dalam



urutan



terbalik



PAIR CONTROL VALVE



BOLTS



VACUUM HOSE



dari



AIR SUPPLY HOSE



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



PAIR CHECK VALVE COVER



SCREW



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



PAIR CHECK VALVE



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



RUBBER SEAT



REED



5-24



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



PAIR AIR SUPPLY HOSE



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



PAIR AIR SUPPLY PIPE Remove the gasket. Lepaskan gasket.



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



GASKET Set the PAIR air supply in position. Letakkan PAIR air pipe supply pipe pada posisi pemasangannya. Apply locking agent to the PAIR air supply pipe mounting bolts as shown, then install and tighten them. Oleskan cairan pengunci pada PAIR air supply pipe mounting bolts seperti diperlihatkan, kemudian pasang dan kencangkan.



BOLTS



6.5 ± 1.0 mm (0.26 ± 0.04 in)



PAIR AIR SUPPLY PIPE



5-25



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



PAIR AIR SUPPLY HOSE



TANDA



PEMERIKSAAN



INSPECTION



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



PAIR AIR SUPPLY PIPE



FUEL TANK TANK (TANGKI BAHAN BAKAR) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan body cover (hal. 2-9). Remove the body cover (page 2-9). Wipe off spilled out Sekalah bahan bakar fuel. yang tertumpah.



FUEL HOSE



fuel Letakkan penampung di bawah Place an tempat approved container yang undersesuai the fuel auto valve and clamp the fuel auto valve dan jepithose. fuel hose dengan clamp. Disconnectfuel the fuel vacuum hosedari fromfuel the auto fuel Lepaskan hosehose danand vacuum hose auto valve, then tarik pull them out keluar of the dari holelubang on the pada rear valve, kemudian mereka fender. rear fender (spakbor belakang).



VACUUM HOSE



5-26



CLAMP



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



adalah



dalam



urutan



terbalik



BOLTS



FUEL TANK



BOLTS/COLLARS



dari



3P CONNECTOR



CLAMP



FUEL FUEL AUTO AUTO VALVE VALVE PEMERIKSAAN INSPECTION Lepaskan body cover (hal. 2-9). Remove the body cover (page 2-9). Sekalah bahan bakar penampung bakar yang di Place an approved fuelbahan container under the sesuai fuel auto Wipe off tertumpah. spilled out Letakkan yang valve and the fuel hose. fuelclamp auto valve dan jepit fuel hose dengan clamp. fuel. bawah



FUEL AUTO VALVE



FUEL HOSE



Disconnectfuel thehose. fuel hose. Lepaskan Check that the fuel does not come out from the joint of Periksa bahwa bahan bakar tidak mengalir keluar dari the fuel auto valve. joint dari fuel auto valve.



CLAMP



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



FUEL DRAIN HOSE



VACUUM PUMP



Jika aliran bahan bakar terbatasi atau tidak mengalir, gantilah fuel auto valve.



5-27



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



FUEL AUTO VALVE LOCK NUT



Longgarkan lock nut dan keluarkan fuel auto valve.



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



O-RING STRAINER SCREEN



FUEL AUTO VALVE



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



O-RING Install the fuel strainer screenpada ontofuel the auto fuel auto as Pasang fuel strainer screen valvevalve seperti shown. diperlihatkan.



FUEL AUTO VALVE



STRAINER SCREEN



5-28



SISTEM BAHAN BAKAR Install the auto valve set it in the correct Pasang fuelfuel auto valve danand tempatkan pada sudutangle yang as shown. benar seperti diperlihatkan.



45 ± 3°



Tahan fuelfuel auto valve danand kencangkan Hold the auto valve tighten thelock locknut nutdengan to the specified torsi yang torque. ditentukan.



TORQUE:22.5 N·m (2.3 kgf·m, 17 lbf·ft) TORSI: 22,5 N.m (2,3 kgf.m; 17 lbf.ft) (page 5-26). Install the tank Pasang fuelfuel tank (hal. 5-26).



FUEL AUTO VALVE LOCK NUT



5-29



CATATAN



6. PENURUNAN / PEMASANGAN MESIN



6 COMPONENT LOCATION ????????????? 6-2 LOKASI KOMPONEN ............................6-2



ENGINE REMOVAL ??????????????????? 6-4 PENURUNAN MESIN ............................6-4



SERVICE INFORMATION ?????????????? 6-3 KETERANGAN SERVIS ........................6-3



ENGINE INSTALLATION ?????????????? 6-6 PEMASANGAN MESIN .........................6-6



6-1



PENURUNAN / PEMASANGAN MESIN



COMPONENT LOCATION LOKASI KOMPONEN ENGINE REMOVAL/INSTALLATION



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



6-2



PENURUNAN / PEMASANGAN MESIN



SERVICE INFORMATION KETERANGAN SERVIS UMUM GENERAL •• • • • •



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



SPESIFIKASI



Engine dry weight Engine oil capacity BAGIAN Berat kosong mesin Kapasitas oli mesin



TORQUE VALUES



ITEM After draining After disassembly Pada penggantian periodik Setelah pembongkaran mesin



Engine hanger link nut (Engine side)



NILAI TORSI



Engine hanger link nut (sisi Mesin)



SPECIFICATIONS 24.9 kg (54.9 lbs) 0.7 liter (0.7 US qt, 0.6 lmp qt) SPESIFIKASI 0.8 liter (0.8 US qt,24,9 0.7 kg lmp qt) 0,7 liter 0,8 liter



49 N·m (5.0 kgf·m, 36 lbf·ft)



49 N.m (5,0 kgf.m; 36 lbf.ft)



6-3



PENURUNAN / PEMASANGAN MESIN



ENGINE REMOVAL PENURUNAN MESIN Remove the following: Lepaskan sebagai berikut: – Under cover (page 2-10) - Under cover (hal. 2-10) Center body cover (page 2-8) – - Center body cover (hal. 2-8) Luggagebox box(hal. (page 2-7) -– Luggage 2-7)



SPRING



ADJUSTING NUT



Remove the rear brake adjusting nut and joint pin from Lepaskan rear cable. brake adjusting nut dan joint pin dari rear the rear brake brake cable. Remove the return spring from the brake arm. Lepaskan return spring dari brake arm.



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



JOINT PIN



BRAKE CABLE



CABLE CLAMP/ BOLT



CABLE HOLDER



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



WIRE CLAMP



Remove the bolt and ground cables. Disconnect thedan following Lepaskan bolt groundconnectors: cables. – Alternator 3P connector Lepaskan connectors berikut ini: – Starter motor 2P connector SE thermal 3P connector - –Alternator 3P valve connector - Starter motor 2P connector - SE thermal valve 3P connector



BOLT/GROUND CABLES



SPARK PLUG CAP



ALTERNATOR 3P CONNECTOR



SE THERMAL VALVE 3P CONNECTOR STARTER MOTOR 2P CONNECTOR



6-4



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



SE THERMAL VALVE WIRE CLAMP



ALTERNATOR WIRE CLAMP STARTER MOTOR WIRE CLAMP Disconnect the following: Lepaskan sebagai berikut: – Fuel hose -–Fuel hose Fuel auto valve vacuum hose - Fuel auto valve vacuum hose Loosen the lock nut and disconnect the throttle cable. Longgarkan lock nut dan lepaskan throttle cable.



THROTTLE CABLE



FUEL HOSE



LOCK NUT VACUUM HOSE



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



SHOCK ABSORBER



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



NUT/BOLT



6-5



PENURUNAN / PEMASANGAN MESIN



ENGINE INSTALLATION PEMASANGAN MESIN Maneuver mesin the engine into therangka frame from sidedari of Gerakkan ke dalam dari the sisi right kanan the vehicle. kendaraan. Set the engine straight the frame the Tempatkan mesin lurus with dengan rangkaand danpush 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 tightenhanger the nut to thebolt specified Pasang engine link (bauttorque. penyambung penggantung mesin) dari sisi kiri dari skuter. TORQUE:49 N·m (5.0 kgf·m, 36 lbf·ft)



Pasang dan kencangkan nut dengan torsi yang ditentukan.



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



To ease installation of Untuk mempermudah the rear shock pemasangan shock absorberrear mounting absorber mounting bolt, bolt, slightly lift the angkat roda belakang rear sedikit. wheel.



NUT/BOLT



Tempatkan sedemikian Set the rearshock shockabsorber absorberbelakang so that the bolt holesrupa are sehingga aligned. lubang-lubang bolt telah disejajarkan. Install and tighten the rear shock absorber lower mountPasang ing bolt. dan kencangkan rear shock absorber lower mounting bolt (baut pemasangan bawah sokbreker belakang.



SHOCK ABSORBER



MOUNTING BOLT



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



THROTTLE CABLE



FUEL HOSE



- Fuel auto valve vacuum hose - Fuel hose



VACUUM HOSE



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



SE THERMAL VALVE WIRE CLAMP



ALTERNATOR WIRE CLAMP STARTER MOTOR WIRE CLAMP



6-6



PENURUNAN / PEMASANGAN MESIN



Route the wire Alurkan sire harness harnessproperly dengan benar(page (hal. 1-14). 1-14).



Sambungkan connectors berikut ini: Connect the following connectors: – Alternator 3P connector - Alternator 3P connector Starter motorwire wire2P 2Pconnector connector -– Starter motor – SE thermal valve 3P connector - SE thermal valve 3P connector Set the ground cables in position, then install and tighten Tempatkan kabel-kabel massa pada tempatnya, the bolt. kemudian pasang dan kencangkan bolt.



BOLT/GROUND CABLES



ALTERNATOR 3P CONNECTOR



SE THERMAL VALVE 3P CONNECTOR



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



WIRE CLAMP



Set theand brake cablethe through the cable holder. Tempatkan brake cable rem) melalui cable Install tighten cable (kabel clamp/bolt. holder. Route the rear brake



SPARK PLUG CAP



BRAKE CABLE



Alurkan rear brake cable properly cable dengan Pasang dan kencangkan cable clamp bolt. benar(page (hal. 1-14). 1-14).



CABLE CLAMP/ BOLT



Pasang joint pada Install the jointpinpindan andadjusting adjusting nut nut to the rear rear brake cable. cable. Set the return spring ends intoreturn the hole on the left(pegas crankTempatkan ujung-ujung spring case and pin onke thedalam brake arm. pengembalian) lubang pada left crankcase dan pinthe pada brake arm (lengan rem). (page 3-16). Adjust rear brake lever free play



SPRING



CABLE HOLDER ADJUSTING NUT



Install the following: Setel jarak main bebas rear brake lever (hal. 3-16). – Under cover (page 2-10) Pasang sebagai berikut: body cover (page 2-8) – Center Luggage box (page 2-7) -– Under cover (hal. 2-10) - Center body cover (hal. 2-8) - Luggage box (hal. 2-7) BRAKE CABLE



JOINT PIN



6-7



CATATAN



7. CYLINDER HEAD/VALVES/CYLINDER/PISTON



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



CYLINDER HEAD HEAD··········································7-14 CYLINDER ..................................7-14



SERVICE INFORMATION ····························· 7-3 KETERANGAN SERVIS ........................7-3



CAMCHAIN CHAIN GUIDE...............................7-29 GUIDE······································7-29 CAM



TROUBLESHOOTING ···································· 7-6 TROUBLESHOOTING ...........................7-6



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



CYLINDER COMPRESSION TEST ·············· 7-7 TEST KOMPRESSI CYLINDER.............7-7



CAMCHAIN CHAIN TENSIONER TENSIONER LIFTER ···········7-31 CAM LIFTER........7-31



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



CYLINDER CYLINDER .............................................7-32 ······················································7-32



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



PISTON ..................................................7-34 PISTON·····························································7-34



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



7-1



7



CYLINDER HEAD/VALVES/CYLINDER/PISTON



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



0.8 N·m (0.1 kgf·m, 0.6 lbf·ft)



10 N·m (1.0 kgf·m, 7 lbf·ft)



4 N·m (0.4 kgf·m, 3.0 lbf·ft)



18 N·m (1.8 kgf·m, 13 lbf·ft)



12 N·m (1.2 kgf·m, 9 lbf·ft)



8 N·m (0.8 kgf·m, 5.9 lbf·ft) 12 N·m (1.2 kgf·m, 9 lbf·ft) 7 N·m (0.7 kgf·m, 5.1 lbf·ft)



7-2



CYLINDER HEAD/VALVES/CYLINDER/PISTON



SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM



• •• •• •• • • • • • ••



This section covers service of the cylinder head, valves, rocker arms, camshaft, cylinder and piston. Babengine ini meliputi darifrom cylinder head,tovalves, rocker arms, camshaft, cylinder dan piston. The must beservis removed the frame service the cylinder head, valves, camshaft, cylinder and piston. Mesindisassembling, harus dilepaskan daristore rangka untuk dapat menservis cylinder head, valves, camshaft, cylinder dan piston. When mark and the disassembled parts to ensure that they are reinstalled in their original locations. yang dibongkar memastikan dipasang kembali Sewaktu pembongkaran, tandai dan solvent simpanlah parts Clean all disassembled parts with cleaning and dry them by blowing themuntuk off with compressed bahwa air beforemereka inspection. pada lokasi mereka. Camshaft and semula rocker arm lubricating oil is fed through oil passages in the cylinder head. Clean the oil passages before assembling cylinder head. Bersihkan semua parts yang dibongkar dengan larutan pembersih dan keringkan dengan meniup dengan udara dari Be careful not to damagepemeriksaan. the mating surfaces when removing the cylinder head cover and cylinder head. Do not tap the cylinder head cover kompressor sebelum and cylinder head too hard during removal. Minyak pelumasan camshaft dan rocker arm disalurkan melalui jalan lintasan oli di dalam cylinder head. Bersihkan jalan Take care not to damagemerakit the cylinder wallcylinder and piston. lintasan oli sebelum kembali head. When removing the piston, clean carbon and sludge from the penyatuan top of the cylinder. Hati-hati agar tidak merusak permukaan-permukaan 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 STANDARD BAGIAN STANDARD BATAS LIMIT SERVIS 2 2 Tekanan kompressi cylinder 1341 kgf/cm ,psi) 191 psi) , 191 Cylinder compression 1314 kPakPa (13.4(13,4 kgf/cm – -1 menit-1 (rpm) pada 520 (rpm) at 520 min Perubahan bentuk melengkung cylinder head -– 0,05 0.05 (0.002) Cylinder head warpage Rocker arm D.D. rocker IN/EX 10,000 – 10,015 10,04 10.04 (0.395) Rocker arm Rocker armarm I.D. IN/EX 10.000 – 10.015 (0.3937 – 0.3943) (MASUK/ 9.972 – 9.987 (0.3926 – 0.3932) Rocker arm shaft O.D. IN/EX 9.91 (0.390) BUANG) 0.013 – 0.043 (0.0005 – 0.0017) Arm to shaft clearance IN/EX 0.08 (0.003) D.L. rocker arm shaft IN/EX 9,972––32.6406 9,987 (1.27561 – 1.28506) 9,91 32.37 (1.274) Camshaft Cam lobe height IN 32.4006 Jarak renggang antara IN/EX 0,013––32.2464 0,043 (1.26009 – 1.26954) 0,08 31.97 (1.259) EX 32.0064 arm ke shaft Valve, valve Valve clearance IN 0.14 ± 0.02 (0.006 ± 0.001) – Camshaft Ketinggian cam lobe IN 32,4006 – 32,6406 32,37 guide EX 0.14 ± 0.02 (0.006 ± 0.001) – (bubungan) EX 32,0064 32,2464– 0.1965) 31,97 4.90 (0.193) Valve stem O.D. IN 4.975 – 4.990– (0.1959 Valve, valve Jarak renggang klep IN 0,14 ± 0,02 EX 4.955 – 4.970 (0.1951 – 0.1957) 4.90 -(0.193) guide EX 0,14 ± 0,02 Valve guide I.D. IN/EX 5.000 – 5.012 (0.1969 – 0.1973) 5.03 -(0.198) D.L. valve stem IN 4,975 – 4,990 4,90 Stem-to-guide clearance IN 0.010 – 0.037 (0.0004 – 0.0015) 0.08 (0.003) EX 4,955 – 4,970 4,90 0.10 (0.004) EX 0.030 – 0.057 (0.0012 – 0.0022) D.D. valve guide IN/EX – 5,012 5,03 Valve guide projection above IN/EX 9.15,000 – 9.3 (0.36 – 0.37) – Jarak renggang stem IN 0,010 – 0,037 0,08 cylinder head keValve guideseat width EX 0,10 1.5 (0.06) IN/EX 1.00,030 (0.04)– 0,057 Proyeksi IN/EX 9,1(1.172) – 9,3 Valve spring IN/EX valve guide 29.78 29.11- (1.146) di atas cylinder head free length Lebar valve seat IN/EX 1,0 1,5 Panjang bebas IN/EX 29,78 29,11 valve spring CYLINDER/PISTON SPECIFICATIONS



SPESIFIKASI CYLINDER/PISTON ITEM BAGIAN D.D. I.D. Kelonjongan Out-of-round Ketirusan Taper Perubahan bentuk melengkung Warpage Piston, piston D.L. piston Piston, piston Piston O.D. rings, piston pengukuran D.L. piston rings, piston pin Titik Piston O.D. measurement point pin D.D. lubang piston pin Piston pin bore I.D. D.L. piston pin Piston pin O.D. Jarak renggang antara piston-ke- piston pin Piston-to-piston pin clearance Jarak renggang Ring paling atas Pistonpiston ring-to-ring Top antara Ring kedua groove clearance Second ring-ke-alurnya Piston ring end gap Top atas Celah pada Ring paling Second ujung piston ring Ring kedua Oil(side (side rail) rail) Ring oli Cylinder-to-piston clearance Jarak renggang antara cylinder-ke-piston Connecting small end I.D. rod D.D. kepalarod kecil connecting Connecting rod-to-piston pin clearancerod-ke-piston pin Jarak renggang antara connecting



Cylinder Cylinder



STANDARD STANDARD 50,005 – 50,015 50.005 – 50.015 (1.9687 – 1.9691) – – – 49,970 – 49,990 49.970 – 49.990 (1.9673 – 1.9681) 6 mm dari bagian bawah piston 6.0 (0.24) from bottom of skirt 13,002 – 13,008 13.002 – 13.008 (0.5119 – 0.5121) 12,994 – 13,000 12.994 – 13.000 (0.5116 – 0.5118) 0,002 – 0,014 0.002 – 0.014 (0.0001 – 0.0006) 0,015 – 0,050 0.015 – 0.050 (0.0006 – 0.0020) 0,015 – 0,050 0.015 – 0.050 (0.0006 – 0.0020) 0.10 – 0.25 (0.004 – 0.010) 0,10 – 0,25 0.10 – 0.25 (0.004 0,10 – 0,25 – 0.010) 0.20 – 0.70 (0.008 – 0.028) 0,20 – 0,70 0.015 – 0.045 (0.0006 – 0.0018) 0,015 – 0,045 13.010 – 13.028 (0.5122 – 0.5129) 13,010 – 13,028 0.010 – 0.034 (0.0004 – 0.0013) 0,010 – 0,034



Unit: mm (in) Satuan: mm SERVICE BATAS LIMIT SERVIS 50,10 50.10 (1.972) 0,05 0.05 (0.002) 0,05 0.05 (0.002) 0,05 0.05 (0.002) 49,95 49.95 (1.967) – 13,04 13.04 (0.513) 12,96 12.96 (0.510) 0,02 0.02 (0.001) 0,08 0.08 (0.003) 0,08 0.08 (0.003) 0,45 0.45 (0.018) 0,45 0.45 (0.018) - – 0.09 (0.004) 0,09 13.05 (0.514) 13,05 0,05 0.05 (0.002)



7-3



CYLINDER HEAD/VALVES/CYLINDER/PISTON NILAI TORSI TORQUE VALUES Cylinder head Cylinder headcover coverspecial special bolt bolt Cam sprocket Cam sprocketbolt bolt Cylinder head Cylinder headnut nut Cylinder head Cylinder headbolt bolt Exhaust shroud mounting bolt Exhaust shroud mounting bolt Intake shroud mounting screw Intake shroud mounting screw Cam chain tensioner lifter screw Cam chaintensioner tensionerslider lifter screw Cam chain pivot pin bolt Cam chain tensioner slider pivot pin bolt



12 N.m (1,2(1.2 kgf.m; 9 lbf.ft) 12 N·m kgf·m, 9 lbf·ft) 8 N.m (0,8(0.8 kgf.m; 5,95.9 lbf.ft) mesin pada dan permukaan duduk. 8 N·m kgf·m, lbf·ft) Oleskan oli Apply engine oilulir to the threads and seating surface. 18 N.m (1,8(1.8 kgf.m; 13 13 lbf.ft) mesin pada dan permukaan duduk. 18 N·m kgf·m, lbf·ft) Oleskan oli Apply engine oil ulir to the threads and seating surface. 12 N.m (1,2(1.2 kgf.m; 9 lbf.ft) oli mesin pada dan permukaan duduk. 12 N·m kgf·m, 9 lbf·ft) Oleskan Apply engine oil ulir to the threads and seating surface. 7 N.m (0,7 kgf.m; 5,1 lbf.ft) 7 N·m (0.7 kgf·m, 5.1 lbf·ft) 0,8 N.m (0,1 kgf.m, 0,6 lbf.ft) 0.8 N·m (0.1 kgf·m, 0.6 lbf·ft) 4 N.m (0,4 kgf.m; 3,0 lbf.ft) 4 N·m (0.4 kgf·m,7 3.0 lbf·ft) 10 N.m (1,0 kgf.m; lbf.ft) 10 N·m (1.0 kgf·m, 7 lbf·ft)



TOOLS TOOLS Valve spring compressor 07757-0010000



Valve spring compressor attachment 07959-KM30101



Valve guide reamer, 5.0 mm 07984-MA60001



Valve guide driver, 5.0 mm 07942-MA60000



Valve guide adjusting driver 07743-0020000



Cam chain tensioner lifter stopper 070MG-0010100



Seat cutter, 27.5 mm (IN, 45°) 07780-0010200



Seat cutter, 24 mm (EX, 45°) 07780-0010600



Flat cutter, 27 mm (IN, 32°) 07780-0013300



7-4



CYLINDER HEAD/VALVES/CYLINDER/PISTON Flat cutter, 22 mm (EX, 32°) 07780-0012601



Interior cutter, 26 mm (IN, 60°) 07780-0014500



Interior cutter, 22 mm (EX, 60°) 07780-0014202



Cutter holder 5.0 mm 07781-0010400



7-5



CYLINDER HEAD/VALVES/CYLINDER/PISTON



TROUBLESHOOTING TROUBLESHOOTING ? Engine top-end problems usually affect engine performance. These can be diagnosed by a compression test or by tracPersoalan pada bagian atasnoises mesin biasanya unjuk kerja mesin. Persoalan-persoalan ini dapat didiagnosa ing engine to the top-end mempengaruhi with a sounding rod or stethoscope. dengan test kompressi dengan is menelusuri mesin padasmoke bagian atascrankcase dengan breather tangkai hose. suaraIfatau stethoscope. • If theatau performance poor at lowsuara-suara speeds, check for white in the the hose is smoky, • Jika unjuk kerja mesin buruk pada kecepatan rendah, periksalah terhadap asap putih pada crankcase breather hose (slang check for a seized piston ring. pernapasan bak mesin). Jika hose berasap, periksa terhadap piston ring yang macet. Compression too low, hard starting or poor performance at low speed • Valves: Kompressi terlalu rendah, mesin sulit dihidupkan atau unjuk kerja buruk pada kecepatan rendah – Incorrect valve adjustment • Valves (klep-klep): – Burned or bent valves - Penyetelan valve–tidak benar Incorrect valve timing - Valves terbakar atau bengkok – Broken valve spring - Tertib waktu klep–tidak benar Uneven valve seating - Valve spring patah – Valve stuck open - Valve seating (dudukan – Weak klep) valve tidak springmerata - Valve macet terbuka • Cylinder head: - Valve spring lemah – Leaking or damaged cylinder head gasket • Cylinder head: – Warped or cracked cylinder head - Cylinder head gasket bocor atau rusak – Loose spark plug - Ada perubahan melengkung atau retak-retak pada cylinder head ? bentuk Worn cylinder - Spark plug (busi) longgar ? Worn piston or piston rings ? Bent connecting rod • Cylinder aus • Piston atau piston rings aus too high, overheating or knocking Compression • Connecting rod bengkok • Excessive carbon build-up on piston head or on combustion chamber •



Excessive smoke Kompressi terlalu tinggi, overheating atau knocking • Worn valve stemberlebihan or valve guide • Ada pembentukan karbon secara pada piston head (kepala piston) atau di ruang pembakaran ? Damaged stem seal ? Worn cylinder Asap berlebihan ? Worn piston or piston rings • Valve stem atau?valve guideinstallation aus Improper of piston rings • Stem seal rusak? Scored or scratched piston or cylinder wall • Cylinder aus Excessive noise • Piston atau piston rings aus • Incorrect valve adjustment • Pemasangan piston rings tidak benar ? Sticking valve or broken valve spring • Piston atau dinding cylinder tergerus atau tergores ? Excessively worn valve seat ? Worn or damaged camshaft Mesin berisik ? Worn or damaged cam chain • Penyetelan klep?tidak tepat Worn cam sprocket teeth • Valve macet atau patah ? valve Worn spring rocker arm and/or shaft • Valve seat (dudukan klep) berlebihan ? Worn or aus damaged cam chain tensioner • Camshaft aus atau rusakcylinder ? Worn ? Worn piston or piston rings • Cam chain aus atau rusak • Gigi-gigi cam sprocket aus Rough idle • Rocker arm dan/atau aus compression • Lowshaft cylinder • Cam chain tensioner aus atau rusak Abnormal noise • Cylinder aus • Worn piston pin or piston pin hole • Piston atau piston • rings Worn aus connecting rod small end • Worn cylinder, piston or piston rings Putaran stasioner kasar Piston ring sticking/scuffing, bearing damage • Tekanan kompressi cylinder rendah • Clogged oil gallery or oil strainer screen Suara tidak normal • Internal oil leak • Not using engine oil • Piston pin atau lubang pistonrecommended pin aus • •



Kepala kecil connecting rod aus Cylinder, piston atau piston rings aus



Piston ring macet/menggeser, kerusakan bearing (bantalan) • Saluran oli atau oil strainer screen tersumbat • Ada kebocoran oli di dalam • Tidak menggunakan oli mesin yang dianjurkan



7-6



CYLINDER HEAD/VALVES/CYLINDER/PISTON



CYLINDER COMPRESSION TEST TEST KOMPRESSI CYLINDER Warm the engine normalsuhu operating temperature. Panaskan mesin to sampai operasi normal. Stop the mesin enginedan and lepaskan remove thespark sparkplug plugcap cap(topi and spark Matikan busi) plugspark (page plug 3-7). (busi) (hal. 3-7). dan Untuk mencegah To avoid discharging menghabiskan muatan thebaterai, battery,jangan do not listrik operate the starter starter menjalankan motor fordari more7 than motor lebih detik.7 seconds.



Install a compression gauge into the spark plug hole. (meter pengukur Pasang compression gauge Open the throttle all the way and kompressi) ke dalam lubang busi.crank the engine with the starterthrottle until the gauge reading Buka seluruhnya danstops putarrising. mesin dengan starter The maximum reading is usually reached sampai pembacaan gauge berhenti naik.within 4 – 7 seconds. Pembacaan maksimum biasanya dicapai dalam 4 – 7 detik. COMPRESSION PRESSURE: TEKANAN psi) at 520 min-1(rpm) 1,314 kPaKOMPRESSI: (13.4 kgf/cm2, 191 2 -1 1.314 kPa (13,4 kgf/cm ; 191 psi) pada 520 menit (rpm) If compression is high, it indicates that carbon deposits have Jika kompressi tinggi, ini menunjukkan bahwa telah accumulated on the combustion chamber and/or the piston crown. terkumpul endapan karbon pada ruang pembakaran dan/atau mahkota piston. If compression is low, pour 3 – 5 cc (0.1 – 0.2 oz) of engine oil into the cylinder through the spark plug hole and recheck Jika kompressi rendah, tuangkan 3 – 5 cc oli mesin ke the compression. dalam cylinder melalui lubang spark plug dan periksa If the compression kembali kompressi.increases from the previous value, check the cylinder, piston and piston rings. Jika kompressi naikhead darigasket nilai sebelumnya, periksalah • Leaking cylinder cylinder, piston dan piston rings. • Worn piston ring • • Worn Kebocoran cylinder head gasket cylinderpada and piston • Piston ring aus If compression is the same as the previous value, check the •valves Cylinder dan piston aus for leakage.



COMPRESSION GAUGE



Jika kompressi sama dengan nilai sebelumnya, periksalah valves (klep-klep) terhadap kebocoran.



CYLINDER HEAD COVER CYLINDERREMOVAL HEAD COVER



PELEPASAN Remove the center body cover (page 2-8). Disconnect the crankcase breather hose.



Jangan sampai oliengine mesin Lepaskan Remove the special bolts, mounting rubbers and cylinder Do not let the center body cover (hal. 2-8). menetes ke atas oil drip downrangka to the head cover. Lepaskan crankcase breather hose. dari frame cylinder head. from the bolts, mounting rubbers dan cylinder Remove thespecial rubber seal from the cylinder head cover. cylinder head. Lepaskan



CRANKCASE BREATHER HOSE



RUBBER SEAL



head cover.



Lepaskan rubber seal dari cylinder head cover.



SPECIAL BOLTS/ MOUNTING RUBBERS



PEMASANGAN INSTALLATION Make surebahwa the sealseal rubber is in good condition replace it Pastikan rubber berada pada and kondisi baik if necessary. dan ganti bila perlu. Apply adhesive (CEMEDINE 575 or Three Bond 1194 or Oleskan perekat (CEMEDINE 575 mating atau area Three Bond equivalent) to the cylinder head cover as speci1194 fied. atau sejenisnya) pada daerah penyatuan cylinder head cover seperti ditentukan.



5 – 15 mm (0.2 – 0.6 in)



SEAL POINTS



CYLINDER HEAD COVER



7-7



CYLINDER HEAD/VALVES/CYLINDER/PISTON Install the seal rubberkeinto the alur groove on cylinder the cylinder head Pasang seal rubber dalam pada head cover. cover.



SEAL RUBBER



CYLINDER HEAD COVER



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



SEAL RUBBER



SEAL POINTS



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



TANDA "UP"



MOUNTING RUBBER



Tempatkan cylinder pada cylinder Set the cylinder head head cover cover onto the cylinder head.head. Pasang kencangkan torsi Install thespecial special bolts bolts dan and tighten them todengan the specified yang ditentukan. torque.



CRANKCASE BREATHER HOSE



CYLINDER HEAD COVER



TORQUE:12 N·m (1.2 kgf·m,99lbf.ft) lbf·ft) TORSI: 12 N.m (1,2 kgf.m, Connect the crankcase crankcase breather hose. Hubungkan breather hose. Install the centerbody bodycover cover (hal. (page2-8). 2-8). Pasang center



SPECIAL BOLTS



7-8



CYLINDER HEAD/VALVES/CYLINDER/PISTON



INTAKE/EXHAUST INTAKE/EXHAUSTSHROUDS SHROUDS (SELUBUNGREMOVAL/INSTALLATION PEMASUKAN/PENGELUARAN) Remove the following: PELEPASAN/PEMASANGAN



STARTER MOTOR WIRE CLAMP



Lepaskan sebagai berikut: – Center body cover (page 2-8) Luggage boxcover (page(hal. 2-7) 2-8) -– Center body Inlet pipebox (page 5-22) -– Luggage (hal. 2-7) Muffler 2-14) -– Inlet pipe (page (hal. 5-22) PAIR air supply -– Muffler (hal. 2-14)pipe (page 5-25) -Release PAIR air pipe (hal. 5-25)from intake shroud: the supply following wire clamps Lepaskan wirewire clamps berikut dari intake shroud: – Spark plug clamp – Alternator wire clamp - Spark plug wire clamp (penjepit kabel busi) – SE thermal valve wire clamp - Alternator wire clamp – Starter motor wire clamp - SE thermal valve wire clamp threewire screws and a bolt. -Remove Starterthe motor clamp Remove the intake/exhaust shrouds by releasing the tabs of Lepaskan ketiga sebuah intake shroud fromscrews the slotdan of the exhaustbolt. shroud. Lepaskan shrouds dengan melepaskan Remove theintake/exhaust rubber seal. tabs dari intake shroud dari slot pada exhaust shroud. Be sure to align the Lepaskan Installationrubber is in theseal. reverse order of removal.



"IN" mark and "EX" TORQUE: untuk Pemasangan adalaha dalam urutan markPastikan on the rubber mentepatkan tanda Intake shroud mounting screw: seal with the inlet"IN" side pelepasan. danand "EX" pada rubber 0.8 N·m (0.1 kgf·m, 0.6 lbf·ft) exhaust side of TORSI: seal dengan sisi masuk Intake shroud Exhaust shroudmounting mounting screw: bolt: cylinder head. dan keluar dari cylinder 0,8 N.m(0.7 (0,1kgf·m, kgf.m; 0,6 lbf.ft) 7 N·m 5.1 lbf·ft) head.



terbalik



SE THERMAL VALVE WIRE CLAMP



SPARK PLUG WIRE CLAMP



ALTERNATOR WIRE CLAMP



dari



Exhaust shroud mounting bolt: 7 N.m (0,7 kgf.m; 5,1 lbf.ft)



INTAKE SHROUD



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



RUBBER SEAL



EXHAUST SHROUD BOLT 7 N·m (0.7 kgf·m, 5.1 lbf·ft)



7-9



CYLINDER HEAD/VALVES/CYLINDER/PISTON



CAMSHAFT CAMSHAFT PELEPASAN REMOVAL Lepaskan berikut: Remove thesebagai following: -– Mesin (hal. 6-4) Engine (page 6-4) Cylinderhead head cover cover (page 7-7) -– Cylinder (hal. 7-7) Coolingfan fancover cover (hal. (page2-12) 2-12) -– Cooling Intake/exhaust shroud shroud (page -– Intake/exhaust (hal. 7-9) 7-9)



7-10



INDEX NOTCH



Rotatecrankshaft the crankshaft clockwise by rotating thejam cooling fan searah perputaran jarum dengan Putar slowly andcooling align thefan "T" dengan mark on the flywheel the index memutar pelan dan with mentepatkan notch on"T" the pada right crankcase. tanda flywheel dengan index notch (takik penunjuk) pada right crankcase. Make sure the piston is at TDC (Top Dead Center) on the compression stroke. (Topis Dead Pastikan bahwa berada pada TDC This position can bepiston confirmed by checking that there slack Center) [TMA = Titik Mati Atas] pada langkah in the rocker arm. kompressi. If there is no slack, it is because the piston is moving through Posisi ini dapat dipastikan dengan memeriksa bahwa the exhaust stroke to TDC. ada kerenggangan rocker Rotate the crankshaftpada one full turn arm. by rotating the cooling fan Jika tidak oleh karena slowly and ada matchkerenggangan, up the "T" mark disebabkan again. piston sedang bergerak melalui langkah pembuangan Make sure that the index line on the cam sprocket is flush ke TDC. with the top surfacesatu of cylinder and dengan that the "memutar " mark putaranhead penuh Putar crankshaft on the cam facing up shown (TDC ontanda the comcooling fansprocket denganis pelan danas mentepatkan "T" pression stroke). sekali lagi. If the cam sprocket " " mark is not facing up, turn the cooling fan (crankshaft) one revolution realign thepada "T" mark cam Pastikan bahwa index line (garisand penunjuk) with the index notch on the right crankcase. sprocket adalah segaris dengan permukaan atas dari cylinder head dan bahwa tanda "O" pada cam sprocket menghadap ke atas seperti diperlihatkan (TDC pada langkah kompressi). Jika tanda "O" cam sprocket tidak menghadap ke atas, putar cooling fan (crankshaft) satu putaran dan tepatkan tanda "T" kembali dengan index notch pada right crankcase.



TANDA "



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



SCREWS



Remove thescrew screw dan and O-ring camchain chain tensioner tensioner cam Lepaskan O-ringfrom darithe lifter. lifter.



SCREW



TANDA "T"



"



INDEX LINE



LOCK NUTS



O-RING



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



LIFTER STOPPER



070MG-



Tepatkan



Putar cooling fanfan (crankshaft) dan tepatkan Turn the cooling (crankshaft)satu oneputaran revolution and realign kembali tanda dengan pada right the "T" mark with"T" the index notchindex on the notch right crankcase. crankcase. Make sure that the cam sprocket " " mark is not facing up. Remove the bolts, cam sprocket from the andtidak cam Pastikan bahwa tanda "O" pada camcamshaft sprocket chain off the ke camatas. sprocket. menghadap Attach a piece of wire to the cam chain to prevent it from falling into thebolts, crankcase. Lepaskan cam sprocket dari camshaft dan cam



TANDA" "



BOLTS



Letakkan pada Place akain shoplap towel at bagianthe cranakcase yang opening of the terbuka untuktomenjaga crankcase prevent agar the cam cam sprocket sprocket bolts bolts tidak jatuh ke dalam chain lepas dari cam sprocket. from falling into the Ikatkan seutas kawat pada cam chain agar ia tidak jatuh crankcase. crankcase.



ke dalam crankcase.



CAM CHAIN CAM SPROCKET



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



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



BOLT



ROCKER ARMS



CAMSHAFT



7-11



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



Pastikan tabs Make surebahwa the tabs of dari camshaft and dan the camshaft decompressor cam decompressor cam menghadap ke sisi ruang are facing the pembakaran. combustion chamber side.



sementara Pasang ke dalam cylinder Install thecamshaft camshaft into the cylinder head head while holding the menahan arms untuk mempermudah rocker arms torocker ease installation. pemasangan.



ROCKER ARMS



CAMSHAFT



TAB



Install and tighten the bolt. bolt. Pasang dan kencangkan



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



BOLT



INDEX NOTCH



TANDA"T"



7-12



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



CAM SPROCKET



Oleskan oli mesin pada permukaan duduk dan dari Apply engine oil to the seating surface and thread of ulir the cam cam sprocket sprocket bolts. bolts. Install and tighten the cam sprocket bolts to specified torque Pasang dan kencangkan cam sprocket bolts dengan in the sequence shown. torsi yang ditentukan pada urutan yang diperlihatkan.



TANDA" "



CAM CHAIN



INDEX LINES



BOLTS



2



Letakkan pada Place a kain shoplap towel at lubang dari crankcase the opening of the untuk mencegah crankcase to prevent TORQUE:8 N·m (0.8 kgf·m, 5.9 lbf·ft) jatuhnya cam sprocket TORSI: 8 N.m (0,8 kgf.m; 5,9 lbf.ft) sprocket bolt boltthe ke cam dalam crankcase. from falling into the crankcase.



1



Lepaskan cam pasang Remove the camchain chaintensioner tensioner lifter lifterstopper stopper dan and install a new O-ring to thebaru cam chain lifter. tensioner lifter. sebuah O-ring padatensioner cam chain Install anddan tighten the screw to screw the specified torque. Pasang kencangkan dengan torsi yang ditentukan. TORQUE:4 N·m (0.4 kgf·m, 3.0 lbf·ft)



STOPPER



SCREW



TORSI: N.m (0,4 kgf.m; 3,0 lbf.ft) Install the4following: Pasang sebagai berikut: – Intake/exhaust shroud (page 7-9) – Cooling fan cover (page(hal. 2-12) - Intake/exhaust shroud 7-9) Cylinder cover (page 7-7) -– Cooling fanhead cover (hal. 2-12) Engine (page -– Cylinder head 6-6) cover (hal. 7-7) -Adjust Mesinthe (hal. 6-6) valve clearance (page 3-8). Setel jarak renggang klep (hal. 3-8).



O-RING



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



DECOMPRESSOR CAM



Jika decompressor cam tidak bekerja dengan baik, ganti camshaft sebagai sebuah kesatuan.



7-13



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



BEARING



(bubungan) Periksa lobes Check thecam cam lobes for excessive wearterhadap and damage.keausan berlebihan dan kerusakan. Measure the height of masing-masing each cam lobe. cam lobe. Ukur ketinggian dari BATAS SERVIS: SERVICE LIMIT: IN: 32,37 mm IN: 32.37mm(1.274 in) EX: 31,97 mm EX: 31.97mm(1.259 in)



CYLINDER CYLINDERHEAD HEAD PELEPASAN REMOVAL • • When Ketikaremoving melepaskan cylinderhead headnuts, nutsalways (mur replace kepala the cylinder silinder), ganti and cylinder head gasket dan the cylinderselalu head gasket cylinder gasket with new cylinder gasket dengan yang baru. ones.



Remove the following: Lepaskan sebagai berikut: – Engine (page 6-4) -– Mesin (hal.head 6-4)cover (page 7-7) Cylinder -– Cylinder cover (hal.2-12) 7-7) Coolinghead fan cover (page -– Cooling fan cover (hal.(page 2-12)7-9) Intake/exhaust shroud - 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 piston is TDC (Top Dead dengan Center) on the mentepatkan "T"at pada flywheel index compression stroke. notch pada right crankcase. This position can be confirmed by checking that there slack Pastikan bahwa piston berada pada TDC (TopisDead in the rocker arm. = Titik Mati Atas] pada langkah Center) [TMA If there is no slack, it is because the piston is moving through kompressi. the exhaust stroke to TDC. Rotate the one full turn by rotating the cooling fan Posisi ini crankshaft dapat dipastikan dengan memeriksa bahwa slowly and match uppada the "T" mark arm. again. ada kerenggangan rocker 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



INDEX NOTCH



TANDA"T"



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



TANDA" "



tepatkan kembali tanda "T" dengan index notch pada right crankcase.



INDEX LINE



Lepaskan O-ringfrom dari the cam Remove thescrew screw dan and O-ring camchain chaintensioner tensioner lifter. lifter.



SCREW



O-RING



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



LIFTER



Tepatkan



Letakkan kain lap pada lubang crankcase Place adari shop towel at untuk menghindari the opening of the jatuhnya camtosprocket crankcase prevent boltthe ke cam dalam crankcase. sprocket bolt from falling into the crankcase.



Lepaskan sprocketfrom darithe camshaft Remove thebolts, bolts,cam cam sprocket camshaftdan and cam cam chain sprocket. chain lepas off thedari camcam sprocket.



CAM CHAIN



Attach a piece of wire to the cam chain to prevent it from fallIkat seutas kawat pada cam chain untuk mencegahnya ing into the crankcase. jatuh ke dalam crankcase.



BOLTS



CAM SPROCKET



7-15



CYLINDER HEAD/VALVES/CYLINDER/PISTON Remove thecylinder cylinderhead head bolts. Lepaskan Loosen the cylinder head nutsnuts in a crisscross pattern in two or dalam pola bersilangan Longgarkan cylinder head three steps. dalam dua atau tiga langkah.



BOLTS



NUTS



Remove the nuts and plates. Lepaskan nuts dan plates.



PLATES



Lepaskan Remove thespring springdan and plunger. plunger.



PLUNGER



SPRING



Remove thecylinder cylinderhead. head. Lepaskan



CYLINDER HEAD



Remove the gasket and dowel pins.



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



DOWEL PINS



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



GASKET



7-16



CYLINDER HEAD/VALVES/CYLINDER/PISTON Alurkan melaluithecylinder daninstall pasang Route thecam cam chain chain through cylinderhead head and the cylinder head head onto cylinder. cylinder padathecylinder.



CAM CHAIN



CYLINDER HEAD



Apply engine oil to the plunger whole surface. Oleskan mesinand pada seluruh permukaan plunger. Install theoliplunger spring. Pasang plunger dan spring.



PLUNGER



SPRING



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



NUTS



BOLTS



dan kencangkan dengan torsi yang ditentukan. TORQUE:12 N?m (1.2 kgf?m, 9 lbf?ft) TORSI: 12 N.m (1,2 kgf.m; 9 lbf.ft) PLATES



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



INDEX NOTCH



TANDA"T"



7-17



CYLINDER HEAD/VALVES/CYLINDER/PISTON Semprotkan mesin pada chain dan cam Apply engine oli oil to the cam chaingigi andcam cam sprocket teeth. sprocket. Install the cam chain on the cam sprocket. Install the cam sprocket to the camshaft then make sure that Pasang sprocket. the indexcam linechain on thepada cam cam sprocket is flush with the cylinder Pasang sprocket pada camshaft head and "cam " mark is facing up as shown (TDC onkemudian the compastikan 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).



CAM CHAIN TANDA" "



INDEX LINES CAM SPROCKET Letakkan kain lap menutupi lubang dari Place a shop towel at crankcase the opening untuk of the mencegah to agar cam crankcase prevent sprocket boltsprocket tidak jatuh the cam bolt ke dalam crankcase. from falling into the crankcase.



Semprotkan pada permukaan dudukof dan ulir Apply engineoli oil mesin to the seating surface and thread the cam dari cam bolts. sprocket bolts. sprocket



BOLTS



Install and tighten the cam sprocket bolts to specified torque Pasang dan kencangkan cam sprocket bolts dengan in the sequence of the cam sprocket numbers. torsi yang ditentukan dalam urutan dari nomor cam sprocket. 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 cam pasanga Remove the camchain chaintensioner tensionerlifter lifterstopper stopper dan and install sebuah O-ring baru chainlifter. tensioner lifter. new O-ring to the campada chaincam tensioner dengan torsi yang Pasang kencangkan Install anddan tighten the screw to screw the specified torque. ditentukan. TORQUE:4 N?m (0.4 kgf?m, 3.0 lbf?ft)



STOPPER



SCREW



TORSI: N.m (0,4 kgf/m, 3,0 lbf.ft) Install the4 following: Pasang sebagai berikut: – Intake/exhaust shroud (page 7-9) – Engine (page 6-6) - Intake/exhaust shroud (hal. 7–9) -Adjust Mesinthe (hal. 6-6) valve clearance (page 3-8). Setel jarak renggang klep (hal.3-8). O-RING



DISASSEMBLY



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



ROCKER ARMS



BOLT



ROCKER ARM SHAFT



7-18



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



CAMSHAFT



BOLT



TAB



VALVE VALVE To prevent loss of Lepaskan Remove thevalve valve cotters the valve spring compressor. cottersusing dengan menggunakan valve Untuk mencegah tension, do not spring compressor. hilangnya tegangan,



jangan tekan valve compress the valve springs lebihmore dari pada springs than yang diperlukan untuk necessary to remove melepaskan cotters. the cotters.



Mark all parts Tandai semuaduring parts selama pembongkaran disassembly so they sehingga merekaback dapat can be placed in diletakkan their kembali pada original lokasi mereka semula. locations.



VALVE SPRING COMPRESSOR



TOOLS: TOOLS: Valve spring compressor 07757-0010000 Valve spring compressor 07757-0010000 Valve spring compressor attachment 07959-KM30101 Valve spring compressor attachment 07959-M30101



Lepaskan spring compressor dan the lepaskan Remove the valve valve spring compressor and remove followsebagai berikut: ing: - Valve spring retainers – Valve spring retainers - Valve springs – Valve springs - Valve spring seats – Valve spring seats -– Valves Valves -– Valve Valvestem stemseals seals



VALVE



VALVE STEM SEAL



VALVE SPRING SEAT VALVE SPRING VALVE SPRING RETAINER Avoiduntuk damaging the Lepaskan Remove the carbon deposits form ruang the combustion chamber endapan karbon dari pembakaran dan Hindari merusak permukaan penyatuan and clean off thepermukaan cylinder head gasket head surface. cylinder mating bersihkan dari cylinder gasket. cylinder surfacedan andpermukaan valve seat valve seat . surfaces.



COMBUSTION CHAMBER



7-19



CYLINDER HEAD/VALVES/CYLINDER/PISTON ASSEMBLY PERAKITAN COTTERS VALVE SPRING



SPRING RETAINER



SPRING SEAT VALVE STEM SEAL EXHAUST ROCKER ARME



VALVE GUIDE EXHAUST ROCKER ARM SHAFT



CLIP



INLET ROCKER ARM SHAFT BOLT



INLET ROCKER ARM



CAMSHAFT



INLET VALVE



EXHAUST VALVE



VALVE VALVE



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



VALVE



SPRING SEAT



STEM SEAL



7-20



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



Ke ruang pembakaran



Install the valvespring springretainer. retainer. Pasang valve Untuk mencegah To prevent loss of hilangnya tegangan, tension, do not jangan tekan compress the valve valve springspring lebih dari morepada than yang diperlukan untuk necessary to install memasang cotters. the cotters.



VALVE SPRING COMPRESSOR



Install thevalve valve cotters using the valvemenggunakan spring compressor. valve Pasang cotters dengan spring compressor. TOOLS: TOOLS: Valve compressor 07757Valve spring spring compressor 07757-0010000 0010000 Valve spring compressor Valve spring compressor attachment 07959attachment 07959-KM30101 KM30101



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



TOOL YANG SESUAI



VALVE STEM



CAMSHAFT CAMSHAFT Oleskan – 1,0 mesin perputaran Apply 0.50,5 – 1.0 cc cc of oli engine oil pada to thedaerah decompressor cam decompressor dan camshaft rotating area andcam camshaft bearing. bearing.



Apply molybdenum oil solution to the cam lobes. Oleskan larutan molybdenum oil pada cam lobes. Install the camshaft with its tab and tab of the decompressor Pasang camshaft dengan dan tab dari cam is facing combustion chambertab-nya side. decompressor cam menghadap ke sisi ruang pembakaran.



TAB TAB



7-21



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



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



ROCKER ARMS



ROCKER ARM SHAFTS



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



ROCKER ARM SHAFTS



menggunakan obeng sementara mentepatkan potongan dari shaft dengan lubang stud bolt pada cylinder head.



Tepatkan



7-22



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



ROCKERARM/SHAFT ARM/SHAFT ROCKER Disassemble the cylinder head7-18). (page 7-18). Bongkar cylinder head (hal. Check the rockerarm armshafts shafts dan and rocker wear or Periksa rocker rockerarms armsforterhadap damage. atau kerusakan. keausan Turn the rocker arm roller with your finger. Putar rocker arm (penggelinding The roller should turn roller smoothly and quietly. rocker arm) dengan jari-jari. Measure the I.D. of each rocker halus arm. dan tanpa suara. Roller harus berputar dengan SERVICE Ukur D.D. dari masing-masing arm. in) LIMIT: IN/EX: 10.04rocker mm (0.395 BATAS SERVIS: IN/EX: 10,04 mm Measure the O.D. of each rocker arm shaft. Ukur D.L. dari masing-masing rocker arm shaft. SERVICE BATAS IN/EX: 9.91 9,91mm mm(0.390 in) LIMIT: SERVIS: IN/EX: Hitung jarak rocker arm-ke-shaft. Calculate therenggang rocker arm-to-shaft clearance. BATAS SERVIS: IN/EX: 0,08 mm SERVICE



LIMIT:



IN/EX: 0.08 mm (0.003 in)



VALVESPRING SPRING VALVE Disassemble the cylinder head7-18). (page 7-18). Bongkar cylinder head (hal. Measure the free length of the valve springs. Ukur panjang bebas dari valve springs. SERVICE BATAS SERVIS: IN/EX: 29,11 mm LIMIT: IN/EX: 29.11 mm (1.146 in) Ganti springs jika mereka lebih pendek dari batas servis. Replace the springs if they are shorter than the service limit.



7-23



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



Selalu putar reamer Always rotate the searah jam, reamerjarum clockwise, jangan sekali-kali never berlawanan arah jarum counterclockwise jam ketika when inserting, memasukkannya, removing and mengeluarkannya dan reaming. selama pekerjaan reaming.



Ream guide untuk menghilangkan pembentukan Ream valve the valve guide to remove any carbon build up before karbon sebelum mengukur guide. measuring the guide. dari ruang chamber pembakaran Masukkan reamer Insert the reamer from the sisi combustion side ofdari the cylinder dan selalu putar reamerclockwise. searah jarum cylinder head head and always rotate the reamer jam. TOOL: Valve guide reamer, 5.0 mm 07984-MA60001 TOOL: Valve guide reamer, 5.0 MM 07984-MA60001



Periksa reface D.D.each masing-masing valve Inspect anddan reface the Ukur Measure valve guide I.D. andguide recorddan it. catat. valve kali valveseats seatssetiap whenever SERVIS: IN/EX: 5,03 mm valve guides diganti BATAS the valve guides are SERVICE (hal. 7-26). LIMIT: IN/EX: 5.03 mm (0.198 in) replaced (page 7-26).



Kurangi D.L. masing-masing valve stem dari D.D. guide Subtract each valve stem O.D. from the corresponding guide yang bersangkutan untuk mendapatkan jarak renggang I.D. to obtain the stem-to-guide clearance. stem-ke-guide



SERVICE BATAS 0,08mm mm(0.003 in) LIMIT:SERVIS: IN: IN: 0.08 EX: 0,10 mm EX: 0.10 mm (0.004 in) Jika jarak renggang clearance stem-ke-guide If the stem-to-guide exceedsmelampaui the service batas limit, servis, tentukan sebuah guide baru dengan determine if a newapakah guide with standard dimensions would ukuran bring thestandard clearance akan within membawa tolerance. jarak renggang ke If so, replace any guides as necessary and ream to fit (page 7dalam toleransi. 25). demikian, ganti guides yang diperlukan dan ream Jika If thepas stem-to-guide agar (hal. 7-25).clearance exceeds the service limit with new jarak guide, also replace stem-ke-guide the valve. Jika renggang melampaui batas servis dengan sebuah guide baru, ganti valve juga.



7-24



VALVE GUIDE REAMER



CYLINDER HEAD/VALVES/CYLINDER/PISTON VALVE GUIDEVALVE REPLACEMENT PENGGANTIAN GUIDE Disassemble the cylinder head 7-18). (page 7-18). Bongkar cylinder head (hal. Chill new valve in abaru freezer for about 1 hour. Dinginkan valveguides guides dalam bagian freezer dari lemari es selama kira-kira 1 jam. CATATAN: • Be sure to wear heavy gloves to avoid burns when han• dling Pastikan untukcylinder memakai sarung tangan berat untuk the heated head. menghindari luka-luka bakar • Using a torch to heat the cylindersewaktu head maymenangani cause warcylinder head yang telah dipanaskan. page. • • Drive Jangan obor untuk memanaskan new menggunakan guides from the camshaft side while the cylincylinder head karena dapat mengakibatkan der head is still heated. perubahan bentuk melengkung. Heat the cylinder head to 130 – 140°C (275 – 290°F) with a • Dorong masuk guides baru dari sisi camshaft hot plate or oven. Do not heat the cylinder head beyond sementara head masih dipanaskan. 150°C (300°F). cylinder Use temperature indicator sticks, available



VALVE GUIDE DRIVER



VALVE GUIDE



from welding supply stores, to be sure the cylinder head is Panaskan cylinder head sampai 130 - 140° C dengan heated to the proper temperature. kompor listrik atau oven. Jangan memanaskan cylinder Support the cylinder150 head and Pakailah drive the valve guides out of head melampaui ° C. tongkat indikator the cylinder headdapat from the dibeli combustion suhu, yang darichamber toko side. pemasok perlengkapan pengelasan, untuk memastikan bahwa TOOL: head telah dipanaskan sampai ke suhu yang cylinder Valve guide driver, 5.0 mm 07942-MA60000 tepat. Take outcylinder new valvehead guides from the freezer. Topang dan dorong keluar valve guides dari cylinder head dari sisi ruang pembakaran. Drive new valve guides into the cylinder head to the specified TOOL: height from the cylinder head. Valve guide driver, 5,0 mm 07942-MA60000 TOOL: Keluarkan guides baru dari freezer. Valve guidevalve adjusting driver 07743-0020000 Dorong masuk valve guides baru ke dalam cylinder VALVE GUIDE PROJECTION: head sampai ke ketinggian yang ditentukan dari cylinder IN/EX: 9.1 – 9.3 mm (0.36 – 0.37 in) head.



VALVE GUIDE ADJUSTING DRIVER



9.1 – 9.3 mm (0.36 – 0.37 in)



Let the cylinder head cool to room temperature. TOOL: Valve guide adjusting driver 07743-0020000 PROJEKSI VALVE GUIDE: IN/EX: 9,1 – 9,3 mm Ream new valve guides after installation. Biarkan cylinder head menjadi dingin kembali sampai ke suhu ruangan. • Take care not to tilt or lean the reamer in the guide while reaming. Lakukan pekerjaan reaming pada valve guides baru. • Use cutting oil on the reamer during this operation. memiringkan •Insert Hati-hati the reamer agar from the tidak combustion chamber side ofatau the mencondongkan reamer sementara cylinder head and always rotate di thedalam reamerguide clockwise. meng-reaming. •TOOL: Gunakan cutting oil pada reamer selama Valve guide reamer, 07984-MA60001 pengerjaan ini. 5.0 mm



VALVE GUIDE VALVE GUIDE REAMER



Clean the cylinder thoroughly to remove any metal dari parMasukkan reamerhead dari sisi ruang pembakaran ticles after reaming reface the valve seatsearah (page 7-26). cylinder head dan and selalu putar reamer dengan arah perputaran jarum jam. TOOL; Valve guide reamer, 5.0 mm



07984-MA60001



Bersihkan cylinder head secara menyeluruh untuk membuang partikel-partikel logam setelah pekerjaan reaming dan reface (bentuk kembali permukaan) valve seat (hal. 7-26).



7-25



CYLINDER HEAD/VALVES/CYLINDER/PISTON VALVE SEAT INSPECTION/REFACING PEMERIKSAAN/REFACING VALVE SEAT Disassemble the cylinder head7-18). (page 7-18). Bongkar cylinder head (hal. Clean the intake and exhaust valves thoroughly to remove Bersihkan intake (masuk) dan exhaust (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 Blue pada valveaseats hand-lapping tool,ringan withoutPrussian rotating the valve to make clear (dudukan pattern. klep). Ketuk valve terhadap valve seat beberapa kali dengan menggunakan hand-lapping tool (alat skir klep dengan tangan), tanpa memutar valve agar mendapatkan pola jelas.



Valves dapat The valvestidak cannot be digerinda. ground. IfJika the muka valve valve face terbakar, is burned,sangat badly jika ia worn aus or ifatau it contacts engkontak seat secara the seat unevenly, tidak merata, gantilah replace the valve. valve.



Remove thevalve valvedan andperiksa inspect the valve seat face. Lepaskan valve seat face. The valve seatseat contact should be within specified width Kontak valve harus di dalam lebartheyang ditentukan and merata even all sepanjang around the circumference. dan kelilingnya. STANDARD: 1.0 mm (0.04 in) STANDARD: 1,0 mm 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 valve seat seat face for: Periksa muka valve terhadap: • Damaged face: • Kerusakan pada muka: –- Replace the valve reface the seat valve seat Ganti valve dan and reface valve • Uneven seat width: • Lebar seat tidak merata: – Bent or collapsed valve stem; Replace the valve and - Valve stem bengkok atau runtuh. Ganti valve dan reface the valve seat reface valve seat



MUKA RUSAK



LEBAR SEAT TIDAK MERATA



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



TERLALU RENDAH



7-26



TERLALU TINGGI



CYLINDER HEAD/VALVES/CYLINDER/PISTON the refacer manufacturer’s instructions. • • Follow Ikuti petunjuk pemakaian pabrikoperating pembuat refacer. careful not to grind the seat more than necessary. • • Be Hati-hati agar tidak menggerinda seat lebih daripada yang diperlukan. 45° 60° 32°



Jika valve, seatmust harus If thedaerah contactkontak area is terlalu too hightinggi on thepada valve, the seat be KONTAK TERLALU TINGGI lowered using a 32° flat cutter. diturunkan dengan menggunakan 32° flat cutter.



LEBAR SEAT LAMA



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 dengan menggunakan 60° cutter. interior Refinishdinaikkan the seat to specifications, using a 45° finish cutter. Haluskan permukaan seat sesuai dengan spesifikasi, dengan menggunakan 45° finish cutter. KONTAK TERLALU RENDAH LEBAR SEAT LAMA



60° Reface seat remove cutter, any hilangkan kekasaran atau Reface theseat seatdengan with a Pakailah Use a 45° 45 seat° cutter, roughness or irregularities sebuah 45° cutter setiap dari seat. from the seat. whenever a ketidak-teraturan 45° cutter kali sebuah valve guide valve guide is diganti. replaced. TOOLS:



TOOLS: Seat cutter, 27.5 mm (45° IN) Seat cutter, 27.5 mm (45° IN) Seat cutter, 24 mm (45° EX) Seat cutter, 24 mm Cutter holder, 5.0 (45° mm EX) Cutter holder, 5.0 mm



KEKASARAN



07780-0010200 07780-0010200 07780-0010600 07780-0010600 07781-0010400 07781-0010400



Pakailah cutter, hilangkan ¼ bagian teratasvalve dari Use a 32°32 flat° flat cutter, remove the top 1/4 of the existing bahan valve seat yang ada sekarang. seat material.



TOOLS: TOOLS: IN) Flat 27mm mm(32° (32°IN) Flat cutter, cutter, 27 Flat 22mm mm(32° (32°EX) EX) Flat cutter, cutter, 22 Cutter 5.0mm mm Cutter holder, holder, 5.0



07780-0013300 07780-0013300 07780-0012601 07780-0012601 07781-0010400 07781-0010400



LEBAR SEAT LAMA



32°



7-27



CYLINDER HEAD/VALVES/CYLINDER/PISTON Use a 60° interior cutter, remove bottom 1/4 of existPakailah 60° interior cutter,thehilangkan ¼ thebagian ing valve seat terbawah darimaterial. bahan valve seat yang ada sekarang. TOOLS: TOOLS: Interior 26mm mm(60° (60°IN) IN) Interior cutter, cutter, 26 Interior 22mm mm(60° (60°EX) EX) Interior cutter, cutter, 22 Cutter holder, 5.0 mm Cutter holder, 5.0 mm



LEBAR DUDUKAN LAMA



07780-0014500 07780-0014500 07780-0014202 07780-0014202 07781-0010400 07781-0010400



60°



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



1.0 mm (0.04 in)



45°



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



7-28



HAND-LAPPING TOOL



CYLINDER HEAD/VALVES/CYLINDER/PISTON



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



CAM CHAIN GUIDE



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



CAM CHAIN GUIDE



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



Tepatkan



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



7-29



CYLINDER HEAD/VALVES/CYLINDER/PISTON



CAM CHAIN CHAINTENSIONER TENSIONERSLIDER SLIDER CAM REMOVAL PELEPASAN Remove thesebagai following: Lepaskan berikut: – Drive pulley (page 8-12) - Drive pulley (hal. 8-11) Cylinderhead head(hal. (page7-14). 7-14) -– Cylinder



PIVOT PIN BOLT



Remove thepivot pivotpin pinbolt. bolt. Lepaskan



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



O-RING



TENSIONER SLIDER



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



O-RING



TENSIONER SLIDER



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



7-30



PIVOT PIN BOLT



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



CAM CHAIN CHAINTENSIONER TENSIONERLIFTER LIFTER CAM PELEPASAN REMOVAL • • The Camcam chain dengan chaintensioner tensioner lifter lifter dapat can be diservis serviced with the mesininstalled terpasang pada rangka. engine in the 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 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 tensioner lifterchain stopper 070MG-0010100 lifter stopper 070MG-0010100 Remove the bolts and cam chain tensioner lifter. Lepaskan bolts dan cam chain tensioner lifter. Remove the gasketdari fromtensioner the tensioner lifter. Lepaskan gasket lifter.



SCREW



LIFTER STOPPER



GASKET



O-RING



TENSIONER LIFTER



BOLTS



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



CAM CHAIN TENSIONER LIFTER



BOLTS



GASKET



7-31



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



SCREW



Pasang luggage box (hal. 2-7).



O-RING



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



TENSIONER SHAFT



TENSIONER LIFTER



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



Remove the cylinder. Lepaskan cylinder head (hal. 7-14). Lepaskan cylinder.



7-32



CYLINDER



LIFTER STOPPER



CYLINDER HEAD/VALVES/CYLINDER/PISTON Lepaskan gasket dan dowel pins. INSTALLATION



Clean the cylinder mating surface. PEMASANGAN Install dowel pins and a penyatuan new gasket. cylinder. Bersihkan permukaan



GASKET



Pasang dowel pins dan sebuah gasket baru.



DOWEL PINS Ikatlah seutasofkawat Attach a piece wire pada camcam chain untuk to the chain to mencegahnya agarfalling tidak prevent it from jatuh ke dalam into the crankcase. crankcase.



Semprotkan permukaan dalam Apply engineolioilmesin to thepada cylinder inner surface andcylinder piston rings. dan piston rings.



PISTON RINGS



CAM CHAIN



Route the cam chain through the cylinder and install the cylAlurkan cam cylinder dan cylinder inder over thechain pistonmelalui while compressing thepasang piston ring with dari atas piston sementara menekan piston ring dengan your finger. jari-jari. Install the cylinder head (page 7-16). Pasang cylinder head (hal. 7-16).



CYLINDER



PEMERIKSAAN INSPECTION Lepaskan 7-32). Remove thecylinder cylinder(hal. (page 7-32). Periksa cylinder Inspect thediameter cylinder bore for wearterhadap or damage.keausan atau kerusakan. Measure the cylinder I.D. in the X and Y axis at three levels. Take the maximum reading determine the cylinder wear. Ukur D.D. cylinder padato poros X dan Y pada tiga 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: 50,10 mm reading to determine both and Y axis. Take the 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: round: 0.05 mm (0.002 in) BATAS 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 dikorterpistons/piston dan oversize piston/piston The following rings are available:rings dipasang jika batas servis dilampaui. 0.25 mm (0.0098 in) rings berikut tersedia: Oversize pistons/piston 0.50 mm (0.0197 in) 0,25 mm (0.0295 in) 0.75 mm 0,50 mm (0.0394 in) 1.00 mm 0,75 mm The piston 1,00 mmto cylinder clearance for the oversize piston must be: 0.015 – 0.045 mm (0.0006 – 0.0018 in). Jarak renggang antara piston-ke-cylinder untuk oversize Check the cylinder for warpage with a straight edge and piston harus sebesar: 0,015 – 0,045mm. feeler gauge in the directions as shown. Periksa cylinder terhadap perubahan melengkung dengan mistar lurus dan feeler gauge dalam arah-arah SERVICE seperti diperlihatkan. LIMIT: 0.05 mm (0.002 in) BATAS SERVIS: 0,05 mm



7-33



CYLINDER HEAD/VALVES/CYLINDER/PISTON STUD BOLT REPLACEMENT PENGGANTIAN STUD BOLT Remove thecylinder cylinder(hal. (page 7-32). Lepaskan 7-32). Thread dua two nuts the stud and tighten them kencangkan together, and Putar nutsonto (mur) pada stud dan use wrench on sama them tolain, turn dan the stud bolt out.kunci pas pada mereka satu pakailah mereka untuk memutar boltthe keluar. Install new stud bolts A,stud B into 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 specification. pemasangan crankcase stud bolts, periksa Setelah bahwa panjang dari kepala sampai ke permukaan SPECIFIED LENGTH 177.5 bolt – 178.5 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



STUD BOLTS A 177.5 – 178.5 mm (6.99 – 7.03 in)



Pasang cylinder (hal. 7-33).



STUD BOLTS B 177.5 – 178.5 mm (6.99 – 7.03 in)



PISTON PELEPASAN REMOVAL Remove the cylinder(hal. (page 7-32). Lepaskan cylinder 7-32). Hati-hati agar piston pin Beclips careful to let tidaknot jatuh ke the piston pin clips dalam lubang dari fall into the opening crankcase. of the crankcase.



PISTON



Lepaskan piston pin clips dengan tang. Remove the piston pin clips with the pliers. Dorong piston pin keluar dari piston dan connecting rod, Push the piston pin out of the piston and connecting rod, then kemudian lepaskan piston. remove the piston.



PISTON PIN



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



PISTON RING



7-34



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



PEMASANGAN



Hati-hati agar tidak merusak piston dan rings. Be careful not to damage the piston and rings.



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



RING TERATAS



TANDA



120°



RING KEDUA



120°



120°



RING TERATAS RING KEDUA



RING OLI



SIDE RAIL



SPACER



20 mm atau lebih 20 mm atau lebih



7-35



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



CONNECTING ROD



Pasang tanda "IN" menghadap Install thepiston piston dengan with the "IN" mark facing the intake ke side.sisi pemasukan. Apply engine oil to the piston pin and install it.



TANDA"IN"



PISTON PIN



Semprotkan oli mesin pada piston pin dan pasang.



Hati-hati agar piston piston pinpin clips baru. Be careful not to pin let Pasang Install new piston clips. clips tidak jatuh ke the piston pin clips • Pastikan piston pin clips telahsecurely. duduk dengan dalam lubang dari ? Make sure bahwa the piston pin clips are seated fall into the opening crankcase. erat. ? Do not align the piston pin clip end gap with the piston of the crankcase.



•



Jangan mentepatkan celah pada ujung piston pin cut-out. clip dengan potongan pada piston. Install the cylinder (page 7-33).



Pasang cylinder (hal.7-33).



CLIP



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



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



Periksa piston terhadap Check thepermukaan piston outerluar surface for scratches or goresan damage. atau kerusakan. Measure the piston pin hole. Take the maximum reading to determine I.D. piston pin. Ambil pembacaan maksimum Ukur lubang untuk menentukan D.D. SERVICE LIMIT: 13.04 mm (0.513 in) BATAS SERVIS: 13,04 mm Measure the piston pin O.D. at piston and connecting rod Ukur slidingD.L. areas.piston pin pada piston dan daerah luncur connecting rod. SERVICE LIMIT: SERVIS: 12.96 BATAS 12,96mm mm(0.510 in)



Calculate the renggang piston-to-piston pin clearance.pin. Hitung jarak piston-ke-piston BATAS SERVIS: 0,02 mm SERVICE LIMIT: 0.02 mm (0.001 in)



Ukur D.L.the piston 6,0mm mm(0.24 dari in) bagian Measure pistonpada O.D. titik at thesejauh point 6.0 from the bottom dan and 90° thelubang piston pin hole.pin. bawahnya 90°todari piston



SERVICE BATAS SERVIS: 49,95 mm LIMIT: 49.95 mm (1.967 in) Hitung jarak renggang cylinder-ke-piston (D.D. cylinder: Calculate the cylinder-to-piston clearance (cylinder I.D.: See Lihat hal. 7-33). page 7-33). BATAS SERVIS: 0,09 mm SERVICE LIMIT: 0.09 mm (0.004 in)



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



CalculateSERVIS: the connecting pin clearance. BATAS 0,05rod-to-piston mm SERVICE LIMIT:



0.05 mm (0.002 in)



7-37



CATATAN



CYLINDER HEAD/VALVES/CYLINDER/PISTON



7-39



8. KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH



LOKASI KOMPONEN-KOMPONEN......8-2



DRIVE BELT ..........................................8-11



KETERANGAN SERVIS ........................8-3



DRIVE PULLEY......................................8-11



TROUBLESHOOTING ...........................8-4



CLUTCH/DRIVEN PULLEY ...................8-15



COMPONENT LOCATION ···························· 8-2 SERVICE INFORMATION ····························· 8-3 TROUBLESHOOTING ···································· 8-4



DRIVE BELT ···················································8-12



8



DRIVE PULLEY··············································8-12 CLUTCH/DRIVEN PULLEY ························8-16



LEFT CRANKCASE COVER .................8-5



LEFT CRANKCASE COVER ························· 8-5



8-1



KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH



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



108 N·m (11.0 kgf·m, 80 lbf·ft)



49 N·m (5.0 kgf·m, 36 lbf·ft)



8-2



KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH



SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM



• ?• ?• ?• •



This section covers maintenance of the kickstarter, drive pulley, driven pulley and clutch. Babservices ini meliputi perawatan kickstarter, drive pulley, driven pulley dan clutch. These can be done with dari the engine installed in the frame. Avoid getting servis grease and oil on dilakukan the drive belt and drive/driven pulley faces order to prevent belt slippage. Pekerjaan ini dapat dengan mesin terpasang padainrangka. DoJagalah not applyagar grease to thedan weight rollers. gemuk oli tidak mengenai drive belt dan drive/driven pulley faces supaya belt tidak slip. Jangan mengoleskan gemuk pada weight rollers.



SPECIFICATIONS SPESIFIKASI BAGIAN Lebar drive belt Movable drive face Drive belt width Movable drive face Clutch



Clutch pulley Driven Driven pulley



ITEM D.D. bushing D.L. boss I.D. D.L. Bushing weight roller Boss O.D. Tebal lining D.D.Weight clutch roller outer O.D. Lining thickness Panjang bebas face spring D.L. Clutch driven outer face I.D. springdriven free length D.D.Face movable face Driven face O.D. Movable driven face I.D.



Satuan: mm STANDARD BATAS SERVIS 18,5 17,5 STANDARD 22,035 – 22,085 22,11 18.5 (0.73) 22,010 – 22,025 21,98 22.035 – 22.085 (0.8675 –15,3 0.8695) 15,92 – 16,08 0.8671) - 22.010 – 22.025 (0.8665 –2,0 15.92––112,2 16.08 (0.627 – 0.633) 112,0 112,5 – 121,4 124,2 112.0 – 112.2 (4.41 – 4.42) 33,965 33,985 33,94 124.2 – (4.89) 34,000 34,025 34,06 33.965 – 33.985 (1.3372 – 1.3380) 34.000 – 34.025 (1.3386 – 1.3396)



Unit: mm (in) SERVICE LIMIT 17.5 (0.69) 22.11 (0.871) 21.98 (0.865) 15.3 (0.60) 2.0 (0.08) 112.5 (4.43) 121.4 (4.78) 33.94 (1.336) 34.06 (1.341)



NILAI TORSI Left crankcase cover plate screw TORQUE VALUES Drive pulley face nut Left crankcase cover plate screw Clutch/driven pulley Drive pulley face nutnut Clutch outer nut Clutch/driven pulley nut Clutch outer nut



3 N.m (0,3 kgf.m; 2,2 lbf.t) 108 N.m (11,0 kgf.m; 80 lbf.ft) Oleskan oli mesin pada ulir dan 3 N·m (0.3 kgf·m, 2.2 lbf·ft)permukaan duduk 54 N.m (5,5108 kgf.m; lbf.ft) N·m40 (11.0 kgf·m, 80 lbf·ft) Apply engine oil to the threads and seating surface 49 N.m (5,0 kgf.m; 36 lbf.ft) 54 N·m (5.5 kgf·m, 40 lbt·ft) 49 N·m (5.0 kgf·m, 36 lbt·ft)



TOOLS TOOLS Clutch center holder 07724-0050002



Socket wrench, 39 x 41 mm 07GMA-KS40100



Clutch spring compressor 07LME-GZ40201



Driver 07749-0010000



Pilot, 28 mm 07746-0041100



Pilot, 20 mm 07746-0040500



8-3



KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Flywheel holder 07725-0040001



Bearing remover, 20 mm 07931-MA70000



Attachment, 28 x 30 mm 07946-1870100



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



8-4



Fork seal driver attachment, 35.2 mm 07947-KA20200



KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH



LEFT CRANKCASE CRANKCASE COVER COVER LEFT PELEPASAN REMOVAL Remove the crankcasecover cover duct 2-12) Lepaskan leftleft crankcase duct (page (hal. 2-12) Remove the following: Lepaskan sebagai berikut:



CARBURETOR DRAIN HOSE CLAMP



BOLTS



Coverbolts bolts - ?Cover Carburetordrain drainhose hose clamp - ?Carburetor clamp Rearbrake brakecable cable clamp clamp - ?Rear Vent holecover cover - ?Vent hole Remove the crankcasecover. cover. Lepaskan leftleft crankcase



REAR BRAKE CABLE CLAMP



left Lepaskan dowel cover from gasket daricrankRemove thekedua two dowel pins,pins, cover gasket the left crankcase. case.



VENT HOLE COVER



GASKET



Clean the gasket mating surface. Bersihkan permukaan penyatuan gasket.



PEMASANGAN Bersihkan oli dan gemuk dari bearing bushing pada left crankcase cover. Pasang kedua dowel pins. Pasang cover gasket baru. DOWEL PINS



INSTALLATION Pasang crankcase cover pada bushing left crankcase Clean anyleft oil and grease from the bearing on the left crankcase cover. dengan mentepatkan dowel pins dengan lubang-lubang. Pasang carburetor Install the two doweldrain hose clamp, rear brake cable clamp, vent hole cover dan kencangkan left crankcase left crankcase cover onto the left crankcase aligning the cover bolts dalam pola bersilangan dalam by dua atau tiga dowel pins with the holes. langkah.



CARBURETOR DRAIN HOSE CLAMP



BOLTS



Install the carburetor drain hose clamp, rear brake cable Pasang left crankcase duct (hal. 2-12) clamp, vent hole cover cover and tighten the left crankcase cover bolts in a crisscross pattern in two or three steps. Install the left crankcase cover duct (page 2-12) REAR BRAKE CABLE CLAMP



VENT HOLE COVER



PEMBONGKARAN DISASSEMBLY Naikkan leftleft crankcase Raise thelock locktabs tabs dari of the crankcasecover coverplate plate dan and lepaskan screws. remove the screws.



LOCK TABS/SCREWS



8-5



KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Lepaskan gear while sementara Remove thekickstarter kickstarter driven driven gear turning memutar the kickkickstarter spindle. starter spindle.



KICKSTARTER DRIVEN GEAR



Remove the thrust washer. Lepaskan thrust washer.



THRUST WASHER



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



KICKSTARTER PEDAL



TANDA



Remove thebolt boltdan andkickstarter the kickstarter pedal. Lepaskan pedal.



BOLT



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



Lepaskan snap spindle. Remove the snapring ringdan andwasher washer dari fromkickstarter the kickstarter spindle.



DUST SEAL



WASHER



SNAP RING



8-6



KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Unhook thekaitan returnreturn springspring from the the crankcase crankcase Lepaskan dari pin pin on pada cover. cover.



KICKSTARTER SPINDLE



RETURN SPRING



Remove the kickstarter spindle and return spring. Lepaskan kickstarter spindle dan return spring.



PIN



Remove thespindle spindlebushing bushing and Lepaskan dancollar. collar. BUSHING



ASSEMBLY



COLLAR



PERAKITAN COLLAR



KICKSTARTER SPINDLE *1



BUSHING



3 N·m (0.3 kgf·m, 2.2 lbf·ft)



RETURN SPRING DRIVEN GEAR *2



COVER PLATE



FRICTION SPRING THRUST WASHER



LEFT CRANKCASE COVER



SNAP RING WASHER DUST SEAL



KICKSTARTER PEDAL



BOLT



*1: Oleskan 0.1 – 0.3 g *2: Oleskan 0.2 – 0.3 g



8-7



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



BUSHING



COLLAR



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



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



RETURN SPRING



Kaitkan



Hold the kickstarter spindle in position. Tahan kickstarter spindle pada posisinya.



KICKSTARTER SPINDLE



UJUNG PENDEK



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



WASHER



8-8



SNAP RING



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



UJUNG PANJANG



PIN



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



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



KICKSTARTER PEDAL



TANDA



BOLT



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



THRUST WASHER



8-9



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



DRIVEN GEAR WELD BEAD



Tepatkan FRICTION SPRING



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



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



LOCK TABS/SCREWS



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



RETURN SPRING COLLAR



SPINDLE



BUSHING



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



FRICTION SPRING



DRIVEN GEAR



8-10



STARTER RATCHET TEETH



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



JOURNALS



DRIVE DRIVEBELT BELT PENGGANTIAN REPLACEMENT CATATAN: • ? The Drive belt dapat drive belt can bediservis serviceddengan with the mesin engine terpasang installed in pada rangka. the frame.



Remove the drivepulley pulleyface face(hal. (page8-11). 8-11). Lepaskan drive Remove the drivebelt beltdan andganti replace it with yang a newbaru. one. Lepaskan drive dengan Install the drive pulleyface face(hal. (page8-12). 8-12). Pasang drive pulley



BELT



DRIVE DRIVEPULLEY PULLEY



PELEPASAN



REMOVAL



CATATAN: • Drive pulley dapat diservis dengan mesin terpasang ? The drive pulley can be serviced with the engine installed pada rangka. in the frame. Lepaskan left (hal. 8-5). Remove the leftcrankcase crankcase cover cover (page 8-5). Tahan drive face pulley special tool dan Hold themuka drive pulley withdengan special tool and loosen the longgarkan pulley face nut. drive pulley drive face nut.



TOOL: TOOL: Clutch center center holder Clutch holder Remove the following: Lepaskan sebagai berikut: ? Nut -? Nut Washer -? Washer Starter ratchet plate -? Starter Drive ratchet face fin plate - Drive face fin



NUT/WASHER/ RATCHET PLATE



DRIVE PULLEY FACE



07724-0050002 07724-0050002



DRIVE FACE FIN



CLUTCH CENTER HOLDER



8-11



KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Geser lepas drivebelt belt dari pulley boss bossbydengan Slide off the drive from thedrive drive pulley squeezmemencet ing the drivedrive belt.belt.



BOSS



BELT



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



MOVABLE DRIVE FACE ASSEMBLY



BOSS



PEMASANGAN INSTALLATION Clean any oli oil dan and gemuk grease from the drive thebelt. drive Bersihkan dari drive faceface dan and drive belt.



Hati-hati agar movable Pasang movable drive face assembly pada crankshaft drive facenot assembly Install the movable drive face assembly onto the crankshaft Be careful to get sementara menahan ramp plate. tidak dan while holding the ramp plate. theterbongkar movable drive pastikan untuk face assembly memasang assembly disassembled and be sampai duduk dengan sure to install the penuh. assembly until fully seated.



Compress the driven face spring by squeezing thedrive drive belt Tekan driven face spring dengan memencet until there is enough to installuntuk the drive belt to the drive sampai ada cukup slack kekenduran memasang pulley boss. belt pada drive pulley boss.



8-12



MOVABLE DRIVE FACE ASSEMBLY



DRIVE BELT



KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH beltthepada drive boss pulley dengan Be careful to Tempatkan Set the drive drive belt onto drive pulley by boss squeezing it to Hati-hati agarnot tidak untuk mendapatkan kerenggangan damage the spline. memencetnya obtain the clearance between the belt and shaft. merusak



DRIVE PULLEY FACE



antara dan shaft. Install belt the drive pulley face while aligning its splines with crankshaftdrive splines.pulley face sementara mentepatkan Pasang splines-nya dengan crankshaft splines.



Tepatkan



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



Duduk sepenuhnya (Drive pulley face and



Install the drive facefin findan andratchet ratchet plate. Pasang drive face plate. Apply engine oil to the driveulir pulley facepulley nut threads Oleskan oli mesin pada drive face and nut seatdan ing surface then install it with the washer. permukaan duduk kemudian pasang dengan washer. Hold the drive pulley face with the special tool and tighten Tahan pulley torque. face dengan special tool dan the nut todrive the specified kencangkan nut dengan torsi yang ditentukan. TOOL: Clutch center holder 07724-0050002 TOOL: Clutch center holder 07724-0050002 TORQUE:108 N·m (11.0 kgf·m, 80 lbf·ft) TORSI: 108 N.m (11,0 kgf.m; 80 lbf.ft) Install the left crankcase cover (page 8-5). Pasang left crankcase cover (hal. 8-5).



RATCHET PLATE



DRIVE FACE FIN



CLUTCH CENTER HOLDER



NUT WASHER



PEMERIKSAAN INSPECTION DRIVE DRIVEPULLEY PULLEYFACE FACE



Check thedrive drivepulley pulley face scratches,goresan, scoring or gerusan damage. Periksa faceforterhadap atau kerusakan.



DRIVE PULLEY FACE



8-13



KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH DISASSEMBLY/ASSEMBLY PEMBONGKARAN/PERAKITAN



Clean any oil and Bersihkan weight grease from the rollers dan movable weight rollers and drive face dariface. oli movable drive dan gemuk.



Remove the following: Lepaskan sebagai berikut: ? Drive face boss - Driven face boss ? Ramp plate - ? Ramp Slideplate pieces - ? Slide pieces Weight rollers - Weight rollers Assembly is in the reverse order of disassembly. Perakitan adalah dalam urutan terbalik pembongkaran.



dari



MOVABLE DRIVE FACE



DRIVE FACE BOSS



Sisi left crankcase cover



RAMP PLATE WEIGHT ROLLERS SLIDE PIECES



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



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



8-14



KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MOVABLEDRIVE DRIVEFACE FACE MOVABLE Check the movable drive face terhadap for scratches, scoringgerusan or damPeriksa movable drive face goresan, MOVABLE DRIVE FACE age. atau kerusakan. Measure the drive face bushing I.D. Ukur D.D. drive face bushing. BATAS SERVIS: 22,11 mm SERVICE LIMIT: 22.11 mm (0.871 in)



CLUTCH/DRIVEN CLUTCH/DRIVENPULLEY PULLEY PELEPASAN REMOVAL



CATATAN: • Clutch/driven pulley dapat diservis dengan mesin ? The clutch/driven pulley can be serviced with the engine installed in the frame. terpasang pada rangka. Pakailah special tool Use the special tool ketika melonggarkan lock nut. when loosening the Menahan roda belakang lock nut. atau rem belakang Holding theakan rear merusak final wheel orsistem rear brake reduction. will damage the final reduction system.



Remove the leftcrankcase crankcase cover cover (page 8-5). Lepaskan left (hal. 8-5). Hold the clutch outer with the special the danremove lepaskan Tahan clutch outer dengan special tool tool and nut. nut.



CLUTCH OUTER



NUT/WASHER



TOOL: TOOL: Flywheel holder 07725-0040001 Flywheel holder 07725-0040001 Remove the washer and clutch outer. Lepaskan washer dan clutch outer.



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



CLUTCH/DRIVEN PULLEY ASSEMBLY



8-15



KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Untuk menghindari lukaTo avoid injury to luka jari-jari, yourpada finger, do not jangan lepaskan release the driven driven pulleypulley whilesementara removing melepaskan drive belt. the drive belt. If Jika dilepaskan drive released drive face face spring akan springdengan will extend memanjang tibasuddenly and tiba dan movable driven movable face face akandriven berputar, will turn, resulting in sehingga menimbulkan luka-luka pada jari-jari. injury to your finger.



Remove the clutch/drivenpulley pulleyassembly assembly dari from drive the drive Lepaskan clutch/driven belt belt by holding the movable movable driven dengan menahan drivenface. face.



BELT



Remove the drive belt from the clutch/driven pulley assemclutch/driven pulley assembly Lepaskan drive beltthedari bly while removing clutch/driven pulley assembly from sementara melepaskan clutch/driven pulley assembly the drive shaft. dari drive shaft.



CLUTCH/DRIVEN PULLEY ASSEMBLY



PEMASANGAN INSTALLATION Bersihkan oli and dangrease gemuk darithe driven Clean any oil from drivenface facedan anddrive drive belt. belt. Tahan clutch/driven dan compress tekan drive Hold the clutch/drivenpulley pulleyassembly assembly and the face dengan memutar movable driven face drive spring face spring by turning movable driven face clockwise searah jarum jam sampai ia berhenti. until it stops.



CLUTCH/DRIVEN PULLEY ASSEMBLY



MOVABLE DRIVEN FACE



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



BELT



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



8-16



CLUTCH/DRIVEN PULLEY ASSEMBLY



KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Clean any oil from clutchouter. outer. Bersihkan oli and dangrease gemuk darithe clutch Install theclutch clutchouter outer while aligning its splines with drivePasang sementara mentepatkan splinesshaftdengan splines.driveshaft splines. nya



Tepatkan



CLUTCH OUTER



Install the washerdan andclutch clutch outer outer nut. Pasang washer nut.



FLYWHEEL HOLDER



Hold the clutch outer with the special tool and tighten the Tahan clutch outer dengan special tool dan kencangkan clutch outer outer nut the specified torque. clutch nutto dengan torsi yang ditentukan. TOOL: TOOL: Flywheel holder Flywheel holder



07725-0040001 07725-0040001



TORQUE:49 N·m (5.0kgf.m; kgf·m,36 36lbf.ft) lbf·ft) TORSI: 49 N.m (5,0 Pasang leftleft crankcase (hal. 8-5). Install the crankcasecover cover (page 8-5).



NUT/WASHER



PEMBONGKARAN DISASSEMBLY CLUTCH/DRIVEN CLUTCH/DRIVENPULLEY PULLEY



Set the clutch spring compressor onto the clutch/driven pulclutch/driven Tempatkan clutch spring compressor pada ley by aligning bosses of the compressor withcompressor the holes of pulley denganthe mentepatkan bosses dari the clutch. dengan lubang-lubang dari clutch. TOOL: TOOL: Clutch spring spring compressor Clutch compressor



CLUTCH SPRING COMPRESSOR CLUTCH/DRIVEN PULLEY



07LME-GZ40201 07LME-GZ40201



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



CLUTCH/DRIVEN PULLEY



8-17



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



SOCKET WRENCH



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



CLUTCH/DRIVEN PULLEY NUT



CLUTCH ASSEMBLY SPRING SEAT



DRIVEN PULLEY ASSEMBLY



DRIVEN FACE



CLUTCH CLUTCH Remove the three E-clips E-clips and Lepaskan ketiga danwashers. washers. Remove the clutchshoes shoes dari fromdrive the drive plate. Lepaskan clutch plate.



E-CLIPS/WASHERS



Remove the clutchshoe shoesprings. springs. Lepaskan clutch Remove the damperrubbers rubbers dari fromdrive the drive plate. Lepaskan damper plate. SPRINGS



DAMPER RUBBERS



8-18



DRIVE PLATE



KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH DRIVEN DRIVENPULLEY PULLEY



Remove the sealcollar. collar. Lepaskan seal



SEAL COLLAR



Remove the guidepins pinsdan and guide driven face. Lepaskan guide guiderollers rollersfrom darithe driven face. Remove the movabledriven drivenface face dari fromdriven the driven face. Lepaskan movable face.



O-RINGS



Remove theO-rings O-rings dan and oil movable driven driven Lepaskan oil seals sealsfrom darithemovable face. face. OIL SEALS



MOVABLE DRIVEN FACE GUIDE PINS DRIVEN FACE GUIDE ROLLERS



ASSEMBLY PERAKITAN GUIDE PINS



GUIDE ROLLERS



OIL SEALS O-RINGS SEAL COLLAR DRIVEN FACE



DRIVEN FACE SPRING



MOVABLE DRIVEN FACE SPRING SEAT WASHERS E-CLIPS CLUTCH SHOES SPRINGS CLUTCH DRIVEN PULLEY NUT 54 N·m (5.5 kgf·m, 40 lbf·ft)



DRIVE PLATE



DAMPER RUBBERS



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



O-RINGS OIL SEALS



8-19



KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Bersihkan oli and dangrease gemukfrom darithe pulley face. Clean any oil pulley face.



PINS/ROLLERS



Install the movabledriven drivenface face pada onto the driven face. Pasang movable driven face. Install the guiderollers rollersdan andguide guide pins. Pasang guide pins. Apply 2.0 – 2.5 g of grease (Shell ALVANIA R3 or Oleskan 2,0 – 2,5 g gemuk (Shell ALVANIA R3 atau IDEMITSU AUTOREX B or equivalent) to each guide IDEMITSU AUTOREX B atau sejenisnya) pada masinggroove. masing alur guide.



MOVABLE DRIVEN FACE



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



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



DRIVE PLATE



DAMPER RUBBERS



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



CLUTCH SHOES



DRIVE PLATE



8-20



SPRINGS



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



CLUTCH/DRIVEN CLUTCH/DRIVENPULLEY PULLEY Rakit sebagai berikut: Assemble the following:



CLUTCH ASSEMBLY



-? Driven Drivenpulley pulleyassembly assembly -? Driven Drivenface facespring spring -? Spring Springseat seat -? Clutch Clutchassembly assembly



SPRING SEAT



DRIVEN PULLEY ASSEMBLY



To prevent loss of Untuk mencegah tension, do not hilangnya tegangan, compress the jangan tekan driven face driven face spring spring lebih daripada more untuk than yang diperlukan to merakitnecessary clutch/driven pulley nut. Jangan assemble the merusak clutch/driven ulir pulley nut. pulley nut. Do not damage the pulley nut threads.



Tempatkan clutch compressor spring over compressor di atas Set the clutch spring the clutch/driven pulclutch/driven pulley the assembly mentepatkan ley assembly aligning bosses of dengan the compressor with the bosses dariclutch. compressor dengan lubang-lubang dari holes of the clutch. TOOL: TOOL: Clutch spring compressor 07LME-GZ40201 Compress the driven face spring while07LME-GZ40201 aligning the cutout of Clutch spring compressor the pulley nut threads with the drive plate hole and install the clutch/driven Tekan drivenpulley facenut.spring sementara mentepatkan potongan dari ulir pulley nut dengan lubang drive plate dan pasang clutch/driven pulley nut.



Tepatkan (BOSSES/ HOLES



CLUTCH SPRING COMPRESSOR



Hold the springcompressor compressor pada in a vice. Tahan spring sebuah catok. Tighten the clutch/driven pulley nut using the socket wrench Kencangkan clutch/driven pulley nut dengan memakai to the specified torque. torsi yang ditentukan. socket wrench dengan TOOL: TOOL: Socket wrench, 39 x 41 mm Socket wrench, 39 x 41 mm



DRIVEN FACE



Tepatkan (CUTOUT/ PLATE HOLES



CLUTCH SPRING COMPRESSOR



07GMA-KS40100 07GMA-KS40100



TORQUE:54 N·m (5.5kgf.m; kgf·m,40 40lbf.ft) lbf·ft) TORSI: 54 N.m (5,5 Lepaskan daritheclutch/driven Remove thespring spring compressor compressor from clutch/driven pulley assembly. assembly.



SOCKET WRENCH



8-21



KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH INSPECTION PEMERIKSAAN CLUTCH OUTER CLUTCH OUTER Check the clutch outer for wear or damage. Periksa clutch outer terhadap keausan atau kerusakan. Measure clutchouter. outer I.D. Ukur D.D.the clutch BATAS SERVIS: 112,5 mm SERVICE LIMIT: 112.5 mm (4.43 in)



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



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



8-22



KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MOVABLE MOVABLEDRIVEN DRIVENFACE FACE



Check the movabledriven drivenface face terhadap for scratches, scoringgerusan or damPeriksa movable goresan, age. kerusakan. atau Check thealur-alur guide grooves stepped wear or damage. keausan bertingkat Periksa guideforterhadap Measure the movable driven face I.D. atau kerusakan. Ukur D.D. movable driven face. SERVICE LIMIT:SERVIS: 34,06 34.06 mm BATAS mm(1.341 in)



PEMERIKSAAN FACE BEARING DRIVEN FACEDRIVEN BEARING INSPECTION Juga bahwa bearingouter outerrace racefitsduduk Also periksa check that the bearing tightlydengan in the driven face. erat pada driven face.



Install the driven face to the driveshaft. Pasang driven face pada driveshaft. Turn the driven face with your hand. The bearing should turn Putar driven face dengan tangan. Bearing harus smoothly and quietly. berputar dengan halus dando tanpa suara. Replace the bearings if they not turn smoothly, quietly, or tidak dengan halus, Ganti if theybearings fit looselyjika on mereka the driven faceberputar (page 8-23). tanpa suara, atau jika mereka duduk dengan longgar pada driven face (hal. 8-23).



DRIVEN FACE



DRIVEN FACE BEARING



PENGGANTIAN DRIVEN FACE BEARING REPLACEMENT Lepaskan faceneedle needle Remove the driven driven face bearingbearing using thedengan special menggunakan special tools. tools. TOOLS: TOOLS: Bearing remover, 20 mm Bearing 20 mm Fork sealremover, driver attachment, Forkmm seal driver attachment, 35.2 35.2 mm



BEARING REMOVER



07931-MA70000 07931-MA70000



ATTACHMENT



07947-KA20200 07947-KA20200



NEEDLE BEARING



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



BEARING



SNAP RING



8-23



KICKSTARTER/DRIVE PULLEY/DRIVEN PULLEY/CLUTCH Pack new ball bearing with greasegemuk (Shell ALVANIA R3 or Isilah ball bearing baru dengan (Shell ALVANIA IDEMITSU AUTOREX B or equivalent). R3 atau IDEMITSU AUTOREX B atau sejenisnya). sealeddari sideball of SisiThe tertutup ball bearing is facing bearing menghadap ke driven face. the driven face.



DRIVER



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



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



SNAP RING



The sealed side of Sisi tertutup needle needledari bearing is bearing menghadap ke facing the special special tools. tools.



Apply grease R3 atau or IDEMITSU Oleskan gemuk (Shell (Shell ALVANIA ALVANIA R3 AUTOREX B equivalent) to a newpada needleneedle bearing.bearing AUTOREX B oratau sejenisnya) baru. Press the needle bearing into the driven face squarely as shown. needle bearing secara tegaklurus ke dalam Dorong driven face seperti diperlihatkan. TOOLS: TOOLS: Driver 07749-0010000 Driver 07749-0010000 Attachment, 28 x 30 mm 07946-1870100 Attachment, 07946-1870100 Pilot, 20 mm 28 x 30 mm 07746-0040500 Pilot, 20 mm 07746-0040500



ATTACHMENT



DRIVER



1.0 mm (0.04 in)



PILOT



NEEDLE BEARING



8-24



9. FINAL REDUCTION



LOKASI KOMPONEN-KOMPONEN......9-2 FINAL REDUCTION CASE .........9-7 FINAL REDUCTION CASE ASSEMBLY ·····9-7 COMPONENT LOCATION ···························· 9-2PERAKITAN KETERANGAN SERVIS ........................9-3 FINAL REDUCTION CASE ...9-8 FINAL REDUCTION INSPECTION ··············9-8 SERVICE INFORMATION ····························· 9-3PEMERIKSAAN TROUBLESHOOTING ...........................9-5 FINAL REDUCTION FINAL REDUCTION BEARING .............. TROUBLESHOOTING ···································· 9-5PENGGANTIAN BEARING ..........................................................9-10 REPLACEMENT·············································9-10 PEMBELAHAN FINAL FINAL REDUCTION CASE REDUCTION CASE ...............................9-6 9-6 SEPARATION ···················································



9-1



9



FINAL REDUCTION



COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN FINAL REDUCTION



9-2



FINAL REDUCTION



SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM



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



SPECIFICATIONS SPESIFIKASI ITEM Final reduction oil capacity BAGIAN After draining Kapasitas oli final Pada penggantian periodik After disassembly reduction Setelah pembongkaran Recommended final reduction oil Oli final reduction yang dianjurkan



NILAI TORSI Final reduction oil check bolt



Final reduction oil drain bolt TORQUE VALUE



Final reduction oil check bolt Final reduction oil drain bolt



Unit: mm (in) STANDARD SPESIFIKASI 0.10 liter (0.11 US qt, 0.09 lmp qt) 0,10 liter 0.12 liter (0.13 US qt, 0.11 lmp qt) 0,12 liter motorcycle oil" or equivalent motor oil Honda "4-stroke Federalclassification: Oil Supreme SG Flick klasifikasi Service API service ordengan higher (except oilsAPI labeled as SG., Viskositas: SAE 10W-30 JASO MB energy conserving on the circular API service label) JASO T 903 standard: MB Viscosity: SAE 10W-30



13 N.m (1,3 kgf.m; 10 lbf.ft) 13 N.m (1,3 kgf.m; 10 lbf.ft)



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



TOOLS TOOLS Case puller 07SMC-0010001



Remover weight 07741-0010201



Bearing remover shaft, 10 mm 07936-GE00100



Bearing remover head, 10 mm 07936-GE00200



Bearing remover shaft, 12 mm 07936-1660120



Bearing remover head, 12 mm 07936-1660110



9-3



FINAL REDUCTION Bearing remover shaft, 15 mm 07936-KC10100



Bearing remover head, 15 mm 07936-KC10200



Driver 07749-0010000



Attachment, 32 x 35 mm 07746-0010100



Attachment, 37 x 40 mm 07746-0010200



Attachment, 40 x 42 mm 07746-0010900



Attachment, 42 x 47 mm 07746-0010300



Pilot, 10 mm 07746-0040100



Pilot, 12 mm 07746-0040200



Pilot, 15 mm 07746-0040300



Pilot, 20 mm 07746-0040500



Pilot, 22 mm 07746-0041000



9-4



FINAL REDUCTION Assembly collar 07965-GM00100



Assembly shaft 07965-1660200



Assembly collar attachment 07965-GM00200



TROUBLESHOOTING TROUBLESHOOTING Mesin tetapi skuter tidak mau bergerak Enginebisa does hidup start but scooter won’t move •• Damaged Final reduction rusak final reduction •• Seized Final reduction macet final reduction •• Faulty Drivedrive pulley dan and driven pulley/clutch rusak pulley driven pulley/clutch



Abnormal noise Suara tidak normal • Worn, seized or chipped gears • Gears aus, macet atau sumbing • Worn or damaged final reduction bearing • Final reduction bearing aus atau rusak Oil leak • Oil level too Kebocoran oli high or permukaan damaged oil oli sealterlalu tinggi •• Worn Tinggi • Cracked crankcase and/or • Oil seal aus atau rusakfinal reduction case • Crankcase dan/atau final reduction case retak



9-5



FINAL REDUCTION



FINAL REDUCTION PEMBELAHAN FINALCASE REDUCTION CASE SEPARATION PELEPASAN



REMOVAL



•• The Final reduction dapat dengan mesin final reduction candiservis be serviced with the ter engine pasanginpada rangka. installed the frame.



BREATHER HOSE



Drain the final reduction oil (page Keluarkan oli final reduction (hal.3-13). 3-13). Remove the following: Lepaskan sebagai berikut: Clutch/drivenpulley pulley (hal. (page8-15) 8-16) -– Clutch/driven – Rear wheel (page 12-4) - Roda belakang (hal. 12-4) – Rear brake shoes (page 13-5) - Rear brake shoes (hal. 13-5) Disconnect the final reduction case breather hose from the Lepaskan final reduction case breather hose dari final final reduction case hose joint. reduction case hose joint.



Remove thebolts boltsdan and final reduction Lepaskan reductioncase. case.



FINAL REDUCTION CASE



BOLTS



Lepaskan gasket. Remove thedowel dowelpins pins dan and gasket.



DOWEL PINS



GASKET



9-6



FINAL REDUCTION Remove the following: Lepaskan sebagai berikut: COUNTER GEAR



Countergear gear - –Counter Final gearshaft shaft - –Final gear Countershaft - –Countershaft



COUNTERSHAFT



FINAL GEAR SHAFT



FINAL REDUCTION CASE ASSEMBLY FINAL REDUCTION CASE ASSEMBLY Apply engineolioilmesin to each gearmasing-masing tooth and each bearing sliding Semprotkan pada gigi gear areamasing-masing of shaft. dan daerah luncur bearing dari shaft.



COUNTERSHAFT



Install the final gear shaft.



Pasang final gear shaft.



Install the countershaft into the counter gear while aligning



Pasang countershaft ke with dalam the countershaft splines thecounter counter gear gear sementara splines and mentepatkan splines install them tocountershaft the final reduction case.dengan counter gear splines dan pasang mereka pada final reduction case.



SPLINES



FINAL GEAR SHAFT



COUNTER GEAR



9-7



FINAL REDUCTION Install the dowel pinsdan andgasket a new gasket. Pasang dowel pins baru.



DOWEL PINS



GASKET



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



FINAL REDUCTION CASE



BOLTS



Sambungkan breatherhose hose finalreduction reductioncase case Connect the breather to pada the final hose hose joint.joint.



BREATHER HOSE



Install the following: Pasang sebagai berikut: – Rear brake shoes (page 13-5) - –Rear Rearbrake wheelshoes (page (sepatu 12-4) rem belakang) (hal. 13-5) - –Roda belakangpulley (hal. 12-4) Clutch/driven (page 8-17) - Clutch/driven pulley (hal. 8-16) Fill the final reduction case with the recommended oil (page Isi final reduction case dengan oli yang dianjurkan (hal. 3-13). 3-13).



PEMERIKSAAN FINAL REDUCTION BEARING



FINAL REDUCTION INSPECTION LEFT CRANKCASE



BEARING



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



9-8



FINAL GEAR SHAFT BEARING



COUNTERSHAFT BEARING



DRIVESHAFT BEARING



FINAL REDUCTION FINAL CASE FINALREDUCTION REDUCTION CASE



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



COUNTERSHAFT BEARING



FINAL GEAR SHAFT BEARING



FINAL GEAR SHAFT OIL SEAL



LEFT LEFTCRANKCASE CRANKCASECOVER COVER Lepaskan leftleft crankcase Remove the crankcasecover cover (hal. (page8-5). 8-5).



DRIVESHAFT BEARING



Putar inner race driveshaft bearing jari-jari. Turn the inner racedari of the driveshaft bearingdengan with your finger. Bearing harusshould berputar dan tanpa The bearing turn dengan smoothlyhalus and quietly. Alsosuara. check Juga periksa bearing outerinrace duduk dengan that the bearingbahwa outer race fits tightly the crankcase cover. Replace bearing ifcover. it does not turn smoothly, quietly, or if erat padathe crankcase it fits bearing loosely on theiacrankcase cover. dengan halus, tanpa jika tidak berputar Ganti suara, atau jika ia duduk dengan longgar pada crankcase cover.



GEAR/SHAFT GEAR/SHAFT DRIVESHAFT DRIVESHAFT



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



DRIVESHAFT



9-9



FINAL REDUCTION COUNTER GEAR/COUNTERSHAFT/FINALGEAR GEAR COUNTER GEAR/COUNTERSHAFT/FINAL SHAFT SHAFT



Check the countershaft, counter gear and final gear shaft for Periksa countershaft, counter gear dan final gear shaft wear or damage. terhadap keausan atau kerusakan.



FINAL GEAR SHAFT



COUNTER GEAR



COUNTERSHAFT



FINAL REDUCTION BEARING PENGGANTIAN REPLACEMENTFINAL REDUCTION BEARING DRIVESHAFT BEARING 10 x 32



DRIVESHAFT



DRIVESHAFT BEARING (6204)



LEFT CRANKCASE COUNTERSHAFT BEARING (6201)



FINAL GEAR SHAFT BEARING (6022 UU) LEFT CRANKCASE COVER



OIL SEAL 20 x 32 x 6 COUNTERSHAFT BEARING (6301)



FINAL GEAR SHAFT BEARING (6302)



9-10



OIL SEAL 29 x 44 x 7



FINAL REDUCTION CASE



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



SNAP RING



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



DRIVESHAFT BEARING/BUSHING Jika bearing tertinggal di dalam left crankcase cover:



DRIVESHAFT BEARING



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



DRIVER



ATTACHMENT



DRIVESHAFT BEARING



PILOT



9-11



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



SNAP RING



LEFT LEFTCRANKCASE CRANKCASE Separate thereduction final reduction Belah final case case (hal.(page 9-6). 9-6).



SET PLATE



Remove the two bolts setset plate. Lepaskan kedua boltsand dan plate.



BOLTS Hati-hati agar not tidakto Lepaskan danfinal finalgear gear bearings Be careful Remove thecountershaft countershaft and shaftshaft bearings using merusak permukaan menggunakan special tools. damage the final dengan the special tools. penyatuan final reduction case mating reduction case. TOOLS: surface. TOOLS:



Countershaft bearing: Countershaft bearing: Bearing remover 1212 mm Bearing removerhead, head, mm Bearing removershaft, shaft, mm Bearing remover 1212 mm Remover weight Remover weight Final bearing: Finalgear gear shaft shaft bearing: Bearing removerhead, head, mm Bearing remover 1515 mm Bearing remover shaft, 15 mm Bearing remover shaft, 15 mm Remover weight Remover weight



9-12



07936-1660110 07936-1660110 07936-1660120 07936-1660120 07741-0010201 07741-0010201 07936-KC10200 07936-KC10200 07936-KC10100 07936-KC10100 07741-0010201 07741-0010201



FINAL GEAR SHAFT BEARING



COUNTERSHAFT BEARING



FINAL REDUCTION Sisi yang bertandaside dariof The marked masing-masing each bearing bearing is facing menghadap ke special the special tools. tools.



Apply engine oil topada each bearing cavity. rongga bearing. Oleskan oli mesin masing-masing Drive each new bearing into the left crankcase baru squarely until Dorong masuk masing-masing bearing secara it is fully seated, using the special tools. tegaklurus ke dalam left crankcase sampai ia duduk sepenuhnya, dengan menggunakan special tools. TOOLS: Countershaft bearing: TOOLS: Driver 07749-0010000 Countershaft Attachment,bearing: 37 x 40 mm 07746-0010200 Driver 07749-0010000 Pilot, 12 mm 07746-0040200 Attachment, 37 x 40 mm 07746-0010200 Final gear shaft bearing: Pilot, 12 mm 07746-0040200 Driver 07749-0010000 Final gear shaft bearing: Attachment, 42 x 47 mm 07746-0010300 Driver 07749-0010000 Pilot, 15 mm 42 x 47 mm 07746-0040300 Attachment, 07746-0010300 Pilot, 15 mm 07746-0040300



COUNTERSHAFT BEARING



FINAL GEAR SHAFT BEARING DRIVER



ATTACHMENT



PILOT



BEARING



Bersihkan dan oleskan cairanto pengunci pada set Clean and apply locking agent the set plate bolt ulir threads from bolt its tipdari to 6.5 ± 1.0 mm (0.26 ±6,5 0.04 in) down. plate ujungnya sampai ± 1,0 mm ke bawah.



SET PLATE TANDA"OUT"



Install the set plate with its "OUT" mark facing out. Pasang set plate dengan tanda "OUT" padanya Install and tighten the set plate bolts. menghadap ke luar. Pasang dan kencangkan set plate bolts.



6.5 ± 0.1 mm (0.26 ± 0.04 in) BOLTS



DRIVESHAFT DRIVESHAFT Remove the two bolts and set plate.



SET PLATE



Lepaskan kedua bolts dan set plate.



BOLTS



9-13



FINAL REDUCTION Remove the driveshaftdengan using the special tool. special tool. Lepaskan driveshaft menggunakan TOOL: TOOL: Case puller Case puller



DRIVESHAFT



07SMC-0010001 07SMC-0010001



CASE PULLER



CASE PULLER



DRIVESHAFT



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



Remove thedriveshaft driveshaft bearing using a hydraulic press. Lepaskan bearing dengan menggunakan hydraulic press.



SNAP RING



BEARING



DRIVESHAFT



9-14



FINAL REDUCTION Lepaskan driveshaft Remove the driveshaftoiloilseal. seal.



Sisi yang bertanda dari masing-masing bearing The marked side of menghadap ke special each bearing is tools. facing the special tools.



DRIVESHAFT OIL SEAL



Apply engineolioilmesin to the pada bearing cavity.bearing. Semprotkan rongga Drive a new driveshaft bearing into the left crankcase squarely until it is fully seated,driveshaft using the special tools.secara Dorong masuk sebuah bearing tegaklurus ke dalam left crankcase sampai ia duduk TOOLS: sepenuhnya, dengan menggunakan special tools. Driver 07749-0010000 Attachment, 42 x 47 mm 07746-0010300 TOOLS: Pilot, 20 mm 07746-0040500 Driver 07749-0010000 Attachment, 42 x 47 mm 07746-0010300 Pilot, 20 mm 07746-0040500



DRIVESHAFT BEARING



DRIVER



ATTACHMENT



DRIVESHAFT BEARING



Install the driveshaftkeinto the bearing. Pasang driveshaft dalam bearing. Position the assembly collar on pada the driveshaft bearing inner Tempatkan assembly collar driveshaft bearing race and drive shaft drive into the bearing until itbearing is fully inner racepull danthe tarik keluar shaft ke dalam seated. ia duduk sepenuhnya. sampai TOOLS: TOOLS: Assembly shaft Assembly shaft Assembly collar Assembly collar Assembly collarattachment attachment Assembly collar



PILOT



ASSEMBLY COLLAR



DRIVESHAFT BEARING



ASSEMBLY SHAFT



07965-1660200 07965-1660200 07965-GM00100 07965-GM00100 07965-GM00200 07965-GM00200



ASSEMBLY COLLAR ATTACHMENT



DRIVESHAFT BEARING



ASSEMBLY COLLAR



ASSEMBLY COLLAR ATTACHMENT



ASSEMBLY SHAFT



9-15



FINAL REDUCTION Pasang Install thesnap snapring ring Pasang Install the snapring ringpada to thealur driveshaft groove. snap driveshaft. dengan yang withujungnya the chamfered dipotong edge menghadap ke facing the bearing. bearing.



SNAP RING



Semprotkan pada bibir driveshaft oil seal baru. Apply engineoli oilmesin to a new driveshaft oil seal lip.



DRIVESHAFT OIL SEAL



Jangan driveshaft ia flush rata with dengan Install the driveshaftoiloilseal seal sampai until it is the left Do notmasukkan insert the oil oil Pasang seal terlalu dalam crankcase. seal too far. crankcase.



TOOLS: TOOLS: Assembly shaft Assembly shaft Assembly collar Assembly collar Assembly collar attachment Assembly collar attachment



ASSEMBLY COLLAR



07965-1660200 07965-1660200 07965-GM00100 07965-GM00100 07965-GM00200 07965-GM00200



ASSEMBLY SHAFT



ASSEMBLY COLLAR ATTACHMENT ASSEMBLY COLLAR ATTACHMENT ASSEMBLY COLLAR



DRIVESHAFT OIL SEAL



Bersihkan dan locking oleskanagent cairan pengunci pada ulir set Clean and apply to the set plate bolt threads from tip to 6.5 sampai ± 1.0 mm6,5 (0.26 ± 0.04 plate bolt dariitsujungnya ± 1,0 mm in) ke down. bawah.



ASSEMBLY SHAFT



SET PLATE TANDA"OUT"



Install the set plate with its "OUT" mark facing out. Pasang set plate dengan tanda "OUT" menghadap Install and tighten the set plate bolts. keluar. Pasang dan kencangkan set plate bolts.



6.5 ± 0.1 mm (0.26 ± 0.04 in) BOLTS



9-16



FINAL REDUCTION FINAL REDUCTION CASE FINAL REDUCTION CASE Separate the final reduction case (page 9-6). Belah final reduction case (hal. 9-6). Remove the final gearshaft shaftoil oilseal. seal. Be careful Hati-hati agar not tidakto Lepaskan final gear



COUNTERSHAFT BEARING



FINAL GEAR SHAFT BEARING



damage the final merusak permukaan Remove the final gear shaft bearing. reduction case mating penyatuan final Lepaskan final gear shaft bearing. surface. reduction cace Remove the countershaft bearing using the special tools.



Lepaskan countershaft bearing dengan menggunakan special tools. TOOLS: TOOLS: Bearing remover remover head, 07936-1660110 Bearing head,1212mm mm 07936Bearing remover shaft, 12 mm 07936-1660120 1660110 Removerremover weight shaft, 12 mm 07741-0010201 Bearing 079361660120 Remover weight 077410010201



The marked side of Sisi yang di tandai dari bearing is facing the masing – masing tools. bantalan special menghadapi special tools.



Apply engine oil the countershaft Semprotkan oli to mesin pada bearing ronggacavity. countershaft bearing. Drive a new final gear shaft bearing into the final reduction Dorong masuk final gear shaft bearing baru secara case squarely until it is fully seated, using the special tools. tegaklurus ke dalam final reduction case sampai duduk sepenuhnya, dengan menggunakan special tools. TOOLS: Driver 07749-0010000 TOOLS: Attachment, 32 x 35 mm 07746-0010100 Driver 077490010000 Pilot, 12 mm 07746-0040200 Attachment, 32 x 35 mm 077460010100 Pilot, 12 mm 077460040200



OIL SEAL



DRIVER



ATTACHMENT



PILOT



COUNTERSHAFT BEARING



The marked Hati-hati agarside tidakof bearing is facing the merusak permukaan special tools. penyatuan final reduction cace



Semprotkan oli tomesin final cavity. gear shaft Apply engine oil the finalke gearrongga shaft bearing bearing. Drive a new final gear bearing into bearing the final reduction secara Dorong masuk finalshaft gear shaft case squarely until it is fully seated, using the special tools. tegaklurus ke dalam final reduction case sampai ia duduk sepenuhnya, dengan menggunakan special TOOLS: tools. Driver 07749-0010000 TOOLS: Attachment, 40 x 42 mm 07746-0010900 Driver 07749Pilot, 22 mm 07746-0041000 0010000 Attachment, 40 x 42 mm 077460010900 Pilot, 22 mm 077460041000 Apply engineoli oilmesin to a new finalbibir gearfinal shaftgear oil seal lip.oil seal Semprotkan pada shaft baru. Install the oil seal with the flat side facing the rear wheel side so that the depth from the final reduction case surface is 1.0 ± Pasang seal dengan sisinya yang datar 0.4 mm oil (0.04 ± 0.02 in) using the special tools. menghadap ke sisi roda belakang sehingga kedalamannya dari permukaan final reduction case adalah 1,0 ± 0,4 mm TOOLS: dengan menggunakan special tools. Driver 07749-0010000 Attachment, 42 x 47 mm 07746-0010300 TOOLS: Driver 077490010000 Attachment, 42 x 47 mm 077460010300



DRIVER



ATTACHMENT



FINAL GEAR SHAFT BEARING



PILOT



DRIVER ATTACHMENT



1.0 ± 0.4 mm (0.04 ± 0.02 in) FINAL GEAR SHAFT OIL SEAL



9-17



CATATAN



10. CRANKCASE/CRANKSHAFT



LOKASI KOMPONEN ............................10-2



PEMBELAHAN CRANKCASE...............10-5



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



PERAKITAN CRANKCASE ...................10-8



TROUBLESHOOTING ...........................10-4



PEMERIKSAAN CRANKSHAFT ...........10-12



COMPONENT LOCATION ··························10-2 SERVICE INFORMATION ···························10-3 TROUBLESHOOTING ··································10-4



CRANKCASE SEPARATION ·······················10-5 CRANKCASE ASSEMBLY ···························10-8 CRANKSHAFT INSPECTION····················10-12



10



10-1



CRANKCASE/CRANKSHAFT



COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN CRANKCASE/CRANKSHAFT



10-2



CRANKCASE/CRANKSHAFT



SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM



• This section covers the crankcase separation to service the crankshaft. ?• The following parts pembelahan must be removed before separating the crankcase. Bab ini meliputi crankcase untuk menservis crankshaft. Engineberikut (page 6-4) • ? Parts ini harus dilepaskan sebelum membelah crankcase. ? -Cylinder Mesin head (hal. (page 6-4) 7-14) ? -Cylinder (page 7-32) Cylinder head (hal. 7-14) ? -Piston (page 7-34) Cylinder (hal. 7-32) ? -Starter pinion Piston (hal.(page 7-34)16-10) ? -Drive pulley (page 8-12) Starter pinion (hal. 16-10) ? -Clutch/driven Drive pulleypulley (hal. (page 8-11) 8-16) ? -Starter motor (page 16-6)(hal. 8-15) Clutch/driven pulley ? -Flywheel/stator Starter motor(page (hal.14-7) 16-6) ? In addition to the parts listed above, remove the following parts when the left crankcase must be replaced. - Flywheel/stator (hal. 14-8) ? Final reduction (page 9-6) di atas, lepaskan parts berikut ini jika ?• In Selain additionparts to theyang partsdisebut listed above, remove the following parts when the left rightcrankcase crankcase harus must bediganti. replaced. ? -OilFinal pumpreduction (page 4-4)(hal. 9-6) disebut di atas, lepaskan parts when berikut ini jika right crankcasethe harus diganti. ?• BeSelain carefulparts not toyang damage the crankcase mating surfaces separating and assembling crankcase halves. - Oilallpump (hal. 4-4) ? Clean disassembled parts with clean solvent and dry them using compressed air before inspection. Hati-hati agarthe tidak merusak penyatuan crankcase sewaktu merakit ?• When installing crankshaft, be permukaan sure to use the special tools; position the specialmembelah tools on thedan bearing innerbelahan race and crankcase. pull the crankshaft into • theBersihkan semua parts yang dibongkar dengan cairan pelarut bersih dan keringkan dengan udara dari kompressor bearing until it is fully seated. sebelum pemeriksaan. • Sewaktu memasang crankshaft, pastikan untuk memakai special tools; tempatkan special tools pada bearing inner race SPECIFICATIONS dan tarik crankshaft ke dalam bearing sampai ia duduk sepenuhnya.



SPESIFIKASI Crankshaft Crankshaft



Satuan: mm ITEM STANDARD BAGIAN STANDARD BATAS SERVIS Jarak renggang 0,10 – 0,35 Connecting rod ke sidesamping clearanceconnecting rod 0.10 – 0.35 (0.004 – 0.014) 0,55 Jarak renggang connecting rod – 0,012 0,05 Connecting rod radial radial clearance 0 –00.012 (0 – 0.0005) Keolengan 0,10 Runout –



Unit: mm (in) SERVICE LIMIT 0.55 (0.022) 0.05 (0.002) 0.10 (0.004)



TOOLS TOOLS Case puller 07SMC-0010001



Assembly shaft 07965-VM00200



Assembly collar 07965-VM00100



Assembly shaft adaptor 07WMF-KFF0200



Assembly collar 07931-KF00100



Attachment, 62 x 68 mm 07746-0010500



10-3



CRANKCASE/CRANKSHAFT Pilot, 35 mm 07746-0040800



Driver 07749-0010000



Oil seal driver 07965-KE80200



Fork seal driver attachment 41.2 mm 07947-KF00100



Universal bearing puller 07631-0010000



Attachment, 24 x 26 mm 07746-0010700



TROUBLESHOOTING TROUBLESHOOTING



Abnormal noise Suara tidak normal ? Worn crankshaft bearing • Crankshaft bearing aus ? Worn connecting rod big end bearing • Connecting rod big end bearing (bantalan kepala ? Worn connecting rod small end (page 7-37) besar connecting rod) • Connecting rod small end (kepala kecil connecting rod) aus (hal. 7-37)



10-4



CRANKCASE/CRANKSHAFT



CRANKCASE SEPARATION PEMBELAHAN CRANKCASE Refer keterangan to service information (page 10-3)untuk for theparts parts mana which Lihat servis (hal. 10-3) must harus be removed before sebelum separatingmembelah the crankcase. yang dilepaskan crankcase. Unhook the centerstand return spring. Lepaskan kaitan dari centerstand return spring (pegas pengembalian standard utama).



RETURN SPRING



Lepaskan cotter Remove the cotterpin pindan andwasher. washer.



COTTER PIN



WASHER



Remove the boltdan andcollar collardari frompivot the pivot Lepaskan bolt shaft.shaft. Pull out the pivot remove the centerstand. Tarik keluar pivotshaft shaftand dan lepaskan centerstand.



COLLAR



BOLT



PIVOT SHAFT



Lepaskan crankcase dari right crankcase. Remove the crankcase bolts bolts from the right crankcase.



CENTERSTAND



BOLTS



10-5



CRANKCASE/CRANKSHAFT Be careful to Letakkan Place the crankcase crankcase with the left facing down and Hati-hati agar not tidak dengan leftcrankcase crankcase menghadap merusak damage permukaan the ke separate leftpisahkan and right left crankcase. bawahthe dan dan right crankcase. penyatuan crankcase. crankcase mating surface.



RIGHT CRANKCASE



LEFT CRANKCASE



Lepaskan dowel Remove the dowelpins pinsdari fromleft thecrankcase. left crankcase.



DOWEL PINS



Lepaskan oiloil seal right Remove the sealdari from the crankcase. right crankcase.



OIL SEAL



Release the cam from dari the timing sprocket on the crankLepaskan camchain chain timing sprocket pada shaft using a screwdriver as shown. crankshaft dengan menggunakan obeng seperti diperlihatkan.



SCREWDRIVER



TIMING SPROCKET



10-6



CAM CHAIN



CRANKCASE/CRANKSHAFT Sewaktu melepaskan When removing the crankshaft, crankshaft, beberhaticareful agar nothatilah to pinch thetidak cam menjepit camtiming chain chain between antarasprocket timing sprocket and left dan left crankcase. crankcase.



Hold the cam cam chain the timing remove dan the Pegang chainoffterlepas darisprocket timing and sprocket crankshaft from the left crankcase usingcrankcase the case puller. keluarkan crankshaft dari left dengan menggunakan puller. Remove the camcase chain. Lepaskan cam chain. TOOL: TOOL: Case puller Case puller



LEFT CRANKCASE CRANKSHAFT CASE PULLER



07SMC-0010001 07SMC-0010001



CAM CHAIN (Jangan di jepit)



CASE PULLER



CRANKSHAFT



Remove snap ringring anddan oil seal. Lepaskan snap oil seal.



OIL SEAL



SNAP RING



10-7



CRANKCASE/CRANKSHAFT Lepaskan leftleftcrankshaft dengan Remove the crankshaft bearing bearing using the menggunakan special tool. special tool. TOOL: Universal bearing puller 07631-0010000 TOOL: Universal bearing puller 07631-0010000 ? If the left crankshaft bearing remains in the crankcase, remove it to the right side. - Jika left crankshaft bearing tertinggal pada crankcase, lepaskan ke sisi kanan.



CRANKSHAFT



BEARING



BEARING PULLER Jika left crankshaft bearing tertinggal pada crankcase:



LEFT CRANKSHAFT BEARING



PERAKITAN CRANKCASE CRANKCASE ASSEMBLY Hati-hati agar tidak Be careful not to Bersihkan Clean the inside and mating surface of the crankcases. bagian dalam dan permukaan penyatuan dari merusak permukaan Check for cracks or other damage. damage the crankcases. penyatuan crankcase. crankcase mating Periksa terhadap retak-retak atau kerusakan lain. Remove any roughness or irregularities with an oil stone. surface.



PERMUKAAN PENYATUAN



Buanglah kekasaran atau ketidak-teraturan dengan batu asah.



Apply 2 cc minimum to a pada new left crankcase Semprotkan minimumof2 engine cc oli oil mesin sebuah left bearing. bearing baru. crankcase Drive the left crankcase bearing into the left crankcase secaratool. tegaklurus Dorong crankcase bearing squarelymasuk until it left is fully seated, using the special ke dalam left crankcase sampai ia duduk sepenuhnya, dengan menggunakan special tool. TOOLS: Driver 07749-0010000 TOOLS: Attachment, 62 x 68 mm 07746-0010500 Driver 07749-0010000 Pilot, 35 mm 07746-0040800 Attachment, 62 x 68 mm 07746-0010500 Pilot, 35 mm 07746-0040800



DRIVER



ATTACHMENT



PILOT LEFT CRANKCASE BEARING



10-8



CRANKCASE/CRANKSHAFT Install the crankshaftkeinto the left bearing. Pasang crankshaft dalam leftcrankcase crankcase bearing. Install the assemblyshaft shaftadaptor adaptor to the left Pasang assembly pada left crankshaft. crankshaft.



When pulling the Sewaktu menarik crankshaft into the crankshaft bearing, ke be dalam careful bearing, berhati-hatilah not to damage the agar tidak merusak connectingrod. rod. connecting



Position the assembly A onA the left crankcase bearing Tempatkan assemblycollar collar pada left crankcase inner race and set the assembly collar B to the assembly colbearing inner race (lingkaran dalam bantalan crankcase lar A. kiri) dan tempatkan assembly collar B pada assembly collar InstallA.the assembly shaft to the assembly collar B and screw it onto the crankshaft while aligning the center of the assemPasang shaft pada assembly collar B dan bly collarassembly B and the assembly shaft. sekrupkan pada crankshaft sementara mentepatkan Pull thetengah crankshaft intoassembly the bearingcollar until itBis dan fully assembly seated. bagian dari shaft. TOOLS: Tarik crankshaft ke dalam bearing07WMF-KFF0200 sampai ia duduk Assembly shaft adaptor sepenuhnya. Assembly shaft 07965-VM00200 Assembly collar A 07965-VM00100 TOOLS: Assembly collar B 07931-KF00100 Assembly shaft adaptor 07WMF-KFF0200 Assembly shaft 07965-VM00200 Assembly collar A 07965-VM00100 Assembly collar B 07931-KF00100



ASSEMBLY SHAFT ADAPTOR



ASSEMBLY COLLAR B



ASSEMBLY SHAFT



ASSEMBLY COLLAR A ASSEMBLY COLLAR A



CRANKSHAFT



ASSEMBLY SHAFT ADAPTOR



ASSEMBLY COLLAR B



Apply engine oil topada a newbibir oil seal lip. Oleskan oli mesin oil seal. Install the sealsecara to the right crankcase squarely shown. Pasang oil oil seal tegaklurus pada right as crankcase seperti diperlihatkan. TOOLS: TOOLS: Driver 07749-0010000 Driver 07749-0010000 Attachment, 24 x 26 mm 07746-0010700 Attachment, 24 x 26 mm 07746-0010700



ASSEMBLY SHAFT



DRIVER OIL SEAL ATTACHMENT 10.4-10.9 mm (0.41-0.43 in)



OIL SEAL



Apply liquid sealant (Three Bond 1207B or three bondBond 1215 Oleskan liquid sealant (cairan perapat) (Three or equivalent) to the crankcase mating 1207B atau Three Bond 1215 atausurface. sejenisnya) pada permukaan penyatuan crankcase.



10-9



CRANKCASE/CRANKSHAFT Apply 2 cc minimum of engine crankshaft bearSemprotkan minimum 2 cc oilolito right mesin pada right ing. crankshaft bearing. Apply 3 cc minimum of engine oil to connecting rod big end. Semprotkan minimum 3 cc oli mesin pada connecting Install dowel pins to the left crankcase. rod big the end. Pasang dowel pins pada left crankcase.



DOWEL PINS



Rakit left dan crankcase. Assemble the right left and right crankcase.



RIGHT CRANKCASE



LEFT CRANKCASE



Install the crankcase bolts bolts dan and tighten them indalam a crisscross Pasang crankcase kencangkan pola pattern in 2 -dalam 3 steps.2 – 3 langkah. bersilangan



Semprotkan padasprocket timing and sprocket dan cam Apply engineoli oil mesin to the timing cam chain. chain. Install the cam chain to the timing sprocket. Pasang cam chain pada timing sprocket.



BOLTS



CAM CHAIN



TIMING SPROCKET



10-10



CRANKCASE/CRANKSHAFT Apply engine oil to apada new bibir oil seal Oleskan oli mesin oil lip. seal baru.



OIL SEAL DRIVER



Install theoiloil sealsecara to the tegaklurus left crankcase squarely until it is left crankcase Pasang seal pada fully seated, using thesepenuhnya, special tool. dengan menggunakan sampai ia duduk special tool. TOOLS: TOOLS: Oil seal driver 07965-KE80200 Oil seal 07965-KE80200 Fork sealdriver driver attachment, Fork seal driver attachment, 41.2 mm 07947-KF00100 41.2 mm 07947-KF00100



FORK SEAL DRIVER ATTACHMENT



OIL SEAL



Set the snap ring into thepada left crankcase groove. Tempatkan snap ring alur left crankcase.



SNAP RING



Apply thin coat of grease centerstand shaft surOleskan lapisan tipisto the gemuk padapivot permukaan face. centerstand pivot shaft (poros engsel standard utama).



COLLAR



Install the centerstand and insert the pivot shaft from the left PIVOT SHAFT Pasang dan masukkan pivot shaft dari sisi crankcasecenterstand side. left crankcase. Install the collar to the pivot shaft. Pasang collar pada pivotagent shaft.to the pivot shaft mounting Clean and apply locking bolt threads from its tip to 6.5 ± 1.0agent mm (0.26 0.04 in) (cat ±pengunci) Bersihkan dan oleskan locking down, ulir thenpivot installshaft and tighten it. bolt (baut pemasangan pada mounting poros engsel) dari ujungnya sampai 6,5 ± 1,0 mm kebawah, kemudian pasang dan kencangkan. CENTERSTAND



6.5 ± 0.1 mm (0.26 ± 0.04 in)



BOLT



Pasang pin baru. Install thewasher washerdan and cotter new cotter pin. COTTER PIN



WASHER



10-11



CRANKCASE/CRANKSHAFT Hook thecenterstand centerstand return Kaitkan returnspring. spring (pegas pengembalian standard utama). Refer to service information (page 10-3) for installation of parts removed to perform 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 crankshaft(hal. (page10-5). 10-5). Lepaskan crankshaft Turn the outerrace racedari of the rightcrankshaft crankshaft bearing your Putar outer right bearingwith dengan finger. The bearing should turn smoothly quietly. Also jari-jari. Bearing harus berputar dengan and halus dan tanpa check that bearingbahwa inner race fits tightly on theduduk right suara. Jugatheperiksa bearing inner race crankshaft. dengan erat pada right crankshaft. Replace the bearings if they do not turn or Ganti bearings apabila mereka tidaksmoothly, berputarquietly, dengan if they fit loosely on theatau right jika crankshaft. halus, tanpa suara, mereka duduk dengan longgar pada right crankshaft.



Jika gigi timing sprocket aus rusak,sprocket periksa Periksa If atau the timing Check the pump drive drive gear teeth for oiloilpump gearand dantiming gigi sprocket timing sprocket cam chain, wear or damage. teethtensioner are worndan or terhadap keausan atau kerusakan. cam check sprocket. damaged, the cam chain, tensioner and cam sprocket.



RIGHT CRANKCASE BEARING



OIL PUMP DRIVE GEAR



TIMING SPROCKET



Ukur jarakthe renggang ke rod samping connecting rod big enda Measure connecting big end side clearance with dengan feeler gauge. feeler gauge. BATAS SERVIS: 0,55 mm SERVICE LIMIT: 0.55 mm (0.022 in)



10-12



FEELER GAUGE



CRANKCASE/CRANKSHAFT Set the crankshaft on V-blocks and measure connecting Tempatkan crankshaft pada V-blocks dantheukur jarak rod big end radialconnecting clearance. rod big end. renggang radial BATAS SERVIS: 0,05 mm SERVICE LIMIT: 0.05 mm (0.002 in)



Set the crankshaft on V-blocks and measure the runout using a dial indicator. Actual runoutcrankshaft is 1/2 of total pada indicatorV-blocks reading. dan ukur Tempatkan keolengan dengan menggunakan dial indicator. Keolengan SERVICE sebenarnya adalah ½ dari pembacaan total indicator. LIMIT: 0.10 mm (0.004 in) BATAS SERVIS: 0,10 mm



65 mm (2.6 in)



35 mm (1.4 in)



10-13



CATATAN



11. RODA DEPAN/SUSPENSI/KEMUDI



LOKASI KOMPONEN-KOMPONEN......11-2 COMPONENT LOCATION ··························11-2



FORK .............................................11-11 FORK ······························································11-11



KETERANGAN SERVIS ........................11-3 SERVICE INFORMATION ···························11-3



HANDLEBAR .................................11-19 HANDLEBAR ················································11-19



TROUBLESHOOTING TROUBLESHOOTING...........................11-6 ··································11-6



STEERING STEM ..........................11-21 STEERING STEM·········································11-21



RODA DEPAN........................................11-7 FRONT WHEEL··············································11-7



11



11-1



RODA DEPAN/SUSPENSI/KEMUDI



COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN FRONT WHEEL/SUSPENSION/STEERING



1 N·m (0.1 kgf·m, 0.7 lbf·ft)



4.5 N·m (0.5 kgf·m, 3.3 lbf·ft)



59 N·m (6.0 kgf·m, 44 lbf·ft)



64 N·m (6.5 kgf·m, 47 lbf·ft)



59 N·m (6.0 kgf·m, 44 lbf·ft)



11-2



RODA DEPAN/SUSPENSI/KEMUDI



SERVICE INFORMATION KETERANGAN SERVIS GENERAL



UMUM



! PERINGATAN Frequentmenghirup inhalation ofdebu brakebrake pad and regardless material composition hazardous to yourkesehatan. health. Seringkali padshoe dandust, shoe, apapunofkomposisi bahannya,could dapatbemembahayakan • Avoid breathing dust particles. • Jangan menghirup partikel-partikel debu. • Never use an air hose or brush to clean brake assemblies. Use an OSHA-approved vacuum cleaner. • Jangan sekali-kali memakai slang udara atau sikat untuk membersihkan susunan rem. Pakailah alat penghisap debu yang baik. • This section covers the front wheel, fork, handlebar and steering stem. •• When Bab ini meliputi fork or (garpu), (stang stir) dan steering (poros kemudi). servicing theroda frontdepan, wheel, fork steeringhandlebar stem, support the scooter using a jackstem or other support. •• AKetika menservis roda depan, fork atau steering stem, dukung skuter dengan menggunakan dongkrakdisc atau alata high pendukung contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated with quality lain. degreasing agent. brake •• After Brake pad yang terkontaminasi mengurangi pengereman. Buanglah pads yang terkontaminasi dan bersihkan thedisc frontatau wheel installation, check the brake operation bydaya applying the brake lever. disc yang terkontaminasi dengan • For brake system service, refer to pagebahan 13-3. pembersih gemuk berkualitas tinggi untuk peralatan rem. • Setelah pemasangan roda depan, periksa cara kerja rem dengan menarik brake lever (handel rem). • Untuk servis sistem rem, lihat hal. 13-3.



SPECIFICATIONS SPESIFIKASI



ITEM BAGIAN Minimum tire tread depth Kedalaman minimum alur kembang ban Cold tire pressure Driver only Tekanan udara ban Pengendara saja Driver and passenger (dingin) Pengendara dan pembonceng Axle runout Keolengan poros roda Wheel rim runout Radial Keolengan pelek roda Radial Axial Aksial Fork Spring free length Fork Panjang bebas pegas Pipe runout Keolengan pipe Recommended fluid Fluida garpu yang dianjurkan Fluid level Tinggi permukaan fluida Fluidfluida capacity Kapasitas



STANDARD STANDARD – 2 200 kPa (2.00 kgf/cm , 29 psi) 2 200 kPa (2,00 kgf/cm , 29 2 psi) , 29 psi) 200 kPa (2.00 kgf/cm 2 200 kPa (2,00 kgf/cm , 29 psi) – – – 311.3 (12.26) 311,3 – Fork fluid Fluida garpu (minyak sokbreker) 50 (2.0) 50 75 ± 31 cm3 (2.5 ± 0.03 US oz, 75 ± 1 cm 2.6 ± 0.04 Imp oz)



Unit: mm (in) SERVICE Satuan: mm LIMIT BATAS SERVIS To the indicator Sampai ke indikator – – 0.2 (0.01) 0,2 2.0 (0.08) 2,0 2.0 (0.08) 2,0 305.1 (12.01) 305,1 0.2 (0.01) 0,20 – – – -



NILAI TORSI



TORQUE Front axle nutVALUES Front brake disc socket bolt Front axlepost nut nut Handlebar Front brake disc pivot socketbolt bolt Rear brake lever Handlebar post nut Rear brake lever pivot nut Rear brake lever pivot bolt Bottom bridge pinch bolt Rear brake bolt lever pivot nut Fork socket Bottomstem bridgetop pinch bolt Steering thread Fork socket Steering stembolt lock nut Steering stem top thread Steering stem lock nut



59 N.m (6,0 kgf.; 44 lbf.ft) 42 N.m (4,3 kgf.m; 31 lbf.ft) 59 N·m kgf·m, lbf·ft) 59 N.m (6,0(6.0 kgf.m; 4444 lbf.ft) 42 N·m (4.3 kgf·m, 31 lbf·ft) 1 N.m (0,1 kgf.m; 0,7 lbf.ft) 59 N·m (6.0 kgf·m, 44 lbf·ft) 4,5 N.m (0,5 kgf.m; 3,3 lbf.ft) 1 N·m (0.1kgf.m; kgf·m,47 0.7lbf.ft) lbf·ft) 64 N.m (6,5 4.5 N·m kgf·m, lbf·ft) 20 N.m (2,0(0.5 kgf.m; 15 3.3 lbf.ft) 64hal. N·m11-22 (6.5 kgf·m, 47 lbf·ft) Lihat 20hal. N·m11-22 (2.0 kgf·m, 15 lbf·ft) Lihat See page 11-22 See page 11-22



U-nut ALOC bolt; ganti dengan yang baru U-nut ALOC bolt; replace with new ones



Oleskan locking agent pada ulir



Apply locking agent to the threads



11-3



RODA DEPAN/SUSPENSI/KEMUDI TOOLS Bearing remover shaft 07746-0050100



Bearing remover head, 12 mm 07746-0050300



Driver 07749-0010000



Attachment, 32 x 35 mm 07746-0010100



Pilot, 12 mm 07746-0040200



Fork seal driver body 07747-0010100



Fork seal driver attachment, 27.2 mm 07747-0010300



Pin spanner 07702-0020001



Socket wrench 07916-KM10000



Steering stem socket 07916-3710101



Ball race remover shaft 07GMD-KS40100



Ball race remover, 34.5 mm 07948-4630100



11-4



RODA DEPAN/SUSPENSI/KEMUDI Bearing driver attachment 07946-3710701



Oil seal driver, 53.5 mm 07947-SB00200



Fork seal driver attachment, 35.2 mm 07947-KA20200



Oil seal remover 07748-0010001



11-5



RODA DEPAN/SUSPENSI/KEMUDI



TROUBLESHOOTING TROUBLESHOOTING Hard steering Kemudi berattire pressure • Insufficient •• Faulty Tekanan tire udara ban kurang •• Steering Ban rusak stem lock nut too tight steering head •• Faulty Steering stem lockbearing nut terlalu kencang steering head bearing race •• Faulty Steering head bearing rusak steering stembearing race rusak •• Bent Steering head •Steers Steering stem to one side orbengkok does not track straight • Bent front axle Kemudi ke satu sisi atau tidak dapat berjalan lurus • Wheelmenarik installed incorrectly •• Worn Frontoraxle bengkok damaged front wheel bearings fork •• Bent Roda tidak terpasang dengan benar or damaged engineaus mounting bushings •• Worn Bearings roda depan atau rusak •• Bent Forkframe bengkok steering head bushings bearing aus atau rusak •• Faulty Engine mounting •FrontRangka bengkok wheel wobbles fronthead axle fasteners •• Loose Steering bearing rusak • Bent rim • Worn or damaged front wheel bearings Roda depan bergoyang •FrontPengikat fronthard axle longgar wheel turns •• Front Pelek bengkok brake drag •• Bent Bearings roda depan aus atau rusak front axle • Faulty front wheel bearings Roda depan berat perputarannya Soft suspension •• Low Rem menyangkut tiredepan pressure •• Deteriorated Front axle fork bengkok fluid •• Incorrect Bearings roda depan rusak fork fluid weight • Insufficient fluid in fork Suspensi lunak • Weak fork spring • Tekanan udara ban rendah Hard suspension • Fork fluid memburuk kondisinya • High tire pressure •• Too Berat fork fluid much fluid in tidak fork benar fluid di dalam fork •• Incorrect Tidak ada forkcukup fluid weight •• Bent Forkfork spring lemah pipes • 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 •• Loose Beratfork forkfasteners fluid tidak benar • Fork pipes bengkok • Jalan lintasan fork fluid tersumbat Suspensi berisik • Fork slider bengkok • Fluid di dalam fork kurang • Pengikat fork longgar



11-6



RODA DEPAN/SUSPENSI/KEMUDI



FRONTDEPAN WHEEL RODA REMOVAL/INSTALLATION PELEPASAN/PEMASANGAN Raise and support the scooter using dengan safety stand. Naikkan dan dukung skuter menggunakan dongkrak. Remove/install the following: Lepaskan/pasang sebagai berikutnya: – Speedometer cable -– Speedometer cable O-ring -– O-ring Axle nut -– Axle nut Front axle -– Front Frontaxle wheel -– Roda Side depan collar -– Side collar Speedometer gearbox - Speedometer gearbox CATATAN: • Replace the speedometer cable O-ring with a new one. •• Apply Ganti grease speedometer cable O-ring dengan yang baru. to the O-ring, front axle and speedometer • gearbox Periksaascara kerja rem setelah pemasangan ini. specified.



• Check the brake operation after installation.



Lepaskan tab sementara mendorongnya ke dalam dan lepaskan sepeedometer



O-RING FRONT AXLE



Tepatkan alur speedometer gearbox dengan boss paka kaki



* SPEEDOMETER GEARBOX



AXLE NUT 59 N·m (6.0 kgf·m, 44 lbf·ft)



SIDE COLLAR Tepatkan speedometer tabs dengan alur-alur wheel hub.



RODA DEPAN *: Shell BEARING GREASE HD atau sejenisnya.



11-7



RODA DEPAN/SUSPENSI/KEMUDI DISASSEMBLY/ASSEMBLY PEMBONGKARAN/PERAKITAN Remove/install the following: Lepaskan/pasang sebagai berikut: – Dust seals - Dust seals Socketbolts bolts -– Socket – Brake disc - Brake disc – Wheel bearings - Wheel bearings – Distance collar - Distance collar Refer to page 11-9 for wheel bearing replacement. Lihat hal. 11-9 untuk penggantian wheel bearing. • Apply grease to the bearings, dust seal lips and distance collar as specified. • Replace the brake disc socket bolts with new ones.



RIGHT WHEEL BEARING (6201U)



DUST SEAL DUST SEAL



SOCKET BOLTS 42 N·m (4.3 kgf·m, 31 lbf·ft) Kencangkan baut-baut dalam pola bersilangan dalam 2 atau 3 langkah.



DISTANCE COLLAR



LEFT WHEEL BEARING (6201U) BRAKE DISC Pasang brake disc dengan sisi yang bertanda menghadap ke atas.



11-8



RODA DEPAN/SUSPENSI/KEMUDI BEARING REPLACEMENT PENGGANTIAN BEARING (BANTALAN) Install the bearingremover removerhead head into the bearing. Pasang bearing ke dalam bearing. Fromsisi theberlawanan, opposite side,pasang install the bearing removershaft shaft dan and Dari bearing remover drivebearing the bearing out of thewheel wheelhub. hub. drive keluar dari Remove thedistance distance collar drive out the keluar other bearing. Lepaskan collarand dan dorong bearing yang lain. TOOLS: TOOLS: Bearing remover head, 12 mm 07746-0050300 Bearing head, 12 mm 07746-0050300 Bearing remover remover shaft 07746-0050100 Bearing remover shaft 07746-0050100



REMOVER SHAFT



REMOVER HEAD



REMOVER HEAD



BEARING



BEARINGS



REMOVER SHAFT



Jangan sekali-kali Never install the old memasang kembali bearings. Once the bearings lama. bearings haveSekali been bearings telah removed, the bearings dilepaskan, bearings must be replaced with harus diganti dengan new ones. yang baru.



Pack all bearing cavities with grease.gemuk. Isi semua rongga bearing dengan Drive in a new left bearing squarely with its sealed side facing up until it is sebuah fully seated. Dorong masuk bearing kiri baru dengan sisinya yang tertutup menghadap ke atas sampai ia duduk sepenuhnya. TOOLS: Driver 07749-0010000 TOOLS: Attachment, 32 x 35 mm 07746-0010100 Driver 07749-0010000 Pilot, 12 mm 07746-0040200 Attachment, 32 x 35 mm 07746-0010100 Pilot, 12 mm 07746-0040200



REMOVER HEAD



ATTACHMENT



BEARING



DRIVER



PILOT



Apply thin coat of tipis greasegemuk to the distance collar andcollar installdan it. Oleskan lapisan pada distance pasang. Drive in a new right bearing squarely with its sealed side facing up. Dorong masuk bearing kanan baru secara tegaklurus dengan sisinya yang tertutup menghadap ke atas. TOOLS: Driver 07749-0010000 TOOLS: Attachment, 32 x 35 mm 07746-0010100 Driver 07749-0010000 Pilot, 12 mm 32 x 35 mm 07746-0040200 Attachment, 07746-0010100 Pilot, 12 mm 07746-0040200



DISTANCE COLLAR



BEARING



11-9



RODA DEPAN/SUSPENSI/KEMUDI INSPECTION PEMERIKSAAN AXLE(POROS) AXLE Place the axle on V-blocks and measure runoutkeolengan with a dial dantheukur Letakkan axle pada V-blocks indicator. dengan dial indicator. SERVICE BATAS 0,2 mm mm(0.01 in) LIMIT: SERVIS: 0.2 Keolengan sebenarnya ½ darireading. pembacaan total Actual runout is 1/2 of theadalah total indicator indicator.



WHEEL WHEELBEARING BEARING(BANTALAN RODA) Putar inner dari masing-masing bearing dengan Turn the innerrace race of each bearing with your finger, the bearjari-jari, bearing harus berputar dengan halus dan tanpa ing should turn smoothly and quietly. Also check that the bearing outer race fits tightly in the hub. suara. Juga periksa bahwa bearing outer race duduk dengan Replace the bearings Remove and discard the bearings if the races do not turn erat pada hub. in pairs. smoothly, quietly, or if they fit loosely in the hub. Keluarkan dan buanglah bearings jika races tidak



Ganti bantalan dalam berputar dengan halus, tanpa suara, atau jika mereka pasangan. duduk dengan longgar pada hub.



WHEEL WHEELRIM RIM(PELEK RODA) Periksa keolengan dengan wheel Check the wheel rim wheel runout rim by placing themeletakkan wheel on a turning pada stand. turning stand (alat pegangan roda untuk stel pelek). Spin the wheel by hand and read the runout using a dial indicator. roda dengan tangan dan baca keolengan dengan Putar Actual runout isdial 1/2 indicator. the total indicator reading. menggunakan Keolengan sebenarnya adalah ½ dari pembacaan total indicator. SERVICE LIMIT: Axial: 2.0 mm (0.08 in) BATAS SERVIS: 2.0 mm (0.08 in) Radial: Aksial: 2,0 mm Radial: 2,0 mm



11-10



RODA DEPAN/SUSPENSI/KEMUDI



FORK (GARPU) FORK REMOVAL PELEPASAN



Support thebrake front Dukung front caliper brake dengan caliper seutas with a kawat tidak piecesehingga of wire soiathat it bergantung does not pada hang front from brake hose. the front brake hose. Jangan memlintir Do not twist the brake brake hose. hose.



Lepaskan sebagai berikut: Remove the following: - –Front Frontupper uppercover cover (hal. (page2-4) 2-4) - –Front fender (spakbor Front fender (page 2-7)depan) (hal. 2-7) - –Front Frontwheel wheel(roda (pagedepan) 11-7) (hal. 11-7) Remove the brake caliper (page 13-13). Lepaskan brake caliper (hal. 13-13). Remove the bottom bridge upper pinch bolts. Lepaskan bolts.and remove the Loosen thebottom bottombridge bridge upper lower pinch pinch bolts Longgarkan bottom bridge lower pinch bolts dan fork legs. lepaskan fork legs.



UPPER PINCH BOLT



INSTALLATION PEMASANGAN Install the fork pipe into the steering stem.



Align the bolt hole with the groove of the fork pipe as shown. Pasang fork pipe ke dalam steering stem. Install the lubang bottom bridge upper pinch Tepatkan bolt dengan alur bolts. dari fork pipe seperti Tighten the bottom bridge pinch bolts to the specified torque. diperlihatkan.



LOWER PINCH BOLT



TORQUE:64 (6.5 upper kgf·m,pinch 47 lbf·ft) Pasang bottomN·m bridge bolts. Kencangkan bottom bridge pinch bolts dengan torsi Install the following: yang ditentukan. – Front wheel (page 11-7) – Front64 fender 2-7) TORSI: N.m(page (6,5 kgf.m; 47 lbf.ft) – Front upper cover (page 2-4) – Brake caliper (page 13-13) Pasang sebagai berikut: -



Front wheel (hal. 11-7) Front fender (hal. 2-7) Front upper cover (hal. 2-4) Brake caliper (hal. 13-13)



GROOVE



FORK BOLT HOLE



11-11



RODA DEPAN/SUSPENSI/KEMUDI PEMBONGKARAN DISASSEMBLY Hold the fork fork slider a vice catok with soft jaws orpenjepit a shop towel. Pegang slider indalam dengan lunak atau dengan kain lap. Loosen the fork socket bolt but do not remove yet.



FORK SLIDER



SOCKET BOLT



Longgarkan fork socket bolt tetapi jangan lepaskan dulu.



Put the suitable tool ontool the spring Tempatkan suitable (kunciseat. perkakas yang sesuai) pada spring seat. Press the spring seat into the fork pipe using a suitable tool and hydraulic press, then remove the stopper ring using a Tekan spring seat ke dalam fork pipe dengan small screwdriver. menggunakan suitable tool dan hydraulic press, Remove thelepaskan spring seat, O-ringring and spring from the fork pipe. kemudian stopper dengan menggunakan obeng kecil.



To prevent loss of tension, do not Untuk mencegah compress the fork hilangnya tegangan, springfork more than jangan tekan spring necessary. The spring lebih daripada yang diperlukan.seat Sprint seat is under berada bawah spring di pressure. Lepaskan spring seat, O-ring dan spring dari fork pipe. tekanan Use carepegas. when Berhati-hatilah ketika removing the fork melepaskan assembly fromfork the assembly dari hydraulic hydraulic press. press.



SUITABLE TOOL SPRING SEAT



STOPPER RING



SPRING



Pour out the fluid by pumping the fork pipedengan several (minyak sokbreker) keluar Tuangkan forkfork fluid times. memompa fork pipe beberapa kali.



Remove thedust dustseal. seal. Keluarkan DUST SEAL



11-12



O-RING



RODA DEPAN/SUSPENSI/KEMUDI Lepaskan oiloil seal Remove the sealstopper stopper ring. STOPPER RING



Lepaskan socket washer. Remove the socketbolt boltdan and sealing sealing washer. SEALING WASHER



SOCKET BOLT



Remove the piston rebound spring from fork Lepaskan forkfork piston danand rebound spring dari forkthe pipe. pipe.



FORK PISTON



REBOUND SPRING



Tarik fork pipe keluar darithe forkfork slider. Pull the fork pipe out from slider.



FORK SLIDER



FORK PIPE



11-13



RODA DEPAN/SUSPENSI/KEMUDI Remove theoil oilseal sealdengan using themenggunakan special tool. special tool. Keluarkan TOOL: TOOL: Oil seall remover Oil seal remover atau sejenisnya



OIL SEAL REMOVER



07748-0010001 07748-0010001 or equivalent



OIL SEAL



ASSEMBLY



PERAKITAN DUST SEAL



FORK PIPE



FORK PISTON



FORK PISTON RING SPRING SEAT



STOPPER RING



STOPPER RING OIL SEAL



FORK SLIDER O-RING



FORK SPRING



SOCKET BOLT 20 N·m (2.0 kgf·m, 15 lbf·ft)



SEALING WASHER



REBOUND SPRING



Sebelum perakitan, cucilah semua parts dengan larutan Before assembly, wash all parts with high flash point or nonflammable solvent wipe dry. pembersih denganand titik apithem tinggi atau yang tidak dapat terbakar dan seka kering. Install the fork pipe into the fork slider.



FORK SLIDER



Pasang fork pipe ke dalam fork slider.



FORK PIPE



11-14



RODA DEPAN/SUSPENSI/KEMUDI Make sure thatfork the Pasang Install therebound rebound spring spring and piston intoke thedalam fork pipe. Pastikan bahwa danfork fork piston fork ring is pipe. pistonfork ringpiston telah duduk alur. seateddiindalam the groove.



FORK PISTON



REBOUND SPRING



Bersihkan ulir bolt socket dan locking oleskan Clean the socket threadsbolt and apply agentcairan to the bolt threads. pada ulir bolt. penguncian



SEALING WASHER



Install and tighten the socket bolt with a new sealing washer Pasang dan kencangkan socket bolt dengan sebuah to the fork piston. sealing washer baru pada fork piston.



SOCKET BOLT



Apply fork fluid to pada the lipbibir of a sebuah new oil seal. Oleskan fork fluid oil seal baru.



FORK SEAL DRIVER



Pasang oil seal dengan Drive themasuk oil sealoil intoseal the fork slider using special tools ke dalam fork the slider Install the dengan oil seal Dorong sisinya yang bertanda until it is fully seated. with its marked side menggunakan special tools sampai ia duduk menghadap ke atas. facing up. sepenuhnya.



TOOLS: TOOLS: Fork seal driver body Fork seal driver body Fork seal driver attachment, Fork seal driver attachment, 27.2 mm 27.2 mm



07747-0010100 07747-0010100 07747-0010300 07747-0010300



ATTACHMENT



Pasang oiloilseal ringinto ke the dalam alurring stopper Install the sealstopper stopper ring stopper groovering on pada forkslider. slider. the fork



OIL SEAL



STOPPER RING



11-15



RODA DEPAN/SUSPENSI/KEMUDI Oleskan fork fluid seal baru. Apply fork fluid topada a newbibir dust dust seal lip. Jangan bibir dust duduk sepenuhnya. Install the dustseal sealsampai until it isiafully seated. Do ketuk not tap the dust dust Pasang seal sealterlalu lip tookeras. hard.



DUST SEAL



Tuangkan jumlah amount fork fluid yang dianjurkan dalam Pour the specified of recommended fork fluid into the forkyang pipe.ditentukan ke dalam fork pipe. jumlah



FORK FLUID CAPACITY: KAPASITAS FORK FLUID: 33 75 ±± 11 cm 75 cm (2.5 ± 0.03 US oz, 2.6 ± 0.04 Imp oz) Pump thefork forkpipe pipe several timeskali to remove air from beberapa untuk trapped mengeluarkan Pompa the lower portion of the fork pipe. udara yang terperangkap dari bagian bawah dari fork pipe.



Pastikan bahwa tinggi sepenuhnya ukur the tinggi permukaan forkthe legfork Be sure the oil level is Tekan Compress leg fully anddan measure fluid level from permukaan di fluid dariofbagian same in fluida the both the top the forkatas pipe.dari fork pipe. dalam kedua forks. forks adalah sama. FORK FLUID



TINGGI PERMUKAAN FORK FLUID: 50 mm LEVEL: 50 mm (2.0 in)



50 mm (2.0 in)



Tarik forkfork pipepipe ke atas daninstall pasang Pull the up and the fork fork spring spring dengan with its sisinya meruncing taperedyang side facing down.menghadap ke bawah.



FORK SPRING



FORK PIPE



Sisi yang meruncing



11-16



RODA DEPAN/SUSPENSI/KEMUDI Coat aO-ring new O-ring fork fork fluid fluid and install it into the Lapisi baru with dengan dan pasang ke groovealur in the spring seat.seat. dalam pada spring Set the fork assembly, spring seat and stopper ring onto the Tempatkan fork assembly, spring seat dan stopper ring hydraulic press. pada hydraulic Put the suitable press. tool on the spring seat. Letakkan suitable tool pada spring seat. To prevent loss of Press the spring seat into the fork pipe until the stopper ring Untuk menghindari groove ismasuk visible.spring seat ke dalam fork pipe sampai tension, do not Dorong hilangnya tegangan, jangancompress tekan forkthe spring fork alur stopper ring tampak.



TOOL YANG SESUAI



STOPPER RING O-RING



lebih daripada spring moreyang than diperlukan. necessary.



SPRING SEAT



Install the stopperring ringke intodalam the stopper ring groove the pada Pasang stopper alur stopper ring on forkpipe. pipe. fork



STOPPER RING Tahan fork slider catok dengan penjepit lunak atau Hold the fork sliderpada in a vise with soft jaws or a shop towel. dengan kain lap.



Tighten the fork socket bolt to the specified torque.



Kencangkan fork socket bolt dengan TORQUE:20 N·m (2.0 kgf·m, 15 lbf·ft) ditentukan. TO R SI: 20 N .m (2,0 kgf.m ; 15 lbf.ft)



torsi



FORK SLIDER



yang



SOCKET BOLT



PEMERIKSAAN INSPECTION FORKSPRING SPRING FORK Measure the fork spring free length. Ukur panjang bebas fork spring. SERVICE BATAS SERVIS: 305,1 mm LIMIT: 305.1 mm (12.01 in)



SPRING



11-17



RODA DEPAN/SUSPENSI/KEMUDI FORK FORK PIPE/SLIDER/PISTON PIPE/SLIDER/PISTON Periksa fork pipe, terhadap Check the fork pipe,fork forkslider sliderdan and fork fork piston piston for score mark, and excessive or abnormal wear. tanda-tanda gerusan, dan keausan berlebihan atau tidak normal. Check the fork piston ring for wear or damage. Check the rebound spring for fatigue or damage. Periksa fork piston ring terhadap keausan atau Replace the components if necessary. kerusakan. Periksa rebound spring terhadap keletihan atau kerusakan. Ganti komponen-komponen bila perlu.



FORK SLIDER



FORK PIPE REBOUND SPRING



Letakkan forkpipe pipeonpada V-block dan ukur Place the fork V-block and measure thekeolengan. runout. Keolengan sebenarnya adalah ½ dari pembacaan total Actual runout is 1/2 the total indicator reading. indicator.



SERVICE BATAS SERVIS: 0,2 mm LIMIT: 0.2 mm (0.01 in)



11-18



FORK PISTON



FORK PISTON RING



RODA DEPAN/SUSPENSI/KEMUDI



HANDLEBAR HANDLEBAR (STANG STIR) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Longgarkan rear brake (kabel rem belakang) Loosen the rear brake cable cable by turning the adjusting nut. dengan memutar adjusting nut. Remove/install the following: Lepaskan/pasang sebagai berikut: – Front handlebar cover (page 2-5) - –Front cover(page (hal. 2-5) 2-5) Rearhandlebar handlebar cover - –Rear handlebar cover (hal. 2-5) Front upper cover (page 2-4) - –Front (hal. bolt/nut 2-4) Rearupper brake cover lever pivot - –Rear brake lever pivot bolt/nut Rear brake cable/lever - –Rear brake cable/lever Master cylinder/holder/bolts - –Master cylinder/holder/bolts Screw/upper throttle housing/lower throttle housing - –Screw/upper throttle housing/lower throttle housing Throttle cable/throttle pipe - –Throttle cable/throttle Left handlebar grip pipe - –Left handlebar grip Nut/collars/bolt/handlebar post - Nut/collars/bolt/handlebar post



ADJUSTING NUT



CATATAN: • Refer to page 11-20 for handlebar post/handlebar grip/ • throttle Lihat hal. 11-20 untuk pemasangan handlebar housing installation. post/handlebar grip/throttle • Route the wires/cables properlyhousing. (page 1-14). • • Adjust Alurkan dengan benar (hal. 1-14). thekawat/kabel rear brake lever free play (page 3-16). • Setel jarak main bebas rear brake lever (hal. 3-16).



Kencangkan baut atas dulu, kemudian baru baut bawah.



Tepatkan ujung master cylinder dengan tanda titik pada handlebar.



SCREW UPPER HOUSING



THROTTLE PIPE



Letakkan holder dengan tanda "UP" menghadap ke atas.



HOLDER BOLTS PIVOT BOLT 1 N·m (0.1 kgf·m, 0.7 lbf·ft)



MASTER CYLINDER



THROTTLE CABLE



PIVOT NUT COLLAR



COLLAR



4.5 N·m (0.5 kgf·m, 3.3 lbf·ft) REAR BRAKE LEVER



BOLT NUT



REAR BRAKE CABLE



59 N·m (6.0 kgf·m, 44 lbf·ft)



11-19



RODA DEPAN/SUSPENSI/KEMUDI PEMASANGAN HANDLEBAR POST HANDLEBAR POST INSTALLATION



Install the handlebar post post onto steeringstem stem while alignPasang handlebar padathe steering sementara ing the bolt holes. mentepatkan lubang-lubang bolt. Install the front/rear collars, bolt and nut. Rear collar is taller Rear collar lebih tinggi Pasang front/rear collars, bolt dan nut. thandari the front collar. collar.



BOLT



REAR COLLAR



Tighten the nut to the specified torque. Kencangkan nut dengan torsi yang ditentukan.



TORSI: 59 N.m (6,0 kgf.m; TORQUE:59 N·m (6.0 kgf·m,44 44lbf.ft) lbf·ft)



FRONT COLLAR



NUT



PEMASANGAN HANDLEBAR GRIP HANDLEBAR GRIP INSTALLATION Jika gripswere telah dilepaskan, oleskan Honda If thehandlebar handlebar grips removed, apply Honda Bond A or equivalent to the inside of the gripbagian and to the cleandari surfaces Bond A atau sejenisnya pada dalam grip of the left permukaan handlebar. bersih dari left handlebar. dan pada



HANDLEBAR GRIP



Wait 3 – 5 minutes and install the grip. Tunggu 3 - 5 menit dan pasang grip. Allow the to Rotate the grip for even application of the adhesive. Biarkan lemadhesive mengering Putar grip agar lem terbagi merata. dry for11jam hoursebelum before selama memakainya. using.



LEFT HANDLEBAR



PEMASANGAN THROTTLE HOUSING THROTTLE HOUSING INSTALLATION Pasang throttle pipe. Install the throttle pipe. Oleskan 0,1 – 0,2 g gemuk pada daerah luncur throttle Apply 0.1 – 0.2 g of grease to the throttle cable sliding area cable dan hubungkan dengan throttle pipe. and connect it to the throttle pipe.



Install thelower lower throttle throttle housing aligning the hole on the mentepatkan Pasang housingby dengan handlebar withhandlebar the locatingdengan pin of the lower throttle housing. lubang pada locating pin dari lower throttle housing.



Tepatkan THROTTLE CABLE



Install theupper upperhousing housing by aligningmentepatkan the groove of alur the upper Pasang dengan dari housing and tabdan of the upper housing tablower dari housing. lower housing.



SCREW



Install the screw and tighten it. Pasang screw dan kencangkan.



LOWER HOUSING



11-20



UPPER HOUSING



RODA DEPAN/SUSPENSI/KEMUDI



STEERING STEM STEM STEERING PELEPASAN REMOVAL Remove the following: Lepaskan sebagai berikut: – Fork (page 11-11) - Fork (hal. 11-11) Handlebar(hal. (page11-19) 11-19) -– Handlebar



SPEEDOMETER CABLE BOLT



Remove the boltdan andbrake brake hose hose clamp. Lepaskan bolt clamp. Release the speedometer cable from cable guide. Lepaskan speedometer cable darithe cable guide.



CABLE GUIDE



pinloosen spanner Tahan toptopthread Hold the threaddengan using themenggunakan pin spanner and the dan longgarkan lock nut dengan steering stem lock nutsteering using the stem socket wrench. menggunakan socket wrench. TOOLS: Socket wrench 07916-KM10000 TOOLS: Socket wrench 07916-KM10000 Pin spanner 07702-0020001 Pin spanner 07702-0020001 Remove the steering stem lock nut. Lepaskan steering stem lock nut.



SOCKET WRENCH STEM LOCK NUT PIN SPANNER



agar dengan steering top thread threadusing BeHati-hati careful not totidak drop Tahan Hold the steeringstem stemdan andlonggarkan loosen the top the menjatuhkan steering stem socket. stem socket. the steering stem. menggunakan stem.



TOOL: TOOL: Steering stem socket Steering stem socket



07916-3710101 07916-3710101



agar BeHati-hati careful not totidak drop Lepaskan Remove theupper upper bearing racerace and the upper steel steel balls bearinginner inner dan upper menjatuhkan steering (23 balls) while sementara holding the steering stem.steering stem. the steering stem and balls (23 balls) memegang stem dan upper steel the upper steel balls. balls.



HOSE CLAMP



STEM SOCKET



TOP THREAD



UPPER INNER RACE STEEL BALLS (23)



STEERING STEM



11-21



RODA DEPAN/SUSPENSI/KEMUDI BeHati-hati careful not to tidak drop Lepaskan Remove the steeringstem stem dan and lower (29 balls). steering lowersteel steelballs balls (29 balls). agar the steering stem and menjatuhkan steering the lower stem dan steel lowerballs. steel balls.



STEERING STEM



STEEL BALLS (29)



INSTALLATION PEMASANGAN Lihat hal. untuk penggantian stem Refer to page11-24 11-24 for steering stem bearingsteering replacement. bearing. TOP THREAD



LOWER OUTER RACE



LOWER BEARING (29)



UPPER BEARING (23)



LOCK NUT



UPPER INNER RACE



LOWER INNER RACE



DUST SEAL WASHER UPPER OUTER RACE



BOLT STEERING STEM



FRONT BRAKE HOSE CLAMP



Apply 3g3gofgemuk grease dengan with extreme agent (recomOleskan bahanpressure tahan tekanan tinggi mended: EXCELIGHT by KYODO (dianjurkan: EXCELIGHTEP2 EP2manufactured yang dibuat oleh YUSHI, japan or Shell EP2 or equivalent) the YUSHI, Japan atauALVANIA Shell ALVANIA EP2 toatau lower bearing races. sejenisnya) pada lower bearing races.



gemuk dengan bahan tahan tekanan tinggi (dianjurkan : EXCELIGHT EP2 yang di buat oleh KYODO YUSHI, japan atau Shell ALVANIA EP2 atau sejenisnya)



STEEL BALLS (29 balls)



Attach new steel balls (29 balls) to the lower bearing outer Letakkan steel balls baru (29 balls) pada lower bearing race. outer race. Be careful not to drop Insert the steering stem into the steering head pipe, being Hati-hati careful not to drop thestem steel ke balls. the steeringagar stemtidak and Masukkan steering dalam steering head pipe, menjatuhkanthe steering lower dengan berhati-hati agar tidak menjatuhkan steel balls. stem dan lower steel steel balls. balls.



STEERING STEM



11-22



RODA DEPAN/SUSPENSI/KEMUDI



Hati-hati agar tidak menjatuhkan steering stem dan upper Be careful not to steel drop the steering stemballs. and the upper steel balls.



Apply 3g3gofgemuk grease dengan with extreme agent (recomOleskan bahanpressure tahan tekanan tinggi mended: EXCELIGHT by KYODO (dianjurkan: EXCELIGHTEP2 EP2manufactured yang dibuat oleh YUSHI, japan or Shell EP2 or equivalent) the YUSHI, Japan atauALVANIA Shell ALVANIA EP2 toatau upper bearing races. sejenisnya) pada lower bearing races. Install new steel balls (23 balls) onto the upper bearing outer Letakkan steel balls baru (29 balls) pada lower bearing race. outer race. Install a new upper bearing inner race onto the stem. Masukkan steering stem ke dalam steering head pipe, dengan berhati-hati agar tidak menjatuhkan steel balls.



Pasang toptop thread. Install the thread. top thread Tahan steering kencangkan Hold the steeringstem stem dan and tighten the stemstem top thread to the initial torque using dengan the special tool. dengan torsi awal menggunakan special tool.



TOOL: TOOL: Steering stem Steering stemsocket socket



07916-3710101 07916-3710101



UPPER INNER RACE



STEEL BALLS (23 balls)



STEM SOCKET



TOP THREAD



TORSI: 25 N.m (2,5 kgf.m; TORQUE:25 N·m (2.5 kgf·m,18 18lbf.ft) lbf·ft)



Putar steering kali dari times ujung-ke-ujung Turn the steeringstem stembeberapa lock-to-lock several to seat the untuk mendudukkan bearing. bearing.



Loosen the top retightenkencangkan the top thread to the Longgarkan topthread, thread,then kemudian kembali specified torque using thetorsi special tool. ditentukan dengan top thread dengan yang menggunakan special tool. TOOL: Steering stem socket 07916-3710101 TOOL: Steering stem socket 07916-3710101 TORQUE:2.5 N·m (0.3 kgf·m, 1.8 lbf·ft)



STEM SOCKET



TOP THREAD



TORSI: N.m (0,3 kgf.m; 1,8about lbf.ft) Turn the 2,5 thread counterclockwise 15 degrees.



Recheck that the steering stem moves smoothly without Putar thread berlawanan arah perputaran jarum play jam or binding.15 derajat. sebanyak Periksa kembali bahwa steering stem bergerak dengan halus tanpa kelonggaran atau mengikat.



11-23



RODA DEPAN/SUSPENSI/KEMUDI Install the following: Pasang sebagai berikut: Fork (page 11-11) - –Fork (hal. 11-11) Frontdepan wheel(hal. (page11-7) 11-7) - –Roda Hold the top thread using the pin spanner and tighten the Tahan dengan menggunakan steeringtop stemthread lock nut to the specified torque. pin spanner dan kencangkan steering stem lock nut dengan torsi TOOLS: yang ditentukan. Socket wrench 07916-KM10000 TOOLS: Pin spanner 07702-0020001 Socket wrench 07916-KM10000 Pin spanner N·m (7.5 kgf·m, 55 lbf·ft) 07702-0020001 TORQUE:74 TORSI: N.m (7,5 55 lbf.ft) Turn the 74 steering stem kgf.m; lock-to-lock several times. Make sure the steering stem moves smoothly without play Putar steering stem dari ujung-ke-ujung beberapa kali. or binding. bahwa steering stem bergerak dengan halus Pastikan



STEM LOCK NUT



SOCKET WRENCH PIN SPANNER



tanpa mengikat. Installkelonggaran the brake hoseatau clamp and tighten the bolt.



SPEEDOMETER CABLE



Route the speedometer cabledan through the cable guide. Pasang brake hose clamp kencangkan bolt. Install the handlebar (page 11-19). Alurkan speedometer cable melalui cable guide.



BOLT



Pasang handlebar (hal. 11-19).



CABLE GUIDE



HOSE CLAMP



STEERING STEM BEARINGS



PENGGANTIAN STEERING STEM REPLACEMENT BEARINGS



• Always replace the steel balls and races as a set.



theganti steering stem (page •Remove Selalu steel balls dan11-21). races sabagai satu set. Remove the upper bearing outer race using the following Lepaskan steering stem (hal. 11-21). tool. Lepaskan upper bearing outer race dengan menggunakan tool sebagai berikut. TOOL: Ball race remover shaft 07GMD-KS40100 TOOL: Ball race remover shaft 07GMD-KS40100



UPPER OUTER RACE



BALL RACE REMOVER SHAFT



Keluarkan lower bearing bearing race dengan Remove the lower outer outer race using the following tools. menggunakan tools sebagai beirkut.



TOOLS: TOOLS: Ballrace race remover, remover, 34.5 Ball 34.5mm mm Ballrace race remover remover shaft Ball shaft



BALL RACE REMOVER SHAFT



07948-4630100 07948-4630100 07GMD-KS40100 07GMD-KS40100



BALL RACE REMOVER



11-24



LOWER OUTER RACE



RODA DEPAN/SUSPENSI/KEMUDI Remove thedust dustseal seal from the steering stemlower lower bearing bearing Lepaskan dari steering stem inner race. race. inner Remove the lower bearing inner race with a chisel or equivaLepaskan lower bearing race lent tool being careful not toinner damage thedengan stem. pahat atau tool sejenis, dengan berhati-hati agar tidak merusak Remove the washer from the steering stem. stem.



DUST SEAL



STEERING STEM



LOWER INNER RACE



WASHER



Lepaskan washer dari steering stem.



Install the washerpada to thesteering steering stem. stem. Pasang washer Install alower new lower bearing usingmenggunakan the following Pasang bearing innerinner race race dengan toolberikut and hydraulic tool ini danpress. hydraulic press. TOOL: TOOL: Fork driver attachment, attachment, Forkseal seal driver 35.2 35.2 mm mm



WASHER



LOWER INNER RACE



07947-KA20200 07947-KA20200



FORK SEAL DRIVER ATTACHMENT



Apply 3g3gofgemuk grease dengan with extreme agent (recomOleskan bahanpressure tahan tekanan tinggi mended: EXCELIGHT by KYODO (dianjurkan: EXCELIGHTEP2 EP2manufactured yang dibuat oleh YUSHI, japan or Shell EP2 or equivalent) to a YUSHI, Japan atau ALVANIA Shell ALVANIA EP2 atau new dust seal lip bibir then install it tobaru the lower bearing inner sejenisnya) pada dust seal kemudian pasang race. lower bearing inner race. pada



DUST SEAL



Dorong masuk upper bearing race dalam Drive a new upper bearing outer outer race into theke head pipe head using pipe dengan menggunakan tools sebagai berikut. the following tools. TOOLS: TOOLS: Driver Driver driver attachment Bearing Bearing driver attachment



DRIVER/ATTACHMENT



07749-0010000 07749-0010000 07946-3710701 07946-3710701



UPPER OUTER RACE



11-25



RODA DEPAN/SUSPENSI/KEMUDI Drive a new lower bearing outer outer race into thebaru head pipe using Dorong masuk lower bearing race ke dalam the following tools. menggunakan tools berikut ini. head pipe dengan TOOL: TOOL: Oilseal seal driver Oil driver 53.5 53.5mm mm



LOWER OUTER RACE



07947-SB00200 07749-SB00200



Install the steeringstem stem (hal. (page11-22). 11-22). Pasang steering



OIL SEAL DRIVER



11-26



12. RODA BELAKANG/SUSPENSI



LOKASI KOMPONEN-KOMPONEN... 12-2



RODA BELAKANG............................. 12-4



KETERANGAN SERVIS ..................... 12-3



SHOCK ABSORBER BELAKANG ..... 12-5



TROUBLESHOOTING ........................ 12-3



HANGER LINKAGE ............................ 12-6



COMPONENT LOCATION ··························12-2 SERVICE INFORMATION ···························12-3 TROUBLESHOOTING ··································12-3



REAR WHEEL ················································12-4 REAR SHOCK ABSORBER ··························12-5 HANGER LINKAGE ······································12-6



12



12-1



RODA BELAKANG/SUSPENSI



COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN 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



RODA BELAKANG/SUSPENSI



SERVICE INFORMATION KETERANGAN SERVIS GENERAL



UMUM



! PERINGATAN Frequentmenghirup inhalation ofdebu brakebrake shoe dust, regardless material composition could be hazardous to your health. kesehatan. Seringkali pad dan shoe,of apapun komposisi bahannya, dapat membahayakan Avoid breathing dustpartikel-partikel particles. • • Jangan menghirup debu. Never use an air hose or brush slang to cleanudara brake atau assemblies. Use anmembersihkan OSHA-approvedsusunan vacuum cleaner. • • Jangan sekali-kali memakai sikat untuk rem. Pakailah alat penghisap debu yang baik. • Use genuine Honda replacement bolts and nut for all suspension pivots and mounting points. • Pakailah bolts dan nut asli Honda untuk semua titik engsel dan penggantungan suspensi. • For brake system service, refer to section 13. • Untuk servis sistem rem, lihat Bab 13.



SPECIFICATIONS



SPESIFIKASI



BAGIAN ITEM Kedalaman minimum alur kembang ban Minimum tire tread depth Tekanan udara ban Pengendara saja Cold tire pressure Driver only (dingin) Pengendara dan pembonceng Driver and passenger Keolengan pelek roda Radial Wheel rim runout Radial Aksial Axial



STANDARD STANDARD – 2 225 kPa (2,25 kgf/cm , 33 2 psi) , 33 psi) 225 kPa (2.25 kgf/cm 2 psi) 225 kPa (2,25 kgf/cm , 33 225 kPa (2.25 kgf/cm2, 33 psi) – –



Unit:mm mm (in) Satuan: SERVICE BATAS SERVIS LIMIT Sampai ke indikator To the indicator – – 2,0 2.0 (0.08) 2,0 2.0 (0.08)



TORQUE VALUES NILAI TORSI Rear axle Rear axlenut nut Engine hanger link nut (sisi rangka) Engine hanger link nut (Frame side)



118 N.m (12,0 kgf.m; lbf.ft)87 lbf·ft) 118 N·m (12.087kgf·m, 69 N.m (7,0 kgf.m; 51 lbf.ft) 69 N·m (7.0 kgf·m, 51 lbf·ft)



U-nut U-nut Oleskan oli mesin pada ulir Apply engine oil to the threads



TROUBLESHOOTING TROUBLESHOOTING



Roda belakang bergoyang Rear wheel wobbles •• Bent Pelek rimbengkok •• Faulty Ban rusak tire •• Axle Axlenut dan/atau enginemounting mounting bolt/nut penggantung mesin) tidak dikencangkan dengan benar and/or engine bolt/nut not(baut/mur tightened properly •• Loose Finalor gear shaft longgar worn finalbearing gear shaft bearingatau aus •• Insufficient Tekanan udara ban kurang tire pressure



Soft suspension Suspensi lunak • Weak rear shock absorber spring •• Oil Rear shock absorber leakage from damper spring unit lemah •• Low Adatire kebocoran oli dari damper unit pressure • Tekanan udara ban rendah Stiff suspension • Bent damper rod Suspensi Keras • High tire pressure • Damper rod bengkok suspension noisy •RearTekanan udara ban tinggi • Loose mounting fasteners Suspensi belakang berisik shockpenggantung absorber •• Faulty Pengikat longgar rear suspension bushings •• Weak Shock absorber rusak •



Rear suspension bushings lemah



12-3



RODA BELAKANG/SUSPENSI



REAR RODA WHEEL BELAKANG REMOVAL PELEPASAN Support the scooter withstandard its centerstand. Letakkan skuter pada utamanya. Remove the exhaust pipe/muffler (page 2-14). Lepaskan exhaust pipe/muffler (hal. 2-14). Remove the rearaxle axlenut, nut, washer washer and wheel. Lepaskan rear danrear roda belakang.



RODA BELAKANG



PEMASANGAN



INSTALLATION



Semprotkan oli mesin pada ulir rear axle nut dan Apply engine oil to the rear axle nut threads and seating surpermukaan duduk. face. dengan Pasang roda finalgear gearshaft, shaft, Install the rear belakang wheel ontopada the final aligning its mentepatkan splines-nya dengan final gear shaft Be careful to splines with the final gear shaft splines. Hati-hati agarnot tidak Install the washer onto the final gear shaft. damage the splines. splines. merusak Pasang washer pada Install the rear axle nut.final gear shaft. Kencangkan rear axle dengan torsitorque. yang ditentukan. Tighten the rear axle nutnut to the specified



TORQUE:118 N·m (12.0kgf.m; kgf·m,87 87 lbf.ft) lbf·ft) TORSI: 118 N.m (12,0 Install the exhaustpipe/muffler pipe/muffler (hal. (page2-14). 2-14). Pasang exhaust Tepatkan (splines) WASHER AXLE NUT



PEMERIKSAAN INSPECTION Periksa keolengan dengan dial indicators. Check the wheel rimpelek runoutroda using dial indicators. Actual runout is 1/2 the total indicator readings. sebenarnya adalah ½ dari pembacaan total Keolengan indicator. SERVICE LIMITS: BATAS SERVIS: Radial: 2.0 mm (0.08 in) Radial: 2,0 mm Axial: 2.0 mm (0.08 in) Aksial: 2,0 mm



12-4



RODA BELAKANG/SUSPENSI



ABSORBER REAR SHOCK ABSORBER REMOVAL PELEPASAN Remove the bodycover cover(hal. (page2-9). 2-9). Lepaskan body Remove the bolts and rear shock absorber. To avoid damage to Lepaskan bolts dan rear shock absorber. Untuk menghindari



kerusakan the pada ulirshock rear rear shock mounting absorber absorber mounting bolt, slightly angkat bolt threads, rodalift belakang the rearsedikit. wheel.



SHOCK ABSORBER



PEMASANGAN 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 terhadap atau Check the damper damper unitunit for leakage or otherkebocoran damage. kerusakan lain. Check the shock absorber bushing for wear or damage.



BUSHING



Replaceshock the shock absorber assembly if necessary. Periksa absorber bushing terhadap keausan atau kerusakan. Ganti shock absorber assembly bila perlu.



SHOCK ABSORBER



Check the rearshock shockabsorber absorber mount wear or Periksa rear mount bushing bushingforterhadap damage. atau kerusakan. keausan



REAR SHOCK ABSORBER MOUNT BUSHING



12-5



RODA BELAKANG/SUSPENSI



HANGER LINKAGE 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 rangka. Install the enginehanger hanger link link pada onto the frame. Pasang engine hanger dari sisithe kirileft dariside rangka. Install the engine hangerlink linkbolt bolt from of the frame. engine hanger link nut dan washer dan Pasang kencangkan nut dengan torsinut yang Install the engine hanger link andditentukan. tighten it to the specified torque. TORSI: 69 N.m (7,0 kgf.m; 51 lbf.ft) TORQUE:69 N·m (7.0 kgf·m, 51 lbf·ft) Pasang mesin (hal. 6-6). Install the engine (page 6-6).



NUT



BOLT



ENGINE HANGER LINK



PEMERIKSAAN INSPECTION Check thehanger hanger link and dan stopper rubbers for wear Periksa link bushings bushings stopper rubbers or damage. terhadap keausan atau kerusakan.



HANGER LINK BUSHINGS



STOPPER RUBBERS



terhadap keausan atau Periksa engine Check the enginemount mount bushings bushings for wear or damage. kerusakan.



ENGINE MOUNT BUSHINGS



12-6



13. SISTEM REM



LOKASI KOMPONEN-KOMPONEN... 13-2



COMPONENT LOCATION ··························13-2



KETERANGAN SERVIS ..................... 13-3



SERVICE INFORMATION ···························13-3



TROUBLESHOOTING ........................ 13-4



TROUBLESHOOTING ··································13-4



REAR DRUM BRAKE ......................... 13-5



REAR DRUM BRAKE····································13-5



PENGGANTIAN BRAKE FLUID/ BRAKE FLUID REPLACEMENT/AIR AIR BLEEDING ................................... 13-6 BLEEDING·······················································13-6 BRAKE 13-8 BRAKEPAD/DISC.............................. PAD/DISC··········································13-8 BRAKE 13-11 BRAKEMASTER MASTER CYLINDER............. CYLINDER ···················13-11 BRAKE CALIPER ............................... 13-13 BRAKE CALIPER ········································13-13



13



13-1



SISTEM REM



COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN BRAKE SYSTEM



FRONT BRAKE REM 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 your 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 berbahaya Spilled brake fluid willdari severely bagi beberapa parts karet.damage instrument lenses and painted surfaces. It is also harmful to some rubber parts. Be careful whenever you remove the reservoir cap; make the master cylinder horizontalpada first.posisi horisontal dulu. Berhati-hatilah setiap kali melepaskan reservoir cap; sure pastikan bahwa masterreservoir cylinderisreservoir • A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a high quality • brake Brakedegreasing disc atauagent. pad yang terkontaminasi mengurangi daya pengereman. Buanglah pads yang terkontaminasi dan bersihkan disc yang terkontaminasi denganthe bahan gemuk berkualitas tinggi untuk peralatan rem. • Check the brake system by applying brakepembersih lever after the air bleeding. allow contaminants (dirt,menjalankan water, etc.) to handel get into rem an open reservoir. • • Never Periksa sistem rem dengan setelah proses air bleeding (pembuangan udara palsu). the hydraulic system has been or ifair, thedsb.) braketidak feels masuk spongy,ke thedalam systemreservoir must be bled. • • Once Jagalah agar benda-benda asingopened, (kotoran, terbuka. use fresh DOT 3 or DOT 4 brakeatau fluidjika from a sealed when servicing the system. Do notdari mixsistem. different types of fluid, they • • Always Sekali sistem hidraulik telah dibuka, rem terasacontainer seperti sepons, buanglah udara palsu not pakai be compatible. Selalu minyak rem baru DOT 3 atau DOT 4 dari kemasan yang belum pernah dibuka ketika menservis sistem. Jangan • may • Always check brake operation before riding scooter. mencampurkan bermacam-macam jenisthe minyak rem, mereka mungkin tidak cocok satu sama lain. • Selalu periksa cara kerja rem sebelum mengendarai skuter.



SPECIFICATIONS SPESIFIKASI



BAGIAN ITEM Jarak main bebas brake lever (handel rem) Rear rear brakebrake lever drum free play D.D. Rear brake drum Minyak rem yangI.D. ditentukan Specified Brake discbrake fluid Ketebalan Brake disc Thickness bentuk melengkung Perubahan Warpage Master cylinder D.D. cylinder Master cylinder Cylinder I.D. D.L. piston Piston O.D. Caliper D.D. cylinder Caliper Cylinder I.D. D.L. piston Piston O.D.



Unit: mm Satuan: mm(in) SERVICE STANDARD BATAS SERVIS STANDARD LIMIT 10 – 20 10 – 130,0 20 (0.4 – 0.8) – 131,0 130.0DOT (5.12) 131.0 (5.16) 3 atau 4 DOT3,3 3 or–DOT – 3,7 4 3,0 3.3 –-3.7 (0.13 – 0.15) 3.0 (0.12) 0,10 0.10 (0.004) 11,000 – 11,043– 11,055 11.000 – 11.043 (0.4331 – 0.4348) 11.055 (0.4352) 10,957 – 10,984 10,945 10.957 – 10.984 (0.4314 – 0.4324)32,090 10.945 (0.4309) 32,030 – 32,080 32.030 – 32.080 (1.2610 – 1.2630) 32.090 (1.2634) 31,948 – 31,998 31,94 31.948 – 31.998 (1.2578 – 1.2598) 31.94 (1.257)



NILAI TORSI



TORQUE VALUES Rear Rearbrake brakearm arm bolt bolt Brake caliper Brake caliperbleed bleed valve valve Brake capscrew screw Brakemaster mastercylinder cylinder reservoir reservoir cap Brake pad pin Brake pad pin Front brake lever pivot bolt Front brake lever pivot bolt Front brake lever pivot nut Front brakelight leverswitch pivot nut Front brake screw Fronthose brakeoillight Brake boltswitch screw Brakecaliper hose oil bolt Brake mounting bolt Brake caliper mounting bolt Brake caliper pin Brake caliper pin



10 N.m (1,0 7 lf.ft) ganti dengan 10 kgf.m; N·m (1.0 kgf·m, 7 lbf·ft) ALOC bolt; ALOC bolt; replaceyang withbaru new one. 6 N.m (0,66 kgf.m; 4,4 lbf.ft) N·m (0.6 kgf·m, 4.4 lbf·ft) 2 N.m (0,2 kgf.m, 2 N·m 1,5 (0.2lbf.ft) kgf·m, 1.5 lbf·ft) 18 N.m (1,8 kgf.m; 13 lbf.ft) 18 N·m (1.8 kgf·m, 13 lbf·ft) 1 N.m (0,1 kgf.m; 0,7 lbf.ft) 1 N·m (0.1 kgf·m, 0.7 lbf·ft) 6 N.m (0,6 kgf.m; 4,4 lbf.ft) 6 N·m (0.6 1 N.m (0,1 kgf.m; 0,7kgf·m, lbf.ft)4.4 lbf·ft) 1 N·m (0.125 kgf·m, 34 N.m (3,5 kgf.m; lbf.ft)0.7 lbf·ft) 34 N·m (3.5 kgf·m, 30 N.m (3,1 kgf.m; 22 lbf.ft) 25 lbf·ft) ALOC bolt; ganti dengan yang baru 30 kgf.m; N·m (3.1 ALOC bolt; replace with new ones. 18 N.m (1,8 13kgf·m, lbf.ft) 22 lbf·ft) 18 N·m (1.8 kgf·m, 13 lbf·ft)



13-3



SISTEM REM TOOL TOOL Snap ring pliers 07914-SA50001



TROUBLESHOOTING TROUBLESHOOTING



Front brake lever (handel rem depan) terasa lunak atau seperti sepons Front brake lever soft or spongy •• Air Ada dalam sistem hidraulik in udara hydraulic system •• Leaking Ada kebocoran hydraulic pada systemsistem hidraulik •• Contaminated Brake pad/disc terkontaminasi brake pad/disc •• Worn Caliper piston seals aus caliper piston seals master cylinder piston cups •• Worn Master cylinder piston cups aus brake pad/disc •• Worn Brake pad/disc aus caliper •• Contaminated Caliper terkontaminasi • Contaminated master cylinder • Master cylinder terkontaminasi sliding properlydengan benar •• Caliper Calipernot tidak meluncur • Low brake fluid level • Tinggi permukaan minyak rem terlalu rendah • Clogged fluid passage •• Warped/deformed Jalan lintasan fluid tersumbat brake disc •• Sticking/worn Brake disc berubah bentuk melengkung/berubah bentuk caliper piston •• Sticking/worn Caliper piston macet/aus master cylinder piston •• Bent Master cylinder brake lever piston macet/aus • Brake lever bengkok Front brake lever hard • Clogged/restricted brake system Brake lever depan keras • Sticking/worn caliper piston •• Caliper Sistemnot rem tersumbat/terbatasi sliding properly •• Worn Caliper piston macet/aus caliper piston seal •• Sticking/worn Caliper tidakmaster meluncur dengan benar cylinder piston •• Bent Caliper brakepiston lever seal aus • Master cylinder piston macet/aus Front brake drags •• Contaminated Brake lever bengkok brake pad/disc



• Misaligned wheel Rem depan menyangkut • Badly worn brake pad/disc •• Warped/deformed Brake pad/disc terkontaminasi brake disc •• Caliper Roda salah pasang not sliding properly •• Clogged/restricted Brake pad/disc sangat aus fluid passage caliper piston bentuk melengkung/berubah bentuk •• Sticking Brake disc berubah •PoorCaliper tidakperformance meluncur dengan benar rear brake •• Incorrect Jalan lintasan fluidoftersumbat/terbatasi adjustment rear brake lever •• Contaminated Caliper piston macet brake shoes • Worn brake shoes Unjuk kerja rem • Worn brake cambelakang buruk •• Worn Penyetelan brake lever belakang tidak benar brake drum installed brake arm •• Improperly Brake shoes terkontaminasi engaged •• Improperly Brake shoes aus brake arm serrations • Brake cam aus • Brake drum aus • Brake arm tidak terpasang dengan benar • Gerigi brake arm tidak berhubungan dengan baik



13-4



SISTEM REM



DRUM BRAKE BRAKE REAR DRUM (REM TEROMOL BELAKANG) DISASSEMBLY/ASSEMBLY • Always replace the brake shoes as a set. PEMBONGKARAN/PERAKITAN



• Mark all parts during disassembly so they can be placed • back Selalu ganti brakelocations. shoes sebagai satu set. in the original • Tandai semua parts selama pembongkaran Remove the rear wheel (page 12-4). sehingga mereka dapat diletakkan kembali pada Remove the adjusting nut and brake cable from the joint pin. posisinya semula. Remove theroda jointbelakang pin and return Lepaskan (hal.spring. 12-4). Expand theadjusting brake shoes and brake removecable the brake shoes/shoe Lepaskan nut dan dari joint pin. springs from thepin brake panel. Lepaskan joint dan return spring. Remove the following: Renggangkan – Brake arm boltbrake shoes dan lepaskan brake shoes/shoe springscam dari brake panel. – Brake arm/brake Lepaskan sebagai berikut: – Dust seals - Brake arm bolt Applyarm/brake grease to cam the dust seals, brake cam and brake - • Brake anchor pin as specified. - Dust seals • Replace the dust seals and brake arm bolt with new ones. Pasang yang dilepaskan dalam urutan Install theparts removed partstelah in the reverse order of removal. terbalik dari pelepasan. Adjust the rear brake lever free play (page 3-16). Setel jarak main bebas rear brake lever (hal. 3-16). *: Berikut 0.2 - 0.3 g gemuk. DUST SEAL



Tepatkan



* ANCHOR PIN



* BRAKE CAM BRAKE SHOES BRAKE ARM Pasang shoe springs dengan ujungnya yang terbuka menghadap keluar . BRAKE ARM BOLT 10 N·m (1.0 kgf·m, 7 lbf·ft)



ADJUSTING NUT SHOE SPRINGS JOINT PIN Letakkan ujung-ujung return spring ke dalam lubang pada brake panel dan pada pin pada brake arm.



RETURN SPRING



13-5



SISTEM REM PEMERIKSAAN INSPECTION Measure therear rearbrake brake drum drum I.D. Ukur D.D. (teromol rem belakang) BATAS SERVIS: 131,0 mm SERVICE LIMIT: 131.0 mm (5.16 in)



PENGGANTIAN BRAKE FLUID (MINYAK BRAKE FLUID REPLACEMENT/AIR REM) /AIR BLEEDING (PEMBUANGAN BLEEDING UDARA PALSU) BRAKE FLUID DRAINING



PENGELUARAN BRAKE FLUID



• Do not mix different types of fluid, as they are not compatible withmencampurkan each other. Jangan bermacam-macam jenis • Do notoleh allowkarena foreign mereka material tidak to enter the system when fluid, cocok satu sama 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 parts whenever the system is serviced.



Do not allow foreign material to enter the systemwhen filling the Jangan membiarkan reservoir. benda asing memasuki sistem ketika mengisi reservoir.



Fluid yang tertumpah dapat merusak parts yang dicat, Turn the handlebar until the reservoir is parallel to the ground atau terbuat daritheplastik atau before removing reservoir cap.karet. Letakkan kain lap menutupi parts ini ketika sistem diservis. Remove the screws, reservoir cap, diaphragm plate and diaPutar handlebar sampai reservoir parallel dengan tanah phragm. sebelum melepaskan reservoir cap. Lepaskan screws, reservoir cap, diaphragm plate dan diaphragm.



(slang pembuangan) pada Sambungkan Connect a bleedbleed hose tohose the caliper bleed valve. caliper bleed valve. Loosen the bleed valve and pump the brake lever until no more fluid flows out of the bleed valve. Longgarkan bleed valve dan pompa brake lever sampai fluid tidak mengalir keluar lagi dari bleed valve.



13-6



RESERVOIR CAP



SCREWS



DIAPHRAGM PLATE DIAPHRAGM



BLEED VALVE BLEED HOSE



SISTEM REM BRAKE FLUID FILLING/AIR



PENGISIAN BLEEDINGBRAKE FLUID/AIR BLEEDING Jangan mencampurkan cylinder reservoir brake 3 Do not mix different Isi Fillmaster the master cylinder reservoirdengan with DOT 3 or fluid DOT DOT 4 brake bermacam-macam jenis atau 4 dari kemasan pernah dibuka fluid DOT from the sealed containeryang to the belum upper level. types of fluid. They fluida. tidak sampai ke upper level (tinggi permukaan teratas). are notMereka compatible. cocok satu sama lain. • Check the fluid level often while bleeding the brake to



•



UPPER LEVEL



prevent pumped into fluid the system. Periksaair from tinggibeing permukaan sering-sering sewaktu membuang udara dari sistem rem untuk mencegah dipompanya masuk udara ke dalam sistem.



Connect a commercially available yang brake dapatbleeder dibeli to di the pasaran bleed Hubungkan brake bleeder valve.bleed valve. pada



BLEED HOSE



Operate the brake bleeder and loosen the bleed valve. Jalankan brake bleeder dan longgarkan bleed valve. Perform the bleeding procedure until the system is comJalankan prosedur bleeding sampai sistem sama sekali pletely flushed/bled. dibilas. Close the bleed valve and operate the brake lever. Tutup bleed danbleed jalankan brakeagain. lever. If it still feelsvalve spongy, the system Jika masih terasa seperti sepons, buanglah udara palsu After bleeding system completely, tighten the bleed valve sekali lagi dari the sistem. to the specified torque. Setelah sistem telah di-bleeding sama sekali, TORQUE:6 N·m (0.6 kgf·m, 4.4 lbf·ft) kencangkan bleed valve dengan torsi yang ditentukan.



If air enters the Jika udara memasuki bleeder around bleeder darifrom sekitar ulir the bleed bleed valve, rapativalve ulir threads, seal the dengan teflon tape. threads with tinggi teflon Periksa tape. permukaan fluid seringsering Checksewaktu the fluidmemlevel bleeding sistem rem often while bleeding untuk menghindari the brake to prevent dipompanya air from udara being masuk ke dalaminto sistem. pumped the TORSI: 6 N.m (0,6 kgf.m; 4,4 lbf.ft) system.



BLEED VALVE



Jika tersedia,perform jalankan If thebrake brake bleeder bleeder istidak not available, the prosedur 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.



CheckPeriksa the fluidtinggi level permukaan fluidbleeding seringoften while sering sewaktu memthe brake to prevent bleeding sistembeing rem air from untuk menghindari pumped into the dipompanya udara system. masuk ke dalam sistem. Do not release the Jangan melepaskan until the brakebrake leverlever sampai bleed bleed been valvevalve telahhas ditutup. closed.



dan the buanglah Hubungkan bleed hose pada Connect a bleed hose to the bleedbleed valvevalve and bleed system udara palsu dari sistem sebagai berikut: as follows:



BLEED VALVE



BLEED HOSE



1. Squeeze the brake lever all the way and loosen the bleed danandlonggarkan • valve Tekan lever 1/2 brake of a turn. Waitseluruhnya several seconds then close bleed valve ½ putaran. Tunggu beberapa detik the bleed valve. kemudian valve. and wait several seconds 2. Release the tutup brake bleed lever slowly • after Lepaskan brake lever pelan-pelan dan tunggu it reaches the end of its travel. beberapa detik ia are mencapai ujung 3. Repeat the steps 1 andsetelah 2 until there no air bubbles in perjalanannya. the bleed hose. Ulangi langkah 1 dan 2 sampai tidak ada lagi • Aftergelembung-gelembung bleeding the system completely, bleedhose. valve udara ditighten dalamthe bleed to the specified torque. Setelah mem-bleeding sistem sama sekali, kencangkan TORQUE:6 N·m (0.6 kgf·m, 4.4ditentukan. lbf·ft) bleed valve dengan torsi yang TORSI: 6 N.m (0,6 kgf.m; 4,4 lbf.ft)



13-7



SISTEM REM Do not mix different Isi Fillreservoir the reservoir to the upper permukaan level with DOT 3 ordengan DOT 4 Jangan mencampurkan sampai ke tinggi teratas bermacam-macam jenis brake types of fluid. They brake fluid container. fluid from DOTa sealed 3 atau DOT 4 dari kemasan yang brake Mereka belum pernah dibuka sebelumnya. are notfluid. compatible. tidak cocok satu sama lain.



Pasang diaphragm, Install the diaphragm,diaphragm diaphragmplate platedan and reservoir reservoir cap, cap, kemudian then tighten kencangkan the screws to thescrews specifieddengan torque. torsi yang ditentukan.



UPPER LEVEL



RESERVOIR CAP



SCREWS



TORQUE:2 N·m (0.2 kgf·m,1,5 1.5lbf.ft) lbf·ft) TORSI: 2 N.m (0,2 kgf.m; DIAPHRAGM PLATE DIAPHRAGM



BRAKE BRAKE PAD/DISC PAD/DISC PENGGANTIAN BRAKE PAD BRAKE PAD REPLACEMENT Periksa Check the braketinggi fluid Dorong Push the caliper caliper pistons all the way in to allow installation of pistons seluruhnya ke dalam untuk permukaan brake fluid level in the reservoir memungkinkan new brake pads. pemasangan brake pads baru. di dalam reservoir as this operation sering-sering oleh causes levelini to karena the operasi rise. menyebabkan naiknya tinggi permukaan brake fluid.



BRAKE CALIPER



Remove the padpin pinplug plugdari frombrake the brake caliper. Lepaskan pad caliper.



PAD PIN PLUG



13-8



SISTEM REM Remove thepad padpin pinplug fromdari the brake Lepaskan brakecaliper. caliper.



PAD PIN



Lepaskan caliper. Remove thebrake brakepads pads dari frombrake the brake caliper.



BRAKE PADS



Selalu brake Alwaysganti replace the Pasang Install new brake padsbaru so that they are set on the ditempatkan brake caliper brake pads sehingga mereka pads dalam brake pads in pairs to pada bracket and bracket brake caliper pin. bracket dan bracket pin. pasangan untuk assure even disc memastikan pressure. tekanan



Tempatkan



BRACKET PIN



merata pada disc.



BRAKE PADS



Pasang pinby dengan brakethepads Install the pad pad pin pushing themendorong brake pads against pad spring to align pad pin holes on the pads and caliper. terhadap pad the spring untuk mentepatkan lubang-lubang pad pin pada pads dan caliper.



PAD PIN



13-9



SISTEM REM Kencangkan pad dengan torsitorque. yang ditentukan. Tighten the pad pinpin to the specified TORSI: 18 N.m (1,8 kgf.m; 13 lbf.ft) TORQUE:18 N·m (1.8 kgf·m, 13 lbf·ft)



PAD PIN Setelah penggantian dan kencangkan padplug. pin plug. brakecara pad Pasang Install and tighten the pad pin brakeAfter pad,the periksa replacement, check kerja rem dengan the brake operation menekan brake lever. by applying the brake lever.



PAD PIN PLUG



PEMERIKSAAN BRAKE DISC BRAKE DISC INSPECTION Visually brake inspect disc the brake disc visual for damage or cracks. Periksa secara terhadap kerusakan atau retak-retak. Measure the brake disc thickness at several points. Ukur ketebalan brake disc pada beberapa titik. SERVICE BATAS 3,0 mm mm(0.12 in) LIMIT: SERVIS: 3.0



Periksa disc terhadap perubahan Check the brake brake disc for warpage. melengkung. SERVICE LIMIT: SERVIS: 0.10 BATAS 0,10mm mm(0.004 in)



bentuk



If theperubahan warpage exceeds service limit, check the wheel Jika bentukthe melengkung melampaui batas bearingsperiksa for excessive servis, wheel 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 MASTER CYLINDER CYLINDER BRAKE REMOVAL/INSTALLATION PELEPASAN/PEMASANGAN Drain the brake fluid (page 13-6). Keluarkan fluid (minyak Remove thebrake 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. • Replace the sealing washers with new ones. (buang udara palsu) Isi bleedthe Filldan and air air bleed hydraulic system (pagesistem 13-7). hidraulik (hal. 13-7). SCREW 2 N·m (0.2 kgf·m, 1.5 lbf·ft)



HOLDER



BOLTS



RESERVOIR CAP



Tepatkan ujung master cylinder dengan tanda titik pada handlebar. Kencangkan baut atas dulu, baru kemudian baut bawah.



DIAPHRAGM PLATE



Letakkan holder dengan tanda "UP" menghadap keatas.



DIAPHRAGM SEALING WASHERS



OIL BOLT 34 N·m (3.5 kgf·m, 25 lbf·ft)



MASTER CYLINDER CONNECTORS



BRAKE HOSE



Tepatkan brake hose eyelet terhadap stopper.



13-11



SISTEM REM DISASSEMBLY/ASSEMBLY PEMBONGKARAN/PERAKITAN Remove/install the following: Lepaskan/pasang sebagai berikut: – Brake lever pivot nut, bolt bolt dan and brake - Brake lever pivot nut, brakelever lever Screwdan andbrake brake light light switch -– Screw switch Boot -– Boot Remove/install the snap ring using the special tool. TOOL: Snap ring pliers 07914-SA50001 TOOL: Snap ring pliers Lepaskan washer, master piston dan07914-SA50001 spring. the washer,piston, master piston spring.snap ring dan •Remove Pertahankan cups, and spring, boot sebagai satu set; jangan mengganti parts secara terpisah. • Keep the piston, cups, spring, snap ring and boot as a set; • do Ketika memasang cups,parts. jaga agar bibirnya tidak not substitute individual berputar terbalik bagian dalam di luar. • Apply brake fluid to the spring, master piston and piston • cups. Pastikan 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.



* BOOT



SPRING



WASHER



PISTON CUPS



SNAP RING



SNAP RING PLIERS



PIVOT BOLT 1 N·m (0.1 kgf·m, 0.7 lbf·ft) MASTER CYLINDER BODY



SNAP RING MASTER PISTON



BRAKE LIGHT SWITCH



BRAKE LEVER *: Oleskan 0.1 g silicone grease



PIVOT NUT 6 N·m (0.6 kgf·m, 4.4 lbf·ft)



PEMERIKSAAN INSPECTION Periksa Check thepiston piston cups cupsforterhadap wear, deterioration keausan,orpemburukan damage. Check the master cylinder inner surface and piston outer surkondisi atau kerusakan. face for scratches or damage. Periksa permukaan dalam master cylinder dan permukaan luar cylinder piston I.D.terhadap goresan atau Measure the master kerusakan. SERVICE Ukur D.D. master cylinder. LIMIT: 11.055 mm (0.4352 in)



MeasureSERVIS: the master 11,055 piston O.D. BATAS mm SERVICE Ukur D.L. master piston. LIMIT: 10.945 mm (0.4309 in) BATAS SERVIS: 10,945 mm



13-12



SCREW 1 N·m (0.1 kgf·m, 0.7 lbf·ft)



SISTEM REM



BRAKE CALIPER CALIPER BRAKE REMOVAL PELEPASAN Avoidagar spilling fluidrem on Jaga minyak painted, plastic, or tidak tertumpah atas rubber parts yang dicat,parts. atau Place adari shopplastik towel terbuat atau karet. over these parts Letakkan lap whenever thekain system menutupi parts ini is serviced. setiap kali sistem diservis.



Drain the brake fluid (page 13-6). Keluarkan brake fluid (hal. 13-6). Remove the following: Lepaskan sebagai berikut: – Oil bolt/sealing washers - Oil bolt/sealing washers – Pad spring -– Pad spring Brake pads (page 13-8) -– Brake padsbolts (hal. 13-8) Mounting -– Mounting bolts Brake caliper (baut pemasangan) - Brake caliper



INSTALLATION



PEMASANGAN



Install the front brake caliper onto the left fork leg. Pasang front brake caliper pada kaki them kiri fork. Install new mounting bolts and tighten to the specified Pasang torque. mounting bolts baru dan kencangkan dengan torsi yang ditentukan. TORQUE:30 N·m (3.1 kgf·m, 22 lbf·ft) TORSI: 30 N.m 22 lbf.ft) Connect the brake(3,1 hosekgf.m; to the brake caliper with the oil bolt Tighten the oil bolt Kencangkan oil bolt while pushing the sementara menekan brakebrake hose hose eyeleteyelet joint joint against the terhadap stopper. stopper.



and new sealingbrake washers. Sambungkan hose pada brake caliper dengan oil bolt dan sealing washers baru. torque. Tighten the oil bolt to the specified Kencangkan oil bolt dengan torsi yang ditentukan. TORQUE:34 N·m (3.5 kgf·m, 25 lbf·ft) TORSI: 34 N.m (3,5 kgf.m; 25 lbf.ft) Install the brake pads (page 13-9). Pasang brake pads (hal. 13-9). Fill the brake fluid and bleed the hydraulic system (page 13Isi 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



not useudara high Jangan Do memakai pressure air or bring bertekanan tinggi atau meletakkan nozzle the nozzle too terlalu dekat pada close to the inlet. lubang.



Remove/install the following: Lepaskan/pasang sebagai berikut: – Caliper bracket - Caliper bracket Pin boots - –Pin boots – Pad spring - Pad spring Place a shop towel over the piston. Letakkan kain lap di atas piston. Position the caliper body with the piston facing down and Tempatkan caliper body dengan piston menghadap ke apply small squirts of air pressure to the fluid inlet to remove bawah dan jalankan semprotan-semprotan kecil udara the piston. bertekanan pada lubang masuk fluid untuk 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 piston seals and dust seals with new ones. terbalik dari the 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



PEMERIKSAAN INSPECTION Periksa caliper cylinder gerusan, goresan atau Check the caliper cylinderterhadap for scoring, scratches or damage. kerusakan. Measure the caliper cylinder I.D. Ukur D.D. caliper cylinder. SERVICE LIMIT: 32.090 mm BATAS SERVIS: 32,090 mm(1.2634 in)



Check the caliperpiston piston terhadap for scoring,gerusan, scratches goresan or damage. Periksa caliper atau kerusakan. Measure the caliper piston O.D. Ukur D.L. caliper piston. SERVICE LIMIT:SERVIS: 31,94 31.94 mm BATAS mm(1.257 in)



13-14



*: Oleskan minimum 0.4 g grease



14. BATERAI/SISTEM PENGISIAN/ALTERNATOR



LOKASI SISTEM....................................14-2 SYSTEM LOCATION ····································14-2



FLYWHEEL / ALTERNATOR STATOR... 14-7 FLYWHEEL/ALTERNATOR STATOR······14-7



DIAGRAM ................................14-2 SYSTEMSISTEM DIAGRAM ······································14-2



PEMERIKSAAN 14-11 ALTERNATORALTERNATOR.............. INSPECTION····················14-12



LOKASI KOMPONEN-KOMPONEN......14-3 COMPONENT LOCATION ··························14-3



BATERAI.................................................. 14-12 BATTERY ······················································14-12



KETERANGAN SERVIS ........................14-4 SERVICE INFORMATION ···························14-4



SISTEM PENGISIAN................................ 14-13 CHARGING SYSTEM ·································14-13



TROUBLESHOOTING TROUBLESHOOTING...........................14-6 ··································14-6



REGULATOR / RECTIFIER ..................... 14-14 REGULATOR/RECTIFIER·························14-14



14



14-1



BATERAI/SISTEM PENGISIAN/ALTERNATOR



SYSTEMSISTEM LOCATION LOKASI BATTERY/CHARGING SYSTEM/ALTERNATOR



DIMMER SWITCH



LIGHTING SWITCH



BATTERY



REGULATOR/RECTIFIER



ALTERNATOR



W Y



SYSTEM DIAGRAM DIAGRAM SISTEM



G



G



4P



W Y



3P



R Y W G



R



MAIN FUSE 15A



BATTERY



14-2



REGULATOR/ RECTIFIER



ALTERNATOR



R: Red G: Green Y: Yellow W: White



BATERAI/SISTEM PENGISIAN/ALTERNATOR



COMPONENT LOCATION LOKASI KOMPONEN-KOMPONEN



6 N·m (0.6 kgf·m, 4.4 lbf·ft)



39 N·m (4.0 kgf·m, 29 lbf·ft)



10 N·m (1.0 kgf·m, 7 lbf·ft)



14-3



BATERAI/SISTEM PENGISIAN/ALTERNATOR



KETERANGAN SERVIS SERVICE INFORMATION UMUM GENERAL ! PERINGATAN • Baterai mengeluarkan gas-gas eksplosif; jauhkan percikan bunga api, lidah api dan rokok. Sediakan ventilasi • The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charging. memadai ketika mengisi muatan listrik. Contact with skin or eyes may cause severe burns. Wear protective clothing and a face • The battery contains sulfuric acid (electrolyte). • shield. Baterai mengandung asam sulfat (elektrolit). Kontak dengan kulit atau mata dapat menyebabkan luka bakar parah. Pakailah pakaian – If electrolyte gets onpelindung your skin, dan flushpelindung with water.mata. - electrolyte Jika elektrolit kulit, bilas air. – If gets mengenai in your eyes, flush withdengan water for at least 15 minutes and call a physician immediately. Jika elektrolit mengenai mata, bilas dengan air selama sekurangnya 15 menit dan mintalah • Electrolyte is poisonous. bantuan dokter dengan segera. – If swallowed, drink large quantities of water or milk and call your local Poison Control Center or a call a physician 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 off the ignition switch before disconnecting any electrical component. • Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition switch is ON and CATATAN is present.kunci kontak sebelum melepaskan komponen listrik. • current Selalu matikan Beberapa listrikthe dapat rusak atau dilepaskan sementara kunci • • For extendedkomponen storage, remove battery, givejika it aterminal full charge, andconnector store it in adisambungkan cool, dry space.atau For maximum service life, charge thekontak stored battery every ON two weeks. pada posisi dan arus listrik mengalir. • For a battery remaining in a stored scooter, disconnect the negative battery cable from the battery terminal. maintenance free battery be replaced whenbaterai, it reachesberikan the endmuatan of its service life.dan simpan di tempat kering yang sejuk. Untuk • • The Untuk penyimpanan jangkamust panjang, lepaskan penuh, • The battery can be damaged if overcharged or undercharged, or yang if left to discharge for longmuatan period. These same conditions contribute to shortmendapatkan umur pemakaian maksimum, isilah baterai disimpan dengan listrik setiap dua minggu. ening the "life span" of the battery. Even under normal use, the performance of the battery deteriorates after 2-3 years. • Untuk baterai yang tetap dipasang pada skuter yang disimpan, lepaskan kabel negatif baterai dari terminal baterai. may recover after battery but under akhir heavydari load,umur battery voltage will drop quickly and eventually die out. For this • • Battery Bateraivoltage maintenance free harus diganticharging, jika ia mencapai pemakaiannya. reason, the charging system is often suspected as the problem. Battery overcharge often results from problems in the battery itself, which may • appear Bateraitodapat rusak jika di-overcharge (diisi muatan di-undercharge muatan listrik), be an overcharging symptom. If one of the batterylistrik cells isberlebihan) shorted and atau battery voltage does not(kurang increase,pengisian the regulator/rectifier supatau bila ia dibiarkan berkurang sendiri muatannya untuk jangka waktu lama. Keadaan-keadaan sama ini ikut berperan dalam plies excess voltage to the battery. Under these conditions, the electrolyte level goes down quickly. memperpendek umurthe pemakaian baterai. Bahkan pada use pemakaian normal,ofunjuk kerja baterai memburuk setelah 2-3 • Before troubleshooting charging system, check for proper and maintenance the battery. Check ifakan the battery is frequently under tahun. heavy load, such as having the headlight and taillight ON for long periods of time without riding the scooter. listrik baterai, tetapi every di bawah bebantoberat, baterai • • The Voltase baterai dapat membaik setelah battery will self-discharge whenkembali the scooter is notpengisian in use. Formuatan this reason, charge the battery two weeks preventvoltase sulfation from akan turun dengan cepat dan akhirnya mati. Karena itu, sistem pengisian seringkali diduga sebagai penyebab persoalannya. occurring. Battery overcharge seringkali diakibatkan oleh dalam baterai yang mungkin tampak sebagai gejala • When checking the charging system, always follow thepersoalan steps in the di troubleshooting flowsendiri, chart (page 14-6). overcharging. Jika do salah satu sel baterai ada hubungan singkat dan tidak bertambah, regulator/rectifier • For battery charging, not exceed the charging current and time specified on thevoltase battery. baterai Use of excessive current or charging time may damage the voltase battery. berlebihan ke baterai. Di bawah kondisi ini, tinggi permukaan elektrolit akan menurun dengan cepat. memasok flywheel, alternator and ignition pulse generator services can beapakah done withbaterai the engine installed in thedengan frame. baik dan bagaimana • • The Sebelum troubleshooting sistem pengisian, periksalah dipergunakan • Refer to page 15-7Periksa for ignition pulsebaterai generator inspection. perawatannya. apakah 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 • BATTERY muatan CHARGING listrik setiap dua minggu untuk mencegah terjadinya sulfasi. the power ON/OFF at the pengisian, charger, notselalu at the battery terminal. • • Turn Sewaktu memeriksa sistem ikuti langkah-langkah pada peta aliran troubleshooting (hal. 14-6). battery charging, do notmuatan exceed the charging current and time specified arus on thepengisian battery. Using current or extending the charging • • For Pada waktu pengisian listrik baterai, jangan melampaui danexcessive waktu yang ditentukan pada baterai. time may damage battery. Pemakaian arusthe atau waktu pengisian berlebihan dapat merusak baterai. charging should only bealternator done in andan emergency; slow charging is preferred. • • Quick Pekerjaan servis flywheel, ignition pulse generator dapat dijalankan dengan mesin terpasang pada rangka. • Lihat hal. 15-7 untuk pemeriksaan ignition pulse generator. BATTERY TESTING PENGISIAN MUATAN LISTRIK BATERAI to the instruction of the Operation thecharger recommended battery tester for details battery testing. •Refer Hidup/matikan daya listrik denganManual saklar for pada (alat pengisian muatan listrikabout baterai), dan bukan pada terminal baterai. recommended battery tester puts onjangan the battery so that thearus actual battery condition of the load can be measured. •TheSewaktu mengisi muatan listrika "load" baterai, melampaui dan waktu pengisian seperti tertera pada baterai. Pemakaian



arus listrik berlebihan atau memperpanjang waktu pengisian dapat merusak baterai. battery tester: muatan BM-210 BATTERY MATE or equivalent •Recommended Quick charging (pengisian listrikordengan cepat) hanya boleh 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 dianjurkan:



14-4



BM-210 atau BATTERY MATE atau sejenisnya



BATERAI/SISTEM PENGISIAN/ALTERNATOR SPESIFIKASI SPECIFICATIONS BAGIAN Baterai Battery



Alternator Alternator



Kapasitas ITEM Capacity Kebocoran arus Current leakage Voltase Voltage Arus pengisian Charging current Kapasitas Capacity



Terisi penuh Fullydiisi charged Perlu listrik kembali Needs charging Normal Normal Cepat Quick



SPESIFIKASI SPECIFICATIONS 12 V – 3,5 Ah 12 V – 3.5 maksimum 0,5 mAAh 0.5 mA Di atas 12,8 V max. 12.8 V Di bawahAbove 12,3 V 12.3 V 0,4 A / 5 Below – 10 jam 0.4jam A/5 – 10 h 3,0 A / 0,5 A/0.5menit h -1 (rpm) 0,140 kW 3.0 / 5.000 0.111 kW/5,000 min-1 (rpm)



NILAI TORSI



TORQUE VALUES Cooling fan mounting bolt Flywheel nut Coolingpulse fan mounting boltbolt Ignition generator Flywheel nut Ignition pulse generator bolt



10 N.m (1,0 kgf.m; 7 lbf.ft) 39N. (4,0 kgf.m; 29 lbf.ft) 10 kgf.m; N·m (1.0 6 N.m (0,6 4,4kgf·m, lbf.ft)7 lbf·ft) 39 N·m (4.0 kgf·m, 29 lbf·ft) 6 N·m (0.6 kgf·m, 4.4 lbf·ft)



TOOLS



TOOLS



Holder P.D. 32-92 07NAB-HAC0100



Flywheel puller 07733-0010000



14-5



BATERAI/SISTEM PENGISIAN/ALTERNATOR



TROUBLESHOOTING TROUBLESHOOTING BATTERY IS DAMAGED OR WEAK BATERAI RUSAK ATAU LEMAH 1. Battery Test • Test Baterai Remove the battery (page 14-12). Lepaskan baterai (hal. 14-12). Check the battery condition using the recommended battery tester. Periksa kondisi baterai dengan menggunakan battery RECOMMENDED BATTERY TES-tester yang direkomendasikan. TER: BM-210 BATTERY MATE or equivalent BATTERY TESTER YANG DIREKOMENDASIKAN: BM-210 atau or BATTERY MATE atau sejenisnya. Is thekondisi battery inbaik? good condition? Apakah baterai dalam YA



YES DENGAN – GO TO STEP 2. - LANJUTKAN LANGKAH 2.



- Baterai NO rusak – Faulty battery 2. Current Leakage Test Test Kebocoran Arus Listrik TIDAK



•



Install the battery (page 14-12). Pasang baterai (hal. 14-12). the battery current Periksa kebocoran Check arus listrik baterai (hal. leakage 14-13).(page 14-12).



•



•



Is the current leakage below 0.5 mA? Apakah kebocoran arus listrik di bawah 0,5 mA? YES – GO TO STEP 4. YA - LANJUTKAN DENGAN LANGKAH 4. NO – GO TO STEP 3. TIDAK - LANJUTKAN DENGAN LANGKAH 3. 3. Current Leakage Test Without Regulator/rectifier 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? Apakah kebocoran arus listrik di bawah 0,5 mA? YES – Faulty regulator/rectifier YA - Regulator/rectifier rusak NO – • Shorted wire harness TIDAK - • Ada hubungan •singkat wire harness Faultypada ignition switch • Ignition switch (kunci kontak) rusak 4. Alternator Charging Coil Inspection Pemeriksaan Kumparan Pengisian Check the alternator Alternator charging coil (page 14-11). Periksa kumparan pengisian alternator (hal.coil 14-11). Is the alternator charging resistance within 0.2 – 1.0 Ω (20°C/68°F)? Apakah tahanan kumparan pengisian di antara 0,2 – 1,0 Ω (20° C)? YES – GO TO STEPalternator 5.



•



YA



- LANJUTKAN LANGKAH NO DENGAN – Faulty charging coil 5.



TIDAK



- Kumparan pengisian rusak 5. Charging Voltage Inspection



Measure and record the battery voltage using a digital multimeter (page 14-12). Pemeriksaan Voltase Pengisian Startbaterai the engine. Ukur dan catat voltase dengan menggunakan digital multimeter (hal. 14-12). Hidupkan mesin. Measure the charging voltage (page 14-12). Compare measurements to result of the following calculation. Ukur voltase pengisian (hal.the 14-13). STANDARD: Measured battery Voltage < Measured charging voltage < 15.5 V Bandingkan hasil pengukuran dengan hasil dari perhitungan berikut ini. Is the measured charging within the standard voltage? STANDARD: Voltase baterai yang diukurvoltage < Voltase pengisian yang diukur < 15,5 V



•



YES – Faulty battery Apakah voltase pengisian yang diukur di dalam voltase standard? NO – GO TO STEP 6. YA - Baterai rusak 6. Regulator/rectifier System Inspection TIDAK - LANJUTKAN DENGAN LANGKAH 6. Check the voltage and resistance at the regulator/rectifier connectors (page 14-14). Pemeriksaan Sistem Regulator/Rectifier Are the results of checked voltage and resistance correct? Periksa voltase dan tahanan pada regulator/rectifier connectors (hal. 14-14). YES – Faulty regulator/rectifier Apakah hasil dari voltase dan tahanan yang diperiksa benar? NO – • Open circuit in related wire YA - Regulator/rectifier• rusak Loose or poor contacts of related terminal • Shorted wire harness TIDAK - • Rangkaian terbuka pada kawat yang bersangkutan • Kontak longgar atau buruk dari terminal yang bersangkutan • Ada hubungan singkat pada wire harness



14-6



BATERAI/SISTEM PENGISIAN/ALTERNATOR



FLYW HEEL/ALTERN ATO R STATO R FLYWHEEL/ALTERNATOR STATOR PELEPASAN REMOVAL Lepaskan cooling Remove the coolingfan fancover cover(hal. (page2-12). 2-12). Lepaskan mounting bolts dan Remove the mounting bolts and(baut coolingpemasangan) fan. cooling fan.



BOLTS



COOLING FAN



(slang Lepaskan crankcase breather drain Release the crankcase breather drain hose fromhose the clamp. pembuangan pernapasan dari clamp. Remove the two air cleaner crankcase) housing mounting bolts from the Lepaskan left side. kedua air cleaner housing mounting bolts dari Remove sisi kiri. the bolt from the right side of air cleaner housing. Lepaskan bolt dari sisi kanan dari air cleaner housing.



BOLTS



DRAIN HOSE Be careful not to disconnect the air cleaner housing connecting hose from the carburetor.



CLAMP



Angkat housing sedikit air cleaner Slightly air lift cleaner the air cleaner housing overditheatas air cleaner houshousing bolt boss. ing bolt boss.



BOLT AIR CLEANER HOUSING BOLT BOSS



Hold the flywheel with the special tool and loosen the flyTahan flywheel dengan special tool dan longgarkan wheel nut. flywheel nut. TOOL: TOOL: Holder 32-92 07NAB-HAC0100 Holder P.D. P.D. 32-92 07NAB-HAC0100 Lepaskan flywheel Remove the flywheelnut nutdan andwasher. washer.



HOLDER P.D. 32-92



NUT/WASHER



Lepaskan flywheel menggunakan Remove the flywheeldengan using the special tool. special tool. TOOL: TOOL: puller Flywheel Flywheel puller



07733-0010000 07733-0010000



FLYWHEEL PULLER



14-7



BATERAI/SISTEM PENGISIAN/ALTERNATOR Disconnect the alternator/ignition pulse 3P connecLepaskan alternator/ignition pulsegenerator 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 shroud dan rangka. bosses from the intake shroud and frame.



WIRE BAND BOSS



Lepaskan bolt, Remove the bolt,wire wireholder holderdan and lepaskan release thewire wiregrommet grommet fromright the right crankcase. dari crankcase.



WIRE GROMMET



WIRE HOLDER



Remove the two bolts plate from theignition ignitionpulse pulse Lepaskan kedua boltsand dansetset plate dari generator. generator.



WIRE BAND BOSS



BOLT



BOLTS



Remove the two mounting bolts, stator and ignition pulse Lepaskan kedua mounting bolts, stator dan ignition generator from the right crankcase. pulse generator dari right crankcase.



STATOR



BOLTS



SET PLATE IGNITION PULSE GENERATOR



14-8



BATERAI/SISTEM PENGISIAN/ALTERNATOR Be careful to Lepaskan Remove the woodruffkey. key. Hati-hati agar not tidak woodruff merusak keythedan damage keyalur. and groove.



WOODRUFF KEY



PEMASANGAN Hati-hati agar tidak Pasang woodruff key ke dalam alur crankshaft key. merusak key dan alur.



INSTALLATION Be careful not to damage the key and the groove.



Install the woodruff key into the crankshaft key groove.



Set the statorstator and ignition pulse generator onto the pada right Tempatkan dan ignition pulse generator crankcase. right crankcase. Install and tighten the statorstator mounting bolts. bolts. Pasang dan kencangkan mounting



BOLTS STATOR



Install the plate pada onto the ignition pulsegenerator generator dan and Pasang setsetplate ignition pulse tighten the mounting bolts tobolts the specified torque. kencangkan mounting dengan torsi yang ditentukan. TORQUE:6 N·m (0.6 kgf·m, 4.4 lbf·ft)



BOLT



TORSI: 6 N.m (0,6 kgf.m; 4,4 lbf.ft)



SET PLATE IGNITION PULSE GENERATOR



Route thekawat wire properly set thedan wire tempatkan grommet intowire the Alurkan denganandbenar 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 GROMMET



WIRE HOLDER



BOLTS



Alurkan Route thealternator alternator// Tempatkan Set the alternator/ignition pulse generator wire band bosses to alternator/ignition pulse generator wire band ignition pulse generator ignition pulse bosses the intake shroud and frame. pada intake shroud dan rangka. wire dengan benar (hal. generator wire 1-14). properly (page 1-14).



WIRE BAND BOSS



WIRE BAND BOSS



14-9



BATERAI/SISTEM PENGISIAN/ALTERNATOR Set the alternator/ignition pulsepulse generator wire band to Tempatkan alternator/ignition generator wireboss 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



Install the flywheel ontocrankshaft the crankshaft by aligning the key Pasang flywheel pada dengan mentepatkan way way on the(alur flywheel the key on the dengan crankshaft. key spie)with pada flywheel key pada crankshaft.



WIRE BAND BOSS



WOODRUFF KEY



KEY WAY



Tepatkan



Pasang washer Install the washerdan andflywheel flywheel nut. nut. WASHER



NUT



Tahan flywheel dengan special Hold the flywheel with the specialtool tooldan and kencangkan tighten the nutnut to dengan torsi torque. yang ditentukan. the specified TOOL: TOOL:P.D. 32-92 Holder 07NAB-HAC0100 Holder P.D. 32-92 07NAB-HAC0100 TORSI: 39 N.m (4,0 kgf.m; 29 lbf.ft) TORQUE:39 N·m (4.0 kgf·m, 29 lbf·ft)



HOLDER P.D. 32-92



14-10



FLYWHEEL NUT



BATERAI/SISTEM PENGISIAN/ALTERNATOR Set the airair cleaner housing in position. Letakkan cleaner housing pada tempatnya. 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 housing.drain hose with the clamp. Secure the breather



BOLTS



DRAIN HOSE



CLAMP



Pasang cooling dan tighten kencangkan mounting bolts Install the coolingfan fan and the mounting bolts to the dengan yang ditentukan. specifiedtorsi torque.



BOLT BOLTS



TORQUE:10 N·m (1.0 kgf·m,77lbf.ft) lbf·ft) TORSI: 10 N.m (1,0 kgf.m; Pasang cooling fan Install the cooling fancover cover(hal. (page2-12). 2-12).



COOLING FAN



PEMERIKSAAN ALTERNATOR ALTERNATOR INSPECTION Remove the centerbody bodycover cover (hal. (page2-8). 2-8). Lepaskan center Disconnectalternator the alternator 3P connector. Lepaskan 3P connector. Check the resistance between the following Periksa tahanan antara terminals berikut terminals. ini. STANDARD: STANDARD: Charging coil (White – (Putih ground): Kumparan pengisian – massa): 0.2 –– 1,0 1.0 Ω 20°C/68°F) 0,2 Ω (at (pada 20° C) Kumparan (Kuning – massa): Lighting coilpenerangan (Yellow – ground): 0,1 Ω (at (pada 20° C) 0.1 –– 0,8 0.8 Ω 20°C/68°F) Replace the alternator statorpembacaan if measuredyang readings arejauh far Ganti alternator stator jika diukur the standard. dibeyond luar standard.



ALTERNATOR 3P CONNECTOR CHARGING COIL:



LIGHTING COIL:



14-11



BATERAI/SISTEM PENGISIAN/ALTERNATOR



BATTERY BATERAI PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION CATATAN: thekunci ignitionkontak switch ke "OFF" before removing • • Always Selalu turn putar posisi "OFF" dulu the battery.melepaskan baterai. sebelum



Connect theterminal positive Sambungkan terminal first and positif dulu dan then the negative kemudian baru terminalterminal. negatif.



Remove the battery cover (page 2-13). Lepaskan battery cover (hal. 2-13). Remove the bolt and disconnect the negative (–) cable. Keluarkan negatif(+) ( -cable. ). Remove thebolt boltdan andlepaskan disconnectkabel the positive Keluarkan bolt dan lepaskan kabel positif ( + ). Remove the battery. Keluarkan baterai. Install the battery in the reverse order of removal. Pasang baterai dalam urutan terbalik dari pelepasan. After installing the battery, coat the terminals with clean Setelah grease. memasang baterai, lapisi terminal-terminal dengan gemuk bersih. Reinstall the removed parts. Pasang kembali parts yang dilepaskan.



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: Below 12.3 V 12,8 V Bermuatan penuh: Di atas Muatan kurang: Di bawah 12,3 V



CHARGING SYST CHARGING VOLTAGE INSPECTION •



14-12



BATTERY



BATTERY/NEGATIVE (–) TERMINAL



BATTERY/POSITIVE (+) TERMINAL



BATERAI/SISTEM PENGISIAN/ALTERNATOR



SISTEM PENGISIAN TEST KEBOCORAN ARUS LISTRIK Buka battery cover (hal. 2-13).



(–) JARUM



(+) JARUM



Putar kunci kontak ke OFF dan lepaskan kabel negatif ( - ) dari baterai. Hubungkan jarum pemeriksaan ( + ) ammeter ke kabel negatif ( - ) dan jarum pemeriksaan ( - ) ammeter ke terminal ( - ) baterai. Dengan kunci kontak pada posisi OFF, periksa terhadap kebocoran arus listrik. CATATAN: Ketika mengukur arus listrik dengan menggunakan • tester, letakkan pada daerah jangkauan tinggi dulu, kemudian turunkan daerah jangkauan ke tingkat yang sesuai. Aliran arus listrik yang lebih tinggi dari daerah jangkauan yang dipilih dapat memutuskan sekring di dalam tester. Sewaktu mengukur arus listrik, jangan putar arus • kunci kontak ke ON. Lonjakan arus listrik dengan mendadak dapat memutuskan sekring di dalam tester.



(–) KABEL



KETENTUAN KEBOCORAN ARUS LISTRIK: maksimum 0,5 mA. Make sure the battery is in good condition before perthis test. Jika forming kebocoran arus listrik melampaui nilai yang • Do not disconnect the battery or any cable in the charging ditentukan, kemungkinan ada hubungan singkat. system without first switching the dengan ignition switch to OFF. Carilah lokasi hubungan singkat melepaskan Failuresatu to follow precaution can damage tester or hubungan demithis satu dan mengukur arus the listrik. electrical components.



Warm up the engine to normal operating temperature.



PEMERIKSAAN VOLTASE PENGISIAN Stop the engine.



Remove the battery cover (page 2-13) and connect the multi-



meter as shown. To prevent a short, CATATAN: Pastikan bahwa baterai dalam kondisi baik sebelum make absolutely • Connect a tachometer. menjalankan test ini. certain which are the Jangan melepaskan baterai atauthe kabel apapun di the headlight on high beam, restart engine. positive and negative • With dalamthe voltage sistem onpengisian tanpa the multimeter when terlebih the enginedulu runs terminals or cables. Measure mematikan kunci kontak ke OFF. Kegagalan untuk at 5,000 min-1 (rpm). mengikuti tindakan pencegahan ini dapat merusak tester atau komponen-komponen listrik. STANDARD:



Measured battery voltage (page 14-12) Panaskan mesin ke suhu operasi normal. < Measured charging voltage (page 14-12) Matikan mesin. < 15.5 V at 5,000 min-1 (rpm) Lepaskan battery cover (hal. 2-13) dan hubungkan Untuk menghindari hubungan singkat, multimeter seperti diperlihatkan.



REGULATOR/RECTIFIER



pastikan dengan benar REMOVAL/INSTALLATION manalah terminal atau Hubungkan tachometer. kabel positif dan negatif.



Remo lampu besar pada sinar lampu jauh, hidupkan Dengan mesin kembali. Ukur voltase pada multimeter sewaktu mesin berputar -1 pada 5.000 menit (rpm). STANDARD: Ukur voltase baterai (hal. 14-12) < Voltase pengisian yang diukur (hal. 14-13) -1 < 15,5 V pada 5.000 menit (rpm)



14-13



BATERAI/SISTEM PENGISIAN/ALTERNATOR



REGULATOR/RECTIFIER



e the body cover (page 2-9).



PELEPASAN/PEMASANGAN Turn the ignition



BOLT



switch to OFF. Lepaskan body cover (hal. 2-9). Disconnect regulator/rectifier 4P connector. Putar kunci the kontak ke OFF. Remove the bolt and the regulator/rectifier. Lepaskan regulator/rectifier 4P connector. Installation is in the reverse order of removal. Lepaskan bolt dan regulator/rectifier. Pemasangan pelepasan.



adalah



dalam



urutan



terbalik



dari 4P CONNECTOR



SYSTEM INSPECTION Remove the body cover (page 2-9). Disconnect the regulator/rectifier 4P connector and check it for loose contact or corroded terminals. PEMERIKSAAN SISTEM If the battery charging voltage reading (page 14-12) is out of Lepaskan body cover (hal. 2-9). the specification, inspect the connector terminals (wire harness side) asregulator/rectifier follows: Lepaskan 4P connector dan periksa terhadap kontak longgar atau terminal-terminal Item Terminal Specification berkarat. Battery charging Red (+) and Battery voltage line pembacaan voltase ground pengisian (–) should(hal. register Jika baterai 14-13) Charging coil line White and 0.2 – 1.0 Ω di luar spesifikasi, periksa terminal-terminal connector (sisi wire harness) ground sebagai berikut: (at 20°C/68°F) Ground line Green and ground Continuity should exist Bagian Terminal Spesifikasi Saluran Merah (+) dan Harusandada omponents of the charging system are normal there pengisian massa replace (-) voltase are no loose connections, the regulator/rectifier baterai baterai unit. Saluran Putih dan 0,2 – 1,0 Ω kumparan massa (pada 20°C) pengisian Saluran massa Hijau dan Harus ada massa kontinuitas



REGULATOR/RECTIFIER 4P CONNECTOR



Jika semua komponen sistem pengisian adalah normal dan tidak ada sambungan longgar, gantilah regulator/rectifier unit.



REGULATOR/ RECTIFIER 4P CONNECTOR



REGULATOR/ RECTIFIER 4P CONNECTOR



REGULATOR/RECTIFIER 4P REGULATOR/ CONNECTOR RECTIFIER



14-14



REGULATOR/ RECTIFIER



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



REGULATOR/RECTIFIER 4P CONNECTOR



REGULATOR/RECTIFIER 4P CONNECTOR



14-15



CATATAN



15. SISTEM PENGAPIAN



LOKASI SISTEM...................................... 15-2 SYSTEM LOCATION ····································15-2



IGNITION COIL ......................................15-8 IGNITION COIL ·············································15-8



DIAGRAM SISTEM .................................. 15-2



IGNITION SWITCH.................................15-8



KETERANGAN SERVIS .......................... 15-3



SIDESTAND SWITCH............................15-9



TROUBLESHOOTING ............................. 15-4



IGNITION CONTROL MODULE (ICM)...15-11



PEMERIKSAAN SISTEM PENGAPIAN... 15-5



IGNITION TIMING ..................................15-12



SYSTEM DIAGRAM ······································15-2 SERVICE INFORMATION ···························15-3 TROUBLESHOOTING ··································15-4 IGNITION SYSTEM INSPECTION ·············15-5



IGNITION SWITCH ·······································15-8 SIDESTAND SWITCH ···································15-9 IGNITION CONTROL MODULE (ICM) ··15-11



IGNITION TIMING······································15-12



15



15-1



SISTEM PENGAPIAN



SYSTEM LOCATION LOKASI SISTEM IGNITION SYSTEM



MAIN FUSE 15A



IGNITION SWITCH BATTERY



IGNITION CONTROL MODULE (ICM)



SIDESTAND SWITCH IGNITION PULSE GENERATOR



IGNITION COIL



SYSTEM DIAGRAM DIAGRAM SISTEM



IGNITION SIDE STAND SWITCH SWITCH



Bl/Y



4P



G



G/W



G



G



Br 6P



IGNITION CONTROL MODULE (ICM)



BATTERY



15-2



3P



R/Bl



3P



G/W



G/W



G



Bu/Y



G



2P



IGNITION COIL



Bu/Y



R/Bl



G



R/Bl



R R



G



R



MAIN FUSE 15A



IGNITION PULSE GENELATOR



SPARK PLUG



SISTEM PENGAPIAN



SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM



! PERINGATAN If the engineharus must be running to do some work, makemelakukan sure the areasesuatu is well ventilated. Never run thebahwa engine in an enclosed The exhaust Jika mesin dalam keadaan hidup untuk pekerjaan, pastikan tempat kerja area. berventilasi baik. containssekali-kali poisonousmenjalankan carbon monoxide gasdi that may cause loss of consciousness and may mengandung gas karbon monoksida beracun Jangan mesin dalam tempat tertutup. Gas pembuangan lead dapat to death. yang mengakibatkan hilangnya kesadaran dan akhirnya dapat membawa kematian.



CATATAN Beberapa dapat rusak jika terminal-terminal atau connector-connector dilepaskan •• Some electricalkomponen componentslistrik may be damaged if terminals or connectors are connected or disconnecteddisambungkan while the ignitionatau switch is ON and sementara kunci kontak pada posisi ON dan ada arus listrik yang mengalir. current is present. • Sewaktu menservis sistem pengapian, selalu ikuti langkah-langkah pada urutan troubleshooting pada hal. 15-4. •• When servicing the(waktu ignitionpengapian) system, always stepsoleh in thekarena troubleshooting sequenceModule on page(ICM) 15-4. telah disetel awal di pabrik. Ignition timing tidakfollow perluthe disetel Ignition Control •• The ignition timing does not normally need to be adjusted since the Ignition Control Module (ICM) is factory preset. arus listrik sedang Ignition Control Module (ICM) dapat rusak jika dijatuhkan. Juga jika connector dilepaskan sewaktu • The Ignition Control (ICM) may be damaged if dropped. Alsomatikan if the connector is disconnected current is flowing, the excessive mengalir, voltaseModule berlebihan dapat merusak module. Selalu kunci kontak sebelumwhen 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. baterai lemah menghasilkan kecepatan mesin lebih rendah maupun tidak • Use spark plug of the correct heat range. Usingperputaran spark plug with an yang incorrect heat range can 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 Spark plug Standard BAGIAN For extended high speed riding Busi Spark plugStandard gap Untuk lama pada kecepatan tinggi Ignition coil peakpengendaraan voltage Jarak renggang busi peak voltage Ignition pulse generator Peak voltage Ignition timing(voltase puncak) ignition coil Peak voltage ignition pulse generator Ignition timing (pengaturan waktu pengapian)



SPECIFICATIONS CPR8EA-9 (NGK) / U24EPR9 (DENSO) SPESIFIKASI CPR9EA-9 (NGK) CPR 8EA -0.80 9 (NGK), – 0.90 U24EPR9 mm (0.031 (DENSO) – 0.035 in) CPR 9EA – 9 (NGK) 100 V minimum 0,80 – 0,90 mm 0.7 V minimum minimum 100 V14° BTDC at idle speed minimum 0,7 V 14° sebelum TMA pada putaran stasioner



TORQUE VALUE Key shutter socket bolt NILAI TORSI Key shutter socket bolt



10 N·m (1.0 kgf·m, 7 lbf·ft.) 10 N.m (1,0 kgf.m; 7 lbf.ft.)



TOOL TOOL Imrie diagnostic tester (model 625) atau Peak voltage adaptor 07HGJ-0020100



Dengandigital digitalmultimeter multimeter(indepedansi (indepedDengan ansi minimum 10 WM/DCv)yang )yang dapatdapat di beli minimum 10 MΩ/DCV beli di pasaran. didipasaran.



15-3



SISTEM PENGAPIAN



TROUBLESHOOTING TROUBLESHOOTING • Inspect the following before diagnosing the system. • – Faulty Periksa sebagai spark plug berikut ini sebelum mendiagnosa sistem. - Spark plug (busi) rusak. – Loose spark plug cap or spark plug wire connection - Spark capspark (topiplug busi) atau sambungan kabel busi longgarvoltage) – Water got plug into the cap (Leaking the ignition coil secondary - Air memasuki spark plug cap (Voltase sekunder ignition coil bocor) No spark at spark plug Unusual Tidak ada percikan bunga apicondition pada busi. Ignition coil Low peak voltage. primary voltage Kejadian luar biasa



Probable cause (Check in numerical order) 1. The multimeter impedance is too low; below 10 MΩ/ DCV. 2. Cranking speed is penyebab too slow. (Battery is undercharged or operatKemungkinan ing force of the kickstarter is weak) (periksa menurut urutan angka) 3. The sampling timediofbawah the tester measured pulse were not Peak voltage 1. Impedansi multimeter terlalu rendah; 10and MΩ/DCV. Voltase synchronized. normalatau if measured voltagepada is over the primer (voltase puncak) rendah 2. Putaran start mesin terlalu rendah(System (Bateraiislemah gaya dorong ignition kickstarter lemah) standard voltage at least once.) 4. contoh Poorly connected or an opentidak circuitsinkron in the ignition coil 3. Waktu pengambilan tester danconnectors pulsa yang diukur system. (Sistem adalah normal bila voltase yang diukur adalah sekurangnya sekali di atas voltase standard.) 5. Faulty ignition coil. 4. Connectors tersambung dengan buruk atau ada rangkaian terbuka 6. Faulty ignition control module (ICM) (in case whenpada above No. 1 ignition system (sistem – 5pengapian). are normal). 5. Ignition coil tidak bekerja dengan No peak voltage. 1. Incorrect peakbaik. voltage adaptor connections. 6. Ignition control module (ICM) tidak switch. bekerja dengan baik (dalam hal bila No. 2. Faulty ignition 1-5 di atas adalah3.normal). Loose or poorly connected ICM connectors. Open adapter circuit or tidak poor connection in the Red/Black wire of the Tidak ada peak voltage 1. Sambungan peak4.voltage benar. 2. Ignition switch (kunciICM. kontak) tidak bekerja dengan baik. 5. Openatau circuit or poor connection in the Green wire of the ICM. 3. ICM connectors longgar buruk sambungannya. 6. atau Opensambungan circuit in theburuk Green/White wire or Green wire ofdari the side4. Rangkaian terbuka pada kawat Merah/Hitam stand switch. ICM. 7. atau Faulty sidestand switch. 5. Rangkaian terbuka sambungan buruk pada kawat Hijau dari ICM. 8. pada Faulty peak Hijau/Putih voltage adaptor (page 15-5). 6. Rangkaian terbuka kawat atau kawat Hijau dari sidestand 9. Faulty ignition pulse generator. (Measure the peak voltage.) switch. Faulty ICMdengan (in case baik. when above No.1 – 9 are normal). 7. Sidestand switch 10. tidak bekerja Peak voltage is normal, but sparkvoltage jumps adapter 1. Faulty spark plug leaking dengan ignition coil 8. noPeak (hal. 15-5) tidakorbekerja baik.secondary current. at the plug. 2. Faulty ignition coil.dengan baik (Ukur peak voltage). 9. Ignition pulse generator tidak bekerja Ignition pulse Low peak voltage. The multimeter impedance too1-9 low.di atas adalah 10. ICM tidak bekerja1.dengan baik (dalam hal bilaisNo. generator 2. Cranking speed is too slow. (Operating force of the kickstarter is normal). weak) baik atau ada kebocoran pada arus sekunder Peak voltage normal, 1. Busi tidak bekerja dengan 3. The sampling time of the tester and measured pulse were not ignition coil. tetapi tidak ada synchronized. (System is normal if measured voltage is over the 2. Ignition coil tidak bekerja dengan baik. percikan bunga api standard voltage at least once.) pada busi 4. Faulty ignition pulse generator (in case when above No.1 – 3 are Peak voltage rendah 1. Impedansi multimeter terlalu rendah. Ignition normal). 2. Putaran start mesin terlalu rendah (Gaya dorong pada kickstarter lemah). pulse No peak voltage. 1. Faulty peak voltage adapter (page 15-5). 3. Waktu pengambilan contoh dari tester dan pulsa yang diukur tidak sinkron generator 2. Faulty ignition pulse generator. (Sistem adalah normal bila voltase yang diukur adalah sekurangnya sekali di atas voltase standard.) 4. Ignition pulse generator tidak bekerja dengan baik (dalam hal bila No. 1-3 di atas adalah normal). Tidak ada peak voltage. 1. Peak voltage adapter tidak bekerja dengan baik (hal. 15-5). 2. Ignition pulse generator tidak bekerja dengan baik.



15-4



SISTEM PENGAPIAN



IGNITION SYSTEM INSPECTION PEMERIKSAAN SISTEM PENGAPIAN CATATAN: theretidak is no spark plug, check all connections for busi, loose • • IfJika ada atpercikan bunga api pada or poor contact beforesambungan measuring peakterhadap voltage. kontak periksa semua • Use commercially available digital multimeter an longgar atau buruk sebelum mengukur with peak impedance of 10 MΩ/DCV voltage (voltase puncak).minimum. displaydigital value differs depending upon the internal Pakailah multimeter dengan impedansi • • The impedance of the multimeter. minimum 10 MΩ/DCV yang dapat dibeli di pasaran. • If using Imrie diagnostic tester (model 625), follow the • manufacturer’s Nilai yang ditayangkan instructions. berbeda tergantung pada impedansi internal dari multimeter. Connect the peak voltage adaptor to the digital multimeter, or •use Jika Imrie diagnostic the Imrie diagnostic tester. tester (model 625) yang dipakai, ikutilah petunjuk pabrik pembuatnya. TOOLS: Imrie diagnostic testervoltage (model 625) or Hubungkan peak adaptor pada digital multimeter, atau pakailah Imrie diagnostic tester. Peak voltage adaptor 07HGJ-0020100 with Commercially available digital multimeter (impedTOOLS: ance 10 MΩ/DCV minimum) Imrie diagnostic tester (model 625) atauPeak voltage adaptor 07HGJ-0020100 dengan digital multimeter yang PEAK VOLTAGE ADAPTORdapat dibeli di pasaran (dengan impedansi minimum 10 MΩ/DCV) INSPECTION



DIGITAL MULTIMETER



PEAK VOLTAGE ADAPTOR



When



PEMERIKSAAN PEAK VOLTAGE ADAPTOR



If you touch the adaptor jack immediately after disconnecting the Jika adaptor jack adaptor, you may get disentuh segera setelah electrical shock. melepaskan adaptor, Be sure to disconnect anda mungkin terkena the adaptor after kejutan listrik. allowing the voltage Pastikan untuk to decrease melepaskan adaptor sufficiently. setelah membiarkan voltase turun sendiri dengan cukup.



Sewaktu mengetes tegangan sisi sekunder testing the high tension on the tinggi ignitionpada coil secondary side ignition denganadaptor, menggunakan peak using the coil peak voltage the inner diode may voltage be damadaptor, di adaptor sebelahwill dalam dapat rusak. Oleh aged. As adiode damaged cause incorrect peak voltage readings, alwaysadaptor consideryang a defective if the peak voltkarena sebuah rusak adaptor akan mengakibatkan age readings are all abnormal. pembacaan peak voltage yang tidak benar, selalu The adaptor diode can be easilyadaptor checkedyang by therusak following pertimbangkan kemungkinan jika procedure. Therefore, be sure to check the normal. adaptor before pembacaan peak voltage semuanya tidak replacing the parts that display an abnormal testing value. Diode dapat diperiksa dengan dengan Set theadaptor multimeter to the AC voltage rangemudah and measure the prosedur sebagai berikut. Oleh karena itu, pastikan local line voltage. untuk adaptor sebelum parts Then, memeriksa connect the peak voltage adaptor mengganti to the multimeter, yang memperlihatkan pengetesan normal. measure the same AC nilai voltage with DC tidak voltage range and compare it to AC voltage measured previously. Pasang multimeter pada daerah jangkauan voltase AC • The normal iflokal. the DC voltage measured via the dan ukuradaptor voltaseissaluran adaptor ishubungkan 1.4 times of AC voltage. Kemudian peak voltage adaptor ke • The adaptor is defective if the DC voltage measured via multimeter, ukur voltase AC yang sama dengan daerah the adaptor is 0 V. jangkauan voltase DC dan bandingkan dengan voltase AC yang diukur sebelumnya. • Adaptor adalah normal jika voltase DC yang diukur melalui adaptor adalah 1,4 kali voltase AC (sekitar 300V). • Adaptor adalah rusak jika voltase DC yang diukur melalui adaptor adalah 0 V.



PEAK VOLTAGE ADAPTOR



15-5



SISTEM PENGAPIAN IGNITION COIL PRIMARY IGNITION COIL PRIMARY PEAKPEAK VOLTAGE VOLTAGE (VOLTAGE PUNCAK PRIMER COIL PENGAPIAN) CATATAN: • Check all system connections before inspection. If the system is disconnected, incorrect peak voltage sebelum might be • Periksa semua sambungan sistem measured. Jika sistem terlepas, peak voltage yang pemeriksaan. • diukur Checkmungkin cylinder compression tidak benar. and check that the spark plug is installed correctly.cylinder dan periksa bahwa busi • Periksa kompressi telahthe dipasang dengan benar. on a level surface. Place scooter with its centerstand



Remove theskuter body cover (page 2-9). Letakkan dengan standard utama pada permukaan Release themendatar. spark plug wire clamp boss from the intake shroud. Lepaskan body cover (hal. 2-9). Lepaskan spark plug wire clamp boss dari intake shroud.



WIRE CLAMP



Lepaskan plug busi) dari spark plug Disconnectspark the spark plugcap cap (topi from the spark plug. (busi). Connect a known-good spark plug to the spark plug cap and ground the spark plug to the cylinder as done in a spark test. Sambungkan busi yang diketahui dalam keadaan baik pada spark plug cap dan hubungkan busi dengan massa pada cylinder seperti dilakukan pada test percikan api busi.



BUSI BAGUS



Avoid touching the testermenyentuh probes to Jangan prevent electric jarum pemeriksaan shock. tester untuk menghindari kejutan listrik.



15-6



With the ignition primary wire connected, connect the Dengan ignition coilcoil primary wire tersambung, peak voltage peak adaptorvoltage or tester adaptor probes to the ignition coil prihubungkan atau jarum-jarum mary wire terminal andpada ground.ignition coil primary wire pemeriksaan tester terminal dan massa. TOOLS: Imrie diagnostic tester (model 625) or TOOLS: Peak diagnostic voltage adaptor Imrie tester (model 625)07HGJ-0020100 atau with commercially available digital07HGJ-0020100 multimeter (impedPeak voltage adaptor ance 10 MΩ/DCV minimum)(impedansi minimum 10 dengan digital multimeter MΩ/DCV) CONNECTION: Black/Yellow (–) – Body ground (+) HUBUNGAN: Hitam/Kuning ( - ) - Massa badan ( + ) IGNITION COIL PRIMARY Retract the sidestand. WIRE TERMINAL (Bl/Y) Turn the ignition switch "ON" then squeeze the brake lever Tarik sidestand ke atas. fully. Putar kunci kontak ke "ON" kemudian tekan handel rem JARUM IGNITION COIL Crank the engine with the starter motor and measure the igni- PEMERIKSAAN(–) sepenuhnya. tion coil primary peak voltage. Putar mesin dengan starter motor dan ukur ignition coil PEAK VOLTprimary peak voltage (voltase puncak primer coil AGE: 100 V minimum pengapian). BI/Y G If the peak voltage is abnormal, check each item following PEAK VOLTAGE (VOLTASE PUNCAK): the troubleshooting chart (page 15-4). minimum 100 V Connect the spark plug cap to the spark plug. Dari ICM Jika peak voltage tidak normal, periksa masing-masing BUSI BAGUS Set the spark plug wire clamp boss to the intake shroud. bagian mengikukti peta troubleshooting (hal. 15-4) Install the body cover (page 2-9). JARUM Sambungkan spark plug cap pada spark plug. PEMERIKSAAN(+) Tempatkan spark plug wire clamp boss pada intake shroud. Pasang body cover (hal. 2-9).



SISTEM PENGAPIAN IGNITION PULSE GENERATOR PEAK IGNITION PULSE GENERATOR PEAK VOLTASE VOLTAGE (VOLTASE PUNCAK IGNITION PULSE GENERATOR) • Check cylinder compression and make sure the spark plug



CATATAN: is installed correctly. • • Check Periksa kompressi cylinder dan pastikanIf the bahwa all system connection before inspection. system is disconnected, incorrect peak voltage might be measpark plug terpasang dengan benar. • sured. Periksa semua sambungan sistem sebelum Jika to sistem Turnpemeriksaan. the ignition switch "OFF".terlepas sambungannya, maka voltase puncak yang salah yang akan Remove the battery cover (page 2-13). terukur.



Disconnect the ICM 6P connector. Putar kunci kontak ke "OFF". Connect the peak voltage adaptor or tester probes to the ICM Lepaskan battery cover (hal. 2-13). 6P connector. Lepaskan TOOLS: ICM 6P connector. Imrie diagnostic (model 625) or atau jarum-jarum Hubungkan peaktester voltage adaptor Peak ke voltage 07HGJ-0020100 tester ICM adaptor 6P connector. TOOLS: with commercially available digital multimeter (impedImrie diagnostic tester (model 625) atau ance 10 MΩ/DCV minimum) Peak voltage adaptor 07HGJ-0020100 CONNECTION:Blue/yellow – Body ground (–) dengan digital multimeter (+) (impedansi minimum 10 MΩ/DCV) yang dapat dibeli di pasaran Turn the ignition switch "ON" and squeeze the brake lever fully. HUBUNGAN: Biru/kuning ( + ) - Massa badan ( - ) Jangan menyentuh Crank kunci the engine withke the "ON" kickstarter measure the igniAvoid touching the Putar kontak dan and tekan handel rem jarum-jarum tion pulse generator peak voltage. tester probes to sepenuhnya. pemeriksaan testerelectric untuk prevent PEAK VOLTmenghindari kejutan shock. listrik. Putar AGE:mesin dengan 0.7kickstarter V minimumdan ukur ignition pulse



generator peak voltage. If the peak voltage minimum 0,7 V PEAK VOLTAGE:



Jika peak voltage yang diukur pada ICM connector adalah tidak normal, ukur peak voltage pada ignition measured at the ICM connector is abnormal, measuthe ignipulse generator 3P3P connector. tin pulse generator connector.



IGNITION CONTROL MODULE (ICM)



6P CONNECTOR



Bu/ Y



Bu/ Y



ICM 6P CONNECTOR IGNITION PULSE GENERATOR



Remove the centerbody bodycover cover (hal. (page2-8). 2-8). Lepaskan center Connect the peak voltage tester or adaptor probes to the 3P Hubungkan peakof voltage tester atau jarum-jarum connector terminal the ignition pulse generator side. pemeriksaan adaptor pada 3P connector terminal dari In the same manner as at the ICM connector, measure the sisi ignition pulse generator. peak voltage and compare it to the voltage measured at the ICM connector. Dengan cara sama seperti pada ICM connector, ukurlah peak dan bandingkan dengan yang • If voltage the peak voltage measured at the ICM isvoltase abnormal and diukur pada ICM connector. the one measured at the ignition pulse generator is normal, the wire harness has an open or short circuit, or loose • connection. Jika peak voltage yang diukur pada ICM tidak normal danvoltages yang measure diukur are pada ignition • If both peak abnormal, checkpulse each generator adalah normal, maka wire harness ada item in the troubleshooting chart (page 15-4). rangkaian atau the adaignition hubungan atau If all items terbuka are normal, pulsesingkat, generator is hubungan longgar. faulty. See page 14-7 for ignition pulse generator replace• ment. Jika kedua peak voltages yang diukur tidak normal, periksalah masing-masing bagian pada peta Install the removed parts in the reverse order of removal. troubleshooting (hal. 15-4). Jika semua bagian adalah normal, maka ignition pulse generator rusak. Lihat hal. 14-7 untuk penggantian ignition pulse generator.



IGNITION PULSE GENERATOR 3P CONNECTOR 3P CONNECTOR



Pasang parts yang telah dilepaskan dalam urutan terbalik dari pelepasan.



IGNITION PULSE GENERATOR



15-7



SISTEM PENGAPIAN



IGNITIONCOIL COIL(COIL PENGAPIAN) IGNITION PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Remove the bodycover cover(hal. (page2-9). 2-9). Lepaskan body Disconnectspark the spark releasespark spark plug plug wire Lepaskan plug plug cap cap dan and lepaskan clamp dari fromintake the intake shroud. clamp shroud.



CLAMP



Disconnectignition the ignition coil primary connectors. Lepaskan coil primary wirewire connectors.



SPARK PLUG CAP



PRIMARY WIRE CONNECTORS



Release thespark sparkplug plug wire wire clamp clamp from the frame. Lepaskan dari rangka.



IGNITION COIL



Remove the two mounting and ignition coil. Lepaskan kedua mountingbolts bolts dan ignition coil. Installation is in adalah the reversedalam order of urutan removal. terbalik the wire Pemasangan AlurkanRoute wire harness dengan benar (hal. pelepasan. harness properly (page 1-14). 1-14).



dari



CLAMP



BOLTS



IGNITION IGNITIONSWITCH SWITCH(KUNCI KONTAK) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Remove the steeringstem stem (hal. (page11-21). 11-21). Lepaskan steering



BOLT



Disconnectignition the ignition switch 2P connector. Lepaskan switch 2P connector. Remove the socketbolt boltdan and key key shutter. shutter. Lepaskan socket



SCREWS



IGNITION SWITCH



Remove the screwsdan and ignition ignition switch. switch. Lepaskan screws Installation is in adalah the reversedalam order of urutan removal. terbalik dari Pemasangan 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)



2P CONNECTOR



15-8



KEY SHUTTER



SISTEM PENGAPIAN INSPECTION PEMERIKSAAN Remove the front uppercover cover(hal. (page2-4). 2-4). Lepaskan front upper Disconnect the ignition switch 2P connector. Lepaskan ignition switch 2P connector.



IGNITION SWITCH 2P CONNECTOR



Periksa switchforterhadap antara Check theignition ignition switch continuity kontinuitas between the connector terminals in each switch position. connector terminals pada setiap posisi switch.



IGNITION SWITCH



IGNITION SWITCH BAT1



BAT



R/Bl



R



ON OFF LOCK COLOR



SIDESTAND SWITCH (SAKLAR STANDARD SAMPING) SIDESTAND SWITCH PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Remove the centerbody bodycover cover (hal. (page2-8). 2-8). Lepaskan center Disconnectsidestand the sidestand switch connector. Lepaskan switch 3P 3P connector.



SIDESTAND SWITCH 3P CONNECTOR



15-9



SISTEM PENGAPIAN Release thekawat sidestand switch switch wire from frameclamps. clamps. Lepaskan sidestand darithe frame



SIDESTAND SWITCH WIRE



CLAMPS



Lepaskan bolt dan switch. Remove the bolt andsidestand sidestand switch.



Install thesidestand sidestand switch whilesementara aligning its groove with the Pasang switch mentepatkan spring pin, making sure that tabs arememastikan positioned as bahwa shown. alurnya dengan spring pin,the dengan tabs telah ditempatkan seperti diperlihatkan. Install and tighten the sidestand switch bolt.



SPRING PIN



BOLT GROOVE



AlurkanRoute wire harness kencangkan sidestand switch bolt. Connectdan the sidestand switch 3P connector. the wire Pasang dengan benar (hal. harness properly Sambungkan sidestand switch 3P2-8). connector. Install the center body cover (page (page 1-14). 1-14).



Pasang center body cover (hal. 2-8). • Do not reuse the broken sidestand switch. CATATAN: sidestandkembali switch before retightening theyang side• • Remove Jangan the memakai sidestand switch stand pivot nut. patah. sebelum • Lepaskan sidestand switch mengencangkan kembali sidestand pivot nut.



SIDESTAND SWITCH



TABS



INSPECTION



Remove the battery cover (page 2-13). PEMERIKSAAN Turn the ignition Lepaskan batteryswitch cover"OFF". (hal. 2-13). Disconnect the ICM 6P connector. Putar ignition switch ke "OFF".



IGNITION CONTROL MODULE (ICM)



Lepaskan ICM 6P connector.



6P CONNECTOR



15-10



SISTEM PENGAPIAN Periksa terhadap kontinuitas antara 6P connector Check for continuity between the ICM ICM 6P connector of the wiresisi harness and ground. dari wire side harness dan massa.



CONNECTION:Green/White – Bodybadan ground HUBUNGAN: Hijau/Putih – Massa There should be continuitydengan with thesidestand sidestand retracted, and ditarik, dan Harus ada kontinuitas there should continuity with the sidestand tidak bolehbe no ada kontinuitas dengan applied. sidestand diturunkan. If there is no continuity with the sidestand retracted, the wire harness is broken or the sidestand switch is faulty. Jika tidak ada kontinuitas dengan sidestand ditarik ke atas, wire harness patah atau sidestand switch rusak.



SIDESTAND Kontinuitas (Sidestand ditarik):



Tidak ada Kontinuitas (Sidestand diturunkan):



ICM 6P CONNECTOR



ICM 6P CONNECTOR



G/W G



G/W G



UP



SIDESTAND SWITCH



UP



SIDESTAND SWITCH



IGNITION IGNITIONCONTROL CONTROLMODULE MODULE(ICM) (ICM) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan battery Remove the batterycover cover(hal. (page2-13). 2-13).



IGNITION CONTROL MODULE (ICM)



Putar ignition switch ke"OFF". "OFF". Turn the ignition switch



DisconnectICM the ICM 4P/6P connectors. Lepaskan 4P/6P connectors. Installation is in the reverse order ofurutan removal. terbalik Pemasangan dalah dalam pelepasan.



dari



4P/6P CONNECTORS



15-11



SISTEM PENGAPIAN POWER/GROUND LINE INSPECTION PEMERIKSAAN POWER/GROUND LINE (SALURAN POWER LINEDAYA/MASSA) Remove the batterycover cover(hal. (page2-13). 2-13). Lepaskan battery Disconnect the (SALURAN ICM 4P connector. POWER LINE DAYA) Turn the ignition "ON". Lepaskan ICM 4Pswitch connector. Measure the battery between the ICM 4P connector Putar ignition switchvoltage ke "ON". of the wire harness side and ground. Ukur voltase baterai antara ICM 4P connector dari sisi CONNECTION:Red/Black wire harness dan massa. (+) – Body ground (–) There should be battery voltage with the ignition switch HUBUNGAN: Merah/Hitam ( + ) - Massa badan ( - ) "ON". Harus ignition switch pada If thereada is novoltase voltage baterai with the dengan ignition switch "ON", check the "ON". following: Jika tidak ada voltase dengan ignition switch pada "ON", – Wire harness between the battery and ICM periksa sebagai berikut: – Ignition switch - Wire harness antara baterai dan ICM – Fuse - Ignition switch - GROUND Sekring LINE



IGNITION CONTROL MODULE (ICM)



4P CONNECTORS POWER LINE: ICM 4P CONNECTOR



Turn the ignition switch "OFF".MASSA) GROUND LINE (SALURAN Disconnect theswitch ICM 4P Putar ignition keconnector. "OFF". Check for ICM continuity between the ICM 4P connector of the Lepaskan 4P connector. wire harness side and ground. Periksa terhadap kontinuitas antara ICM 4P connector CONNECTION:Green – Body ground dari sisi wire harness dan massa. HUBUNGAN: Hijau – Massa badan There should be continuity at all time. AlurkanRoute wire the harness wire dengan benar (hal. harness properly (page 1-14). 1-14).



Harus kontinuitas If thereada is no continuity,setiap check waktu. the open circuit in green wire. Jika tidak ada kontinuitas, periksa rangkaian terbuka pada kawat hijau.



GROUND LINE: ICM 4P CONNECTOR



R/Bl



IGNITION SWITCH



G



FUSE 15A



IGNITION (WAKTU PENGAPIAN) IGNITIONTIMING TIMING CATATAN: • • The Ignition timing telah disetelpreset awaland di need pabrik ignition timing is factory onlydan be hanya perlu diperiksa sebuah komponen dari checked when an electricaljika system component is replaced. sistem telah diganti. • Read thelistrik instructions for timing light operation. • Bacalah petunjuk pemakaian timing light. Remove the cooling fan cover (page 2-12). Lepaskan cooling Connect the timingfan lightcover to the(hal. spark2-12). plug wire.



NOTCH



Hubungkan timing light "ON". pada kabel lbusi. Turn the ignition switch Putar ignition switch Start the engine and letkeit "ON". idle. -1 Hidupkan dan biarkan berputar stasioner. ENGINE mesin IDLE SPEED:1,700 ± 100 min (rpm) -1 PUTARAN STASIONER MESIN: 1.700 ± 100 menit The ignition timing is correct if the index notch on the right (rpm) crankcase aligns with the "F" mark on the flywheel as shown.



If the ignition is incorrect, inspect the ignition pulse Ignition timingtiming adalah tepat jika index notch (takik generator (page penunjuk) pada15-7). right crankcase bertepatan dengan tanda "F" pada flywheel seperti diperlihatkan. Jika ignition timing tidak tepat, periksa ignition pulse generator (hal. 15-7).



15-12



TANDA "F"



TIMING LIGHT



16. SISTEM STARTER LISTRIK



LOKASI SISTEM....................................16-2



STARTER PINION .................................16-10



DIAGRAM SISTEM ................................16-2



STARTER RELAY..................................16-11



KETERANGAN SERVIS ........................16-3



STARTER SWITCH................................16-14



TROUBLESHOOTING ...........................16-4



BRAKE LIGHT SWITCH ........................16-14



SYSTEM LOCATION ····································16-2 SYSTEM DIAGRAM ······································16-2 SERVICE INFORMATION ···························16-3 TROUBLESHOOTING ··································16-4



STARTER PINION ·······································16-10



STARTER RELAY········································16-11



STARTER SWITCH ·····································16-14



BRAKE LIGHT SWITCH ····························16-14



STARTER MOTOR ................................16-6



STARTER MOTOR ········································16-6



16



16-1



SISTEM STARTER LISTRIK



SYSTEMSISTEM LOCATION LOKASI ELECTRIC STARTER SYSTEM



REAR BRAKE LIGHT SWITCH STARTER SWITCH MAIN FUSE 15A



FRONT BRAKE LIGHT SWITCH



SUB FUSE 10A IGNITION CONTROL MODULE (ICM) BATTERY



IGNITION SWITCH STARTER RELAY



STARTER MOTOR



DIAGRAM SISTEM SYSTEM DIAGRAM MAIN FUSE 15A R



R



Bl



R



BATTERY



SUB FUSE 10A



R/Bl



R/Bl



STARTER RELAY



5P 2P



6P



Bl



R R/W Y/R R/Bl



R/W



4P



R



R/Bl



G/Y Bl



G/Y Bl



G/Y



Y/G



G



Y/G



R/Bl G



R/W



2P



Br 6P



Bl



G/W



4P



STARTER MOTOR



16-2



IGNITION CONTROL MODULE (ICM)



BRAKE LIGHT SWITCHES STARTER SWITCH



IGNITION SWITCH



SISTEM STARTER LISTRIK



SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM • •• • •• • •• • •



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



2 N·m (0.2 kgf·m, 1.5 lbf·ft)



NILAI TORSI Starter motor case screw



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



16-3



SISTEM STARTER LISTRIK



TROUBLESHOOTING TROUBLESHOOTING Starter motor turn Starter motordoes tidaknot berputar 1. Standard Inspection 1. Pemeriksaan Standard Check for following: Periksa terhadap berikutnya: –- Kondisi Battery condition baterai –- Sekring Burned fuse putus terbakar Are the above itemsdiinatas gooddalam condition? Apakah hal-hal kondisi baik?



2. 2.



3. 3.



4.



4.



YES – GO TO STEP 2. DENGAN LANGKAH 2. YA - LANJUTKAN NO – Replace or repair the malfunction part(s). TIDAK - Ganti atau perbaiki parts yang tidak bekerja dengan baik. Starter Relay Operation Cara Kerja Starter Relay Turn the ignition switch "ON". Putar kunci kontak kefully "ON". Squeeze the brake lever and push the starter switch. Tekan handel sepenuhnya tekan starter switch. You should hearrem the relay "CLICK"dan when the starter switch is depressed. Harus terdengar bunyi "KLIK" dari relay ketika starter switch ditekan. Is the "CLICK" heard? Apakah bunyi "KLIK" terdengar? YES – GO TO STEP 3. YA - LANJUTKAN DENGAN LANGKAH 3. NO – GO TO STEP 5. TIDAK - LANJUTKAN DENGAN LANGKAH 5. Starter Motor Cable Inspection Pemeriksaan Starter Motor Cable Turn the ignition switch "OFF". Putar for kunci kontak Check open circuitke in "OFF". starter motor cable and starter motor ground cable. Periksa terhadap rangkaian terbuka pada starter motor cable dan starter motor ground cable (kabel massa Are the above cables in good condition? starter motor). YES – GO TO STEP 4. Apakah kabel-kabel di atas dalam kondisi baik? NO – • Loose or poorly connected starter motor cable. YA LANGKAH 4. (Green) and battery negative terminal. •- LANJUTKAN Open circuit inDENGAN starter motor ground cable • Open circuit in starter motor Red/White cable between the starter relay and starter motor. TIDAK - • Starter motor cable longgar atau tersambung dengan buruk. Starter Motor • Inspection Rangkaian terbuka pada starter motor ground cable (Hijau) dan terminal negatif baterai. Rangkaian padadirectly kabel and Merah/Putih motor antara starter relay dan starter Apply battery•voltage to the terbuka starter motor check the starter operation. motor. Does the starter motor turn? Pemeriksaan Starter Motor YES – • Open circuit in Red wire between the starter relay and battery. Hubungkan voltasestarter baterai langsung ke starter motor dan periksa cara kerja. • Faulty relay. Apakah starterstarter motor berputar? NO – Faulty motor.



5. Starter Relay Circuit Inspection YA - • Coil Rangkaian terbuka pada kawat Merah antara starter relay dan baterai. • Starter relay rusak. Disconnect the ICM 4P connector. Turn the ignition switch "ON". TIDAK - Starter motor tidak bekerja dengan baik. Measure the battery voltage between the ICM connector of the wire harness side and ground. 5. Pemeriksaan Rangkaian Starter Relay Coil CONNECTION:Yellow/Red (+) – Ground (–) Lepaskan ICM 4P connector. Putarthe kunci kontak ke "ON". Does battery voltage exist? Ukur voltase baterai antara ICM connector dari sisi wire harness dan massa. YES – GO TO STEP 6. HUBUNGAN: Kuning/Merah ( + ) - Massa ( - ) NO – • Loose or poorly connected connector. Apakah ada voltase baterai? • Open circuit in battery cable between the battery and ignition switch. • Open circuit starter relayLANGKAH Red/Black 6. wire between the ignition switch and starter relay. YA - LANJUTKANinDENGAN • Open circuit in starter relay Yellow/Red wire between the ICM and starter relay. ignitionyang switch (page 15-8).dengan buruk. TIDAK •- •Faulty Connector tersambung • •Faulty starter relay coil.pada kabel baterai antara baterai dan kunci kontak. Rangkaian terbuka • Rangkaian terbuka pada kawat Merah/Hitam starter relay antara kunci kontak dan starter relay. • Rangkaian terbuka pada kawat Kuning/Merah starter relay antara ICM dan starter relay. • Kunci kontak tidak bekerja dengan baik (hal. 15-8). • Starter relay coil tidak bekerja dengan baik.



16-4



SISTEM STARTER LISTRIK Brake Light Switch/Starter SwitchLight Circuit Inspection 6.6. Pemeriksaan Rangkaian Brake Switch/Starter Switch Turn the ignition switch "ON". Putar kunci kontak ke "ON". Squeezehandel the brake fully and push starter switch. Tekan remlever sepenuhnya dan the tekan starter switch. Measure the battery voltage the ICM connector of theharness wire harness side and ground. Ukur voltase baterai antarabetween ICM connector dari sisi wire dan massa. HUBUNGAN: Kuning/Hijau ((+) + )– -Ground Massa(–) (-) CONNECTION:Yellow/Green Apakah voltase Does the ada battery voltagebaterai? exist? YA LANJUTKAN YES – GO TO STEP 7. DENGAN LANGKAH 7. TIDAK Connector longgar atau connector. tersambung dengan buruk. NO – -• • Loose or poorly connected Brakebrake light light switch tidak bekerja dengan baik. • • Faulty switch. • • Open circuit in Black wire sub antara fuse andsekring brake light switch. dan brake light switch. Rangkaian terbuka padabetween kawat the Hitam tambahan • • Open circuit in Green/Yellow between the brake light switch and starter switch. Starter switch tidak bekerjawire dengan baik. • • Faulty starter terbuka switch. pada kawat Kuning/Hijau antara ICM dan starter switch. Rangkaian • Open circuit in Yellow/Green wire between the ICM and starter switch.



7. Starter Relay Continuity Inspection 7.



Check the starterKontinuitas relay for continuity 16-13). Pemeriksaan Starter(page Relay Is there continuity? Periksa starter relay terhadap kontinuitas (hal. 16-13)



YES – • Open circuit in ICM Red/Black wire. Apakah ada kontinuitas? • Open circuit in ICM Green wire. ICM. terbuka pada kawat Merah/Hitam ICM. YA -• • Faulty Rangkaian • Rangkaian terbuka pada kawat Hijau ICM. NO – Faulty starter relay. • ICM tidak bekerja dengan baik. Starter motor turns engine slowly TIDAK - Starter • Low battery voltage. relay tidak bekerja dengan baik. • Poorly connected battery terminal cable. • Poorly connected starter motor cable. Starter motor memutar • Faulty starter motor. mesin dengan pelan Poorlybaterai connected battery ground cable. • •Voltase rendah. • Starter Batterymotor terminal cable dengan turns, buttersambung engine does not turn buruk. • •Starter tersambung dengan buruk. Startermotor motorcable is running backwards. • Starter motor tidak bekerja dengan baik. – Case assembled improperly. • Battery groundconnected cable tidak tersambung dengan baik. – Terminals improperly. • Faulty starter pinion. Starter berputar, but tetapi mesin berputar Startermotor relay "CLICK", engine doestidak not turn • •Starter motor berputar terbalik. Crankshaft does not turn due to engine problems. Case telah •- Faulty starterdirakit pinion.dengan salah. - Terminals disambung dengan salah. • Starter pinion tidak bekerja dengan baik. Starter relay berbunyi "KLIK", tetapi mesin tidak berputar • Crankshaft tidak berputar disebabkan persoalan di dalam mesin. • Starter pinion tidak bekerja dengan baik.



16-5



SISTEM STARTER LISTRIK



STARTER MOTOR MOTOR PELEPASAN REMOVAL Lepaskan airair cleaner Remove the cleanerhousing housing (hal. (page5-6). 5-6). Tarik lepas cover. Pull off the dust dust cover. Lepaskan motorcable cable dari Remove thescrew screwdan and starter starter motor from thestarter starter motor. motor.



SCREW/STARTER MOTOR CABLE



MOUNT BOLT



Remove the mounting bolts, ground cable and starter motor. Lepaskan mounting bolts, ground cable dan starter Remove the starter motor case screw and ground cable. motor. Lepaskan starter motor case screw dan ground cable.



DUST COVER



MOUNT BOLT/ GROUND CABLE



Remove the O-ring from the starter motor. Lepaskan O-ring dari starter motor.



PEMASANGAN



SCREW/GROUND CABLE



STARTER MOTOR



Lapisi sebuah O-ring baru dengan oli mesin dan pasang ke dalam alur starter motor.



O-RING



Route the starter Set the ground cable cable and tighten the starter motor casemotor screw Alurkan starter motor Tempatkan ground dan kencangkan starter cable dan ground motor cablecable and case to thescrew specified torque. dengan torsi yang ditentukan. dengan benarcable (hal. ground 1-14). TORSI: TORQUE:2 N·m (0.2 kgf·m,1,5 1.5lbf.ft) lbf·ft) properly 2 N.m (0,2 kgf.m; (page 1-14).



SCREW/STARTER MOTOR CABLE



MOUNT BOLT



Install the startermotor motorpada to themesin. engine. Pasang starter Set the groundground cable andcable tightendan the starter mounting bolts. starter Tempatkan kencangkan mounting Install thebolts. starter motor cable and tighten the screw. Put the dust cover back in the appropriate position. Pasang starter motor cable dan kencangkan screw. Install the air cleaner housing (page 5-7). Letakkan dust cover kembali pada posisi yang sesuai. Pasang air cleaner housing (hal. 5-7).



16-6



DUST COVER



MOUNT BOLT/ GROUND CABLE



SCREW/GROUND CABLE



SISTEM STARTER LISTRIK DISASSEMBLY PEMBONGKARAN Remove the screwsdan andstarter starter motor Lepaskan screws motor case. case. Remove the following: Lepaskan sebagai berikut: Armature - –Armature Bracket - –Bracket Springs - –Springs Gasket - –Gasket MOTOR CASE



ARMATURE SPRING



SCREW



GASKET



BRACKET



PERAKITAN ASSEMBLY Pasang springs brush holders. Install the springsdiindalam the brush holders.



BRUSH HOLDERS



SPRINGS



16-7



SISTEM STARTER LISTRIK Pasang ke the dalam bracket sementara Install thearmature armature into bracket while holding the brushes. brushes. menahan



ARMATURE



BRUSHES Coil dapat rusak jika magnet The coilmenarik may be armature terhadap damaged case. if the magnet pulls the armature against the case.



Install agasket new gasket thebracket. bracket. Pasang baruonto pada Install thebracket bracket and armature to the motor while case holdPasang dan armature pada case motor ing the bracket side armature shaft tightly. sementara memegang armature shaft dari sisi bracket dengan erat.



BRACKET



MOTOR CASE



GASKET



Pasang motor screwsand dan kencangkan dengan Install the motorcase case screws tighten them to the specitorsi ditentukan. fied yang torque. TORSI: 2 N.m (0,2 kgf.m; 1,5 lbf.ft) TORQUE:2 N·m (0.2 kgf·m, 1.5 lbf·ft)



PEMERIKSAAN INSPECTION BRUSH BRUSH Periksa brushes kerusakan dantheukur panjang Inspect the brushesterhadap for damage and measure brush length. brush. SERVICE BATAS SERVIS: 3,5 mm LIMIT: 3.5 mm (0.14 in)



16-8



SCREWS



ARMATURE



SISTEM STARTER LISTRIK ARMATURE ARMATURE



Jangan menggunakan commutator armaturefor terhadap Do not use emery or Periksa Inspect the commutator bars bars ofdari the armature discolorkertas amplas pada ation. sand commutator. paper on the perubahan warna. commutator.



COMMUTATOR BARS



Bars discolored in pairs indicate shorted coils. Bars yang berubah warna dalam pasangan menunjukkan coils yang ada hubungan singkat.



Periksa kontinuitas masing-masing Check forterhadap continuity between each antara pair of commutator bars. pasangan commutator bars. There should be continuity.



KONTINUITAS:



Tidak boleh ada kontinuitas.



Check forterhadap continuity kontinuitas between eachantara commutator bar and the Periksa masing-masing armature shaft. commutator bar dan armature shaft. Thereboleh shouldada be no continuity. Tidak kontinuitas.



TIDAK ADA KONTINUITAS:



16-9



SISTEM STARTER LISTRIK



STARTER PINION PINION STARTER PELEPASAN REMOVAL Lepaskan leftleft crankcase (hal. 8-5). Remove the crankcasecover cover (page 8-5).



Remove the starterpinion pinionholder. holder. Lepaskan starter



Remove the starterpiniion. pinion. Lepaskan starter



STARTER PINION HOLDER



STARTER PINION



PEMASANGAN INSTALLATION Oleskan 0,1– –0.3 0,3gg ofgemuk R3R3 atau Apply 0.1 grease(Shell (ShellALVANIA ALVANIA or IDEMITSUAUTOREX AUTOREX BB atau or equivalent) to the endsujungof the IDEMITSU sejenisnya) pada starterstarter pinion.pinion. ujung



STARTER PINION



Install the starter pinion into the left crankcase. Pasang starter pinion ke dalam left crankcase.



Pasang starter left crankcase. Install the starterpinion pinionholder holderke intodalam the left crankcase. Pasang leftleft crankcase Install the crankcasecover cover (hal. (page8-5). 8-5).



16-10



STARTER PINION HOLDER



SISTEM STARTER LISTRIK PEMERIKSAAN INSPECTION Check that the starter operates smoothly. Periksa bahwa starterpinion pinion bekerja dengan halus.



DRIVEN GEAR



Check the pinion geargear teeth and forterhadap wear or damage. keausan Periksa gigi pinion danshaft shaft atau kerusakan. Check the starter driven gear teeth of the drive pulley face for wear or damage. Periksa gigi starter driven gear dari muka drive pulley terhadap keausan atau kerusakan.



PINION GEAR



STARTER STARTER RELAY RELAY PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan battery Remove the batterycover cover(hal. (page2-13). 2-13).



5P CONNECTOR



Lepaskan starter holder stay. Remove the starterrelay relaydari frombattery the battery holder stay. Lepaskan relayrelay 5P 5P connector. Disconnectstarter the starter connector. Pemasangan Installation is in adalah the reversedalam order of urutan removal. terbalik pelepasan.



dari



STARTER RELAY



PEMERIKSAAN CARA KERJA OPERATION INSPECTION Remove the batterycover cover(hal. (page2-13). 2-13). Lepaskan battery Turn the ignition switch "ON". Putar kunci kontak ke "ON". Squeeze the brake fully and push the starter switch. Tekan handel remlever sepenuhnya dan tekan starter switch. The system is normal the starter Sistem adalah normalif jika starterrelay relayclicks. berbunyi klik. If yourelay don’t hear relay "CLICK", inspect the tidakthe berbunyi "KLIK", periksa sebagai Jika following: berikut:



- –Rangkaian starter relay coil (hal. 16-12) Starter relay coil circuit (page 16-12) - –Rangkaian light switch/starter switch Brake lightbrake switch/starter switch circuit (page(hal.16-12) 16-12) - –Rangkaian ICM power/ground 15-12) ICM power/ground circuit (page(hal. 15-12) If you hear the suara relay "CLICK", but relay, starter does turn, Jika terdengar "KLIK" dari tetapinotstarter inspect the starter relay continuity (page 16-13). kontinuitas tidak berputar, periksa starter relay terhadap (hal. 16-13).



STARTER RELAY



16-11



SISTEM STARTER LISTRIK PEMERIKSAAN RANGKAIAN STARTER RELAY COIL CIRCUIT STARTER RELAY COIL INSPECTION Remove the batterycover cover(hal. (page2-13). 2-13). Lepaskan battery DisconnectICM the ICM 4P connector. Lepaskan 4P connector. Turn the ignition switch "ON". Putar kunci kontak ke "ON". Measure the voltage between ICM connector the wire wire Ukur voltase antara ICM the connector dari of sisi harness side and ground. harness dan massa. CONNECTION:Yellow/Red (+) – Ground (–) HUBUNGAN: Kuning/Merah ( + ) - Massa ( - ) If the battery voltage appears only when the ignition switch is Jika voltase baterai hanya tampak sewaktu kunci kontak "ON", the circuit is normal. pada posisi "ON", rangkaian adalah normal. IGNITION CONTROL MODULE (ICM) 4P CONNECTOR ICM 4P CONNECTOR



Dari BATTERY R/Bl Y/R



IGNITION SWITCH



STARTER RELAY



PEMERIKSAAN RANGKAIAN BRAKE LIGHT SWITCH/STARTER BRAKE LIGHT SWITCH/STARTER SWITCH SWITCH CIRCUIT INSPECTION Lepaskan battery Remove the batterycover cover(hal. (page2-13). 2-13). Lepaskan ICM 6P connector. Disconnect the ICM 6P connector. Putar kunci kontak ke "ON". Turn the ignition switch "ON". Tekan handel remlever sepenuhnya starter switch. Squeeze the brake fully and dan push tekan the starter switch. Ukur voltase antara ICM the connector dari of sisi Measure the voltage between ICM connector the wire wire harness dan and massa. harness side ground.



CONNECTION:Yellow/Green HUBUNGAN: Kuning/Hijau ( (+) - ) –- Ground Massa ((–) -) If the battery voltage appears only when the ignition is Jika voltase baterai hanya tampak ketika kunciswitch kontak "ON",posisi the brake lever is fully squeezed and the sepenuhnya starter switch pada "ON", handel rem telah ditekan is pushed, circuit is normal. dan starterthe switch ditekan, rangkaian adalah normal.



IGNITION CONTROL MODULE (ICM) 6P CONNECTOR ICM 6P CONNECTOR



Dari BATTERY FRONT BRAKE LIGHT SWITCH



Y/G G/Y



STARTER SWITCH



Bl



G/Y



REAR BRAKE LIGHT SWITCH Bl



16-12



SISTEM STARTER LISTRIK PEMERIKSAAN KONTINUITAS STARTER RELAY CONTINUITY STARTER RELAY INSPECTION Remove the starterrelay relay(hal. (page16-11). 16-11). Lepaskan starter Connect a fully charged V battery wire penuh to the Hubungkan kawat positif12 baterai 12 Vpositive bermuatan relay switch terminal A and negative to thenegatif terminal B. pada terminal A relay switch danwire kawat pada terminal B. Check for continuity at the terminal C and terminal D. There should be continuity between the C and D terminals Periksa terhadap kontinuitas pada terminal C dan while theD.battery is connected, and no continuity when the terminal battery is disconnected. Harus ada kontinuitas antara terminal C dan D sewaktu baterai dihubungkan, dan tidak ada kontinuitas ketika baterai dilepaskan.



A



C



B



D



STARTER RELAY A



B



C



D



16-13



SISTEM STARTER LISTRIK



STARTER STARTER SWITCH SWITCH PEMERIKSAAN INSPECTION Remove the front handlebarcover cover (hal. (page2-5). 2-5). Lepaskan front handlebar Turn the ignition switch "OFF". Putar kunci kontak ke "OFF". Disconnectstarter the starter switch connector. Lepaskan switch connector. Check for continuity between the connector terminals in each Periksa terhadap kontinuitas antara connector terminals switch position. pada masing-masing posisi switch. Continuity should exist between the color coded wire termiHarus kontinuitas antara terminal-terminal kawat nals as ada follows: dengan kode warna sebagai berikut:



STARTER SWITCH



STARTER SWITCH CONNECTOR



STARTER SWITCH ST



ICM



G/Y



Y/G



FREE PUSH COLOR



BRAKE BRAKE LIGHT LIGHTSWITCH SWITCH PEMERIKSAAN INSPECTION Lepaskan front handlebar Remove the front handlebarcover cover (hal. (page2-5). 2-5).



Disconnect the brake light switch wire wire connectors (Green/ Lepaskan brake switch connectors Yellow and Black) check for the (Hijau/Kuning dan andHitam) dancontinuity periksabetween terhadap switch side antara terminals. kontinuitas terminal-terminal pada sisi switch.



DEPAN:



BELAKANG:



BRAKE LIGHT SWITCH CONNECTORS



BRAKE LIGHT SWITCH WIRE CONNECTORS



There should be continuity with the brake lever squeezed, Harus ada kontinuitas dengan handel rem ditekan, dan and there should be no continuity with the brake lever tidak boleh ada kontinuitas sewaktu handel rem released. dilepaskan.



16-14



17. LAMPU/METER/SAKLAR-SAKLAR



LOKASI SISTEM............................................17-2 SYSTEM LOCATION ····································17-2



RELAY LAMPU SEIN·······························17-10 ...................... 17-10 TURN SIGNAL RELAY



KETERANGAN SERVIS ................................17-3 SERVICE INFORMATION ···························17-3



LAMPU REM/BELAKANG............... 17-11 TAIL/BRAKE LIGHT ··································17-10



PEMERIKSAAN SISTEM PENERANGAN ....17-4 LIGHTING SYSTEM INSPECTION············17-4



SPEEDOMETER ···········································17-11



LAMPU BESAR .............................................17-6 HEADLIGHT ···················································17-6



LAMPU SENJA..............................................17-7 POSITION LIGHT ··········································17-7



LAMPU SEIN .................................................17-8 TURN SIGNAL LIGHT··································17-8



FUEL LEVEL SENSOR.................... 17-13



FUEL METER................................... 17-14



FUEL LEVEL SENSOR ·······························17-13



KLAKSON........................................ 17-15



FUEL METER ···············································17-14 HORN······························································17-15



SAKLAR LAMPU SEIN..................................17-9 TURN SIGNAL SWITCH·······························17-9



17



17-1



LAMPU/METER/SAKLAR-SAKLAR



SYSTEMSISTEM LOCATION LOKASI LIGHTS/METERS/SWITCHES



DIMMER SWITCH TURN SIGNAL SWITCH HORN SWITCH



SPEEDOMETER TURN SIGNAL RELAY



FUEL LEVEL SENSOR



LIGHTING SWITCH



HORN



17-2



LAMPU/METER/SAKLAR-SAKLAR



SERVICE INFORMATION KETERANGAN SERVIS GENERAL UMUM



• Check the battery condition before performing any inspection that requires proper battery voltage. Periksa kondisi sebelum menjalankan sesuatu pemeriksaan yang memerlukan voltase baterai yang memadai. •• Route the wires and baterai cables properly after servicing each component (page 1-14). •• The following color codesdan are used throughout this section. Alurkan kawat-kawat kabel-kabel dengan benar setelah menservis masing-masing komponen (hal. 1-14). • Kode warna berikut ini dipakai sepanjang bab ini. Bu==Blue Blue (biru) Bu Black (hitam) BlBl == Black Brown (coklat) BrBr==Brown G = Green (hijau)



G = Gr Green Lg = Light green = Gray (abu-abu) Gr =Lb Gray O =muda) Orange = Light blue (biru Lb =Lg Light blue green (hijau R = Red = Light muda) O = Orange (jingga)



W= White R = Red (merah) Y = Yellow W = White (putih) Y = Yellow (kuning)



SPECIFICATIONS SPESIFIKASI Bulbs Bola lampu



Fuse Sekering



ITEM Headlight BAGIAN Lampu besar light Position Lampu senja light Tail/brake Lampu rem/belakang Front turn signal light Lampu sein depan Rear turn signal light Lampu sein belakang Instrument light Lampu instrumen High beam indicator Lampu indikator sinar jauh Turn signal indicator Lampu indikator lampu sein Main fuse Sekering utama Sub fuse Sekering tambahan



SPECIFICATIONS SPESIFIKASI 12 V – 32/32 W 12 V W 12–V32/32 – 3.4 W 1212VV––3,4 W 5/18 W 1212VV–– 5/18 10 WW x2 1212 VV – –1010WWxx22 1212VV– –10 1.7WWx x2 2 12 V12–V1,7 W xW2 – 1.7 1212V V – –1,7 3.4WW 12 V – 3,4 W 15 A x 1 1510AAx x1 1 10 A x 1



17-3



LAMPU/METER/SAKLAR-SAKLAR



LIGHTING SYSTEM INSPECTION PEMERIKSAAN SISTEM PENERANGAN LAMPU BESAR DOES TIDAKNOT MENYALA HEADLIGHT COME ON OR IS WEAK ATAU REDUP NYALANYA Standard Inspection Pemeriksaan Standard Check the following Periksa sebagai berikut Burned out bulb or terbakar bulb with atau unspecified wattagedengan - – Bola lampu putus bola lampu –watt Loose connector yang tidak sesuai Lighting switch - –Connector longgar Dimmer switch(saklar lampu) - –Lighting switch - IfDimmer switch dim)check as follows: the above items (saklar are normal, Lighting Circuit Inspection di atas adalah normal, periksa sebagai Jika hal-hal berikut: Remove the followings: Pemeriksaan Rangkaian Penerangan – Front upper cover (page 2-4) Lepaskan berikut: – Center sebagai body cover (page 2-8) - Front upper cover (hal. 2-4) - Center body cover (hal. 2-8)



HEADLIGHT 6P CONNECTOR



Disconnect the alternator/ignition pulse 3P connecLepaskan alternator/ignition pulsegenerator generator 3P tor. connector.



ALTERNATOR/IGNITION PULSE GENERATOR 3P CONNECTOR



Putar lighting switch ketoposisi dan dimmer switch ke Turn the lighting switch H andHdimmer switch to Hi posiHi. tion.



Check the continuity between the Blue terminal of the headPeriksa kontinuitas antara terminal Biru dari headlight light 6P connector and yellow terminal of the alternator/igni6P connector dan terminal Kuning dari alternator/ignition tion pulse generator 3P connector. pulse generator 3P connector. If there is continuity, check the following: Jika ada kontinuitas, periksa sebagai berikut:



HEADLIGHT 6P CONNECTOR



Bu Bu/W



Y



DIMMER SWITCH LIGHTING SWITCH



17-4



ALTERNATOR/IGNITION PULSE GENERATOR 3P CONNECTOR



LAMPU/METER/SAKLAR-SAKLAR Lepaskan body Remove the bodycover cover(hal. (page2-9). 2-9). Lepaskan 4P connector. Disconnectregulator/rectifier the regulator/rectifier 4P connector.



REGULATOR/RECTIFIER 4P CONNECTOR



Check thekontinuitas continuity between Yellow terminals the Periksa antara theterminal Kuning ofdari regulator/rectifier 4P and dan alternator/ignition pulse regulator/rectifier 4Pconnector connector alternator/ignition generator 3P connector. pulse generator 3P connector. If there is continuity, check the following: Jika ada kontinuitas, periksa sebagai berikut:



REGULATOR/RECTIFIER 4P CONNECTOR



Y



ALTERNATOR/IGNITION PULSE GENERATOR 3P CONNECTOR



Pemeriksaan Massa Ground Inspection



Check the continuity antara betweenterminal the GreenHijau terminal the headPeriksa kontinuitas dariofheadlight light 6P connector ground. 6P connector dan and ground (massa). If there is continuity, check the lighting coil (page 14-12). Jika ada kontinuitas, periksa lighting coil (kumparan If the lighting coil is normal, check the regulator/rectipenerangan) (hal. 14-11). fier(page 14-14). adalah normal, periksa Jika lighting coil regulator/rectifier (hal. 14-14).



HEADLIGHT 6P CONNECTOR



G



17-5



LAMPU/METER/SAKLAR-SAKLAR



HEADLIGHT HEADLIGHT(LAMPU BESAR) PENGGANTIAN BULB (BOLA LAMPU) BULB REPLACEMENT Lepaskan front upper Remove the front uppercover cover(hal. (page2-4). 2-4). Lepaskan dust Remove the dustcover. cover. Slightly headlight push the headlight socket and turndan it counterTekan bulb bulb socket sedikit putar clockwise. arah jarum jam. berlawanan Remove the headlightbulb bulbdan and ganti replace it with yang a new baru. one. Lepaskan headlight dengan



Install a new headlight bulb by aligning the tab on the headPasang bulb baru tab light bulbheadlight with the groove on thedengan headlightmentepatkan unit. pada bulb dengan alur the pada unit. Installheadlight the bulb socket by aligning tabsheadlight on the bulb socket Pasang bulb on socket dengan mentepatkan tabs pada with the slots the headlight unit. bulb dengan slots pada headlight unit. Pushsocket the bulb socket in, turn it clockwise. Tekan bulb socket ke dalam, putar searah jarum jam. Install the dust cover Install the dust cover tightly on the headlight unit. Pasang dengan "TOP" with itstanda "TOP" mark Pasang dust cover dengan erat pada headlight unit. Install the front upper cover (page 2-4). menghadap ke atas. facing up. Pasang front upper cover (hal. 2-4).



HEADLIGHT BULB



TANDA "TOP"



DUST COVER



BULB SOCKET



LIGHTING SWITCH INSPECTION



PEMERIKSAAN LIGHTING SWITCH Lepaskan front handlebar Remove the front handlebarcover cover (hal. (page2-5). 2-5).



Turn the ignition switch "OFF". Putar kunci kontak ke "OFF". Disconnectlighting the lighting switch connector. Lepaskan switch connector.



LIGHTING SWITCH



Check for continuity between the connector terminals in each connector terminals Periksa terhadap kontinuitas antara switch position. pada masing-masing posisi switch. Continuity exist between color coded wire termiHarus ada should kontinuitas antara the terminal kawat dengan nals as follows: kode warna sebagai berikut:



LIGHTING SWITCH CONNECTORS



LIGHTING SWITCH HL



C1



TL



Bu/W



Y



Br



(N) P (N) H COLOR



17-6



LAMPU/METER/SAKLAR-SAKLAR PEMERIKSAAN DIMMER SWITCH DIMMER SWITCH INSPECTION Remove the front handlebarcover cover (page 2-5). Lepaskan front handlebar (hal. 2-5). Turn the ignition switch "OFF". Putar kunci kontak ke "OFF". Disconnectdimmer the dimmer switch connector. Lepaskan switch connector. Check for continuity between the connector terminals in each connector terminals Periksa terhadap kontinuitas antara switch position. pada masing-masing posisi switch. Continuity exist between color coded wire kawat termiHarus ada should kontinuitas antara the terminal-terminal nals as follows: dengan kode warna sebagai berikut:



DIMMER SWITCH



DIMMER SWITCH CONNECTOR



DIMMER SWITCH Hi



Lo



HL



Bu



W



Bu/W



HI (N) LO COLOR



POSITION POSITIONLIGHT LIGHT(LAMPU SENJA) PENGGANTIAN BOLA LAMPU BULB REPLACEMENT Lepaskan front upper Remove the front uppercover cover(hal. (page2-4). 2-4). Tarik keluar position light bulb socket dari Pull out the position light bulb socket from theheadlight headlightunit. unit. Keluarkan light bulb bulband dan gantiit with dengan Remove theposition position light replace a newyang one. baru. Install the position light bulb socket in the reverse order of removal.position light bulb socket dalam urutan terbalik Pasang



BULB SOCKET



POSITION LIGHT BULB



dari pelepasan.



17-7



LAMPU/METER/SAKLAR-SAKLAR



TURN SIGNAL SIGNAL LIGHT LIGHT(LAMPU SEIN) PENGGANTIAN BULB (BOLA LAMPU) BULB REPLACEMENT DEPAN FRONT



Remove the front uppercover cover (hal. (page2-4). 2-4). Lepaskan front upper Turn the front signal light bulb socketberlawanan counterclockwise arah Putar front turnturn signal light bulb socket and remove it from the light unit. jarum jam dan lepaskan dari light unit. Remove the bulbdari from the socket and replace with baru. a new Keluarkan bulb socket dan ganti denganityang one. Pasang turn signal light bulb socket dalam urutan Install the turn signal light bulb socket in the reverse order of terbalik dari pelepasan. removal.



FRONT TURN SIGNAL LIGHT BULB



BELAKANG REAR Lepaskan tail/brake Remove the tail/brakelight lightlens lens(hal. (page17-10). 17-10).



REAR TURN SIGNAL LIGHT LENS



rear Remove the rearturn turnsignal signal light light lens. lens. Be careful to Lepaskan Hati-hati agarnot tidak menggores permukaan scratch the reflector reflector. surface. agarnot tidak Hati-hati Be careful to merusak lens. damage the lens.



Remove therear rearturn turn signal signal light socket dan and Lepaskan lightbulb bulbfrom darithesocket Installation is ina new the reverse replace it with one. order of removal. ganti dengan yang baru. Pemasangan pelepasan.



17-8



adalah



dalam



urutan



BULB SOCKET



terbalik



dari



REAR TURN SIGNAL LIGHT BULB



LAMPU/METER/SAKLAR-SAKLAR



TURN SIGNAL SWITCH (SAKLAR LAMPU SEIN) PEMERIKSAAN



TURN SIGNAL SWITCH



INSPECTION



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



TURN SIGNAL SWITCH



TURN SIGNAL SWITCH CONNECTOR



TURN SIGNAL SWITCH R



W



L



Lb



Gr



O



R N L COLOR



17-9



LAMPU/METER/SAKLAR-SAKLAR



TURN SIGNAL SIGNAL RELAY RELAY TURN PEMERIKSAAN INSPECTION Lepaskan front handlebar Remove the front handlebarcover cover (hal. (page2-5). 2-5).



Check the following: Periksa sebagai berikut: Batterybaterai condition - –Kondisi Burned out bulb or non-specified wattage - –Bola lampu putus terbakar atau dengan watt yang – tidak Burned fuse sesuai Ignitionputus switch and turn signal switch function - –Sekring terbakar Looseignition connector - –Fungsi switch dan turn signal switch - IfConnector longgar the above items are normal, check as follows: Jika hal-halthediturn atas adalah normal, periksa sebagai Disconnect signal relay 2P connector from the relay. berikut: Short the turn signal relay connector terminals of the wire harness side with a jumper Lepaskan turn signal relaywire. 2P connector dari relay. CONNECTION:Black Gray relay connector terminals Hubungkan singkat turn–signal dari sisi wire harness dengan kawatthe penghubung. Check the turn signal light by turning switch ON. If the light comes on, the signal relay is faulty or the conHUBUNGAN: Hitam – turn Abu-abu nector has poor connection. Periksa lampu sein dengan memutar switch ke ON. If the light does not come on, the wire harness is broken. Jika lampu sein menyala, maka turn signal relay rusak atau connector sambungannya buruk. Jika lampu sein tidak menyala, maka wire harness putus.



TURN SIGNAL RELAY KAWAT PENGHUBUNG



Dari MAIN FUSE



IGNITION SWITCH



TURN SIGNAL RELAY 2P CONNECTOR



O Bl



Gr Lb



TURN SIGNAL SWITCH



G



TURN SIGNAL LIGHT



TAIL/BRAKE LIGHT (LAMPU BELAKANG/REM) TAIL/BRAKE LIGHT PENGGANTIAN BULB BULB REPLACEMENT



Tekan bagian atas dari Lepaskan screws dan tail/brake light lens. Slightly down rear fenderpress sedikit ke Remove the screws and tail/brake light lens. the upperbawah side ofuntuk rear mempermudah fender to ease pelepasan. removal. Hati-hati agarnot tidak Be careful to merusak damagelens the dan lensrear and rear fender. fender.



SCREWS



TAIL/BRAKE LIGHT LENS



danand putar arah berlawanan Tekan Slightlybulb presssedikit the bulb turndalam it counterclockwise, then jarum jam, dan the lepaskan dari light unit. remove it from light unit. Ganti tail/brake light bulb baru. Replace the tail/brake lightdengan bulb withyang a new one.



Installation is in adalah the reversedalam order of urutan removal. terbalik Make sure that the Pemasangan lens packing is in pelepasan. place.



17-10



dari



TAIL/BRAKE LIGHT BULB



LAMPU/METER/SAKLAR-SAKLAR



SPEEDOMETER SPEEDOMETER PENGGANTIAN BULB BULB REPLACEMENT Lepaskan front handlebar Remove the front handlebarcover cover (hal. (page2-5). 2-5). Tarik keluar bulbsocket socketfrom darithe speedometer Pull out the bulb speedometerunit. unit. Remove the bulb from the socket and dengan replace ityang with baru. a new Lepaskan bulb dari socket dan ganti one. Pemasangan adalah dalam urutan terbalik dari Installation is in the reverse order of removal. pelepasan.



BULB



BULB SOCKET



PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Lepaskan rear (hal. 2-5). Remove the rearhandlebar handlebar cover cover (page 2-5). Lepaskan sebagai berikut: Disconnect the following:



CONNECTORS



- –Starter Starterswitch switchconnector connector - –Lighting switch Lighting switchconnectors connectors - –Dimmer switch Dimmer switchconnector connector - –Turn signal Turn signalswitch switchconnector connector - –Horn switch Horn switchconnector connector



Remove the threescrews screws and unit. Lepaskan ketiga danspeedometer speedometer unit. Installation is in adalah the reversedalam order ofurutan removal. terbalik Pemasangan pelepasan.



dari



SCREWS SPEEDOMETER



17-11



LAMPU/METER/SAKLAR-SAKLAR PEMBONGKARAN/PERAKITAN DISASSEMBLY/ASSEMBLY Remove thesebagai following: Lepaskan berikut: Turnsignal signalrelay relay -– Turn Meterlens lens -– Meter Four bulb -– Empat bulbsockets sockets Three terminal screwsdan and wire wire terminals terminals -– Tiga terminal screws Twoscrews screwsdan and speedometer/fuel speedometer/fuel meter unitunit -– Dua meter Metercase case -– Meter Assembly is inadalah the reverse order of urutan disassembly. Perakitan dalam terbalik



dari



pembongkaran. TURN SIGNAL RELAY



SCREWS



TERMINAL SCREWS



SPEEDOMETER/ HANDLEBAR SWITCH WIRE



METER CASE



SPEEDOMETER/ FUEL METER UNIT



METER LENS



INSTRUMENT LIGHT (BI and G)



TURN SIGNAL INDICATOR (O and Lb)



HI BEAM INDICATOR (Bu and G) INSTRUMENT LIGHT (BI and G)



TERMINAL (BI)



TERMINAL (Bu/W)



TERMINAL (Y/W)



17-12



LAMPU/METER/SAKLAR-SAKLAR



FUEL LEVEL LEVELSENSOR SENSOR FUEL PELEPASAN REMOVAL Unlockkunci and open the seat usingdan the ignition Buka tempat duduk naikkankey. tempat duduk Disconnect the fuel unit 3P connector. dengan menggunakan anak kunci kontak. Lepaskan fuel unitsensor 3P connector. Turn the fuel level holder plate counterclockwise with a pair offuel needle nose sensor pliers andholder align theplate tabs ofdalam the fuel arah tank Putar level and grooves of the fuel sensortang holder plate.dan tepatkan berlawanan jarum jamlevel dengan lancip tabs darithe fuel alur-alur pada fuel level sensor Remove fueltank leveldan sensor holder plate. Removeplate. the fuel level sensor and the O-ring. holder Be careful not to Hati-hati agar tidak Lepaskan fuel level sensor holder plate.



damage the float float arm. arm. merusak Lepaskan fuel level sensor dan O-ring.



INSTALLATION PEMASANGAN



Install the new O-ring to the fuel tank. Install theO-ring fuel level thetank. fuel tank. Pasang barusensor padatofuel



Hati-hati agar not tidak Be careful to Set the holder plate by aligning the tabs of the fuel tank and merusak damage the float float arm. arm. Pasang fuel level sensor pada fuel tank.



grooves of the holder plate. Tempatkan holder dengan tabs Turn the holder plateplate clockwise untilmentepatkan the arrow marks on dari the fuel tank dan alur-alur plate. holder plate and the fuel dari tank holder are aligned. Puter holder plate searah jarum jam sampai tandatanda panah pada holder plate dan fuel tank telah ditepatkan. Pelepasan:



HOLDER PLATE



Tepatkan



HOLDER PLATE



HOLDER PLATE



FUEL LEVEL SENSOR



Pemasangan: FUEL LEVEL SENSOR



Tepatkan HOLDER PLATE



TANDA PANAH



O-RING



Tepatkan



17-13



LAMPU/METER/SAKLAR-SAKLAR PEMERIKSAAN INSPECTION Ukur tahanan antara terminal-terminal connector Measure the resistance between the connector terminals with the floatfloat at upper (full) and lower dengan (pelampung) pada(empty) posisi positions. teratas (penuh) dan paling bawah (kosong). (20°C/68°F)



G



CONNECTION FLOAT POSITION (20° C) FULL EMPTY HUBUNGAN POSISI PELAMPUNG Blue/White - Green 25 – 45 Ω 400 – 700 Ω PENUH KOSONG Yellow/White – Green 400 – 700 Ω 25 – 45 Ω Biru/Putih – Hijau 25 – 45 Ω 400 – 700 Ω Yellow/White – Blue/ 450 – 750 Ω 450 – 750 Ω Kuning/Putih – 400 – 700 Ω 25 – 45 Ω White Hijau Kuning/Putih 450 750 450 – 750 Ω Replace the fuel– level sensor if it– is outΩof specification. Biru/Putih



Y/W



Bu/W



FUEL LEVEL SENSOR



FUEL METER METER CIRCUIT INSPECTION FUEL METER DOES NOT MOVE • Before performing the system inspection, make sure that the following items are normal. – Battery condition – Fuse PEMERIKSAAN RANGKAIAN METER – Meter indicators •Unlock Sebelum sistem, and open menjalankan the seat using the pemeriksaan ignition key. pastikan bahwa bagian-bagian berikut ini adalah Disconnect the fuel level sensor 3P connector. normal. Short the fuel level sensor connector terminals of the wire Kondisi baterai harness side with the jumper wire. - Sekring CONNECTION:Blue/White – Green - Meter indicators



FUEL METER



FUEL LEVEL SENSOR 3P CONNECTOR



Jangan Do nottinggalkan leave the terminal-terminal terminals connected tersambung dengan with the jumper wire kawatforlistrik untuk a long time,waktu as it Turn the METER ignitionTIDAK switchBERGERAK "ON" and check the fuel meter. lama, oleh karena FUEL causes damage to the menyebabkan kerusakan Buka meter gaugeduduk moves dan to thenaikkan "F", it is tempat normal. duduk kunci tempat fuel meter. meter. If the fuel pada fuel



dengan anak kunci kontak. • If the above inspection is normal, check the fuel level sensor (see page 17-14). Lepaskan fuel level • If the meter gaugesensor moves3P to connector. "E" with connector shorted, check the following: Hubungkan singkat fuel level sensor connector – Fuel level circuitdengan kawat terminals dari sensor sisi wire wirefor open harness – Fuel meter Black wire for open circuit penghubung. If the wire harness is normal, replace the speedometer/ fuel HUBUNGAN: – Hijau meter unit with Biru/Putih a new one, and recheck. Putar kunci kontak ke "ON" dan periksa fuel meter.



FUEL METER



FUEL LEVEL SENSOR 3P CONNECTOR



Jika fuel meter gauge bergerak ke "F", ia adalah normal. • •



Jika pemeriksaan di atas adalah normal, periksa fuel level sensor (lihat hal. 17-14). Jika meter gauge bergerak ke "E" dengan connector dihubungkan singakt, periksa sebagai berikut: - Rangkaian terbuka pada kawat fuel level sensor - Rangkaian terbuka pada kawat Hitam fuel meter



Jika wire harness adalah normal, ganti speedometer/fuel meter unit dengan yang baru, dan periksa kembali.



17-14



Dari MAIN FUSE



IGNITION SWITCH BI



Bu/ W Y/ W G



KAWAT PENGHUBUNG



LAMPU/METER/SAKLAR-SAKLAR FUEL "F" FUELMETER METERTETAP STAYSPADA AT "F" Lepaskan handlebar (hal. 2-5) dan Remove the rear rear handlebar covercover (page 2-5) and connect the handlebar switch/speedometer 4P/6P connectors. sambungkan handlebar switch/speedometer 4P/6P connectors. Turn the ignition switch "OFF".



Disconnect fuel level sensor 3P connector (page 17-14). Putar kunci the kontak ke "OFF". Check for fuel continuity between3P theconnector fuel level sensor connector Lepaskan level sensor (hal. 17-14). of the wire harness side and meter terminal. Periksa terhadap kontinuitas antara fuel level sensor CONNECTION:Yellow/White Yellow/White connector dari sisi wire harness– dan meter terminal. • If there is noKuning/Putih continuity, there is open circuit in Yellow/ HUBUNGAN: – Kuning/Putih White wire. theretidak is continuity, check the fuel sensor (page 17Jika ada kontinuitas, adalevel rangkaian terbuka • • If 14). pada kawat Kuning/Putih. • If Jika periksa levelthe sensor (hal. the ada fuel kontinuitas, level sensor is normal,fuel replace speedome17-14). 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 (hal. 17-12) dan periksa kembali.



FUEL METER Y/W TERMINAL



FUEL METER



Dari MAIN FUSE



IGNITION SWITCH Bu/ W Y/W G



FUEL LEVEL SENSOR 3P CONNECTOR



HORN HORN (KLAKSON) PELEPASAN/PEMASANGAN REMOVAL/INSTALLATION Remove the front uppercover cover(hal. (page2-4). 2-4). Lepaskan front upper



HORN



Disconnecthorn the horn connectors the horn. Lepaskan connectors darifrom horn.



CONNECTORS



Remove the bolt, washer,rubber rubber dan and horn. Lepaskan bolt, washer, horn. Installation is in adalah the reversedalam order of urutan removal. terbalik Pemasangan pelepasan.



dari



BOLT/WASHER/RUBBER



PEMERIKSAAN HORN HORN INSPECTION Remove the front uppercover cover(hal. (page2-4). 2-4). Lepaskan front upper Disconnecthorn the horn connectors the horn. Lepaskan connectors darifrom horn. Connect a 12V battery to the horn terminals. Hubungkan baterai 12V pada horn terminals. The horn is normal if itjika sounds when sewaktu the 12V battery conHorn adalah normal berbunyi bateraiis 12V nected to the horn terminals. dihubungkan ke horn terminals.



17-15



LAMPU/METER/SAKLAR-SAKLAR PEMERIKSAAN HORN SWITCH HORN SWITCH INSPECTION Remove the fronthandlebar handlebar cover cover (page 2-5). Lepaskan front (hal. 2-5). Turn the ignition switch "OFF". Putar kunci kontak ke "OFF". Disconnecthorn the horn switch connector. Lepaskan switch connector. Check for continuity between the connector terminals in each Periksa terhadap kontinuitas antara connector terminals switchmasing-masing position. pada posisi switch. Continuity exist between colorterminals coded wire termidengan Harus adashould kontinuitas antarathe wire nals as follows: kode warna sebagai berikut:



HORN SWITCH



HORN SWITCH CONNECTOR



HORN SWITCH BAT



HO



Bl



Lg



FREE PUSH COLOR



17-16



18. DIAGRAM LISTRIK



WIRING DIAGRAM·······································18-2 DIAGRAM LISTRIK.......................... 18-2



18



18-1



G O



G/Y Bl



LEFT FRONT TURN SIGNAL LIGHT (12V10W)



FRONT BRAKE LIGHT SWITCH



COLOR



H



Br



COLOR



L



R



LOCK



R



C1



HL Bu/W Y



Lb



R



R



Gr



W



O



L



2P



R



Bl



Bl



Bu/W



COLOR W



LO Bu



FREE



COLOR



G



HORN



Lg



Bl



BAT



Lg



HO



HORN SWITCH



PUSH



HL



HI



Lo



(N)



Hi



DIMMER SWITCH



TURN SIGNAL HORN SWITCH SWITCH



TL



Y Br



DIMMER SWITCH



TURN SIGNAL SWITCH



COLOR



R/Bl



BAT



P



ON



BAT1



IGNITION SWITCH



(N)



Y



TL



N



Bu/W



C1



Bl G/Y



Lb Br Bu W G O



OFF



(N)



HL



LIGHTING SWITCH



REAR BRAKE LIGHT SWITCH



ILLUMINATION (12V 1.7W) HI BEAM INDICATOR (12V 1.7W)



ILLUMINATION (12V 1.7W)



FUEL METER



TURN SIGNAL INDICATOR (12V 3.4W)



SPEEDOMETER



Bu W G



HEAD LIGHT (12V32W/32W)



G



MINI



6P



Br



LO



POSITION LIGHT (12V3.4W)



WR



LIGHTING SWITCH



Lg



Lb G



G/Y



ST Y/G HO



C1 W Bu Bu/W HI HL



Bl Gr Lb O Gr WL W



G Y/W Bu/W Y/G



G Y/W Bu/W Y/G



FREE



COLOR



PUSH G/Y



ST



Y/G



ICM



STARTER SWITCH



Bl Br Y Lb O G/Y



MINI Bl 3P



FUEL LEVEL SENSOR



Bl Br Y Lb O G/Y MINI 6P 4P MINI



BAT BAT1



2P



BLACK YELLOW BLUE GREEN RED WHITE



FRAME GROUND



R R



15A



5P



COLOR COMB : GROUND/MARKING



Bl Y Bu G R W



IGNITION SWITCH FUSE BOX



STARTER RELAY



BROWN ORANGE LIGHT BLUE LIGHT GREEN PINK GRAY



STARTER MOTOR



Bl 3P MINI G 3P MINI



MINI



4P



MINI



IGNITION CONTROL MODULE (ICM)



Br 6P



UP



STARTER ENRICHMENT (SE) THERMAL VALVE SIDESTAND SWITCH



ALTERNATOR



3P



IGNITION PULSE



4P G



REGULATOR/ RECTIFIER



2P



G



ENGINE GROUND



Br O Lb Lg P Gr



BATTERY 12V3.5AH



R R



RIGHT FRONT TURN SIGNAL LIGHT (12V10W)



G Y/W Bu/W



10A R/Bl Bl G G G/W



E Bl BAT



G/O Bu/Y Y/G G/W



R R/Bl R R/Bl



Bl Bl



G/W G/W



G/O G/O



G G G Y/R R/Bl Bl/Y



STARTER SWITCH



G



G



Y/R R/Bl R/W R R/W R/W



R W Y G Bu/Y W Y Bu/Y W Y



G



Br Lb O G/Y G



SPARK PLUG



IGNITION COIL



Br Lb O G/Y MINI



18-2 6P



TURN SIGNAL RELAY



LEFT REAR TURN SIGNAL LIGHT (12V10W)



TAIL&BRAKE LIGHT (12V5/18W)



0030Z-KVY-9600



O



G



Br G G/Y



G



Lb



RIGHT REAR TURN SIGNAL LIGHT (12V10W)



DIAGRAM LISTRIK



WIRING DIAGRAM DIAGRAM LISTRIK



19. TROUBLESHOOTING



MESIN TIDAK MAU HIDUP ATAU SULIT DIHIDUPKAN..............................19-2



UNJUK KERJA BURUK PADA ENGINE LACKS POWER19-3 KECEPATAN TINGGI ............................19-6



MESIN KEKURANGAN TENAGA .........19-3



AND IDLE SPEED19-5 PENGENDALIAN BURUK .....................19-6



UNJUK KERJA BURUK PADA GIGI SATU DAN PUTARAN STASIONER.....19-5 ENGINE DOES NOT START OR IS HARD TO START ·······························19-2



POOR PERFORMANCE AT LOW



POOR PERFORMANCE AT HIGH SPEED19-6 POOR HANDLING19-6



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19-1



TROUBLESHOOTING



ENGINE DOESMAU NOTHIDUP STARTATAU OR ISSULIT HARDDIHIDUPKAN TO START MESIN TIDAK TROUBLESHOOTING



Plug Inspection 1.1. Spark Pemeriksaan Busi Remove and inspect spark Lepaskan dan periksa busi.plug.



Is the spark plug wet? Apakah busi basah? YES – • Flooded carburetor YA -• •Faulty Karburator startingbanjir enrichment (SE) thermal valve • •Throttle open (SE) thermal valve tidak bekerja dengan baik Startingvalve enrichment • •Dirty air cleaner Throttle valve terbuka • Improperly adjusted pilot screw • Air cleaner kotor NO – GO• TO STEP 2. tidak disetel dengan baik Pilot screw 2. Spark TIDAKTest- LANJUTKAN DENGAN LANGKAH 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 api lemah atau tidak ada? • Fouledbunga spark plug • Loose or disconnected ignition system wires YA - • Busi tidak bekerja dengan baik • Broken or shorted spark plug wire Busi kotor • •Faulty ignition coil Kabel-kabel pengapian longgar atau terlepas • •Faulty igniting sistem pulse generator • •Faulty switch Kabelignition busi putus atau ada hubungan singkat • •Faulty ignition control module (ICM)baik Ignition coil tidak bekerja dengan • Faulty sidestand switch Ignitionsidestand pulse generator tidak bekerja dengan baik • •Broken switch wire • Ignition switch tidak bekerja dengan baik NO – GO TO STEP 3. • Ignition control module (ICM) tidak bekerja dengan baik 3. Carburetor •Inspection Sidestand switch tidak bekerja dengan baik • Kawat Check carburetor for sidestand clogging. switch putus



2.



TIDAK - LANJUTKAN Is the carburetor clogged? DENGAN LANGKAH 3. 3.



Pemeriksaan Karburator not serviced frequently enough YES – Carburetor



NO GO TO STEP 4. Periksa– karburator terhadap sumbatan. 4. Fuel Line Inspection Apakah karburator tersumbat? Disconnect fuel hose at carburetor and apply vacuum teratur pressure to the fuel auto valve. YA - the Karburator kurang mendapatkan perawatan 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 bahan bakar) pada karburator dan terapkan tekanan vakuum pada fuel auto Clogged 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 - • Fuelwithin line (saluran bahan bakar) tersumbat Is the compression specification? • Fuel auto valve tersumbat YES – GO TO STEP 6. • Fuel tank breather tersumbat open NO – • •Valve Fuel stuck strainer tersumbat • Worn cylinder and piston rings 5. Pemeriksaan Kompressi Cylinder • Damaged cylinder head gasket • Seized valve Periksa kompressi cylinder. • Incorrect valve seat contact • Improper valve timing Apakah kompressi sesuai dengan spesifikasi?



19-2



YA



- LANJUTKAN DENGAN LANGKAH 6.



TIDAK



- • • • • • •



Valve macet terbuka Cylinder dan piston rings aus Cylinder head gasket rusak Valve macet Kontak valve seat tidak benar Valve timing tidak sesuai



TROUBLESHOOTING 6 Kondisi Start Mesin 6. Engine Starting Condition Start by following Hidupkan mesin normal denganprocedure. mengikuti prosedur normal. Apakah mesin hidup mati lagi? Does the engine start thenkemudian stops?



YA YES



SE thermal valve tidak bekerja dengan baik SE thermal valve – •- •Faulty • •Leaking inletbocor pipe Inlet pipe • •Incorrectly adjusted carburetor Karburator tidak disetel dengan benar • Clogged carburetor Karburator tersumbat • •Improper ignition timing (Faulty ICM or ignition pulse generator) Ignition timing tidak benar (ICM atau ignition pulse generator rusak) • •Contaminated fuel • Bahan bakar terkontaminasi



ENGINE LACKS POWER MESIN KEKURANGAN TENAGA 1. Engine Oil Inspection 1. Pemeriksaan Oli Mesin Periksa tinggi permukaan oli dan kondisinya. Apakah tinggi permukaan oli benar dan oli berada dalam kondisi baik? Check level and condition. YA the -oilLANJUTKAN DENGAN LANGKAH 2.



IsTIDAK the oil level the oil in oli good condition? - • correct Tinggiand permukaan terlalu tinggi/rendah OliSTEP terkontaminasi YES – GO•TO 2. 2. NO Pemeriksaan Penggerak level too high/low – • Oil Peralatan • 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. YA - LANJUTKAN DENGAN LANGKAH 3. Does the wheel spin freely? TIDAK– GO - •TO Rem menyangkut YES STEP 3. • Final reduction dan driven pulley bearings aus atau rusak NO – • •Brake Finaldragging shaft bengkok • Worn or damaged final reduction and driven pulley bearings • Bent final shaft 3. Pemeriksaan Tekanan Udara Ban 3. Tire Pressure Inspection Periksa tekanan udara ban depan dan belakang. Check front and rear tire pressure. Apakah tekanan udara ban rendah? Is the tire pressure low? YA - • Tire valve tidak bekerja dengan baik valve YES – • •Faulty Ban tire bocor • Punctured tire TIDAK - LANJUTKAN DENGAN LANGKAH 4. NO – GO TO STEP 4. 4. Pemeriksaan Busi 4. Spark Plug Inspection Lepaskan dan periksa Remove and inspect thebusi. spark plug.



busi baik? IsApakah the spark plugdalam in goodkondisi condition? YA – GO - LANJUTKAN YES TO STEP 5. DENGAN LANGKAH 5. •Plug Busi mendapatkan perawatan teratur notkurang serviced frequently enough range •Incorrect Derajatspark panasplug busiheat tidak sesuai plug •Faulty Busi spark tidak bekerja dengan baik Carburetor Inspection 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 NO – GO TO STEP 6. TIDAK - LANJUTKAN DENGAN LANGKAH 6. Ignition Timing Inspection Pemeriksaan Ignition Timing Check the ignition timing. ignition timing. IsPeriksa the ignition timing correct? TIDAK– •NO • •



5. 5.



6. 6.



Apakah ignition timing YES – GO TO STEP 7. benar? YA – •- LANJUTKAN LANGKAH Faulty ignition DENGAN control module (ICM) 7. NO • Faulty ignition pulse generator TIDAK - • Ignition control module (ICM) tidak bekerja dengan baik • Ignition pulse generator tidak bekerja dengan baik



19-3



TROUBLESHOOTING compression Inspection 7.7. Cylinder Pemeriksaan Kompressi Cylinder Test the cylinder compression. Test kompressi cylinder. Is the compression within specification? Apakah kompressi sesuai dengan spesifikasi? YES – GO TO STEP 8. YA - LANJUTKAN DENGAN LANGKAH 8. NO – • Valve stuck open TIDAK -• •Worn Valve macet and terbuka cylinder piston rings Cylinder dan piston rings aus • •Damaged cylinder head 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 • Campuran bahan bakar miskin 9. Engine Knocking Inspection TIDAK - or LANJUTKAN DENGAN LANGKAH 9. Accelerate run at high speed. 9.



Is the engine knocking? Pemeriksaan Engine Knocking (mesin mengelitik)



piston andpada cylinder YES – • Wornatau Berakselerasilah jalan 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 cylinder aus fueldan mixture • Jenis bahan bakar tidak sesuai NO – GO TO STEP 10. • Pembentukan karbon secara berlebihan di ruang pembakaran 10. Valve Timing • Inspection Ignition timing terlalu maju (ICM tidak bekerja dengan baik) • Campuran Check the valve timing. bahan bakar miskin



TIDAK LANJUTKAN Is the valve- timing correct?DENGAN LANGKAH 10.



– GO TO STEPTiming 11. 10. YES Pemeriksaan Valve Cam timing sprocket not installed properly NO Periksa–valve (tertib buka klep). 11. Drive Train Inspection Apakah valve timing benar? Check the- drive train. YA 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 or faulty driven pulley Periksa drive train. • Worn clutch shoes Apakah drive train normal?



TIDAK



19-4



- • • • •



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



TROUBLESHOOTING



POOR PERFORMANCE AT LOW AND IDLE SPEED UNJUK KERJA BURUK PADA GIGI SATU DAN PUTARAN 1. Idle Adjustment Inspection STASIONER 1.



Check the idle speed. Pemeriksaan Penyetelan Putaran Stasioner Is the idle speed correct? Periksa putaran stasioner. YES – GO TO STEP 2. Apakah stasioner benar? Adjust the idle speed NO – putaran



YA Test- LANJUTKAN DENGAN LANGKAH 2. 2. Spark TIDAK spark - Setel putaran stasioner Perform test. 2.



Test Percikan Api spark? Busi Is there weak or Bunga intermittent



• Faulty spark plug api busi. YES – test Jalankan percikan bunga • Fouled spark plug Apakah percikan • Faulty bunga ignition api coil lemah atau tidak teratur? • Faulty ignition control module (ICM) YA - • Busi tidak bekerja dengan baik NO – GO STEP 3. • TO Busi kotor • Ignition coil tidak bekerja dengan baik 3. Intake Air Leaking Inspection • Ignition control module (ICM) tidak bekerja dengan baik Check for air leaks at the inlet pipe. TIDAK LANJUTKAN DENGAN LANGKAH 3. Is there air- leaking?



3.



Pemeriksaan Kebocoran inlet pipeUdara Pemasukan YES – • Loose • Damaged inlet pipe Periksa terhadap kebocoran udara pada inlet pipe. • Damaged inlet pipe gasket Apakah kebocoran NO – ada GO TO STEP 4. udara pemasukan?



YA - • Inlet pipe longgar 4. Starting Enrichment (SE) Thermal Valve Inspection • Inlet pipe rusak Check the SE thermal valve (page 5-18). • Inlet pipe gasket rusak Is the SE Thermal valve OK? TIDAK - LANJUTKAN DENGAN LANGKAH 4. YES – GO TO STEP 5. 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. YA - LANJUTKAN DENGAN LANGKAH 5. Is the ignition timing correct? TIDAK - SE thermal valve tidak bekerja dengan baik. YES – Improper valve timing 5. NO Pemeriksaan Ignition Timing – • Faulty ignition control module (ICM) • Faulty ignition pulse generato Periksa ignition timing (waktu 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?



2.



YA



- LANJUTKAN DENGAN LANGKAH 2.



TIDAK



- • Ignition control module (ICM) tidak bekerja dengan baik • Ignition pulse generator tidak bekerja dengan baik



Pemeriksaan Karburator Periksa karburator terhadap sumbatan. Apakah karburator tersumbat?



3.



YA



- Karburator kurang mendapatkan perawatan teratur



TIDAK



- LANJUTKAN DENGAN LANGKAH 3.



Pemeriksaan Saluran Bahan Bakar Lepaskan fuel hose pada karburator dan terapkan tekanan vacuum pada fuel auto valve. Apakah bahan bakar mengalir bebas?



4.



YA



- LANJUTKAN DENGAN LANGKAH 4.



TIDAK



- • • • •



Fuel line tersumbat. Fuel tank breather tersumbat. Fuel auto valve tidak bekerja dengan baik Fuel strainer tersumbat



Pemeriksaan Valve Timing Periksalah valve timing (tertib waktu buka klep). Apakah valve timing benar?



5.



YA



- LANJUTKAN DENGAN LANGKAH 5.



TIDAK



- Cam sprocket tidak terpasang dengan benar



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