BPR REVO AT - KWZG - 3 Juli 2010 PDF

1.
KETERANGAN UMUM
PERATUR
SERVICEAN SERVIS
RULES ........................................ 1-2
··········································1-2 SPESIFIK
REAR ASI ROD A BELAK ANG /
WHEEL/BRAKE/SUSPENSION
REM / SU SPENSI..........................................1-7
SPECIFICATIONS········································· 1-7
IDENTIFIKASI MODEL ....................................... 1-2
MODEL IDENTIFICATION ····························1-2
SPESIFIK ASI REM HIDRAULIK ................... 1-7
HYDRAULIC BRAKE SPECIFICATIONS····· 1-7
SPESIFIKASI UMUM .......................................... 1-4
GENERAL SPECIFICATIONS ······················1-4 SPESIFIK ASI BATERAI / SISTEM
SPESIFIKASI SISTEM PELUMASAN ................ 1-5 BATTERY/CHARGING SYSTEM/
PENGISIAN LISTRIK / ALTERNATOR ......... 1-8
LUBRICATION SYSTEM ALTERNATOR SPECIFICATIONS ··············· 1-8
SPECIFICATIONS
SPESIFIKASI ·········································1-5
SISTEM BAH AN BAKAR SPESIFIK ASI SISTEM PENGAPIAN ............ 1-8
IGNITION SYSTEM SPECIFICATIONS ········ 1-8
(Programmed
FUEL SYSTEMFuel Injection)............................
(Programmed Fuel Injection) 1-5 SPESIFIK ASI SISTEM
SPECIFICATIONS ·········································1-5 STARTER LISTRIK
ELECTRIC STARTER ........................................
SYSTEM 1-8
SPESIFIKASI CYLINDER HEAD / VALVES...... 1-5 SPECIFICATION ··········································· 1-8
CYLINDER HEAD/VALVES SPESIFIK ASI LAMPU /
SPESIFIKASI CYLINDER
SPECIFICATIONS / PISTON .................. 1-6
·········································1-5 INSTR UMEN / SAKLAR ................................ 1-8
LIGHTS/METERS/SWITCHES
SPECIFICATION ··········································· 1-8
SPESIFIKASI DRIVE PULLEY / TORSI PENGENCANGAN STAND ARD ....... 1-9
CYLINDER/PISTON SPECIFICATIONS ·······1-6
STANDARD TORQUE VALUES··················· 1-9
DRIVEN PULLEY / CLUTCH .............................. 1-6 TORSI PENGENCANGAN
DRIVE PULLEY/DRIVEN PULLEY/CLUTCH MESIN & RANGKA ........................................ 1-9
SPECIFICATIONS
SPESIFIKASI ·········································1-6
ALTERNATOR / ENGINE & FRAME TORQUE VALUES········ 1-9
STARTER CLUTCH ........................................... 1-6 TITIK2 PELUMASAN & PER APATAN.......... 1-12
ALTERNATOR/STARTER CLUTCH LUBRICATION & SEAL POINTS ··············· 1-12
SPECIFICATIONS
SPESIFIKASI ·········································1-6
CRANKSHAFT / PERLETAKAN K ABEL & HARNESS ........... 1-14
KICKSTARTER / SECONDARY REDUCTION .. 1-6 CABLE & HARNESS ROUTING················· 1-14
CRANKSHAFT/KICKSTARTER/SECONDARY SISTEM PENGATURAN EMISSI................... 1-23
REDUCTION RODA
SPESIFIKASI SPECIFICATIONS···················1-6
DEPAN / EMISSION CONTROL SYSTEMS ·············· 1-23
SUSPENSI / KEMUDI ......................................... 1-7
FRONT WHEEL/SUSPENSION/STEERING
SPECIFICATIONS ·········································1-7
1-1
KETERANGAN SERVIS
PERATURAN SERVIS
SERVICE RULES
GENERAL INFORMATION
1. Pakailah partsHonda
Use genuine dan pelumas asli Honda atau yang
or Honda-recommended partsdirekomendasikan oleh equivalents.
and lubricants or their Honda atau sejenisnya.
Parts that do Parts yang tidak
not meet memenuhi
Honda's design
spesifikasi rancangan
specifications may cause Honda
damagedapattomengakibatkan
the motorcycle.kerusakan pada sepedamotor.
2. Pakailah specialtools
Use the special toolsdesigned
yang telah fordirancang untuk
this product produk
to avoid ini untuk
damage menghindari
and kerusakan dan pemasangan yang tidak benar.
incorrect assembly.
3. Hanya
Use onlypergunakan metric
metric tools whentools ketika menservis
servicing sepedamotor.
the motorcycle. Metric Baut,
bolts, mur,
nutsdan
andsekrup
screws metric tidak
are not dapat dipertukarkan
interchangeable dengan
with English
pengikat sistem Inggris.
fasteners.
4. Pasanglah
Install new gasket,
gaskets,O-ring,
O-rings, cotter pin,
cotter danand
pins, locklock
plates baruwhen
plates padareassembling.
waktu perakitan kembali.
5. Sewaktu mengencangkan
When tightening bolts or nuts, bautbegin
atau with
mur,the
mulailah
larger dengan
diameterbaut dengan
or inner boltdiameter
first. Thenyang lebih
tighten tobesar atau baut
the specified di sebelah
torque dalam
diagonally in
dulu. Kemudian
incremental stepskencangkan dengan
unless a particular torsi pengencangan
sequence is specified. yang telah ditentukan secara bersilang dalam langkah-langkah
peningkatan
6. Clean parts inkecuali
cleaningjikasolvent
telah ditentukan urutan tertentu.
upon disassembly. Lubricate any sliding surfaces before reassembly.
6.
7. Bersihkan parts yang
After reassembly, checktelahall dilepaskan dalaminstallation
parts for proper larutan pembersih. Lumasi semua permukaan luncur sebelum perakitan kembali.
and operation.
7.
8. Setelah
Route allperakitan
electricalkembali,
wires asperiksalah
shown in thesemua
Cableparts
andterhadap
Harnesspemasangan
Routing (page dan pengoperasian yang benar.
1-14).
8.
9. Alurkan semua
Do not bend or kawat listrik seperti
twist control cables.diperlihatkan
Damaged controldalamcables
Perletakan
will notKabel dansmoothly
operate Harness and
(hal.may
1-14).
stick or bind.
9. Jangan membengkokkan atau memlintir control cables (kabel-kabel pengaturan). Control cables yang rusak tidak dapat
beroperasi dengan lancar dan dapat macet atau mengikat.
SINGKATAN
Di dalam manual ini dipakai singkatan-singkatan sebagai berikut untuk mengidentifikasi parts atau sistem yang bersangkutan.
Istilah singkatan Istilah lengkap
CKP sensor Crankshaft Position sensor
DLC Data L ink Connector
ECM Engine Control Module
EOT sensor Engine Oil Temperature sensor
IAT sensor Intake Air Temperature sensor
MAP sensor Manifold Absolute Pressure sensor
MIL Malfunction Indicator Lamp
PGM-FI Programmed Fuel Injection
SCS connector Service Check Short connector
TP sensor Throttle Position sensor
IACV Idle Air Control Valve
IDENTIFIKASI MODEL
1-2
KETERANGAN SERVIS
Nomor Identifikasi kendaraan [1] dicetak pada seat stay seperti
diperlihatkan. [1]
Nomor serie mesin [1] dicetak pada bagian samping kiri bawah dari
crankcase.
[1]
Nomor identifikasi [1] throttle body dicetak pada bagian depan dari throttle
body.
[1]
1-3
KETERANGAN SERVIS
SPESIFIKASI UMUM
BAGIAN SPESIFIKASI
DIMENSI Panjang menyeluruh 1.963 mm
Lebar menyeluruh 712 mm
Tinggi menyeluruh 1.077 mm
Jarak sumbu roda 1.252 mm
Tinggi tempat duduk 760 mm
Tinggi pijakan kaki 273 mm
Jarak terendah ke tanah 136 mm
Berat motor- 107 kg
siap pakai
RANGKA Jenis rangka Jenis back bone (tulang belakang)
Suspensi depan Garpu teleskopik
Jarak pergerakan poros depan 80 mm
Suspensi belakang Swingarm
Jarak pergerakan poros belakang 83 mm
Ukuran ban depan 70/90 - 17M/C38P
Ukuran ban belakang 80/90 - 17M/C44P
Merek ban Depan NF63B (IRC)
Belakang NR78Y (IRC)
Rem depan Rem cakram hidraulik
Rem belakang Mekanis, mendahului-mengikuti
Sudut caster 26°30’
Panjang trail 68 mm
Kapasitas tangki bahan bakar 3,7 liter
MESIN Diameter dan langkah 50,0 x 55,6 mm
Volume langkah 109,1 cm3
Perbandingan kompressi 9,0 : 1
Peralatan penggerak klep 2 valve, single chain driven SOHC
Klep masuk Membuka 5° BTDC
Menutup 30° ABDC
Klep buang Membuka 34° BBDC
Menutup 0° ATDC
Sistem pelumasan Di bawah tekanan paksaan dgn bak oli basah
Jenis pompa oli Trochoid
Sistem pendinginan Pendinginan dengan udara
Saringan udara Elemen kertas viscous
Berat kosong mesin 27,3 kg
SISTEM Jenis PGM-FI (Programmed Fuel Injection)
BAHAN BAKAR Diameter throttle 22 mm atau ekuivalennya
PERALATAN Sistem kopeling Basah, kopling sentrifugal otomatis
PENGGERAK Perbandingan drive belt (reduksi primer) 2,26 : 1 - 0,8 : 1
Reduksi akhir 12,598
KELISTRIKAN Sistem pengapian Full transistorized
Sistem starter Kickstarter dengan motor starter listrik
Sistem pengisian Single phase output alternator
Regulator/rectifier SCR opened/single phase, half wave rectifica-
tion
Sistem penerangan Alternator
1-4
KETERANGAN SERVIS
SPESIFIKASI SISTEM PELUMASAN
Satuan: mm
BAGIAN STANDARD BATAS SERVIS
Kapasitas oli mesin Pada penggantian oli 1,0 liter –
Pada pembongkaran mesin 1,2 liter –
Oli mesin yang dianjurkan AHM-OIL MPX1 4T 10W-30 SJ JASO MA –
Oil pump rotor Jarak renggang pada ujung – 0,15
Jarak renggang ke badan 0,15 – 0,21 0,26
Jarak renggang ke samping 0,03 – 0,09 0,15
SPESIFIKASI SISTEM BAHAN BAKAR (Programmed Fuel Injection)

BAGIAN SPESIFIKASI
Nomor identifikasi throttle body GQR9A
Putaran stasioner mesin 1.400 ± 100 min-1 (rpm)
Jarak main bebas throttle grip 2 – 6 mm
Tahanan ECT sensor (20°C) 2,5 – 2,8 kΩ
(100°C) 0,21 – 0,22 kΩ
Tahanan fuel injector (20°C) 9 – 12 Ω
Tekanan bahan bakar pada putaran stasioner 294 kPa (3,0 kgf/cm2, 43 psi)
Aliran fuel pump (pada 12 V) minimum 100 cm3/10 detik
SPESIFIKASI CYLINDER HEAD/VALVES

Satuan: mm
Kompressi cylinder 1.196 kPa (12,2 kgf/cm2, 174 psi) pada
–
600 min-1 (rpm)
Perubahan bentuk melengkung pada cylinder head – 0,05
Rock- D.D. Rocker arm IN/EX 10,000 – 10,015 10,10
er arm D.L.Rocker arm shaft IN/EX 9,972 – 9,987 9,91
Jarak renggang arm ke shaft IN/EX 0,013 – 0,043 0,044
Cam- Tinggi cam lobe (bubungan) IN 32,194 – 32,434 32,16
shaft EX 31,990 – 32,230 31,96
Valve, Valve clearance IN/EX 0,10 –
valve D.L. Valve stem IN 4,975 – 4,990 4,965
guide EX 4,955 – 4,970 4,945
D.D. Valve guide IN/EX 5,000 – 5,012 5,03
Jarak renggang stem-ke- IN 0,010 – 0,037 0,065
guide EX 0,030 – 0,057 0,085
Proyeksi valve guide di atas IN/EX 9,1 – 9,3 –
cylinder head
Lebar valve seat IN/EX 0,90 – 1,10 1,6
Panjang bebas valve spring IN/EX 30,62 29,70
Cam chain tensioner D.L. push rod 11,985 – 12,000 11,94
Panjang bebas spring 111,3 109
1-5
KETERANGAN SERVIS
SPESIFIKASI CYLINDER/PISTON
Satuan: mm
Cylinder D.D. 50,005 – 50,015 50,05
Kelonjongan – 0,10
Ketirusan – 0,10
Perubahan bentuk melengkung – 0,05
Piston, D.L. piston 49,980 – 49,995 49,91
piston pin, Titik pengukuran D.L. piston 6,0 dari dasar gaun –
piston rings D.D. lubang piston pin 13,002 – 13,008 13,04
D.L. piston pin 12,994 – 13,000 12,98
Jarak renggang piston-ke-piston pin 0,002 – 0,014 0,075
Jarak renggang Atas 0,015 – 0,045 0,09
piston ring-ke- 0,09
Kedua 0,015 – 0,045
alurnya
Celah pada ujung Atas 0,10 – 0,25 0,45
piston ring (Riken) Kedua 0,10 – 0,25 0,45
Oil (side rail) 0,20 – 0,70 1,1
piston Kedua 0,35 – 0,50 0,75
Ring (Teikoku) Oil (side rail) 0,10 – 0,40 1,1
Jarak renggang cylinder-ke-piston 0,010 – 0,035 0,10
D.D. kepala kecil connecting rod 13,016 – 13,034 13,05
Jarak renggang connecting rod-ke-piston pin 0,016 – 0,040 0,07
SPESIFIKASI DRIVE PULLEY/DRIVEN PULLEY/CLUTCH

Satuan : mm
Lebar drive belt 19,0 18,0
Movable drive face D.D. bushing. 22,035 – 22,085 22,11
D.L. boss 22,010 – 22,025 21,98
D.L. weight roller 17,92 – 18,08 17,5
Driven pulley Panjang bebas face spring 109,4 93,0
D.L. driven face boss 33,965 – 33,985 33,94
D.D. movable driven face 34,000 – 34,025 34,06
Clutch Tebal lining 2,0 1,5
D.D. clutch outer 126,00 – 126,20 126,30
SPESIFIKASI ALTERNATOR/STARTER CLUTCH

Satuan : mm
D.L. Starter driven gear boss 45,660 – 45,673 45,2
SPESIFIKASI CRANKSHAFT/KICKSTARTER/SECONDARY
REDUCTION
Satuan : mm
Crankshaft Jarak renggang ke samping connecting rod 0,10 – 0,35 0,55
Jarak renggang radial connecting rod 0 – 0,008 0,05
Keolengan – 0,10
1-6
KETERANGAN SERVIS
SPESIFIKASI FRONT WHEEL/SUSPENSION/STEERING
Satuan : mm
Kedalaman minimum alur kembang ban – Sampai ke indikator
Tekanan udara ban Pengendara saja 175 kPa (1,75 kgf/cm2, 25 psi) –
dingin Pengendara dan pembonceng 175 kPa (1,75 kgf/cm2, 25 psi) –
Keolengan poros – 0,2
Keolengan pelek Radial – 2,0
roda Axial – 2,0
Garpu Panjang bebas pegas 290,1 284,3
Kebengkokan pipa – 0,2
Fluid garpu yang dianjurkan Fork fluid –
Tinggi permukaan fluid 73 –
Kapasitas fluid 63,5 ± 1,0 cm3 –
SPESIFIKASI RODA BELAKANG/REM/SUSPENSI

Satuan : mm
Tekanan udara Pengendara saja 225 kPa (2,25 kgf/cm2, 33 psi) –
ban dingin Pengendara dan pembonceng 225 kPa (2,25 kgf/cm2, 33 psi) –
roda Axial – 2,0
Rantai roda Size – link RK 420SL – 102RJ –
DID 420DX – 102RB –
Kekenduran 30 – 40 –
Jarak main bebas pedal rem 20 – 30 –
Jarak main bebas rear brake pedal lock arm 1,0 – 2,0 –
D.D. teromol rem 110 – 110,2 111,0
SPESIFIKASI REM HIDRAULIK

Satuan : mm
Minyak rem yang ditentukan DOT 3 atau 4 –
Brake disc Tebal 3,3 – 3,7 3,0
Master cylinder D.D. cylinder 11,000 – 11,043 11,055
D.L. piston 10,957 – 10,984 10,945
Caliper D.D. cylinder 33,96 – 34,01 34,02
D.L. piston 33,878 – 33,928 33,87
SPESIFIKASI BATERAI/SISTEM PENGISIAN LISTRIK/ALTERNATOR

BAGIAN SPESIFIKASI
Baterai Kapasitas 12 V – 3,0 Ah
Kebocoran arus listrik Maksimal 0,1 mA
Voltage Terisi penuh 13,0 – 13,2 V
(20°C) Perlu diisi Dibawah 12,4 V
kembali
Charging cur- Normal 0,3 A/5 – 10 jam
rent (20°C) Cepat 3,0 A/0,5 jam
Alternator Kapasitas 0,170 kW/5,000 min-1 (rpm)
Tahanan coil pengisian (20°C) 0,2 – 1,0 Ω
1-7
KETERANGAN SERVIS
SPESIFIKASI SISTEM PENGAPIAN
BAGIAN SPESIFIKASI
Busi Standard CPR6EA – 9S (NGK), U20EPR9S (DENSO)
Untuk berkendaraan lama pada CPR7EA – 9S (NGK), U22EPR9S (DENSO)
kecepatan tinggi
Jarak renggang busi 0,80 – 0,90 mm
Voltase puncak coil pengapian minimum 100 V
Voltase puncak CKP sensor minimum 0,7 V
Waktu pengapian 10° BTDC (STMA) pada putaran stasioner
SPESIFIKASI SISTEM ELECTRIC STARTER

Satuan : mm
Panjang sikat starter motor 7,0 3,5
SPESIFIKASI LAMPU/ INSTRUMEN/ SAKELAR

BAGIAN SPESIFIKASI
Bola lampu Lampu besar 12 V – 32/32 W
Lampu senja 12 V – 5 W
Lampu rem/belakang 12 V – 18/5 W
Lampu sein depan 12 V – 10 W x 2
Lampu sein belakang 12 V – 10 W x 2
Lampu instrumen 12 V – 1,7 W x 2
Lampu indicator tidak bekerjanya 12 V – 1,7 W
PGM-FI (MIL)
Indicator lampu jauh 12 V – 1,7 W
Indicator lampu sein 12 V – 3,4 W x 2
Sekring Sekring utama 15 A x 1
Sekring tambahan 10 A x 1
Tahanan fuel level sensor (20°C) Penuh 6 – 10 Ω
Kosong 90 – 100 Ω
Tahanan resistor (20°C) 9,5 – 10,5 Ω
1-8
KETERANGAN SERVIS
TORSI PENGENCANGAN STANDARD
TORSI TORSI
JENIS PENGIKAT JENIS PENGIKAT
N·m (kgf·m; lbf·ft) N·m (kgf·m; lbf·ft)
Baut dan mur hex 5 mm 5,2 (0,5; 3,8) Sekrup 5 mm 4,2 (0,4; 3,1)
Baut dan mur hex 6 mm 10 (1,0; 7) Sekrup 6 mm 9,0 (0,9; 6,6)
(termasuk baut flens SH) Baut flens 6 mm 12 (1,2; 9)
Baut dan mur hex 8 mm 22 (2,2; 16) (termasuk NSHF) dan mur
Baut dan mur hex 10 mm 34 (3,5; 25) Baut flens 9 mm dan mur 27 (2,8; 20)
Baut dan mur hex 12 mm 54 (5,5; 40) Baut flens 10 mm dan mur 39 (4,0; 29)
ENGINE
TORSI & FRAME TORQUE
PENGENCANGAN VALUES
MESIN & RANGKA
•• Torque specifications
Spes ifikasi torsi yanglisted below
tertera are for
di bawah inispecified fasteners.
adalah untuk pengikat tertentu.
•• Others should
Yang lain be dikencangkan
harus tightened to standard
dengan torque values
nilai torsi listedyang
standard above.
tertera di atas.
RANGKA/BODY PANELS/SISTEM PEMBUANGAN GAS
DIAMETER TORSI
BAGIAN JUMLAH CATATAN
ULIR(mm) N·m (kgf·m; lbf·ft)
Mur pengunci throttle cable(sisi handlebar) 1 10 3 (0,31; 2,2)
Mur rear brake pedal lock knob stopper 1 – 2,6 (0,27; 1,9)
Mur exhaust pipe joint 2 8 27 (2,8; 20)
Baut stud exhaust pipe 2 – – Lihat hal. 3-20
PERAWATAN
DIAMETER TORSI
Mur pengunci throttle cable (sisi throttle 1 6 3 (0,31; 2,2)
body)
Busi 1 10 16 (1,6; 12)
Mur pengunci sekrup penyetelan klep 2 5 9 (0,92; 6,6) Berikan oli mesin pada
ulir dan permukaan
duduk.
Baut pembuangan oli mesin 1 12 24 (2,4; 18)
Mur pengunci rear brake pedal lock cable 1 6 3 (0,31; 2,2)
Sekrup air cleaner housing cover 5 5 1,1 (0,11; 0,8)
SISTEM PELUMASAN
DIAMETER TORSI
Sekrup oil pump cover 3 5 5 (0,51; 3,7)
SISTEM BAHAN BAKAR (Programmed Fuel Injection)

DIAMETER TORSI
Sekrup air cleaner connecting hose band 1 – 2,1 (0,21; 1,5)
Sekrup air cleaner duct 4 5 1,1 (0,11; 0,8)
Sekrup fuel pump set plate 1 4 2 (0,20; 1,5)
Baut pemasangan throttle body insulator 2 6 12 (1,2; 9)
EOT sensor 1 10 14 (1,4; 10)
Sekrup torx sensor unit 3 5 3,4 (0,35; 2,5)
Sekrup pemasangan throttle cable stay 1 5 3,4 (0,35; 2,5)
Sekrup torx IACV 2 4 2,1 (0,21; 1,5)
O2 sensor 1 12 25 (2,5; 18)
Baut pemasangan injector joint 2 5 5,1 (0,52; 3,8)
PELEPASAN/PEMASANGAN MESIN
DIAMETER TORSI
Mur engine hanger 3 10 59 (6,0; 44)
Baut drive sprocket fixing plate 2 6 12 (1,2; 9)
1-9
KETERANGAN SERVIS
CYLINDER HEAD/VALVES
DIAMETER TORSI
Baut khusus cylinder head cover 2 6 10 (1,0; 7)
Mur cylinder head 4 7 18 (1,8; 13) Berikan oli mesin pada ulir
dan permukaan duduk.
Baut cam sprocket 2 5 8 (0,82; 5,9) Berikan cairan pengunci
pada ulir. Lihat hal. 8-11.
Baut perapatan cam chain tensioner 1 14 22 (2,2; 16)
Baut engsel cam chain tensioner arm 1 8 16 (1,6; 12)
CYLINDER/PISTON
DIAMETER TORSI
Baut cam chain guide roller pin 1 8 10 (1,0; 7)
Baut stud cylinder 4 7 – Lihat hal. 9-9
DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
DIAMETER TORSI
BAGIAN JUMLAH N·m (kgf·m; CATATAN
ULIR(mm)
lbf·ft)
Sekrup air feed plate 3 4 3 (0,31; 2,2)
Mur drive pulley face 1 14 83 (8,5; 61) Berikan oli mesin pada ulir
Mur driven pulley 1 12 49 (5,0; 36)
Sekrup inlet duct band 1 4 2,1 (0,21; 1,5)
Sekrup clutch cover duct band 2 4 2,1 (0,21; 1,5)
ALTERNATOR/STARTER CLUTCH
DIAMETER TORSI
Mur flywheel 1 14 49 (5,0; 36) Berikan oli mesin pada ulir
Baut torx pemasangan starter clutch 6 6 16 (1,6; 12) Berikan cairan pengunci
outer pada ulir. Lihat hal. 11-12
CRANKSHAFT/KICKSTARTER/SECONDARY REDUCTION
DIAMETER TORSI
Cam chain guide sprocket spindle 1 6 10 (1,0; 7)
Baut sidestand bracket 3 10 44 (4,5; 32)
DIAMETER TORSI
ULIR(mm) N·m (kgf·m;lbf·ft)
Mur front axle 1 12 59 (6,0; 44) U-nut
Baut brake disc socket 4 8 42 (4,3; 31) ALOC bolt
Jari-jari depan 36 BC 2,9 3,2 (0,33; 2,4)
Mur handlebar post 1 10 59 (6,0; 44) U-nut
Sekrup handlebar weight 2 6 9 (0,92; 6,6) SL thread screw
Baut penjepit bottom bridge 4 10 64 (6,5; 47)
Baut fork pipe seat socket 2 8 20 (2,0; 15) Berikan cairan pengunci
pada ulir.
Steering stem top thread 1 26 – Untuk urutan pengen-
cang-an. Lihat hal. 13-25
1-10
KETERANGAN SERVIS
RODA BELAKANG/REM/SUSPENSI
DIAMETER TORSI
Mur poros belakang 1 12 59 (6,0; 44) U-nut
Mur driven sprocket 4 8 32 (3,3; 24) U-nut
Baut stud driven flange 4 – – Lihat hal. 14-11
Mur rear brake stopper arm 2 8 22 (2,2; 16)
Mur rear brake arm 1 6 10 (1,0; 7) U-nut
Mur pemasangan atas shock absorber 2 10 24 (2,4; 18)
Mur topi pemasangan bawah shock ab- 2 10 24 (2,4; 18)
sorber
Mur engsel swingarm 1 10 39 (4,0; 29)
Baut engsel rear brake pedal lock arm 1 6 12 (1,2; 9)
SISTEM REM
DIAMETER TORSI
Brake caliper bleed valve 1 8 5,4 (0,55; 4,0)
Sekrup brake master cylinder reservoir 2 4 1,5 (0,15; 1,1)
cap
Brake pad pin 1 10 17 (1,7; 13)
Baut engsel front brake lever 1 6 1 (0,10; 0,7)
Mur engsel front brake lever 1 6 5,9 (0,60; 4,4)
Sekrup front brake light switch 1 4 1,2 (0,12; 0,9)
Brake hose oil bolt 2 10 34 (3,5; 25)
Baut pemasangan brake caliper 2 8 30 (3,1; 22) ALOC bolt: ganti den-
gan yang baru.
Brake caliper torque pin 1 8 22(2,2; 16)
Brake caliper pin 1 8 17 (1,7; 13)
Baut brake hose clamp 1 6 12 (1,2; 9) ALOC bolt: ganti den-
gan yang baru.
SISTEM PENGAPIAN
DIAMETER TORSI
Timing hole cap 1 14 1,5 (0,15; 1,1)
SISTEM STARTER LISTRIK

DIAMETER TORSI
Sekrup starter motor cable 1 4 2 (0,20; 1,5)
Sekrup starter motor case 3 5 4,2 (0,43; 3,1)
LAMPU/INSTRUMEN/SAKLAR
DIAMETER TORSI
Sekrup pemasangan ignition switch 2 6 9 (0,92; 6,6) ALOC bolt: ganti dengan
yang baru.
Baut key shutter socket 1 5 5,1 (0,52; 3,8) ALOC bolt: ganti dengan
yang baru.
LAIN-LAIN
DIAMETER TORSI
Baut front muffler cover 1 6 10 (1,0; 7)
Sekrup belakang muffler cover 2 6 9 (0,92; 6,6)
Mur engsel sidestand 1 10 30 (3,1; 22)
Baut engsel sidestand 1 10 10 (1,0; 0,7)
1-11
KETERANGAN SERVIS
TITIK-TITIK PELUMASAN & PERAPATAN
MESIN
BAHAN LOKASI CATATAN
Liquid sealant (dianjurkan: Permukaan penyatuan left crankcase Lihat hal. 12-12
Three Bond 1207B atau Permukaan perapatan alternator wire grommet
Three Bond 1215 atau LOC-
TITE 5020 atau sejenisnya)
Liquid sealant (dianjurkan: Permukaan penyatuan cylinder head rubber seal (daerah Lihat hal. 8-7
Three Bond 5211C atau setengah lingkaran)
SHINETSU-SILICONE
KE45 atau Three Bond 1215
atau sejenisnya)
Locking agent (cairan pen- Ulir baut right counter/finalshaft bearing set plate Lihat hal. 12-24
gunci) (dianjurkan: Three Ulir baut oil stopper plate Lihat hal. 8-28
Bond 2415 atau 1322 atau
1322N atau 1324Z atau
LOCTITE 200 atau sejenis-
nya)
Multi-purpose grease (ge- Bibir kickstarter spindle oil seal
muk serba-guna) Bibir crankshaft oil seal
Bibir driveshaft oil seal
Grease (gemuk) (Shell Movable driven face each guide groove 1.5 – 2.0 g
ALVA-NIA R3 atau IDEMIT-
SU AUTOREX B atau NIP-
PON OIL POWER-NOC
WB3 atau sejenisnya)
Oli mesin (Tanpa molybde- Seluruh permukaan oil pump inner/outer rotor
num additives) Permukaan luncur rocker arm shaft
Permukaan dalam rocker arm dan daerah luncur roller
Daerah perputaran camshaft decompressor cam
Seluruh permukaan decompressor plunger
Camshaft cam lobes (bubungan camshaft)
Bagian dalam cam chain tensioner push rod Inject 4 cc minimum
Seluruh permukaan cam chain
Permukaan luncur cam chain guide sprocket spindle
Permukaan2 luncur piston dan cylinder
Seluruh permukaan piston ring dan alur2 ring
Permukaan luar piston pin
Permukaan dalam lubang piston pin
Permukaan dalam kepala kecil connecting rod
Bearing kepala besar connecting rod 1 – 2 cc
Valve stem (daerah luncur valve guide dan ujung stem)
Permukaan kontak clutch outer dengan needle bearing
Permukaan gelinding starter clutch
Seluruh permukaan kickstarter idle shaft
Gigi-gigi masing-masing gear
Daerah luncur ball/needle bearing
Seluruh permukaan dari masing-masing O-ring
Bibir-bibir dan permukaan luar oil seal
Bersihkan dari gemuk Bidang meruncing dari left crankshaft
Muka drive/driven pulley dan drive belt
1-12
KETERANGAN SERVIS
RANGKA
BAHAN LOKASI CATATAN
Multipurpose grease (gemuk Steering bearing race Minimum 3 g
serba-guna) yang tahan te- Bibir steering stem dust seal Minimum 3 g
kanan sangat tinggi (dianjur-
kan: EXCELITE EP2 yang
dibuat oleh KYODO YUSHI,
Japan, atau Shell ALVANIA
EP2 atau sejenisnya)
Grease (gemuk) (Shell Gigi speedometer gear Suntikkan 3 g
BEARING GREASE HD Permukaan dalam speedometer gear Sebarkan 0,5 - 1,0 g
atau sejenisnya) Speedometer pinion shaft Sebarkan 0,1 g
Multi-purpose grease Bibir wheel dust seal
Seluruh permukaan rear wheel O-ring
Permukaan luncur wheel axle
Daerah luncur throttle housing Sebarkan 0,1-0,2 g
Rear brake cam dan shaft Sebarkan masing2 0,2-0,3 g
Rear brake anchor pin shaft Sebarkan 0,2-0,3 g
Bibir driven flange dust seal
Daerah kontak seat catch
Daerah engsel centerstand
Daerah engsel brake pedal
Daerah luncur baut engsel rear brake pedal lock arm dan
collar
Daerah engsel sidestand
Daerah luncur kickstarter arm dan steel ball
Daerah luncur steering lock
Silicone grease Daerah kontak front brake lever-ke-master piston Berikan 0,1 g
Daerah luncur engsel front brake lever Berikan 0,1 g
Daerah luncur brake caliper bracket pin
Seluruh permukaan brake caliper pad pin O-ring
Seluruh permukaan brake caliper dust seal
Bagian dalam speedometer cable
Bagian dalam throttle cable boot
Bagian dalam throttle cable Isi dengan 0,1 cc
Brake fluid Bagian dalam dan daerah luncur master cylinder
(DOT 3 or DOT 4) Seluruh permukaan brake caliper piston seal
Seluruh permukaan brake caliper piston
Master cylinder piston cup
Fork fluid Bibir2 fork dust seal dan oil seal
Seluruh permukaan fork spring seat O-ring
Adhesive (lem) (Honda bond Bagian dalam handlebar grip rubber
A atau sejenisnya) Bidang penyatuan air cleaner connecting hose-ke-housing
Daerah penyatuan air cleaner duct-ke-housing
Oli mesin Fuel pump unit packing Maksimum 1 g
Injector O-ring dan seal ring
1-13
KETERANGAN SERVIS
PERLETAKAN KABEL & HARNESS
FRONT BRAKE LIGHT SWITCH WIRE

LEFT HANDLEBAR DIMMER SWITCH
SWITCH WIRE 3P CONNECTOR
RIGHT HANDLEBAR
SWITCH WIRE
HORN SWITCH
SPEEDOMETER
3P CONNECTOR
CABLE
Untuk dipantek (HITAM)
FRONT BRAKE LIGHT

SWITCH WIRE TURN SIGNAL LIGHT
SWITCH 3P (RED)
CONNECTOR
LIGHTING SWITCH 4P HEADLIGHT 9P

(NATURAL) CONNECTOR
CONNECTOR
SPEEDOMETER
SUB HARNESS
STARTER SWITCH 3P
CONNECTOR (HITAM)
THROTTLE CABLE
FRONT BRAKE
HOSE
IGNITION SWITCH WIRE
FRONT BRAKE HOSE

SPEEDOMETER
FRONT BRAKE SUB HARNESS
REAR BRAKE PEDAL
HOSE
LOCK CABLE
SPEEDOMETER
CABLE
1-14
KETERANGAN SERVIS
FRONT BRAKE HOSE
SPEEDOMETER SUB HARNESS
RESISTOR
THROTTLE CABLE
HORN WIRE
POSITION LIGHT 3P
CONNECTOR (PUTIH)
EOT SENSOR WIRE
SPEEDOMETER CABLE
1-15
KETERANGAN SERVIS
FRONT BRAKE HOSE
THROTTLE CABLE
IGNITION SWITCH
4P CONNECTOR
DLC
REAR BRAKE
PEDAL LOCK
CABLE
CONNECTORS:
- SPEEDOMETER SUB HARNESS 6P
- SPEEDOMETER SUB HARNESS 9P
THROTTLE CABLE
REAR BRAKE PEDAL

FRONT BRAKE HOSE
LOCK CABLE
MAIN WIRE HARNESS
FRONT BRAKE HOSE
Untuk dipantek
1-16
KETERANGAN SERVIS
THROTTLE CABLE IGNITION SWITCH

4P CONNECTOR
REAR BRAKE
PEDAL LOCK CABLE
MAIN WIRE HARNESS Ke
SENSOR
UNIT
45º
INJECTOR WIRE
AIR INLET CLUTCH COVER

DUCT INLET DUCT Ke O2 SENSOR
Ke INJECTOR
EOT
SENSOR
WIRE
IGNITION COIL WIRES

Tepatkan
tanda
penunjuk
O2 SENSOR WIRE
FUEL FEED HOSE
STARTER MOTOR CABLE 2P CONNECTOR
1-17
KETERANGAN SERVIS
O2 SENSOR 1P CONNECTOR (HITAM)
FUEL FEED HOSE
CRANKCASE BREATHER HOSE

MAIN WIRE HARNESS
SIDESTAND
SWITCH WIRE
EOT SENSOR 2P CONNECTOR
CONNECTORS:
SLIT
- SIDESTAND SWITCH 3P (HIJAU)
- ALTERNATOR 2P
- CKP SENSOR WIRE (PUTIH/KUNING, BIRUI/KUNING)
INDEX MARK
Posisi standard kickstarter pedal :

Pedal slit ditepatkan pada tanda penunjuk
1-18
KETERANGAN SERVIS
IGNITION COIL STAY REAR BRAKE PEDAL LOCK CABLE
IGNITION COIL WIRE IACV 4P CONNECTOR (HITAM)
MAIN WIRE
HARNESS SENSOR UNIT 5P CONNECTOR (HITAM)
O2 SENSOR 1P
CONNECTOR
(HITAM)
SPARK PLUG WIRE
STARTER MOTOR CABLE
Untuk di pantek
O2 SENSOR WIRE
STARTER MOTOR CABLE 2P CONNECTOR

FRAME PIPE
REAR BRAKE PEDAL LOCK CABLE
BATTERY SUB HARNESS
LUGGAGE BOX
STARTER MOTOR CABLE
BATTERY SUB
HARNESS
MAIN WIRE
HARNESS
REAR BRAKE
LIGHT SWITCH
1-19
KETERANGAN SERVIS
BATTERY NEGATIVE (-) TERMINAL

MAIN FUSE 15A
SUB FUSE 10A

BATTERY
STARTER RELAY
BATTERY POSITIVE
(+) TERMINAL
FUEL PUMP 5P CONNECTOR
FUEL FEED HOSE
FUEL PUMP WIRE
1-20
KETERANGAN SERVIS
Untuk di pantek
FUEL PUMP WIRE
FRAME GROUND POINT
ECM
BATTERY SUB HARNESS
BATTERY SUB HARNESS REGULATOR/

2P CONNECTORS RECTIFIER
MAIN WIRE MAIN WIRE HARNESS

HARNESS
STARTER
MOTOR CABLE
BRAKE/TAIL LIGHT 6P CONNECTOR
REAR BRAKE LIGHT SWITCH
Sisi pendek
Sisi panjang Arah penempatan centerstand spring:
1-21
KETERANGAN SERVIS
MAIN WIRE HARNESS FRAME PIPE

REAR FENDER
MAIN WIRE HARNESS

REAR
COMBINATION
LIGHT UNIT
MAIN WIRE HARNESS
HEADLIGHT WIRE
LEFT FRONT TURN RIGHT FRONT TURN

SIGNAL LIGHT WIRE SIGNAL LIGHT WIRE
HEADLIGHT 9P CONNECTOR
BRAKE/TAIL LIGHT WIRE
LEFT REAR TURN SIGNAL LIGHT WIRE

RIGHT REAR TURN
SIGNAL LIGHT WIRE
MAIN WIRE HARNESS BRAKE/TAIL LIGHT 6P CONNECTOR
1-22
KETERANGAN SERVIS
EMISSION CONTROL SYSTEMS (SISTEM PENGATURAN EMISI)
SOURCE OF
SUMBER EMISSIONS
EMISI
Proses pembakaran
The combustion menghasilkan
process produces karbon
carbonmonoksida (CO), oxides
monoxide (CO), oksida dari nitrogen(NOx)
of nitrogen (NOx)anddanhydrocarbons
hidrokarbon (HC).
(HC).Pengaturan karbon
Control of carbon
monoks ida, oxides
monoxide, oksida dari nitrogen and
of nitrogen dan hidrokarbon
hydrocarbons adalah s angat
is very pentingbecause,
important oleh karena,
underdi bawah
certainkondisi tertentu,
conditions, theymereka
react bereaksi
to form
membentuk
photochemical smog jika
smog when subject
photochemical terkena cahaya
to sunlight. Carbon matahari.
monoxide Karbon
does notmonoksida tidak
react in the samebereaksi dengan
way, but cara yang sama, tetapi
it is toxic.
ia beracun.
Honda Motor Co., Ltd. utilizes various systems (page 1-23), to reduce carbon monoxide, oxides of nitrogen and hydrocarbons.
Honda Motor Co., Ltd. memanfaatkan bermacam-macam sistem (hal. 1-23) 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
CRANKCASE EMISSION
gas is returned to the combustionCONTROL SYSTEM
chamber through the air cleaner and throttle body.
(SISTEM PENGATURAN EMISI BAK MESIN)
Mesin dilengkapi dengan sistem crank case (bak mesin) tertutup untuk mencegah dilepaskannya emisi crankc ase ke dalam
atmosfir. Blow-by-gas (gas hasil pembakaran yang masuk ke dalam crankcase melewati pis ton ring) dikembalikan ke ruang
pembakaran melalui air cleaner dan throttle body.
AIR CLEANER HOUSING
CRANKCASE BREATHER HOSE
THROTTLE BODY
FRESH AIR
BLOW-BY GAS
THREE-WAY C ATALYTIC CONVERTER (KATALISATOR PENGUB AH DENGAN TIGA-JALAN)

THREE-WAY
Sepedamotor CATALYTIC
ini dilengkapi CONVERTER
dengan sebuah three-way catalytic converter.
This motorcycle
Three-way is equipped
catalytic converterwith a three-way
berada di dalamcatalytic converter. gas. Melalui reaks i kimia, mereka mengubah HC, CO dan NOx
s istem pembuangan
di dalam gas hasil pembakaran mesin menjadi karbon dioksida
The three-way catalytic converter is in the exhaust system. Through(CO2), nitrogen
chemical(Nreactions,
2) dan uap they
air. convert HC, CO and NOx in the
engine’s exhaust
Sistem-sistem to carbon
ini tidak dioxide (CO
memerlukan 2), nitrogen
penyetelan (N2) and
walaupun water vapor.berkala dari komponennya dianjurkan.
pemeriksaan
No adjustment to these systems should be made although periodic inspection of the components is recommended.
NOISE
NOISEEMISSION
EMISSIONCONTROL
CONTROLSYSTEM (SISTEM PENGATURAN EMISI KEBISINGAN)
SYSTEM
DILARANG MENGUTAK-ATIK SISTEM PENGATURAN EMISI KEBISINGAN: Undang-undang melarang tindakan-tindakan berikut
TAMPERING
atau penyebabWITH THE NOISE
daripada: CONTROL
(1) Pelepasan atauSYSTEM IS PROHIBITED:
dibuat tidak bekerjanya olehLocal law mayselain
seseorang, prohibit the following
untuk acts or theperbaikan
tujuan perawatan, causing
thereof:
atau (1) The removal
penggantian, or rendering
dari setiap inoperative
peralatan by any rancangan
atau elemen person, other thantelah
yang for purposes
dipasangof pada
maintenance,
s ebuah repair or replacement,
kendaraan untuk tujuan of
any device kebisingan
pengaturan or element sebelum
of designpenjualan
incorporated
atauinto any vehicle for
penyerahannya the purpose
kepada pelangganof noise control
akhir atau prior to its
sementara sale or deliveryatau
ia dipergunakan: to the
(2)
ultimate
pemak customer
aian sebuahorkendaraan
while it is setelah
in use; peralatan
(2) the useatau
of the vehicle
elemen after such
rancangan device or telah
sedemikian element of designatau
dilepaskan has dibuat
been removed
tidak dapator
rendered
bekerja inoperative
oleh by any person.
seseorang.
AMONG THOSE ACTS PRESUMED TO CONSTITUTE TAMPERING ARE THE ACTS LISTED BELOW:
DI ANTARA TINDAKAN YANG DIANGGAP MERUPAKAN PENGUTAK-ATIKAN ADALAH TINDAKAN-TINDAKAN DI BAWAH INI:
1. Removal
1. of, oratau
Melepaskan puncturing of the knalpot,
melubangi muffler, baffles,
komponenheader pipes or any
pengaturan otherpipa
aliran, component whichatau
pendahulu conducts
setiapexhaust gases.lain yang
komponen
2. Removal of, or puncturing of any part of the intake system.
menyalurkan gas pembuangan.
3. Lack of proper maintenance.
2. Melepaskan atau melubangi setiap bagian dari sistem pemasukan udara.
4. Replacing any moving parts of the vehicle, or parts of the exhaust or intake system, with parts other than those specified by the
3. Tidak menjalankan perawatan yang layak.
manufacturer.
4. Mengganti bagian bergerak dari kendaraan, atau bagian dari sistem pembuangan atau pemasukan, dengan part lain daripada
yang telah ditentukan oleh pabrik pembuatnya.
1-23
CATATAN
2. FITUR TEKNIK
CV
CV MAT IC SYSTEM.....................................
MATIC 2-2
SYSTEM ······································2-2 KICKSTARTER
KICKSTARTERINHIB ITOR SYSTEM
INHIBITOR SYSTEM........ 2-4
·········· 2-4
2-1
FITUR TEKNIK
CV MATIC SYSTEM
CVMATIC SYSTEM
TECHNICAL FEATURES
OUTLINE
GARIS BESAR
This model
Model utilizes CV MATIC
ini menggunakan sistemtransmission
transmissi CVsystem,
MATIC,which
yangrealizes fully automatic
memungkinkan riding just
pengendaraan like scooters,
dengan otomatiseliminating the pada
penuh seperti need of
shifting through the gears.
skuter, sehingga meniadakan kebutuhan untuk mengoper gigi-gigi transmissi.
CV MATIC engine has very compact configuration compared to conventional scooter engines, making it possible to be mounted on
Mesin CV MATIC
a motorcycle mempunyai susunan yang sangat kompak dibandingkan dengan mesin skuter konvensional, sehingga
chassis.
memungkinkan untuk dipasang pada rangka sepedamotor.
KOMPONEN SISTEM/PENERUSAN DAYA
SYSTEM COMPONENTS/POWER TRANSMISSION
CV
TheMATIC system
CV MATIC terdiriconsists
system dari drive/driven pulleys, drive
of the drive/driven belt,drive
pulleys, centrifugal clutch, driveshaft,
belt, centrifugal countershaft
clutch, driveshaft, dan finalshaft.
countershaft and finalshaft.
DRIVE PULLEY
CENTRIFUGAL CLUTCH
DRIVESHAFT
DRIVE BELT
COUNTERSHAFT
DRIVE SPROCKET
DRIVEN PULLEY
To rear wheel
FINALSHAFT
Drive pulley, drive belt dan driven pulley memungkinkan perbandingan pengendaraan yang berubah terus. Masing-masing
The drive pulley,
komponen drive belt and
pada drive/driven driven
pulleys pulley enables
mempunyai fungsithe
danconstantly
rancangan variable driving dengan
yang serupa ratio. Each
yangcomponent in drive/driven pulleys
ada pada skuter.
have same functions and similar designs as those of scooters.
Untuk mengurangi
To reduce ukuran
the engine size,mesin, crankshaft
the crankshaft anddandriveshaft
driveshaftare
ditempatkan
positioned cukup dekat,close,
significantly sehingga menghasilkan
resulting in shorterpanjang drive
drive belt belt
length,
yang lebih to
compared pendek,
that ofdibandingkan
scooters. dengan yang dipakai pada skuter.
The centrifugal
Centrifugal clutch,
clutch, which is soaked
yang direndam di dalaminolioil in menghasilkan
agar order to provideumura pemakaian
longer service
yanglife, engages/disengages
lebih according to the
panjang, menggerakkan/melepaskan
driveshaft rotation speed. When the centrifugal clutch is engaged, the drive gear located at the end of
sesuai dengan kecepatan perputaran driveshaft. Sewaktu centrifugal clutch dalam keadaan terpasang, drive gear yang terletak centrifugal clutch outer
pada
transmits
ujung dari the engine torque
centrifugal to themeneruskan
clutch outer countershaft.torsi mesin ke countershaft.
The finalshaft, which is engaged with the countershaft, is equipped with a drive sprocket which transmits the power to the rear
Finalshaft, yangchain.
wheel via drive digerakkan bersama dengan countershaft, dilengkapi dengan sebuah drive sprocket yang meneruskan daya ke roda
belakang melalui drive chain.
2-2
FITUR TEKNIK
PULLEYCHAMBER
PULLEY CHAMBER VENTILATION/COOLING
VENTILATION/COOLING SYSTEM
SYSTEM
The heat
Panas generated
yang by belt/pulley
dibangkitkan frictionbelt/pulley
oleh gesekan raises themenaikkan
pulley chamber temperature
suhu pulley significantly
chamber high,terutama
cukup tinggi, especially with smaller
dengan badan chamber
bodyCV
dari of MATIC
CV MATIC engine.
engine yang lebih kecil.
The chamber temperature is also affected by the heated engine oil as the pulley chamber is located next to the crankcase.
Suhu chamber juga dipengaruhi oleh oli mesin yang panas oleh karena pulley chamber letaknya di sebelah crankcase.
To prevent the chamber temperature from rising too high, the chamber is designed to provide the cooling air effectively to entire
Untuk menjaga agar suhu chamber tidak naik terlalu tinggi, chamber dirancang untuk mengalirkan udara pendinginan secara efektif
chamber.
melalui seluruh
The engine chamber.
is also equipped with an oil cooler, which is located at the right side of cylinder where adequate cooling air is available
while running,
Mesin cools down
juga dilengkapi the engine
dengan sebuah oiloil
temperature.
cooler, yang letaknya pada sisi kanan dari cylinder dimana ada cukup banyak udara
pendinginan pada waktu sepedamotor dijalankan,
The cooling air inlet and outlet is positioned at the topyang
of mendinginkan suhu and
the pulley chamber oli mesin.
connected to the ducts, preventing water entrance
into the chamber
Tempat masuk danwhich causes
tempat beltpendinginan
keluar slippage. udara terletak pada bagian atas pulley chamber dan dihubungkan dengan saluran,
sehingga air tidak dapat masuk ke dalam chamber dan mengakibatkan slip pada belt.
COOLING AIR INLET
AIR OUTLET
ENGINE OIL COOLER

DRIVEN PULLEY
DRIVE PULLEY
DRIVE BELT
FINAL
FINALGEAR
GEARDAMPER
DAMPER
Finalshaft
The finalshaft[1] memiliki fungsi
[1] contains thegear
geardamper
damperyang menyerap
function which getaran
absorbsdan the
suara yang
vibration and disebabkan
noise caused olehbyloncatan
the rearroda
wheel belakang.
hopping.
The finalshaft
Finalshaft consists
terdiri of the damper
atas damper holder
holder [2], yang [2],dipasang
which isdengan
press-fitted onto
press-fit Posisi standard :
the shaft, and
(dipasang denganfinal mesin
gear [3],
press)which is pushed
pada shaft, dan against
finalthegear
holder
[3], by the
yang
diaphragm
didorong spring [4].
terhadap holder oleh diaphragm spring [4].
Duringwaktu
Pada acceleration,
akselerasi,or when the rear brake
atau sewaktu is applied,
rem belakang the relative
dijalankan, speed of
kecepatan [1]
engine revolution exceeds the rear wheel rotation speed,
relatif dari perputaran mesin lebih tinggi daripada kecepatan perputaran the damper holder
bosses
roda [5] are rested
belakang, sehingga toward
damperthe opposite direction
holder bosses [5] of final gearmenuju
bersandar rotation.arah
berlawanan
During rapiddari perputaranbyfinal
deceleration gear.
strong rear brake application and intermittent
release,
Pada hopping
waktu vibrationcepat
deselerasi of the yang
rear wheel could occur
disebabkan oleh when the relative
penerapan rem
speed of rear
belakang yangwheel rotation
kuat dan exceeds
pelepasan the dengan
engine revolution speed. getaran
terputus-putus, [3] [5]
In order todari
meloncat reduce
rodathe speed fluctuation
belakang between
dapat terjadi sewaktu the kecepatan
rear wheel and engine
relatif dari
rotation, theroda
perputaran damper holderlebih
belakang slipstinggi
toward the
dari same direction
kecepatan as themesin.
perputaran final gear
rotation, which helps absorbing the vibration and noise caused by rear Sewaktu dijalankan:
Agar
wheel dapat
hopping. mengurangi fluktuasi kecepatan antara perputaran roda
belakang dan perputaran mesin, damper holder menggeser menuju arah
sama dengan perputaran final gear, sehingga membantu menyerap getaran
dan suara yang diakibatkan oleh loncatan roda belakang. [4]
[2]
[3]
[3] [5]
2-3
FITUR TEKNIK
KICKSTARTER INHIBITOR SYSTEM
(SISTEM
OUTLINE PENGHALANG KICKSTARTER)
GARIS BESAR
This model is equipped with a kickstarter inhibitor system, which shuts off
the ignition and fuel injection when the brake lever or pedal is not applied,
Model ini dilengkapi dengan sebuah kickstarter inhibitor system, yang mematikan ignition (pengapian) dan fuel injection
preventing the sudden vehicle movement when the engine is kick-started
(penyemprotan bahan bakar) sewaktu brake lever (handel rem) atau brake pedal (pedal rem) tidak dijalankan, sehingga mencegah
with the rear wheel touching the ground.
pergerakan kendaraan dengan tiba-tiba sewaktu mesin di kick-starter dengan roda belakang menyentuh tanah.
When the brake pedal or lever is applied, brake light switch turns ON.
Sewaktu brake pedal atau brake lever dijalankan, brake light switch berputar ke ON.
During start-up mode, ECM allows the ignition system and fuel injection
Pada
system waktu start-up
to operate mode,
only whenECM hanya between
the voltage memungkinkan dijalankannya
the brake ignition system dan fuel injection system sewaktu voltase
light switch and
antara brake
brake light is light switch dan brake light terdeteksi.
detected.
Sekali mesin
Once the dihidupkan
engine dan
is started sinyal
and perputaran
engine mesin from
rotation signal dari the
CKPCKP
sensor diterima,
sensor ECM berpindah
is received, ke normal
the ECM switches to running mode
the normal (cara
running
berjalan
mode. normal).
MAIN SUB IGNITION

FUSE FUSE SWITCH
15 A 10 A
R/Y R/Y Bl/R Bl
R R
R/Y Bl/Bu
R
Bl
G G REGULATOR/ BRAKE
RECTIFIER LIGHT
BATTERY SWITCHES
G/Y
Bu/Y
W/Y W/Y Bl/Bu

G: Green (Hijau) G/Y
R: Red (Merah) CKP

SENSOR
Y: Yellow (Kuning)
Bl: Black (Hitam) G ECM
Bu: Blue (Biru) Bu/Y
W: White (Putih)
2-4
3. RANGKA/BODY PANELS/SISTEM PEMBUANGAN GAS
LOK
BODYASIPANEL
BODY LOCATIONS
PANEL.................................. 3-2
·························3-2 TAILCOVER
TAIL COVER···············································
............................................ 3-12
3-12
PET
BODYA PELEPASAN BODY CHART
PANEL REMOVAL PANEL ···············3-2
.............. 3-2 GRAB RAIL
GRAB RAIL·················································
.............................................. 3-13
3-13
KETERANGAN SERVIS ................................ 3-3 BODY COVER .......................................... 3-13

SERVICE INFORMATION ·····························3-3 BODY COVER············································· 3-13
TROUBLESHOOTING ................................... 3-3 CENTER COVER ..................................... 3-14
TROUBLESHOOTING···································3-3 CENTER COVER ········································ 3-14
SN AP FIT CLIP .............................................. 3-4 MAIN PIPE COVER .................................. 3-15
SNAP FIT CLIP··············································3-4 MAIN PIPE COVER····································· 3-15
HANDLEBAR TOP COVER........................... 3-4 SEAT ......................................................... 3-16
HANDLEBAR TOP COVER ··························3-4 SEAT ··························································· 3-16
HANDLEBAR FRONT COVER...................... 3-5 LUGGAGE BOX ....................................... 3-17
HANDLEBAR FRONT COVER ·····················3-5 LUGGAGE BOX ·········································· 3-17
HANDLEBAR REAR COVER ........................ 3-6 LEFT CR ANKCASE REAR C OVER ....... 3-17
HANDLEBAR REAR COVER ·······················3-6 LEFT CRANKCASE REAR COVER ··········· 3-17
FRONT TOP COVER ..................................... 3-10 PASSENGER FOOTPEG HOLDER ........ 3-18
FRONT COVER
FRONT TOP COVER···································3-10
.............................................. 3-10 PASSENGER FOOTPEG HOLDER ···········3-18
CHAIN C ASE............................................ 3-18
FRONT FENDER
FRONT COVER ···········································3-10
A ........................................ 3-11 CHAIN CASE ··············································
REAR FENDER 3-18
........................................ 3-19
FRONT
FRONT FENDER
FENDER B
A ........................................ 3-11
·····································3-11 FOOTPEG
REAR BAR........................................
FENDER ···········································3-19
3-19
LOWER SIDE COVER

FRONT FENDER ................................... 3-12
B ·····································3-11 EXHAUST BAR
FOOTPEG PIPE/MUFFLER ..................... 3-20
·········································· 3-19
LOWER SIDE COVER·································3-12 EXHAUST PIPE/MUFFLER ························ 3-20
3-1
RANGKA/BODY PANEL/SISTEM PEMBUANGAN GAS
LOKASI BODY PANEL
FRAME/BODY PANELS/EXHAUST SYSTEM
[1]
[14] [2]
[3]
[4]
[10] [13] [9]
[6]
[19]
[5]
[15]
[11]
[12] [8] [7] [18]
[16] [17]
[1] Handlebar top cover (Hal. 3-4) [11] Body cover (Hal. 3-13)
[2] Handlebar front cover (Hal. 3-5) [12] Center cover (Hal. 3-14)
[3] Handlebar rear cover (Hal. 3-6) [13] Main pipe cover (Hal. 3-15)
[4] Front top cover (Hal. 3-7) [14] Seat (Hal. 3-16)
[5] Front cover (Hal. 3-10) [15] Luggage box (Hal. 3-17)
[6] Front fender A (Hal. 3-11) [16] Left crankcase rear cover (Hal. 3-17)
[7] Front fender B (Hal. 3-11) [17] Passenger footpeg holder (Hal. 3-18)
[8] Lower side cover (Hal. 3-12) [18] Drive chain cover (Hal. 3-18)
[9] Tail cover (Hal. 3-12) [19] Rear fender (Hal. 3-19)
[10] Grab rail (Hal. 3-13)
PETA PELEPASAN BODY PANEL

• Peta ini memperlihatkan urutan pelepasan dari penutup rangka.
[1] Handlebar top cover [2] Handlebar front cover [3] Handlebar rear cover
[4] Front top cover
[5] Front cover
[6] Front fender A [7] Front fender B
[8] Lower side cover [9] Tail cover [10] Grab rail
[11] Body cover [19] Rear fender [17] Passenger footpeg holder
[12] Center cover [14] Seat [18] Drive chain cover
[13] Main pipe cover [15] Luggage box [16] Left crankcase rear cover
3-2
KETERANGAN SERVIS
SERVICE INFORMATION
GENERAL
UMUM
•This section covers removal and installation of the body panels and exhaust system.
•• Bab ini meliputi
Serious burns may pelepasan danexhaust
result if the pemasangan
systembody panels
is not alloweddantoexhaust system
cool before (s istem pembuangan
components are removedgas).
or serviced.
•• Luka bakar
Always replaceparah dapat terjadi
the exhaust jika sistem
pipe gasket pembuangan
after removing gas tidak
the exhaust dibiarkan
pipe from menjadi dingin dulu sebelum komponen-
the engine.
• komponennya
When installing dilepaskan
the exhaustatau diservis.
system, loosely install all of the muffler fasteners. Always tighten the exhaust joint first, then tighten
• Selalu
the ganti exhaust
mounting fasteners.pipe gasket
If you setelah
tighten melepaskan
the mounting exhausfirst,
fasteners t pipe (pipa
the knalpot)
exhaust pipedari
maymesin.
not seat properly.
•• Sewaktu
Always memas
inspect theang exhaust
exhaust system,
system pasanglah
for leaks semua pengikat muffler (knalpot) dengan longgar dulu. Selalu kencangkan
after installation.
exhaust joint (penyambung pipa knalpot) dulu, kemudian kencangkan mounting fasteners (pengikat pemas angan). Jika
mounting fasteners dikencangkan lebih dulu, exhaust pipe mungkin tidak dapat duduk dengan benar.
•TORQUE VALUES
Selalu periks a exhaust system terhadap keboc oran setelah pemasangan.
Throttle cable lock nut (handlebar side) 3 N·m (0.31 kgf·m, 2.2 lbf·ft)
TORSI PENGENCANGAN
Rear brake pedal lock knob stopper nut 2.6 N·m (0.27 kgf·m, 1.9 lbf·ft)
Exhaust
Mur pipe joint
penguncian nut cable (sisi handlebar)27 N·m (2.83 kgf·m,
throttle 20 lbf·ft)
N.m (0,31 kgf.m; 2,2 lbf.ft)
Exhaust
Mur pipe stud
rear brake pedalbolt
lock knob stopper 2,6 N.m– (0,27 kgf.m; 1,9 lbf.ft) See page 3-20
Mur exhaust pipe joint 27 N.m (2,8 kgf.m; 20 lbf.ft)
Baut stud exhaust pipe - Lihat hal. 3-20
TROUBLESHOOTING
TROUBLESHOOTING
Excessive exhaust noise
• Broken
Suara exhaust
knalpot yangsystem
berlebihan
• Exhaust gas leak
• Exhaust system rusak
•Poor performance
Ada kebocoran gas pembuangan
• Deformed exhaust system
Performa buruk
• Exhaust gas leak
• • Clogged
Exhaust muffler
system berubah bentuk
• Ada kebocoran gas pembuangan
• Muffler tersumbat
3-3
SNAP FIT CLIP
PELEPASAN/PEMASANGAN
REMOVAL/INSTALLATION
MakePastikan
sure thatbahwa the Pisahkan
Separateparts dengan
the parts menarik
by pulling snap fit
the snap fitclip
clip[1][1]straight
lurus
bagian insertion
insertion of thedariclip keluar darihole,
out of the lubang,
beingdengan berhati-hati
careful not agar tidak
to tilt the insertion [2]
isclip
nottidak
tiltedmiring
when memiringkan bagian
of the snap fit clip. insertion [2] dari snap fit clip. [2]
sewaktu
removing or
me ngeluarkan atau Check snap
Periksa the snap fit clip
fit clip for damage
terhadap and dan
kerusakan replace
gantiif
installing the
memasang snap snap
fit necessary.
apabila perlu.
fitclip.
clip.
Jika If tiltedpada
miring upon Install
Pas ang the parts
parts by inserting
dengan memastheukkan snap fit clip
snap straight
fit clip lurusinto
ke
removal or
waktu pengeluaran the hole,lubang,
dalam being careful not to berhati-hati
dengan tilt the insertion of thetidak
agar clip.
installation,
atau pemasangan, memiringkan insertion dari clip.
damage
dapat teto the
rjadi
kerusakanor/and
insertion pada
insertion
hole may dan/atau
occur. [1]
lubang.
HANDLEBAR TOP COVER

Remove the
Lepaskan four screws
keempat screws[1].
[1].
Hati-hati agar tidak Lepaskan handlebar top cover [2] dengan melepaskan
Be not to Remove the handlebar top cover [2] by releasing the
carefulhooks.
merusak boss [3] dan hooks [4] dari grommet [5] dan slots [6] dari
damage the hooks. boss [3] and hooks [4] from the grommet [5] and slots
handlebar front cover.
[6] of the handlebar front cover.
Pemasangan
Installation is inadalah dalam
the reverse orderurutan terbaik
of removal. dari
pelepas an.
[3]
[2]
[4]
[5]
[6]
[1]
3-4
HANDLEBAR FRONT COVER
Remove handlebar
Lepaskan the handlebar top cover
top cover (hal.(page
3-4). 3-4).
[3] [1]
Pull lepas
Tarik off therubber
rubberdust
dustc covers [1].
overs [1].
Loosen themur
Longgarkan lockpengunci
nuts [2] [2]
anddan remove the rearview
lepaskan rearview
mirrors[3]
mirrors [3] dengan
by turning them counterclockwise.
memutar mereka berlawanan arah
jarum jam.
[2]
Remove the following:

Lepaskan sebagai berikut:
- –Baut
Bolt [1],
[1], collar
collar [2][2]
danand rubber
rubber [3][3] on the
pada frontdepan.
bagian side
- –Enam
Six screws/washers
sekrup/washers [4] [4]
Be careful
Hati-hati agar not Release sebagai
to Lepaskan
tidak the following:
berikut:
merusak tabs
damage dan - Dua bosses [5] dari lubang2 [6]
the tabs
– Two bosses [5] from the holes [6]
bosses. - Dua tabs [7] dari slots [8]
and bosses.
– Two tabs [7] from the slots [8]
Lepaskan
Remove handlebar frontfront
the handlebar cover [9] dengan
cover melepaskan
[9] by disconnecting
headllight 9P connector
the headlight [10]. [10].
9P connector
Pemasangan
the reverse orderurutan terbalik
of removal. dari
pelepas an.
[5]
[7]
[3]
[1]
[6]
[8]
[2]
[9]
[10]
[4]
3-5
PEMBONGK ARAN/PERAKITAN
DISASSEMBLY/ASSEMBLY
Lepaskan
Remove the sebagai berikut:
following: [2]
- Buat khusus [1] [3]
– Special bolt [1]
- Dua holders [2]
– Two holders [2]
Keluarkan
Remove the headlight
headlight [3] [3]
unitunit dengan melepaskan
by releasing kedua
the two tabs
tabs [4] dari slots [5] pada handlebar front cover.
[4] from the slots [5] of the handlebar front cover.
Sete lah memasang Perakitan
After installing
handlebar the Assembly isadalah
front
dalamorderurutan
in the reverse terbalik
of disassembly. dari
handlebar front pembongkaran.
cover, setel arah
cover,
sinar adjust
headlight the
(hal. [5]
headlight aim
4-17).
(page 4-17).
[1] [4]
HANDLEBAR REAR COVER

PELEPASAN
REMOVAL
Lepaskan sebagai
Remove the berikut:
following:
- Handlebar front cover (hal. 3-5)
- –Front
Handlebar front3-10)
cover (hal. cover (page 3-5)
– Front cover (page 3-10)
Lepaskan speedometer sub harness 9P/6P connectors
Disconnect the speedometer sub harness 9P/6P
[1].
connectors
Lepaskan [1].band boss [2] dari rangka.
wire
Release the wire band boss [2] from the frame.
[1] [2]
Disconnect
Lepaskan the speedometer
speedometer cable
cable [1] dari [1] fromunit.
speedometer the [4]
speedometer unit. [1]
Lepaskan connectors berikut ini:
- Disconnect the following
Horn wire connectors [2]connectors:
- –Resistor
Horn wire connectors [3]
wire connector [2]
- –Front brak ewire
Resistor lightconnector
s witch wire[3]connectors [4]
– Front brake
Lepaskan light switch
speedometer wireharness
sub connectors
[5] [4]
dari cable
guides [6].
Release the speedometer sub harness [5] from the
cable guides [6].
[6]
[3]
[5]
[2]
3-6
Lepaskan kedua
Remove the two sekrup depan[1][1]
front screws anddan sekrup
special khusus
screw [2].
[2]. [3]
Release the handlebar rear cover [3] from the
Lepaskan handlebar rear cover [3] dari handlebar.
handlebar.
[2]
[1]
Remove the
Lepaskan screw[1]
sekrup [1] dan
and throttle
throttle upper
upperhousing
housing[2] [2]
by
[1] [2]
unhooking
dengan the lowerkaitan
melepaskan housing
daritab [3]. housing tab [3].
lower
[3]
Lepaskan
Disconnect throttle cable [1]cable
the throttle dari throttle
[1] frompipe
the[2].
throttle pipe
[2]. [2]
Longgarkan mur pengunci throttle cable [3] dan
Loosen throttle
lepaskan the throttle
lowercable lock[4]
housing nut [3]throttle
dari and remove
cable. the
throttle lower housing [4] from the throttle cable.
[1]
[3] [4]
Lepaskan
Remove the handlebar
handlebar rearrearcov cover
er [1] [1]
dengan menarik
by pulling the
throttle
keluar cablecable
throttle [2] out[2]ofdari
its hole.
lubangnya. [1]
[2]
3-7
INSTALLATION
PEMASANGAN
Route throttle
Alurkan the throttle
cablecable [1] through
[1] melalui lubang the hole
pada on the
handlebar
handlebar rear cover [2]. [1]
rear cover [2].
[2]
Alurkan throttle
Route the cable
throttle [1] melalui
cable throttle
[1] through thelower housing
throttle lower
housing
[2] [2] and
dan untuk temporarily
sementara tighten the
kencangkan mur lock nut [3]. [3].
pengunci
Apply 0.1
Berikan 0,1 -– 0.2
0,2 gg of grease
gemuk padato the throttle
daerah pipe
luncur [4]sliding
pada
area [4].
throttle pipe. [4]
Connect the throttle
Sambungkan throttle cable
cable pada
to thethrottle
throttlepipe.
pipe.
Install the
Pasang throttle
throttle lower
lower housing
housing in position
pada by dengan
posisinya aligning
the pin with the hole on the handlebar.
mentepatkan pin dengan lubang pada handlebar. [1]
Tepatkan
[3] [2]
Pas ang the

Install throttle upper
throttle housing
upper [1] [1]
housing dengan mentepatkan
by aligning its slot
[3] [1]
slot-nya
with the dengan lower tab
lower housing housing tabinstall
[2], then [2], and
kemudian
tighten
the screw
pasang dan[3].
kenc angkan sekrup [3].
[2]
Kencangkan
Tighten the throttle
throttlec cable
able lock
locknut
nut[1][1]
dengan
to thetorsi yang
specified
ditentukan sementara
torque while holding themenahan
throttlethrottle
cable. cable.
TORSI: 3 N.m
TORQUE: (0,31
3 N·m kgf.m;
(0.31 2,22.2
kgf·m, lbf.ft)
lbf·ft)
[1]
3-8
Tempatkan handlebar
Set the handlebar rearrear
covercover
[1] in[1] pada then
position, posisinya,
install [1]
kemudian pasang
and tighten dan front
the two kencangkan
screws kedua
[2] andsekrup depan
rear special
screw
[2] [3].
dan sekrup khusus belakang [3].
[2] [3]
Alurkan wire the

Route harness
wire Alurkan
Route thespeedometer s ub
speedometer subharness
harness [1]
[1] pada
to the cable
cable
dengan benarproperly
(hal. 1- guides [5]
harness guides(pembimbing
[2]. kabel) [2]. [6]
14).
(page 1-14).
Connect the connectors
Sambungkan following connectors:
berikut ini:
- Horn wire connectors [3]
– Horn wire connectors [3]
- Resistor wire connector [4]
– Resistor wire connector [4]
- Front brak e light s witch wire connectors [5]
– Front brake light switch wire connectors [5]
Hubungkan
Connect thespeedometer
speedometerc cable
able [6]
[6] pada
to the speedometer
speedometer
unit.
unit.
[2]
[4]
[1] [3]
Sambungkan
Connect the speedometer
speedometer sub sub harness
harness 9P/6P
9P/6P
connectors[1].
connectors [1].
Install the
Pasang wirewire
band band boss
boss [2] to rangka.
[2] pada the frame.
Install the following:
Pasang sebagai berikut:
- –Front
Front cover
cover (page
(hal. 3-10)
3-10).
- –Handlebar
Handlebar front
front cover
cover (page
(hal. 3-5)3-5)
[1] [2]
3-9
FRONT TOP COVER
Remove sekrup
Lepaskan the following:
[1].
– Two bolts
Hati-hati agar tidak Lepaskan kedua[1]snap
and licence
fit clips plate holder
[2] (hal. 3-4)[2]
danfrom the
hooks [1] [4]
merusak clips dan [3] dari [5]
frontfront
sidecover dengan menarik front top cover [4]
hooks. dalam
– Screw
arah [3]
yang ditunjukkan.
Lepaskan front top cover.
Be careful not to Release the two snap fit clips [4] (page 3-4) and hooks
[5] from the front
damage the clips Pemasangan cover by
adalah pullingurutan
dalam the frontterbalik
top coverdari
[6]
in the shown
and hooks. pelepas an. direction.
Remove the front top cover.
Installation is in the reverse order of removal.
[2]
[6]
[3]
FRONT COVER
Remove sebagai
berikut:
- –Dua Two bolts [1] andsisi
sekrup [1] dari depanplate holder [2] from the
licence
- Dua sekrup
front side khus us [2] dari sisi depan bawah
- –Delapan sekrupscrews
Two special khusus[3][3]from
darithe
sis ilower
belakang.
front side
Hati-hati agar tidak – Eight special screws [4] from
Tarik front cover [4] ke depan dan lepaskan the rear side
tabs [5] dari
merusak tabs. slots
Be careful not to Pull [6]
thepada
frontlower
coverside cover. and release the tabs [6]
[5] forward
damage the tabs. Lepaskan front [7]
from the slots cover dengan
of the side cover. position light
lower melepaskan
3P c onnector
Remove the[7].
front cover by disconnecting the position
light 3P connector
Lepaskan [8]. [8] dari front cover stay.
kedua rubbers
Remove the two
Pemasangan adalah dalam rubbers [9] fromurutan
the frontterbalik
cover stay.
dari
pelepas an. is in the reverse order of removal.
Installation
[4]
[5]
[9]
[2]
[1]
[3] [7]
[6] [8]
3-10
FRONT FENDER A
Lepaskan
following:
- Front cover (hal. 3-10).
– Front cover (page 3-10).
- Baut [1], speedometer cable guide [2] dan collar [3]
– Bolt [1], speedometer cable guide [2] and collar [3]
- Baut [4], brake hose clamp [5] dan collar [6]
– Bolt [4], brake hose clamp [5] and collar [6]
- Baut [7] dan collar [8].
– Bolt [7] and collar [8]
Hati-hati agar tidak Lepaskan front fender A [9] dengan melepaskan kedua
Bemerusak not to Remove the front fender A [9] by releasing the two
careful hooks.
hooks [10] dari slots [11] pada front fender B.
damage the hooks. hooks [10] from the slots [11] of the front fender B.
Pemasangan
the reverse order urutan terbalik dari
of removal.
pelepasan.
[6] [5]
[4]
[1]
[10]
[3]
[9] [11]
[7]/[8] [2]
FRONT FENDER B
Lepaskan
following:
- Roda depan (hal. 13-7).
– Front wheel (page 13-7)
- Front fender A (hal. 3-11).
– Front fender A (page 3-11)
-– Dua
Twobaut [1][1]
bolts dan collars
and collars[2][2]
- Front fender B [3]
– Front fender B [3]
Pemasangan
Installation is in adalah dalam
the reverse order urutan terbalik
of removal. dari
pelepas an.
[3]
[1]/[2]
3-11
LOWER SIDE COVER
Remove the
Lepaskan frontfollowing:
cover (hal. 3-10).
– Front cover
Lepaskan sekrup(page
[1]. 3-10)
– Screw [1]
Hati-hati agar tidak Tarik lower side cover [2] ke depan dan lepaskan slots
Bemerusak
carefulhooks. Pull
not to [3] darithe lower
hooks [4] side
padacover
body [3] forward
cover and pipe
dan main release the
cover.
slots [4] from
damage the hooks. Lepaskan lowerthe
sidehooks
cov er[5]dan
of the body
rubber [5].cover and main
pipe cover.
Pemasangan
Remove the lower adalah dalamandurutan
side cover terbalik dari
rubber [6].
pelepas an.
[5]
SISI KIRI DI PERLIHATKAN:
[4]
[6]
[3]
[1]
TAIL COVER
Buka penguncian
Unlock and opendan
the angkat
seat. seat.
[3]
Lepaskan kedua
Remove the twosscrews
ekrup [1].
[1].
[4]
Hati-hati agar not
Be careful to Lepaskan
tidak tabstabs
Release the [2] pada
[2] oftail
thec over [3] dari
tail cover [3]body
fromcover.
the body
merusak tabs
damage dan Lepaskan
the tabs cover. hooks [4] dari tail cover dari s lots [5] pada
hooks. body
and hooks. Release
coverthe hooksmenarik
dengan [4] of the tailcover
tail coverkefrom the slots [5]
depan.
of the body
Lepaskan tailcover
cover.by pulling the tail cover forward.
Remove the tail cover. [1]
Pemasangan adalah dalam urutan terbalik dari [2]
Installation
[5]
3-12
GRAB RAIL
Remove tail
Lepaskan the cover
tail cover
(hal.(page
3-12).3-12).
[1] [2]
Support
Peganglah thegrab
grabrail Remove the
rail Lepaskan four mounting
keempat bolts [1] and
baut pemasangan [1]grab
danrail
grab[2].rail
sewhile
wakturemoving
melepaskanthe [2].
bolts.
bolts. Pemasangan adalah dalam urutan terbalik dari
pelepas an.
BODY COVER
Remove sebagai
berikut:
- –Lower
Lower side cover
side cover(hal. 3-12)
(page 3-12)
- –TailTail
c over (hal.
cover 3-12)
(page 3-12)
- –Sekrup
Specialkhusus
screw[1][1]
- –Sekrup
Three[2] screws [2]
- –Tiga sekrup
Body [3]stay screw [3]
cover
Release the
Lepaskan following:
sebagai berikut:
- Lubang [4] dari boss [5] pada body c over stay
– Hole [4] from the boss [5] of the body cover stay
- –Tab [6] [6]
Tab darifrom
alurthe
[7] groove
pada rear fender
[7] of the rear fender
- –Snap fit clip [8] (hal. 3-4) dari rear
Snap fit clip [8] (page 3-4) from the fender
rear fender
Hati-hati agar tidak Tarik body cover [9] ke depan dan lepaskan slots [10]
Be not to Pull the body cover [9] forward and release the slots
carefulhooks.
merusak dari hooks [11] pada center cover, kemudian lepaskan
damage the hooks. [10] from the hooks [11] of the center cover, then
body cover.
remove the body cover.
Pemasangan
of removal. dari
pelepas an.
SISI KIRI DI PERLIHATKAN: [7] [5] [2]
[11]
[3]
[4]
[10]
[9]
[1] [8] [6]
3-13
Remove the
Lepaskan three
ketiga screws
sekrup [1] [1]
danand
rearrear
ducduct
t [2].[2]. SISI KIRI DI PERLIHATKAN:
Lepaskan keempat sekrup [3] dan rear body
Remove the four screws [3] and rear body cover [4]
cover [4] [1]
from the sub body cover [5]. [6] [7]
dari sub body cover [5].
[2]
Remove the three screws [6] and body cover [7] from
Lepaskan ketiga sekrup [6] dan body cover [7] dari sub
the sub body cover.
body cover.
Assembly is in the reverse order of disassembly.
Perakitan adalah dalam urutan terbalik dari
pembongkaran.
[3]
[4] [5]
CENTER COVER
Remove the
Lepaskan following:
sebagai berikut: [2]
[1]
- Body cover (hal. 3-13)
– Body cover (page 3-13)
- –Sekrup
Screw[1][1]
Lepaskan
Remove the center cover
center [2] dengan
cover melepaskan
[2] by releasing the tabs
tabs [3]
[3]
dari
fromslots
the [4] pada
slots [4] main
of thepipe
maincover.
pipe cover.
Pemasangan
the reverse orderurutan terbalik dari
of removal.
pelepas an.
[3]
[4]
3-14
MAIN PIPE COVER
Remove center
Lepaskan the center cover
cover (hal.(page
3-14).3-14).
Release the
Lepaskan rearrear brake
brak e pedalpedal lock
lock cableclip
cable clip[1]
[1]dari
fromrear
the [2] [1]
rear brake
brake pedal pedal lock[2]arm
lock arm [2] asdiperlihatkan.
seperti shown.
Loosen the lock
Longgarkan mur nut [3] and adjuster
pengunci [3] dan[4],adjus
thenter
release
[4],
the rear brake
kemudian pedal
lepaskan lockbrake
rear cablelock
[5] from
cablethe
[5]cable guide
dari cable
[6]. [6].
guide
[3] [4]
[5] [6]
Lepaskan
Release therearrear
brake pedal
brake locklock
pedal cable [1] [1]
cable dari cable
from the
clamps [2].
cable clamps [2] and aircleaner housing [3]. [2] [1]
[3]
Lepaskan rearrear
Release the brake pedal
brake pedallocklock
cable [1] [1]
cable dari cable
from the
clamp
cable[2] dari [2]
clamp front
of cover stay.
the front cover stay. [2]
[1]
3-15
Longgarkan
Loosen the rearrear brake
brake pedal
pedal lock
lock knob
knob stopper
stoppernut
nut[1]
[1]
dan lepas kan
and release thetab
tab[2]
[2]dari
frommain pipe pipe
the main cover [3] seperti
cover [3] as
shown.
diperlihatkan.
Pull out
Tarik the rear brake pedal lock cable [4] dari
keluar from main
the
mainover
pipe pipe hole.
cover hole.
Lepaskan
following:
- Sekrup [5]
-– Dua
Screw [5] khus us [6]
sekrup
-– Baut/washer
Two special[7] screws [6]
-– Main
Bolt pipe
/washer [7]
cover
– Main pipe cover
Sete lah memasang Pemasangan adalah dalam urutan terbalik dari
rear brake
After pedal lock
installing Installation
the pelepas an. is in the reverse order of removal.
rearcable,
brakelak ukan
pedal
penyetelan
lock (hal. 4-
cable, adjust it
TORSI:
17).
(page 4-17). REAR BRAKE 2,6 N·m (0,27 kgf·m; 1,9 lbf·ft)
PEDAL LOCK
KNOB STOPPER
NUT
[1] [4] [3]

[2]
[6]
[5]
[7]
SEAT
Unlock
Buka and open dan
penguncian the seat.
angkat seat.
Peganglah
Support seat Lepaskan
the seat Remove the kedua
twomur
nuts[1]
[1]dan
andseat
seat[2].
[2].
se wakturemoving
while melepaskan
the
nuts. Installation is inadalah
Pemasangan the reverse orderurutan
dalam of removal.
terbalik dari
nuts.
pelepas an.
[2] [1]
3-16
LUGGAGE BOX
Remove sebagai
berikut:
[1] [3]/[4]
- –Starter relay
Starter relay(hal. 18-10)
(page 18-10)
- –Baterai (hal. 16-6)
Battery (page 16-7) [2]
- –Seat (hal.
Seat 3-16)
(page 3-16)
- –Center
Centerc over (hal.
cover 3-14).
(page 3-14)
Lepaskan
Release thefusefuse
boxbox
[1][1]dari luggage
from box [2]
the luggage boxseperti
[2] as
diperlihatkan.
shown.
Remove ketiga
Lepaskan the three bolts
baut [3] and
[3] dan collars
collars [4]. [4].
Raise luggage
Angkat the luggage
boxbox whilemenarik
sambil pulling keluar
out thebattery
battery wire
wire
harness[5].
harness [5].
Alurkan wire harness
Route Installation is inadalah
the wire Pemasangan the reverse orderurutan
dalam of removal.
terbalik dari
harnesses (hal. 1- pelepas an.
14).
(page 1-14).
Hati-hati agar tidak
Be careful not to
menjepit wire harness
pinch the wire
antara luggage box
harness
danbetween
rangka.
the luggage box and
frame.
[5]
LEFT CRANKCASE REAR COVER

Remove kedua
Lepaskan the twobaut
bolts[1].
[1].
[1]
Openk ickstarter
Buka the kickstarter
arm [2]arm dan [2] and remove
lepaskan thecase
left crank left
crankcase
rear rear cover [3].
cover [3].
Installation is inadalah
dalam of removal.
terbalik dari
pelepas an.
[3]
[2]
3-17
PASSENGER FOOTPEG HOLDER
LEFT
SISI SIDE
KIRI
Remove the
Lepaskan following:
- –Mur [1]
Nut [1]
- –Baut
Bolt[2][2]
- –Left passenger
Left passenger footpeg holder
footpeg [3][3]
holder
Pemas anganis inadalah
Installation dalam
of removal. dari
pelepasan.
[2] [3]
SISI KANAN
RIGHT SIDE
Remove the
Lepaskan following:
- Exhaust pipe/muffler (hal. 3-20)
– Exhaust pipe/muffler (page 3-20)
- –Mur [1][1]
Nut
- –Right passenger
Right passengerfootpeg
footpegholder [2][2]
holder
Pemasangan
of removal. dari
pelepas an.
[2]
DRIVE CHAIN COVER

Remove left
Lepaskan thepassenger
bolt [1] and drive
footpeg chain
holder cover
(hal. 3-18).[2] by
releasing its tab [3] from the slot [4] on the swing arm. [2]
Lepaskan baut [1], collars [2], rubbers [3] dan baut [3]
Installation
khusus [4]. is in the reverse order of removal.
Lepaskan upper c hain case [5] dan lower chain case [6]
dengan melepaskan s ebagai berikut:
- Dua tabs [7] pada lower chain case dari slots [8] pada
upper c hain c ase.
- Alur2 [9] dari swingarm [10]
Pemasangan adalah dalam urutan terbalik dari
pelepas an.
[4] [1]
3-18
REAR FENDER
Lepaskan sebagai
Remove the berikut:
following:
- –Rear combination
Rear combinationlight unit
light (hal.
unit 19-8)
(page 19-9)
- –Body cover (hal. 3-13).
Body cover (page 3-13)
Release the
Lepaskan main
main wirewire harness
ha rness [1] from
[1] dari thewire
keti ga three wire
guides
guides [2].
[2].
Remove kedua
Lepaskan the twobaut
bolts
[3],[3], three
ti ga bautspecial
khususbolts [4] rear
[4] dan and
rear fender
fender [5]. [5].
Remove the
Alurkan wire harness Lepaskan spring
spring [6], [6], retainer
retainer [7] and
[7] dan keykey cylinder
cylinder [8]. [8].
dengan benar (hal. 1- Installation is in the reverse order of removal.
Route the wire Pemasangan adalah dal am urutan terbalik dari
14).
harness properly pelepasan.
(page 1-14).
[1] [2]
[3]
[5]
[6]
[7]
[4]
[8]
FOOTPEG BAR
FOOTPEG REMOVAL/INSTALLATION
BAR
Support the footpeg Remove the front two bolts [1] and skid plate [2]
bar while removing Lepaskan dua baut [2] pada s isi depan dan skid plate
Remove the rear two bolts [3], washers [4] and footpeg
the bolts. [2]. [1]
bar [5] while depressing the rear brake pedal [6].
Peganglah footpeg Lepaskan dua baut [3] pada sisi belakang, washers [4]
Installation
bar sementara dan footpegisbar
in the
[5]reverse order menekan
sementara of removal.rear brake
melepaskan bolts. pedal [6].

pelepas an.
[2]
[6] [3]/[4] [5]
3-19
EXHAUST PIPE/MUFFLER
PELEPASAN
REMOVAL
Remove the
Lepaskan exhaust
mur-mur pipe joint
exhaust pipenuts
joint [1].
[1].
[1]
Remove the
Lepaskan following:
sebagai berikut: [3]/[4] [2]
- –Baut pemasangan
Muffler mountingmuffler
bolt [1][1]
-–MurMuffler
pemasangan
mounting muffler
nut [2][2]bydengan
holdingmenahan baut [3]
the bolt [3]
- –Baut
Boltdan
andwasher
washer[4][4]
- –Exhaust
Exhaustpipe/muffler [5][5]
pipe/muffler
[5] [1]
Lepaskan
Remove thegasket [1] [1]
gasket darifrom
lubang pembuangan
the exhaust port ofpada
the
cylinder
cylinderhead.
head.
[1]
PEMASANGAN
INSTALLATION
EXHAUSTPIPE
EXHAUST PIPESTUD
STUDBOLT
BOLT
Thread
Pas ang duatwo nuts
mur to the baut
pada stud sbolt
tud anddan tighten them
kencangkan
together,
mereka then
satu use lain,
sama a wrench on them
kemudian to turnkunci
pakailah the stud
pas
bolt out.
untuk memutar baut stud keluar.
Install
Pas ang and
dantighten new stud
kencangkan bolts
baut studinto the pada
baru cylinder head
cylinder
to the
head specified
dengan torsitorque.
yang ditentukan.
TORQUE: 11 N·m (1.1 kgf·m, 8 lbf·ft)
TORSI: 11 N.m (1,1 kgf.m; 8 lbf.ft)
After tightening
Setelah the stud bolts,
mengencangkan check periksa
baut stud, that the bahwa
length 29,5 ± 1,0 mm
from thedari
panjang boltkepala
head tobaut
the cylinder head surface
ke permukaan is within
cylinder head
specification.
adalah s esuai dengan spesifikasi.
3-20
Selalu ganti
Always the Pas
gasket
replace angagasket
Install baru pada
new gasket lubang
into the pembuangan
exhaust port of thegas dari
cylinder
de ngan yang
gasket with abaru. head. head.
new cylinder
one.
[1]
Tempatkan exhaust
Set the exhaust pipe/muffler
pipe/muffler [1][1]
anddan pasang
install the washer
washer
COLLAR [2]
[2], baut
[2], bolt [3],
[3], mur
muffler mounting muffler
pemasangan nut [4] [4]
anddanmuffler
baut [3]
pemasangan
mounting boltmuffler
[5] but[5]
dotetapi janganthem.
not tighten kencangkan dulu.
Install
Pas ang and
dan tighten the exhaust
kencangkan pipe
mur-mur joint nuts
exhaust pipe[6]joint
to the
[6]
specified
dengan torque.
torsi yang ditentukan.
TORQUE:
TORSI: 27 27
N.mN·m
(2,8(2.8 kgf·m,
kgf.m; 20 20 lbf·ft)
lbf.ft)
Tighten the baut
Kencangkan muffler mounting
pemas anganbolt [6]. [6].
muffler RUBBER BUSH
Hold the
Tahan bolt
baut danand tighten themur
kencangkan muffler
pemasmounting
angan nut.
muffler. [4]
After installation, inspect the exhaust system for leaks. PASSENGER
Setelah pemasangan, periksalah sistem pembuangan
FOOTPEG HOLDER
gas terhadap kebocoran.
[1] [5]
[6]
3-21
CATATAN
4. PERAWATAN
SERVICE
KETER INFORMATION
ANGAN ·····························4-2
SERVIS .............................. 4-2 DRIVE BELT .............................................
··············································· 4-14
4-14
JADWAL PER AWATAN

MAINTENANCE .............................. 4-4
SCHEDULE························4-4 MINYAKFLUID
BRAKE REM........................................... 4-14
············································ 4-14
SALURAN B AHAN B AK AR ........................ 4-5

FUEL LINE·····················································4-5 KEAUSAN
BRAKE BRAKE SHOES/PAD
SHOES/PADS S ......... 4-15
WEAR ··················· 4-15
CARA KERJA THROTTLE .......................... 4-5 SISTEM REM............................................ 4-15
THROTTLE OPERATION······························4-5 BRAKE SYSTEM ········································ 4-15
AIR CLEANER ............................................. 4-6 BRAKE LIGHT SWITCH .......................... 4-16
AIR CLEANER···············································4-6 BRAKE LIGHT SWITCH ····························· 4-16
CRANKCASE BREATHER .......................... 4-6 CARA KER JA BRAKE LOCK ................. 4-17
CRANKCASE BREATHER ···························4-6 BRAKE LOCK OPERATION ······················ 4-17
BUSI .............................................................. 4-7 PENYETELAN ARAH SINAR
SPARK PLUG················································4-7 LAMPU BESAR
HEADLIGHT AIM........................................ 4-18
········································ 4-18
JARAK RENGGANG KLEP ........................ 4-8
VALVE CLEARANCE····································4-8 SIDESTAND ················································
SIDESTAND ............................................. 4-18
4-18
OLI MES ....................................................... 4-9
SUSPENSI................................................ 4-18
ENGINE OIL
ENGINE OIL STR
··················································4-9
AIN ER SCREEN ............. 4-10 SUSPENSION ············································· 4-18
MUR, BAUT, PENGIK AT ......................... 4-19
ENGINE OIL
PUTARAN STSTRAINER SCREEN ·············4-10
ASIONER MESIN.................. 4-10 NUTS, BOLTS, FASTENERS ····················· 4-19
RODA/BAN ............................................... 4-20
ENGINE
DRIVE IDLE
CH SPEED ·································4-10
AIN............................................... 4-11 WHEELS/TIRES ·········································· 4-20
BANTALAN KEPALA KEMUD I............... 4-21
DRIVE CHAIN··············································4-11 STEERING HEAD BEARINGS ··················· 4-21
4-1
PERAWATAN
KETERANGAN SERVIS
SERVICE INFORMATION
MAINTENANCE
UMUM
GENERAL
• Letakkan sepedamotor di atas tanah mendatar sebelum memulai sesuatu pekerjaan.
• Place the motorcycle on a level ground before starting any work.
•• Bensin sangat
Gasoline mudahflammable
is extremely terbakar dananddapat meledak
is explosive di bawah
under kondisi
certain tertentu.
conditions.
•• Bekerjalah
Work di tempat
in a well yang
ventilated bervSmoking
area. entilasi baik. Merokok
or allowing atau or
flames memperbolehkan
sparks in the worklidah apioratau
area percikan
where api di tempat
the gasoline kerja
is stored canatau
causedi
atempat
fire or dimana
explosion.bensin disimpan dapat menyebabkan kebakaran atau ledakan.
•• The
Gas exhaust
pembuangancontainsmengandung gas karbon
poisonous carbon monoxidemonoksida beracun
gas that may causeyang dapat
loss of menghilangkan
consciousness kesadaran
and may dan akhirnya
lead to death. Run the
menyebabkan
engine in and openkematian.
area or Jwith
alankan mes inevacuation
an exhaust di tempatsystem
terbuka atau
in an di tempat
enclosed area. tertutup yang dilengkapi dengan sistem
pengeluaran gas pembuangan sepedamotor.
SPESIFIKASI
BAGIAN SPESIFIKASI
Jarak main bebas throttle grip 2 – 6 mm
Busi Standard CPR6EA-9S (NGK) U20EPR9S (DENSO)
Untuk berkendaraan lama pd kecepatan tinggi CPR7EA-9S (NGK) U22EPR9S (DENSO)
Jarak renggang busi 0,80 – 0,90 mm
Kapasitas oli mesin Pada penggantian periodik 1,0 liter
Pada pembongkaran 1,2 liter
Oli mesin yang dianjurkan AHM-OIL MPX1 4T 10W-30 SJ JASO MA
Jarak renggang klep IN/EX (masuk/buang) 0,10 mm
Drive chain Size – link RK 420SL – 102RJ
DID 420AD – 102RB
Kekenduran 30 – 40 mm
Panjang drive chain pada 41 pins (40 links) 508 mm
Lebar drive belt Batas servis: 18,0 mm
Brake fluid yang dianjurkan DOT 3 atau DOT 4
Jarak main bebas brake pedal 20 – 30 mm
Jarak main bebas rear brake pedal lock arm 1,0 – 2,0 mm
Ukuran ban Depan 70/90-17 M/C 38P
Belakang 80/90-17 M/C 50P
Merek ban IRC Depan NF63B Z
Belakang NR78Y
Tekanan udara ban Pengendara saja Depan 175 kPa (1,75 kgf/cm2; 25 psi)
dingin Belakang 225 kPa (2,25 kgf/cm2; 33 psi)
Pengendaran dan pem- Depan 175 kPa (1,75 kgf/cm2; 25 psi)
bonceng Belakang 280 kPa (2,80 kgf/cm2; 41 psi)
Kedalaman minimum alur ban Depan Sampai ke indikator
Belakang Sampai ke indikator
TORSI PENGENCANGAN
Mur penguncian throttle cable 3 N.m (0,31 kgf.m; 2,2 lbf.ft) sisi throttle body
Throttle cable lock nut (throttle body side) 3 N·m (0.31 kgf·m, 2.2 lbf·ft)
Busi 16 N.m (1,6 kgf.m; 12 lbf.ft)
Spark plug
Mur penguncian sekrup penyetelan klep
16 N·m (1.6 kgf·m, 12 lbf·ft)
9 N.m (0,92 kgf.m; 6,6 lbf.ft) Semprotkan oli mes in ke ulir dan
Valve adjusting screw lock nut 9 N·m (0.92 kgf·m, 6.6 lbf·ft) Applypermukaan
engine oil duduk.
to the threads and seating
Baut pembuangan oli mes in 24 N.m (2,4 kgf.m; 18 lbf.ft) surface.
Engineair
Sekrup oilcleaner
drain bolt
housing cover 24 N·m (2.4 kgf·m,
1,1 N.m 18 lbf·ft)
(0,11 kgf.m; 0,8 lbf.ft)
Air penguncian
Mur cleaner housing
rear cover
brake screw
pedal lock cable 1.1 N·m
3 N.m(0.11
(0,31kgf·m, 0.82,2
kgf.m; lbf·ft)
lbf.ft)
Rear brake
Jari-jari roda pedal lock cable lock nut 3 N·m
3,2(0.31
N.m kgf·m, 2.2 lbf·ft)
(0,33 kgf.m; 2,4 lbf.ft)
Rear
Mur axlebelakang
poros nut 59 N·m (6.0 (6,0
59 N.m kgf·m, 44 lbf·ft)
kgf.m; 44 lbf.ft) U-nutU-nut
4-2
PERAWATAN
TOOLS
Tappet adjusting wrench, ( □3 )
07708-0030400
4-3
PERAWATAN
MAINTENANCE SCHEDULE
Perform the Pre-ride inspection in the Owner’s Manual at each scheduled maintenance period.
I: Inspect and Clean, Adjust, Lubricate or Replace if necessary. C: Clean. R: Replace. A: Adjust. L: Lubricate.
The following items require some mechanical knowledge. Certain items (particularly those marked * and **) may require more
technical information and tools. Consult an authorized Honda dealer.
FREQUENCY WHICHEVER ODOMETER READING (NOTE 1)
COMES FIRST X1,000 km 1 4 8 12 REFER TO
X1,000 mi 0.6 2.5 5 7.5 PAGE
ITEMS Months 6 12 18
* FUEL LINE I I I 4-5
* THROTTLE OPERATION I I I 4-5
AIR CLEANER NOTE2 EVERY 16,000 km (10,000 mi) R 4-6
CRANKCASE BREATHER NOTE3 C C C 4-6
** SPARK PLUG I R I 4-7
** VALVE CLEARANCE I I I I 4-8
ENGINE OIL R R R R 4-9
* ENGINE OIL STRAINER SCREEN C 4-10
** ENGINE IDLE SPEED I I I I 4-10
DRIVE CHAIN EVERY 1,000 km (600 mi) I, L 4-11
* DRIVE BELT EVERY 8,000 km (5,000 mi) I,
4-13
EVERY 24,000 km (15,000 mi) R
BRAKE FLUID NOTE4 I I I 4-14
BRAKE SHOES/PADS WEAR I I I 4-14
BRAKE SYSTEM I I I I 4-15
* BRAKE LIGHT SWITCH I I I 4-16
* BRAKE LOCK OPERATION I I I I 4-16
* HEADLIGHT AIM I I I 4-17
SIDESTAND I I I 4-17
* SUSPENSION I I I 4-18
* NUTS, BOLTS, FASTENERS I I 4-19
** WHEELS/TIRES I I I I 4-19
** STEERING HEAD BEARINGS I I 4-20
* SHOULD BE SERVICED BY AN AUTHORIZED Honda DEALER, UNLESS THE OWNER HAS PROPER TOOLS AND SERVICE
DATA AND IS MECHANICALLY QUALIFIED.
** IN THE INTEREST OF SAFETY, WE RECOMMEND THESE ITEMS BE SERVICED ONLY BY AN AUTHORIZED Honda
DEALER.
Honda recommends that an authorized Honda dealer should road test your motorcycle after each periodic maintenance is carried
out.
NOTES:
1. At higher odometer readings, repeat at the frequency interval established here.
2. Service more frequently when riding in unusually wet or dusty areas.
3. Service more frequently when riding in rain or at full throttle.
4. Replace every 2 years. Replacement requires mechanical skill.
4-4
PERAWATAN
FUEL LINE
Remove the
Lepaskan following:
sebagai berikut:
Sisi injector: Sisi fuel pump:
- –Left body cover (hal.
Left body cover (page 3-13)
3-13).
- Fuel pump cover (hal. 6-23)
– Fuel pump cover (page 6-23)
Periksa
Check fuel (saluran
line line
the fuel bahan
[1] for bakar) [1]damage
deterioration, terhadap
or
pemburukan
leakage. kondisi, kerusakan atau kebocoran.
Ganti fuel the
Replace bila line
line fuel perlu.
if necessary.
Periksa
Check the daerah pemasangan
fuel pump mounting area
fuel forpump terhadap
leakage.
kebocoran.
Replace
Ganti the packing
fuel pump fuel pump packing
bila perlu if necessary
(hal. 6-30).
(page 6-31).
Pas ang parts yang dilepaskan.
Install the removed parts.
[1] [1]
THROTTLE OPERATION
Periksa
Check terhadap pemburukanorkondisi
for any deterioration damage atau kerusakan
to the throttle
cable.throttle
pada Check cable.
the throttle grip throttle
Periksa for smooth
grip operation.
terhadap
Check thatcara
kelancaran the kerja.
throttlePeriksa
opens bahwa
and automatically closes
throttle membuka
2 – 6 mm
in allmenutup
dan steering positions.
secara otomatis pada s emua posisi
kemudi.
If the throttle grip does not return properly, lubricate the
throttle
Jika cable,
throttle gripand overhaul
(putaran gasand lubricate
tangan) tidakthekembali
throttle
grip housing.
dengan benar, lumasi throttle cable, dan bongkar dan
lumasi throttle
For cable grip housing
lubrication: (rumahthe
Disconnect putaran gas
throttle tangan).
cable at its
upper end. Thoroughly lubricate the cable
Untuk pelumasan cable: Lepas kan throttle cable pada and its pivot
point atasnya.
ujung with a commercially
Lumasi secara available cable lubricant
menyeluruh cable danor a
lightweight oil.
titik engselnya dengan cable lubricant (pelumas kabel)
yang
If thedapat
Reusing a dibeli
throttle gripdistill
pasaran
does atau dengan
not return oli ringan.
properly, replace
the throttle cable.
damaged,
Pemakaian k embaliJika throttle grip tetap tidak dapat kembali dengan
abnormally bent or
throttle cable With the
benar,
yang engine
gantilah idling,cable.
throttle turn the handlebar all the way to
kinkedrusak,
throttle cable
the right and left to ensure that the idle speed does not
bengkok
can prevent
secara Sementara
proper
change. If idle
tidak normal mesin
speed berputar stasioner,
increases, check putarlah
the throttle grip
throttle
atau operation
te rtekuk handlebar
dapat (stang stir) seluruhnya
freeplay and throttle cable connection. ke kanan dan kiri
and untuk memastikan bahwa putaran stasioner tidak
may leadc ara
me nrintangi to a
kerjaloss
throttle MeasureJika
yang
of throttle
berubah. theputaran
throttle stasioner
grip freeplay
naik, at the throttle
periksa grip
jarak main
benar
control while flange.
dan riding.
dapat
bebas throttle grip dan sambungan throttle cable.
mengakibatkan
kehilangan kendali Ukur FREEPLAY:2
jarak main– 6 mm (0.1
bebas – 0.2grip
throttle in) pada throttle grip
atas throttle pada flange.
waktu pengendaraan. Throttle grip freeplay can be adjusted at lower end of [3]
the throttle
JARAK MAIN cable [1]. 2 – 6 mm
BEBAS:
Loosen the lock nut
Jarak main bebas throttle[2], turn
gripthe adjuster
dapat [3] pada
disetel as required
ujung
and tighten the lock nut
bawah dari throttle cable [1]. to the specified torque while
holding the adjuster.
Longgarkan mur pengunci [2], putar adjus ter [3]
sebanyak
TORQUE:diperlukan
3 N·m (0.31dan kenc2.2
kgf·m, angkan
lbf·ft) mur pengunci
dengan torsi yang ditentukan s ementara menahan
Recheck the throttle operation.
adjuster.
Replace3 any
TORSI: N.mdamaged parts,
(0,31 kgf.m; if necessary.
2,2 lbf.ft)
Periksa kembali cara kerja throttle.
Gantilah parts yang rusak, bila perlu.
[1] [2]
4-5
PERAWATAN
AIR CLEANER
CATATAN:
• Vis cous paper element tidak dapat dibersihkan oleh
karena element mengandung perekat debu.
• The viscous paper element cannot be cleaned
• J ika sepedamotor
because the element dipakai
containsdi a daerah yang luar
dust adhesive.
•biasanya basah atau
If the motorcycle berdebu,
is used akanwet
in unusually diperlukan
or dusty
pemeriksaan yang lebih sering.
areas, more frequent inspections are required.
Lepaskan
Remove sekrup2 [1] dan
the screws air cleaner
[1] and housing
air cleaner [2].
covercover
housing
Lepaskan dan buanglah air cleaner element [3] sesuai [1]
[2].
dengan jadwal perawatan (hal. 4-4).
Remove and discard the air cleaner element [3] in
Ganti
accordance setiap
elementwith waktu jika ia luar
the maintenance biasa(page
schedule kotor 4-4).
atau
rusak.
Replace the element any time if it is excessively dirty or
Pas ang parts yang dilepaskan dalam urutan terbalik dari
damaged.
pelepas an.
Install
Make sure the seals Pas tikanthe removed
bahwa parts ditempatkan
seals telah in the reverse
denganorder
benarof
removal.
are properly pada alur pada air cleaner housing dan cover.
positioned in the
grooves on air
TORSI:
cleaner housing AIR CLEANER HOUSING COVER SCREW:
and cover. 1.1 N·m (0.11 kgf·m, 0.8 lbf·ft)
[2] [3]
CRANKCASE BREATHER
CATATAN:
Servis lebih sering apabila sepedamotor dijalankan
Service more frequently when ridden in rain, at full
dalam hujan, pada gas penuh, atau setelah
throttle, or after the motorcycle is washed or overturned.
sepedamotor dicuci atau terbalik. Lakukan s ervis jika
Service if the deposit level can be seen in the drain cap.
tinggi permukaan endapan dapat terlihat di dalam drain
Check the crankcase breather drain cap [1].
cap.
[2]
If deposits has collected, remove the clip [2] and
Periksa
crankcasecrankcas e breather
breather drain cap [1].
drain cap.
Jika endapan2
Drain telahthe
deposits into terkumpul, lepaskan clip [2] dan
suitable container.
crankcase
Install thebreather
crankcase drain cap. drain cap and clip.
breather
Buanglah endapan2 ke dalam penampung yang sesuai.
Pas ang c rankc ase breather drain cap dan clip.
[1]
Lepaskan left body cover (hal. 3-13).
Remove the left body cover (page 3-13).
Periksa crankc ase breather hose [1] terhadap
pemburukan kondisi, kerusakan
Check the crankcase atau [1]
breather hose kebocoran.
for deterioration,
damage or leakage.
Pas ang parts yang dilepaskan.
Install the removed parts.
[1]
4-6
PERAWATAN
SPARK PLUG (BUSI)
PELEPASAN
REMOVAL
Disconnect
Lepaskan the plug
spark sparkcap
plug
[1].cap [1]. [2]
Clean around
Bersihkan Remove the
the Lepaskan
di sekitar busispark
[2]. plug [2].
dasar busi
spark dengan
plug base
Inspect or replace as described in the maintenance
udara dari
with compressed air Periksa atau ganti seperti diuraikan pada jadwal
kompressor sebelum schedule (page
perawatan 4-4).
(hal. 4-4).
before removing the
melepaskan
plug and makebusi sure
dan
pastikan bahwa
no debris is allowed
kotoran tidak akan
to enter the
memasuki ruang
combustion
pembakaran.
chamber.
[1]
PEMERIKSAAN
INSPECTION
Bersihkan
Clean theelektrode-elektrode busi with
spark plug electrodes dengan sikat
a wire kawat
brush or
atau [2]
special plugplug
special cleaner.
cleaner.
Inspectsebagai
Periksa the following:
berikut:
- Insulator [1] terhadap retak-retak atau kerusakan.
– Insulator [1] for cracks or damage
- –Center
Centerelectrode
electrode[2][2]dan
andside electrode[3]
sideelectrode [3] terhadap
for wear,
keaus an,or
fouling pengotoran
discolorationatau perubahan warna.
Selalu pakai busi Ganti busithe
Replace bilaspark
perlu.plug if necessary.
yang dite ntukan
untuk use the BUSI
sepedamotor
Always YANG DIANJURKAN:
RECOMMENDED SPARK PLUG:
ini. Standard:
specified spark plug Standard: NGK:NGK: CPR6EA-9S
CPR6EA-9S
on this motorcycle. DENSO: U20EPR9S
DENSO: U20EPR9S
Untuk pengendar aan lamaN NGK: CPR7EA-9S
For extended highNGK: CPR7EA-9S
pada kecepatan tinggi: DENSO: U22EPR9S
speed riding: DENSO: U22EPR9S [1] [3]
Ukur jarak renggang busi antara center dan side
Measure dengan
electrodes feeler
the spark pluggauge (voeler). the center and
gap between
side electrodes with
JARAK RENGGANG BUSI: a feeler gauge.
0,80 – 0,90
SPARK mmGAP:
PLUG
Bila perlu, s etelmm
0.80 – 0.90 jarak renggang
(0.031 – 0.035busi
in) dengan menekuk
side electrode (elektrode samping) dengan hati-hati. 0,80 – 0,90 mm
If necessary, adjust the gap by bending the side
electrode carefully.
INSTALLATION
PEMASANGAN
Install
Pas ang and
danhand
kenctighten
angkanthe spark
busi [1] plug [1] to
dengan the cylinder
tangan pada [1]
head, then
cylinder head,tighten thekencangkan
kemudian spark plug busi
to the specified
dengan torsi
torque.
yang ditentukan.
TORQUE:
TORSI: 16 N·m
16 N.m (1,6(1.6 kgf·m,
lbf.ft)
Sambungkan
Connect the spark
spark plug cap [2].
plug cap [2].
[2]
4-7
PERAWATAN
JARAK RENGGANG KLEP
PEMERIKSAAN
INSPECTION
• • Inspect
Periks a and
dan adjust
setel the
jarakvalve
renggang klepwhile
clearance dengan
the
engine is coldkeadaan
mesin dalam (below 35°C/95°F).
dingin (di bawah 35 C)
o [2]
• • Check
Periks athe engine
putaran idle speed
s tasioner mesin(page
(hal.4-10)
4-10)after the
setelah
valve clearance
pemeriksaan inspection.
jarak renggang klep.
Remove the
Lepaskan following:
sebagai berikut:
- – Left
Left lower
lower side
side cover (hal. 3-12)
cover (page 3-12)
- – Cylinder head cover (hal. 8-6)
cover (page 8-6) [3]
Gerakkan
Move the kkickstarter
ickstarter pedal [1]little
pedal [1] sedikit demi
by little, in asedik
quickit,
dengan
motion.gerakkan cepat.
Tempatkan
Position thecamcam sprocket so sehingga permukaan
that the cylinder headatas
top
surface head
cylinder comes berada
betweenantara garis2
the "ll" lines“ll”
[2][2]
anddan"l" garis “l”
lines [3]
onpada
[3] the sprocket.
s procket.
Make
Pas sure
tikan the piston
bahwa pistonisberada
at TDCpada(Top TDC
Dead (Top
Center) on
Dead
the compression
Center = Titik Matistroke.
Atas) pada langkah kompressi.
This
Pos isiposition candiketahui
ini dapat be obtained by confirming
dengan that there is
mengkonfirmasikan
slack inada
bahwa thekerenggangan
rocker arms. If pada
there rocker
is no slack,
arms move the
. Apabila
kickstarter
tidak pedal again until
ada kerenggangan, the correct
gerakkan position
kickstarter is
pedal
obtained.
sekali lagi sampai posisi yang benar diperoleh.
[1]
Periksa masing-masing
Check each jarakbyrenggang
valve clearance inserting aklep
feelerdengan
gauge
memasukkan sebuah
[1] between the valve adjusting screw[1]
feeler gauge andantara sekrup
valve stem.
penyetelan klep dan valve s tem.
VALVE CLEARANCE:
JARAK
IN/EX:RENGGANG KLEP:
0.10 mm (0.004 in)
IN/EX: 0,10 mm
[1]
PENYETELAN
ADJUSTMENT
Setel
Adjustdengan melonggarkan
by loosening mur pengunci
the valve adjusting s ekrup
screw lock nut
penyetelan klep [1} [2] [1]
[1] and turning thedan memutar
adjusting screws ekrup penyetelan
[2] until there is[2]
a
sampai ada on
slight drag tahanan sedikit
a feeler gaugepada
[3]. feeler gauge [3].
Apply engineolioilmes
Semprotkan to in
the pada
lock nut
ulir threads and seating
mur pengunci dan
surface. duduk.
permukaan
Hold the
Tahan adjusting
sekrup screw
penyetel usingmenggunakan
dengan the special tool and
special
tighten
tool dan the lock nut to mur
kencangkan the specified
penguncitorque.
dengan torsi yang
ditentukan.
TOOL:
[4] Valve adjusting wrench
TOOL: 07708-0030400
[4] Valve adjusting wr ench 07708-0030400
TORQUE: 9 N·m (0.92 kgf·m, 6.6 lbf·ft)
TORSI: 9 N.m (0,92 kgf.m; 6,6 lbf.ft)
Recheck the valve clearance.
Periksa jarak renggang klep. [4] [3]
Pas ang s ebagai berikut:
- –CyCylinder head
linder head covcover (page
er (hal. 8-7)8-7)
- –Left
Left lower
lower side
side cover
c over (page
(hal. 3-12)3-12)
4-8
PERAWATAN
ENGINE OIL
PEMERIKSAAN OLI MESIN
OIL LEVEL INSPECTION
Start the mesin
Hidupkan enginedan andbiarkan
let it idleberputar
for 3 – 5stasioner
minutes. selama
Stop
3-5 the engine and wait 2 – 3 minutes.
menit. [1]
Hold the
Matikan motorcycle
mesin in an 2-3
dan tunggu upright position.
menit.
Remove
Tahan the oil filler
sepedamotor cap/dipstick
pada posisi tegak.[1] and wipe oil from
the dipstick
Lepaskan oilwith a clean
filler cloth. [1] dan seka oli dari
cap/dipstick
Insert the
dipstick oil filler
dengan kain cap/dipstick
bersih. without screwing it in,
remove it oil
Masukkan andfiller
check the oil level.
cap/dipstick tanpa menyekrupnya ke
dalam,
If the lepaskan
level is belowdan periksa
or neartinggi permukaan
the lower oli. on the
level [2]
Jika tinggi permukaan berada di bawah ataulevel
dipstick, add the recommended oil to the upper [3].
dekat
dengan batas permukaan terendah [2] pada dipstick, [3]
tambahkan oli yang dianjurkan sampai ke batas
RECOMMENDED
permukaan ENGINE OIL:
teratas [3].
Honda "4-stroke motorcycle oil" or equivalent [2]
OLImotor
MESINoilYANG DIANJURKAN:
AHM-OIL MPX1 4T 10W-30
API classification: SG orSJ JASO MA
higher
(except oils labeled as energy conserving on the
Pasang oil filler cap/dipstick.
circular API service label)
Viscosity: SAE 10W-30
JASO T 903 standard: MA
Install the oil filler cap/dipstick.
ENGINE OILOLICHANGE
PENGGANTIAN MESIN
Panaskan
Warm up mesin.
the engine.
Matikan mesin, lepaskan dan seka [2]
Stop the engine, removeoilthe oilcfiller
filler cap/dipstick
ap/dipstick and
oliwipe
darioil dengan
from the
dipstick kain
dipstick bers
with a ih.
clean cloth.
Remove the
Lepaskan engine
engine oil oil drain
drain bolt[1][1]dan
bolt andssealing washer
ealing washer
[2].
[2].
Drain oil completely.
Keluarkan oli seluruhnya.
Install
Pas ang the engine
engine oil drain
oil drain bolt bolt with sebuah
dengan a new sealing
sealing
washer and
washer barutighten
dan itkencangkan
to the specified torque.torsi yang
dengan
ditentukan.
TORSI: 24 N.m (2,4 kgf.m; 18 lbf.ft) [1]
IsiFill the engine

mesin denganwith recommended
oli mesin engine oil.
yang dianjurkan. [1]
KAPASITAS
ENGINE OILOLI MESIN:
CAPACITY:
1,0
1.0liter
literpada
(1.1 US penggantian
qt, 0.9 lmpperiodik
qt) at draining
1,2 liter pada pembongkaran
1.2 liter (1.3 US qt, 1.1 lmp qt) at disassembly
Periksa
Check thatbahwa the O-ring [1]on
O-ring [1] pada
the oiloil filler
fillercap berada
capis in good
dalam kondisi
condition, andbaik dan gantilah
replace bila perlu.
it if necessary.
Pas ang the
Install oil filler cap/dipstick
oil filler cap/dipstick[2]. [2].
Pas tikansure
Make bahwa
theretidak
are ada kebocoran
no oil leaks. oli.
Periksa
Check tinggi permukaan
the engine oil leveloli(page
mesin4-9).
(hal. 4-9). [2]
4-9
PERAWATAN
ENGINE OIL STRAINER SCREEN
Remove clutch
Lepaskan the clutch cover
c over (hal.(page 10-18).
10-18).
[1]
Remove the
Lepaskan oil strainer
oil strainer screen
screen [1] [1]
danand clean it in
bersihkan non-
dalam
flammable
bahan or high
pelarut flash point
yang tidak solvent.
dapat terbakar atau
mempunyai titikstrainer
Install the oil api tinggi.
screen with its tapered side facing
theang
Pas crankcase side and
oil strainer thinner
screen edge sfacing
dengan isinya up as
yang
shown. menghadap ke sisi crankcase dan sisi yang
meruncing
lebih tipis
Install menghadap
the ke(page
clutch cover atas seperti
10-20).diperlihatkan.
Pas ang c lutch cover (hal. 10-20).
Sisi
crankcase
PUTARAN STASIONER MESIN

• • Periksa
Inspect putaran
the idlestasspeed
ioner after
setelahall semua
other bagian
engine
maintenancemesin
perawatan items lainnya
have been telahperformed
dijalankanand dan
are
within specifications.
adalah sesuai dengan spesifikasi.
• • Sebelum
Before checking
memeriks the idle speed,
a putaran inspectperiksalah
stasioner, following
items. sebagai berikut:
hal-hal
– No MIL blinking
- MIL tidak berkedip
– Spark plug condition (page 4-7)
- Kondisi busi (hal. 4-7)
– Air cleaner condition (page 4-6)
- Kondisi air cleaner (hal. 4-6)
• The engine must be warm for accurate idle speed
• Mes in harus dalam keadaan panas untuk
inspection.
• pemeriksaan
This system putaran stasioner
eliminates yangfor
the need akurat.
manual idle
• Sis tem ini meniadakan
speed adjustment. kebutuhan untuk penyetelan
putaran stas ioner dengan manual.
• Use a tachometer with graduations of 50 min-1-1 (rpm)
• Pakailah
or smaller tachometer dengan skala
that will accurately 50 menit
indicate a 50 (rpm)
min-1
atau lebih
(rpm) change. kecil yang dapat memperlihatkan dengan
-1
akurat perubahan sebesar 50 menit (rpm).
Support the motorcycle with its centerstand.
Letakkan
Warm upsepedamotor pada ten
the engine about minutes.
centerstand-nya.
Panaskan mestachometer
Connect the in selama kira-kira
and checksepuluh menit.
the idle speed.
Hubungkan SPEED:dan
tachometer
ENGINE IDLE periksa
1,400 ± 100putaran stasioner.
min-1 (rpm)
-1
PUTARAN
If the idle STASIONER
speed is out MESIN: 1.400 ± 100
of the specification, menit
check the
(rpm)
following:
Jika putaran stasioner tidak ses uai dengan spesifikasi,
• Throttle
periksalah operation
sebagai and throttle grip freeplay (page 4-
berikut:
• 5). kerja throttle dan jarak main bebas throttle
Cara
• grip
Intake air4-5).
(hal. leak or engine top-end problem (page 8-
5).
• Ada kebocoran udara masuk atau pers oalan pada
• IACV operation (page 6-37).
bagian atas mesin (hal. 8-5).
• Cara kerja IACV (hal. 6-36).
4-10
PERAWATAN
DRIVE CHAIN
CATATAN:
Jangan sekali-kali mem eriksa dan menyetel drive chain
Never inspect and adjust the drive chain while the
sementara mesin dalam keadaan hidup.
engine is running.
PEM ERIKS
DRIVE AAN SLACK
CHAIN KE KENDURAN DRIVE
INSPECTION
CHAIN
Support sepedam
Letakkan the motorcycle withcenters
otor pada its centerstand.
tand-nya.
Measure chain
Lepaskan the drive chain slack,
inspection on the
hole cap [1].chain run midway
between the sprockets.
Ukur kekenduran drive chain pada chain pada tempat
CHAIN SLACK:di30
ditengah-tengah – 40 sprockets.
antara mm (1.2 – 1.6 in)
KEKEND URA N CH AIN: 30 – 40 mm
Excessive chain slack, 50 mm (2.0 in)

or more, may damage the frame.
Kekenduran chain yang berlebihan, yaitu 50 mm atau
lebih, dapat merusak rangka.
Pasang chain inspection hole cap.
30 – 40 mm
ADJUSTMENT
PENYETELAN
Loosen the rear
Longgarkan mur axle nutbelakang
poros [1] and both
[1] lock
dannuts [2]. mur
kedua
pengunci [2]. [3]
Turn both drive chain adjusters [3] until the correct drive
chain slack
Putar keduais obtained.
drive chain adjusters [3] sampai
kekenduran drive chain yang tepat diperoleh.
[2] [1]
Make
Pas tikansure the front
bahwa end of
bagian both adjuster
depan platesadjuster
dari kedua [1] are
[1]
aligned
plates [1]with
telahthe same index
bertepatan lines
pada [2] on
garis the swingarm.
penunjuk [2] yang
sama pada swingarm.
[2]
4-11
PERAWATAN
Kencangkan mur axle
Tighten the rear porosnutbelakang
[1] to the[1] dengantorque.
specified torsi yang
ditentukan. [2]
Tighten the both drive chain adjusters [2] and lock nuts
Kencangkan kedua drive chain adjusters [2] dan mur
[3] securely.
pengunci [3] dengan erat.
Recheck the drive chain slack and free wheel rotation.
Periksa ulang kekenduran drive chain dan kebebasan
Check theroda.
perputaran rear brake pedal freeplay (page 4-15) and
adjust it if necessary.
Periksa jarak main bebas rear brake pedal (hal. 4-16)
dan setel bila perlu.
[3] [1]
CLEANING, LUBRICATION
PEMBERSIHAN AND
, PELUMASAN DAN
INSPECTION
PEMERIKSAAN
Letakkan
Support sepedamotor
the motorcyclepada
with centerstand-nya.
its centerstand.
Lepaskan
Remove the
drivechain case
chain (hal. 3-18).
(page
case 3-18).
If thedrive
Jika drive chain
chain becomes
menjadi extremely dirty, it should
sangat kotor, be
ia harus
removed and
dilepaskan dancleaned priorsebelum
dibersihkan to lubrication.
melumas inya.
Remove the
Lepaskan left cleft crankcase
rankcase rearrear cover
cover (hal.(page
3-17).3-17).
Carefully remove [1]
Lepaskan retainingtheclip
retaining clip [1] with
[1] dengan pliers.dengan
hati-hati
Remove the master link [2] and link plate [3], and
tang.
disconnect
Lepaskan the drive
master chain.
link [2] dan link plate [3], dan lepaskan
Remove the drive
sambungan drive chain. chain.
Keluarkan drive chain.
[2]
[3]
Bersihkan
Clean the chain with dengan pelarut yang
non-flammable or hightidak
flashdapat
point
Pelarut yang tidak dapat terbakar
solvent and
terbakar atauwipe it dry.
mempunyai titik api tinggi dan s eka
atau mempunyai titik api tinggi
Be sure
sampai the chain has dried completely before
kering.
lubricating.
Pas tikan bahwa chain telah mengering sama sekali
Inspect melumasinya.
sebelum the drive chain for possible damage or wear. Bersihkan
Replace
Periksa anychain
drive chain that has
terhadap damaged
kerusakan ataurollers, loose
keausan.
fitting links,
Gantilah or otherwise
chain appears unserviceable.
yang mempunyai rollers yang rusak,
Installing
links a new chain
yang terpasang on badly
dengan worn
longgar, atausprockets will
jika tampak
cause the new chain to wear quickly.
keadaannya tidak dapat diservis/diperbaiki lagi.
Inspect and replace
Pemasangan sebuahthe sprocket
chain baru as necessary.
pada sprockets yang
sangat aus akan mengakibatkan keausan dengan cepat Seka dan keringkan
pada chain baru.
Periksa dan ganti sprock et bila perlu.
Lumasi
Lubricate
drive drivedengan
thechain #80#80
chain with – 90
– 90 gear
gear atau
oil oil or drive
drive
Lumasi
chainlubricant
chain lubricant. Wipe off
(pelumas anyroda).
rantai excess oil oroli chain
Sekalah atau
lubricant.
chain lubricant yang berlebihan.
#80 – 90 Gear oir atau drive chain lubricant
4-12
PERAWATAN
Ukur jarak antara
Measure rangkaian
the distance yang aterdiri
between spandari 41 pins (40
of 41
links) dari
links) from titik pusat topin
pin center pinke titik bypusat
center pinsodengan
holding that all
memegangnya
links are straight.sedemikian sehingga s emua links
adalah lurus .
DRIVE CHAIN LENGTH (41 pins/40 links)
STANDARD: 508 mm (20.0 in) BATAS SERVIS: 518 mm
SERVICE LIMIT: 518 mm (20.4 in)
PEMERIKSAAN SPROCKET
SPROCKET INSPECTION
Inspect gigi-gigi
Periksa the drive drive
and driven sprocket
sprocket dan teeth
driv enforsprock
wear or
et
damage,keausan
terhadap replace atau
them kerusakan,
if necessary.
ganti bila perlu. KEAUSAN
Never use
Jangan a new drive
sekali-kali chain on
memasang worn sprockets.
sebuah drive chain baru
diBoth
ataschain and sprockets
sprockets yang aus. must be in good condition, or
the new
Baik replacement
chain chainkets
maupun sproc will wear
harusrapidly.
dalam keadaan
baik, atau chain pengganti yang baru akan mengalami
keausan dengan cepat. KERUSAKAN NORMAL
Install
Pas ang the drive
drive chain
chain pada onto the sprockets.
sprockets.
Install Arah pergerakan
Pas ang the
masmaster
ter linklink
[1] [1]
danand
linklink plate
plate [2]. [2]. drive chain
Install
Pas ang the retaining
retaining clip clip [3] with ujungnya
[3] dengan its open yangend opposite
terbuka
the directiondengan
berlawanan of chain travel.
arah pergerakan chain.
- –Left
Left crankcase
crankcase rear
rear cover
cover (page
(hal. 3-17)
3-17).
- –Chain
Chain case
case (page
(hal. 3-18)3-18)
[3]
Adjust
Setel the drive chain
kekenduran drive slack
chain(page 4-11).
(hal. 4-11).
[1]
[2]
DRIVE BELT (SABUK PENGGERAK)

Remove the
Lepaskan pulley
pulley cover
c over (hal.(page
10-7).10-7).
Check drive
the drive beltterhadap
[1] for retak-retak,
cracks, separation or [1]
Periksa belt [1] pemisahan
abnormal
atau keausan or excessive
tidak normal wear and
atau replace itdan
belebihan if necessary
ganti bila
(page
perlu 10-8).
(hal. 10-8).
4-13
PERAWATAN
Using the
Dengan suitable two flat
menggunakan duaplates,
pelatmeasure the drive
datar yang belt
sesuai,
[1] width
ukurlah as shown.
lebar drive belt seperti diperlihatkan.
SERVICE
BATAS LIMIT: 18,0
SERVIS: 18.0 mm
mm (0.71 in)
Ganti
Replace
drivethe jikabelt
drive
belt lebarnya kurang
if it is less thandari
thebatas servis
service limit
(page
(hal. 10-8).
10-8).
[1]
BRAKE FLUID
Spilled
Fluid yangfluid can damage
tertumpa painted, parts
h dap at merusak plasticyang
or rubber
dicat,
parts. dari
terbuat Place a rag
plastik atauover
karet.these partsparts
Tutupilah whenever the
ini dengan
system is serviced.
kain lap setia p kali siste m diservis.
CATATAN:
• • Jangan
Do not mix different typesbermacam-macam
mencampurkan of fluid, as they arefluid,not
compatible with each other.
oleh karena mereka tidak cocok satu sama lain.
• • Jagalah
Do not allow foreign2 material
a gar bahan asing tidak to enter
dapat the system
memasu ki
when filling the reservoir.
sistem sewaktu mengisi reservoir.
Turn the handlebar so that the reservoir is level and
Putar
checkhandlebar (stangfluid
the front brake stir)level
sehingga the sight pada
throughreservoir glass [1]
posisi
[1]. mendatar d an per iksa tinggi permukaan br ake
flu id mel alui kaca l ubang pengintaian [1].
When the front brake fluid level is near the "LOWER"
Sewaktu
level linepermukaan
[2], check thefront brake
brake wearmendekati
padfluid (page 4-14). gar is
permukaan
A low fluid “LOWER”
level may [2], per iksal
be due ah keausan
to wear brakepads.
of the brake pad
(hal. 4-15).
If the brake pads are worn, the caliper pistons are
Permukaan
pushed out,fluid and yang rendah for
this accounts dapat
a lowdi akibatkan oleh
reservoir level.
keausan
If the brake
brakepads
pads.areJika
notbrake and telah
wornpads a us, caliper
fluid level is low,
check the
pistons entire system
terdorong for leaks
keluar, dan (page 4-15).
ini mengakibatkan
menurunnya permukaan flu ida di dalam reservoir.
Jika br ake pads tida k aus dan permukaan fluid rendah,
periksalah seluruh si stem terhadap kebocoran (hal. 4-
15). [2]
BRAKE SHOES/PADS WEAR

FRONT
FRONTDISC DISC BRAKE
BRAKE PADS (BRAKE PADS
PADS
CAKRAM DEPAN)
Check the brake pads for wear.
Periksa brake pads ber hadap keausan.
Replace the brake pads if either pad is worn to the wear
limit groove
Gantilah [1]. pads jika salah satu pad tel ah aus
brake
sampai ke al ur batas keausan [1].
Always replace the For brake pad replacement (page 15-7).
Selalu
brake ganti
pads a set Un tuk penggantian brake pad (hal. 15-6)
asbrake
pads dalam even
to assure pasangan
disc
agar tekanan pada
pressure.
disc merata.
[1]
4-14
PERAWATAN
REARBRAKE
REAR BRAKE SHOES
SHOES (BRAKE SHOES
BELAKANG)
Check the wear indicator position when the brake pedal
is applied.
Periksa posisi indikator keausan sewaktu pedal rem [1]
If the indicator plate [1] aligns with the "" mark [2] on the
ditekan.
brake panel, inspect the brake drum (page 14-13).
Jika indicator plate [1] bertepatan dengan tanda " " [2]
If thebrake
pada brakepanel,
drumperiksalah
I.D. is within the drum
brake service limit,
(hal. replace
14-14).
the brake shoes (page 14-13).
Jika D.D. brake drum di bawah batas servis, gantilah [2]
brake shoes (hal. 14-14).
BRAKE SYSTEM
FRONT DISC
FRONT DISC BRAKE
BR AKE (REM CAKRAM
DEPAN)
Firmly apply the brake lever and check that no air has
Tekan
entered lever (handel rem) dengan kuat dan
the system.
brake [1]
periksa bahwa tidak ada udara yang telah memasuki
If tem.
sis the lever feels soft or spongy when operated, bleed
the air from the system (page 15-5).
Jika lever terasa lunak atau seperti spons sewaktu
Remove the handlebar front cover (page 3-5).
dijalankan, buanglah udara palsu dari sistem (hal. 15-5).
Inspect the brake hose [1] and fittings for deterioration,
Lepaskan
cracks and handlebar
signs of front cover (hal. 3-5).
leakage.
Tighten any loose fittings.
Periksa brake hos e (slang rem) [1] dan fittings
Replace hoses
(peralatan and fittings
pemasangan) as required.
terhadap pemburukan kondisi,
retak-retak dan tanda-tanda kebocoran.
Install the handlebar front cover (page 3-5).
Kencangkan fittings yang longgar.
Gantilah hoses dan fittings bila perlu.
Pas ang handlebar front cover (hal. 3-5).
REAR BRAKE
JARAK MAIN PEDALBEBAS FREEPLAY
REAR BRAKE
Measure the rear brake
PEDAL(PEDAL REMpedal freeplay
BELAK ANG) at the tip of the
brakejarak
Ukur pedal.
main bebas rear brake pedal pada ujung
brake pedal.
FREEPLAY:20 – 30 mm (0.8 – 1.2 in)
JARAK MAIN BEBAS: 20 – 30 mm
20 – 30 mm
Make sure the

Pastikan bahwacut- Setel jarak
Adjust the main
brake bebas
pedal freeplay dengan
by turning
brake pedal the memutar
adjusting
potongan
out of pada mur
the adjusting nutpenyetel
[1]. [1].
adjusting
nut nut duduk
is seated on the
Recheck the freeplay, then check and adjust the rear
pada joint
jointpin [2]. Periksa ulang jarak main bebas, kemudian periksa dan
pin[2].
brake
setel light
rear switch
brake (page
light 4-16).
switch (saklar lampu rem belakang
(hal. 4-16).
[1]
[2]
4-15
PERAWATAN
BRAKE LIGHT SWITCH
CATATAN:
• Front brake light switch (saklar lampu rem depan)
• The front brake light switch on the master cylinder
pada master cylinder tidak dapat disetel. Jika
cannot be adjusted. If the front brake light switch
penggerakan
actuation andfront brake brake light s witch
engagement are dannot
beroperasinya rem tidak sinkron, gantilah
synchronized, either replace the switch unit switch or the
unit atau partsparts
malfunctioning dari ofsistem yang tidak berfungsi
the system.
dengan baik.
• Adjust the rear brake light switch after the brake
• Setel rear brake
pedal freeplay light switch setelah penyetelan
adjustment.
jarak main bebas brake pedal.
Check that the brake light comes on just prior to the
brake actually being engaged. [1]
Tahan badan switch Periksa bahwa lampu rem menyala tepat sebelum rem
dan putar mur sendiri mulai beroperasi.
Hold the switch If the light fails to come on, adjust the brake light switch
penyetel.
body and turn the Jika[1] lampu tidakthe
by turning menyala,
adjusting setel
nutbrake
[2] solight
thatswitch [1]
the light
Jangan memutar dengan memutar mur penyetel [2] s ehingga lampu
adjusting
badan switch nut. comes on at the proper time.
sewaktu
Do menot the menyala pada wak tu yang tepat.
turnmur
mutar Recheck the brake light switch operation.
switch body while
penyetel. Periksa ulang cara kerja brake light switch.
turning the
adjusting nut.
[2]
CARA KERJA BRAKE LOCK

INSPECTION
CATATAN:
• Periksa cara kerja brake lock setelah jarak main
bebas
• Check rear brake lock
the brake pedal telah diperiksa
operation after thedan
reardisetel
brake
(hal.
pedal4-16).
freeplay is checked and adjusted (page 4-15).
Tekan
Depressrear
thebrake [1] [1]
pedalpedal
rear brake danandtahan
hold itke bawah,
down, then
kemudian tarik
pull the rear brake pedal lock knob [2].
rear brake pedal lock knob (tombol [2]
Mengunci:
penguncian
Release the pedal
rear rem belakang
brake pedal. [2].
Lepaskan
Check that thebrake
rear rear pedal.
wheel is locked completely.
Periksa bahwa roda belakang telah terkunci sama
Depress the rear brake pedal and hold it down, then
sekali.
press the lock knob while pushing the center button [3].
Checkrear
Tekan thatbrake
the rear wheel
pedal danistahan
unlocked.
ke bawah, kemudian
tekan lock knob sementara mendorong center button
[3].
Periksa bahwa penguncian roda belakang telah dibuka.
[1]
[3]
Membuka pengunci:
[1]
4-16
PERAWATAN
ADJUSTMENT
PENYETELAN
Remove the right body cover (page 3-13).
Lepaskan right body cover (hal. 3-13).
Before adjustment, Loosen the rear brake pedal lock cable lock nut [1]. [1]
Sebelum melakukan Longgarkan mur pengunci rear brak e pedal lock cable
that the Turn the adjuster [2] so that the play of the rear brake
make surepastikan
penyetelan, [1].
rear brake pedal pedal lock arm [3] is 1.0 - 2.0 mm (0.04 - 0.08 in) as
bahwa jarak main Putar penyetel [2] sehingga jarak main bebas dari rear
freeplay is adjusted
bebas rear shown.
brake brake pedal lock arm [3] adalah 1,0 – 2,0 mm seperti
properly
pedal disetel4- Tighten the lock nut to the specified torque while
telah(page
dengan baik (hal.15).
4-
diperlihatkan.
holding the adjuster.
16). Kencangkan mur pengunci dengan tors i yang
ditentukan
TORQUE:sementara
3 N·m (0.31menahan penyetel.
kgf·m, 2.2 lbf·ft)
[2]
After adjustment, check the rear brake lock operation
(page 4-16).
Setelah penyetelan,
Install the right bodyperiksa cara 3-13).
cover (page kerja rear brake lock 1,0 – 2,0 mm
(hal. 4-17).
Pas ang right body cover (hal. 3-13).
[3]
HEADLIGHT AIM
Place the
Letakkan motorcycle on
sepedamotor thetanah
pada level ground.
mendatar.
Adjust thearah
Setel headlight Adjust
sinar Setel the lampu
sinar headlight beam
besar vertically
dalam arah by loosening
vertikal the
dengan
beam besar
lampu as specified bolt [1] and moving
sesuai melonggarkan the dan
baut [1] headlight unit, then tighten
menggerakkan the
headlight
kebytentuan
local laws bolt.kemudian kenc angkan baut.
and unit,
me nurut
undang2 dan
regulations.
peraturan lokal.
[1]
SIDESTAND (STANDARD SAMPING)

Support sepedamotor
Letakkan the motorcycle withcenterstand-nya.
pada its centerstand.
Check sidestand
the sidestand spring [1] for damage or loss of [1]
Periksa spring [1] terhadap kerusakan atau
tension. tegangan.
hilangnya
Check sidestand
Periksa the sidestand [2] for freedom
[2] terhadap of an
kebebas movement and
pergerakan
lubricate the sidestand pivot if necessary.
dan lumasi engsel sides tand bila perlu.
Check the sidestand switch system:
Periksa sidestand switch system.
1.1.Tarik
Retract the sidestand.
sidestand ke atas. [2]
2.2.Hidupkan
Start themesin.
engine.
3.3.Gerakkan
Move thesidestand
sidestandpenuh
full down.
ke bawah.
4. Theseharusnya
4.Mesin engine should stop
mati as thesidestand
sewaktu sidestandditurunkan.
is lowered.
Jika ada persoalan
If there denganwith
is a problem sistem,
the periksalah sidestand
system, check the
switch (hal. switch
sidestand 19-16).(page 19-18).
4-17
PERAWATAN
SUSPENSION
SUSPENSI DEPAN
FRONT SUSPENSION
Periksa
Check cara kerja forks
the action of the(garpu)
forks bydengan menjalankan
operating the front
rem depan
brake anddan menekan suspensi
compressing the frontdepan beberapa
suspension kali.
several suspensi depan :
Periksa
times. kes eluruhan rakitan terhadap tanda-tanda
Check thekerusakan
kebocoran, entire assembly for signs
atau pengikat of leaks, damage
longgar.
or loose fasteners.
Parts suspensi yang Gantilah komponen-komponen rusak yang tidak dapat
longgar,
Loose,aus atau
worn or Replace damaged components which cannot be
diperbaiki.
rusak mempengaruhi
damaged repaired.
stabilitas dan
suspension parts Kencangkan s emua baut dan mur.
pengendalian atas Tighten all nuts and bolts.
impair motorcycle
sepedamotor. Untuk s ervis fork (hal. 13-11)
stability and control. For fork service (page 13-11).
REAR SUSPENSION
SUSPENSI BELAKANG
Rear shock absorber
Re ar shock
Check the absorber
action of(Sokbreker belakang)
the rear shock absorbers by Rear shock absorbers:
compressing them several times.
Periksa cara kerja rear shock absor ber s dengan
Check the
menekan entirebeberapa
mereka shock absorber
kali. assembly for signs of
leaks, damage
Periksa or loose
keseluruhan fasteners.
rakitan shock absorber terhadap
Tighten all nuts and bolts.
tanda2 kebocoran, kerusakan atau pengikat longgar.
For rearkan
Kencang shock absorber
semua service
baut dan mur.(page 14-21).
Un tuk servis rear shock absorber (hal. 14-21).
Swingarm
Swingarmbushing
bushing
Leta
Support the motorcyclepada
kkan sepedamotor with centerstand-nya.
its centerstand.
Swingarm bushings:
Periksa
Check terhadap
for worn swinga
swingarm bushingsyang
rm bushings aus dengan
by grabbing the
memegang
rear ends ofujung2 belakang
the swingarm dari swingarm
and attempting to movedan
the
mencoba
swingarmuntu
sidek to
menggerakkan
side. swingarm dari samping
ke samping.
Replace the swingarm bushings if any looseness is
notedswinga
Ganti (pagerm14-17).
bushings jika ada kel onggaran (hal. 14-
17).
4-18
PERAWATAN
NUTS, BOLTS, FASTENERS
Periksa bahwa
Check that semua nuts
all chassis baut anddanbolts
murarerangka telah
tightened to
dikencangkan dengan nilai torsi yang
their correct torque values (page 1-9). benar (hal. 1-9).
Periksa bahwa
Check that semua
all cotter pins, safety
cotter clips,
pins, hose clips,
safety clamps and
hose
clamps dan cable
cable stays berada
stays and
are in place padasecured.
properly tempatnya dan
telah terpasang dengan erat.
WHEELS/TIRES
WHEEL
WHEELBEAR ING (BANTALAN RODA)
BEARING
Depan:
Front:
Supportsepedamotor
Dukung the motorcycle securely
dengan kokohand
danraise the roda
naikkan front
wheellepas
off the ground. Front wheel bearings:
depan tanah.
Hold the
Tahan kakifork
fork leg and move
(garpu) the frontfront
dan gerakkan wheel sideways
wheel (roda
with force
depan) ke to see if thedengan
samping front wheel
kuatbearings are worn.
untuk mengetahui
apakah
Replacefront bearingsif (bantalan
wheel bearings
the wheel roda isdepan)
any looseness noted
telah aus.
(page 13-9).
Gantilah wheel bearings jika ada kelonggaran (hal. 13-
9).
Belakang:
Rear:
Periksalah
Check forterhadap
worn rear
rearwheel
wheelbearings (bantalan
bearings by holdingroda
the
Rear wheel bearings:
belakang)
swingarmyang aus dengan
and moving the rearmenahan swingarm dan
wheel sideways.
menggerakkan rear wheel ke samping.
Replace the rear wheel bearings if any looseness is
noted (page
Gantilah 14-9). bearings jika ada kelonggaran (hal.
rear wheel
14-9).
TEKANAN U DAR A B AN/KED ALAMAN

AIR PRESSURE/TREAD
ALUR BAN DEPTH
Periksa
Check tekanan udara banwith
the tire pressure dengan
a tiretire
pressure gauge
pres sure [1]
gauge
[1] dengan
when ban dalam
the tires keadaan dingin.
are cold.
TEKANAN UDARA BAN YANG DIANJURKAN DAN
RECOMMENDED TIRE PRESSURE AND SIZE:
UKURAN BAN:
Satuan: kPa (kgf/cm2, psi)
Depan Belakang
Tekanan udara ban
Pengendara saja: 175 (1.75, 25) 225 (2.25, 33)
Pengendara dan
pembonceng: 175 (1.75, 25) 280 (2.80, 41)
Ukuran ban 70/90-17 80/90-17
M/C 38P M/C 50P
Tire brand IRC NF63B Z NR78Y
Periksa [1]
Check roda depanfordan
the tires belakang
cuts, apakah
embedded lurusordalam
nails, other
sebidang.
damage.
Ukur kedalaman
Check the front alur
and ban
rearpada bagian
wheels tengah ban.
for trueness.
Ganti ban jika kedalaman alur ban mencapai batas
Measure
berikut ini. the tread depth at the center of the tires.
Replace the tires when the tread depth reaches the
fowing limits. MINIMUM ALUR BAN: Sampai ke
KEDALAMAN
indicator
4-19
PERAWATAN
STEERING HEAD BEARINGS
(BANTALAN KEPALA KEMUDI)
Dukung
Supportsepedamotor
the motorcycledengan kokohand
securely danraise
naikkan
the roda
front
depan
wheellepas
off thetanah.
ground.
Periksa bahwa handlebar bergerak dengan bebas dari
Check that the handlebar moves freely from side to
ujung ke ujung. Pastikan bahwa control cables (kabel
side. Make sure the control cables do not interfere with
pengatur)
handlebar tidak mengganggu kebebasan perputaran
rotation.
handlebar.
Periksalah
Check for steering
steering stem
stembearings
bearings (bantalantheporos
by grabbing fork
legs anddengan
kemudi) attempting to move the
memegang front
kaki forkdan
fork sidemencoba
to side.
untuk menggerakkan front fork dari samping ke
If the handlebar moves unevenly, binds, or has vertical
samping.
movement, inspect the steering head bearings (page
13-21).
Jika handlebar bergerak dengan tidak merata,
mengikat, atau ada pergerakan vertikal, periksalah
steering head bearings (hal. 13-21).
4-20
5. SISTEM PELUMASAN
LUBRICATION
DIAGRAM SYSTEM
SISTEM DIAGRAM
PELUMASAN ············5-2
................ 5-2 OIL PUMP..................................................... 5-4
KETERANGAN SERVIS ................................

SERVICE INFORMATION 5-3
·····························5-3 OIL COOLER COVER.................................. 5-7
TROUBLESHOOTING ................................... 5-3

TROUBLESHOOTING···································5-3
OIL PUMP······················································5-4
OIL COOLER COVER ···································5-7
5-1
SISTEM PELUMASAN
DIAGRAM SISTEM PELUMASAN
LUBRICATION SYSTEM
ROCKER ARM
CAMSHAFT
PISTON
OIL COOLER
OIL PUMP
CRANKSHAFT
DRIVESHAFT
OIL STRAINER SCREEN
5-2
SISTEM PELUMASAN
KETERANGAN SERVIS
UMUM
PERHATIAN
Oli mesin bekas dapat menyebabkan kanker kulit jika berulangkali dibiarkan mengenai kulit untuk waktu lama. Walaupun ini
tidak besar kemungkinannya terjadi kecuali jika anda menangani oli bekas setiap hari, tetap dianjurkan untuk secara menyelu-
ruh mencuci tangan anda dengan sabun dan air sesegera mungkin setelah menangani oli bekas.
•• Babsection
This ini meliputi
coversservis dariofoil
service thepump (pompa
oil pump and oli) dan oilThese
oil cooler. coolerservices
(pendingin
can oli). Pekerjaan
be done with theservis
engine iniinstalled
dapat dilakukan dengan
in the frame.
• mesin
The terpasang
service pada rangka.
procedures in this section must be performed with the engine oil drained.
•• Prosedur
When servisand
removing di dalam babthe
installing ini harus dijalankan
oil pump, use care dengan
not to oli dik eluarkan
allow dari
dust or dirt to mesin.
enter the engine.
•• IfSewaktu melepaskan
any portion dan memasang
of the oil pump oil pump,
is worn beyond jagalah agar
the specified debu
service atau replace
limits, kotoranthe
tidak
oilmemasuki
pump as an mesin.
assembly.
•• After
Jika the oil pump
sebuah bagianhasdari
beenoil installed,
pump telah check
aus that there are
melampaui no oil
batas leaks.
servis yang ditentukan, gantilah oil pump sebagai sebuah rakitan.
• Setelah oil pump telah dipasang, periksalah bahwa tidak ada kebocoran oli.
SPESIFIKASI
Satuan: mm
Kapasitas oli mesin Pada penggantian oli 1,0 liter –
Pada pembongkaran mesin 1,2 liter –
Oli mesin yang dianjurkan AHM-OIL MPX1 4T 10W-30 SJ
–
JASO MA
Oil pump rotor Jarak renggang pada ujung – 0,15 (0,006)
Jarak renggang ke badan 0,15 – 0,21 0,26 (0,010)
Jarak renggang ke samping 0,03 – 0,09 0,15 (0,006)
TORQUE VALUE
TORSI PENGENCANGAN
Oil pump cover screw 5 N·m (0.51 kgf·m, 3.7 lbf·ft)
Oil pump cover s crew 5 N.m (0,51 kgf.m; 3,7 lbf.ft)
TROUBLESHOOTING
TROUBLESHOOTING
Engine oil level too low
Tinggi permukaan oli mesin terlalu rendah
• Oil consumption
•• External
Ada pemak aian oli
oil leak
•• Worn piston ringsoli(page
Ada kebocoran ke luar9-6)
•• Improperly
Piston rings installed
aus (hal.piston
9-7)rings (page 9-8)
•• Worn
Pistonvalve
ringsguide
tidakor stem sealdengan
terpasang (page 8-15)
benar (hal. 9-9)
•• Worn
Valvecylinder
guide atau (page 9-6)seal aus (hal. 8-15)
stem
•Oil contamination
Cylinder aus (hal. 9-7)
Kontaminasi
• Worn piston olirings (page 9-6)
•• Improperly
Piston rings installed
aus (hal.piston
9-7)rings (page 9-8)
•• Worn
Pistonvalve
ringsguide
tidakor stem seal
dipasang (page benar
dengan 8-15) (hal. 9-9)
•• Oil not changed
Valve guide atau frequently
stem seal enough
aus (hal. 8-15)
•• Clogged
Oli jarangoil diganti
strainer screen (page 4-10)
• Oil strainer screen tersumbat (hal. 4-10)
5-3
SISTEM PELUMASAN
OIL PUMP (POMPA OLI)
REMOVAL
PELEPASAN
Drain the oli
Keluarkan engine
mesin oil(hal.
(page 4-9).
4-9). [2]
Remove the
Lepaskan following:
sebagai berikut:
- –Clutch cov er
Clutch cover (hal. 10-18)
(page 10-18)
- –Tiga bautbolts
Three [1] [1]
- –OilOil
pump
pump[2][2]
[1]
Remove the
Lepaskan gaskgasket [1] from
et [1] dari the oil
oil pump pump [2].
[2].
[2]
[1]
PEMBONGKARAN/PERAKITAN
OIL PUMP BODY
OIL PUMP SHAFT
SCREWS
5 N·m (0,51 kgf·m; 3,7 lbf·ft)
OUTER ROTOR
INNER ROTOR
OIL PUMP COVER
5-4
SISTEM PELUMASAN
Semprotkan
Apply engine olioil
mesin
to thekeinner
seluruh
rotorpermukaan inner
[1] and outer rotor
rotor [2]
[1] [3]
[1] dan outer
whole rotor [2].
surfaces.
Install
Pas ang the inner
inner dan and
outerouter rotors
rotors ke oiltopump
the oil pump
body [3]. body
[3].ang oil pump shaft [4] sementara mentepatkan
Pas
Install the mendatar
permukaan oil pump shaft [4] pump
dari oil while shaft
aligning
dantheinner
flat
surfaces of the oil pump shaft and inner rotor.
rotor.
[4]
Tepatkan
[2]
Install
Pas ang the oil pump
oil pump covcover
er [1].[1].
Install
Pas ang and
dan tighten the three
kencangkan ketiga screws [2] [2]
sekkrup to the specified
dengan torsi [2]
torque.
yang ditentukan.
TORQUE:
TORSI: 5 N·m
5 N.m (0.51
(0,51 kgf·m,
kgf.m; 3,73.7 lbf·ft)
lbf.ft)
Install
oil pump (page
(hal. 5-6).5-6).
[1]
PEMERIKSAAN
INSPECTION
Jika
If anyada bagianofdari
portion the Disassemble
Bongkar the (hal.
oil pump oil pump
5-4).(page 5-4).
oil
oilpump
pumpyang aus
is worn Jarak renggang pada ujung:
melampaui batas Temporarily
Untuk installpas
sementara theang
outerouter
and inner
dan rotors
inner into the ke
rotors oil
beyond the service
servis, gantilah pumpoil
dalam body.
pump body.
limit, replace the oil
oil
pump sebagai sebuah Install
oil pump shaft.
shaft.
pump as an
rakitan.
assembly. Measure
Ukur jarak the tip clearance
renggang between
pada ujung the inner
antara inner dan
and outer
outer
rotors.
rotors.
SERVICE
BATAS LIMIT: 0,15
SERVIS: 0.15 mm
mm (0.006 in)
Ukur
Measurejarak the
renggang pump clearance
pump body body antara outer rotor
between dan
the outer
oilrotor
pumpandbody.
oil pump body. Jarak renggang badan:
BATAS SERVIS:
SERVICE LIMIT: 0,26
0.26 mm
mm (0.010 in)
5-5
SISTEM PELUMASAN
Ukur jarak the
Measure renggang ke s amping
side clearance usingdengan menggunakan
a straight edge and a Jarak renggang sisi:
sebuah straight edge (mistar lurus) dan feeler gauge.
feeler gauge.
BATAS
SERVICE SERVIS:
LIMIT: 0,15
0.15 mm
mm (0.006 in)
Rakit oil pump (hal. 5-4).
Assemble the oil pump (page 5-4).
PEMASANGAN
INSTALLATION
Install
Pas ang as ebuah
new gasket [1]baru
gasket to the
[1]oil pump
pada oil [2].
pump [2].
[2] Tepatkan
Install
Pas ang theoiloil pump
pumpto the crankcase
pada while aligning
crankcase the
sementara
oil pump shaft
mentepatkan alur groove
oil pumpwith thedengan
shaft cam chain guide
cam chain
sprocket
guide spindle.
sprocket spindle.
[1]
Install
Pas ang and
dantighten the three
kencangkan bolts
ketiga [1].[1].
baut
Clean theoil
Bersihkan oilstrainer
strainerscreen
screen(hal.
(page 4-10).
4-10).
Install
Pas ang the clutch
c lutch cover
cover (hal.(page 10-20).
10-20).
After installation,
Setelah pemasangan, fill the
isi crankcase
crankcase with recommended
dengan oli mesin
engine
yang oil (page
dianjurkan 4-9)4-9)
(hal. anddancheck thatbahwa
periksa there are
tidaknoada
oil
leaks.
kebocoran oli.
[1]
OIL COOLER COVER

PELEPASAN
REMOVAL
Lepaskan
Remove thesebagai berikut:
following:
- Right lower side cover (hal. 3-12). [1] [4]
– Right lower side cover (page 3-12)
- Tiga baut [1]
– Three bolts [1]
- O2 sensor wire clamp [2]
– O2 sensor wire clamp [2]
- Oil c ooler cover [3]
– Oil cooler cover [3]
- –O-ring [4][4]
O-ring
[3] [2]
5-6
SISTEM PELUMASAN
INSPECTION/CLEANING
PEMERIKSAAN /PEMBERSIHAN
Check sthe
Periksa oil passages
aluran lintasan oli[1][1]indithe oil cooler
dalam cover
oil cooler and
cover [1]
clutch
dan cover
clutch for terhadap
cover clogs. sumbatan.
Blow each
Tiuplah oil passage
masing2 saluraninlintasan
the oil cooler cover and
oli di dalam clutch
oil cooler
coverdan
cover withclutc
thehcompressed
cover dengan air.udara dari kompressor.
• Do not use high pressure air or bring the nozzle too
• J angan
close tomemakai udara
the oil cooler coverbertekanan tinggi atau
and clutch cover.
membawa nozzle terlalu dekat ke oil cooler cover
dan clutch cov er.
PEMASANGAN
INSTALLATION
Install
Pas ang asebuah
new O-ring [1]baru
O-ring into the
[1] groove on alur
ke dalam the oil cooler
pada oil
covercover
[2]. [2]. [1]
cooler
[2]
Install
Pas ang the
oil coil cooler
ooler cover
cover [1] to clutch
[1] pada the clutch cover.
c over. [2]
Install and tighten the bolts [2]
Pas ang dan kencangkan baut2 [2] dengan with the O 2 sensor wire
O2 sensor
clamp[3]
clamp [3]seperti
as shown.
diperlihatkan.
Install
Pas ang the
rightright lower
lower sideside cover
cover (hal.(page
3-12).3-12).
[1] [3]
5-7
CATATAN
6. SISTEM BAHAN BAKAR (Programmed Fuel Injection)
LOK ASI KOMPONEN

COMPONENT ....................................
LOCATION 6-2
····························6-2 FUEL PUMP UNIT ......................................
LINE INSPECTION ···························6-29
6-23
KETER ANGAN
SERVICE SERVIS ................................
INFORMATION 6-3
·····························6-3 FUEL
FUEL TANK
PUMP................................................
UNIT·······································6-31 6-29
TROU BLESHOOTING GEJALA PFM-FI ...... 6-5 AIR CLEANER HOUSING ......................... 6-32
PGM-FI SYMPTOM FUEL TANK ················································ 6-31
TROUBLESHOOTING···································6-5
LOK ASI PGM-FI SYSTEM............................. 6-6 SENSOR UNIT ........................................... 6-32
AIR CLEANER HOUSING ·························· 6-32
PGM-FI SYSTEM LOCATION ·······················6-6
DIAGRAM PGM-FI SYSTEM ......................... 6-7 IACV............................................................ 6-35
SENSOR UNIT ············································ 6-32
PGM-FI
LOK ASI SYSTEM DIAGRAM·························6-7
CONNECTOR .................................. 6-8 THROTTLE BOD Y ..................................... 6-37
IACV ···························································· 6-35
CONNECTOR
INFORMASI LOCATION ····························6-8
TROUBLESHOOTING ECM ............................................................ 6-41
PGM-FI............................................................ 6-10 THROTTLE BODY ······································ 6-37
PGM-FI TROUBLESHOOTING INJECTOR .................................................. 6-43
MIL CODE INDEX .......................................... 6-13
INFORMATION············································6-10 ECM ····························································· 6-41
EOT SENSOR ............................................ 6-45
MIL
MIL TROUBLESHOOTING ............................ 6-14
CODE INDEX········································6-13 INJECTOR···················································
O2 6-43
SENSOR ............................................... 6-47
PEMERIK SAAN RANGKAIAN MIL ............... 6-22
MIL TROUBLESHOOTING ·························6-14 EOT SENSOR ············································· 6-45
PEMERIK SAAN SALURAN
MIL CIRCUIT
BAHAN INSPECTION
BAK AR ························6-22
............................................. 6-23 O2 SENSOR················································ 6-47
6-1
LOKASI KOMPONEN
FUEL SYSTEM (Programmed Fuel Injection)
2 N·m (0,20 kgf·m; 1,5 lbf·ft)
5,1 N·m (0,52 kgf·m;

3,8 lbf·ft)
12 N·m (1,2 kgf·m; 9 lbf·ft)
1,1 N·m (0,11 kgf·m; 0,8 lbf·ft)
6-2
SERVICE INFORMATION
KETERANGAN SERVIS
UMUM
GENERAL
• Bekerjalah di tempat dengan ventilasi baik. Merokok atau membiarkan adanya lidah api atau percikan bunga api di tempat kerja
• atau
Workdiin a welldiventilated
tempat mana bensin area.disimpan
Smokingdapat or allowing flames or kebakaran
mengakibatkan sparks in the work
atau area or where gasoline is stored can cause a
ledakan.
fire or explosion.
• Sebelum melepask an fuel feed hose (s lang pemasokan bahan bakar), bebaskan tekanan bahan bakar dari sistem dengan
• menghidupkan
Before disconnecting the fuelfuel
mesin dengan feed
pump hose, relieve tor
5P connec fueldalam
pressure fromterlepas
k eadaan the system by starting the engine with fuel pump 5P
sambungannya.
connector disconnected.
• Membengkokkan atau memilin control cables (kabel2 pengatur) akan mempengaruhi kelancaran bekerjanya dan dapat
• Bending or twisting the control cables will impair smooth operation and could cause the cables to stick or bind, resulting in loss
menyebabkan bahwa cables menyangkut atau mengikat, sehingga mengakibatkan kehilangan k endali atas kendaraan.
of vehicle control.
• Pakailah kompor listrik untuk memanaskan coolant (cairan pendingin) untuk pemeriksaan EOT sensor, jauhkan bahan yang
• Use an electric heating element to heat the coolant for the EOT sensor inspection, keep flammable materials away from the
mudah
electricterbakar
heating dari kompor
element. Wearlistrik. Pakailah
protective pakaian
clothing, pelindung,
insulated sarung
gloves andtangan berisolasi dan perlindungan mata.
eye protection.
•• Jangan memakai
Do not apply carburetor
commercially cleaners
available (semprotan
carburetor pembersih
cleaners karburator)
to the inside of the yang dapat
throttle bore.dibeli di pasaran pada bagian dalam
• lubang
Do notthrottle.
snap the throttle valve from full open to full close after the throttle cable has been removed. It may cause incorrect idle
• Jangan
operation.menghentakkan throttle valve dari terbuka penuh ke tertutup penuh setelah throttle cable (kable gas) telah dilepaskan.
• Ini dapat
Seal themengakibatkan
intake port withcara tapekerja
or a putaran
clean cloth stasioner
to keepyang dirt tidak benar.from entering the engine after the throttle body has been
and debris
• Tutuplah
removed.lubang pemas ukan dengan pita atau kain bersih untuk menc egah masuknya kotoran dan benda asing ke dalam mesin
• setelah
Do not throttle
damagebody dilepaskan.
the throttle body. It may cause incorrect throttle valve operation.
•• Jangan
Preventmenimbulkan
dirt and debris from entering
kerusakan pada the throttle
throttle body. bore and airmenyebabkan
Ini dapat passages after thekerja
cara throttle bodyvalve
throttle has been removed.
yang tidak benar.Clean them
using compressed
• Jagalah agar kotoran air ifdan
necessary.
benda asing tidak memasuki lubang throttle dan saluran udara setelah throttle body dilepaskan.
• Bersihkan
The throttle body is
mereka factoryudara
dengan pre-set. Do not disassemble
bertekanan bila perlu. in a way other than shown in this manual.
•• Throttle
Do not loosen
body telahor tighten
disetelthe awalwhite painted Jangan
di pabrik. nut andmembongkar
screw of the throttle
denganbody.cara Loosening
lain daripadaor tightening them candicause
yang diperlihatkan dalam throttle
buku
valve andreparasi
pedoman idle control
ini. failure.
•• Jangan
The parts of the throttleatau
melonggarkan bodymengencangkan
not shown in thismur manual
dan sek should
rup not
daribe disassembled.
throttle body yang diberikan tanda cat putih. Melonggarkan
• atau
Always replace the packing
mengencangkan merekawhen dapat themengakibatkan
fuel pump is removed. kegagalan pada throttle valve dan pengaturan putaran stasioner.
• A faulty PGM-FI system is often related to poorly connected or corroded connectors. Check those connections before
• Parts dari throttle body yang tidak diperlihatkan di dalam buku pedoman reparasi ini tidak boleh dibongkar.
proceeding.
•• Selalu ganti packing
The PGM-FI systemdengan yang baru
is equipped with sewaktu fuel pump telah
the Self-Diagnostic dilepaskan.
System described (page 6-10). If the MIL blinks, follow the Self-
• Sistem PGM-FI
Diagnostic yang tidak
Procedures bekerjathe
to remedy dengan
problem. baik seringkali disebabkan oleh connector yang berkarat atau tersambung dengan
• buruk.
When Perik salahthe
checking PGM-FI, ini
connectors sebelum
always follow melanjutkan.
the steps in the troubleshooting flow chart.
•• Sistem PGM-FI
The PGM-FI dilengkapi
system dengan
is provided Self
with Diagnos
fail-safe tic System
function (sistem
to secure pendiagnosaan
a minimum runningdiri sendiri)even
capability yangwhen
diuraikan
therepada
is any(hal. 6-10).
trouble in
Jika
the MIL berkedip,
system. When ikuti
any Self
abnormality
Diagnostic is detected
Procedures by the(Prosedur Pendiagnosaan
self-diagnosis Diri Sendiri)
function, running untukismemperbaiki
capability persoalan,
secured by making use of the
• Sewaktu
numerical memeriksa
values of a PGM-FI,
situationselalu
presetikuti langkah
in the pada program
simulated peta aliran map.
troubleshooting.
• Sistem
It mustPGM-FI dilengkapihowever,
be remembered, dengan fail-safe
that when (fungsi aman
any abnormality
function terhadap inkegagalan)
is detected injector, theuntuk memastikan
fail-safe functionadanya kemampuan
stops the engine to
protect it untuk
minimum from damage.
menjalankan mesin bahkan walaupun ada persoalan pada sistem. Jika ada hal tidak normal yang terdeteksi
• oleh
For PGM-FI systemfunction,
self-diagnosis location (page 6-6). untuk berjalan telah diamankan dengan memanfaatkan nilai numerik dari sebuah
kemampuan
• situasi
When yangdisassembling the fuelawal
telah ditentukan system
pada parts,
petanoteprogramthe location
simulasi. of the O-rings. Replace them with new ones upon reassembly.
•• Akan
Use atetapi,
digital tester
harus for PGM-FI
diingat, system
bahwa inspection.
jika ada keadaan tidak normal yang terdeteksi pada injector, fail-safe function akan
• mematikan
For fuel level sensor
mesin inspection
untuk melindunginya(page 19-11).
dari kerusakan.
• Untuk lokas i sistem PGM-FI (hal. 6-6).
• Sewaktu membongkar parts sistem bahan bakar, perhatikan lokasi dari O-rings. Ganti dengan yang baru pada waktu perakitan
kembali.
• Pakailah digital tester untuk pemeriks aan sistem PGM-FI.
• Untuk pemeriksaan fuel level sensor (hal. 19-9).
SPESIFIKASI
BAGIAN SPESIFIKASI
Nomor identifikasi throttle body GQR9A
Jarak bebas throttle grip 2 – 6 mm
Tahanan EOT sensor (20°C/68°F) 2,5 – 2,8 kΩ
(100°C/212°F) 0,21 – 0,22 kΩ
Tahanan fuel injector (20°C) 9 – 12 Ω
Tekanan bahan bakar pada putaran stasioner 294 kPa (3,0 kgf/cm2, 43 psi)
Aliran fuel pump (pada 12 V) minimum 100 cm3 /10 detik
TORSI PENGENCANGAN
TORQUE VALUES
Sekrup air cleaner connecting hose band 2,1 N.m (0,21 kgf.m; 1,5 lbf.ft)
Sekrup air cleaner duct 1,1 N.m (0,11 kgf.m; 0,8 lbf.ft)
Sekrup fuel connecting
Air cleaner pump set platehose band screw 2.1 N·m 2(0.21
N.mkgf·m,
(0,20 kgf.m; 1,5 lbf.ft)
1.5 lbf·ft)
Baut pemasangan
Air cleaner throttle body insulator
duct screw 1.1 N·m 12 N.m
(0.11 (1,2 kgf.m;
kgf·m, 9 lbf.ft)
0.8 lbf·ft)
EOT
Fuel sensor
pump set plate screw 14 N.m
2 N·m (0.20 (1,41.5
kgf·m, kgf.m;
lbf·ft)10 lbf.ft)
Sekrup
Throttletorx
body sens or unit mounting bolt
insulator 12 N·m (1.2 kgf·m, 9 lbf·ft) 2,5 lbf.ft)
3,4 N.m (0,35 kgf.m;
Sekrup pemasangan throttle cable stay
EOT sensor 3,4 N.m
14 N·m (1.4 (0,35
kgf·m, kgf.m; 2,5 lbf.ft)
10 lbf·ft)
Sekrup
Sensor torx
unit IACV
torx screw 3.4 N·m 2,1 N.m
(0.35 (0,212.5
kgf·m, kgf.m;
lbf·ft)1,5 lbf.ft)
O2 sensor 25 N.m (2,5 kgf.m; 18 lbf.ft)
Throttle cable stay mounting screw 3.4 N·m (0.35 kgf·m, 2.5 lbf·ft)
Baut pemasangan injector joint 5,1 N.m (0,52 kgf.m; 3,8 lbf.ft)
6-3
TOOLS
Fuel pressure gauge Pressure gauge manifold Hose attachment, 9 mm/9 mm
07406-0040004 07ZAJ-S5A0111 07ZAJ-S5A0120
Hose attachment, 6 mm/9 mm Attachment joint, 6 mm/9 mm Test probe

07ZAJ-S5A0130 07ZAJ-S5A0150 07ZAJ-RDJA110
SCS connector
070PZ-ZY30100
6-4
PGM-FI SYMPTOM TROUBLESHOOTING
TROUBLESHOOTING GEJALA PGM-FI
Jika
Whensepedamotor memperlihatkan
the motorcycle salah
has one of these satu dari check
symptoms, gejala the
ini, MIL
perhatikan
blinking,kedipan
refer to MIL, bacalah
the MIL code MIL
indexcode 6-13)(hal.
index
(page and6-13)
begindanthe
jalankan prosedur troubleshooting yang sesuai. Jika tidak ada kedipan MIL yang disimpan di dalam memori
appropriate troubleshooting procedure. If there are no MIL blinking stored in the ECM memory, do the diagnostic procedure ECM, jalankan
for the
prosedur
symptom,pendiagnosaan untuk
in sequence listed gejalauntil
below, itu, you
dalam
findurutan
cause.yang didaftarkan di bawah, sampai anda menemukan penyebabnya.
Gejala Prosedur pendiagnosaan Juga periksa terhadap
Mesin berputar tetapi tidak 1. Putar mesin selama lebih dari • Tidak ada bahan bakar ke injector
mau hidup (MIL tidak berke- sepuluh Detik dan periksa MIL – Fuel filter tersumbat
dip) (hal. 6-10) dan jalankan trouble- – Lubang pernapasan tutup tangki tersumbat
shooting berdasarkan MIL. – Slang pemasokan bahan bakar terjepit atau
2. Periksa sistem Pemasokan bahan tersumbat
Bakar (hal. 6-23). – Fuel pump tidak bekerja dengan baik
– Rangkaian2 listrik fuel pump tidak bekerja
dengan baik
• Ada kebocoran udara masuk
• Bahan bakar terkontaminasi/memburuk kon-
disinya
• Fuel injector tidak bekerja dengan baik
• IACV macet
• Sistem pengapian tidak bekerja dengan baik
Mesin berputar tetapi tidak 1. Rangkaian2 daya/massa ECM • Rangkaian terbuka pada kawat pemasukan
mau hidup tidak berfungsi dengan baik (hal. daya dan/atau massa dari ECM.
(Tidak ada suara peng-opera- 6-42). • Sekring utama (15 A) putus
sian fuel pump sewaktu igni- 2. Periksa sistem pemasokan bahan
tion switch diputar ke ON) bakar (hal. 6-23).
Mesin mendadak mati, 1. Periksa putaran stasioner (hal. • Slang pemasokan bahan bakar terhambat
sulit dihidupkan, 4-10). • Lubang pernapasan tutup tangki tersumbat
putaran stasioner kasar 2. Periksa IACV (hal. 6-36). • Bahan bakar terkontaminasi/memburuk kon-
3. Periksa sistem pemasokan bahan disinya
bakar (hal. 6-23). • Ada kebocoran udara masuk
4. Periksa sistem pengisian baterai • Lubang pernapasan tutup tangki terhambat
(hal. 16-6). • Sistem pengapian tidak bekerja dengan baik
Ada peristiwa afterburn Periksa sistem pengapian (hal. 17-5).
sewaktu engine braking dipa-
ka
Ada backfiring atau misfiring Periksa sistem pengapian (hal. 17-5).
pada waktu akselerasi
Performa buruk (kemu-dahan Periksa sistem pemasokan bahan • Slang pemasokan bahan bakar terjepit atau
dikendarai) dan bahan bakar bakar (hal. 6-23). tersumbat
boros • Pressure regulator (fuel pump) tidak bekerja
dengan baik
• Injector tidak bekerja dengan baik
• Sistem pengapian tidak bekerja dengan baik
Putaran stasioner di bawah 1. Periksa putaran stasioner (hal. • Sistem pemasokan bahan bakar tidak bekerja
spesifikasi 4-10). dengan baik.
(MIL tidak berkedip) 2. Periksa IACV (hal. 6-36). • Sistem pengapian tidak bekerja dengan baik
Putaran stasioner di atas 1. Periksa putaran stasioner (hal. • Sistem pengapian tidak bekerja dengan baik
spesifikasi 4-10). • Ada kebocoran udara masuk
(MIL tidak berkedip) 2. Periksa cara kerja dan jarak • Ada persoalan pada bagian atas mesin
main bebas throttle (hal. 4-5). • Kondisi pada air cleaner
3. Periksa IACV (hal. 6-36).
MIL menyala terus atau tidak Periksa rangkaian listrik MIL
menyala sama sekali (Mesin (hal. 6-22).
berfungsi dengan normal).
MIL menyala terus Periksa rangkaian listrik DLC.
(Mesin beroperasi normal dan
tidak ada kode MIL yang
masuk)
6-5
LOKASI PGM-FI SYSTEM
SENSOR UNIT (MAP/
IGNITION IAT/TP SENSORS)
SWITCH ECM
REGULATOR/
DLC RECTIFIER
IACV
INJECTOR
EOT SENSOR FUEL PUMP

O2 SENSOR CKP SENSOR
MIL
6-6
DIAGRAM PGM-FI SYSTEM
MAIN
FUSE 15A
R/Y R G
BATTERY
R/Y SUB
FUSE 10A
R/Y Bl/R Bl
REGULATOR/
RECTIFIER R Bl/Bu
W
IGNITION
ALTERNATOR SWITCH
Bl/Bu
SENSOR UNIT Bl/Bu
Bl/Bu
IGP 1
(1) Lg/Y Bl/Bu
27 PB
MAP SENSOR
Br FUEL PUMP
FL 8
(8) Y
5 THR INJECTOR
TP SENSOR Bl/Bu
INJ 16
P/G (12)
Gr/Bu
14 TA
(9)
IAT SENSOR
Y/Bu WARN 22 W/Bu Bl

24 TO
(7) MIL
Bl
EOT SENSOR
FRONT/REAR
G/O BRAKE LIGHT
4 SG SWITCH
Y/R
6 VCC G/Y
(21) Bl Bl/O G/Y
3 O2 STOP SW 13
O2 SENSOR
G/Y
ECM STARTER
Lg/R
SWITCH
21 IACV1A
Gr/R Y/R
32 IACV1B ST SW 29
(29)
Br/R
IACV 20 IACV2A
P/Bu
Bl/R IGPLS 11
31 IACV2B
Bl/Bu
Bu Bl/Bu
15 SCS
Y
30 K-LINE
SCS Bu/Y
12 PCP IGNITION COIL
CONNECTOR DLC CKP W/Y
SENSOR 23 PCM
G G/W G/W
25 SSTAND SW
SPARK PLUG
SIDESTAND 2 LG 9 PG1 10 PG2
G/Bl SWITCH
G/Bl G G
Br : Brown
Bl : Black
1 2 3 4 5 6 7 8 9 10 11 Y : Yellow
( ) : MIL blinks number 12 13 14 15 16 17 18 19 20 21 22 Bu : Blue
23 24 25 26 27 28 29 30 31 32 33 G : Green
: Engine does not start
R : Red
W : White
ECM 33P CONNECTOR O : Orange
ECM side of male terminals Lg : Light green
P : Pink
Gr : Gray
6-7
LOKASI CONNECTOR
CATATAN 1: Lepaskan front cover (hal. 3-10).
DLC (NOTE 1)
CATATAN 2: Lepaskan right body cover (hal. 3-13).
ECM 33P CONNECTOR (Hitam)(CATATAN 2)
6-8
CATATAN 3:
Lepaskan left lower side cover (Hal. 3-12).
INJECTOR 2P
CONNECTOR (Hitam)
CATATAN 3)
EOT SENSOR 2P
CONNECTOR (CATATAN 3)
CATATAN 4: Lepaskan lower side cover (hal. 3-12).
SENSOR UNIT 5P
IACV 4P CONNECTOR (Hitam) (CATATAN 4) CONNECTOR(Hitam) (CATATAN 4)
O2 SENSOR CAP (CATATAN 4)
6-9
INFORMASI TROUBLESHOOTING
PGM-FI TROUBLESHOOTING PGM-FI
INFORMATION
URAIAN
SYSTEMSISTEM
DESCRIPTION
SELF-DIAGNOSIS SYSTEM
SELF-DIAGNOSIS SYSTEM
Sistem PGM-FI dilengkapi dengan sebuah self-diagnosis system (sistem
The PGM-FIaan
pendiagnos system is equipped
diri sendiri). Jikawith the keadaan
terjadi self-diagnostic system.
yang tidak Whenpada
normal any
abnormality occurs in the system, the ECM turns on the MIL (Malfunction [1]
sis tem, ECM menyalakan MIL (Malfunction Indicator Lamp = lampu
Indicator Lamp)
indicator [1] and[1]
gangguan) stores
dana failure
menyimpancode inkode
its erasable
kegagalanmemory.di dalam
memorinya yang dapat dihapuskan.
CURRENT FAILURE CODE/STORED FAILURE CODE
KODE KEGAGALAN SEKARANG/KODE KEGAGALAN YANG
The failure code is indicated in two ways according to the failure status.
DISIMPAN
Kode kegagalan
• In case the ECM diperlihatkan
detects the dengan
problem duaatcara sesuai
present, thedengan
MIL willstatus
start
kegagalan.
blinking as its failure code. It is possible to read out the MIL blink pattern
• Dalam
as the current failure ECM
hal dimana code. mendeteksi sesuatu persoalan yang ada
• sIn case the
ekarang, MILECM akandoes notberkedip
mulai detect any problem
dengan kodeatkegagalannya.
present but has Kitaa
problem
dapat stored inpola
membaca its memory,
kedipan the MILMIL will not
sebagai blink.
kode If it is necessary
k egagalan yang ada to
sretrieve
ekarang.the past problem, read out the stored failure code by following
the failure
• Dalam hal code
dimana readout
ECM procedure (page 6-11).
tidak mendeteksi sesuatu persoalan sekarang
tetapi mempunyai
MIL BLINK PATTERN persoalan yang telah disimpan di dalam memorinya,
MIL tidak akan berkedip. Untuk dapat membaca kode kegagalan masa
• lalu
Failure
yangcode
telahcan be readkby
disimpan, ita the MILmengeluark
harus blink pattern.
annya dengan mengik uti
• In case the ECM does not detect any problem at present, when the ignition switch is turned "ON", the MIL will stay on for a few
prosedur pembacaan kode kegagalan (hal. 6-11).
seconds, then go off.
POLA KEDIPAN
• In case the ECM MIL detects the problem at present, when the ignition switch is turned "ON", the MIL will stay on for a few seconds
• Kode
and go kegagalan
off, then thedapatMILdibaca
blinksmenurut pola code.
as its failure kedipan MIL.
•• Dalam
The MILhal dimana
has two typesECMoftidak mendeteks
blinks, i sesuatu
a long blink persoalan
and short sekarang,
blink. The pada waktu
long blinking lasts for s witch diputar
1.3 seconds,
ignition keblinking
the short “ON”, MIL
lastsakan
for
menyala terusOne
0.3 seconds. selama longbeberapa
blink is thedetik kemudian
equivalent to akan mati.blinks. For example, when two long blinks are followed by five short
ten short
• Dalam hal MIL
blinks, the dimanais 25ECM(two mendetek
long blinkssi=sesuatu
20 blinks,persoalan
plus five yang
short ada sekarang, pada waktu ignition switc h diputar ke “ON”, MIL
blinks).
• akan menyala
The MIL terus
will start selamawhen
blinking beberapa detik kemudian
the ignition akan or
switch is "ON" mati, lalu MIL
engine revsberkedip dengan
are below 1800 kode
min-1 kegagalannya.
(rpm). In any other conditions,
• MIL mempunyai
the MIL dua jenis
will illuminate kedipan,
and stay on. kedipan panjang dan kedipan pendek. Kedipan panjang berlangsung selama 1,3 detik,
k edipan pendek berlangsung s elama 0,3 detik. Satu kedipan panjang adalah ekuivalen dengan sepuluh kedipan pendek.
Sebagai contoh, jika dua kedipan panjang diikuti oleh lima kedipan pendek, MIL adalah 25 (dua kedipan panjang = 20 kedipan,
ditambah dengan 5 kedipan pendek).
-1
• MIL akan mulai berkedip sewaktu ignition switch diputar ke “ON” atau sewaktu putaran mesin berada di bawah 1.800 menit
(rpm). Pada kondisi lain, MIL akan hidup dan tetap menyala.
ON
IGNITION
SWITCH OFF
ON
MIL (Tidak ada
persoalan sekarang)
OFF
0.5 detik.
0.3 detik. 0.4 detik. 2.8 detik. 1.3 detik. 0.3 detik.
MIL ON
( Mendekati adanya
persoalan sekarang)
OFF
CODE "7" CODE "12"

PEMERIKSAAN
MIL CIRCUIT CHECK RANGKAIAN LISTRIK MIL
Jika
If theMIL
MILtidak
doesmenyala atau
not come on tetap menyala
or stays sewaktu
on when the ignition switch
ignition is diputar
switch ke “ON”,
turned "ON", periksalah
inspect rangkaian
the MIL listrik6-22).
circuit (page MIL (hal. 6-22).
FAIL-SAFE FUNCTION
FAIL-SAFE FUNCTION
The PGM-FI system is provided with a fail-safe function to secure a minimum running capability even when there is trouble in the
Sistem
system.PGM-FI dilengkapi
When any dengan
abnormality sebuah by
is detected fail-safe function (fungsi
the self-diagnosis amanrunning
function, terhadap kegagalan)
capability untuk mendapatkan
is maintained kemampuan
by pre-programed value
untuk
in the berjalan
simulatedsecara minimal
program map. bahkan
When any walaupun ada is
abnormality persoalan
detectedpada
in thesistem.
injectorJika sebuah
and/or keadaan
crankshaft tidak (CKP)
position normalsensor,
dideteksi
the oleh
fail-
self-diagnosis the(fungsi
function
safe function stops enginependiagnosaan
to protect it fromdiri sendiri), kemampuan untuk tetap berjalan dipelihara oleh sebuah nilai yang telah
damage.
diprogram-awal pada peta program simulasi. Jika sebuah keadaan tidak normal dideteksi pada injector dan/atau crankshaft
pos ition (CKP) sensor, fail-safe function mematikan mesin untuk melindunginya terhadap kerusakan.
6-10
FAILURE
FAILURECODE
CODE READOUT
READOUT
(PEMBACAAN
CURRENT FAILURE CODEKEGAGALAN)
KODE
KODE KEGAGALAN
Support SEKARANG
the motorcycle with its centerstand and check the MIL [1].
[1]
Letakkan
• When sepedamotor di atas
the ignition switch is turned "ON",(standard
centerstand utama)
the MIL will danfor
stay on periksa
a few
MILseconds,
[1]. then go off.
•If the MIL stays
Sewaktu on or
ignition blinks,
switch note ke
diputar how“ON”,
manyMILtimes themenyala
akan MIL blinks and
s elama
determine the detik,
beberapa causekemudian
of the problem.
akan mati.
If theMIL
Jika MILtetap
doesmenyala
not blink,atau
the system is normal
berkedip, at present.
perhatikan berapaIf banyak
you wishkali
to read
MIL
the stored
berkedip failure
dan code,penyebab
tentukan perform the following:
persoalan.
Jika MIL tidak berkedip, s istem adalah normal pada saat sekarang. Jika
anda ingin membaca kode kegagalan yang telah disimpan, lakukan
sebagai berikut:
TO READ THE STORED FAILURE CODE

UNTUK
Turn theMEMBACA KODE
ignition switch KEGAGALAN YANG DISIMPAN
"OFF".
[1]
Remove
Putar the front
ignition cover
switch (page 3-10).
ke “OFF”.
Release the
Lepaskan connector
front cover
cover (hal. [1] from the guide [2] of the frame.
3-10).
Remove the connector cover from the DLC [3] and short the DLC terminals
Lepaskan connector
using the special cover [1] dari guide [2] pada rangka.
tool.
Lepaskan connector cover dari DLC [3] dan hubungkan singkat terminal
TOOL:
DLC dengan memakai special tool.
[4] SCS connector 070PZ-ZY30100
TOOL:
CONNECTION: Blue – Green/black
HUBUNGAN: Biru – Hijau/hitam
[2] [3] [4]

Jika
If theECM
ECMtidak
has mempunyai kodecode,
no stored failure kegagalan yang
the MIL willdisimpan,
illuminate,MIL akan
when menyala,
you turn the sewaktu anda memutar
ignition switch "ON". ignition switch ke “ON”.
Jika
If theECM
ECMmempunyai
has stored kode
failurekegagalan
code, the yang disimpan,
MIL will MIL0.3
illuminate akan menyala
seconds and selama 0,3 detik
go off, then start dan kemudian
blinking akan mati,
as its failure code lalu
whenmulai
you
mengkedipkan
turn the ignitionkode kegagalannya,
switch "ON". setelah anda memutar ignition switch ke “ON”.
Note how many
Perhatikan times
berapa the MIL
banyak blinks,
kali MIL and determine
berkedip, the cause
dan tentukan of the persoalan.
penyebab problem.
ON
IGNITION
dan SWITCH
OFF
ON
MIL (Tidak ada kode
kegagalan yang disimpan) OFF
ON
MIL (Ada kode kegagalan
yang di simpan) OFF
0,3 detik. KODE KEGAGALAN YANG

DISIMPAN
6-11
MENGHAPUS KODE KEGAGALAN
ERASING STORED YANG DISIMPAN
FAILURE CODE
CATATAN:
•• The
Kode kegagalan
stored yangcan
failure code disimpan tidak dapat
not be erased dihapus
by simply hanya dengan
disconnecting the battery negative cable.
melepaskan kabel negatif baterai.
1. Turn
1. Putarthe ignition switch
h ke "OFF".
“OFF”.
ignition switc [1]
2. Remove the front cover (page 3-10).
2. Lepaskan front cover (hal. 3-10).
3. Release the connector cover [1] from the guide [2] of the frame.
3. Lepaskan connector cover [1] dari guide [2] pada rangka.
Remove the connector cover from the DLC [3] and short the DLC
Lepaskan
terminals connector
using cover
the special tool.dari DLC [3] dan hubungkan singkat
terminal2 DLC dengan menggunakan special tool.
TOOL:
TOOL:
CONNECTION: Blue – Green/black
HUBUNGAN: Biru – Hijau/hitam
4. Turn
4. Putarthe ignition
ignition switch
switch k e"ON".
“ON”.
[2] [3] [4]

5. Lepaskan special tool [1] dari DLC [2].
5. Disconnect the special tool [1] from the DLC [2].
Hubungkan special tool ke DLC sekali lagi sementara MIL tetap [1]
Connect the special tool to the DLC again while the MIL stays ON about
MENYALA selama kira2 5 detik (pola penerimaan reset).
5 seconds (reset receiving pattern).
6.6.The
Kode kegagalan
stored yang is
failure code disimpan
erased iftelah
the dihapus
MIL goesjikoff
a MIL
andmati dan
starts mulai
blinking
berkedip (pola
(successful berhasil).
pattern).
•• The
DLCDLC harusmustdihubungkan singkat
be jumped while thesementara
MIL lights.MIL menyala.
If not, the MILJika tidak,
will go off
MIL akan mati dan kemudian menyala terus (pola tidak berhasil).
and stay on (unsuccessful pattern). In that case, turn the ignition switch Jika
toini"OFF"
terjadi,
andputar
try again step 3.ke “OFF” dan coba sekali lagi dari
fromswitch
ignition
langkah
• Note that 3.the self-diagnostic memory cannot be erased if the ignition
• switch
Perhatik an bahwa
is turned “OFF” before the MIL
self-diagnostic starts (memori
memory blinking. pendiagnosaan diri
sendiri) tidak dapat dihapus jika ignition switch diputar ke “OFF”
sebelum MIL mulai berkedip.
[2] Lepaskan: Hubungkan:
2 – 3 detik.
0.3 detik.
MIL dalam 5 detik.

KODE
ON KEGAGALAN
YANG
OFF DISIMPAN
IGNITION
SWITCH POLA PENERIMAAN POLA
RESET BERHASIL
ON
OFF
lebih dari 5 detik.

MIL
TIDAK
ON
DIHAPUS. COBA
LAGI DARI
OFF LANGKAH 3.
IGNITION
SWITCH POLA KEGAGALAN POLA PENERIMAAN POLA TIDAK
RESET DIHAPUS
ON
OFF
6-12
TROUBLESHOOTING UMUM
GENERAL TROUBLESHOOTING
INTERMITTENT
KEGAGAL FAILURE
AN TERPUTUS-PUT US
Istilah “kegagalan terputus-putus” berarti bahwa sebuah sistem mungkin telah mengalami k egagalan, tetapi ia dalam keadaan
The term "intermittent failure" means a system may have had a failure, but it checks OK now. If the MIL does not come on, check
baik sekarang.
for poor contact orJika MILpins
loose tidak menyala,
at all periksa
connectors relatedterhadap kontak
to the circuit. buruk
If the MIL atau butlonggar
pins
was on, pada
then went out,semua
the original problemyang
c onnectors may
berhubungan
be intermittent.dengan rangkaian listrik yang sedang di-troubleshooting. Jika MIL pernah menyala, tetapi kemudian mati, maka
persoalan semula mungkin adalah terputus-putus.
OPENS AND SHORTS
TERBUKA DAN ADA HUBUNGAN SINGKAT
"Opens" and
“Terbuka” dan"Shorts" are common
“Ada hubungan electrical
singkat” merupakterms. An open
an istilah listrikisumum.
a breakDengan
in a wire or at a dimaksudk
“Terbuka” connection.
anAkeadaan
short is terputus
an accidental
pada
connection
sebuah of a atau
kawat wire to ground
pada or tohubungan.
sebuah another wire. In simple electronics,
“Hubungan singkat” adalah this usually means
hubungan yangsomething will notdari
tidak sengaja worksebuah
at all. With ECM
k awat ke
this can sometimes mean something works, but not the way it’s supposed to.
massa atau ke sebuah k awat lain. Pada elektronika sederhana, ini biasanya berarti bahwa sesuatu tidak akan bekerja sama
sekali. Denganhas
If the Engine ECM ini kadang2
problem, and dapat berartion
MIL comes sesuatu bekerja, tetapi bukan dengan cara yang seharusnya.
ReferMesin
Jika to FAILURE CODE
mempun READOUT dan
yai persoalan, (page 6-11).
MIL menyala
Lihat
If the Engine has problem, but MIL does not6-11).
PEMBACAAN KODE KEGAGALAN (hal. stay on or blink
Jika Mesin
Do the mempun
SYMPTOM yai persoalan, tetapi(page
TROUBLESHOOTING MIL tid ak menyala terus atau b erked ip
6-5).
Jalankan TROUBLESHOOTING GEJALA (hal. 6-5).
PEMERIKSAAN RANGKAIAN LISTRIK
CIRCUIT INSPECTION
PEMERIKSAAN
INSPECTION ATPADA ECM SENSOR
ECM AND DAN SENSOR UNIT CONNECTOR
UNIT CONNECTOR
•• Always clean around
Selalu bersihkan and di
keadaan keep any foreign
sekitarnya materialbenda
dan jauhkan awayasing
from dari
the
connector
connectors before disconnecting
sebelum it.
melepaskannya.
•• ASebuah
faulty PGM-FI
PGM-FI system is often
sistem yang related to poorlydengan
tidak bekerja connected
baikorseringkali
corroded
connections.
diakibatkan Check those connections
oleh hubungan before proceeding.
yang tersambung dengan buruk atau
• When testing
berkarat. at connector
Periksa hubungan2(wire ituharness
sebelumside) terminal, always use the
melanjutkan.
• test probe. melakukan
Sewaktu Insert the test probe into pada
pengetesan the connector
terminal terminal,
connectorthen connect
(pada sisi
the digital
wire multimeter
harness), selaluprobe
pakaitotest
theprobe.
test probe.
Masukkan test probe ke dalam
terminal connector, kemudian hubungkan jarum pengetesan digital
TOOL:
multimeter
[1] Test probek e test probe.
07ZAJ-RDJA110
TOOL:
[1] Test probe 07ZAJ-RDJA110
[1]
MIL CODE INDEX

Lihat
MIL Kegagalan Fungsi Gejala/Fail-safe function
pd
MAP sensor tidak berfungsi dengan baik • Mesin beroperasi normal
1 • Kontak MAP sensor connector longgar atau buruk • Nilai pra-program: 481 mmHg/641 6-14
• MAP sensor atau rangkaiannya tidak berfungsi dengan baik kPa
ECT sensor tidak bekerja dengan baik • Sulit dihidupkan pada suhu ren-
7 • Kontak ECT sensor connector longgar atau buruk dah 6-15
• ECT sensor atau rangkaiannya tidak berfungsi dengan baik • Nilai pra-program: 83°C
TP sensor tidak bekerja dengan baik • Akselerasi mesin buruk
8 • Kontak TP sensor connector longgar atau buruk • Nilai pra-program: 0° 6-16
• TP sensor atau rangkaiannya tidak berfungsi dengan baik
IAT sensor tidak bekerja dengan baik • Mesin beroperasi normal
9 • Kontak IAT sensor connector longgar atau buruk • Nilai pra-program: 35°C 6-18
• IAT sensor atau rangkaiannya tidak berfungsi dengan baik
Injector tidak bekerja dengan baik • Mesin tidak dapat dihidupkan
12 • Kontak injector connector longgar atau buruk • Injector, fuel pump dan ignition coil 6-19
• Injector atau rangkaiannya tidak berfungsi dengan baik dimatikan
O2 sensor tidak bekerja dengan baik • Mesin beroperasi normal
21 • Kontak O2 sensor connector longgar atau buruk 6-20
• O2 sensor atau rangkaiannya tidak berfungsi dengan baik
IACV tidak bekerja dengan baik • Mesin mati mendadak, sulit di-
29 • Kontak IACV connector longgar atau buruk hidupkan, putaran stasioner kasar 6-21
• IACV atau rangkaiannya tidak berfungsi dengan baik
6-13
MIL TROUBLESHOOTING
MIL1 1KEDIPAN
MIL BLINK (MAP
(MAP SENSOR)
SENSOR)
• • Before
Sebelum starting the inspection,
memulai check forperiksalah
penyelidikan, loose or
poor contact on the sensor unit 5P (Black)
terhadap kontak longgar atau buruk pada sensorconnector
and ECM
unit 5P 33P (Black)
connector connector
(Hitam) dan ECM and
33Precheck
connecthe
tor
MIL blinking.
(Hitam) dan periksa ulang kedipan MIL.
1.1. Pemeriksaan
Sensor Unit PowerVoltaseInput Voltage Inspection
Pemasukan Daya Sensor
Unit
Turn the ignition switch "OFF".
SENSOR UNIT 5P CONNECTOR (Hitam)
Disconnect
Putar the
ignition sensor
switch ke unit 5P (Black) connector.
“OFF”.
(Sisi kawat terminal betina)
Lepaskan sensor unit 5P connector (Hitam) [1].
Turn the ignition switch "ON".
Measure
Putar the voltage
ignition switch ke at “ON”.
the wire side.
Ukur voltase pada sisi wire harness.
CONNECTION:
Yellow/red (+) – Green/orange (–)
HUBUNGAN:
STANDARD:
Kuning/m erah 4.75(+)– –5.25 V
Hijau/orange (-) Kuning/merah Hijau/orange
STANDARD:
Is the voltage4,75 – 5,25
within 4.75V– 5.25 V?
Apakah
YES voltase
GO TO antara
STEP 3.4,75 – 5,25 V?
YA
NO - GO
LANJUTKAN DENGAN LANGKAH 3
TO STEP 2.
TIDAK - LANJUTKAN DENGAN LANGKAH 2
2. Sensor Unit Circuit

Pemeriksaan Inspection
Rangkaian Sensor Unit
Turn the
Putar ignition
ignition switch
switch ke"OFF".
“OFF”. SENSOR UNIT 5P (Black) CONNECTOR
Disconnect
Lepaskan ECMthe ECM
33P33P (Black)(Hitam)
connector connector.
[1]. (Sisi kawat/terminal betina)
Check
Periksa terhadap kontinuitas antara sens or unit
for continuity between the sensor 5P
unit 5P
connector and ECM 33P connector of
connector [2] dan ECM 33P connector pada sisithe wire
harness side.
wire harness.
TOOL: Hijau/
TOOL: Kuning/merah
Test probe 07ZAJ-RDJA110 orange
Test probe 07ZAJ-RDJA110
CONNECTION
HUBUNG AN STANDARD
S TANDARD
Yellow/red – Yellow/red
Kuning/merah–Kuning/merah Kontinuitas
Continuity
Green/orange
Hijau/orange – – Green/orange
Hijau/orange
Are the above inspections normal?
Apakah pemeriksaan di atas normal? ECM 33P (Black) CONNECTOR
YES Replace the ECM with a known good one, (Sisi kawat/terminal betina)
YA - Ganti ECM dengan ECM lain yang
and recheck.
diketahui dalam keadaan baik, dan periksa ulang.
NO
TIDAK -• Open circuit in Yellow/red wire
• Open
• Rangkaian circuitpada
terbuka in Green/orange wire
kawat Kuning/merah
• Rangkaian
3. MAP terbuka
Sensor Input padaInspection
Voltage kawat Hijau/jingga
3. Pemeriksaan
Turn the ignitionVoltase
switchPemasukan
"ON". MAP Sensor
Measure the voltage at the sensor unit 5P (Black) SENSOR UNIT 5P (Black) CONNECTOR
Putar ignition
connector wireke
s witch
of the “ON”.
side.
Ukur voltase pada sens or unit 5P connector (Hitam) (Sisi kawat/terminal betina)
CONNECTION:
[1] pada sisi wire harness.
Light green/yellow (+) – Ground (–)
HUBUNGAN:
STANDARD: 4.75 – 5.25 V
Hijau muda/kuning (+) – Massa (-)
Is the voltage4,75
STANDARD: within 4.75V– 5.25 V?
– 5,25
YES
Apakah Replaceantara
voltase the sensor
4,75 – unit
5,25with
V? a new one
and recheck (faulty MAP sensor) Hijau muda/kuning
YA -
NO • GO TO
Ganti STEPunit
sensor 4. dengan yang baru dan
periksa kembali (MAP sensor tidak bekerja
dengan baik)
6-14
4.4. Pemeriksaan
MAP Sensor OutputRangkaian Saluran
Line Circuit Pengeluaran
Inspection
MAP Sensor
Turn the
Putar ignition
ignition switch
switch ke "OFF".
“OFF”. SENSOR UNIT 5P CONNECTOR (Hitam)
Disconnect the ECM 33P (Black) connector.
Lepaskan ECM 33P connector (Hitam) [1]. (Sisi kawat/terminal betina)
Check kontinuitas
Periksa the continuity
antara between
ECM 33Pthe ECM 33P
connector dan
sconnector
ensor unitand5Psensor unit 5P(Hitam)
connector (Black)[2]
connector of
pada sisi
the wire side.
kawat.
Check for
Periksa continuity
terhadap between
kontinuitas sensor
antara sens orunit
unit 5P
5P
cconnector
onnector and
dan ground.
massa.
TOOL: Hijau muda/ kuning
HUBUNGAN STANDARD
Hijau muda/kuning - Kontinuitas
Hijau muda/kuning
Hijau muda/kuning - Massa Tidak ada Konti- ECM 33P CONNECTOR (Hitam)
nuitas (Sisi kawat/terminal betina)
Apakah pemeriksaan
Are the above di atas
inspections normal?
normal?
YA - Ganti ECM dengan ECM lain yang
YES – Replace the ECM with a known good one,
diketahui dalam keadaan baik, dan periks a ulang.
and recheck
TIDAK -
NO – • Openterbuka
• Rangkaian circuit in Light
padagreen/yellow
kawat wire
Hijau
• Short circuit in Light green yellow wire
muda/kuning
• Hubungan singkat pada kawat Hijau
muda/kuning
MIL 7 BLINKS (EOT SENSOR)
MIL 7 KEDIPAN
• Before (EOT
starting theSENSOR)
inspection, check for loose or
• poor contact
Sebelum memulaiEOTpenyelidikan,
on the sensor 2P connector and
periksalah
ECM 33P kontak
terhadap (Black) longgar
connector andburuk
atau recheck the EOT
pada MIL
blinking.
sensor 2P connector (Hitam) dan ECM 33P
1. connector
EOT Sensor (Hitam)
Inputdan periksa
Voltage ulang kedipan MIL.
Inspection
1. Pemeriksaan Voltase
Turn the ignition switchPem asukan EOT Sensor
"OFF".
EOT SENSOR 2P CONNECTOR
Disconnect the EOT sensor 2P connector.
Putar ignition switch ke “OFF”. (Sisi kawat/terminal betina)
Turn the ignition
Lepaskan switch2P
EOT sensor "ON".
connector [1].
Measure the voltage at the EOT sensor 2P
Putar ignition switch ke “ON”.
connector of the wire side.
Ukur voltase pada EOT sensor 2P connector pada
CONNECTION:
sisi kawat. Yellow/blue (+) – Green/orange (–)
STANDARD: 4.75 – 5.25 V
HUBUNGAN: Kuning/biru (+) – Hijau/orange (-) Kuning/biru Hijau/orange
Is the voltage within
STANDARD: 4.75 –
4,75 – 5,25 V 5.25 V?
YES – voltase
Apakah Inspect the EOT4,75
antara sensor (page
– 5,25 V? 6-47), and if
the sensor is normal, replace the ECM with
YA -a Periks
knownagood
EOTone, and(hal.
sensor 6-46), dan jika
recheck.
sensor adalah normal, gantilah ECM dengan ECM
NO yang
lain – GOdiketahui
TO STEPdalam
2. keadaan baik , dan
periksa ulang.
TIDAK - LANJUTKAN DENAN LANGKAH 2.
6-15
2. EOT
2. Pemeriksaan Rangkaian
Sensor Circuit EOT Sensor
Inspection
Turn the
Putar ignition
ignition switch
switc "OFF".
h ke “OFF”.
ECM 33P (Black) CONNECTOR
Lepas kan ECM
Disconnect the ECM (Hitam)
33P (Black)
33P connector [1].
connector.
(Sisi kawat/terminal betina)
Periksa terhadap kontinuitas antara ECM 33P
Check the continuities between the ECM 33P
connector
connector anddan EOT
EOT sensor
sensor2P connectorof[2]
2Pconnector thepada
wire
sisi
side.kawat. Hijau/orange
Periksa
Check terhadap kontinuitas
for continuity antara
between EOTsensor
EOT sensor 2P
2P
connector dan massa.
connector and ground.
TOOL:
TOOL:
Test
Test probe
probe 07ZAJ-RDJA110
07ZAJ-RDJA110
HUBUNGAN
CONNECTION STANDARD
STANDARD
Kuning/biru – Kuning/biru
Yellow/blue – Yellow/blue Kontinuitas Kuning/biru
Hijau/jingga –– Hijau/jingga Continuity
Green/orange Green/orange EOT SENSOR 2P CONNECTOR
Kuning/biru – Massa Tidak ada
Yellow/blue – Ground No Continuity (Sisi kawat/terminal betina)
Kontinuitas
Apakah pemeriksaan di atas normal?
YES – Replace
YA theECM
- Ganti ECM dengan
with a known
ECM good one,
lain yang
and recheck.
diketahui dalam keadaan baik dan periksa ulang.
TIDAK
NO –- • Open circuit in Yellow/blue wire
• Rangkaian
• Openterbuka
circuit pada kawat Kuning/biru
in Green/orange wire
• Rangkaian terbuka
• Short circuit pada kawat Hijau/jingga
in Yellow/blue wire
• Hubungan singkat pada kawat Kuning/biru
MIL 8 BLINKS (TP SENSOR)

MIL 8 KEDIPAN (TP SENSOR)
• Before starting the inspection, check for loose or
• poor contact memulai
Sebelum on the sensor unit 5P (Black)periksalah
penyelidikan, connector
and ECM kontak
terhadap 33P (Black)
longgarconnector andpada
atau buruk recheck the
sensor
MIL
unit blinking.
5P connector (Hitam) dan ECM 33P connec tor
1. (Hitam)
Sensor danUnitperiksa
Power ulang
Inputkedipan
VoltageMIL.
Inspection
1. Pemeriksaan Voltase Pemasukan
Turn the ignition switch "OFF". Daya Sensor
Unit SENSOR UNIT 5P (Black) CONNECTOR
Disconnect the sensor unit 5P (Black) connector.
Putar ignition switch ke “OFF”. (Sisi kawat/terminal betina)
Lepaskan sensor unit 5P connector (Hitam) [1].
Measure the voltage at the wire side.
CONNECTION:
Ukur voltase pada
Yellow/red (+) –sisi kawat.
Green/orange (–)
STANDARD: 4.75 – 5.25 V
HUBUNGAN:
Kuning/m erah (+) – Hijau/orange (-) kuning/merah Hijau/orange
If the voltage 4,75
STANDARD: within 4.75 V
– 5,25 – 5.25 V?
YES – GO TO STEP 3.
Apakah voltase antara 4,75 – 5,25 V?
NO – GO TO STEP 2.
YA - LANJUTKAN DENGAN LANGKAH 3
2. Sensor Unit Circuit Inspection

2. Pemeriksaan Rangkaian Sensor Unit
Turn
Putarthe ignition
ignition switch
switc h ke "OFF".
“OFF”.
SENSOR UNIT 5P CONNECTOR (Hitam)
Disconnect
Lepaskan ECM the ECM33P 33P (Black)
connector connector.
(Hitam) [1].
Periksa terhadap kontinuitas antara
Check for continuity between the sensor unitsensor unit 5P
5P
connector (Hitam) [2] dan ECM 33P
(Black) connector and ECM 33P connector of the c onnector
padaharness
wire sisi wireside.
harness.
TOOL:
TOOL:
Test probe 07ZAJ-RDJA110 Hijau/
Kuning/Merah
Test probe 07ZAJ-RDJA110 orange
HUBUNGAN STANDAR
CONNECTION D
STANDARD
Kuning/merah–Kuning/merah
Yellow/red – Yellow/red Kontinuitas
Continuity
Hijau/jingga ––Hijau/orange
Green/orange Green/orange
Apakah pemeriksaan di atas normal?
Are
YA the above inspections
- Ganti normal?
ECM dengan ECM lain yang
ECM 33P CONNECTOR (Hitam)
diketahui
YES dalam keadaan
– Replace the ECMbaik,withdan periksa
a known ulang.
good one, (sisi kawat/terminal betina)
TIDAK -and recheck.
• Rangkaian terbuka pada kawat Kuning/merah
NO – • Open circuit in Yellow/red wire
• Rangkaian
• Open terbuka
circuitpada kawat Hijau/jingga
6-16
3.3. Pemeriksaan TP Sensor
TP Sensor Inspection
Turn the
Putar ignition
ignition switch
switch ke "OFF".
“OFF”. Pemeriksaan tahanan
Periksa
Check for
Periksa continuity
terhadap between antara
kontinuitas the following terminals
terminal berikut kontinuitas: (dengan pengoperasian
of the
dari sensorunit
sensor side.
5P connector [1] pada sis i s ensor. throttle)
CONNECTION: C D B C
HUBUNGAN: CC– –DD
STANDARD:
STANDARD: Kontinuitas Continuity
Check that
Periksa the tahanan
bahwa resistanceantara
between the following
terminal2 berikut
terminalsses
berubah changes in accordance
uai dengan with throttle.
pengoperasian the throttle
operation.
HUBUNGAN: B–C
CONNECTION: B–C
Apakah pemeriksaan2 di atas normal?
YA - LANJUTKAN DENGAN LANGKAH 4 SENSOR UNIT 5P CONNECTOR
YES – GO TO STEP 4. (Sisi sensor/terminal betina)
TIDAK -
NO • Ganti
– Replace theunit
sensor sensor unit with
dengan yanga baru,
new one,
dan
and recheck.
periksa (Faulty TPTP
ulang(Sensor sensor)
tidak bekerja
dengan
4. TP Sensor baik)Line Circuit Inspection
Signal
4. Pemeriksaan Rangkaian
Disconnect the ECM Saluran
33P (Black) Sinyal TP
connector.
Sensor ECM 33P CONNECTOR ( Hitam)
Lepaskan ECM 33P connector (Hitam) [1].
Periks a terhadap kontinuitas antara sensor unit 5P
Check for continuity between the sensor unit 5P
connector (Hitam) [2] pada sisi kawat dan ECM
(Black) connector of the wire side and ECM 33P
33P
connector of thepada
connector wiresisi wire harness.
harness side.
Periks
Check for continuity betweenantara
a terhadap kontinuitas sensor unit
the sensor unit 5P
5P
connector (Hitam) and
(Black) connector dan ground.
massa. Kuning
TOOL:
07ZAJ-RDJA110
HUBUNGAN STANDARD SENSOR UNIT 5P CONNECTOR (Hitam)

Kuning-kuning kontinuitas (Sisi kawat/terminal betina)
kuning-massa Tidak kontinuitas
Are the above
Apakah inspections
pemeriksaan di atasnormal?
normal?
YES
YA – Replace the ECM with
- Ganti ECM dengan a known
ECM good one,
lain yang
and recheck.
diketahui dalam keadaan baik, dan periksa ulang.
TIDAK
NO –- • Open circuit in Yellow wire
• Short
• Rangkaian circuitpada
terbuka in Yellow
kawatwire
Kuning
• Hubungan singkat pada kawat Kuning
6-17
MIL99KEDIPAN
MIL BLINKS (IAT
(IATSENSOR)
SENSOR)
• • Before
poor contact
terhadap on thelonggar
kontak sensor atau
unit 5P (Black)
buruk connector
pada s ensor
and ECM
unit 5P 33P (Black)
connector connector
(Hitam) dan ECM and
33Precheck the
connector
MIL blinking.
1. IAT Sensor Input Voltage Inspection
1. Pemeriksaan Voltase Pemasukan IAT Sensor
Putar ignition switch ke “OFF”. SENSOR UNIT 5P CONNECTOR (Hitam)
Disconnect the sensor unit 5P (Black) connector.
Lepaskan sensor unit 5P connector (Hitam) [1]. (Sisi kawat/terminal betina)
Putar
Measure ignition switch ke
the voltage “ON”.
at the wire side.
Ukur voltase pada sisi kawat.
CONNECTION: Gray/blue (+) – Green/orange (–)
STANDARD: Abu-abu/biru
HUBUNGAN: 4.75 – 5.25 V(+) – Hijau/jingga (-)
STANDARD: 4,75
If the voltage within – 4.75
5,25 V
– 5.25 V?
Apakah
YES – voltase antara3.4,75 – 5,25 V?
GO TO STEP Abu-abu/biru hijau/orange
2. Pemeriksaan Rangkaian IAT Sensor

2. IAT Sensor Circuit Inspection
Putar ignition switch ke “OFF”.
Lepaskan ECM 33P connector (Hitam) [1]. SENSOR UNIT 5P (Black) CONNECTOR
Disconnect the ECM 33P (Black) connector. (Sisi kawat/Terminal betina)
Periksa terhadap kontinuitas antara sensor unit 5P
Check for(Hitam)
connector continuity between
[2] dan the connector
ECM 33P sensor unit
pada5P
(Black) connector
sisi wire harness. and ECM 33P connector of the
wire harness
Periksa side.kontinuitas antara sensor unit 5P
terhadap
connector dan mass a.between sensor unit 5P
Check for continuity Abu-abu/ Hijau/
Biru orange
TOOL:
connector
Test probeand ground. 07ZAJ-RDJA110
TOOL:
HUBUNGAN STANDARD ECM 33P CONNECTOR (Hitam)

Abu-abu/biru– Abu-abu/biru (Sisi kawat/terminal betina)
Kontinuitas
Hijau/orange – Hijau/orange
Abu-abu/biru – massa Tidak kontinui-
tas
Are the above
Apakah inspections
pemeriksaan normal?
di atas n ormal?
YES - Ganti
YA – Replace
ECM the ECMECM
dengan with alain
known
yanggood one,
diketahui
and recheck.
dalam keadaan baik, dan periksa ulang.
TIDAK -
NO – • Open circuit in Gray/blue wire
• Rangkaian
• Open terbuka
circuitpada kawat Abu-abu/biru
• Rangkaian terbuka pada kawat Hijau/jingga
• Short circuit in Gray/blue wire
• Hubungan singkat pada kawat Abu-abu/biru
3. IAT Sensor Resistance Inspection
3. Pemeriksaan Tahanan
Turn the ignition IAT Sensor
switch "OFF".
Putar switch ke “OFF”. A B C D E
Measure the resistance
ignition between the sensor unit 5P
Ukur tahanan
connector antara terminal2 berikut dari sensor
terminals.
CONNECTION:
unit C [1]
5P connector – Epada sisi sensor.
STANDARD: 1 – 4 kΩ (20°C/68°F)
HUBUNGAN: C – E
o
STANDARD: 1 –within
Is the resistance 1 –C)
4 k? (20 4 kΩ (20°C/68°F)?
o
NO
Apakah – tahanan
Replace antara
the sensor
1 – 4unit withC)?
k? (20 a new one,
and recheck. (Faulty IAT sensor)
TIDAK - Ganti sensor unit dengan yang baru, dan
YES – ulang.
periksa Replace the ECM
(Sensor IATwith a known
tidak good
bekerja one,
dengan
baik. and recheck.
YA - Ganti ECM dengan ECM lain yang diketahui SENSOR UNIT 5P CONNECTOR
baik, dan periksa ulang. (Sisi sensor/terminal jantan)
6-18
MIL1212KEDIPAN
MIL BLINKS(INJECTOR)
(INJECTOR)
• • Before
poor contact
terhadap on the
kontak injector
longgar atau2Pburuk
(Black) connector
pada injector
and ECM 33P (Hitam)
2P connector (Black) connector
dan ECM and 33Precheck
connectorthe
MIL blinking.
1. Injector Input Voltage Inspection
1. Pemeriksaan Voltase Pemasukan Injector
Putar ignition
Disconnect theswitch ke 2P
injector ”OFF”.
(Black) connector. INJECTOR 2P CONNECTOR (Hitam)
Lepaskan injector 2P connector (Hitam) [1]. (sisi kawat/terminal betina)
Putar
Measureignition
theswitch
voltageke “ON”.
between the injector 2P
Ukur voltase
connector antara
of the wireinjector connector pada sisi
2Pground.
side and
kawat dan massa.
CONNECTION: Black/blue (+) – Ground (–)
HUBUNGAN:
STANDARD: Hitam/bir u (+) – Massa
Above (Battery (-)– 1.1) V
voltage
STANDARD: Di atas (Voltase baterai – 1,1) V
Does the standard voltage exist?
Apakah
YES – ada
GO voltase
TO STEP standard?
2.
Hitam/biru
YA
NO –- Open
LANJUTKAN DENGAN
or short circuit LANGKAH
in Black/blue 2
wire
TIDAK -Ada rangkaian terbuka atau ada hubungan
s ingkat pada kawat Hitam/biru.
2. Injector Resistance Inspection
2. Pemeriksaan Tahanan Injector
Putar ignition switch ke “OFF”. INJECTOR 2P CONNECTOR
Measure the resistance of the injector 2P connector (Sisi Injector /Terminal jantan)
Ukur tahanan dari terminal injector 2P connector
terminals.
[1].
STANDARD: 9 – 12 Ω (20°C/68°F) O
STANDARD: 9 – 12 ohm (20 C)
Is the resistance
Apakah within 99 –
tahanan antara – 12
12 ?
Ω (20
(20°C/68°F)?
o
C)?
YA - LANJUTKAN DENGAN LANGKAH 3.
NO – Faulty injector
TIDAK - Injector tidak bekerja dengan baik
3.3. Pemeriksaan
Injector Signal Line Circuit
Rangkaian Inspection
Saluran Sinyal Injector
Disconnect the ECM 33P (Black) connector.
Lepaskan ECM 33P connector (Hitam) [1]. INJECTOR 2P CONNECTOR (Hitam)
Check kontinuitas
the continuity (Sisi kawat/terminal betina)
Periksa antarabetween
ECM 33Pthe ECM 33P
connector dan
connector and injector 2P (Black) connector of the
injector 2P connector (Hitam) [2] pada sisi kawat.
wire side. Merah
Periksa kontinuitas antara injector 2P connector
Check the continuity between the injector 2P muda/hijau
pada sisi kawat dan massa.
connector of the wire side and ground.
TOOL:
TOOL:
HUBUNGAN STANDARD
Merah muda/hijau – Merah muda/ Kontinuitas
hijau ECM 33P CONNECTOR (Hitam)
Merah muda/hijau – Massa Tidak kontinui- (Sisi kawat/terminal betina)
tas
Are the above
Apakah inspections normal?
hasil pemeriksaan di atas normal?
YES
YA – Replace the ECM
- Ganti ECM dengan with a known goodyang
ECM lain one,
and recheck.
diketahui baik, dan periksa ulang.
TIDAK
NO –- • Open circuit in Pink/green wire
• • Short terbuk
Rangkaian circuit ain Pink/green wire Merah
pada k awat
muda/hijau
• Hubungan singkat pada kawat Merah
muda/hijau
6-19
MIL
MIL2121KEDIPAN
BLINKS(O
(O2 2SE NSOR)
SENSOR)
• • Before
memulai check forperiks
alah
poor contact
terhadap on longgar
kontak the O2 sensor cappada
atau buruk and OECM 33P
2 sensor
(Black)
c ap danconnector
ECM 33P and recheck the
c onnector MIL blinking.
(H itam) dan periksa
ulang kedipan MIL.
1. O2 Sensor Short Circuit Inspection
1. Pemeriksaan Hubu
Turn the ignition ngan
switch Sin gkat O 2 Sen sor
"OFF".
[1]
Putar ignitionthe
Disconnect ECMke
switch “OFF”.
33P (Black) connector and O2
sensor capECM
Lepaskan [1] (page
33P6-47).
connector (H itam) dan O 2
sCheck the [1]
ensor cap (hal. 6-47).
continuity between the O2 sensor cap
Periks a terhadap
terminal kontinuitas antara O 2 sensor cap
[2] and ground.
terminal [2] dan mass a.
HCONNECTION:
UBUN GAN: OO 2 sensor cap terminal – Ground
2 sen sor cap termin al – Massa
[2]
Ispakah
A there ad
continuity?
a kontin uitas?
YA
YES –- • Short circuit in Black/orange wire
• Ada hubungan
betweensingkat
O2 pada kawat 1P
sensor Hitam/jingga
(Black)
antara Oconnector
2 sensor and c onnector (Hitam) dan
1P ECM
ECM. • Short circuit in O2 sensor Black wire
• Ada hubungan singkat pada kawat Hitam O2
NO sensor.
– GO TO STEP 2.
T IDAK - LANJUT KAN DENGAN LANGKAH 2.
2. O2 Sensor Circuit Continuity Inspection
2. Pemeriksaan Kontinuitas
Check for continuity Rangkaian
between the O2 Osensor
2 Sensorcap
terminal [1] and ECM 33P (Black) connector of the [1]
Periksa terhadap kontinuitas antara O2 sensor cap
wire harness
terminal side.
[1] dan ECM 33P connector (Hitam) pada
TOOL:
sisi wire harness.
TOOL:
Test probe
CONNECTION: 07ZAJ-RDJA110 ECM 33P CONNECTOR Hitam)
O2 sensor cap terminal – Black/orange
HUBUNGAN: (Sisi kawat/terminal betina)
O2 sensor cap terminal – Hitam/orange
Is there continuity?
Apakah ada kontinuitas?
NO – • Open circuit in Black/orange wire
TIDAK - between O2 sensor 1P (Black)
• Ada rangkaian terbuka Hitam/orange
connector andpada
ECMkawat Hitam/jingga
antara •O2Open
sensor 1P inconnector
circuit (Hitam)
O2 sensor Black wiredan
ECM.
Sensor
3. O•2Ada Inspection
rangkaian terbuka pada kawat Hitam O2
Replace the O2 sensor with a known good one
sensor.
(page 6-47).
3. Pemeriksaan O2 Sensor
Erase the self diagnosis memory data from the ECM
(page 6-12).
Ganti O2 sensor dengan O2 sensor lain yang
diketahui dalam keadaan baik (hal. 6-47).
Start the engine and warm it up.
Test-ride
Hapus datathe motorcycle
memori and recheck
self diagnosis dari ECMthe
(hal.MIL
6-
blinking.
12).
Hidupkan
Does the mesin dan 21
MIL blink panas kan.
times?
Uji-jalan s epedamotor dan periksa ulang kedipan
MIL.
and recheck.
Apakah MIL berkedip 21 kali?
NO – Faulty original O2 sensor
YA - Ganti ECM dengan ECM lain yang baik
dan periksa ulang.
TIDAK - O2 sensor semula tidak bekerja dengan
baik.
6-20
MIL
MIL2929KEDIPAN
BLINKS(IACV)
(IACV)
• • Before
poor contact
terhadap on the
kontak IACVatau
longgar 4P (Black) connector
buruk pada IACV and
4P
ECM 33P (Hitam)
c onnector (Black) dan
connector
ECM 33Pandconnector
recheck the MIL
(Hitam)
blinking.
dan periksa ulang kedipan MIL.
1. IACV Short Circuit
1. Pemeriksaan Inspection
Hubungan Pendek pada IACV
Turn the
Putar ignition switch "OFF".
ke “OFF”.
ignition switch IACV 4P CONNECTOR (hitam)
Disconnect the IACV 4P (Black) connector. (Sisi kawat/terminal betina)
Lepaskan IACV 4P connector (Hitam) [1].
Check the connector for loose contacts or corroded hijau muda/
Periksa connector terhadap kontak longgar atau
terminals. merah abu-abu/merah
terminal yang berkarat.
Check for
Periksa continuities
terhadap between
kontinuitas the IACV
antara IACV 4P
4P
cconnector of thesisi
onnector pada wirewire
harness sidedan
harness andmassa.
ground.
Coklat/ Hitam/
Connection: Light
HUBUNGAN: Hijau green/red
muda/merah – Ground
– Massa merah merah
Brown/red –
Coklat/mer ah Ground – Massa
Black/red
Hitam/merah– Ground– Massa
Gray/red – Ground – Massa
Abu-abu/merah
STANDARD: No
STANDARD: continuity
Tidak ada kontinuitas
Are there
Apakah continuities?
ada kontinuitas?
YA
YES –- • Short circuit in Light green/red or
• Ada hubungan
Brown/red singkat
wire pada kawat Hijau
muda/merah
• Short atau kawat
circuit Coklat/merah
in Black/red or Gray/red
• Ada hubungan
wire singkat pada kawat
Hitam/merah atau Abu-abu/merah
NO
TIDAK –- GO TO STEP 2.
2. IACV Circuit Continuity Inspection
2. Pemeriksaan
Disconnect theKontinuitas Rangkaian
ECM 33P (Black) IACV
connector.
IACV 4P CONNECTOR (Hitam)
Check the continuity between the IACV 4P (Black)
Lepaskan ECM 33P connector (Hitam) [1]. (Sisi kawat/terminal betina)
connector terminals and ECM 33P connector
Periksa kontinuitas antara IACV 4P connector
terminals of the wire harness side.
terminals (Hitam) [2] dan ECM 33P connector Hijau muda/merah
Connection:
terminals padaLight green/red
sis i wire – Light green/red
harness.
Brown/red – Brown/red
HUBUNGAN: Black/red – Black/red
HijauGray/red
muda/merah – Hijau muda/merah
– Gray/red
Coklat/merah
STANDARD: Continuity – Coklat/merah
Hitam/merah – Hitam/merah
Coklat/merah
TOOL: Abu-abu/merah – Abu-abu/merah
STANDARD:
Test probe Ada kontinuitas07ZAJ-RDJA110
TOOL:
Are there continuity?
NO – • Open circuit in Light green/red or
Brown/red wire
Hitam/mretah
TIDAK - • Open circuit in Black/red or Gray/red
• wire
Ada rangkaian terbuka pada kawat Hijau
muda/merah atau Coklat/merah
• Ada rangkaian terbuka pada kawat Abu-abu/merah
Hitam/merah atau Abu-abu/merah

(Sisi kawat dari Terminal betina)
6-21
3.3. Pemeriksaan Tahanan
IACV Resistance IACV
Inspection
Ukur tahanan
Measure pada IACV
the resistance at 4P
the connector
IACV 4P connector
terminals
[1].
terminals. IACV 4P CONNECTOR
HUBUNGAN:
Connection: AA– –DD (Sisi IACV dari terminal jantan)
BB–C –C
STANDARD: 110 – 150 ohm (20oC)
STANDARD: 110 – 150 Ω (20 °C/68 °F)
o
Apakah tahanan antara 110 – 150 ohm (20 C)?
Is the resistance within 110 – 150 Ω (20°C/68°F)? B C
TIDAK D
NO – -Faulty
IACVIACV.
tidak Replace
bekerja the
dengan
IACVbaik.
with aGanti
new A
IACV denganone, yang baru, dan periks a ulang.
and recheck.
4.4. Pemeriksaan
IACV Short Circuit Inspection
Hubungan Singkat IACV
Check forterhadap
Periksa continuitykontinuitas
at the IACV 4P IACV
pada connector
4P IACV 4P CONNECTOR
cterminals
onnectorofterminals
the IACV[1]side.
pada sisi IACV. (Sisi IACV dari terminal jantan)
HUBUNGAN:
Connection: A A –B–B
CC –D
–D
STANDARD:
STANDARD: No Tidak ada kontinuitas
continuity
YA - IACV tidakReplace
bekerjathe
dengan C
YES – Faulty IACV. IACV baik.
with aGanti
new
IACV dengan
one, yang baru, dan periks a ulang.
and recheck. A D
TIDAK - Ganti ECM dengan ECM lain yang B
NO – Replace
diketahui baik, danthe ECMulang.
periksa with known good one,
and recheck.
PEMERIKSAAN RANGKAIAN MIL

WHEN THE
SEWAKTU IGNITION
IGNITION SWITCH IS
SWITCH
TURNED ON, THE MIL DOES NOT
DIHIDUPKAN,MIL TIDAK MENYALA
COME ON
Lepaskan right body cover (hal. 3-13). 33P (Hitam)
Remove the right body cover (page 3-13). CONNECTOR (sisi
Lepaskan ECM 33P connector (Hitam) [1].
Disconnect the ECM 33P (Black) connector [1]. kawat/terminal betina)
Hubungkan ECM 33P connector terminal dari connector
Ground
pada sisi the
wireECM 33P ke
harness connector terminal jumper
massa dengan of the wire
wire
harness
(kawat side connector
penghubung) [2]. with a jumper wire [2].
CONNECTION:
HUBUNGAN: White/blue
Putih/biru – Ground
– Massa
TOOL:
TOOL:
Test Putih/biru
Testprobe
probe 07ZAJ-RDJA110
07ZAJ-RDJA110
Putar ignition switch ke “ON”, MIL seharus nya come
Turn the ignition switch "ON", the MIL should menyala.
on.
•• J ika MIL
If the menyala,
MIL ganti
comes on, ECM dengan
replace the ECMECMwith lain yang
a known [2]
diketahui baik, [1]
good one, anddan periksa ulang.
recheck.
•• J ika MIL
If the MILtidak menyala,
does not come periksa terhadap
on, check rangkaian
for open circuit
terbuka pada kawat
in the White/blue wirePutih/biru antara
between the speedometer
speedometer and
dan
ECM.ECM.
6-22
WHEN THE
SEWAKTU IGNITION
IGNITION SWITCH IS
SWITCH
TURNED ON, THE MIL DOES
DIHIDUPKAN,MIL TIDAK MAT NOT GO
I D ALAM
OFF WITHIN A FEW SECONDS
BEBERAPA DETIK(MESIN MULAI HIDU P)
(ENGINE STARTS)
Putar
Turn ignition switch
the ignition ke ”OFF”.
switch "OFF".
Lepaskan right body c over
Remove the right body cover (hal.(page
3-13).3-13).
Lepaskan
Disconnect ECM
the33P
ECMconnector (Hitam)
33P (Black) [1]. [1].
connector
Putar
the ignition ke “ON”,
switch "ON",MIL
theseharus nya turn
MIL should mati.off.
• • J ika
If theMIL
MIL menyala,
comes on,periksa
check for terhadap hubungan
short circuit in the
s ingkat pada wire
White/blue kawatbetween
Putih/biru
theantara
speedometer and
speedometer
danECM.ECM.
• • J ika
If the
MILMIL turns
mati, off, check
periksa the berikut.
sebagai following.
[1]
Check terhadap
Periksa for continuity between
kontinuitas theECM
antara ECM33P
33P (Black)
connector
connector
(Hitam) [1] and
[1] dan ground.
mass a. 33P (Hitam)
CONNECTOR (Sisi
HUBUNGAN: Biru
CONNECTION: – Massa
Blue – Ground kawat/terminal betina)
STANDARD:
STANDARD: Tidak ada kontinuitas
No continuity
TOOL:
TOOL:
• J ika ada kontinuitas, periks a terhadap hubungan
• If there pada
s ingkat is continuity,
kawat Birucheck forDLC
antara short
dancircuit
ECM.in the Biru
• Blue wire between
J ika tidak the DLCganti
ada kontinuitas, and ECM.
ECM dengan ECM
• If there is no continuity, replace the ECM with a
lain yang diketahui baik, dan periksa ulang.
known good one, and recheck.
[1]
FUEL LINE INSPECTION

FUEL PRESSURE RELIEVING
PEMERIKSAAN
• Before SALURAN
disconnecting fuel feed hose, relieve
pressure from the system by following the
BAHAN BAKAR
procedures below.
• This motorcycle uses resin for the part of materials
MEMBEBASK AN TEKAN AN BAHAN
in the fuel feed hose. Do not bend or twist the fuel
BAKAR
feed hose.
• 1.Sebelum
melepaskan fuel feed hose (slang
[2] [3]
pemasokan bahan bakar), bebas kan tekanan dari [5]
2. Unlock and open the seat.
s istem dengan mengikuti pros edur di bawah ini.
Remove the two
• Sepedamotor luggage box mounting
ini menggunakan bolts [1]
resin (damar) and
untuk
slightly push
s ebagian the luggage
bahan pada fuelbox forward.
feed hose. Jangan [1]
3.membengkokkan
Unlock and remove atauthe
memelintir fuel feed hose.
trim clip [2].
1. Putar ignition
Remove theswitch ke “OFF”.
fuel pump cover [3] by releasing the
[4]
grooves [4] from the rail
2. Buka penguncian dan naikkan [5] of seat.
the fuel tank.
Lepaskan kedua luggage box mounting bolts [1] dan
dorong luggage box sedikit ke depan.
3. Buka penguncian dan lepaskan trim clip [2].
Lepaskan fuel pump cover [3] dengan melepaskan
alur2 [4] dari rel [5] pada fuel tank.
6-23
4.4. Disconnect
Lepaskan fuel
the pump
fuel pump 5P connector
5P connector [1]. [1].
[1]
5.5. Turn
Putarthe ignition
ignition switch
switch ke "ON".
“ON”.
6.6. Start the engine
Hidupkan mesinand let itbiarkan
dan idle untilberputar
the engine stalls.
stasioner
s ampai mesin mati.
7. Disconnect the battery negative (–) cable (page 16-
7. 7).
Lepaskan kabel negatif (-) baterai (hal. 16-6).
QUICK CONNECT FITTING REMOVAL

PELEPASAN QUICK CONNECT FITTING
FUEL PUMP SIDE
1. Check
PADA SISIthe fuelPUMP
FUEL pump side quick connect fitting [1] for [1]
dirt, and clean if necessary.
1. Periksa quick connect fitting [1] pada sis i fuel pump
Place
terhadapa shop toweldan
kotoran, [2] over the quick
bersihkan bila connect
perlu. fitting.
Letakkan kain lap [2] di atas quick connec t fitting.
[2]
2.2.Tarik
Pull dan
and lepaskan rubber
release the cap
rubber [1][1]
cap dari retainer.
from the retainer.
[3]
3.3.Tahan
Hold the [2] dengan
connector
connector [2] with satu
one tangan
hand and dansqueeze
penc et
the retainer
retainer [3] dengan
tabs tabs [3] with thetangan
otheryang
hand lain untuk
to release [2]
melepaskan
the locking pawls [4] from
locking [4] darigrooves.
the connector
pawls alur-alur
Pull the connector off and remove the retainer.
c onnector.
Tarik lepas connector dan keluarkan retainer.
• Prevent the remaining fuel in the fuel feed hose from
• Pakailah kain
flowing out, usinglap untuk
a shop towel.mencegah mengalir
• keluarnya
Be carefulsisa
notbahan
to damagebakarthe
di dalam
hose or fuel feedparts.
other hose.
• • Hati-hati agar tidak
Do not use tools. merusak hose atau parts lain.
• • J angan pakai tools.does not move, keep the retainer
If the connector [1]
• J ikatabs connector
pressed down, tidakandbergerak,
alternately dengan
pull and tetap
push
menekan
the connector until
retainer ke dalam,
it comes
tabs secara bergantian
off easily. [4]
tarik dan dorong connector sampai ia terlepas
dengan mudah.
4.4.Untuk
To prevent damagekerusakan
menghindari and keepdan
foreign matter
supaya out,
bahan
cover tidak
asing the disconnected connector
dapat masuk ke and pipe tutupilah
dalam, end with
the plasticyang
c onnector bagsdilepaskan
[1]. dan ujung pipa dengan
kantong plastik [1].
[1]
6-24
PADA SISI INJECTOR
INJECTOR SIDE
1.1.Lepaskan
Remove left
the lower
left lower
sideside cover
c over (hal.(page
3-12).3-12).
2.2.Periksa
Check the
quickinjector sidefitting
connect quick [1]
connect
pada fitting [1] for
sisi injector
dirt, and kotoran,
terhadap clean if necessary.
dan bers ihkan apabila perlu.
Place a shop
Letakkan towel
kain lap [2] [2] over quick
di atas the quick connect
connect fitting.
fitting.
[1] [2]
3.3.Tarik
Pull dan lepaskanthe
and release rubber
rubber [1][1]
cap
c ap dari
from the retainer.
retainer.
[1]
4.4.Tahan
Hold the connector
connector [2] with satu
[2] dengan one hand
tangan anddansqueeze
penc et
the retainer [4]
retainer tabs tabs
[3] [3] with the
dengan otheryang
tangan hand lain
to release
untuk [2]
the locking pawls
melepaskan locking[4] from the connector
pawls [4] darigrooves.
alur-alur
Pull the connector off and remove the retainer.
c onnector.
• Tarik lepas
Prevent the remainingdan
connector fuelkeluarkan
in the fuelretainer.
feed hose from
• Pakailah
flowing out,kain
usinglap a shopuntuk
towel.menc egah mengalir
• keluarnya
Be careful sisa
notbahan
to damage bakarthedi dalam
hose orfuel feed
other hose.
parts.
• • Hati-hati agartools.
Do not use tidak merusak hose atau parts lain. [3]
• • J angan
If the connector
pakai tools.does not move, keep the retainer
• J ikatabs connector
pressed down, tidakandbergerak,
alternately dengan
pull and tetap
push
the connector
menekan untiltabs
retainer it comes off easily.
ke dalam, secara bergantian
tarik dan dorong connector sampai ia terlepas
dengan mudah.
5.5.Untuk
To prevent damagekerusakan
menghindari and keep dan
foreign matter
supaya out,
bahan
cover the
asing tidakdisconnected connector
dapat masuk ke and pipe end
dalam, with
tutupilah
the plasticyang
c onnector bagsdilepaskan
[1]. dan ujung pipa dengan
kantong plastik [1].
[1]
6-25
QUICK CONNECT
PEMASANGAN FITTING
QUICK CONNECT FITTING
INSTALLATION
• Selalu ganti retainer dari quick connect fitting jika
• fuel
Alwaysfeedreplace thedilepaskan.
hose telah retainer of the quick connect
fitting when
• Sewaktu the fuel feed
mengganti hose pakailah
retainer, is disconnected.
retainer dari
• pabrik
When pembuat
replacing yangthe sama
retainer,seperti
use yang
the same
telah
manufacturer’s retainer as the removed one (The
dilepaskan (Pabrik pembuat yang berbeda
several manufactures feature different retainer
mempunyai spesifikasi retainer yang berbeda).
specifications).
•• Jika adaiskerusakan
If there any damage atauorpotongan pada
cut-out on the rubber
rubber cap,
cap
gantilah dengan yang
replace it with a new one. baru.
•• Jangan membengkokkan
Do not bend atauhose.
or twist fuel feed memelintir fuel feed
hose.
FUEL PUMP SIDE
PADA SISI FUEL PUMP
1. Insert a new retainer [1] into the connector [2].
1. Masukkan retainer [1] baru ke dalam connector [2]
• Align the retainer locking pawls with the connector [1]
grooves. retainer locking pawls dengan alur-alur
• Tepatkan
connector.
[2]
Tepatkan
2.2.Tempatkan
Set the rubber capcap
rubber [1] [1]
correctly.
dengan benar.
[3]
Tekan connec tor [2] pada
Press the connector [2]pipe ontosampai kedua
the pipe retainer
until both
pawls [3] mengunci dengan suara
retainer pawls [3] lock with a "CLICK".“KLIK”.
• • Tepatkan
Align thequick
quickconnect fittingdengan
connectfitting with thepipe.
pipe. [1]
J ika
If it ia
is sulit
harddisambungkan,
to connect, put berikan sejumlahofkecil
a small amount oli
engine
mesin
oil onpada ujung
the pipe end.
pipe.
[2]
3.3.Pastikan
Make surebahwathe sambungan
connection is secure and
terpasang that erat
dengan the
pawls
dan are firmly
bahwa pawlslocked into place;
telah terkunci check kokoh
dengan visuallypada
and
[1]
by pulling the
tempatnya; connectorsecara
periksalah [1]. visual dan dengan
4.menarik c onnector
Make sure [1]. cap [2] is positioned correctly
the rubber
(betweenbahwa
4. Pastikan the retainer
rubber tabs).
cap [2] telah ditempatkan
dengan benar (di antara retainer tabs).
[2]
6-26
PADA SISI INJECTOR
INJECTOR SIDE
1.1. Insert a new
Mas ukkan retainer
retainer [1][1] intoke
baru thedalam
connector [2]. [2]
connector
• • Align the retainer
Tepatkan retainer locking
lock ingpawls
pawlswith the connector
dengan alur-alur
grooves.
c onnector.
Tepatkan
[2]
[1]
2.2. Set the rubber

Tempatkan cap c[1]
rubber apcorrectly.
[1] dengan benar.
[1]
Tekan connector [2]
Press the connector [2] pada
ontopipe sampai
the pipe untilkedua
both
retainer pawls [3] mengunci dengan suara “KLIK”. [3]
retainer pawls [3] lock with a "CLICK".
• • Align
Tepatkan quickconnect
the quick connectfitting dengan
fittingwith pipe.
the pipe.
J ika
If it isiahard
s ulittodisambungkan, berikan
connect, put a small sejumlah
amount kecil
of engine
oli on
oil mesinthe pada ujung pipe.
pipe end.
[2]
3.3. Make sure

Pastikan the connection
bahwa sambunganisterpasangsecure and that erat
dengan the
pawls are firmly locked into terkunci
place; check visually and [2]
dan bahwa pawls telah dengan kokoh
by pulling
pada the connector
tempatnya; periks[1].
alah secara visual dan
dengan
4. Make menarik
sure connector
the rubber cap [2] [1].is positioned correctly
4. (between the retainer
Pastikan bahwa tabs).
rubber cap [2] telah ditempatkan
dengan benar (di antara
5. Install the left lower side cover (page
retainer 3-12).
tabs).
5. Pasang left lower side cover (hal. 3-12).
[1]
FUEL PRESSURE
MENAIKKAN INCREASING
TEK ANAN B AHAN B AKAR
1.1. Connect
Sambungkanthe fuel
fuelpump
pump5P 5Pconnector
connec tor[1].
[1]. [1]
Connect
Hubungkan kabel negatif (-) ke baterai battery
the negative (–) cable to the (page
(hal. 16-6).
16-7).
2. Putar ignition switch ke “ON”.
2. Turn the ignition switch "ON".
CATATAN:
• J angan hidupkan mesin.
• Do not start the engine.
Fuel pump akan berjalan selama kira-kira 2 detik,
The tekanan
dan fuel pump will run
bahan for akan
bakar aboutnaik.
2 seconds, and fuel
pressure
Ulangi will rise.
2 atau 3 kali, dan periksa bahwa tidak ada
Repeat 2 or
kebocoran pada 3 times,
sistem and check that
pemasokan bahan there is no
bakar.
leakage in the fuel supply system.
6-27
3.3. Install
Pasangthe fuelfuel
pump pump
cover [1] dengan
cover [1] by mentepatkan
aligning the
[4] [1]
grooves
alur-alur [2]
[2] with the rail
dengan [3] pada
rel [3] of thefuel
fueltank.
tank. [3]
Install and
Pasang danlock the
kunc trimclip
i trim clip[4].
[4].
4.4. Tempatkan
Set the luggage box inbox
luggage position
padaandposisinya
install the dan
two [5]
luggagekedua
pasang box mounting
luggage bolts [5].
box mounting bolts [5].
[2]
TEST
FUELTEK ANAN BAHAN
PRESSURE B AK AR
TEST
Relieve the
Bebaskan fuel pressure
tekanan (page (hal.
bahan bakar 6-23).
6-23).
Disconnect
Lepaskan theconnect
quick fuel pump
fittingside quick
pada connect
sisi fuel pumpfitting
(hal. [1]
(page 6-24).
6-24).
Attach the pressure
fuel pressure [2]
Pas ang fuel gauge gauge, attachments
(meter pengukur and
tekanan
manifold.
bahan bakar), attachments dan manifold. [4]
[3]
(1):Fuel
TOOLS:pressure gauge 07406-0040004
(2):Pressur e gauge manifold
[1]: Fuel pressure gauge 07ZAJ-S5A0111
07406-0040004
(3):Hose attachment,
[2]: Pressure gauge 9manifold
mm/9 mm 07ZAJ-S5A0111
07ZAJ-S5A0120
(4):Hose attachment, 6 mm/9 mm 07ZAJ-S5A0130 [5]
[3]: Hose attachment, 9 mm/9 mm
(5):Attachment joint, 6 mm/9 mm 07ZAJ-S5A0150
07ZAJ-S5A0120
[4]: Hose
Untuk attachment,
s ementara 6 mm/9
hubungkan mm
kabel positif dan negatif ke
baterai dan fuel pump 5P connector. 07ZAJ-S5A0130
Hidupkan mesin dan
[5]: Attachment biarkan
joint, berputar
6 mm/9 mm stasioner.
Bac alah tekanan bahan bakar. 07ZAJ-S5A0150
2
STANDARD: 294 kPa (3,0 kgf/cm
Temporarily connect the positive cable , 43 psi)
and negative
cable
Jika to the battery
tekanan bahan and fuellebih
bakar pumptinggi
5P connector.
daripada yang
Start the engine
ditentukan, and
gantilah letpump
fuel it idle.assembly.
Read
Jika the fuelbahan
tekanan pressure.
bakar lebih rendah daripada yang
ditentukan, periksalah
STANDARD: 294 kPa sebagai berikut:
(3.0 kgf/cm 2
, 43 psi)
- Keboc oran saluran bahan bakar
-If the fuel
Fuel feed pressure is higher
hos e yang than
terjepit specified,
atau tersumbatreplace the
-fuelFuel
pump
pump assembly.
unit (hal. 6-29).
-If the fuel
Fuel pressure
filter is lower than
yang tersumbat specified,
(Perakitan fuelinspect the
pump unit
following:
hal. 6-30)
– Fuel pemeriksaan,
Setelah line leaking bebaskan tekanan bahan bakar
(hal. 6-23). or clogged fuel feed hose
– Pinched
– Fuel pump unit (page 6-29)
Lepaskan
– Clogged fuelfuel filter (Assembly
pressure dan
of the fuel
gauge, attachment pump unit:
manifold
dari page 6-31)
fuel pump.
After inspection,
Sambungkan relieve
quick the fuel
connect pressure
fitting (page
pada sisi fuel6-23).
pump
(hal. 6-26).
Remove the fuel pressure gauge, attachment and
Naikkan
manifoldtekanan
from thebahan bakar (hal. 6-27).
fuel pump.
Connect the fuel pump side quick connect fitting (page
6-26).
Increase the fuel pressure (page 6-27).
6-28
PEMERIKSAAN ALIRAN B AH AN BAKAR
FUEL FLOW INSPECTION
Relieve the
tekanan bahanand disconnect
bakar the fuel pump
dan lepaskan quick
side quick
connect connect
fitting fitting
pada sisi (page
fuel pump6-23).
(hal. 6-23). [1]
Se kalahoffbensin
Wipe yang
spilled Connect the
out Hubungkan special
special toolketofuel
tool thepump
fuel pump
joint. joint.
te gasoline.
rtumpah.
TOOL:
TOOL:
[1]
[1]Hose
Hoseattachment,
attachment, 07ZAJ-S5A0130
07ZAJ-S5A0130
66mm/9
mm/9mmmm
Masukkan
Place theujung darithe
end of ke into
hose
hose dalam
an tempat penampung
approved gasoline
bensin yang ses uai.
container.
Temporarily
Untuk s ementaraconnect the positive
hubungkan cable dan
kabel positif andnegatif
negative
ke
cable to
baterai thefuel
dan battery
pumpand
5P fuel pump 5P connector.
connector.
Turn ignition
Putar the ignition switch
switch "ON".
ke “ON”.
Measure
Ukur jumlah thealiran
amount of fuel
bahan flow.
bakar.
CATATAN:
• • The
Fuel fuel
pumppump operates
beroperas for 22seconds.
i selama Repeat
detik. Ulangi 5
5 kali
times
untuk to meet thejumlah
memenuhi total measuring time.
waktu pengukuran total.
• • Return fuel tobahan
Kembalikan the fuel tankkewhen
bakar fuel the
tankfirstsewaktu
fuel is
flowed.
bahan bakar pertama telah mengalir.
Amount
Jumlah ofan
alir fuel flow:bakar:
bahan
100 cm3 (3.4
minimum US 3oz,
100 cm /10 3.5 Imp oz) minimum/
detik
10 seconds
Jika aliran bahan bakar kurang dari yang ditentukan,
If fuel flowsebagai
periksalah is less than specified, inspect the following:
berikut:
- Fuel pump unit (hal. 6-29)
– Fuel pump unit (page 6-29)
-– Fuel
Clogged tersumbat
filterfuel (Perakitanof dari
filter (Assembly the fuel
fuel pump
pump unit:
unit:
hal.
page6-30)
6-31)
Sambungkan quickpump
Connect the fuel connect
side fitting dari sis ifitting
quick connect fuel pump
(page
(hal. 6-26).
6-26).
Naikkan
Increasetekanan
the fuelbahan bakar
pressure (hal.6-27).
(page 6-27).
FUEL PUMP UNIT

INSPECTION
PEMERIKSAAN
Remove the
Lepaskan fuelfuel
pumppump cover
cover (hal.(page
6-23).6-23). [1]
Turn ignition
Putar the ignition
switchswitch "ON"dan
ke “ON” andkonfirmasikan
confirm that the fuel
bahwa
pump
fuel pump operates for 2 selama
beroperasi seconds.
2 detik.
If the
Jika fuel
fuel pump
pump does
tidak not operate,
beroperasi, inspect
periks as follows:
a sebagai berikut:
Turn the ignition switch
Putar ignition switch ke “OFF”."OFF".
Disconnect the fuel pump 5P connector [1].
Lepaskan fuel pump 5P connector [1].
Turn the ignition switch "ON" and measure the voltage
Putar
at the ignition switc h5P
fuel pump ke connector
“ON” dan ukur v oltase
terminals ofpada fuel
the wire
side. 5P connector terminals pada sisi kawat.
pump
HUBUNGAN:
CONNECTION: Hitam/biru
Black/blue(+)(+)
– Coklat
– Brown(-) (–)
STANDARD: Di atas (Voltase baterai – 1,1) V
STANDARD: Above (Battery voltage – 1.1) V
Harus ada voltas e standard selama beberapa detik.
There should be standard voltage for a few seconds.
Jika ada voltas e standard, gantilah fuel pump unit.
If there is standard voltage, replace the fuel pump unit.
Hitam/biru Coklat
Jika tidak ada voltase standard, periksalah sebagai
If there is no standard voltage, inspect the following:
berikut:
- – Sekring
Main fuse 15 A
utama 15A
- – Ignition
Ignitionswitch
switch
- – Regulator/rec
Regulator/rectifier
tifier
– Open circuitterbuka
- Rangkaian in Red or pada
Red/yellow
kawatwire Merah atau
– Merah/kuning
Open circuit in Black/blue or Brown wire
- – Rangkaian
ECM (pageterbuka
6-42) pada kawat Hitam/biru atau [1]
Coklat
- ECM (hal. 6-41)
6-29
REMOVAL
PELEPASAN
• • This motorcycle
Sepedamotor iniuses resin for the
menggunakan part
resin of materials
(damar) untuk
in the fuel hose.
s ebagian Do not
bahan bend fuel
pada or twisthose.
the fuel Jangan
hose.
membengkokkan
Clean around the fuelatau
pump.memelintir fuel hose.
[3] [4]
Bersihkan daerah
Relieve the disekitar(page
fuel pressure 6-23).
fuel pump.
Disconnect the fuel pump side quick connect fitting
Pastikan bahwa tidak Bebaskan tekanan bahan bakar (hal. 6-23).
(page 6-24).
ada bagian dari fuel Lepaskan quick connect fitting pada sisi fuel pump (hal.
Bepump
sureunit
thatyang
any 6-24).
Remove the screw [1].
meny
partangkut
of thepada
fuel Remove the set plate [2] while pressing it down.
lubang fuel tank pada Lepaskan sekrup [1].
pump unit does not
waktu pele pasan.
interfere with the Lepaskan set plate [2] sementara menekannya ke
fuel tank hole during
bawah.
removal. Lepaskan fuel pump unit [3] dan packing [4].
[1]
[2]
PEMERIKSAAN
Remove the fuel pump unit [1] and packing [2] by gently
[2]
pulling up until the filter [3] of fuel pump unit is above [3]
Periksalah fuel pump unit terhadap kerus akan, ganti bila
the fuel tank hole.
perlu.
Periksa fuel filter [1] terhadap sumbatan atau
kerusakan.
[1]
Slightly rotate the fuel pump unit to the right then check [2]
the float valve position.
PEMASANGAN
Float valve postion have to stay in "Full postion" [4] then
Be sure
gantithat float gently remove the fuel pump unit [2].
Selalu packing Berikan maksimum 1 g oli mesin pada packing [1] baru
valve
dengan yanginbaru.
"Full dan pasang pada fuel pump unit [2].
position"
Hati-hati agarduring
tidak
dan If float valve in "Empty position" [3] while removal will
removal.
menjepit debu
kotoran antara fuel damage the fuel level sensor [1].
pump unit dan packing.
[1]
Pastikan bahwa tidak Pas ang fuel pump unit [1] ke dalam fuel tank dengan
ada bagian dari fuel membengkokkan fuel filter [2] seperti diperlihatkan.
pump unit yang • J angan merus ak filter mes h (jala saringan) dan bone
meny angkut pada
lubang fuel tank pada (tulang) [3] oleh karena menyentuh pinggiran fuel
waktu pele pasan. tank dan karena tertekuk.
[1] [3] [4]
6-30
PEMERIKSAAN
Periksa fuel pump unit dari kerusakan, ganti jika di
perlukan.
Periksa fuel filter [1] dari tersumbat atau kerusakan.
[1]
PEMASANGAN
Always replace
Selalu ganti the Berikan maksimum 1 g oli mesin ke packing baru [1]
packing
denganwith
packing new dan pasankan ke fuel pump unit [2].
yanga baru.
Hati-hati
one. agar tidak
Be careful not
menjepit
to pinch the debu dan
dirt and
kotoran
debris antara the
between fuel
pump unit dan packing.
fuel pump unit and
packing.
[1] [2]
Fuel level sensor

Fuelakan
level mengalami
sensor akan Putar katup
Turn the float
float [1] [1]
valve ke to
posisi penuh
the full dan and
position masukkan ke
insert into
[3]
mengalami kerusakan
kerusakan jika dalam
the fuellubang
tank holetangki bahan
[2] until thebakar [2] edge
fuel filter sampai
[3] ujung
touch
jikaposisi
posisikatup
katup float
float saringan bahan
the fuel tank hole.bakar [3] menyentuh lubang tangki
kosongselama
kosong selama bahan bakar.
instalasi.
instalasi. [1]
[2]
Be sure
Pastikan bahwathat any
bagian Pasang unitfuel
Install the pompa
pump bahan
unit bakar [1] the
[1] into ke dalam tangki
fuel tank by [1]
dari unit pompa
part of thebahan
fuel bahan
bendingbakar dengan
the fuel filtermenekuk saringan bahan bakar [2]
[2] as shown.
bakar
pumptidak
unit terganggu
does not seperti yang ditunjukkan.
dengan lubang tangki • Do not damage the filter mesh and bone [3] by
interfere with the
bahan bakar selama Jangan merusak
contacting thesaringan
tank edge mesh
and dan [tulang 3] dengan
by bending.
fuel tank hole
instalasi menghubungi tepi tangki dan lentur.
during installation.
Bending the fuel filter:

[2] [3]
6-31
Pas ang the
Install set plate [1] sementara
set plate [1] while menekan fuel pump
pushing down unit
the fuel
[2] ke bawah. [2]
pump unit [2].
Pas ang dan kencangkan fuel pump set plate s crew [3].
Install and tighten the fuel pump set plate screw [3].
Alurkan kawat pump Sambungkan quick connect fitting pada sisi fuel pump
unit the
Route dengan
pump benar
unit Connect
(hal. 6-26).the fuel pump side quick connect fitting (page
(hal. 1-14).
wire properly (page 6-26). tekanan bahan bakar (hal. 6-27).
Naikkan
1-14). Increase the fuel pressure (page 6-27).
[3]
[1]
FUEL TANK
FUEL TANK (TANGKI BAHAN BAKAR)
Remove the body cover (page 3-13).
Lepaskan body cover (hal. 3-13)
Relieve the fuel pressure (page 6-23).
Bebaskan tekanan bahan bakar (hal. 6-23).
Disconnect the fuel pump side quick connect fitting
Lepaskan quick connect fitting pada sisi fuel pump (hal.
(page 6-24).
6-24).
Release the
Lepaskan wirewire
bandband boss
boss [1] from
[1] dari fuel the
tankfuel
. tank.
[1]
Remove the
Lepaskan four bolts
keempat baut[1]
[1]and
danfuel
fueltank
tank[2].
[2].
the reverse orderurutan
of removal. [1]
Pemasangan dalam terbalik dari [2]
pelepas an.
6-32
AIR CLEANER HOUSING
PELEPASAN
REMOVAL
Lepaskan
following:
[1] [2]
- Air c leaner element (hal. 4-6)
– Air cleaner element (page 4-6)
- Main pipe cover (hal. 3-15).
– Main pipe cover (page 3-15)
Lepaskan crankcase breather hose [1].
Disconnect the crankcase breather hose [1].
Longgarkan
Loosen thesekrup connecting
connecting hosescrew
hose band [2].
band [2].
Lepaskan
Remove kedua
the twobaut pemasangan
mounting [1] and
bolts [1] dan air
air cleaner
cleaner [2]
housing(2).
housing [2].
Alurkan hose dengan Pemasangan adalah dalam urutan terbalik dari
Route
benar hose Installation is in the reverse order of removal.
the1-14).
(hal.
properly pelepas an.
TORQUE:
(page 1-14). TORSI:
AIR CLEANER 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
SEKRUP AIR
CONNECTING 2,1 N.m (0,21 kgf.m; 1,5 lbf.ft)
CLEANER
HOSE BAND
CONNECTING
SCREW
HOSE BAND
[1]
SENSOR UNIT
PELEPASAN
REMOVAL
• •Selalu
Alwaysbersihkan di sekitar
clean around throttlebody
the throttle sebelum
bodybefore the
melepaskan agar dirt
supaya debu from
dan [2] [1]
sensor unit removal to prevent
sensor unit and debris
kotoran tidak
entering theakan memasuki s aluran lintas an udara.
air passage.
Remove the
Lepaskan rightright lower
cover (hal.(page
3-12).3-12).
Disconnect
Lepaskan theorsensor
sens unit 5Punit 5P (Black)
connector connector
(Hitam) [1]. [1].
Remove sekrup
Lepaskan the torxtorx
screws [2], sensor
[2], sensor unitdan
unit [3] [3] O-ring
and O-ring
[4].
[4].
[3] [4]
6-33
INSTALLATION
PEMASANGAN
If the O-ring is not Install a new O-ring [1] to the throttle body properly.
Jika O-ring tidak Pas ang sebuah O-ring [1] baru pada throttle body [2]
installed properly, [1]
dipasang dengan dengan benar.
Install the sensor unit [2] to the throttle body by aligning
the idleidle
air air
willakan
leak
benar, the clip of the TP sensor and boss of the throttle valve.
and engine
bocor dan putaran idle Pas ang sensor unit [2] pada throttle body dengan
stasionerspeed
mesinwill be
akan • The lightclip
mentepatkan pressure
dari TPissensor
sufficient
dan tobossassemble the
dari throttle
unstable.
tidak stabil. sensor unit and throttle body in their correct position.
valve.
• If you cannot
Untuk merakitassemble themdan
sensor unit easily, the clip
throttle bodymay be
pada
misaligned. Do not attempt to force
posisi mereka yang benar, cukup diperlukan them together
and make
tekanan sure that the clip is aligned.
ringan.
J ika anda tidak dapat merakit mereka dengan
mudah, kemungkinan posis i clip tidak tepat. Jangan
mencoba untuk memasang dengan paksa dan
pastikan bahwa clip sudah tepat pemasangannya.
Tepatkan
Install
Pas ang and
dan tighten the torx
kencangkan screws
sekrup [1] [1]
torx to dengan
the specified
torsi [2]
torque.
yang ditentukan.
TORSI: 3,43.4
TORQUE: N.m (0,35
N·m kgf.m;
(0.35 2,52.5
kgf·m, lbf.ft)
lbf·ft)
Sambungkan
Connect the sensor
sensor unit
unit 5P
5P connector (Hitam) [2].
(Black) connector [2].
Pas ang right lower side cover (hal. 3-12).
Install the right
• J alankan lowervalve
throttle side cover
fully (page
closed3-12).
position res et
•procedure
Perform the(prosedur
throttle valve fully closed
penyetelan positionposisi
kembali reset
procedure
tertutup penuh(page 6-34).
throttle valve) (hal. 6-33).
[1]
TP SENSOR RESET PROCEDURE

TP SENSOR RESET PR OCEDURE
• Make sure that failure code is not stored in ECM. If
• the failurebahwa
Pastikan code istidak
stored in kode
ada ECM, kegagalan
TP sensor yang
reset
mode won’t
disimpan di start
dalamby ECM.
following
Jikathe
adaprocedure below.
kode kegagalan
1. yang
Remove disimpan di dalam
the left lower ECM, (page
side cover TP sensor
3-12). res et
mode tidak dapat dipasang dengan mengikuti [1]
2. prosedur
Turn the ignition
di bawah.switch "OFF".
1.3. Lepaskan
Release the connector
left lower sidecover [1](hal.
cover from3-12).
the guide [2] of
the frame.
2. Putar ignition switch ke “OFF”.
Remove the connector cover from the DLC [3].
3. Lepaskan connector cover [1] dari guide [2] dari
4. Connect the special tool to the DLC.
rangka.
Lepaskan
TOOL: connector cover dari DLC [3].
[4] SCS connector
4. Hubungkan special tool ke DLC.070PZ-ZY30100
TOOL:
[2] [3] [4]
5.5. Lepaskan
DisconnectEOT
the EOT sensor
sensor 2P connector
Short the EOT
Hubungkan sensorEOT
singkat terminals
sens orwith jumper wire
terminals [2].
dengan
jumper wire [2].
CONNECTION: Yellow/blue – Green/orange Kuning Hijau/
/biru Orange
HUBUNGAN: Kuning/biru – Hijau/jingga
[1] [2]
6-34
6.6. Putar
Turn the ignition
ignition switch
s witch ke "ON" then disconnect
“ON” kemudian the
lepas kan
jumper wire
jumper wire [1] from the EOT
dari EOT sensor
sensor 2P connector
2P connector [2]
s[2] while theMIL
ementara MILberkedip
is blinking(pola
(reset receiving pattern)
penerimaan reset)
sfor 10 seconds.
elama 10 detik.
[2] [1]
7.7. Periks
Checkaifapakah
the MILMIL
blinks.
berkedip.
After disconnection of the jumper
Setelah melepaskan jumper wire, wire, the MIL
MIL harus should
mulai start blinking.
berkedip (successful pattern)
(pola berhasil)
dalam 10 detik. 0,3 detik.

0,3 detik.
MIL 0,1 detik.
TP SENSOR
TELAH DIRESET
ON 1,2 detik. DENGAN
BERHASIL.
OFF
IGNITION
SWITCH POLA PENERIMAAN RESET POLA BERHASIL
ON
dan
OFF
JIfika
thejumper
jumperwire dihubungkan
wire is connected selama lebih than
for more dari 10
10
detik,
seconds, MIL akan
the menyala
MIL will terus
stay (pola
ON tidak berhasil).
(unsuccessful
Coba lagiTry
pattern). dariagain
langkah
from4.the step 4.
8.8. Putar
Turn the ignition
ignition ke "OFF".
switch
switch “OFF”.
9.9. Sambungkan
Connect the EOT
EOTsensor
sensor2P
2Pconnector [1].
c onnector[1].
[1]
6-35
10. Lepaskan special
10.Disconnect tool [1]
the special dari
tool [1]DLC
from[2].
the DLC [2].
[2] [3]
11. Pasangthe
11.Install connector
connec [3][3]
cover
tor cover ketoDLC.
the DLC.
Tempatkan
Set the connector
connectorcover ontopada
cover the guide dari
guide of therangka
frame
[4].
12. Pasangthe
12.Install leftleft
lower
lowerside cov
side er (hal.
cover 3-12).
(page 3-12).
13. Letakkanthe
13.Support s epedamotor
motorcycle pada centerstand-nya.
with its centerstand.
Panaskan mesin s elama kira-kira sepuluh menit.
Warm up the engine about ten minutes.
Hubungkan tachometer dan periks a putaran
sConnect
tasioner.the tachometer and check the idle speed.
PUTARAN
ENGINE IDLESTASIONER
SPEED: 1,400 MESIN: 1.400
± 100 min -1 ± 100
(rpm)
-1
menit (rpm)
If the idle speed is out of the specification, check the
Jfollowing:
ika putaran stasioner mesin diluar spesifikasi, [1] [4]
periksalah sebagai berikut:
- – Cara
Throttle operation
kerja throttleand throttle
dan jarak grip
mainfreeplay
bebas(page 4-
throttle
5). (hal. 4-5).
grip
- – Ada
Intake air leak. udara masuk.
kebocoran
- – Cara
IACV kerja
operation
IACV(page 6-37).
(hal. 6-36).
IACV
PELEPASAN
REMOVAL
Lepaskan rightright
Remove the lower sideside
lower cover (hal.(page
cover 3-12).3-12).
[3] [4]
Lepaskan IACV
Disconnect the 4P connector
IACV (Hitam)
4P (Black) [1]. [1].
connector
Lepaskan sekrup2
Remove the torx [2].[2],
torx screws setset [3] [3]
plate
plate danand
IACV [4].[4].
IACV
[1] [2]
INSTALLATION
PEMASANGAN
Turn sthe
Putar lideslide
v alvvalve
e [1] [1] clockwise
searah jarumuntil
jamlightly seated
sampai on
duduk
IACV [2].
dengan ringan pada IACV [2]. [2]
[1]
6-36
Pas ang the
Install IACV [1] dengan
IACV mentepatkan
[1] by aligning the pin dengan
pin with the slide
slide
valveslot
valve slot.
(potongan pada slide valve).
Tepatkan [1]
Install
Pas ang the
set set
plateplate [1] by aligning
[1] dengan the tab
mentepatkan ofdari
tab the IACV
IACV
with theslot
dengan slotdari
of set
set plate
plate as shown.
seperti diperlihatkan. Tepatkan [1]
Pas ang and

Install dan tighten
kencangkan sekrup
the torx torx
screws [1][1]
to dengan torsi
the specified
yang ditentukan. [2]
torque.
TORSI: 2,1 N.m (0,21 kgf.m; 1,5 lbf.ft)
TORQUE: 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
Sambungkan IACV 4P connector (Hitam) [2].
Connect the IACV 4P (Black) connector [2].
Pas ang right lower side cover (hak, 3-12).
Install the right lower side cover (page 3-12).
[1]
PEMERIKSAAN
INSPECTION
IACV [1] dipasang
The IACV pada throttle
[1] is installed on thebody danbody
throttle dijalankan
and is
[1]
oleh
operated
step by Sewaktu
the step
motor. motor. ignition
When the diputar
ignition
switch switchke
is
turned
“ON”, "ON",
IACV the IACVselama
beroperasi operates for a fewdetik.
beberapa seconds.
Check the
Periksa step beroperasinya
suara motor operating step
soundmotor
with thesewaktu
ignition
switch switch
ignition turneddiputar
"ON". ke “ON”.
6-37
Lepaskan IACV
Remove the (hal.(page
IACV 6-36).6-36). [2]
Check the
Periksa IACV IACV
slideslide valve
valve [1] [1]
danand IACV
jalan air passage
lintasan udara
[2] in the
IACV [2] throttle
di dalambodythrottle
for carbon
bodydeposits.
terhadap endapan
Clean the IACV slide valve and IACV air passage if
karbon.
necessary.IACV slide valve dan jalan lintasan udara
Bersihkan
IACV apabila perlu.
[1]
Temporarily
Untuk sementaraconnect the IACV 4P IACV
sambungkan (Black)4P
connector.
connector
Turn the
(Hitam) [1].ignition switch "ON".
The slide
Putar ignitionvalve [1]hshould
switc move back and forth.
ke “ON”. [1]
Slide v alv e [2] harus bergerak
Disconnect the IACV 4P (Black) majuconnector
dan mundur.
and install
the IACV IACV
Lepaskan (page4P
6-36).
c onnector (Hitam) dan pasang IACV
(hal. 6-36).
Recheck the engine idle speed (page 4-10).
Periksa kembali putaran stasioner mesin (hal. 4-10).
THROTTLE BODY
PELEPASAN
REMOVAL
Relieve the
tekanan (page (hal.
bahan bakar 6-23).
6-23).
Disconnect the connect
injector side [2]
Lepaskan quick fittingquick
padaconnect fitting(hal.
sisi injector (page
6-
6-25).
25).
Lepaskan lower
Remove the sideside
lower ers (hal.(page
covcovers 3-12).
3-12).
Lepaskan s ensor
Disconnect unit unit
the sensor 5P 5Pconnec (Hitam) [1]
tor connector
(Black) [1] dan
and
IACV 4P connector (Hitam) [2]
IACV 4P (Black) connector [2].
[1]
Longgarkan mur penguncian
Loosen the throttle cable lock nut [1] andcable
throttle [1] [2].
adjuster dan
[4] [2]
Release[2].the throttle cable [3] from the stay [4] and
adjuster
Lepaskan
throttle drum [5]. c able [3] dari stay [4] dan throttle
throttle
drum [5]/
[1]
[3] [5]
6-38
Longgarkan
Loosen theair
aircleaner
cleanerconnecting
connectinghose
hoseband screw [1].
bandscrew [1].
[1]
Lepaskan
Remove the bautinsulator
pemasangan mounting bolts [1]
ins ulator [1] dan
and throttle
throttle
body[2].
[2]. [2]
body
Remove O-ring
Lepaskan the O-ring [3] from
[3] dari the insulator.
insulator.
CATATAN:
Tutupilah
Seal the lubang
cylinderpemasukan
head intake port with
c ylinder dengan
a shop
head kain
towel or
lap atauit tutupilah
cover dengan
with a piece of sepotong tape agar
tape to prevent any supaya
foreign
benda asing
material tidak
from dapat into
dropping jatuhthe
ke engine.
dalam mesin.
[1] [3]
PEMBONGKARAN
DISASSEMBLY
• •Throttle
The throttle bodydisetel-awal
body telah is factory dipre-set.
pabrik. DoJangannot
disassemble
bongkar in a way
dengan cara otherlain than shown inyang
daripada this
manual.
diperlihatkan di dalam buku pedoman reparasi ini.
• •J angan
Do notmenghentakkan
snap the throttlethrottle
valve from
valvefulldari
open to full
terbuka
penuh ke tertutup penuh setelah throttle cable telahIt
close after the throttle cable has been removed.
dikmay cause incorrect
eluarkan. Ini dapatidlemengakibatkan
operation. cara k erja
•putaran
Do notstasioner
damageyang the tidak
throttle body. It may cause
benar.
incorrect merusak
• J angan throttle valvethrottle
operation.body. Ini dapat
• Do not loosen or tighten the white painted nut [1] of
mengakibatkan cara kerja throttle valve yang tidak
the throttle drum. Loosening or tightening it can
benar.
cause throttle body malfunction.
• J angan longgarkan atau kencangkan mur [1] yang
dic at putih dari throttle drum. Melonggarkan atau
–mengencangkannya
IACV (page 6-36) dapat menyebabkan kegagalan
–pemakaian
Sensor unitdari throttle
(page body.
6-33) [1]
– Injector (page 6-44)
- Loosen
IACVthe
(hal. 6-36)
band screw [1] and remove the insulator [2]
- from
Sens
theor unit (hal.
throttle body6-33)
[3]. [3]
- Injector (hal. 6-44)
Longgarkan sek rup band [1] dan lepaskan insulator [2]
dari throttle body [3].
[1] [2]
6-39
CLEANING
PEMBERSIHAN
- – IACV (page 6-36)
(hal. 6-35)
- – Sens
Sensoror unit
unit (page 6-33)
(hal. 6-32)
- – Injector
Injector (page 6-44)
(hal. 6-43).
Blow open
Tiuplah each air ing
masing-mas passage
jalan inlintas
the throttle
an udarabodydi [1] with
dalam
the compressed
throttle air. udara dari kompress or.
body [1] dengan
• • JDoangan menggunakan
not use high pressure udara bertekanan
air or bring the tinggi
nozzleatautoo
membawa throttleterlalu
close to thenozzle body.dekat pada throttle body.
[1]
ASSEMBLY
PERAKITAN
INJECTOR JOINT MOUNTING BOLTS
IACV IACV TORX SCREWS 5,1 N·m (0,52 kgf·m; 3,8 lbf·ft)
2.1 N·m (0,21 kgf·m; 1,5 lbf·ft)
SENSOR UNIT TORX SCREWS
INJECTOR JOINT
3,4 N·m (0,35 kgf·m; 2,5 lbf·ft)
SET PLATE
RUBBER CAP
O-RING
INJECTOR
SENSOR UNIT
SEAL RING
O-RING
THROTTLE BODY
Pas ang the

Install insulator[1][1] dengan
insulator mentepatkan
by aligning alurnya
its groove with the
dengan
boss ofboss pada throttle
the throttle body [2].
body [2]. [2]
Tepatkan [1]
6-40
Kencangkan
Tighten the sekrupinsulator screw[1][1]
band band
insulator sehingga
so thatjarak
the
renggang
clearanceantara
betweenujung bandadalah
theband 7 ±7 1±mm.
ends is 1 mm (0.3 ± 7 ± 1 mm
CATATAN:
0.04 in).
Jalankan throttle valve fully closed position reset
[1]
procedure (hal. 6-33), jika sensor unit telah dilepaskan
Perform
dari throttlethe throttle valve fully closed position reset
body.
procedure (page 6-34), if the sensor unit has been
Pas ang sebagai
removed from the berik ut: body.
throttle
- Injector (hal. 6-45)
- Install
Sens the
orfollowing:
unit (hal. 6-34)
- – IACV
Injector(hal. 6-36)
(page 6-45)
– Sensor unit (page 6-34)
– IACV (page 6-36)
INSTALLATION
PEMASANGAN
Install
Pas ang aO-ring
new O-ring [1]ke
[1] baru into the insulator
dalam groove.
alur ins ulator.
[1]
Install
Pas ang the throttle
throttle bodybody [1] onto
[1] pada the cylinder
cylinder head. head.
Install [1]
Pas ang and tighten the baut2
dan kencangkan insulator mounting ins
pemasangan bolts [2]
ulator
alternately
[2] to the specified
secara bergantian dengan torque.
TORQUE:
TORSI: 12 N•m
12 N.m (1,2(1.2 kgf•m,
kgf.m; 9 lbf•ft)
9 lbf.ft)
[2]
Kencangkan sekrup
Tighten the air cleaner
air connecting hoseting
cleaner connec band screw
hose [1]
band
[1]
todengan torsi yang
the specified ditentukan.
torque. [1]
TORSI: 2,12.1
TORQUE: N.mN•m
(0,21 kgf.m;
(0.21 1,5 1.5
kgf•m, lbf.ft)
lbf•ft)
6-41
Hubungkan
Connect thethrottle
throttle cable
cable [1] tokethe drum[2]
throttledrum
throttle [2] dan
and
tempatkan pada [3]. [3]
set the cable to the
c able stay [3].
stay
Adjust
Setel the main
jarak throttle grip throttle
bebas freeplaygrip
(page 4-5).
(hal. 4-5).
[1] [2]
Sambungkan
Connect the sens or unit
sensor unit 5P
5P connector (Hitam) [1]
(Black) connector [1] dan
and
IACV4P
IACV 4Pconnector (Hitam) [2].
(Black) connector [2]. [2]
Sambungkan
Connect the quick
injector side quick
c onnect pada sisi
fittingconnect fitting (page
injector (hal.
6-
27).
6-27).
Increase the fuel pressure (page 6-27).
Naikkan tekanan bahan bakar (hal. 6-27).
Install
Pas ang the lower
lower sideside covers
covers (page
(hal. 3-12).
3-12).
[1]
ECM
REMOVAL/ INSTALLATION
Remove the
Lepaskan rightright
bodybody cover
cover (hal.(page
3-13).3-13).
[2]
Disconnect
Lepaskan ECMthe33P
ECMconnector
33P (Black) connector
(Hitam) [1]. [1].
Release the
Lepaskan ECM ECM [2] from
[2] dari the dan
rangka frame and remove it.
ambillah.
dalam of removal.
terbalik dari
pelepas an.
[1]
6-42
ENGINE
MESIN DOES
TIDAK NOT
MAU START (MIL DOES
HIDUP
NOTTIDAK
(MIL BLINK)
BERKEDIP)
1.1. Pemeriksaan
ECM Ground Saluran
Line Inspection
Massa ECM
•• Before starting the inspection,
Sebelum memulai penyelidikan, check for loose or
periksalah
poor contact on the ECM 33P (Black)
terhadap kontak longgar atau buruk pada ECMconnector
and
33Precheck the MIL
connector blinking.
(Hitam) dan periksa ulang
• Make sure that the battery is fully charged.
kedipan MIL.
•TurnPastikan
the ignition
bahwaswitch "OFF".
baterai bermuatan penuh.
Disconnect
Putar ignitionthe ECMke
switch 33P (Black) connector.
“OFF”. (Sisi kawat/terminal betina)
Check forECM
Lepaskan continuity between
33P connector the [1].
(Hitam) ECM 33P
connector of the wire harness side and ground.
Periksa terhadap kontinuitas antara ECM 33P
TOOL:
connector pada sisi wire harness dan massa.
Test probe
TOOL: 07ZAJ-RDJA110
Test probe 07ZAJ-RDJA110 Hijau Hijau Hijau/Hitam
CONNECTION: Green – Ground
HUBUNGAN: Hijau – Massa – Ground
Green/black
Hijau/hitam – Massa
NO – • Open circuit in Green wire.
TIDAK - • Open circuit in Green/black wire.
• Rangkaian terbuka pada kawat Hijau.
2. Sensor Unit Power Input Line Short Circuit
•Inspection
Rangkaian terbuka pada kawat Hijau/hitam.

2. Pemeriksaan Hubungan Singkat pada Saluran SENSOR UNIT 5P CONNECTOR (Hitam)
Pemasukan
Disconnect the Daya Sensor
sensor unit Unit
5P (Black) connector. (Sisi kawat/terminal betina)
Check for continuity between the sensor unit 5P
connector sensor
Lepaskan of the wire
unit harness side and
5P connector ground.
(Hitam) [1].
CONNECTION: Yellow/red – Ground
Periksa terhadap kontinuitas antara sensor unit 5P
STANDARD: No continuity
connector pada sisi wire harness dan massa. Kuning/merah
HUBUNGAN: Kuning/merah – Massa
YES – Short Tidak
STANDARD: circuit ada
in the Yellow/red wire
kontinuitas
NO – ada
Apakah GO kontinuitas?
TO STEP 3.
YA - Ada hubungan singkat pada kawat
Kuning/merah
TIDAK - LANJUTKAN DENGAN LANGKAH 3.
3. ECM Power Line Inspection 1
3. Turn the ignition

Pemeriksaan switch "ON".
1 Saluran Daya ECM ECM 33P CONNECTOR Hitam)
Measure the voltage between the ECM 33P (Black) (sisi kawat/terminal betina)
connector of the wire harness side and ground.
Ukur
TOOL:voltase antara ECM 33P connector (Hitam) [1]
pada sisi wire harness dan massa.
TOOL:
Test probe
CONNECTION: Black/blue (+) 07ZAJ-RDJA110
– Ground (–) Hitam/biru
HUBUNGAN: Hitam/biru (+) – Massa (-)
Does the battery voltage exist?
Apakah ada voltase baterai?
YA and recheck.
- Ganti dengan ECM lain yang diketahui
dalam
NO keadaan
– GO TObaik,
STEPdan
4.periksa ulang.
6-43
4.4. Pemeriksaan 2 Saluran
ECM Power Line Daya2ECM
Inspection
Putar
Turn the ignition
ignition ke “OFF”.
switch
switch "OFF".
Lepaskan
Disconnect the regulator/rectifier
regulator/rectifier [1]. [1].
6P connector
6P connector
Putar
Turn the ignition
ignition switch
switch "ON".
ke “ON”.
Ukur
Measurekontinuitas antara terminal2
the continuity between berikut
the dari
following
ECM
terminals
33P of the(Hitam)
connector [2] padaside
wire harness sisi wire
of ECM 33P
harness
(Black)
dan connector 6P
regulator/rectifier and regulator/rectifier 6P
connector.
connector.
TOOL:
TOOL:
Test
Test probe
probe 07ZAJ-RDJA110
07ZAJ-RDJA110
HUBUNGAN: Hitam/biru – Merah
CONNECTION: Black/blue – Red
YA - Periksa regulator/rectifier (hal. 16-8). [1]
YES – Inspect the regulator/rectifier (page 16-9).
TIDAK -
•NO Rangkaian
– • Open or short
terbuka ataucircuit in Black/blue
ada hubungan wire
singkat
pada kawatbetween ECM 33P
Hitam/biru connector
antara ECM 33P and
ignition switch 4P connector
connector dan ignition switch 4P connector
• • Open
Rangkaian or short
terbuka atau adacircuit in Red
hubungan wire
singkat
between ignition switch 4P
pada kawat Merah antara ignition switch 4P connector
connector anddanregulator/rectifier 6P6P
regulator/rec tifier connector
connector.
INJECTOR
REMOVAL
PELEPASAN
• • Selalu
Always clean arounddithesekitar
bersihkan injector injector
before thesebelum
injector
removal to prevent
melepaskan injectordirt and menghindari
untuk debris from entering the
masuknya
injector
debu passage.
dan kotoran ke dalam jalan lintas an injector.
• This motorcycle uses resin for the part of materials
• Sepedamotor ini menggunakan res in untuk
in the fuel hose. Do not bend or twist the fuel hose.
s ebagian bahan pada fuel hose. Jangan
Relieve the fuel pressure
memengkokkan (page 6-23).
atau memelintir fuel hose.
Remove the
Bebaskan left lower
tekanan bahanside cover
bakar (page
(hal. 3-12).
6-23).
Pull off the
Lepaskan leftdust
lowercover
side[1].
cover (hal. 3-12).
Disconnect the injector 2P (Black) connector [2].
Tarik lepas dust cov er [1].
Lepaskan injector 2P connector (Hitam) [2].
[1] [2]
Lepaskan
Disconnect the connect
quick injector side padaconnect
fittingquick sisi injector
fitting(hal. 6-
(page
[1]
6-25).
25).
Lepaskan baut [1] dan injec tor as sembly [2] dari throttle
Remove the bolts [1] and injector assembly [2] from the
body.
throttle body.
[2]
6-44
Remove the
Lepaskan rubber
rubber cap cap [1] from
[1] dari the joint
injector injector
[2]. joint [2].
Remove the injector [2]
Lepaskan injector jointjoint
darifrom the [3].
injector injector [3].
Check the
Periksa rubber
rubber capcap for wearkeaus
terhadap or damage
an atauandkerusakan
replace it
if necessary.
dan ganti bila perlu.
[1]
[3]
Remove the
Lepaskan O-ring
O-ring [1] and
[1] dan sealseal
ringring [2] from
[2] dari the injector
injector [3].
[3]. [3]
Periksa parts yang dilepaskan terhadap keausan atau
Check thedan
kerusakan removed parts bila
ganti mereka for perlu.
wear or damage and
replace them if necessary.
[2] [1]
INSTALLATION
PEMASANGAN
Coat O-ring
Lapisi new O-ring [1] and
[1] baru dan seal
seal ring
ring [2]
[2] with engine
dengan oil.
oli mesin.
Install [3]
Pas ang aO-ring
new O-ring and seal
baru dan seal ring
ring to the injector
pada injector [3],
[3],
being careful not to damage them.
dengan berhati-hati agar tidak merusak mereka.
[2] [1]
Position
Tempatkan the injector Install
injector Pas ang the injector
injector jointjoint [1] onto
[1] pada the injector
injector [2]. [2]. [1]
Install [3]
connector
connector dan stopperand Pas ang the rubber
rubber capcap [3] to injector
[3] pada the injector
joint.joint.
daristopper
injectorofjoint
the
dengan sudut
injector joint inyang
the
diperlihatkan.
angle as shown.
Align
[2]
6-45
Hati-hati
Being agarnot
careful to Pas
tidak angthe
Install injector
injector assembly [1] [1]
assembly ke into
dalam
thethrottle
throttlebody.
body.
merusak [2]
damageseal the ring.
seal
ring.
Pas ang dan kencangkan baut pemasangan injec tor joint
[2] dengan torsi yang ditentukan.
Install and tighten the injector joint mounting bolts [2] to
the specified
TORSI: torque.
5,1 N.m (0,52 kgf.m; 3,8 lbf.ft)
TORQUE: 5.1quick
Sambungkan N·mc(0.52
onnectkgf·m,
fitting3.8 lbf·ft)
pada sisi injector (hal.
6-27).
Connect the injector side quick connect fitting (page 6-
27).
[1]
Connect the injector
Sambungkan injector 2P
connector (Hitam) [1].
[1]/
Putang
Pas thedust
dustccover [2]kembali
over [2] back in pada
the appropriate
posisi yangposition.
sesuai.
Increasetekanan
Naikkan the fuelbahan
pressure (page
bakar (hal.6-27).
6-27).
Install
Pas the removed
ang parts parts in
yang dilepaskan the urutan
dalam reverse orderdari
terbalik of
removal.
pelepas an.
[1] [2]
EOT SENSOR
• •Ganti
Replace
EOTthe EOT sementara
sensor sensor whilemesin dalamiskeadaan
the engine cold.
dingin. [1]
Lepaskan
– Lowersebagai berikut:
side covers (page 3-12)
- –Lower [1] covers (hal. 3-12).
Boltsside
- –Baut2
Lower[1] side cover stay [2]
- Lower side cover stay [2]
[2]
Disconnect
Lepaskan EOTthesensor
EOT sensor 2P connector
[1]
6-46
Letak kan around
Cover di Lepaskan
kain lapthe Remove the
EOTEOT
sensor [1] dan
sensor [1] and sealing
sealing [2]. [2].
washer
washer
sekitar sensor
sensor oleha
using [1]
karena ada sedikit
shop towel as someoli
yang akan
engine mengalir
oil flows out
keluar dari lubang
from the sensor
sensor.
hole.
Always
Selalu replace
ganti Install
sealinga Pas ang as ealing
new sealing washer
was her andEOT
baru dan EOTsensor.
sensor.
sealing washer with Tighten the EOT sensor to the specified torque.
washer de ngan yang Kencangkan EOT sensor dengan torsi yang ditentukan.
a newbaru.
one.
TORQUE:
TORSI: 14 N•m
14 N.m (1,4(1.4 kgf•m,
kgf.m; 10 lbf•ft)
10 lbf.ft)
Install
Pas the removed
ang parts parts in
terbalik of
removal.
pelepas an.
[2]
PEMERIKSAAN
INSPECTION
Lepaskan
Remove theEOTEOTsensor (hal.(page
sensor 6-45).6-46).
[2]
Pakailah sarung
Wear insulated
Panaskan dengan
coolant with
Heat the coolant komporheating
an electric listrik. element.
tangan berisolasi dan
gloves and Gantunglah
Suspend theEOT sensor [1]
EOTsensor dalam
[1] in heated coolantyang
c oolant and
perlindungan mata
adequate eye dipanaskan dan periksa kontinuitas melalui
check the continuity through the sensor as the coolant sensor
yang memadai. sewaktu coolant memanas.
protection.
Jauhkan bahan2 yang heats up.
Keep flammable • Rendam EOT sensor dalam coolant sampai ke
mudah terbakar dari • ulirnya
Soak thedengan
EOT sensor in coolant up todari
its threads
materials away
kompor from
listrik. sedikitnya 40 mm bagian
with at panci
bawah least 40 mm (1.57
sampai in) from
ke bagian bawahthe dari
bottom of the
switch.
the burner.
•
pan to the bottom of the switch.
Pertahankan suhu agar k onstan selama 3 menit
• Keep temperature constant for 3 minutes before
sebelum pengetesan. Perubahan mendadak pada
testing. A sudden change of temperature will result
suhu akan readings.
in incorrect menghasilkan
Do not pembacaan yang salah.
let the thermometer [2]
Jaga agar thermometer [2] atau EOT sensor tidak
or EOT sensor touch the pan.
menyentuh panci.
CONNECTION: A – B
HUBUNGAN: A – B [1]
Suhu°C 20 100
Tahanan(kΩ) 2,5 – 2,8 0,21 – 0,22
Ganti EOTthe
Replace EOTjik
sensor a ia diluar
sensor if it isspesifikasi.
out of specifications.
Pas ang the
Install EOT sensor
EOT (hal.(page
sensor 6-45).6-46).
O2 SENSOR
• • Jagalah
Do not get grease,
agar gemuk, oil or
oliother
atau materials in the
bahan lain O2
tidak
sensor air
memas uki hole.
lubang udara O2 sensor.
• • O
The2 O 2 sensor
sensor may be
dapat damaged
rusak jika ifdijatuhkan.
dropped. Replace
Ganti
it with a yang
dengan new one,
baru,if jika
dropped.
dijatuhkan.
REMOVAL
PELEPASAN
Replace the O2 Remove the right lower side cover (page 3-12).
Lepaskan right lower side cover (hal. 3-12). [2]
sensor while the
Remove the bolt [1] and O2 sensor holder [2].
engine is cold. Lepaskan baut [1] dan O2 sensor holder [2].
[1]
6-47
Tahan bagian
Hold the centertengah dari
of the O2 sensor cap or
O2 sens [1] cas [1] seperti
apshown.
Disconnect the cap from the sensor while slightly
diperlihatkan.
Lepaskan less dari
turning it, cap 1/2 of asambil
than sensor turn. memutarnya sedikit,
kurang dari ½ putaran.
Kurang dari
1/2 putaran
[1]
Gantilah
Remove the O2 Lepaskan
O 2 sensor Remove the
O2 sensor [1] dari
O2 sensor [1] from the cylinder
dengan mesin
sensor dalam
while the [1]
keadaan dingin. • • JDo not use
angan an impact
memakai impactwrench when
wrench removing
(obeng or
ketok)
engine is cold.
sinstalling
ewaktu the O2 sensor,atau
melepaskan or it memasang
may be damaged.
O2 sensor,
karena mungkin akan menimbulkan kerusakan
padanya.
PEMASANGAN
INSTALLATION
Install
Pas ang and
dantighten the O2 sensor
kencangkan [1] to[1]
O2 sensor thepada
cylinder head
cylinder
to the
head specified
dengan torsitorque.
yang ditentukan. [1]
TORSI: 25 25
TORQUE: N.mN·m
(2,5(2.5
kgf.m; 18 18
kgf·m, lbf.ft)
lbf·ft)
Sambungkan
Connect the O22 sensor cap[1][1]to pada
sensorcap the O2Osensor [2] [2]
2 sensor by
pushingmendorongnya
dengan it straight. lurus ke atasnya. [1]
• • Hati-hati
Be careful nottidak
agar to tilt the O2 sensor
memiringkan cap when
O2 sensor cap
connecting the cap to the O sensor.
sewaktu menyambungkan cap pada O2 sensor.
2
[2]
6-48
Install
Pas ang the
O2 Osensor
2 sensor holder[1]
holder [1]sementara
while aligning its stopper
mentepatkan Tepatkan
[1]
with the cylinder
stopper-nya dengan head tab. head tab.
cylinder
Install
Pas ang and
dan tighten the bolt
kencangkan [2].[2].
baut
After installation,
Setelah pemas angan, make sure the exhaust
pastikan bahwa gas doesada
tidak not
leak.
kebocoran gas pembuangan.
Install
Pas ang the
rightright lower
3-12).
[2]
6-49
CATATAN
7. PENURUNAN/PEMASANGAN MESIN
COMPONENT
LOK LOCATION
ASI KOMPONEN ····························7-2
....................................7-2 ENGINE REMOVAL
PENURUNAN MESIN······································ 7-4
.................................. 7-4 7
KETERANGAN SERVIS ................................7-3

SERVICE INFORMATION ·····························7-3 PEMASANGAN MESIN ............................... 7-6
ENGINE INSTALLATION······························ 7-6
7-1
PENURUNAN/PEMASANGAN MESIN
LOKASI KOMPONEN
ENGINE REMOVAL/INSTALLATION
12 N·m (1,2 kgf·m; 9 lbf·ft)
59 N·m (6,0 kgf·m; 44 lbf·ft)
12 N·m (1,2 kgf·m; 9 lbf·ft)
7-2
KETERANGAN SERVIS
SERVICE INFORMATION
GENERAL
UMUM
• During engine removal and installation, support the motorcycle with its centerstand.
•• Support
Selamathe penurunan dan pemasangan
engine using a jack or othermesin, letakkan
adjustable sepedamotor
support to ease ofpada
enginecenterstand-nya.
hanger bolts removal.
•• The
Topang mesin
following dengan menggunakan
components dongkrak
can be serviced atau
with the alat pendukung
engine lainframe.
installed in the yang dapat disetel untuk mempermudah pelepasan
–baut-baut penggantung
Cylinder head (page 8-12) mes in.
• –Komponen
Cam chainberikut
tensioner (pagediservis
ini dapat 8-25) dengan mesin terpasang pada rangka.
–- Cylinder
Cylinder(page
head 9-4)
(hal. 8-12)
–- Piston (pagetensioner
Cam chain 9-4) (hal. 8-26)
–- Drive pulley
Cylinder (page
(hal. 9-5)10-9)
–- Driven
Pistonpulley (page 10-12)
(hal. 9-5)
–- Driveshaft/clutch
Driv e pulley (hal.(page
10-3) 10-21)
–- Oil pump
Driv (page 5-4)
eshaft/clutch (hal. 10-21)
–- Flywheel/starter
Oil pump (hal. 5-4)clutch (page 11-8)
- Flywheel/starter
• The following componentsclutch (hal. 11-8)
require engine removal for service.
• –Komponen
Crankshaftberikut ini memerlukan penurunan mesin untuk dapat diservis.
(page 12-7)
–- Kickstarter
Crank shaft(page
(hal. 12-7)
12-16)
–- Secondary
Kickstarterreduction
(hal. 12-16)(page 12-21)
- Secondary reduction (hal. 12-21)
SPESIFIKASI
BAGIAN SPESIFIKASI
Berat kosong mesin 27,3 kg
Kapasitas oli mesin Penggantian periodik 1,0 liter
Pada pembongkaran 1,2 liter
mesin
Oli mesin yang dianjurkan AHM-OIL MPX1 4T 10W-30 SJ JASO MA
TORSI PENGENCANGAN
TORQUE VALUES
Mur penggantungan mesin 59 N.m (6,0 kgf.m; 44 lbf.ft)
Engine
Baut hanger nutthrottle body insulator
pemasangan 59 N·m (6.0 kgf·m,
12 N.m 44 lbf·ft)
(1,2 kgf.m; 9 lbf.ft)
Throttle
Baut drivebody insulator
sprocket fixingmounting
plate bolt 12 N·m (1.2 kgf·m,
12 N.m 9 lbf·ft)
(1,2 kgf.m; 9 lbf.ft)
Drive sprocket
Sekrup fixingduct
clutch cover plate bolt
band 12 N·m
2,1(1.2
N.mkgf·m,
(0,21 9 lbf·ft)1,5 lbf.ft)
kgf.m;
Clutch cover duct band screw 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
7-3
PENURUNAN MESIN
Letakkan
Support sepedamotor
the motorcyclediwith
atasits
centerstand-nya.
centerstand.
Keluarkan
Drain the oli mesin
engine oil(hal.
(page4-9).
4-9).
Lepaskan
following:
- Lower side covers (hal. 3-12)
– Lower side covers (page 3-12)
- Right body cov er (hal. 3-13)
– Right body cover (page 3-13)
- –Left crankcase
Left crankcase rear cover
rear (hal.
cover 3-17)
(page 3-17)
- –Chain
Sparkcase (hal.
plug cap3-18)
(page 4-7)
- Spark plug cap (hal. 4-7).
Disconnect the O2 sensor 1P (Black) connector [1].
Lepaskan O2 sensor 1P connector (Hitam) [1]
[1]
Release clutch
Lepaskan the clutch cover
cov er outletoutlet
duc t duct
boss boss [1]clamp
[1] dari from the
[2]
[2] [3]
clamp
pada [2] of the
rangka danframe and disconnect
lepaskan starter motorthe2P
starter motor
connector
2P connector [3].
[3].
[1]
Longgarkan
Loosen thesekrup band [1]
band screw [1] dan
and lepas kan clutch
disconnect cover
the clutch
[2]
cover
inlet inlet
duct [2] duct [2] from the engine.
dari mesin.
[1]
Lepaskan
Disconnectsambungan
the EOTEOT sensor
sensor 2P2Pconnector
connector[1]
[1] dan
and
lepaskan kawat
release the EOTEOT sensor
sensor wire[2][2]dari
fromclamp [3]. [3].
the clamp [3]
[1] [2]
7-4
Lepaskan sebagai
Disconnect berikut:
the following:
[3] [4]
- Connector kawat CKP sensor (Putih/kuning) [1] dan
– connector
CKP sensor wire (White/yellow) connector [1] and
(Biru/kuning) [2]
(Blue/yellow) connector [2]
- Alternator 2P connector [3]
– Alternator 2P connector [3]
-– Sidestand
Sidestand switc h 3P
switch 3P connector (Hijau) [4][4]
(Green) connector
[2] [1]
Disconnect
Lepaskan the crankcase
crankcase breather
breather hose [1].
hose [1] [1]
Remove baut-baut
Lepaskan the throttlepemasangan
body insulator mounting
throttle bolts [1]
body insulator [1]
and
[1] O-ring
dan [2].
O-ring [2].
[2]
Loosen themur-mur
Longgarkan lock nutspengunc
[1], drive chain
i [1], driveadjusters [2] and
c hain adjusters [2]
axle
[2] dannut
mur[3].poros [3].
Push the
Dorong rodarear wheel forward.
belakang ke depan.
[3]
[1]
7-5
Remove the
Lepaskan drive sprocket
baut-baut fixing plate
drive sprocket fixingbolts
plate[1].
[1]. [3]
[1]
Turn dan
Putar and lepaskan
remove the fixing
fixing plate
plate [2].[2].
Remove the
Lepaskan drive
drive sprocket
sprocket [3] [3] from
dari thehaft
finals finalshaft and
dan drive
drive[4].
chain chain [4].
[4] [2]
Topang
Supportmesin dengan
the engine menggunakan
using dongkrak
a jack or other atau
adjustable
alat penopang lain yang dapat disetel. [2]/[4] [1]/[4]
support.
Lepaskan murfront
Remove the penggantung depannut
engine hanger mesin
[1]. [1].
Remove the
Lepaskan murrear upper engine
penggantung hanger nut
belakang atas[2]mesin
and rear
[2]
lower
dan murengine hanger nut
penggantung [3].
belakang bawah mesin [3].
Remove the
Lepaskan enginepenggantung
baut-baut hanger bolts mesin
[4] and [4]engine from
dan mesin
the rangka.
dari frame.
• • Wrap
Bungkuslah inlet manifold
the intake manifold port (lubang
port with pemasukan
a shop towel or
mesin) dengan
cover it with kainoflap
a piece tapeatau tutupilah
to prevent anydengan
foreign
smaterial
epotongfrom
pitadropping
untuk menc egah
into the masuknya benda
engine.
asing ke dalam mesin.
[3]/[4]
PEMASANGAN MESIN
CATATAN:
• • Note
Perhatikan arah pemasukan
the direction bautbolts.
of the hanger penggantung.
• • Pakailah
Use a floordongkrak atauadjustable
jack or other alat penopang
support,lain yang
carefully
dapat disetel,
place the dengan
engine menempatkan
into the mesin dengan
frame and maneuver it into
hati-hati
place. pada rangka dan menggerakkannya ke
• tempat pemasangannya.
Route the wires and hoses properly (page 1-14).
• Alirkan kawat-kawat dan hoses (slang-slang)
dengan benar (hal. 1-14).
Selama pemasangan Tempatkan mesininto

pada rangka
During engine
mesin, peganglah
Place the engine the frame anddan topang
support mesin
the engine [1]/[2] [1]/[4]
installation, holderat
the dengan
using a menggunakan dongkraksupport.
jack or other adjustable atau alat penopang
mesin dengan
engine
dan securely
hati-hati agar lain yang dapat disetel.
Install the engine hanger bolts [1] and nuts.
and
tidak be careful
merusak not
rangka Pas ang baut penggantung mesin [1] dan mur-mur.
to damage the
dan mesin. Tighten the rear upper engine hanger nut [2] to the
frame and engine. specified torque.
Kencangkan mur penggantung belakang atas mesin [2]
dengan torsi yang ditentukan.
Tighten the rear lower engine hanger nut [3] to the
Kencangkan mur penggantung belakang bawah mesin
specified torque.
Tighten the front engine hanger nut [4] to the specified
Kencangkan
torque. mur penggantung depan mesin [4] dengan [1]/[3]
7-6
Pas ang the
Install drive c hain
drive [1] pada
chain drive
[1] onto thesproc
driveket [2].
sprocket [2]. [1] [2]
Install
Pas ang the drive
drive sprocket
s procket padaonto thehaft.
finals finalshaft.
Install
Pas ang the fixingplate
fixing plate [3] topada
the finalshaft
finalshaftwhile aligning
sementara
their teeth. gigi-gigi mereka.
mentepatkan
Rotate
Putar the plate
fixing fixingdan
plate and align
jajarkan theirbaut
lubang bolt holes.
mereka.
Install
Pas ang and
dan tighten the drive
kencangkan sprocket
baut-baut drivefixing plate fixing
sprocket bolts
[4] alternately
plate to the bergantian
[4] secara specified torque.
dengan torsi yang
ditentukan.
[3] [4]
Install
Pas ang aO-ring
new O-ring [1]ke
baru [1] into the insulator
dalam groove.
alur ins ulator.
[2]
Install
Pas ang and tighten the throttle
dan kencangkan body
baut-baut insulator mounting
pemasangan throttle
boltsinsulator
body [2] to the[2]
specified
dengan torque.
TORQUE:
TORSI: 12 N·m
12 N.m (1,2(1.2 kgf·m,
kgf.m; 9 lbf·ft)
9 lbf.ft)
[1]
Connect the crankcase breather hose.

Sambungkan [1]
Connect the sebagai

Sambungkan following:berikut:
[3] [4]
-– Kawat CKP sensor
CKP sensor connector (Putih/kuning)
wire (White/yellow) [1] dan
connector [1] and
connector (Biru/kuning)
[2]
-– Alternator
Alternator 2P
2P connector
connector [3]
[3]
-– Sidestand
Sidestand switc h 3P
switch 3P connector (Hijau) [4][4]
(Green) connector
[2] [1]
7-7
Sambungkan EOT sensor
Connect the EOT sensor 2P 2P connector
connector [1]secure
[1] and dan
amankan
the EOT kawat
sensorEOT
wiresensor
[2] with[2]
thedengan
clamp clamp
[3]. [3]. [3]
[2]
[1]
Sambungkan
Connect the clutch
clutch cover
cover inlet
inlet duct
duct [1]
[1] pada
onto mesin dan
the engine
[1]
kencangkan sekrup
and tighten the band [2][2]to the
band screw dengan torsi
specified yang
torque.
ditentukan.
TORQUE: 2.1 N·m ( 0.21 kgf·m, 1.5 lbf·ft)
[2]
Sambungkan
Connect the starter
startermotor
motor2P 2Pconnector
connector[1][1]danandpasang
install
[3] [1]
clutch covercover
the clutch outlet ductduct
outlet boss [2][2]keinto
boss dalam clamp[3][3]
the clamp of
the frame.
pada rangka.
[2]
Connect the O
Sambungkan sensor 1P
O22 sensor 1P connector
(Black) connector
(Hitam) [1].
[1].
- Spark plug cap (hal. 4-7)
- –Chain
Sparkcaseplug cap3-18)
(hal. (page 4-7)
- –LeftChain case (page
crankcase 3-18)(hal. 3-17)
rear cover
- –Exhaust
Left crankcase rear(hal.
pipe/muffler cover (page 3-17)
3-20)
- –Right
Exhaust
body pipe/muffler (page 3-20)
cov er (hal. 3-13)
- –Lower
Rightside
body cover(hal.
covers (page 3-13)
3-12)
– Lower side covers (page 3-12)
Isi oli mes in yang dianjurkan sampai ke tinggi
Fill the recommended
permukaan yang sesuai engine oil up to the proper level
(hal. 4-9).
(page 4-9).
Setel kekenduran drive chain (hal. 4-11).
Adjust the drive chain slack (page 4-11).
[1]
7-8
8. CYLINDER HEAD/VALVES
LOK ASI KOMPONEN

COMPONENT ..................................
LOCATION 8-2
····························8-2 CYLINDER HEAD
HEAD COVER ..........................
···························8-6
8-6
KETERANGAN SERVIS .............................. 8-3 CAMSH AFT .................................................. 8-8 8

SERVICE INFORMATION ·····························8-3 CAMSHAFT··················································· 8-8
TROUBLESHOOTING ................................. 8-5 CYLINDER HEAD ........................................ 8-12

TROUBLESHOOTING···································8-5 CYLINDER HEAD ······································· 8-12
TEST KOMPRESSI CYLINDER .................. 8-6 CAM CHAIN TENSIONER ........................... 8-26
CYLINDER COMPRESSION TEST···············8-6 CAM CHAIN TENSIONER ·························· 8-26
8-1
LOKASI KOMPONEN
12 N·m (1,2 kgf·m; 9 lbf·ft)
18 N·m (1,8 kgf·m; 13 lbf·ft)
8 N·m (0,82 kgf·m; 5,9 lbf·ft)
10 N·m (1,0 kgf·m; 7 lbf·ft)
16 N·m (1,6 kgf·m; 12 lbf·ft)
22 N·m (2,2 kgf·m; 16 lbf·ft)
8-2
KETERANGAN
SERVICE SERVIS
INFORMATION
GENERAL
UMUM
••This
Babsection covers
ini meliputi service
servis dari of the cylinder
cylinder head, head,
valves,valves, camshaft
camshaft dan camandchain
cam tensioner.
chain tensioner.
••The cylinder
Servis padahead, valves,
cy linder head,camshaft and cam dan
v alv es, camshaft chain tensioner
cam services can
chain tensioner bedilakukan
dapat done withdengan
the engine
mesinstalled
in terpasin
angthepada
frame.
rangka.
••When
Pada disassembling, mark and
waktu pembongkaran, storedan
tandai the sdisassembled
impanlah parts parts
yangto dibongkar
ensure thatuntuk
they are reinstalled
memas in theirmereka
tikan bahwa originaldipasang
locations.kembali
• Clean
pada all disassembled
tempatnya parts with cleaning solvent and dry them by blowing them off with compressed air before inspection.
s emula.
••Camshaft
Bersihkanlubricating
semua partsoil is yang
fed through oil passages
dibongkar dengan in the cylinder
pelarut head.dan
pembersih Clean the oil passages
keringkan before assembling
dengan meniup dengan udara cylinder
dari
head.
kompressor sebelum pemeriksaan.
• Be careful not to damage the mating surfaces when removing the cylinder head.
• Oli pelumas an c amshaft disalurkan melalui jalan lintasan oli di dalam cylinder head. Bersihkan jalan lintasan oli s ebelum
merakit cylinder head.
• Hati-hati agar tidak merusak permukaan penyatuan sewaktu melepaskan cy linder head.
SPESIFIKASI
Satuan: mm
Kompressi cylinder 1.196 kPa (12,2 kgf/cm2; 174
–
psi) at 600 min-1 (rpm)
Perubahan bentuk melengkung pada cylinder head – 0,05
Rocker D.D. rocker arm IN/EX 10,000 – 10,015 10,10
arm D.L. rocker arm shaft IN/EX 9,972 – 9,987 9,91
Jarak renggang arm ke shaft IN/EX 0,013 – 0,043 0,044
Camshaft Tinggi cam lobe (bubungan) IN 32,194 – 32,434 32,16
EX 31,990 – 32,230 31,96
Valve, Valve clearance (jarak renggang klep) IN/EX 0,10 –
valve D.L. valve stem IN 4,975 – 4,990 4,965
guide EX 4,955 – 4,970 4,945
D.D. valve guide IN/EX 5,000 – 5,012 5,03
Jarak renggang stem-ke-guide IN 0,010 – 0,037 0,065
EX 0,030 – 0,057 0,085
Proyeksi valve guide di atas cylinder head IN/EX 9,1 – 9,3 –
Lebar valve seat IN/EX 0,90 – 1,10 1,6
Panjang bebas valve spring IN/EX 30,62 29,70
Cam chain tensioner D.L. push rod 11,985 – 12,000 11,94
Panjang bebas spring 111,3 109
TORQUE
TORSI VALUES
PENGENCANGAN
Baut khusus
Cylinder cylinder
head cover head cov
special er
bolt 10
10N.m
N·m(1,0
(1.0kgf.m;
kgf·m,77lbf.ft)
lbf·ft)
Mur cylinder
Cylinder head
head nut 18
18N.m
N·m(1,8
(1.8kgf.m;
kgf·m,13
13lbf.ft)
lbf·ft) Berikan oli mes
Apply engine oilintopada ulir danand seating sur-
the threads
permukaan
face. duduk.
Baut
Camcam s procket
sprocket bolt 88N.m
N·m(0,82
(0.82kgf.m;
kgf·m,5,9
5.9lbf.ft)
lbf·ft) Berikan cairanagent
Apply locking pengunci pada
to the ulir.
threads:
Lihat hal. 8-11
Baut
Camperapatan cam chain
chain tensioner tensioner
sealing bolt 22
22N.m
N·m(2,2
(2.2kgf.m;
kgf·m,16
16lbf.ft)
lbf·ft)
Baut engsel cam chain tensioner
Cam chain tensioner arm pivot bolt 16
16 N·m (1.6 kgf·m, 12lbf.ft)
N.m (1,6 kgf.m; 12 lbf·ft)
Baut pemasangan
Throttle throttle
body insulator body bolt
mounting 12
12N.m
N·m(1,2
(1.2kgf.m;
kgf·m,99lbf.ft)
lbf·ft)
insulator
8-3
TOOLS
Valve spring compressor Valve spring compressor attachment Valve guide driver, 5.0 mm
07757-0010000 07959-KM30101 07942-MA60000
Valve guide adjusting driver Valve guide reamer, 5.0 mm Seat cutter, 27.5 mm (45° IN)
07743-0020000 07984-MA60001 07780-0010200
Seat cutter, 24 mm (45° EX) Flat cutter, 27 mm (32° IN) Flat cutter, 22 mm (32° EX)
07780-0010600 07780-0013300 07780-0012601
Interior cutter, 26 mm (60° IN) Interior cutter, 22 mm (60° EX) Cutter holder, 5.0 mm
07780-0014500 07780-0014202 07781-0010400
8-4
TROUBLESHOOTING
• Engine top-end problems usually affect engine performance. These problem can be diagnosed by a compression test or by
• tracing
Persoalan-persoalan
engine noises topada bagian with
the top-end atasamesin biasanya
sounding mempengaruhi performa mesin. Persoalan2 ini dapat didiagnosa
rod stethoscope.
dengan test kompress i atau dengan menelusuri
• If the performance is poor at low speeds, check for white smokesuara mesin pada bagian
in the atas mes
crankcase in dengan
breather hose.sounding rodisstethosc
If the hose smoky, ope.
check for
• aJseized
ika performa buruk pada
piston ring (page 9-6). kecepatan rendah, periksalah terhadap asap putih pada crankcase breather hose. Jika hose
berasap, periksalah terhadap piston ring yang macet (hal. 9-7).
Compression too low, hard starting or poor performance at low speed
Kompr essi terlalu rendah, sulit dihidupkan atau performa buruk pada kecepatan rendah
• Valves:
• –Valves (klep):
Incorrect valve clearance
–- Burned
J arak renggang klep tidak tepat
or bent valves
–- Incorrect valve timing
Valve terbakar atau bengkok
–- Broken valve spring
Valve timing (tertib buka klep) tidak tepat
–- Valve
Valvestuck
springopen
(pegas klep) patah
• Cylinder
- Valve head:
macet terbuka
• –Cylinder
Uneven head:valve seating
–- Leaking or damaged
Valve seating cylinder
(dudukan klep)head
tidakgasket
merata
–- Warped
Cylinderorhead
cracked
gaskcylinder
et bocorhead atau rusak
• Worn cylinder,
- Cylinder headpiston or piston
berubah bentukrings (page 9-6) atau retak-retak
melengkung
•Compression
Cylinder, piston atau piston rings aus
too high, overheating or knocking (hal. 9-7)
• Excessive carbon build-up on piston head or combustion chamber
Kompr essi terlalu tinggi, overheating atau knocking (ngelitik)
•Excessive smoke karbon terlalu berlebihan pada piston head atau ruang pembakaran.
Pembentukan
• Cylinder head:
Asap berlebihan
– Worn valve stem or valve guide
• –Cylinder
Damaged head
stem seal
- Valve
• Worn stem atau
cylinder, pistonvalve guiderings
or piston aus (page 9-6)
- Kerusakan pada stem seal
Excessive noise
• Cylinder, piston atau piston rings aus (hal. 9-7)
• Cylinder head:
– Incorrect
Suara berlebihanvalve clearance
• –Cylinder
Stickinghead:
valve or broken valve spring
–- Damaged or wornklep
J arak renggang camshaft
tidak tepat
–- Loose
Valve or wornatau
macet camvalve
chainspring patah
–- Worn or damaged
Camshaft camaus
rusak atau chain guide roller/sprocket
–- Worn
Cam chain longgar atau aus tensioner
or damaged cam chain
–- Worn
Cam cam
chainsprocket teeth
guide roller/sprocket aus atau rusak
–- Worn
Cam rocker arm and/or
chain tensioner ausshaft
atau rus ak
• Worn cylinder, piston or piston rings (page 9-6)
- Gigi-gigi cam sproc ket aus
• Worn cam chain guide sprocket teeth (page 12-25)
- Roc ker arm dan/atau shaft aus
•Rough idle piston atau piston rings aus (hal. 9-7)
Cylinder,
•• Low cylinder
Gigi-gigi camcompression
chain guide sprocket aus (hal. 12-25)
• Faulty fuel system (page 6-3)
Putaran stasioner kasar
• Kompressi cy linder rendah.
• Sis tem bahan bakar tidak bekerja dengan baik (hal. 6-3)
8-5
CYLINDER COMPRESSION TEST
Panaskan
Warm up mesin ke suhu
the engine operasi
to normal normal. temperature.
operating
[1]
Stop the
Matikan engine
mesin and
dan disconnect
lepaskan the
spark spark
plug plug cap.
cap.
Remove the
Lepaskan spark
spark plugplug (page
(busi) (hal.4-7).
4-7).
Install the
Pasang compression
compression gauge
gauge [1] [1]
padain the spark
lubang plug hole.
busi.
Retract
Tarik the sidestand
sidestand ke atasanddanturn
putar the ignition
ignition switch
switch keON.
ON.
Squeeze
Tarik the rear
rear brake brake
lever lever.rem belakang).
(handel
Openthrottle
Buka the throttle
sama all the waydan
sekali and putar
crank the engine
mesin with
dengan
the starter
starter motormotor
sampaiuntil the gauge gauge
pembacaan readingberhenti
stops rising.
naik.
STANDARD:
STANDARD:
1,196 kPa(12,2
(12.2kgf/cm
kgf/cm 2 2, 174 psi) at 600 min-1(rpm)
1,196 kPa ;174 psi) pada 600 menit -1
(rpm)
If compression is high, it indicates that carbon deposits
Jika
havekompressi
accumulated tinggi,
on the halcombustion
ini menunjukkan
chamber bahwa
and/or
endapan karbon
the piston head. telah terkumpul pada ruang
pembakaran dan/atau kepala piston.
If compression is low, pour 3 – 5 cc (0.1 – 0.2 oz) of
Jika kompressi
engine rendah,
oil into the tuangkan
cylinder through3-5
thecc oli mesin
spark ke
plug hole
dalam cylinderthe
and recheck melalui lubang busi dan periksa kembali
compression.
kompressi.
If the compression increases from the previous value,
check
Jika the cylinder,
kompressi naik daripiston
nilaiand piston rings
sebelumnya, for the
periksalah
following:
cylinder, piston dan piston rings terhadap yang berikut
ini:
– Leaking cylinder head gasket
- –Cylinder head gasket
Worn piston ring bocor
- –Piston
Wornring aus and piston
cylinder
- Cylinder dan piston aus
If the compression is the same as the previous value,
check
Jika the valves
kompressi for leakage.
adalah sama seperti nilai sebelumnya,
periksalah valves terhadap kebocoran.
CYLINDER HEAD COVER

PELEPASAN
REMOVAL
Lepaskan
Remove thebautspecial
khususbolts
[1], [1],
karet2 pemasangan
mounting rubbers [2]
[2] dan
and [1]/[2]
cylinder
cylinderhead
headc over
cover[3].
[3].
[3]
Lepaskan
Remove rubber sealseal
the rubber [1] dan dowel
[1] and pin [2]
dowel pindari cylinder
[2] from the
head cover
cylinder [3]. cover [3].
head [1]
[3] [2]
8-6
INSTALLATION
PEMASANGAN
Blow open
Tiuplah jalanthe oil passage
lintasan oli diindalam
the cylinder head
cylinder cover
head [1]
cover
with the compressed air. [1]
[1] dengan udara dari kompress or.
Pas tikansure
Make bahwa rubberseal
the rubber seal[1][1]is berada
in gooddalam kondisi
condition and
baik dan ganti
replace bila perlu.
it if necessary. [1]
Install
Pas ang the rubber
rubber sealseal into thealur
ke dalam groove
padaon the cylinder
cylinder head
head[2].
cover cover [2].
Install
Pas ang the dowel
dowel pin pin
[3]. [3].
[2] [3]
Oleskan liquidsealant
Apply liquid sealant(Three
(bahanbond
perapat cair)
5211C or(Three
Three bond
bond
1215 oratau
5211C SHINETSU-SILICONE
Three bond 1215 KE45 or equivalent)
atau SHINETSU- to
the semicircular
SILICONE KE45areaatau
of rubber seal as shown.
sejenisnya) pada daerah Titik perapatan
berbentuk setengah lingkaran dari rubber s eal (s il karet)
seperti diperlihatkan.
Pas ang the

Install karet2 pemasangan
mounting rubbers [1][1]with
dengan tanda
their "UP" “UP”
mark [2]
facing up.
mereka [2] menghadap ke atas. [2]
[1]
8-7
Tempatkan cylinder
Set the cylinder head
head cover
cover [1] [1]
ontopada
the cylinder head. [2]
Pas ang the
Install baut-baut
specialkhusus [2] dan
bolts [2] and kencangkan
tighten themmereka
to the
dengan torsi
specified yang ditentukan.
torque.
TORSI: 10 10
TORQUE: N.m (1,0(1.0
N·m kgf.m; 7 lbf.ft)
kgf·m, 7 lbf·ft)
[1]
CAMSHAFT
REMOVAL
PELEPASAN
Remove the
Lepaskan following:
sebagai berikut:
- –Left
Leftlower side
lower cover
side cover(hal.
(page3-12)
3-12)
- –CyCylinder
linder head
head covcover
er (hal. 8-6)8-6)
(page
- –Pulley
Pulleycovcover
er (hal. 10-7)
(page 10-7)
- –Sealing
Sealing washer
washer [1]/baut
[1]/bolt[2][2]
[1]/[2]
Putar
Turn drive pulleypulley
the drive [1] (crankshaft) denganbytangan
[1] (crankshaft) hand dalam
in the
direction
arah yangasdiperlihatkan
shown so thatsehingga
the index garis
lines [2] on the cam
penunjuk [2]
sprocket
pada cam [3]
sprocis ket
aligned with the dengan
[3] bertepatan top surface of the
permukaan
cylinder
atas head. head.
dari cylinder
Make
Pas tikansure the piston
bahwa pistonisberada
at TDCpada
(Top TDC
Dead (Top
Center)
Deadon
the compression
Center) { TMA stroke.
– Titik Mati Atas} pada langkah
This position can be obtained by confirming that there is
kompressi.
slack
Pos isi in
ini the rocker
dapat arms. If
diperoleh there is
dengan no slack, turn
memastikan bahwathe
drivekelonggaran
ada pulley (crankshaft) again until
pada rocker the Jika
arms. correct position
tidak ada
is obtained. putar drive pulley (cranks haft) sekali lagi
kelonggaran,
sampai
Remove posis
thei bolts
yang benar telah
[4], cam diperoleh.
sprocket from the camshaft
and cam chain [5] off the cam sprocket. [1]
Lepaskan baut-baut [4], cam sprocket dari camshaft dan
Attach
cam a [5]
chain piece of wire
terlepas tocam
dari the sprocket.
cam chain to prevent it
from falling into the crankcase.
Ikatkan sepotong kawat pada cam c hain untuk menjaga
agar tidak terjatuh ke dalam crankcase.
[2]
[4]
[5]
[3]
8-8
Lepaskan
Remove baut/washer [1] [1]
the bolt/washer darifrom
the cylinder
[1]
Lepaskan
Remove the camshaft [1] [1]
camshaft dari cylinder
from head sementara
the cylinder head while
[2] [1]
holding therocker
menahan rocker arms
arms[2][2]to ease removal.
untuk mempermudah
pelepas an.
PEMERIKSAAN
INSPECTION
DECOMPRESSOR
DECOMPRESSORCAM
CAM
Place the camshaft with
Letakkan its decompressor
dengan side facing
sis inya yang ada [1]
up as shown.
decompress or menghadap ke atas s eperti diperlihatkan.
Turndecompress
Putar the decompressor
or c am cam [1] withjari-jari.
[1] dengan your finger.
Make
Pas tikan sure
bahwathedecompressor
decompressorc amcamhanya only dapat
turn
counterclockwise
berputar andberlawanan
dalam arah does not turn clockwise.
jarum jam dan tidak
dapat
If theberputar searahcam
decompressor jarumis jam.
faulty, replace the camshaft
as an assembly.
Jika decompressor cam tidak bekerja dengan baik,
gantilah camshaft sebagai sebuah rakitan.
CAMSHAFT
CAMSHAFT
Putar
Turn outer race race
the outer dari of
masing-masing
each camshaft camshaft
bearing bearing
[1] with
[1] dengan
your finger.jari-jari. Bantalan
The bearing harusturn
should berputar
smoothlydengan
and
halus dan tanpa suara.
quietly.
Also periksa
Juga check that the bearing
bahwa bearing inner
innerrace
racefits tightlydengan
duduk on the
erat pada camshaft.
camshaft.
Replacesusunan
Gantilah the camshaft assembly
camshaft if the bearing
jika bearing does not
tidak berputar
turn smoothly,
dengan quietly,
halus, tanpa or ifatau
suara, theyjikafit loosely
mereka on the
duduk
camshaft.
dengan longgar pada camshaft.
[1]
8-9
Periksa
Check cam lobeslobes
the cam (telinga bubungan)
[1] for [1] wear
excessive terhadap
and
keausan
damage.berlebihan dan kerusakan. [1]
Measure
Ukur tinggi the
dariheight of eaching
mas ing-mas cam lobe.
cam lobe.
BATAS
SERVICESERVIS:
LIMIT:
IN:
IN: 32,16
32.16 mm
mm (1.266 in)
EX:
EX:31,96
31.96mm
mm (1.258 in)
PEMASANGAN
INSTALLATION
Apply engineolioilmesin
Semprotkan to the ke
camshaft
daerahbearings [1], cam
perputaran lobes
camshaft
[3] [2]
[2] and decompressor
bearings [1], cam lobes cam [3] decompressor
[2] dan rotating area. cam [3].
[1]
Pastikan
Make sure bahwa the Pas
thattab ang the
Install camshaft [1][1]keinto
camshaft dalam cylinderhead
the cylinder head dengan
with its tab
[4]of
tab [4] dari
the tab-nya [2] up
[2] facing menghadap
while holding ke the
atasrocker
sementara
arms [3]menahan
to ease [3]
de compressor cam
decompressor cam rocker arms [3] untuk mempermudah pemasangan.
installation.
[5] menghadap ke
[5] is facing the
sisi ruang
combustion
pembakaran. [4]
chamber side.
[5] [2] [1]
Install
Pas ang and
dan tighten the bolt/washer
kencangkan [1].[1].
baut/was her
[1]
8-10
Lepaskan
Remove the timing hole
timing holecap (tutup lubang
cap/O-ring pengintaian
(page 17-7).
waktu pengapian)/O-ring (hal. 17-8).
Turn the drive pulley [1] (crankshaft) by hand in the
direction
Putar drive as shown
pulley so that thedengan
[1] (crankshaft) "T" mark [2] on
tangan the
dalam
flywheel
arah yangisdiperlihatkan
aligned with sehingga
the index tanda
notch [3]
“T”on[2]the left
pada
crankcase
flywheel cover. dengan takik penunjuk [3] pada left
bertepatan
crankcase cover.
If the left crankcase cover is removed, turn the flywheel
[4] counterclockwise
Jika left crankcase until
c overitstelah
index dilepaskan,
line [5] is aligned
putar
with the index notch [6] on the left crankcase
flywheel [4] berlawanan arah jarum jam sampai as shown.
garis
[3]
penunjuk [5] bertepatan dengan takik penunjuk [6] pada
left c rankc ase seperti diperlihatkan. [1]
[2]
Jika left crankcase cover telah di lepaskan:

[5]
[6]
[4]
Apply engine
Semprotkan olioil to the
mesin camcam
pada chain [1]. [1].
chain
[1]
Install
Pas ang the
camcam chain
chain padaon thesproc
c am cam ket
sprocket [2] with
[2] dengan tandaits
stamp mark [3]
cetakannya [3] facing up, makingkesureatas,
menghadap that the index
dengan
lines [4] onbahwa
memastikan the cam sprocketpenunjuk
garis-garis are flush[4]with
padathecamtop
surface of
sprocket the cylinder
adalah head as shown
sama tingginya dengan(TDC on the
permukaan
compression
atas stroke).
dari cylinder head seperti diperlihatkan (TDC {= [3] [4]
Installpada
TMA} the cam sprocket
langkah to the camshaft.
kompressi).
Pas ang c am s procket pada camshaft.
[2]
Oleskan lock ingagent

Apply locking agentto (cairan
the campengunci) pada[1]ulir
sprocket bolt baut
threads
cam sprocket [1] seperti diperlihatkan.
as shown. [1]
Install
Pas ang anddan tighten the cam
kencangkan sprocketcam
baut-baut boltssprock
to the
et
specified
dengan torque.
TORQUE:
TORSI: 8 N·m
8 N.m (0.82
(0,82 kgf·m,
lbf.ft)
Lebar lapisan : 6.5 ± 1.0 mm

dari ujung
8-11
Semprotkan
Pour 4.0 ccminimum
minimum 4,0 cc oli mesin
of engine oil into ke
thedalam cam
cam chain
tensioner
chain pushpush
tens ioner rod as
rodshown.
seperti diperlihatkan. [2]
Install
Pas a new washer
ang sealing sealing [1]
washer [1] baut
baru dan and [2],
boltkemudian
[2], then
tighten it.
kencangkan.
Install
Pas ang the following:
s ebagai berikut:
- – Timing
Timing hole cap/O-ring
hole cap/O-ring (hal.
(page 17-8)
17-8)
- – Cylinder head c over (hal.
Cylinder head cover (page 8-7) 8-7)
- – Pulley
Pulleyccover
over (hal.
(page10-8)
10-8)
- – Left
Left lower
lower side
side cover
cover (hal.
(page3-12)
3-12)
[1]
CYLINDER HEAD
REMOVAL
PELEPASAN
Remove sebagai
berikut: [4]
- –Lower side covers (hal. 3-12) [1]
Lower side covers (page 3-12)
- –Cam s procket (hal. 8-8)
Cam sprocket (page 8-8)
- –Exhaust
Exhaustpipe/muffler
pipe/muffler(hal. 3-20)
(page 3-20)
Lepaskan baut [1] dan
Remove the bolt [1] and O 2 sensor
O2 sensorholderholder
[2], kemudian
[2], then
lepaskan O2 sensor
disconnect cap [3]cap
the O2 sensor (hal.[3]6-47).
(page 6-47).
Lepaskan spark
Disconnect the plug
sparkcap [4].cap [4].
plug
[3] [2]
Lepaskan
Remove kedua
the twobaut-baut
insulator pemasangan
mounting boltsinsulator
[1]. [1].
[1]
Lepaskan
Disconnect insulator [2] dari[2]
the insulator cylinder head
from the dan keluarkan
cylinder head and
O-ring
remove[3].the O-ring [3].
[2] [3]
Remove baut-baut
Lepaskan the cylinder head bolts
cylinder head[1].
[1]. [2] [1]
Loosen the cylinder head nuts
Longgarkan mur-mur cylinder head [2] in a crisscross
[2] dalampattern
pola
in two or three steps.
bersilangan dalam dua atau tiga langkah.
Remove keempat
Lepaskan the four nuts
murand
danaplate
plate[3].
[3].
[3]
8-12
Remove the
Lepaskan spring
spring [1] and
[1] dan plunger
plunger [2]. [2].
[2]
[1]
Remove the
Lepaskan cylinder
cylinder headhead
[1]. [1]. [1]
Lepaskan dowel
Remove the pinspins
dowel [1] dan gasket
[1] and [2]. [2].
gasket
[1]
[2]
DISASSEMBLY
PEMBONGK ARAN
ROCKER ARM/SHAFT
Remove the
ROCKER following:
ARM/SHAFT
[1]
– Spark sebagai
Lepaskan plug (page 4-7)
berikut:
- –Busi sensor
O2 (hal. (page 6-47)
4-7)
- Remove
O2 sensor
the(hal. 6-47)
rocker arm shaft stopper bolt [1].
Lepaskan baut rocker arm shaft stopper [1].
8-13
Sekrupkan
Screw a 5bautmm5 bolt
mm [1][1] into
ke dalam lubang berulir
the threaded hole inpada
the
[3]
rocker
rocker arm [2] and
arm shafts [2] danpulltarik
themmereka keluar
out of the dari
cylinder
cylinder
head. head.
Lepaskan
Remove therocker arms
rocker [3]. [3].
arms
[2]
[1]
CAMSHAFT
CAMSHAFT
Lepaskan baut/washer
Remove the [1] [1]
bolt/washer danand
camshaft [2].[2].
camshaft
[1]
[2]
VALVE
VALVE
ToUntuk mencloss
prevent egahof Lepaskan
Remove the valve
valvecotters [1]using
cotters [1] dengan menggunakan
the special tools.
hilangnya tegangan, spec ial tools. [2]
tension, do not
jangan tekan
compress the valve
valve TOOLS:
springs lebih TOOLS:
springs more than [2] Valve spring compressor 07757-0010000
daripada yang [2] Valve spring compressor 07757-0010000
diperlukan untukto
necessary [3] Valve spring compressor 07959-KM30101
[3] Valve spring compressor 07959-KM30101
remove
melepaskanthe cotters.
cotters. attachment
attachment
[3] [1]
Tandai semua parts Lepaskan valve
Mark all parts Remove the valvespring
spring compressor danremove
compressor and lepaskan
the
pada waktu sebagai berikut: [4]
during disassembly following:
pembongkaran - Valve s pring retainers [1]
so theymereka
sehingga can be
placed back in their
dapat ditempatkan - –Valve
Valve spring[2]
s prings retainers [1]
[5]
– Valve springs
- Valve s pring seats [2][3]
original
kembali locations.
pada lok asi – Valve spring seats [3]
mere ka semula. - –Valves
Valves[4][4]
- –Valve
Valvestem
stemseals
seals [5]
[5]
[3]
[2] [1]
8-14
Jagalah
Avoid agar tidak
damaging Remove the
the Keluarkan carbon karbon
kerak-kerak depositsdari
from the pembakaran
ruang combustion
merusaksurface
mating permukaan chamber
and [1] [1] anddari
dan bersihkan clean off the cy
permukaan cylinder headgasket.
linder head gasket [1]
valve penyatuan dan surface.
seat surfaces.
permukaan valve
seat.
INSPECTION
PEMERIKSAAN
CYLINDER HEAD
CYLINDER HEADplug hole and valve areas for cracks.
Check the spark
Check the cylinder head for warpage with a straight
Periksa lubang busi dan daerah valve terhadap retak-
edge and a feeler gauge.
retak.
Periksa
SERVICE c ylinder headmm
LIMIT: 0.05 terhadap perubahan bentuk
(0.002 in)
melengkung dengan sebuah straight edge (mistar lurus )
dan feeler gauge (voeler).
BATAS SERVIS: 0,05 mm
ROCKER
ROCKERARM/SHAFT
ARM/SHAFT
Bongkar cylinder
Disassemble thehead (hal.head
cylinder 8-13).
(page 8-13).
Periksa rocker
Check the armarm
rocker shafts dan
shafts androcker arms terhadap
rockerarms for wear [1]
or damage.
keausan atau kerusakan.
Turn rock
Putar the rocker
er arm arm rollers
rollers [1] with jari-jari.
[1] dengan your finger.
The rollers should turn smoothly and quietly.
Rollers harus berputar dengan halus dan tanpa s uara.
Measure the I.D. of each rocker arm.
Ukur D.D. dari masing-masing rocker arm.
SERVICE LIMIT: IN/EX: 10.10 mm (0.398 in)
BAT AS SERVIS: IN/EX: 10,10 mm
Measure the O.D. of each rocker arm shaft.
Ukur D.L. dari masing2 rocker arm shaft.
SERVICE LIMIT: IN/EX: 9.91 mm (0.390 in)
BAT AS SERVIS: IN/EX: 9,91 mm
Calculate
Hitung jarakthe rocker arm-to-shaft
renggang clearance.
rocker arm-ke-shaft.
SERVICE
BAT LIMIT:IN/EX:
AS SERVIS: IN/EX: 0,044
0.044 mm
mm (0.0017 in)
VALVE SPRING
VALVE SPRING
Disassemble the cylinder head (page 8-13).
Bongkar
Measurecylinder
the freehead (hal.
length 8-13).
of the valve springs.
Ukur panjang
SERVICE bebas
LIMIT: valve29.70
IN/EX: s prings.
mm (1.169 in)
BAT AS SERVIS:
Replace IN/EX:
the springs 29,70
if they are mm
shorter than the service
limit. s prings jika mereka lebih pendek daripada batas
Ganti
servis.
8-15
VALVE/VALVE
VALVE/VALVEGUIDE
GUIDE
Disassemble
Bongkar thehead
cylinder cylinder
(hal.head (page 8-13).
8-13).
Check that
Periksa the valve moves
bahwa smoothly
bergerak denganin halus
the guide.
di dalam
Check each valve for bend, burn, scratch or abnormal
guide.
wear. masing-masing valve terhadap kebengkokan,
Periksa
keadaan
Measureterbakar, goresan
each valve atau and
stem O.D. keausan tidak
record it. normal.
Ukur D.L. masing-masing
SERVICE valve
LIMIT: IN: 4.965 mmstem dan in)
(0.1955 catat.
EX:: 4.945
BATAS SERVIS: IN 4,965mm
mm(0.1947 in)
EX : 4,945 mm
Selalu putar
Always reamer
rotate the Lakukan
Ream the pekerjaan reaming
valve guide padaany
to remove valve guide
carbon untuk
build up
searah jarum
reamer jam,
clockwise, membuang penimbunan
before measuring karbon yang telah terbentuk,
the guide. [1]
jangan sekali-kali
never sebelum mengukur
Insert the guide.
reamer from the combustion chamber side of
berlawanan jarum Masukkan reamer
counterclockwise
sewaktu
the cylinder headdari
andsisi ruangrotate
always pembakaran dari
the reamer
when inserting,
me masukkan,
clockwise.
cylinder head dan s elalu putar reamer searah jarum
removing dan
mengeluarkan and jam.
reaming. TOOL:
reaming. TOOL:
[1] Valve guide reamer, 5.0 mm 07984-MA60001
[1] Valve guide reamer, 5,0 mm 07984-MA60001
Periksa and
Inspect dan reface
reface Ukur D.D. masing-masing
Measure each valve guidevalve guide
I.D. and dan catat.
record it.
valve seats setiapseats
the valve kali
valve guides diganti BATAS
SERVICE SERVIS:
LIMIT: IN/EX: 5,03 mm
IN/EX: 5.03 m m(0.198 in)
whenever the valve
(hal. 8-18).
guides are replaced Kurangi D.L. masing-masing valve stem dari D.D. valve
Subtract each valve stem O.D. from the corresponding
(page 8-18). guide
guide yang
I.D. to bers angkutan
obtain untuk mendapatkan
the stem-to-guide clearance. jarak
renggang stem-ke-guide.
SERVICE LIMIT: IN: 0.065 mm (0.0026 in)
BATAS SERVIS: IN EX:: 0.085
0,065mm
mm(0.0033 in)
EX : 0,085 mm
If thejarak
Jika stem-to-guide
renggangclearance exceeds
stem-ke-guide the servicebatas
melampaui limit,
determine if a new guide with standard dimensions
servis, tentukan apakah s ebuah guide baru dengan
would bring the clearance within tolerance.
ukuran standard
If so, replace anyakan mengembalikan
guides as necessary jarak renggang
and ream to fit
ke dalam toleransi.
(page 8-17).
Jika demikian,
If the gantilah
stem-to-guide guides sesuai
clearance dengan
exceeds keperluan
the service limit
dan lakukan pekerjaan reaming
with new guide, also replace the valve. agar ukurannya pas
(hal. 8-17).
Jika jarak renggang stem-ke-guide melampaui batas
servis setelah penggantian dengan guide baru, gantilah
valve juga.
8-16
VALVE GUIDEVALVE
PENGGANTIAN REPLACEMENT
GUIDE
Disassemble
Bongkar thehead
cylinder cylinder
8-13).
[3]
Chill new valve
Dinginkan valve guides
guidesinbaru a freezer for about
di dalam freezer1 hour.
selama
kira-kira 1 jam.
CATATAN:
• Be sure to wear heavy gloves to avoid burns when
• Pastikan the
handling untuk mengenakan
heated cylinder head.sarung tangan tebal
untuk menghindari luka
• Using a torch to heat the cylinder bakar sewaktu
head menangani
may cause
c ylinder head yang telah dipanaskan.
warpage.
• • Drive
Menggunakan
new guides oborfromuntuk memanaskan
the camshaft cylinder
side while the
head dapat
cylinder head is menimbulkan
still heated. perubahan bentuk
melengkung padanya.
• Heat the cylinder
Dorong masukhead to 130
guides – 140°C
baru dari (275 – 290°F)
s isi camshaft
with a hot plate or oven. Do not heat the cylinder head
s ementara cy linder head masih dipanaskan.
beyond 150°C (300°F). Use temperature indicator [1]
o
sticks,
Panaskan available
c ylinderfrom
headwelding
ke 130supply
– 140stores, to be sure
C dengan hot [2]
the cylinder
plate head is heated
(plat pemanas) atautoov the
en.proper
Jangantemperature.
panaskan
o
cylinder
Support thehead lebihhead
cylinder tinggi dari the
and drive 150 C. guides
valve Pakailah
[1]
temperature
and clips [2] out of the cylinder head fromsuhu)
indicator stic ks (tongkat indikator the
yang dapat diperoleh
combustion chamber dari side.toko perlengkapan las, untuk
memastikan bahwa cylinder head telah dipanaskan ke
TOOL:
suhu yang sesuai.
[3] Valve guide driver, 5.0 mm 07942-MA60000
Topang c ylinder head dan dorong valve guides [1] dan
Take[2]
clips out keluar
new valve dariguides [1] from
cylinder headthe dari
freezer.sisi ruang
pembakaran.
Drive new clips [2] and valve guides into the cylinder [3]
head to the specified height from the cylinder head,
TOOL:
using
[3] the guide
Valve specialdriver,
tool. 5,0 m m 07942-MA60000
[1]/[2]
TOOL: valve guides baru [1] dari freezer.
Keluarkan
[3] Valve guide adjusting driver 07743-0020000
Dorong mas uk c lips baru [2] dan valve guides baru ke
dalam
VALVE cylinder
GUIDEhead s ampai tinggi yang ditentukan dari
PROJECTION:
cylinder head dengan menggunakan
IN/EX: 9.1 – 9.3 mm (0.36 – 0.37special
in) tool.
TOOL:
Let the cylinder head cool to room temperature.
[3] Valve guide adjusting driver 07743-0020000
9,1 – 9,3 mm
PROJEKSI VALVE GUIDE: IN/EX: 9,1 – 9,3 mm
Biarkan cylinder head menjadi dingin sampai ke suhu
Ream new valve guides after installation.
ruangan. [1]
Lakukan pekerjaan reaming pada valve guides baru
• Take
setelah care not to tilt or lean the reamer in the guide
pemasangan.
while reaming.
CATATAN:
• Use cutting oil on the reamer during this operation.
• Hati-hati agar tidak memiringkan reamer di dalam
Insert
guidethepada
reamer fromreaming.
waktu the combustion chamber side of
• the cylinder head and
Pakailah cutting oil pada always
reamerrotate
selama thepekerjaan
reamer
clockwise.
ini.
TOOL:
Masukkan reamer dari sisi ruang pembakaran dari
[1] Valve
cylinder guide
head reamer,
dan s elalu 5.0 mmreamer
putar 07984-MA60001
searah jarum
jam.
Clean the cylinder head thoroughly to remove any
metal particles after reaming and reface the valve seat
TOOL:
(page
[1] 8-18).
Valve guide reamer, 5.0 mm 07984-MA60001
Bersihkan cylinder head sec ara menyeluruh untuk
melepas kan partikel-partikel logam setelah melakukan
pekerjaan reaming dan reface (bentuk kembali
permukaan) valve seat (dudukan klep) (hal. 8-18).
8-17
VALVE SEAT /REFACING
PEMERIKSAAN INSPECTION/REFACING
VALVE SEAT
Disassemble
Bongkar thehead
cylinder cylinder
8-13).
Clean theintake
Bersihkan intakeandand exhaust
exhaust valves
valves thoroughly
(klep masuk dan to
removesecara
buang) carbonmenyeluruh
deposits. untuk membuang endapan
karbon.
Apply a light coat of Prussian Blue to the valve seats.
Tap the lapisan
Berikan valve against the valve seat
tipis Prussian Blue several times
(lapisan using
penanda
a hand-lapping
berwarna) tool, without
pada valve rotating the
seats (dudukan valve to make a
klep).
clear pattern.
Ketuk valve terhadap valve seat beberapa kali dengan
menggunakan sebuah hand-lapping tool (alat untuk skir
klep), tanpa memutar valve agar mendapatkan pola
yang jelas.
Valves
The tidakcannot
valves dapat Lepaskan valve
Remove the danand
valve periksa permukaan
inspect the valvevalve
seat seat.
face.
bedigerinda.
ground. IfJika
the
permukaan valveis The valve
Kontak valveseat
seatcontact
harus dishould
bawahbe within
lebar theditentukan
yang specified
valve face
terbakar, sangat aus dan harus
width andmerata
even alldiaround
sepanjang kelilingnya.
the circumference.
burned, badly worn
atau jika ia
or if it contacts the STANDARD
STANDARD: : 0.90 0,90– –1.10
1,10mm
mm (0.035 – 0.043 in)
mengontak seat
seat
secara tidak unevenly,
merata, BATAS SERVIS
SERVICE LIMIT:: 1.6
1,6mm
mm (0.06 in)
replace the valve.
gantilah valve.
Jika
If thelebar
valvevalve
seat seat
widthtidak
is notsesuai dengan spesifikasi,
within specification, reface
reface valve
the valve seat
seat (bentuk
(page kembali dudukan klep) (hal. 8-
8-18).
18).
Lebar seat
Inspectpermukaan
Periksa the valve seat face
valve for:terhadap:
seat
• • Damaged
Kerusakanface:
pada muka
- Replace
– Ganti valve
thedan reface
valve valve seat.
and reface the valve seat
• • Uneven
Lebar seat tidak
seat width:merata:
- Bent
– Valveorstem bengkok
collapsed ataustem;
valve memendek.
ReplaceGanti
the valve
valve
dan
andreface
refacev alve seat. seat
the valve
Kerusakan pada muka Lebar seat tidak merata
• • Contact
Daerah kontak (terlalu
area (too low orrendah atau
too high terlalu tinggi)
area):
- Reface the
– valve seatseat
valve
Terlalu rendah Terlalu tinggi
8-18
• • Ikuti
Followpetunjuk
the pemakaian pabrik pembuatoperating
refacer manufacturer’s refacer
(alat pembentuk dudukan klep)
instructions.
• • Hati-hati
Be carefulagarnot tidak
to grind the seat seat
menggerinda more lebih
than
necessary.
daripada yang diperlukan.
45°
60°
32°
Jika daerah
If the kontak
contact areaterlalu
is tootinggi
high pada
on thevalve, seat
valve, theharus
seat
must be lowered
diturunkan denganusing a 32° flat cutter.
menggunakan sebuah 32° flat cutter. Kontak terlalu tinggi
Lebar seat lama
If thedaerah
Jika contactkontak
area is too low rendah
terlalu on the valve,
padathe seat must
valve, seat
be raised
harus using a dengan
dinaikkan 60° interior cutter.
menggunakan s ebuah 60° 32°
Refinish
interior the seat to specifications, using a 45° finish
cutter.
cutter. permukaan s eat sesuai dengan spesifikasi,
Haluskan
dengan menggunakan sebuah 45° finish cutter.
Kontak terlalu rendah
Lebar seat lama
60°
Reface seatthe
Reface dengan
seat Pakailah
Use a 45°sebuah seat45°cutter,
seat cutter,
removehilangkan kekasaran
any roughness or
sebuah 45 o cutter
with a 45° cutter atau ketidak-teraturan
irregularities from the dari
seat. s eat.
setiap kali sebuah Kekasaran
whenever a valve
valve guide diganti. TOOLS:
guide is replaced. TOOLS:
Seat
Seatcutter,
cutter,27.5
27.5mmmm(IN, 45°)
(45° IN) 07780-0010200
07780-0010200
Seat
Seatcutter,
cutter,24
24mmm
m (EX,
(45°45°)
EX) 07780-0010600
07780-0010600
Cutter
Cutterholder,
holder,5.05.0mm
mm 07781-0010400
07781-0010400
Pakailah sebuah
Use a 32° 32° remove
flat cutter, flat c utter, hilangkan
the top ¼ existing
1/4 of the bagian
teratas dari bahan
valve seat valve seat yang ada sekarang.
material.
TOOLS:
TOOLS:
Flat
Flatcutter,
cutter,27
27mm
mm(IN, 32°
(32° )
IN) 07780-0013300
07780-0013300 Lebar seat lama
Flat cutter, 22 mm (EX, 32°)
Flat cutter, 22 mm (32° EX) 07780-0012601
07780-0012601
Cutter
Cutterholder,
holder,5.0
5.0mm
mm 07781-0010400
07781-0010400
32°
8-19
Pakailah
Use a 60°s ebuah
interior ° interior
60cutter, cutter,the
remove hilangkan ¼ bagian
bottom 1/4 of the
terbawah dari bahan
existing valve valve seat yang ada sekarang.
seat material.
TOOLS:
TOOLS: Lebar seat lama
Interior
Interiorcutter,
cutter,26
26mm
mm(IN,
(60°60°
IN)) 07780-0014500
07780-0014500
Interior
Interiorcutter,
cutter,22
22mm
mm(EX,
(60°60°)
EX) 07780-0014202
07780-0014202
Cutter
Cutterholder,
holder,5.0
5.0mm
mm 07781-0010400
07781-0010400
60°
Dengan
Using a menggunakan
45° seat cutter,sebuah 45° seat
cut the seat to thecutter,
properpotong
width.
seat sampai lebar yang benar.
VALVE SEAT WIDTH: 0.90 – 1.10 mm (0.035 – 0.043 in) 0,90 – 1,10 mm
LEBAR VALVE SEAT: 0,90 - 1,10 mm
Make sure that all pitting and irregularities are removed.
Pas tikan bahwa semua lubang-lubang dan ketidak-
teraturan telah dihilangkan.
45°
CATATAN:
• • Excessive
Tekanan skir klep pressure
lapping yang berlebihan
may deformdapatormerubah
damage
bentuk atau
the seat. merusak seat.
• • Change
Ubah sudut dari lapping
the angle tool [1] sering-sering
of hand-lapping untuk
tool [1] frequently
mencegah keausan seat
to prevent uneven seat wear. yang tidak merata.
• • Do
J agalah agar
not allow lapping
lapping compound
compound (ambril)
to enter tidak
the guides.
memasuki guides .
After cutting the seat, apply lapping compound to the
Setelah memotong
valve face, seat,
and lap the oleskan
valve lapping
using light c ompound
pressure. [1]
pada muka valve, dan s kir klep dengan menggunakan
After lapping, wash any residual compound off the
tekanan
cylinderringan.
head and valve and recheck the seat contact.
Setelah
Assemble menskir klep, cucilah
the cylinder compound
head (page 8-21). yang tersisa
dari cylinder head dan v alve dan periksa kembali kontak
seat.
Rakit cylinder head (hal. 8-21).
8-20
PERAKITAN
COTTERS
VALVE SPRING
SPRING RETAINER
EXHAUST ROCKER ARM
SPRING SEAT
INLET ROCKER ARM
VALVE STEM SEAL
VALVE GUIDE
INLET ROCKER
ARM SHAFT
CLIP
EXHAUST ROCKER
ARM SHAFT
ROCKER ARM SHAFT

STOPPER BOLT
BOLT/WASHER
CAMSHAFT
EXHAUST VALVE
INLET VALVE
VALVE
VALVE
Tiuplah dengantheudara
Blow through dari kompressor
oil passage melalui
in the cylinder headjalan
with
lintasan oli di dalam
compressed air. cylinder head. [3]
Pas ang the
Install v alv valve
e spring seatsseats
spring [1] dan
[1] valve stem valve
and new seals stem
baru
seals [2].
[2].
Coat the
Lapisi valve stem
permukaan sliding
luncur surface
valve stemanddanstem endstem
ujung with
engine oli
dengan oil.mesin.
Insert the valves
Masukkan valves [3]
[3] ke
intodalam
the valve
valveguides
guideswhile turning
sementara
them slowly
memutar to avoidpelan-pelan
mereka damage to theuntukvalve stem seals.
menghindari
kerusakan pada valve stem seals.
[1]
[2]
8-21
Pas ang the
Install valve
valvesprings
springs dengan
with the lilitan
tightly yang
wound rapat
coils
menghadap ke ruang pembakaran.
facing the combustion chamber.
Ke ruang
pembakaran
Install
Pas ang the
v alvvalve spring
e spring retainer
retainer [1].[1]. [3]
ToUntuk
prevent
mencloss
egahof Install
Pas ang the
valvvalve cotters
e c otters [2][2] using the
dengan special tools.
menggunakan special
hilangnya tegangan,
tension, do not tools .
jangan tekan
compress the valve
valve
TOOLS:
spring lebihmore
daripada TOOLS:
[3] Valve spring compressor 07757-0010000
spring than
yang diperlukan
necessary to install [3]
[4]Valve
Valve spring
springcompressor
compressor 07757-0010000
07959-KM30101
untuk memasang [4] Valve spring compressor
attachment 07959-KM30101
the cotters.
cotters. attachment
[4] [1]/[2]
Support
Topang the cylinder
c ylinder Place a suitable
head Letakkan tool yangtool [1] onto
sesuai the valve
[1] pada valvestem
stem[2].
[2].
di head
atas permukaan
above the [1]
meja Tap the
untuk Ketuk
kerjasurface tooltool gently ringan
dengan to seatuntuk
the cotters [3] firmly using
mendudukkan c ottersa
work bench
mencegah kerusakan plastic
[3] hammer.
dengan erat dengan menggunakan palu plastik.
to prevent valve
pada valve.
damage.
[3]
[2]
CAMSHAFT
CAMSHAFT
Semprotkan
Apply engine oli oil tomesin pada bidang
the decompressor cam perputaran
[1] rotating
decompress or cam
area, cam lobes [1], camshaft
[2] and cam lobes [2] dan
bearings [3].camshaft [3]
bearings [3].
Install the camshaft with its tab [4] facing up and tab [5]
Pas
of angthe camshaft
decompressor dengan
camtab-nya [4] the
is facing menghadap
combustion ke
chamber
atas side.
dan tab [5] dari decompressor cam menghadap ke [5]
sis i ruang pembakaran..
[1] [2] [4]
8-22
IPasang dan kencangkan baut/washer [1].nstall and
tighten the bolt/washer [1]. [1]
ROCKER ARM
ROCKER ARM
Jangan
Do not confuse the Semprotkan
Apply engineolioilmesin pada surface
to the inner permukaan dalamsliding
and roller dan
mempertukarkan daerah [1] [2]
exhaust rocker arm area ofluncur roller
the inlet dari arm
rocker inlet [1]
rocker
and arm [1] dan
exhaust exhaust
rocker arm
exhaust
with the rocker arm
inlet rocker rocker
[2]. arm [2].
dengan inlet rocker
arm. The exhaust Apply engineoli
Semprotkan oil mesin
to the sliding
pada surface of thelunc
permukaan rocker
ur arm
dari
arm. Ex haust rocke r
rocker arm has a shaftsarm
rocker [3]. s hafts [3].
arm mempunyai
decompressor heel
de compressor heel
[4].
[4].
[4]
[3]
Install
Pas angthe
rockrocker arms
er arms [1] [1]
padato the cylinder
cy linder head.
head.
[1] [3]
Install
Pas angthe exhaust
exhaust rocker
rocker armarm shaft
s haft [2][2]
keinto the exhaust
dalam exhaust
rocker arm
rocker arm and
dan cylinder
cylinderhead
headuntil it is fully
s ampai seated.
ia telah duduk
sepenuhnya.
Insert the inlet rocker arm shaft [3] into the cylinder
head usinginlet
Masukkan a screwdriver
rocker armwhile aligning
shaft [3] ke the bolt holes
dalam of
cylinder
the shaft and cylinder head.
head dengan menggunakan obeng sementara
menjajarkan lubang2 baut dari shaft dan cy linder head.
[2]
Tepatkan (lubang baut)
[3]
8-23
Pas angand
Install dantighten
kenc angkan bautarm
the rocker rockshaft
er arm s haftbolt
stopper stopper
[1].
[1]. [1]
PEMASANGAN
INSTALLATION
Bersihkan
Clean the cylinder dan cylinder
cylinder and permukaan
headpenyatuan cylinder
mating surface. [1]
head.
Install the dowel pins [1] and a new gasket [2] onto the
Pas ang dowel pins [1] dan gasket baru [2] pada
cylinder.
cylinder.
[2]
Alurkan cam
Route the chain
cam [1][1]melalui
chain throughcylinder head head
the cylinder [2] dan
[2]
[2]
and install
pasang the cylinder
cy linder head padahead onto the cylinder.
cylinder.
[1]
Semprotkan
Apply engineolioilmesin ke seluruh
to the plunger permukaan
[1] whole surface.plunger
Install the plunger and spring [2].
[1]. [1]
Pas ang plunger dan spring [2].
[2]
8-24
Semprotkan
Apply engine olioil
mesin
to thepada permukaan
seating surface duduk dan ulir
and threads of
[1] [3]
the mur-mur
dari cylinder head
cylindernuts [1]. [1].
head
Pas angthe
Install plate
plate[2][2] dan kencangkan
and tighten mur-mur
the cylinder headcylinder
nuts in
a crisscross
head dalam pattern
pola to the specifieddengan
bersilangan torque. torsi yang
ditentukan.
Install and tighten the cylinder head mounting bolts [3].
Pas ang dan kencangkan baut-baut pemasangan
cylinder head [3].
[2]
Pas angaO-ring
Install baru [1]
new O-ring [1]ke dalam
into alur ins ulator
the insulator [2].
[2] groove. [3]
Set the insulator
Tempatkan onto thepada
ins ulator cylinder head andhead
c ylinder tightendan
the
two insulatorkedua
kencangkan mounting bolts [3]
baut-baut to the specified
pemasangan torque.
insulator [3]
[1] [2]
Sambungkan
Connect the O sensor cap
O22 sensor cap [1],
[1],install
pasangthe OO2 2 sensor
holder[2]
holder [2]dan
andkencangkan
tighten the bolt
baut[3]
[3](page
(hal. 6-48). [4]
[3]
Connect the spark plug cap [4].
Sambungkan
Install
Pas angthe following:
s ebagai berikut:
- –Cam s procket
Cam sprocket (hal. 8-11)
(page 8-11)
- –Exhaust pipe/muffler
Exhaust pipe/muffler (hal. 3-20)
(page 3-20)
- –Lower
Lower side covers
side covers(hal.
(page3-12).
3-12)
[1] [2]
CAM CHAIN TENSIONER

PELEPASAN
REMOVAL
Remove the
Lepaskan flywheel
flywheel (hal.(page
11-8).11-8). [3] [4]
Remove the
Lepaskan bautcamperapatan
chain tensioner sealing tensioner
cam chain bolt [1]/
washer [2],[2],
[1]/washer tensioner spring
tensioner [3][3]
spring and push
dan rod
push [4].[4].
rod
[1] [2]
8-25
Lepaskan
Remove the pivpivot
ot bolt
bolt[1], washer [2],
[1], washer [2],tensioner
tensioner
armarm
[3]/
collar [4][4]
[3]/collar and
dantensioner roller
tens ioner roller[5].
[5]. [5]
[1]
[3]/[4] [2]
PEMERIKSAAN
INSPECTION
Measure
Ukur thebebas
panjang tensioner springs[1]
tensioner free[1].
pring length.
BATAS SERVIS:
SERVICE LIMIT: 109
109 mm
mm (4.3 in)
[1]
Check push
Periksa the push rodterhadap
rod [1] [1] for wear or damage.
keausan atau kerusakan. [1]
Measure
Ukur the push
D.L. push rod. rod O.D.
SERVICE
BATAS LIMIT: 11,94
SERVIS: 11.94 mm
mm (0.470 in)
Inspect check
Periksa the check valve
valve [1] [1] in the push
di dalam pushrod
rodforterhadap
wear or
damage.atau kerusakan.
keausan
[1]
8-26
PEMASANGAN
INSTALLATION
Install
s ebagai berikut: [1] [2]
- –Baut
Camcam chain
chain tensioner
tensioner roller
roller [1][1]
- –Collar [2] [2]
Collar
- –Tensioner
Tensioner arm [3] [3]
arm
- –Was her [4][4] [4]
Washer
- –Baut
Cam chaincam
engsel tensioner arm pivot arm
chain tensioner bolt [5]
[5]
Tighten the baut
Kencangkan pivot engsel
bolt to the specified
dengan torque.
TORQUE:
TORSI: 16 N·m
16 N.m (1,6(1.6 kgf·m,
kgf.m; 12 lbf·ft)
12 lbf.ft)
[3] [5]
Pasang tensione r Pas ang the
Install s ebagai berikut:
following:
spring dengan sisinya Tapered side [1]
- Push rod [1]
Install themeruncing
y ang tensioner - –Tensioner
Push rodspring
[1] [2]
me nghadap
springkewith
atas.
its – Tensioner spring [2]
tapered side facing Pas ang dan kencangkan baut perapatan [3] dengan
Install and tighten the sealing bolt [3] with a new sealing
up. sebuah sealing washer baru [4] dengan torsi yang
washer [4] to the specified torque.
ditentukan.
[2]
[3] [4]
Lepaskan
Remove baut [1] [1]
the bolt danandsealing washer
sealing washer[2].[2].
Pour 4.0 ccminimum
Semprotkan minimum 4,0 of engine oil into ke
cc oli mesin thedalam
cam chain
cam [2]
tensioner
chain pushpush
tens ioner rod asrodshown
Install
Pas ang and
dantighten the boltbaut
kencangkan with a new sealing
dengan washer.
sealing washer
baru.
Install the flywheel (page 11-13).
Pas ang fly wheel (hal. 11-13).
[1]
PELEPASAN/PEMASANGAN OIL
OIL STOPPER PLATE REMOVAL/
INSTALLATION
STOPPER PLATE
Remove the flywheel (page 11-8). Lebar pelapisan: 6.5 ± 1.0 mm
Lepaskan flywheel (hal. 11-8).
Remove the bolt [1] and oil stopper plate [2]. dari ujung
Lepaskan baut [1] dan oil stopper plate [2].
Apply locking agent to the bolt threads as specified.
Oleskan locking
Install the agent plate
oil stopper padawhile
ulir-ulir baut
setting its seperti
tab [3]
ditentukan.
against the crankcase rib and tighten the bolt.
Pas ang oil stopper plate sementara menempatkan tab-
Install the flywheel (page 11-13).
nya [3] terhadap crankc ase rib (tulang bak mesin) dan
kencangkan baut.
Pas ang fly wheel (hal. 11-13). [3]
[2]
[1]
8-27
CATATAN
9. CYLINDER/PISTON
LOK ASI KOMPONEN

COMPONENT ....................................
LOCATION 9-2
····························9-2 TROU BLESHOOTING ...................................
TROUBLESHOOTING ·································· 9-4

·····························9-3 CYLINDER/PISTON
CYLINDER/PISTON ....................................... 9-5
······································ 9-5
9
9-1
CYLINDER/PISTON
LOKASI KOMPONEN
CYLINDER/PISTON
10 N·m (1,0 kgf·m; 7 lbf·ft)
9-2
CYLINDER/PISTON
KETERANGAN SERVIS
SERVICE INFORMATION
GENERAL
UMUM
•• This
Babsection covers
ini meliputi service
servis of the cylinder
dari cylinder and piston.
dan piston. These
Pekerjaan services
s ervis can be
ini dapat performed
dilakukan with mesin
dengan the engine installed
terpasang padain the frame.
rangka.
•• Take careagar
Hati-hati not to damage
tidak the cylinder
merusak dinding cywall anddan
linder piston.
piston.
•• Be carefulagar
Hati-hati not to damage
tidak the mating
merusak surfaces when removing
permukaan-permukaan penyatuanthe sewaktu
cylinder. melepaskan
Do not tap the cylinderJangan
cylinder. too hard during
ketuk removal.
cylinder dengan
• When disassembling, mark and
terlalu keras pada waktu pelepasan. store the disassembled parts to ensure that they are reinstalled in their original locations.
•• Clean
Pada all disassembled
waktu parts with
pembongkaran, cleaning
tandai solvent and
dan simpanlah dryyang
parts themdibongkar
by blowinguntuk
themmemastikan
off with compressed air before
bahwa mereka inspection.
dipasang kembali
pada lokasi mereka semula.
• Bersihkan semua parts yang dibongkar dengan pelarut pembers ih dan k eringkan dengan meniupnya dengan udara dari
kompresor sebelum melakukan pemeriksaan.
SPESIFIKASI
Satuan: mm
Cylinder D.D. 50,005 – 50,015 50,05
Kelonjongan – 0,10
Ketirusan – 0,10
Piston, piston D.L. piston 49,980 – 49,995 49,91
rings, piston Titik pengukuran D.L. piston 6,0 dari dasar gaun –
pin D.D. lubang piston pin 13,002 – 13,008 13,04
D.L. piston pin 12,994 – 13,000 12,98
Jarak renggang piston-ke-piston pin 0,002 – 0,014 0,075
Jarak renggang Atas 0,015 – 0,045 0,09
piston ring-ke- 0,09
Kedua 0,015 – 0,045
alurnya
piston ring (Riken) Kedua 0,10 – 0,25 0,45
Oli(side rail) 0,20 – 0,70 1,1
piston Ring Kedua 0,35 – 0,50 0,75
(Teikoku) Oli (side rail) 0,10 – 0,40 1,1
Jarak renggang cylinder-ke-piston 0,010 – 0,035 0,10
D.D. kepala kecil connecting rod 13,016 – 13,034 13,05
Jarak renggang connecting rod-ke-piston pin 0,016 – 0,040 0,07
TORSI PENGENCANGAN
TORQUE VALUES
Baut cam chain guide roller pin 10 N.m (1,0 kgf.m; 7 lbf.ft)
Cam
Baut chain
stud guide roller pin bolt
cylinder. 10 N·m (1.0 kgf·m,
- 7 lbf·ft) Lihat hal. 9-9
Cylinder stud bolt – See page 9-8
TROUBLESHOOTING
LSHOOTINGmpression too low, hard starting or poor performance t
Kompressi terlalu rendah, sulit dihidupkan atau performa buruk pada kecepatan rendah
•lw Kebocoran
speedaking
pada cylindercylinder
head gasket head gasket
•• Worn,
Pistonstuck
ring aus, macetpiston
or broken atau patah
ring
•• orn
Cylinder dan piston
or damaged aus and
cylinder ataupiston
rusak
•• Bent connecting
Connecting rod rod
bengk ok
Compression too high, overheating or knocking
Kompressi terlalu tinggi, overheating atau knocking (ngelitik)
• Excessive carbon built-up on piston head or combustion chamber
• Pembangunan karbon yang berlebihan pada kepala piston atau ruang pembakaran
Excessive smoke
• Worn
Asap cylinder, piston or piston rings
berlebihan
•• Improper
Cylinder,installation
piston atauofpiston
pistonrings
ringsaus
•• Scored or scratched piston
Pemasangan piston rings salah or cylinder wall
• Cylinder head/valve problem (page 8-5)
• Piston atau dinding cy linder tergerus atau tergores
•Abnormal noise
Persoalan pada cylinder head/valve (hal. 8-5)
• Worn piston pin or piston pin hole
• Worn
Suara cylinder,
tidak normalpiston or piston rings
•• Worn
Pistonconnecting rod small
pin atau lubang endpin aus
piston
•• Excessive carbonatau
Cylinder, piston build-up
piston rings aus
• Kepala kec il connec ting rod aus
• Pembangunan karbon yang berlebihan
9-3
CYLINDER/PISTON
CYLINDER/PISTON
PELEPASAN
CYLINDER CYLIN DER
REMOVAL
CATATAN:
• • Cylinder dan piston
Cylinder and dapat
pistoncan diservis with
be serviced dengan mesin
the engine
terpasang
installed onpada rangka.
the frame.
Lepaskan
Remove sebagai berikut:
the following:
- Cy linder head (hal. 8-12) [2] [3]
– Cylinder head (page 8-12)
- Dua baut [1]
– Two bolts [1]
- –Lower
Lowerside cover
side stay
cover [2] [2]
stay
Lepaskan EOT
Disconnect thesensor 2P connector
EOT sensor [3].
2P connector [3].
[1]
Hati-hati not to Lepaskan

agar tidak
Be careful Remove sebagai berikut:
the following:
menjatuhkan
drop the guideguide
roller - Baut cam chain guide roller pin [1]/sealing washer [2] [3]
– Cam chain guide roller pin bolt [1]/sealing washer [2]
intoroller ke dalam - Guide roller [3]
the crankcase.
crankcase. – Guide roller [3]
[1]/[2]
Be careful
Hati-hati Remove cylinder
not to Lepaskan
agar tidak the cylinder
[1]. [1].
merusak
damagepermukaan
the mating
penyatuan.
surface.
[1]
Remove dowel
Lepaskan the dowel
pinspins [1] and
[1] dan gasket
gasket [2]. [2].
[2]
[1]
9-4
CYLINDER/PISTON
PISTON REMOVAL
PELEPASAN PISTON
Place
Letakka an
clean
kainshop Remove piston
lap Lepaskan the piston pin clip
pin clip [1] with tang.
[1] dengan pliers.
towel
bersihover the
di atas [2]
Push the piston
pinpin[2] [2]keluar
out ofdarithe pis
piston [3] dan
and
untukto Dorong
crankcase
crankcase piston
connecting rod, and remove the piston.
ton [3]
prevent
menjaga clip connecting rod dan lepaskan piston.
theclip
agar
tidak
from dapat
fallingjatuh ke
into the
dalam crankcase.
crankcase.
[3] [1]
Do Jangan merusak
not damage the Rentangkan
Spread eachmasing-masing
piston ring andpiston
removering
it bydan lepaskan
lifting it up at
pistonpiston
ring dengan
ring by dengan
a pointmengangkatnya
just opposite theke atas pada sebuah titik tepat
gap.
merentangkan
spreading the ujung-
ends berhadapan dengan celah pada ujungnya.
ujungnya te rlalu
too far.
jauh.
Jangan a wire Tiuplah

sekali-kali
Never use Clean jalan lintasan
carbon oli from
deposits dengan
theudara
pistonkompressor,
ring groovesbila
[1]
memakai brush;
sik at kawat; with a used piston ring [2] that will be discarded.
it will perlu. [2]
ia ak an merusak
damage alur.
the groove.
Blow the oil passage with compressed air, if necessary.
[1]
9-5
CYLINDER/PISTON
PEMERIKSAAN
INSPECTION
CYLINDER
CYLINDER
Periksa
Inspectdinding cy linder
the cylinder wallterhadap goresan
for scratches anddan keausan.
wear.
Ukur dan and
Measure catatrecord
D.D. the
cylinder pada
cylinder I.D.tiga tingkat
at three pada
levels in
poros X dan
both the Y. YAmbil
X and axis. pembacaan maksimum
Take the maximum untuk
reading to
menentukan keausan
determine the cylindercylinder.
wear.
Y
BATAS SERVIS:
SERVICE LIMIT:50,05
50.05 mm
mm (1.970 in)
Untuk pengukuran D.L. piston (hal. 9-8). Atas X
For measurement of the piston O.D. (page 9-7).
Hitung jarakthe
Calculate renggang cylinder-ke-piston.
cylinder-to-piston clearance.
Tengah
BATAS SERVIS:
SERVICE LIMIT:0,10
0.10 mm
mm (0.004 in)
Hitung
Calculatecylinder terhadapforketirusan
the cylinder taper and dan kelonjongan
out-of-round at Bawah
pada
three levels in an X and Y axis. Take the Y.
tiga tingkat pada sumbu X dan Ambil
maximum
pembacaan maksimum
reading to determine the untuk menentukan
taper and ketirusan
out-of-round.
dan kelonjongan.
SERVICE LIMITS:
BATAS SERVIS: 0.10 mm (0.004 in)
Out-of-round:
Kelonjongan:
Taper: 0,10
0.10mm mm (0.004 in)
Ketirusan: 0,10 mm
The cylinder must be rebored and an oversize piston
Cylinder harus dikorter dan sebuah oversize piston
fitted if the service limits are exceeded.
dipasang jika batas2 servis dilampaui.
NomorThese parts The following oversize pistons are available:
part-nomor Ukuran-ukuran oversize pistons berikut tersedia:
partnumbers
ini dapat may be 0.25 mm (0.010 in): 13102-KWZ-305
diubah
changed
tanpa without 0,25 mm 13102-KWZ-305
pemberitahuan 0.50 mm (0.020 in): 13103-KWZ-305
written permission.
di muka. 0,50 mm 13103-KWZ-305
0.75 mm (0.030 in): 13104-KWZ-305
0,75 mm 13104-KWZ-305
1.00 mm (0.040 in): 13105-KWZ-305
1,00 mm 13105-KWZ-305
The cylinder must be rebored so that the clearance for
Cylinder
an oversizeharus piston
dikorteris sehingga
0.010 – jarak
0.035 renggang untuk–
mm (0.0004
sebuah
0.0014oversize
in). piston adalah 0,010 – 0,035 mm.
Periksa
Check thec ylinder terhadap
cylinder for warpage perubahan bentuk
by placing a straight
melengkung
edge and a dengan menempatkan
feeler gauge sebuah
across the straight
stud holes as
shown.
edge dan s ebuah feeler gauge melintasi lubang stud
SERVICE LIMIT: 0.05 mm (0.002 in)
PISTON/PISTON
PISTON/PISTONRING RING
Selalu ganti
Always piston
replace Inspect piston
the Periksa the piston rings for kelancaran
rings terhadap smooth movement by
perger akan
ringspiston
sebagai sebuah
rings rotatingmemutarnya.
as a dengan them. The ringsRinshould
gs harbe
us able to move
da pat in their
bergerak di
set. grooves
set. dalam without
alur-alur catching.
mereka tanpa menyangkut.
Push the
Tekan ringring until the
sampai outer surface
permukaan luarof dari
the piston
pistonring is
ring
nearly rata
hampir flushdeng
withan
thepiston
pistondan
andumeasure the renggang
kurlah jarak clearance
using amenggunakan
dengan feeler gauge. seb uah feeler gauge.
SERVICE
BATAS LIMITS:
SERVIS:
Top: : 0,09
Atas 0.09mm
mm (0.004 in)
Second:
Kedua 0.09mm
: 0,09 mm (0.004 in)
9-6
CYLINDER/PISTON
Insert the piston ring [1]
Masukkan [1] into the bottom
secara of the
tegaklurus kecylinder
dal am
squarely
bagian using the
bawah daripiston
cylind crown.
er deng an mendoro ngnya [1]
Measure
dengan the ring
kepala end gap.
piston.
Ukur celah pada ujung ring.
SERVICE LIMITS:
Top: SERVIS:
BATAS 0.45 mm (0.018 in)
Second (Riken):: 0.450,45
Atas mm mm
(0.018 in)
Kedua
Second (Riken) : 0.750,45 mm mm
(0.030 in)
(Teikoku
Kedua and other
(Teikoku) : 0,75 mm
Osuppliers):
li (side rail) : 1,1 mm
Oil (side rail): 1.1 mm (0.04 in)
Ukur D.L. piston

Measure padaO.D.
the piston s ebuah
at atitik 6,06.0
point mmmm dari(0.24
bagian
in)
o
bawah danbottom
from the 90 terhadap
and 90°lubang pin.hole.
to the piston pin
BATAS SERVIS:
SERVICE LIMIT: 49,91
49.91 mm
mm (1.965 in)
Ukur D.D. cylinder (hal. 9-7).
For measurement of the cylinder I.D. (page 9-6). 90°
Hitung jarakthe
Calculate renggang cylinder-ke-piston.
cylinder-to-piston clearance.
6,0 mm
Measure
Ukur piston pin
D.D. lubang borepin
piston I.D. in an
pada X and
poros Y axis.
X dan Y.
Takepembac
Ambil the maximum reading tountuk
aan maksimum determine I.D.
menentukan D.D.
SERVICE
BATAS LIMIT: 13,04
SERVIS: 13.04 mm
mm (0.513 in)
Measure
Ukur the piston
D.L. piston pin O.D.
pin pada tiga at three points.
titik.
BATAS SERVIS:
12.98 mm
mm (0.511 in)
Hitung jarakthe
Calculate renggang piston-ke-pis
piston-to-piston ton pin.
pin clearance.
BATAS
SERVICE SERVIS:
LIMIT: 0,075
0.075 mm
mm (0.0030 in)
9-7
CYLINDER/PISTON
CONNECTINGROD
CONNECTING ROD
Measure
Ukur the connecting
D.D. kepala rod smallrod.
kecil connecting end I.D.
BATAS SERVIS:
13.05 mm (0.514 in)
Hitung jarakthe
Calculate renggang connecting
connecting rod-ke-piston
rod-to-piston pin.
pin clearance.
CYLINDER STUD BOLT

REPLACEMENT
PENGGANTIAN BAUT STUD CYLINDER
Jika akan mengganti
If replacing baut-baut
the cylinder stud be
stud bolts, cylinder,
sure tolakukan
install
sebagai
them asberikut.
shown.
Pas ang dua mur pada baut stud, dan kencang mereka
Thread two nuts onto the stud bolt, and tighten them
satu s amathen
together, lain, use
laluapakailah kunci
wrench on thempasto pada mereka
turn the stud
untuk memutar
bolt out. baut stud keluar.
Pas ang and
Install dan kencangkan
tighten new baut-baut
stud boltsstud baruspecified
to the dengan
torque.
Setelah mengencangkan baut-baut stud, periksa bahwa 176,0 ± 1,0 mm
After tightening
panjang the stud
dari kepala bautbolts, check ke
sampai thatpermukaan
the length
from the adalah
crankcase bolt head to the
sesuai crankcase
dengan surface is within
spesifikasi.
specification.
PEMASANGAN PISTON
PISTON INSTALLATION
Bersihkan
Clean thekepala piston, ring
piston heads, alur-alur ringand
grooves danskirts.
gaun piston
selama pemasangan.
Carefully install the piston rings onto the piston with * : Tipe riken diperlihatkan
Pas anglah
their piston
markings rings
facing up.dengan hati-hati pada piston
* *
dengan tanda-tanda pada mereka menghadap ke atas. Tanda untuk ring atas
Tanda untuk ring kedua
CATATAN:
• Be careful not to damage the piston and piston rings
• Hati-hati
during agar tidak merusak piston dan piston rings
installation.
• sDo not confuse
elama the top and second rings.
pemasangan.
• • When
J anganinstalling the oil ring,
mempertukarkan ring install thering
atas dan spacer first
kedua.
• and then the
Sewaktu side rails.oil ring, pasang spacer dulu
memasang
dan kemudian
Stagger the piston baru
ringside
endrails.
gaps 120 degrees apart 120°
Do not align the
Jangan RING RING ATAS
gaps ofmenjajarkan from each other as
the oil ring Selang-selingkan shown.
c elah-celah ujung piston ring pada
celah-celah dari
side oil Stagger the side rails gaps as shown.
rails. KEDUA
ring side rails.
jarak 120 derajat terpis ah dari masing-masing seperti
diperlihatkan.
After installation, the piston rings should be free to
Selang-selingkan 120°
rotate in the groove.celah-celah side rails seperti 120°
diperlihatkan.
Setelah pemas angan, piston rings harus dapat berputar
dengan bebas di dalam alur mereka.
SPACER SIDE RAILS
20 mm atau lebih
9-8
CYLINDER/PISTON
Tempatkan kainshop
Place a clean lap towel
di atas
overlubang crankcase
the crankcase to supaya
prevent
kotoran,
the dirt, debu atau
dust or piston
piston pin clips
pin clips from tidak dapat
entering the
memas uki crankcase.
crankcase.
Be careful
Hati-hati Clean thepermukaan
tidakto Bersihkan
agar not gasket mating surfacesgasket
penyatuan of the dari
crankcase and
crank case
merusak the gasket dan
damagepermukaan cylinder thoroughly.
cylinder sec ara menyeluruh.
penyatuan gasket.
mating surfaces.
Apply engine
Semprotkan oli oil
mes tointhe connecting
pada rod dalam
permukaan small end [1]
kepala
inner
kecil surface. rod [1].
connecting
[1]
Semprotkan
Apply engineolioilmesin ke permukaan
to the piston pin hole [1]dalam lubang
inner surface
[4] [2]
piston pin [1]pin
and piston dan[2]permukaan luar piston pin [2].
outer surface.
Pas ang the
Install piston [3]
piston dengan
[3] with tandaIN"“KWZ
the "KWZ mark [4]IN”facing
[4]
the intake side.
menghadap ke sisi pemasukan.
Instal
Pas angthe piston
piston pin.pin.
[3] [1]
Install
Pas ang new piston
piston pin clips
pin clips baru[1].
[1]. [3]
CATATAN:
• • Pastikan
Make sure the piston
bahwa pistonpin
pinclips
clipsare seated
telah securely.
duduk dengan
• erat.
Do not align the piston pin clip end gap [2] with the
• Jpiston
angancutout [3]. celah pada ujung piston pin clip
tepatkan [2]
[2] dengan potongan pada piston [3].
[1]
CYLINDER INSTALLATION
PEMASANGAN CYLINDER
Install
Pas ang the dowel
dowel pinspins [1] and
[1] dan a et
gask new gasket
baru [2]. [2]. [2]
[1]
9-9
CYLINDER/PISTON
Semprotkan
Apply engine oli oil
mesin
to thepada bagian
cylinder dalam
bore cylinderouter
[1], piston [1].
[6] [3]/[4]
permukaan
surface [2],luar
pistonpiston [2], alur-alur
ring grooves pispiston
[3] and ton ring [3] [4].
rings dan
piston rings [4].
Route the cam chain [5] through the cylinder.
Hati-hati agar tidak Alurkan cam c hain [5] melalui cylinder.
Be careful
merusak pistonnot to
rings Install the cylinder [6] over the piston while compressing
damage the piston
dan bagian dalam Pas
theang cylinder
piston [6] diyour
rings with atas piston sementara menekan
fingers.
rings and cylinder.
cylinder piston rings dengan jari-jari.
bore.
[5] [1]/[2]
Hati-hati agar tidak Pas ang cam chain guide roller [1], s ealing was her baru
Be careful not to Install the cam chain guide roller [1], new sealing
menjatuhkan guide
drop the guide roller [2] dan baut
washer camcam
[2] and chain guide
chain roller
guide pin [3].
roller pin bolt [3]. [3]
roller ke dalam Kencangkan baut roller pin dengan torsi yang
into the crankcase.
crankcase. Tighten the roller pin bolt to the specified torque.
ditentukan.
[1] [2]
Sambungkan 2P connector [1].

Connect the EOT sensor 2P
[2] [1]
Install
Pas angthe lowerside
lower side cover
cover stay
stay [2]
[2}and tighten
dan kenc the two
angkan
bolts [3].
kedua baut [3].
Install
Pas angthe cylinder
cy linder head
head (page
(hal. 8-24).
8-24).
[3]
9-10
10. DRIVE PULLEY/DRIVEN PULLEY/CLUTCH
LOK ASI KOMPONEN

COMPONENT ..................................
LOCATION 10-2
··························10-2 DRIVE
DRIVEPULLEY.......................................... 10-9
PULLEY··········································· 10-9
KETERANGAN SERVIS ..............................

···························10-4 DRIVEN
DRIVEN PULLEY
PULLEY.......................................
······································ 10-13
10-13
TROUBLESHOOTING ................................. 10-6 CLUTCH COVER ....................................... 10-18
TROUBLESHOOTING·································10-6 CLUTCH COVER ······································ 10-18
10
PULLEY COVER .......................................... 10-7 DRIVESH AFT/CLUTCH ............................. 10-21
PULLEY COVER ·········································10-7 DRIVESHAFT/CLUTCH ···························· 10-21
DRIVE BELT................................................. 10-8 AIR INLET D UCT ....................................... 10-28
DRIVE BELT················································10-8 AIR INLET DUCT ······································ 10-28
10-1
LOKASI KOMPONEN
49 N·m (5,0 kgf·m; 36 lbf·ft)
83 N·m (8,5 kgf·m; 61 lbf·ft)
10-2
2,1 N·m (0,21 kgf·m; 1,5 lbf·ft)
2,1 N·m (0,21 kgf·m; 1,5 lbf·ft)
10-3
KETERANGAN SERVIS
SERVICE INFORMATION
GENERAL
UMUM
• This section covers maintenance of the drive pulley, driven pulley and clutch.
•• Bab iniservices
These meliputican
perawatan
be donedari
withdriv
theeengine
pulley , installed
driven pulley
in thedan clutch.
frame.
•• Pekerjaan-pekerjaan
Avoid servis
getting grease and ini dapat
oil on dilakukan
the drive belt anddengan mesinpulley
drive/driven terpasang
facespada rangka.
in order to prevent belt slippage.
•• J agalah
Do agargrease
not apply gemuktodan
theoli tidak rollers.
weight mengenai drive belt dan drive/driven pulley faces agar tidak terjadi slip pada belt.
• J angan berikan gemuk pada weight rollers.
SPESIFIKASI
Satuan: mm
Lebar drive belt 19,0 18,0
Movable drive face D.D. bushing 22,035 – 22,085 22,11
D.L. boss 22,010 – 22,025 21,98
D.L. weight roller 17,92 – 18,08 17,5
Driven pulley Panjang bebas face spring 109,4 93,0
D.L. driven face boss 33,965 – 33,985 33,94
D.D. movable driven face 34,000 – 34,025 34,06
Clutch Tebal lining 2,0 1,5
D.D. clutch outer 126,00 – 126,20 126,30
TORSI
TORQUEPENGENCANGAN
VALUES
Sekrup
Air feedair feedscrew
plate plate 3 N.m (0,31
3 N·m kgf.m;
(0.31 2,2 2.2
kgf·m, lbf.ft)
lbf·ft)
Mur drive pulley face 83 N.m (8,5 kgf.m; 61 lbf.ft) Semprotkan oli mesin pada ulir dan
Drive pulley face nut 83 N·m (8.5 kgf·m, 61 lbf·ft) Apply engine oil to the threads and seating
permukaan
surface. duduk
Mur driven
Driven pulley
pulley nut 49 N.m (5,0(5.0
49 N·m kgf.m; 36 lbf.ft)
kgf·m, 36 lbf·ft)
Sekrup inlet duc t band 2,1 N.m (0,21 kgf.m; 1,5 lbf.ft)
Inlet duct band screw 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
Sekrup clutc h cover duct band 2,1 N.m (0,21 kgf.m; 1,5 lbf.ft)
Clutch cover duct band screw 2.1 N·m (0.21 kgf·m, 1.5 lbf·ft)
10-4
TOOLS
Clutch center holder Clutch spring compressor attachment Clutch assembly shaft
07725-0030000 07HAE-PL50100 07GAE-PG40200
Attachment, 37 x 40 mm Attachment, 42 x 47 mm Pilot, 12 mm

07746-0010200 07746-0010300 07746-0040200
Pilot, 20 mm Driver Remover weight

07746-0040500 07749-0010000 07741-0010201
Bearing remover shaft, 12 mm Bearing remover head, 12 mm

07936-1660120 07936-1660110
10-5
TROUBLESHOOTING
Mesin dapat dihidupkan tetapi sepedamotor tidak bergerak
• Drive belt aus
• Ramp plate rusak
• Clutc h shoe aus atau rusak
• Driven face spring patah
Mesin mati mendadak atau sepedamotor merangkak

• Clutc h shoe spring patah
Performa buruk pada kecepatan tinggi atau kekurangan tenaga

• Drive belt aus
• Driven face spring patah.
• Weight rollers aus
• Pulley fac es terkontaminasi
TROUBLESHOOTING
Engine starts but motorcycle won’t move
• Worn drive belt
• Damaged ramp plate
• Worn or damaged clutch shoe
• Broken driven face spring
Engine stalls or motorcycle creeps
• Broken clutch shoe spring
Poor performance at high speed or lack of power
• Worn drive belt
• Weak driven face spring
• Worn weight rollers
• Contaminated pulley faces
10-6
PULLEY COVER
PELEPASAN
REMOVAL
Remove the
Lepaskan following:
- –Baut-baut
Cover bolts [1][1]
cover
- –Pulley covcover
Pulley er [2][2]
[2]
Lepaskan
Remove kedua dowel
the two dowelpins [1] [1]
pins danand
cover gasket
cover [2] dari
gasket [2]
clutch cover.
from the clutch cover. [2]
Bersihkan permukaan penyatuan gask et.
Clean the gasket mating surface.
[1]
Remove the
Lepaskan following:
- –Dua baut [1]
Two bolts [1]
- –Pulley covcover
Pulley er emblem
emblem [2][2]
[1]
Tekuk
Bend lock tabs
up the [1]tabs
lock ke atas danremove
[1] and lepaskan
theketiga sekrup
three screws [3]
[2]
[2]dan
andair
airfeed
feedplate
plate[3].
[3].
Install
Pas ang the
air air feed
feed plate
plate danand tighten thesscrews
kencangkan ekrup-s to the
ekrup
specified
dengan torque.
TORQUE:
TORSI: 3 N·m
3 N.m (0.31
(0,31 kgf·m,
lbf.ft)
Tekuk
Bend lock tabstabs
the lock dariofairthefeed plate plate
air feed terhadap s crew
against the
heads.
screw heads.
Install the removed parts in the reverse order of
pelepas
removal.an.
[1]/[2]
10-7
INSTALLATION
PEMASANGAN
Install
Pas angthe two dowel
kedua dowel pins
pins [1].
[1].
[2]
Install
Pas angac new
over cover
gas ketgasket [2].
baru [2].
[1]
Pas ang the
Install pulley cover
pulley [1] [1]
cover pada
ontoclutch c overcover
the clutch dengan
by
mentepatkan dowel pins
aligning the dowel pins with
dengan lubang-lubang.
the holes. [2]
Install
Pas ang and
dan tighten the cover
kencangkan bolts [2]
baut-baut in a[2]
cover crisscross
dengan
pattern
pola in two ordalam
bersilangan three steps.
dua atau tiga langkah.
[1]
DRIVE BELT
REPLACEMENT
PENGGANTIAN
CATATAN:
• • The
Drivedrive belt can
belt dapat be serviced
dis ervis with the
dengan mesin engine
terpasang
[1]
installed in the frame.
pada rangka.
Lepaskan drive pulley face (hal. 10-9).
Remove the drive pulley face (page 10-9).
Lepaskan
Remove thedrive beltbelt
drive [1] dan ganti
[1] and dengan
replace yanga baru.
it with new one.
Pas angthe
Install drive pulley
drive face
pulley (hal.
face 10-11).
(page 10-11).
10-8
DRIVE PULLEY
REMOVAL
PELEPASAN
CATATAN:
•
• The drive pulley
Drive pulley can be serviced
dapat diservis with the engine
dengan mesin
[2] [4]
installed in the frame.
terpasang pada rangka. [1]
Remove the
Lepaskan pulley
pulley cover
c over (hal.(page
10-7).10-7).
Hold the
Tahan drivedrive pulley
pulley faceface
[1] [1] with special
dengan special tool
tool dan
and
loosen the mur
longgarkan drivedrive
pulley faceface
pulley nut [2].
[2].
TOOL:
TOOL:
[3]Clutch
[3] Clutchcenter
center holder
holder 07725-0030000
07725-0030000
Remove the
Lepaskan following:
sebagai berikut:
- –Mur
Nut
- –Was her [4][4]
Washer
- –Drive pulley face [3]
Drive pulley face
Lepaskan washer
Remove the [1] dari
washer rightthe
[1] from crankshaft.
right crankshaft.
[1]
Slide off
Geser the drive
lepas drivebelt [1] [1]
belt fromdari
the drive face
faceboss [2] [2]
boss by
squeezing
dengan the drive
memencet belt.belt.
drive [1]
[2]
Remove movable
Lepaskan the movable
drivedrive
face face assembly
assembly [1] while
[1] sementara
holding the
menahan ramp
ramp plate
plate [2] [2]
danand drive
drive face
face boss
boss [3].[3]. [1]
[3] [2]
10-9
Remove the
Lepaskan following
sebagai from
berikut themovable
dari movabledrive
driveface
face[1]:
[1]:
- –Drive face boss [2]
Drive face boss [2]
- –Ramp
Ramp plate [3][3]
plate
- –Slide pieces
Slide pieces [4][4]
- –Weight
Weightrollers [5][5]
rollers
Bersihkan
Clean any oli dan Perakitan
oil and Assemblyadalah dalam
is in the urutan
reverse terbalik
order dari pelepasan.
of disassembly.
gemuk dari
grease weight
from the
rollers
weightdan movable
rollers and
drive face.
movable drive face.
[1]
[3]
[2]
[5]
[4]
PEMERIKSAAN
INSPECTION
DRIVE
DRIVEPULLEY
PULLEYFACE
FACE
Periksa
Check drive pulley
the drive faceface
pulley [1] terhadap goresan,scoring
[1] for scratches, gerusanor
damage.
atau kerus akan. [1]
WEIGHT
WEIGHTROLLER
ROLLER
Periksa masing-masing
Check each weight
weight roller [1] roller [1]
for abnormal wear.terhadap
keausan
Measuretidak normal.roller O.D.
the weight [1]
Ukur D.L. weight roller.
10-10
DRIVE
DRIVEFACE
FACEBOSS
BOSS
Check the
Periksa drive
drive faceboss
face boss [1]
[1] for wear or keausan
terhadap damage. atau
Measure the drive face boss O.D.
kerusakan. [1]
Ukur D.L. drive face boss.
MOVABLE
MOVABLEDRIVE DRIVEFACE
FACE
Periksa mov
Check the able drive
movable drive face [1]forterhadap
face [1] scratches,goresan,
scoring
gerus an atau kerusakan.
or damage.
Ukur D.D. drive
Measure faceface
the drive bushing.
bushing I.D.
BATAS SERVIS:
22.11 mm (0.871 in)
[1]
PEMASANGAN
INSTALLATION
Clean anyolioildan
Bersihkan andgemuk
grease from
dari thefac
drive drive face
e dan andbelt.
drive drive
belt. [2]
Hati-hati agar jangan Pas ang movable drive face assembly [1] pada
membongkar
Be careful not movable
to get crankshaft
Install thesementara menahan
movable drive face ramp plate [2]
assembly [1] dan
ontodrive
the
drive face assembly
the movable drive face bos s [3].while holding the ramp plate [2] and drive
crankshaft
dan pastikan untuk
face assembly face boss [3].
memasang asse mbly
disassembled
sampai dudukand
be sure sepenuhnya.
to install the
assembly until fully
seated.
[3] [1]
Tekan
Compressdriven theface spring
driven face[1] dengan
spring memencet
[1] by squeezingdrive
the
[1] [2]
belt [2] belt
drive sampai ada cukup
[2] until there iskekenduran
enough slackuntuktomemasang
install the
drive
drivebelt
beltpada
to thedrive
driveface
faceboss
boss[3].
[3].
[3]
10-11
Hati-hati Set the drive
not to Tempatkan
agar tidak
Be careful drivbelt [1] onto
e belt the drive
[1] pada driveface
fac boss [2] [2]
e boss by
merusak
damage thespline. squeezing
spline. dengan it to obtain the
memencetnya clearance
sampai between thejarak
mendapatkan belt [1] [2] Align
and boss.antara belt dan boss.
renggang
Install
Pas angthe
waswasher
her [3].[3].
Install
Pas angthe
drivdrive pulleyfac
e pulley face [4] sementara
e [4] while aligning its splines
mentepatkan
with crankshaft
splines-nya dengansplines.
crankshaft splines.
[3] [4]
Make
Pas sure
tikan that the
bahwa drive
drive pulley
pulley face[1][1]dan
face and washer
washer [2]
are fully seated on the drive [2] [3]
telah duduk sepenuhnya padaface
drivboss
e face[3].
boss [3]. [1]
Fully seated
[1]/[2]/[3]
Semprotkan
Apply engineolioilpada ulirdrive
to the murpulley
drive face
pulleynutface [1] dan
[1] threads
[1]/[2] [3]
and seatingduduk
permukaan surface then install
kemudian pas itang
with the washer
dengan washer[2].[2].
Hold the
Tahan drive
drive pulleyface
pulley face[3][3]dengan
with thespecial
special tool
tool dan
and
tighten the nut
kencangkan murtodengan
the specified torque.
TOOL:
TOOL:
[4] Clutch
[4] Clutchcenter
center holder
holder 07725-0030000
07725-0030000
TORSI: 83 83
N·m kgf.m; 61 61
kgf·m, lbf.ft)
lbf·ft)
Pas angthe
Install pulley covcover
pulley er (hal. 10-8).
(page 10-8).
[4]
DRIVEN PULLEY
REMOVAL
PELEPASAN
CATATAN:
• • The driven
Driven pulleydapat
pulley can bediservis
serviced dengan
with the engine
mesin
[1] [2]/[3]
installed
terpasang in pada
the frame.
rangka.
Remove the
Lepaskan drive
drive pulley
pulley faceface
(hal.(page 10-9).
10-9).
Hold the
Tahan driven
driven faceface flange
flange with sebuah
dengan a 30 mm wrench
kunci pas [1]
30
and[1]
mm remove the nut [2]
dan lepaskan mur and
[2] washer
dan was[3].her [3].
Remove the
Lepaskan driven
driven pulley
pulley assembly
as sembly [4]. [4].
Remove the
Lepaskan drive
drive beltbelt [5] from
[5] dari thepulley.
driven driven pulley.
[4] [5]
10-12
PEMBONGK ARAN
DISASSEMBLY
Install
Pas angthe specialtools
special tools onto
padathe drivenpulley
driven pulley assembly
as shown. [1] [3]
TOOLS:
Install the TOOLS:
Pasang attachment
dengan sisi with
attachment 37 mmits [1]
[1] Clutch
Clutch Spring
spring compr
compressor
essor 07HAE-PL50100
07HAE-PL50100
menghadap
37 mm side ke driven
facing attachment
attachment
face.
the driven face. [2] Clutch
[2] Clutch assembly
assembly shaft
shaft 07GAE-PG40200
07GAE-PG40200
[3]
[3] Attachment,
Attachment, 37
37 xx 40
40 mm
mm 07746-0010200
07746-0010200
Do not
Jangan compress
te kan Slightlydriven
spring Tekan compress
face the driven
spring facedengan
sedikit spring by turning mur
memutar the
the spring
lebih dari more assemblyshaft
yang assembly shaftsearah
nut clockwise.
jarum jam.
than necessary.
diperlukan.
Remove the
Lepaskan snap snap
ringring [4] from
[4] dari alur the
drivdriven face groove.
en face.
Loosen the assembly shaft nut gradually and remove [2]
Longgarkan mur assembly s haft secara berangsur dan
the special tools from the driven pulley assembly.
lepaskan special tools dari driven pulley assembly.
[4]
Remove the
Lepaskan following:
- –Spring s eat
Spring seat[1][1] [2]
- –Spring c ollar
Spring [2][2]
collar
- –Driven face
Driven s pring
face spring[3][3]
[3]
Remove the
Lepaskan sealseal collar
c ollar [1]. [1].
[1]
10-13
Remove the
Lepaskan guide
guide pinspins
[1] [1]
danand guide
guide rollers
rollers [2] [2] from
dari the
driven
driven face. [1]/[2] [3]
face.
Remove movable
Lepaskan the movable
drivendriven face
face [3] [3]driven
dari from face
the driven
[4].
face [4].
[4]
Remove the
Lepaskan O-rings
O-rings [1] and
[1] dan oil soil
ealsseals [2] from
[2] dari the
movable
movable
driven driven face.
face. [1]
[2]
PEMERIKSAAN
INSPECTION
DRIVEN
DRIVENFACE
FACESPRING
SPRING
Ukur
Measure the bebas
panjang driven driven face s[1]
face spring pring
free[1].
length.
[1]
DRIVEN
DRIVENFACE
FACE
Periksa
Check driven fac e [1]
the driven terhadap
face [1] for goresan, gerusan
scratches, atau
scoring or
kerusakan.
damage. [1]
Measure
Ukur the driven
D.L. driven faceface boss O.D.
boss.
SERVICE
BATAS LIMIT: 33,94
SERVIS: 33.94 mm (1.336 in)
10-14
MOVABLE
MOVABLEDRIVEN
DRIVENFACE
FACE
Check mov
Periksa the able
movable
drivendriven
face face [1] for scratches,
[1] terhadap goresan,
scoring
gerus or damage.
an atau kerusakan. [1]
Check the
Periksa guide grooves
alur-alur for stepped
guide terhadap wear or bertingkat
keausan damage.
Measure
atau the movable driven face I.D.
kerus akan.
Ukur D.D. movable driven face.
PERAKITAN
* : Semprotkan 1,5 - 2,0 g ke masing-masing alur guide.
Shell ALVANIA R3 atau IDEMITSU AUTOREX B
atau NIPPON OIL POWERNOC WB3 atau
GUIDE sejenisnya.
GUIDE ROLLERS
PINS
OIL SEALS
DRIVEN FACE
O-RINGS
SEAL COLLAR
MOVABLE DRIVEN FACE
DRIVEN FACE SPRING
SPRING SEAT
SPRING COLLAR
Apply engine
Semprotkan oli oil to the
mesin lipsbibir-bibir
pada and outerdancircumference of
lingkaran luar
oilnew oilbaru
s eals seals[1] [1]
danand install
pasang them ke
mereka into the movable
dalam movable [3]
drivenface
driven face[2].
[2].
Coat O-rings
Lapisi new O-rings
baru [3]
[3] with engine
dengan oil and dan
oli mesin install them
pasang
into thekemovable
mereka driven face
dalam alur-alur grooves.
movable driv en face.
[1] [2]
10-15
Clean anypulley
Bersihkan oil and grease
face from
dari oli danthe pulley face.
gemuk.
[3]/[4] [1]
Install
Pas ang the
movmovable driven
able driven faceface [1] onto
[1] pada theface
driven driven
[2].face
[2].ang guide rollers [3] dan guide pins [4].
Pas
Install the guide rollers [3] and guide pins [4].
Berikan 1,5 – 2,0 g gemuk (Shell ALVANIA R3 atau
Apply 1.5 –AUTOREX
IDEMITSU 2.0 g of grease
B (Shell ALVANIA
atau NIPPON R3OIL or
IDEMITSU AUTOREX B or NIPPON
POWERNOC WB3 atau s ejenisnya) pada masing- OIL POWERNOC
WB3 oralur
masing equivalent)
guide. to each guide groove.
[2]
Install
Pas ang the
s ealseal collar
collar [1] to driven
[1] pada the driven pulley.
pulley .
[1]
Install
s ebagai berikut: [3]
- –Driven face s pring
Driven face spring [1] [1] [2]
- –Spring c ollar
Spring [2] [2]
collar
- –Spring s eat
Spring [3] [3]
seat
[1]
10-16
Tempatkan snap
Set the snap ringring
[1] [1]
anddan special
special tools
tools ontopada
the driven
pulley
pulleyassembly
assemblyseperti diperlihatkan.
as shown. [1] [4]
Pasang attachment
Install the TOOLS:
TOOLS:
dengan sisi 37 mmits [2]
attachment with [2] Clutch
Clutchspring
spring compressor
compressor 07HAE-PL50100
07HAE-PL50100
menghadap
37 mm sideke driven attachment
facing attachment
face.
the driven face. [3][3] Clutch
Clutchassembly
assembly shaft
shaft 07GAE-PG40200
07GAE-PG40200
[4]
[4] Attachment,
Attachment, 37 37 xx 40
40 mm
mm 07746-0010200
07746-0010200
Jangan te kan spring Tekan driven face spring dengan secara berangsur
Dolebih
not dari
compress
yang Compress the driven face spring by gradually turning
memutar mur assembly shaft searah jarum jam
the spring more
diperlukan. the assembly shaft nut clockwise while aligning the
sementara mentepatkan driven face boss dengan
than necessary. driven face boss with the spring seat hole, until the
lubang s pring
snap ring seat,issampai
groove visible.alur snap ring tampak.
Pas angthe
Install s nap ringring
snap ke into
dalamthealur driven
driven faceface.
groove. [2] [3]
Lepaskan spec ial tools dari driven fac e
Remove the special tools from the driven faceassembly.
assembly. [1]
PEMASANGAN
INSTALLATION
Bersihkan
Clean anydriv
oil en
andface dan from
grease drive the
beltdriven
dari oliface
danand
gemuk.
drive
Tahan
belt. driven pulley assembly dan tekan driven face [3]
spring
Hold the[1] dengan memutar
driven pulley movable
assembly anddriven
compressface the
[2]
berlawanan arah [1]
driven face spring jarum jam movable
by turning sampai driven
ia berhenti
face [2]
sementara memasang
counterclockwise until driv e belt
it stops [3] antara
while driven
installing face
the drive [1]
belt
[4] [3]movable
dan betweendriven
the driven
face. face [4] and movable driven
face.
[2]
[4]
Install
Pas the driven
ang driven pulley assembly
pulley assembly [1] onto the
[1] pada driveshaft.
driveshaft. [1] [2]/[3]
Pas ang was her [2] dan mur driv en pulley [3].
Install the washer [2] and driven pulley nut [3].
Tahan driven face flange dengan kunci pas 30 mm [4]
Holdkencangkan
dan the driven face flange with
mur driven a 30
pulley mm wrench
dengan [4]
tors i yang
and tighten the driven pulley nut to the specified torque.
ditentukan.
TORQUE:
TORSI: 49 49
N.mN·m
(5,0(5.0 kgf·m,
lbf.ft)
Install
Pas angthe drive
drive pulley
pulley face
face (page
(hal. 10-11).
10-11).
[4]
10-17
CLUTCH COVER
REMOVAL
PELEPASAN
Drain the oli
Keluarkan engine
mesinoil(hal.
(page 4-9).
4-9). [1]
Remove the
Lepaskan following:
sebagai berikut:
- –Right body
Right bodycover
cover(hal. 3-13).
(page 3-13)
- –Footpeg
Footpegbarbar
(hal. 3-19)
(page 3-19)
- –Exhaust
Exhaustpipe/muffler
pipe/muffler (hal. 3-20)
(page 3-20)
- –Drive
Drive pulley
pulley (page
(hal. 10-9)
10-9)
- –Driven
Driven pulley
pulley (page
(hal. 10-12)
10-13)
Release the
Lepaskan O2 sensor
kawat wire[1][1]dari
O2 sensor from the clamp
clamp [2]. [2].
[2]
Lepaskan
Release theclutch c over
clutch outlet
cover duct duct
outlet boss boss
[1] dari
[1]rangka.
from the
frame. [1] [3]
Longgarkan s ekrup-s ekrup band [2] dan lepaskan c lutch
Loosen
cover inletthe band
duct screws
[3] dan [2]duct
outlet and [4]
disconnect
dari clutchthe clutch
cover.
cover inlet duct [3] and outlet duct [4] from the clutch
cover.
[4] [2]
Remove the
Lepaskan following:
sebagai berikut: [3]/[4] [1]/[2]
- –Crankshaft
Crankshaftoil oil
seal collar
seal [1]/O-ring
collar [2][2]
[1]/O-ring
- –Driveshaft oiloil
Driveshaft seal collar
seal [3]/O-ring
collar [4][4]
[3]/O-ring
- –Baut-baut cover
Cover bolts [5][5]
- –Clutch covcover
Clutch er [6][6]
[5] [6]
Remove the
Lepaskan dowel
dowel pinspins [1] and
[1] dan gasket
gasket [2]. [2]. [2]
[1]
10-18
CLUTCH COVER
PENGGANTIAN BEARING/OIL
CLUTC H COVER SEAL
REPLACEMENT
BEARING/OIL SEAL
Remove the
Lepaskan rightright crankshaft
c rankshaft oil seal
oil seal [1], [1], right
right driveshaft
driveshaft oil
oil seal [2] and bearing [3] from the clutch cover. [2] [1]
seal [2] dan bearing [3] dari clutch c over.
[3]
Install
Pasangthe be
bearing Apply engine
aring Semprotkan olioil to thekebearing
mesin ronggacavity.
bearing.
with its sisi
dengan marked
yang side
ada Install a new ball bearing [1] into the clutch cover [2]
tandanya mefacing up. Pas ang s ebuah ball bearing baru [1] secara tegaklurus
nghadap squarely until it is fully seated, using the special tools.
ke atas. ke dalam clutc h cover sampai ia telah duduk
sepenuhnya,
TOOLS: dengan menggunakan special tools.
[2] Driver
TOOLS: 07749-0010000
[3]Driver
[2] Attachment, 42 x 47 mm 07746-0010300
07749-0010000 [3]
[4]Attachment,
[3] Pilot, 20 mm42 x 47 mm 07746-0040500
07746-0010300
[4] Pilot, 20 mm 07746-0040500
[1] [4]
Install
Pas ang the rightdriveshaft
right driveshaft oil
oil seal
seal [1]
[1]until it is flush
sampai ia with
rata
the clutch
dengan cover surface,
permukaan clutchusing
c over,the specialmenggunakan
dengan tools. [2]
spec ial tools. [4]
TOOLS:
TOOLS:
[2] Driver 07749-0010000 [3]
[2]
[3]Driver
Attachment, 42 x 47 mm 07749-0010000
07746-0010300
[3] Attachment, 42 x 47 mm 07746-0010300
Install the right crankshaft oil seal [4] to the specified
Pas ang using
depth, rightthecrankshaft oil seal [4] sampai ke
special tools.
kedalaman yang ditentukan, dengan menggunakan
TOOLS:
spec ial tools.
Driver 07749-0010000
TOOLS:
Attachment, 37 x 40 mm 07746-0010200
Driver 07749-0010000
Apply grease37
Attachment, toxthe
40oil
mm seal lips. 07746-0010200 [1]
For leftgemuk
Berikan driveshaft
padabearing replacement
bibir-bibir oil seal. (page 10-26).
Untuk penggantian left driveshaft bearing (hal. 10-26).
RIGHT DRIVESHAFT CRANKSHAFT
OIL SEAL: OIL SEAL:
Flush
1,2 - 1,8 mm
10-19
INSTALLATION
PEMASANGAN
Be sure
Pastikan bahwathatend Install
the Pas ang the dowel
dowel pinspins
[1] [1]
danand a et
gask new gasket
baru [2]. [2]. [3] [2]
end [3]
washer washer [3] is
terpasang
padainstalled onidle
kickstarter the
kickstartershaft.
idle
shaft.
[1]
Install
Pas ang the clutch
c lutch cover
cover [1] [1]
danand bolts [2].
baut-baut [2].
Tighten the baut-baut
Kencangkan bolts in adalam
crisscross pattern in several
pola bersilangan dalam
steps. langkah.
beberapa
[2] [1]
Apply grease
Berikan gemukto the driveshaft
pada oil seal [1]oil
bibir-bibir driveshaft lips.
seal [1]. [2] [3] [4] [6]
Apply engine oil to a new O-ring [2] and
Semprotkan oli mesin pada O-ring baru [2] dan pasang install it onto
the driveshaft.
pada driveshaft.
Install
Pas the eshaft
ang driv driveshaft oil collar
oil seal seal [3]collar
dan[3]
geserandbersama
slide it
together with the O-ring until it is
dengan O-ring sampai ia duduk sepenuhnya. fully seated.
Apply grease to the crankshaft oil seal [4] lips.
Berikan gemuk pada bibir-bibir crankshaft oil s eal [4].
Apply engine oil to a new O-ring [5] and install it onto
Semprotkan oli mesin pada O-ring baru [5] dan pasang
the right crankshaft.
pada right
Install thecrankshaft.
crankshaft oil seal collar [6] and slide it
Pas ang crankshaft
together oil seal
with the O-ring until it is[6]
collar dan
fully geser bersama
seated.
dengan O-ring sampai terduduk sepenuhnya.
[1] [5]
Connect the clutch

Sambungkan clutch cov
cover inlet duct
er inlet duct [1]
[1] dan
and outlet duct
duct
[4] [1]
[2]ketoclutch
[2] the clutch cover.
cover.
Tighten the band
Kencangkan screws [3]band
sekrup-sekrup to the[3]
specified
dengantorque.
torsi yang
ditentukan.
Install the outlet duct boss [4] to the frame.
Pas ang outlet duc t boss [4] pada rangka.
[2] [3]
10-20
Amankan
Secure the pemasangan
O2 sensor wirekawat O2 the
[1] with sensor
clamp[1]
[2].dengan
clamp [2]. [1]
– Driven pulley (page 10-17)
- –Driven
Drivepulley
pulley(hal. 10-17)
(page 10-11)
- –Drive pulleypipe/muffler
Exhaust (hal. 10-11)(page 3-20)
- –Exhaust
Footpegpipe/muffler
bar (page (hal.
3-19)3-20)
- –Footpeg bar (hal.
Right body 3-19)
cover (page 3-13)
- Right body cover (hal. 3-13)
Fill the engine oil (page 4-9) and check that there are no
Isioiloli mesin (hal. 4-9) dan periksa bahwa tidak ada
leaks.
kebocoran oli.
[2]
DRIVESHAFT/CLUTCH
REMOVAL
PELEPASAN
Remove the
Lepaskan clutch
clutch cover
c over (hal.(page 10-18).
10-18). [1]
Remove the
Lepaskan driv driveshaft/clutch assembly[1][1]dari
eshaft/clutch assembly fromright
the
right crankcase.
crankcase.
DISASSEMBLY
PEMBONGK ARAN
Remove the
Lepaskan specspecial washer
ial washer [1] and
[1] dan thrust
thrust washer
was her [2]
[2] dari [1] [2]
from the
driveshaft.driveshaft.
Remove the
Lepaskan clutch
clutch outer
outer [3]. [3].
[3]
Remove the
Lepaskan needle
needle bearing
bearing [1] from
[1] dari the driveshaft.
driv eshaft.
[1]
10-21
Lepaskan drive
Remove the plate
drive assassembly
plate embly [1] [1]
darifrom
driveshaft [2].
the driveshaft
[2]. [2]
[1]
Remove the
Lepaskan four E-clips
keempat E-clips[1][1]and
danplate
plate[2].
[2].
[2]
[1]
Remove the
Lepaskan clutch
clutch shoe
s hoe springs
springs [1]. [1].
[1]
Lepaskan
Remove theclutch s hoes
clutch [1] dan
shoes damper
[1] and rubbers
damper [2] dari
rubbers [2]
from plate.
drive the drive plate. [2]
[1]
10-22
INSPECTION
PEMERIKSAAN
CLUTCHOUTER
CLUTCH OUTER
Check the
Periksa clutch outer
clutch outer [1]
[1]forterhadap
wear or damage.
keausan atau
kerusakan.
Measure the clutch outer I.D.
Ukur D.D. clutc
SERVICE h outer.
LIMIT: 126.30 mm (4.972 in)
BATAS SERVIS : 126,30 mm
[1]
J ikaIf clutch outerouter

the clutch gear Periksa clutcclutch
Check the h outer geargear
outer [1] [1]
terhadap keausan
for abnormal tidak
wear or
aus atau
gearrusak, juga
is worn or normal atau kerus akan.
damage. [1]
periksa counter gear
damaged, also
(hal. 12-22).
inspect the counter
gear (page 12-22).
NEEDLE
NEEDLEBEARING
BEARING
Check the
Periksa needlebearing
needle bearing[1]
[1]
kerusakan.
CLUTCH
CLUTCHSHOES
SHOES
Periksa the clutch Periksa
Inspectpermukaan Check clutch shoesshoes
the clutch [1] terhadap
[1] for keaus an berlebihan
excessive wear or
dalam
outer clutch
inner oute r atau
surface kerus akan.
damage. [1]
jika clutch
if the shoes
clutch ada
shoes
Measure
Ukur tebal the clutch
clutch shoes
shoes lining thickness.
lining.
are kerusakan.
damaged.
SERVICE
BATAS LIMIT: 1,5
SERVIS: 1.5 mm
mm (0.06 in)
10-23
DRIVESHAFT
DRIVESHAFT
Check the
Periksa driveshaft
driveshaft [1] [1] for wear,
terhadap bend or kebengkokan
keausan, damage.
atau kerus akan. [1]
PERAKITAN
DAMPER RUBBERS DRIVE PLATE
PLATE
E-CLIPS
CLUTCH OUTER
SPRINGS
CLUTCH SHOES
SPECIAL WASHER
DRIVESHAFT
NEEDLE BEARING
THRUST WASHER
Pas angthe
Install damper
damperrubbers [1][1]
rubbers dan
andclutc h shoes
clutch shoes[2]
[2]pada
onto
the drive [1]
drive plate.plate.
[2]
10-24
Pas ang the
Install s hoe springs
shoe [1] [1]
springs pada
to clutch shoes
the clutch seperti
shoes as
shown.
diperlihatkan. [1]
Install
Pas angthe plate
plate [1].[1].
Install [1]
Pas ang new E-clips
E-clips baru [2]
[2] with theirujungnya
dengan open endsyangfacing the
terbuka
outer circumference
menghadap of thekeliling
ke lingkaran plate as shown.
luar dari plate seperti
diperlihatkan.
[2]
Install
Pas angthe drive
drive plate
plate assembly
assembly [1] [1]
padato the driveshaft
drives haft [2] [2].
[2]
[1]
Semprotkan
Apply engineoli
oil mesin pada bearing
to the needle needle [1]
bearing [1] dan
and install it to
pasang pada driveshaft.
the driveshaft. [1]
10-25
Semprotkan
to thepada
clutchpermukaan kontaksurface
outer contacting c lutch
outer denganbearing.
with needle needle bearing. [3] [2]
Install
Pas angthe clutch
c lutch outer
outer [1].[1].
Install
Pas angthe thrust
thrust washer
washer [2][2] andspecial
dan specialwasher
washer[3]
[3]pada
onto
the driveshaft.
driveshaft.
[1]
PEMASANGAN
INSTALLATION
Apply engine
Semprotkan olioilmesin
to thepada
counter gearcounter
gigi-gigi and clutch
gearouter
dan
gear teeth. [1] Tepatkan
clutch outer gear.
Install
Pas ang the driveshaft/clutchasassembly
driveshaft/clutch sembly [1][1] to the right
pada
crankcasesementara
crankcase while aligning the clutch
mentepatkan outer clutch
gigi-gigi gear outer
teeth
with the countershaft gear teeth.
gear dengan gigi-gigi countershaft gear.
Install
Pas angthe clutch
c lutch covcover (page
er (hal. 10-20).
10-20).
LEFT DRIVESHAFT BEARING

PENGGANTIAN LEFT DRIVESHAFT
REPLACEMENT
BEARING
Remove the
Lepaskan driveshaft/clutch
driveshaft/clutch assembly
assembly (hal.(page 10-21).
10-21). [1]
Remove the snap ring [1] and lock washer
Lepaskan snap ring [1] dan lock was her [2]. [2].
[2]
Turn set
Putar theplate
set[1]plate [1] kan
dan lepas anddari
remove it from the
countershaft.
[1] [1]
countershaft.
Lepaskan counter gear [2].
Remove the counter gear [2].
[2]
10-26
Lepaskan
Remove theleft driveshaftbearing
left driveshaft bearing [1]the dengan
[1] using special
tools. [4] [1]
menggunakan special tools.
TOOLS:
TOOLS:
[2] Bearing
[2] Bearing remover
remover head,
head, 12 mm 07936-1660110
07936-1660110
12 Bearing
[3] mm remover shaft, 12 mm 07936-1660120
[3] Remover
[4] Bearing remover
weight shaft, 07936-1660120
07741-0010201
12 mm
[4] Remover weight 07741-0010201
[2]
[3]
Semprotkan olioil
Apply engine mesin
to thekebearing
ronggacavity.
bearing.
[2] [1]
Pasang
Install the be aring Pas
bearing ang new
Install ball ball
bearing
bearingbaru[1][1]intosecara tegaklurus
the right ke
crankcase
dengan
with its sisinya
sealedyang
side dalam
squarelyright
untilcrankc ae seated,
it is fully sampai usingia duduk sepenuhnya,
the special tools.
te rtutupfacing
me nghadap
down. dengan menggunakan special tools.
ke bawah. TOOLS:
[2] Driver
TOOLS: 07749-0010000
[3] Driver
[2] Attachment, 37 x 40 mm 07746-0010200
07749-0010000
[4] Pilot, 12 mm37 x 40 mm 07746-0040200 [4]
[3] Attachment, 07746-0010200
[4] Pilot, 12 mm 07746-0040200
[3]
Install
Pas angthe counter
c ounter geargear
[1].[1].
Install
Pas angthe
setset plate[2]
plate [2]dan
and putar
turn it sehingga
so that its grooves are
alur-alurnya [2] tepatkan
aligned with the
bertepatan countershaft
dengan splines assplines
countershaft shown. seperti
diperlihatkan.
[1]
Pas angthe
Install lock washer
lock washer [1][1]sementara mentepatkan
while aligning tabs-
its tabs with the
nya dengan countershaft
countershaft splines. splines. [1] [2]
Pas angthe
Install s nap ringring
snap [2] [2]
ke into
dalam
thealur countershaft.
countershaft groove.
For right
Untuk driveshaftright
penggantian bearing replacement
driveshaft bearing(page
(hal. 10-19).
Install
Pas angthe driveshaft/clutch
drives assembly
haft/clutch assembly (page
(hal. 10-26).
10-26).
Tepatkan
10-27
AIR INLET DUCT
REMOVAL
PELEPASAN
Remove the
Lepaskan center
center cover
cover (hal.(page
3-14).3-14). [6] [5] [2]
Release the
Lepaskan fuelfuel
feedfeed hose
hose [1] [1]
darifrom
hosethe hose clamps
clamps [2]. [2].
Loosen the air inlet duct band screw
Longgarkan s ekrup air inlet duct band [3]. [3].
Remove the
Lepaskan special
special boltbolt
[4] [4]
danand disconnect
lepaskan the duct
air inlet air inlet
[5]
duct [5] from the clutch cover
dari clutch cover inlet duct [6]. inlet duct [6].
[4]
[3] [1]
PEMASANGAN
INSTALLATION
Sambungkan
Connect the air inletinlet duct
ducttoketheclutch
clutchcover
cover inlet
inlet duct
sementara mentepatkan
while aligning their indextanda2
marks penunjuk
[1]. mereka [1].
Tempatkan
Set the ductduct bandband dengan
in the sudut
specified yang
angle ditentukan
while aligning
its slit [2] with
sementara the clutch slit
mentepatkan cover inlet padanya
(celah) duct boss.[2] dengan
clutch cover inlet duct boss.
45º
Tepatkan [1] Tepatkan [2]
Kencangkan band
Tighten the band screw
screw [1] to[1] dengan torque.
the specified torsi yang
ditentukan. [4]
Install and tighten the special bolt [2].
Pas ang dan kencangkan special bolt [2].
Set the fuel feed hose [3] to the hose clamps [4].
Tempatkan fuel feed hose [3] pada hos e clamps [4].
Install the center cover (page 3-14).
Pas ang c enter c over (hal. 3-14).
[2]
[1] [3]
10-28
11. ALTERNATOR/STARTER CLUTCH
LOK ASI KOMPONEN

COMPONENT ..................................
LOCATION 11-2
··························11-2 STATOR ······················································
....................................................... 11-5

···························11-3 FLYWHEEL/STARTER
FLYWHEEL/STARTER CLUTCH
CLUTCH ................ 11-8
··············· 11-8
LEFT CRANKC ASE COVER ....................... 11-4
LEFT CRANKCASE COVER ······················11-4
11
11-1
LOKASI KOMPONEN
49 N·m (5,0 kgf·m; 36 lbf·ft)
11-2
KETERANGAN SERVIS
SERVICE INFORMATION
GENERAL
UMUM
• This section covers service of the alternator and starter clutch.
••Bab ini meliputi
These servicesservis daridone
can be alternator dan
with the starterinstalled
engine clutch. in the frame.
••Pekerjaan-pekerjaan servis(page
For alternator inspection ini dapat dilakukan dengan mesin terpasang pada rangka.
16-9).
••Untuk pemeriksaan
For CKP alternator(page
sensor inspection (hal. 16-8).
17-6).
• Untuk pemeriksaan CKP sensor (hal. 17-6).
SPESIFIKASI
Satuan: mm
D.L. Starter driven gear boss 45,660 – 45,673 45,2
TORSI
TORQUEPENGENCANGAN
VALUES
Mur flywheel 49 N.m (5,0 kgf.m; 35 lbf.ft) Semprotkan oli mesin pada
Flywheel nut 49 N·m (5.0 kgf·m, 36 lbf·ft) Apply engine oil topermukaan
ulir dan the threadsduduk.
and seating sur-
Baut torx pemasangan starter clutch outer 16 N.m (1,6 kgf.m; 12 lbf.ft)face. Oleskan cairan pengunci
Starter clutch outer mounting torx bolt 16 N·m (1.6 kgf·m, 12 lbf·ft) Apply locking
padaagent to the
ulir. Lihat hal.threads:
11-12. See page
11-12
TOOLS
Flywheel holder Flywheel puller, 28 mm Remover weight

07725-0040001 070MC-HP10100 07741-0010201
Bearing remover shaft, 12 mm Bearing remover head, 12 mm Driver

07936-1660120 07936-1660110 07749-0010000
Attachment, 28 x 30 mm Pilot, 12 mm
07946-1870100 07746-0040200
11-3
LEFT CRANKCASE COVER
REMOVAL
PELEPASAN
Drain the engine
Keluarkan oli mesin oil(hal.
(page 4-9).
4-9).
[1]
Remove the
Lepaskan following:
sebagai berikut:
-– Left
Left body ccover
body over (hal.
(page3-13)
3-13)
–- Left crankc ase rear
Left crankcase rear cover
cover (hal.
(page3-17)
3-17)
Lepaskan
Disconnectsambungan dari yang berikut:
the following:
- Alternator 2P connector [1]
–- Connector
Alternator 2P[2] connector
kawat CKP[1]sensor (Putih/kuning) dan
– connector
CKP sensor wire (White/yellow)
(Biru/kuning) [3] connector [2] and
[2]
[3]
Lepaskan
Release the kawat
EOTEOT sensor
sensor wire [1]
[1] dan kawat s idestand
and sidestand switch
switch [2]from
wire [2] dari the
clamps [3]. [3].
clamps [3]/[4] [5]
Longgarkan
Loosen thebaut-baut
bolts in Lepaskan baut-baut
Remove the bolts [4][4]and
danclamps.
clamps.
dalam pola bersilangan
a crisscross pattern
dalam beberapa [2]
in several steps.
langkah. [1]
Le ft crank
The case cover Lepaskan
left crankcase left left
Remove the c rankcase cover
crankcase [5]. [5].
cover
(stator) tertarik
cover secara
(stator) is
magnetis pada
magnetically
fly wheel, berhati-
attached to the
hatilah selama
flywheel, be careful
pelepasan.
during removal.
[4]
Lepaskan dowel
Remove the pinspins
dowel [1] dan gasket
[1] and [2]. [2].
gasket
[2]
[1]
PEMASANGAN
INSTALLATION
Be careful
Hati-hati agarnot
tidak Clean any gasket
to Bersihkan material from
bahan-bahan the leftdari
gasket crankcase cover
permukaan
merusak the
damage mating penyatuan
permukaan left crankcase cover.
mating surface. [2]
pe nyatuan.
surface.
Install
Pas angthe dowel
dowel pinspins
[1] [1]
danand a et
gask new gasket
baru [2]. [2].
[1]
11-4
LeThe
ft crank case cover
left crankcase Pas angthe
Install left left
crankcas e cover
crankcase [1].[1].
cover
tertarikcover
secarais Install
Pas angthe clamps
clamps [2] [2]
danand bolts [3],[3],
baut-baut thenlalu
tighten them in
kencangkan [1]
magnetis pada
magnetically a crisscross
mereka dalam pattern
polain several steps. dalam beberapa
bersilangan [2]/[3]
fly wheel, berhati-
attached to the langkah.
hatilah pada waktu Secure the EOT sensor wire [4] and sidestand switch
flywheel, be careful
pemasangan. wire [5] with
Amankan the clamps. kawat EOT sensor [4] dan
pemasangan [5]
during installation.
kawat sidestand switch [5] dengan clamps. [4]
[3]
Alurkan wire the
Route harness Connect the following:
wire Sambungkan sebagai berikut:
harness (hal. 1- - Alternator 2P connector [1] [1]
14). - Connector 2P
(page 1-14).
– Alternator connector [1]
kawat
– CKP sensor wire(Putih/kuning)
(White/yellow)CKP sensor [2]
connector [2] dan
and
connector (Biru/kuning)
[3]
Install
s ebagai berikut:
-– Left crankc
Left crankcasease rear
rear cover
cover )hal.
(page3-17)
3-17)
–- Left body ccover
over (hal.
(page3-13)
3-13)
Isi
Fillmesin
the dengan
engine oliwith
mesin
theyang dianjurkan (hal.
recommended 4-9). oil
engine
(page 4-9).
[2]
[3]
STATOR
PELEPASAN
REMOVAL
Remove the
Lepaskan left left crankcase
c rankcase cover
11-4).
[2] [3]
Remove the
Lepaskan CKP sensor
baut-baut mountingCKP
pemasangan bolts sens
[1] and
or release
[1] dan
the wire wire
lepaskan grommet [2] and
grommet [2] CKP sensor
dan CKP [3] from
sensor the left
[3] dari
crankcasecover.
crankcase cover.
[1]
Lepaskan
Remove the baut-baut pemas angan
stator mounting bolts stator
[1], then[1],remove
kemudian
the
lepaskan
stator [2]stator
and [2]
CKPdansensor
CKP sensor dari left
from the left crank case
crankcase [2]
cover.
cover.
[1]
11-5
PEMASANGAN
CKP SENSOR MOUNTING BOLTS
STATOR MOUNTING BOLTS
STATOR
WIRE GROMMET
LEFT CRANKCASE COVER
CKP SENSOR
Tempatkan stator[1]
Place the stator [1]into
ke dalam
the leftleft crankc ase
crankcase cover.
cover.
[1]
Pas angand
Install dantighten
kencangkan baut-baut
the stator mounting bolts [2]. stator
pemasangan
[2].
[2]
Apply liquid sealant(THREE
(THREEBOND
BOND1215
1215 oratau 1207B
1207B or
[1] [2]
LOCTITE
atau LOCTITE 5020 or equivalent)
5020 to thepada
atau sejenisnya) alternator wire
permukaan
perapatan
grommet [1] alternator wire grommet
sealing surface [1] the
and install dan grommet
pasang
into the cover
grommet groove.
ke dalam alur cover.
Set the CKP
Tempatkan CKPsensor [2] [2]
s ensor in position.
pada posisinya.
Install
Pas angand dantighten the CKPbaut-baut
kencangkan sensor mounting bolts [3].
pemasangan CKP
sens or [3].
Install the left crankcase cover (page 11-4).
Pas ang left crankcas e cover (hal. 11-4).
[3]
11-6
LEFT CRANKCASE
PENGGANTIAN COVER
LEFT CRAN BEARING
KCASE
REPLACEMENT
COVER BEARING
Remove the
Lepaskan stator
stator (hal.(page
11-5).11-5).
[1]
Remove the snap ring [1] from
Lepaskan snap ring [1] dari the left crankcase
left crankcas e cover. cover.
Lepaskan
Remove thebearing [1] dari
bearing left crankcas
[1] from e cover dengan
the left crankcase cover
[3] [1]
menggunakan special
using the special tools.
tools.
TOOLS:
TOOLS:
[2] Bearing remover head, 12 mm07936-1660110
[2] Bearing
[3] Bearing remover
remover shaft,
head, 1212mm 07936-1660110
mm07936-1660120
[3] Remover
[4] Bearing remover
weight shaft, 12 07741-0010201
mm 07936-1660120
[4] [2]
Apply engine
Semprotkan olioil to thekebearing
mesin ronggacavity.
bearing.
[2]
Pasang
Install the bearing
bearing PasInstall
ang theballnew ball bearing
bearing [1] into
baru [1] the tegaklurus
sec ara left crankcase
ke
withdengan sisi yang
its marked squarely
side dalam left until it is fully
crankcase seated,
sampai ia using the special
telah duduk tools.
sepenuhnya
adafacing
tandanyaup. dengan menggunakan spec ial tools.
menghadap ke atas. TOOLS:
[3]
[2] Driver
TOOLS: 07749-0010000
[3] Driver
[2] Attachment, 28 x 30 mm 07946-1870100
07749-0010000
[3]
[4] Attachment,
Pilot, 12 mm28 x 30 mm 07946-1870100
07746-0040200
[4] Pilot, 12 mm 07746-0040200
[1] [4]
Pasang
Install the snap
snap ring
ring Pas ang the
Install s napsnap
ring ring
[1] ke[1]dalam
into alur
the left ccrankcase
rankcase cover.
cover
dewith
nganitssisinya yang groove.
chamfered [1]
dipotong Pas ang stator (hal. 11-6).
sidemenghadap
facing the
ke bearing. Install the stator (page 11-6).
bearing.
11-7
FLYWHEEL/STARTER CLUTCH
PELEPASAN
REMOVAL
Remove the
Lepaskan left left crankcase
c rankcase cover
11-4).
[2]
Remove the
Lepaskan starter
starter reduction
reduction gearshaft
gear shaft[1]
[1] dan
and starter
reduction
reduc gear[2].
tion gear [2].
[1]
Lepaskan
Remove the murflywheel
flywheel
nut [1]
[1] dan washer [2]
and washer [2]using
dengan
the
[2] [1]
menggunakan
special tool. special tool.
TOOL:
TOOL:
[3]
[3] Flywheel
Flywheel holder
holder 07725-0040001
07725-0040001
[3]
Lepaskan
Remove the flywheel/starter c lutch
flywheel/starter clutch [1] the dengan
[1] using special
menggunakan
tool [2]. special tool. [1]
TOOL:
TOOL:
[2]
[2] Flywheel
Flywheel puller,
puller, 28
28 mm
mm 070MC-HP10100
070MC-HP10100
[2]
Remove the
Lepaskan needle
needle bearing
bearing [1]. [1]. [1]
WhenJika woodruff
woodruff key Remove the
key Lepaskan woodruff
woodruff keykey
[2]. [2].
dilepaskan,
removal, beberhati-
careful
hatilah
not agar tidak
to damage the
merusak alur
key groovekey and
dan
crankshaft.
crankshaft.
Jaga agar woodruff
Do tidak
key not lose the
hilang.
woodruff key.
[2]
11-8
STARTER ARAN
PEMBONGK CLUTCH DISASSEMBLY
STARTER CLUTCH
Remove the
Lepaskan flywheel/starter
flywheel/starter clutch
clutch (hal.(page
11-8).11-8). [1]
Periksa cara kerja one way clutchclutch
Check the operation of the one way by turning
(kopling satu
the driven gear [1].
arah)dengan memutar driven gear [1].
You gear
Driven shouldseharusnya
be able dapat
to turn the dengan
berputar driven halus
gear
counterclockwise smoothly, but the gear should
berlawanan arah jarum jam, dan gear tidak dapat not turn
clockwise.
berputar searah jarum jam.
Remove the starter driven gear from the flywheel/starter
Lepaskan starter driven gear dari flywheel/starter c lutch
clutch while turning the driven gear counterclockwise.
sementara memutar gear berlawanan arah jarum jam.
Hold the
Tahan flywheel
flywheel using menggunakan
dengan the special toolspecial
and remove the
tool dan
starter clutch outerpemasangan
mounting torx boltsclutch
[1]. outer [1]. [1]
lepaskan baut torx s tarter
TOOL:
TOOL:
[2]
[2]Flywheel
Flywheelholder
holder 07725-0040001
07725-0040001
[2]
Remove the
Lepaskan starter
starter clutch
clutch assembly
assembly [1]. [1].
[1]
Remove the
Lepaskan plate
plate [1], [1], rollers
rollers [2] [2]
danand springs
s prings [3][3] from the
dari
starterclutch
clutchouter
outer[4].
[4]. [4]
starter
[3]
[2] [1]
11-9
INSPECTION
PEMERIKSAAN
Check starter
Periksa the starter reduction
reduction gear gear [1] for wear
[1] terhadap or
keausan
damage.
atau kerus akan.
[1]
Check the
Periksa needlebearing
needle bearing[1]
kerusakan
[1]
Periksa starter
Check the driven
starter gear
driven [1][1]terhadap
gear for wear keausan atau
or damage.
kerusakan.
Measure the driven gear boss O.D.
Ukur D.L. driven gear boss.
[1]
StarterStarter
clutch clutch Check the
harus Periksa rollers
rollers [1],[1], springs
s prings [2],starter
[2], starterclutc
clutch outer [3]
h outer
diganti
should sebagai terhadap
be replaced for wear keausan
or damage. [3]
atau kerusakan.
sebuah
as an rakitan
assembly jikaif
ada
any bagian
parts are
daripadanya
damaged yang
or worn.
rusak atau aus.
[2] [1]
11-10
PERAKITAN STARTER CLUTCH
STARTER DRIVEN GEAR
STARTER CLUTCH OUTER
PLATE
FLYWHEEL
SPRINGS
ROLLERS
TORX BOLTS
16 N·m (1,6 kgf·m; 12 lbf·ft)
Pas ang the

Install springs
springs[1][1]
dan
androllers
rollers[2]
[2] pada
to the starter
starter cclutch
lutch
outer
outer[3]
[3]seperti diperlihatkan.
as shown. [3]
[1] [2]
PInstall
as an g the
pla teplate
[1] p[1]ad ato sthe
tartestarter
r cl utchclutch
o ute r outer [2]g an
[2] d en by
maligning
en tep a tkan p la tetabs
the plate ta bs[3][3]
andd an lu b an
starter g sta
outer rte r holes
clutch ou te r [1]
clu tch [4].
[4].
[3]
[4] [2]
11-11
Install
Pas ang the starter
starter clutch
clutch assembly
assembly [1] onto
[1] pada the flywheel
flywheel [2].
[2].
[1]
[2]
Apply locking
Oleskan lock ingagent
agentto (cairan
the starter clutch outer
pengunci) pada mounting
ulir baut Coating width: 6.5 ± 1.0 mm
torx bolt
torx [1] threads starter
pemasangan as specified.
clutch outer [1] seperti from tip
Hold the flywheel using the special tool and tighten the
ditentukan.
bolts to
Tahan the specified
flywheel dengantorque.
menggunakan special tool dan
kencangkan
TOOL: baut-baut dengan torsi yang ditentukan.
[2] Flywheel holder
TOOL: 07725-0040001
[2] Flywheel holder 07725-0040001
TORSI: 16 N.m (1,6 kgf.m; 12 lbf.ft) [1]
[2]
Semprotkan
Apply engineoli oil
mesin pada
to the permukaan
starter gelinding
clutch rolling starter
surface of
clutch dari driven gear
the driven gear [1]. [1]. [1]
Pas ang the

Install s tarter driven
starter drivengear
gear[1]
[1] pada
to the flywheel/starter
flywheel/starter
clutch
clutchsementara
while turningmemutarnya berlawanan arah jarum
it counterclockwise. [1]
jam.
Make sure that the starter driven gear turns
Pas tikan bahwa starter
counterclockwise driv en and
smoothly gear berputar
does not dengan
turn
clockwise.
halus berlawanan arah jarum jam dan tidak dapat
berputar searah jarum jam.
Install the flywheel/starter clutch (page 11-13).
Pas ang fly wheel/starter clutch (hal. 11-13).
11-12
INSTALLATION
PEMASANGAN
During
Selamawoodruff key Pas
pemasangan Install
ang the woodruff
woodruff keykey [1] in the
[1] pada alurcrankshaft
crankshaftkey
key.groove. [2]
installation, be
woodruff key,
Apply engine oil to the needle bearing [2] and install it to
careful not
berhati-hatilah agarto Semprotkan oli mesin pada needle bearing [2] dan
the crankshaft.
tidak merusak
damage key pasang pada crankshaft.
thealur
key atau crankshaft.
groove or
crankshaft.
[1]
Sekalah
Wipe any oli pada
oil offpermukaan
the mating penyatuan
surface of dari
the crankshaft
crankshaft
[3] [2]
andflywheel.
dan flywheel.
Pas ang flywheel/starter clutch [1] pada crankshaft,
Install the flywheel/starter clutch [1] to the crankshaft,
dengan mentepatkan k ey way (alur pemas angan spie)
aligning the key way [2] with the woodruff key [3].
[2] dengan woodruff key [3].
[1]
Install
Pas ang the
waswasher
her [1]. [1].
Apply engine oil to the [1]/[2]
Semprotkan oli mesin padaflywheel nut [2]
ulir-ulir mur threads
flywheel and
[2] dan
seating surface,
permukaan duduk,then install it.
kemudian pasang.
Hold the
Tahan flywheel
flywheel usingmenggunakan
dengan the special toolspecial
and tighten the
tool dan
flywheel nutmur
kencangkan to the specified
flywheel torque.
TOOL:
TOOL:
[3]Flywheel
[3] Flywheelholder
holder 07725-0040001
07725-0040001
TORSI: 49 N.m
TORQUE: (5,0(5.0
49 N·m kgf.m; 36 lbf.ft)
kgf·m, 36 lbf·ft)
[3]
Semprotkan
to the pada
startergigi-gigi
reduction starter reduction
gear [1], starter
drive
gear gear
[1], [2] and
starter starter
drive gear driven
[2] dangear [3] driven
starter teeth. gear [3]. [2] [4]
Install
Pas the starter
ang starter reducreduction gear while mentepatkan
tion gear sementara aligning the
starter drive
gigi-gigi startergear
driveand starter
gear dan driven
starter gear
driven teeth.
gear.
Install the starter reduction gear shaft [4] into the
Pas ang starter
reduction gear and reduction gear shaft [4] ke dalam
left crankcase.
reduc tion gear dan left crankcase. [3]
Install
Pas ang the
left left crankcase
crankcas cover
e cover (hal.(page 11-4).
11-4).
[1]
11-13
CATATAN
12. CRANKSHAFT/KICKSTARTER/SECONDARY REDUCTION
LOK ASI KOMPONEN

COMPONENT ..................................
LOCATION 12-2
··························12-2 KICKSTARTER ............................................ 12-16

···························12-4 SECOND ARY REDUCTION ........................ 12-21
TROUBLESHOOTING ................................. 12-6 CAM CHAIN GUIDE SPROCKET................ 12-25

TROUBLESHOOTING·································12-6
CRANKCASE/CRAN KSHAFT..................... 12-7
CRANKCASE/CRANKSHAFT ····················12-7
KICKSTARTER ·········································12-16 12
SECONDARY REDUCTION······················12-21
CAM CHAIN GUIDE SPROCKET ·············12-25
12-1
LOKASI KOMPONEN
44 N·m (4,5 kgf·m; 32 lbf·ft)
12-2
10 N·m (1,0 kgf·m; 7 lbf·ft)
12-3
KETERANGAN
SERVICE SERVIS
INFORMATION
GENERAL
UMUM
•• Bab
Thisi section
ni mel iputicovers the crankcase
pemisah separation
an crankcase to servicecrankshaft,
untuk menservis the crankshaft, kickstarter
kickstarter dan and secondary
secondary reduction.
reduction.
•• Parts
The following
beri kut ini parts must
harus be removed
di lepaskan before
sebelum separating the
memisahkan crankcase.
crankcase.
– Engine
- Mesin ( hal .(page
7- 4) 7-4)
– Cylinder
- Cylinder head head (page
(hal. 8-12)8-12)
– Cam
- Cam chainchain tensioner
tensioner (page
(hal. 8-26)8-25)
– Cylinder (page
- Cylinder (hal. 9 -5) 9-4)
– Piston
- Piston ( hal(page
. 9-6 ) 9-5)
- Drive pulley ( hal(page
– Drive pulley . 10- 9)10-9)
– Driven pulley (page 10-12)
- Driven pulley (hal. 10- 13)
– Clutch cover (page 10-18)
- Clutch cover (h al. 1 0-18)
– Driveshaft/clutch (page 10-21)
- Driveshaft/clutch (hal. 10-21)
– Oil pump (page 5-4)
- Oil pump ( motor
– Starter hal . 5- 4)
(page 18-6)
- Starter motor
– Flywheel/starter (hal. 18-6)
clutch (page 11-8)
- Flywheel/starte r clutch (hal. 11-8)
• In addition to the parts listed above, remove the following parts when the left crankcase must be replaced.
• –Selai n parts plate
Oil stopper yang (page
terdaftar di atas, lepaskan parts berikut jika left crankcase harus diganti:
8-27)
• Be- careful
Oil stopper
not to plate
damage(hal.the
8-27)
crankcase mating surfaces when separating and assembling the crankcase halves.
•• Clean
Hati-hati agar ti dak merusak
all disassembled permukaa
parts with n penyatuan
clean solvent crankcase
and dry sewaktu
them using memisahkan
compressed dan merakit
air before belahan crankcase.
inspection.
•• When
Bersihkan semua
installing the parts yang dibongkar
crankshaft, be sure to dengan
use the cairan
specialpelarut bersih dan
tools; position keri ngkan
the special mereka
tools on the deng an udara
bearing dari kompressor
inner race and pull the
sebelum pemer
crankshaft into theiksaan.
bearing until it is fully seated.
• Sewaktu memasang crankshaft, pastikan untuk menggunakan special tools, tempatkan special tools pada bearing inner race
dan tarik crankshaft ke d alam bear ing sampai ia telah duduk sepenuhnya.
SPESIFIKASI
Satuan : mm
Crankshaft Jarak renggang ke samping connecting rod 0,10 – 0,35 0,55
Jarak renggang radial connecting rod 0 – 0,008 0,05
Keolengan – 0,10
TORSI
TORQUEPENGENCANGAN
VALUES
Cam
Camchain
chainguide
guidesprocket
sprocketspindle
spindle 10 N.m
10 N·m (1.0 (1,0 kgf.m;
kgf·m, 7 lbf.ft)
7 lbf·ft)
Baut sidestand bracket 44 N.m (4,5 kgf.m; 32 lbf.ft)
Sidestand bracket bolt 44 N·m (4.5 kgf·m, 32 lbf·ft)
12-4
TOOLS
Driver Attachment, 28 × 30 mm Attachment, 32 × 35 mm
07749-0010000 07946-1870100 07746-0010100
Attachment, 37 × 40 mm Attachment, 42 × 47 mm Attachment, 62 × 68 mm

07746-0010200 07746-0010300 07746-0010500
Pilot, 12 mm Pilot, 15 mm Pilot, 17 mm

07746-0040200 07746-0040300 07746-0040400
Pilot, 20 mm Pilot, 25 mm Remover weight

07746-0040500 07746-0040600 07741-0010201
12-5
Bearing remover shaft, 15 mm Bearing remover head, 15 mm Universal bearing puller
07936-KC10100 07936-KC10200 07631-0010000
Assembly shaft adaptor Assembly shaft Assembly collar

07WMF-KFF0200 07965-VM00200 07964-MB00200
Spline shaft holder Case puller

07PAB-0010300 07SMC-0010001
TROUBLESHOOTING
TROUBLESHOOTING
Suara tidak
Abnormal normal
noise
• •Worn crankshaft
Crankshaft bearing
bearing aus
• •Worn connecting
Bearing kepalarod big connecting
besar end bearingrod aus.
• •Worn connecting
Kepala rod small rod
kecil connecting endaus
(page 9-8)
(hal. 9-9)
• •Worn, seized
Gears aus, or chipped
macet ataugears
ada keping yang terlepas
• •Worn or damaged
Secondary secondary
reduction reduction
bearing aus ataubearing
rusak
Engine starts but motorcycle won’t move
Mesin hidup tapi sepedamotor tidak bergerak
• Damaged secondary reduction
• •Seized
Secondary reduction
secondary rusak
reduction
• •Faulty
Secondary reduction
drive belt macet
(page 4-13)
• Drive belt tidak bekerja
• Faulty drive pulley (page 10-10) dengan baik (hal. 4-14)
• •Faulty
Drivedriven
pulleypulley
tidak (page
bekerja dengan baik (hal. 10-10)
10-14)
• •Faulty
Driven pulley tidak
centrifugal bekerja
clutch (pagedengan
10-14) baik (hal. 10-14)
Oil•leak
Centrifugal clutch tidak bekerja dengan baik (hal. 10-14)
• Oilkebocoran
Ada level too high
oli
• •Worn or damaged
Permukaan oil seal
oli terlalu tinggi
• •Cracked crankcase
Oil seal aus atau rus ak
• Crankcase retak
12-6
CRANKCASE/CRANKSHAFT
PEMISAH AN CRANKCASE
CRANKCASE SEPARATION
Bac alahtoketerangan
Refer s ervis (hal.
service information 12-4)
(page mengenai
12-4) for the parts
parts
yang
which harus
must be dilepaskan
removed sebelum memisahkan
before separating the [1]
crankcase.
crankcase.
Lepaskan camcam
Remove the chain [1] dari
chain timing
[1] from thesprocket.
timing sprocket.
Remove the
Lepaskan kickstarter
kickstarter idleidle shaft
shaft endend washer
washer [1]. [1].
[1]
Lepaskan
Remove kickstarter idle gear
the kickstarter idleA gear
[1] dari
A kickstarter
[1] from idle
the
[1]
kickstarter
shaft idle shaft
sementara while turning
memutarnya it counterclockwise.
berlawanan arah jarum
jam.
Lepaskan
Remove the idleidlespring
spring [1] dan spring
[1] and s pringseat
seat [2] dari
[2] from the
[1]
kickstarter
kick idleshaft.
starter idle shaft.
[2]
12-7
Lepaskan
Remove kick
the starter idle gear
kickstarter B [1] dari
idle gear B [1]right crankshaft.
from the right
[1]
crankshaft.
MarkTandai posisi Lepaskan

the original pinch
Remove the boltbolt
pinch [1] dan kickstarter
[1] and pedal
kickstarter [2]. [2].
pedal
pepedal
masangan pedal
position to [1]
semula agarcorrect
ensure dapat
dipasang k embali
reassembly.
dengan benar.
[2]
Lepaskan
Remove thebaut-baut sidestand
sidestand brac
bracket ket [1]
bolts [1] and
dan sidestand
sidestand
bracket
bracket[2].
[2]. [2]
[1]
Lepaskan baut-baut
Remove the crank
crankcase case[1][1]from
bolts darithe
leftleft
crankcase.
crankcase.
[1]
12-8
Be careful
Hati-hati agarnot Place the crankcase
to Letakkan
tidak crankcase with the right
dengan crankcase
right c rankc[1]
asefacing
[1] [2]
merusakdamage
permukaan down as shown,
the menghadap then seperti
ke bawah separate the left crankcase
diperlihatkan, kemudian[2]
crankcasepe nyatuan from theleft
mating pisahkan right crankcase.
crankcase [2] dari right crankc ase.
crankcase.
surface.
[1]
Remove dowel
Lepaskan the dowel
pinspins [1] from
[1] dari right the right crankcase.
crankcase. [1]
Lepaskan
Remove crankshaft [1] dari
the crankshaft right the
[1] from crankcase dengan
right crankcase
menggunakan special
using the special tool.tool. [2]
TOOL:
TOOL:
[2]
[2]Case
Casepuller
puller 07SMC-0010001
07SMC-0010001
[1]
12-9
Lepaskan
Remove the right
rightcranks haft bearing
crankshaft [1] using
bearing [1] dengan
the
menggunakan
special tool. special tool.
TOOL:
TOOL:
[2]
[2]Universal
Universalbearing
bearingpuller
puller 07631-0010000
07631-0010000
- J ika right c rankshaft bearing tetap tertinggal pada
– If the right crankshaft bearing remains in the
c rankc ase, lepaskan ke s isi kiri.
crankcase, remove it to the left side.
[1]
[2]
Jika right crankcase bearing

tetap tertinggal pada crankcase:
[1]
Lepaskan
Remove right
the crankshaft oil seal oil
right crankshaft [1] dari
sealcrankc ase. the
[1] from
[1]
crankcase.
12-10
CRANKSHAFTCRANKSH
PEMERIKSAAN INSPECTION
AFT
Remove the
Lepaskan crankshaft
crankshaft (hal.(page
12-7).12-7). [1]
Turn outer
Putar the outer racerace of the left
(lingkaran luar)crankshaft
dari left bearing
crankshaft [1]
with your
bearing [1]finger. The jari-jari.
dengan bearing should
Bearingturn smoothly
harus and
berputar
quietly. halus
dengan Also check
dan that
tanpathesuara.
bearingJuga
innerperiksa
race fitsbahwa
tightly
on the left
bearing crankshaft.
inner race (lingkaran dalam bantalan) duduk
Replace
dengan eratthe crankshaft
pada if the bearing does not turn
left crankshaft.
smoothly,
Gantilah quietly, jika
c rankshaft or bearing
if it fitstidak
loosely on the
berputar denganleft
crankshaft.
halus, tanpa suara, atau jika ia duduk dengan longgar
If the timing pada
Checkleftthe
crankshaft.
timing sprocket teeth [2] for wear or damage.
sprocket
Jika teeth
gigi-gigi are Periksa gigi-gigi timing sprocket [2] terhadap keausan
timing
worn or damaged,
sprocket aus atau atau kerus akan.
check thecam
rusak, periksalah cam
chain,
chain, tensioner
tensioner dan [2]
and cam sprocket.
cam sprocket.
Measure
Ukur the renggang
jarak connecting rod
ke big end sidekepala
samping clearance with
besar
a feeler gauge [1]. [1]
connecting rod dengan feeler gauge [1].
BATAS SERVIS:
SERVICE LIMIT: 0,55
0.55 mm
mm (0.022 in)
Tempatkan crankshaft on
Set the crankshaft pada V-blocks
V-blocks anddan ukur jarak
measure the
renggang radial
connecting rod kepala
big endbesar
radialconnecting
clearance. rod.
BATAS SERVIS:
SERVICE LIMIT: 0,05
0.05 mm
mm (0.002 in)
Tempatkan crankson
Set the crankshaft haftV-blocks
pada andV-blocks
measuredan ukur
the runout
keolengan dengan
using a dial menggunakan dial indicator.
indicator.
Actual runout
Keolengan is 1/2 of total adalah
sesungguhnya indicator½reading.
dari pembacaan
total indicator.
98 mm 65 mm
12-11
CRANKCASE
PERAK ASSEMBLY
ITAN CRANKCASE
Be careful
Hati-hati agar not
tidakto Clean the
Bersihkan insides
bagian dalamand mating surface
dan permukaan of dari
penyatuan the
merusakdamage
permukaan the crankcases.
crankcases.
crankcase mating
penyatuan Check for
Periksa cracksretak-retak
terhadap or other damage.
atau kerusakan lain.
crankcase.
surface. Remove any roughness or irregularities with an oil
oil
Hilangkan kekasaran atau ketidak-teraturan dengan
stone.(batu as ah).
stone
Semprotkan olioil
Apply engine mesin
to thekebearing
dalam cavity.
rongga bearing.
Pasang
Install the bearing
bearing Dorong
Press amas
newuk right
right crankshaft
crankshaft bearing
bearing [1]
baru
into[1]the
secara
right
dengan
with itssisinya
sealedyang crankcase ke
side tegaklurus squarely until itcrankcase
dalam right is fully seated,
sampai using
ia dudukthe
te rtutup me nghadap ke sepenuhnya,
[2]
facing down. special tools.dengan menggunakan special tools.
bawah.
[3]
TOOLS:
TOOLS:
[2]
[2] Driver
Driver 07749-0010000
07749-0010000
[3]
[3] Attachment,
Attachment, 62
62 xx 68
68 mm
mm 07746-0010500
07746-0010500
[4]
[4] Pilot,
Pilot, 25
25 mm
mm 07746-0040600
07746-0040600
[4] [1]
Suntikkan
Inject 1 - 21cc– of
2 engine
cc oli mesin ke connecting
oil to the dalam connecting rod
rod big end
big end bearing
bearing [1] . [1].
Pas ang crankshaft [2] ke dalam right crankshaft bearing
Install the crankshaft [2] into the right crankshaft
[3] sebagai berikut:
bearing [3] as follows:
Pas ang ass embly shaft adaptor [4] pada right
Install the assembly shaft adaptor [4] to the right
crankshaft. [7]
crankshaft.spline shaft holder [5] pada right crank case
Tempatkan
bearing
Positioninner
the race
splinedanshaft
tempatkan
holder ass
[5]embly collarright
on the [6]
[6]
pada spline shaft
crankcase bearingholder.
inner race and set the assembly
Pas ang[6]assembly
collar to the splineshaft [7] holder.
shaft pada assembly collar dan
sekrupkan pada adaptor
Install the assembly shaft [7]sto ementara menempatkan
the assembly collar and [5] [4]
semua s pecial tools dengan lurus.
screw it onto the adaptor while setting all the special
• tools
Sewaktu
straight. menarik crankshaft ke dalam bearing, [3] [2]
berhati-hatilah agar tidak merus ak connecting rod [8].
• When pulling the crankshaft into the bearing, be
Tahan careful not to damage
mur assembly shaft the connecting
dengan rod [8].
kunci pas.
Tarik crankshaft ke dalam bearing
Hold the assembly shaft nut with a wrench. dengan memutar
assembly shaft sampai ia duduk sepenuhnya
Pull the crankshaft into the bearing by turning the sementara
menempatkan
assembly shaft connecting rod diseated
until it is fully dalamwhile
lubang cylinder
positioning
sleeve pada right c rankcase.
the connecting rod in the cylinder sleeve opening on the
right crankcase.
TOOLS:
Assembly
TOOLS: shaft adaptor 07WMF-KFF0200 [8]
Assembly shaft
Assembly shaft adaptor 07965-VM00200
07WMF-KFF0200
Assembly collar
Assembly shaft 07964-MB00200
07965-VM00200
Spline shaft holder 07PAB-0010300
Assembly collar 07964-MB00200
Spline shaft holder 07PAB-0010300 [1]
12-12
Semprotkan
Apply engine oli oil
mesin
to apada
new right
rightcrankshaft
crankshaftoiloilseal
sealbaru
[1]
[1] dan pasang pada right crankc ase [2] [1]
and install it to the right crankcase untilsampai ia rata
it is flush with
dengan
the rightrightcrankcase,
c rankcase,using
dengan themenggunakan
same tools tools and
procedures
dan proseduras yang
crankshaft
samainstallation.
seperti pada pemasangan
crankshaft.
TOOLS:
TOOLS:
[2] Assembly shaft adaptor 07WMF-KFF0200
[2]
[3] Assembly
Assembly shaft shaft adaptor 07WMF-KFF0200
07965-VM00200
[3]
[4] Assembly
Assembly shaft collar 07965-VM00200
07964-MB00200
[4] Assembly collar
[5] Spline shaft holder 07964-MB00200
07PAB-0010300
[5] Spline shaft holder 07PAB-0010300
[5]
[4]
[3]
Apply liquid sealant (Three
(Three bond
bond 1207B
1207B atau Three
or Three bond
12151215
bond or LOCTITE
atau LOCTITE5020 5020
or equivalent) to thepada
atau sejenisnya) left
crankcase penyatuan
permukaan mating surface.
left crankcase.
Semprotkan olioil
Apply engine mesin
to leftkecrankshaft
left cranksbearing
haft bearing
[1]. [1].
[2]
Install
Pas angthe dowel
dowel pinspins
[2] [2]
padato the
rightright crankcase.
crankcase.
[1]
Pasang left crankcase [1] di atas right crankcase [2].

[1]
[2]
12-13
Pas ang the
Install baut-baut
crankcase crankcase [1] tighten
bolts [1] and dan kencangkan
them in a
mereka dalam
crisscross pola in
pattern bersilangan
2 - 3 steps.dalam 2 – 3 langkah.
[1]
Pas ang the

Install sidestand bracket
sidestand [1] dan
bracket [1] kencangkan
and tightenbaut-
the
sidestand
baut bracket
sidestand bolts[2][2]dengan
bracket to the specified
torsi yangtorque.
ditentukan. [1]
TORSI: 44 44
N·m kgf.m; 32 32
kgf·m, lbf.ft)
lbf·ft)
[2]
UntukTomemasang
install the Pas ang the
Install kickstarter
kickstarterpedal [1][1]pada
pedal in theposisinya semula
original position
kickstarter pedal yang telah ditandai pada waktu pelepasan. [4]
kickstarter pedal in marked during removal.
pada posisi standard,
standard position,
tepatkan tanda Pas Install
angand
dantighten the pinch
kencangkan bolt
pinch [4].[4].
bolt
align the
penunjuk [2] index
pada
mark [2] on thedan
left crankcase left
crankcase
potongan and
pada pedal
pedal cut-out[3].[3].
Tepatkan
[2]/[3]
[1]
Pas ang kthe

Install ickstarter idle gear
kickstarter idleB gear
[1] pada
B right crankshaft.
[1] to the right
[1]
crankshaft. oli mesin pada gigi-gigi gear.
Semprotkan
Apply engine oil to the gear teeth.
12-14
Pas ang the
Install spring seatseat
spring [1] pada kickstarter
[1] onto idle shaft
the kickstarter idledalam
shaft
in the
arah direction
yang as shown.
diperlihatkan. [2]
Install
Pas angthe
idleidle spring
spring [2].[2].
[1]
Pas ang the

Install kickstarter
kickstarteridleidle
gear AA
gear [1][1]pada
ontokickstarter idle
the kickstarter
[1]
idle shaft
shaft while turning
s ementara memutarnya it clockwise
searah and aligning
jarum jam danthe
mentepatkan
friction springujung
end [2]fric tionthespring
with [2] dengan
right crankcase ribstulang
[3].
Applyright
rusuk engine oil to the
c rankcase gear teeth.
[3].
Semprotkan oli mesin pada gigi-gigi gear.
Tepatkan [2]/[3]
Pas angthe
Install k ickstarter idleidle
kickstarter shaft endend
shaft washer [1].[1].
washer
[1]
Semprotkan
Apply engine oli mesin padatiming
oil to the timingsprocket
sprocket[1]
[1] and
dan cam
chain
chain[2].
[2]. [2] [1]
Pas angthe
Install c amcam
c hain pada
chain to timing sprocket.
the timing sprocket.
12-15
KICKSTARTER
PELEPASAN
REMOVAL
Separatecrankcas
Pisahkan the crankcase
e (hal. (page
12-7). 12-7).
[2]
Remove the
Lepaskan kickstarter
kickstarter drivdrive gear[1]
e gear [1] dan
and kickstarter
drivenshaft
driven shaft[2].
[2].
[1]
Putar kickstarter
Turn the idleidleshaft
kickstarter shaft [1] sehingga
[1] so that the permukaan
flat surface
datar
[2] is[2] menghadap
facing ke crankshaft.
the crankshaft. [2]
Lepaskan
Remove kick thestarter idle shaft
kickstarter idledarishaft
right crankcase.
from the right
crankcase.
[1]
Remove the
Lepaskan kickkickstarter return
starter return spring
spring boltbolt
[1]. [1].
[1]
Lepaskan
Unhook thekaitan dari ujung
kickstarter kickstarter
return return
spring end [1]spring [1]
from the
crankcase
dari boss.
crankcase boss .
Remove the
Lepaskan kickkickstarter spindle
starter spindle [2]. [2].
[1] [2]
12-16
DISASSEMBLY
PEMBONGK ARAN
KICKSTARTERSPINDLE
KICKSTARTER SPINDLE
Lepaskan
Remove theyang berikut from
following dari kickstarter spindle:
the kickstarter spindle:
- Return s pindle [1] [2] [4]
– Return spring [1]
- Special washer [2]
– Special washer [2]
- Stopper [3]
– Stopper [3]
- –Collar [4][4]
Collar
[3] [1]
KICKSTARTER
KICKSTARTERDRIVENDRIVENSHAFT
SHAFT
Lepaskan
Remove the following fromkickstarter
yang berikut dari driv en
the kickstarter shaft.
driven shaft.
- Snap ring [1] [1] [2]
– Snap ring [1]
- Driven gear [2]
– Driven gear [2]
INSPECTION
PEMERIKSAAN
KICKSTARTER SPINDLE
KICKSTARTER SPINDLE
Inspect the following: [2]
Periksa sebagai berikut: [3]
–- Kickstarter
Kickstarter spindle
spindle[1] [1]
for bend, wear orkebengkokan,
terhadap damage
– keausan
Kickstarter drive
atau gear [2] for wear or damage
kerusakan
–- Kickstarter
Return spring [3] for
drive weakness
gear or damage
[2] terhadap keausan atau
kerus akan
- Return spring [3] terhadap kelemahan atau
kerus akan.
[1]
12-17
KICKSTARTER
KICKSTARTERDRIVEN
DRIVENSHAFT
SHAFT
Periksa
Inspectsebagai berikut:
the following:
- Kickstarter driven shaft [1] terhadap kebengkokan, [2]
– Kickstarter driven shaft [1] for bend, wear or damage
keausan atau kerusakan
– Kickstarter driven gear [2] for wear or damage
- Kickstarter driven gear [2] terhadap keausan atau
kerusakan
[1]
KICKSTARTER
KICKSTARTERIDLE
IDLESHAFT/IDLE
SHAFT/IDLEGEAR
GEARAA
Inspectsebagai
Periksa the following:
berikut:
- Kickstarter idle shaft [1] terhadap kebengkokan, [4] [2]
– Kickstarter idle shaft [1] for bend, wear or damage
keausan atau kerusakan.
– Kickstarter idle gear A [2] for wear or damage
-– Kickstarter idle[3]gear
Friction spring A [2] terhadap
for weakness keausan atau
or damage
– kerus akan [4] for weakness or damage
Idle spring
- Fric tion spring [3] terhadap kelemahan atau
kerus akan
- Idle spring [4] terhadap kelemahan atau kerusakan
[1]
[3]
KICKSTARTER
KICKSTARTERIDLE
IDLEGEAR
GEARBB
Periksa kickstarter
Check the idleidle
kickstarter gear
gearBB[1]
[1] terhadap keausan
for abnormal wear
tidak normal atau kerusakan.
or damage.
[1]
KICKSTARTER
KICKSTARTEROIL
OILSEAL
SEAL
Periksa
Check thekic kstarter oil oil
kickstarter seal
seal[1]
[1] terhadap pemburukan
for deterioration, wear
kondisi, keaus an atau kerusakan.
or damage. [2]
If replacing
Jika oil sealthediganti,
oil seal, pas
install
angit to
ke the specified depth
kedalaman yang
as shown, using
diperlihatkan, the special
dengan tools. s pecial tools.
menggunakan
TOOLS:
TOOLS: [3]
[2] Driver 07749-0010000
[2] Driver 07749-0010000
[3] Attachment, 28 x 30 mm 07946-1870100
[3] Attachment, 28 x 30 mm 07946-1870100
Berikan gemuk pada bibir-bibir oil seal.
Apply grease to the oil seal lips.
0,5 - 1,5 mm
[1]
12-18
KICKSTARTERJOURNALS
KICKSTARTER JOURNALS
Check the
Periksa kickstarterspindle
kickstarter spindle journals
journals [1]
[1] ofdari
the left
left Crankcase kiri: Crankcase kanan:
crankcase,right
crankcase, rightcrankcase
crankcasedanand clutch
clutch covercover for
terhadap
excessive
keausan wear or damage.
berlebihan atau kerusakan.
[1] [1]
Clutch cover:
[1]
PERAK ITAN
ASSEMBLY
Clean all parts
Bersihkan in solvent
semua parts and dry them
dalam thoroughly.
cairan pelarut dan
keringkan mereka sec ara menyeluruh.
KICKSTARTER SPINDLE
KICKSTARTER SPINDLE
Install the following to the kickstarter spindle [1]:
Install Pasang c ollar
the collar with Pas
– ang yang
Collar [2] berikut pada kicks tarter spindle [1]:
dengan sisinya yang - Collar [2]
its stepped side – Stopper [3]
bertingkat - Stopper [3]
facingmenghadap
the stopper.ke – Special washer [4]
- Special washer [4]
stopper. Install the return spring [5] in the direction as shown.
Pas angthe
Hook return spring
spring end [5] dalam
onto arah yang diperlihatkan.
the stopper.
Kaitkan ujung spring pada s topper.
[4]
Hook
[2]
[3]
[5] [1]
12-19
KICKSTARTER
KICKSTARTERDRIVEN
DRIVENSHAFT
SHAFT
Pas angthe
Install driven geargear
driven [1] pada
[1] to kickstarter driven
the kickstarter shaftshaft
driven [2].
[2]. [3] [1]
Pas ang s nap ring [3] pada alur driven shaft.
Install the snap ring [3] to the driven shaft groove.
[2]
PEMASANGAN
INSTALLATION
Install
Pas ang the kickstarter
kickstarter spindle
spindle [1] while mentepatkan
[1] sementara aligning the
stopper end [2] [1]
ujung stopper [2]with the crankcase
dengan rib crankc
tulang rusuk [3]. ase [3].
Tepatkan [2]/[3]
Kaitkan
Hook theujung kic kstarter
kickstarter returnreturn
springspring [1] topada
end [1] the
crankcaseboss
crankcase bossseperti
as shown.
diperlihatkan. [2]
Install
Pas angand
dantighten the kickstarter
kencangkan return spring
baut kickstarter boltspring
return [2].
[2].
[1]
Semprotkan
Apply engine oli oil tomesin pada seluruh
the kickstarter idle shaftpermukaan
[1] whole
kick starterandidle
surface installshaft
it with [1] dan
its flat pasang
surface dengan
[2] facing the [2]
crankshaft side.yang datar [2] menghadap ke sisi
permukaannya
crankshaft.
[1]
12-20
Install
Pas ang the kickstarter
k ickstarter driven
driven shaftshaft [1] kickstarter
[1] dan and kickstarter
drive
drive[2].
gear gear [2]. [1]
Semprotkan to thepada
geargigi-gigi
teeth. gear.
Assemble
Rakit the crankcase
crankcase (page 12-7).
(hal. 12-7).
[2]
SECONDARY REDUCTION
Remove the
Lepaskan counter
counter gear
gear (page
(hal. 10-26).
10-26)
Separatecrankcas
the crankcase [2]
Pisahkan e (hal.(page
12-7).12-7).
Remove the
Lepaskan following:
sebagai berikut:
-–Finalshaft assembly
Finalshaft assembly [1][1]
-–Countershaft
Countershaft[2][2]
Semprotkan
to thepada
geargigi-gigi
teeth andgear dan bearings.
bearings.
Pas angthe
Install c ountershaft.
countershaft.
Pas ang the
Install finalshaft assembly
finalshaft sementara
assembly mentepatkan
while aligning the
finalshaft gear and countershaft gear teeth.
gigi-gigi finalshaft gear dan c ountershaft gear.
Assemble the crankcase (page 12-12).
Rakit crankcase (hal. 12-12).
Install the counter gear (page 10-27).
Pas ang c ounter gear (hal. 10-27).
[1]
INSPECTION
PEMERIKSAAN
BEARINGS
Check the countershaft bearings [1] , finalshaft bearings Crankcase kiri:
BEARINGS Crankcase kanan:
[2] and finalshaft oil seal [3] for wear or damage.
Periksa countershaft bearings [1], finalshaft bearings [2] [1]
Turn each bearing inner race with your finger.
dan finalshaft oil seal [3] terhadap keausan atau
The bearing should turn smoothly without friction.
kerusakan.
Check that there is no clearance between the outer
race and
Putar crankcase.
masing-mas ing bearing inner race dengan jari-jari.
Bearing harus berputar dengan halus tanpa gesekan.
Periksa bahwa tidak ada kerenggangan antara outer
race dan c rankcase.
[3] [2]
12-21
COUNTER
COUNTERGEAR/COUNTERSHAFT
GEAR/COUNTERSHAFT
Jika counter
If the geargear
counter aus Periksa
Check the countershaft
countershaft [1] [1]
danand counter
c ounter gear[2][2]terhadap
gear for wear
atau rusak, periksa
is worn or damage.
or keausan atau kerusakan. [2]
juga clutch oute
damaged, r
also
gear (hal. 10-23).
inspect the clutch
outer gear (page
10-23).
[1]
FINALSHAFT
FINALSHAFTASSEMBLY
ASSEMBLY
Periksa gigi-gigi
Check the finalshaft
finalshaft gear [1]gear
teeth[1]forterhadap keausan
wear or damage.
atau kerus
Check theakan.
finalshaft [2] for bend, wear or damage. [1]
Periksa finalshaft [2] terhadap kebengkokan, keausan
If necessary, replace the finalshaft as an assembly.
atau kerus akan.
Bila perlu, gantilah finalshaft s ebagai sebuah assembly
(rakitan).
[2]
BEARING REPLACEMENT
PENGGANTIAN BEAR ING
For driveshaft bearing replacement (page 10-26).
Untuk penggantian driveshaft bearing (hal. 10-26).
DRIVESHAFT
LEFT CRANKCASE BEARING (6301U)
COUNTERSHAFT
COUNTERSHAFT BEARING (6203)
BEARING (6202)
FINALSHAFT
BEARING (6201)
OIL SEAL
20 x 34 x 7
FINALSHAFT
CRANKCASE KANAN
BEARING (6204)
12-22
LEFTCRANKCASE
LEFT CRANKCASE
Be careful not to Remove the finalshaft oil seal [1].
Hati-hati agar tidak Lepaskan finalshaft oil s eal [1]. [1]
merusakdamage Drive out
the Dorong
permukaan the finalshaft
finalshaft bearingbearing [2].
[2] keluar.
crankcase
penyatuan mating
crankcase.
surface.
[2]
Lepaskan
Remove the countershaft bearing
countershaft bearing [1] the dengan
[1] using special
[4] [2]
tools.
menggunakan special tools.
TOOLS:
TOOLS:
[2] Bearing remover head, 15 mm 07936-KC10200
[2] Bearing
[3] Bearing remover
remover shaft,
head, 15
15 mm
mm 07936-KC10200
07936-KC10100
[3] Remover
[4] Bearing remover
weight shaft, 15 mm 07936-KC10100
07741-0010201
[3] [1]
Semprotkan
Apply engine oli oil tomes in bearing
each ke rongga
cavity. masing-masing
bearing.
Install the bearings
Pasang bearings Drive each
Dorong new bearing
masuk masing-masinto the
ing left crankcase
bearing barusquarely
secara [2]
with sisi
dengan theiryang
marked
ada until it is fully
tegaklurus ke seated,
dalam using
left cthe special sampai
rankcase tools. ia telah
sidesmefacing
tandanya up.
nghadap duduk sepenuhnya, dengan menggunakan special
ke atas. TOOLS:
tools .
Countershaft bearing [1]: [3]
TOOLS:
[2] Driver 07749-0010000
Countershaft bearing [4]
[3] Attachment, 32 [1]:
x 35 mm 07746-0010100
[2]
[4]Driver
Pilot, 15 mm 07749-0010000
07746-0040300
[3] Attachment, 32 x 35 mm 07746-0010100
Finalshaft bearing [5]:
[4] Pilot, 15 mm 07746-0040300
Driver 07749-0010000
Finalshaft bearing [5]:
[6] Attachment, 42 x 47 mm
Driver 07746-0010300
07749-0010000
[7] Pilot, 20 mm
[6] Attachment, 42 x 47 mm 07746-0040500
07746-0010300 [5] [1]
[7] Pilot, 20 mm 07746-0040500
Semprotkan
Apply engineolioilmesin ke finalshaft
to a new bibir-bibir oil
finalshaft oil seal
seal [1] lips and
install[1]it to
baru danthepasang
specified depth ke
sampai as shown,
kedalaman usingyang
the [1] [2]
special tools.dengan menggunakan s pecial tools.
diperlihatkan,
TOOLS:
TOOLS:
[2]
[2] Driver
Driver 07749-0010000
07749-0010000 [3]
[3]
[3] Attachment,
Attachment, 32
32 xx 35
35 mm
mm 07746-0010100
07746-0010100
0,2 - 1,2 mm
12-23
RIGHT
RIGHT CRANKCASE
CRANKCASE
Remove the
Lepaskan following:
- –Kickstarter (hal.
Kickstarter 12-16)
(page 12-16)
- –Counters haft/finalshaft (hal.
Countershaft/finalshaft 12-21).
(page 12-21)
Lepaskan baut-baut
Remove the [1]and
bolts [1] danbearing
bearingset
setplate
plate[2].
[2].
[1]
Be careful
Hati-hati agarnot
tidak Drive out
to Dorong the counters
keluar countershaft bearing [1]
haft bearing [1] dan
and finalshaft
finalshaft
merusakdamage
permukaan bearing[2]
the bearing [2]dari
from thecrankcase.
right right crankcase. [1]
penyatuan
crankcasecrankcase.
mating
surface.
[2]
Semprotkan olioil
Apply engine mesin
to thekefinalshaft
rongga finalshaft bearing.
bearing cavity.
[2]
Pasang
Install the be aring Dorong
bearing Drive amasuk
new finalshaft
finalshaftbearing
bearing[1] [1]
secara
into tegaklurus
the right
dengan
with its sisi yang side
marked ada ke dalam right
crankcase crankcase
squarely until it sampai
is flushiawithratathe
dengan
case
tandanya me nghadap
facing surface, using
up. permukaan thedengan
case, specialmenggunakan
tools. special tools.
ke atas.
TOOLS:
TOOLS: [3]
[2]
[2]Driver
Driver 07749-0010000
07749-0010000
[3]
[3]Attachment,
Attachment, 32
32 xx 35
35 mm
mm 07746-0010100
07746-0010100
[4]
[4]Pilot,
Pilot, 12
12 mm
mm 07746-0040200
07746-0040200
[1] [4]
Apply engine oli

Semprotkan oil tomesin
the countershaft bearingcountershaft
pada rongga cavity.
bearing. [2]
Install the bearing Drive a new countershaft bearing [1] into the right
with its marked
Pasang crankcase
side Dorong
be aring squarely
masuk until it isbearing
c ountershaft fully seated, using
baru [1] the
secara
dengan sisifacing
yang ada special tools.
up. tegaklurus ke dalam right crankcas e sampai ia duduk
tandanya me nghadap sepenuhnya, dengan menggunakan special tools. [3]
ke atas. TOOLS:
[2] Driver
TOOLS: 07749-0010000
[3]Driver
[2] Attachment, 37 x 40 mm 07746-0010200
07749-0010000
[4]Attachment,
[3] Pilot, 17 mm37 x 40 mm 07746-0040400
07746-0010200
[4] Pilot, 17 mm 07746-0040400
[4] [1]
12-24
Oleskan lockingagent
Apply locking agent topada
the ulir baut set
bearing bearing
plateset plate
bolt [1]
threads
[1] sepertiasditentukan.
specified. [2] "KWZ OUTSIDE" mark
Pas angthe
Install bearing
bearingset [2]with
set plate [2] dengan tanda
its "KWZ “KWX
OUTSIDE"
mark facing
OUTSIDE” up.
menghadap ke atas.
Install
Pas angand
dantighten the bolts.
kencangkan baut-baut. [1]
Install
s ebagai berikut:
- –Countershaft/finalshaft
Countershaft/finalshaft (hal. 12-21)
(page 12-21)
- –Kickstarter
Kickstarter(hal. 12-20)
(page 12-20)
Coating width: 6.5 ± 1.0 mm

(0.26 ± 0.04 in) from tip
CAM CHAIN GUIDE SPROCKET

PELEPASAN
REMOVAL
Separatecrankcas
Pisahkan the crankcase
e (hal. (page
12-7). 12-7).
[2]
Hold the
Tahan camcam
chainchain guide
guide sprocket
sprocket [1], [1], turn
putar thechain
cam cam
chain sprock
guide guide et
sprocket
spindlespindle [2] counterclockwise
[2] berlawanan arah jarum and
jam
remove
dan themmereka
lepaskan from thedari
leftleft
crankcase.
crankcase.
[1]
INSPECTION
PEMERIKSAAN
Inspectsebagai
Periksa cam chain Periksa the following:
berikut:
dan cam sprocket jika
[1]
Inspect the cam
cam chain guide -– Cam chain
chain guidesprocket
guide [1] [1]
sprocket for wear or damage.
terhadap keausan
chain and
sprocket cam – atau
rusak. Cam kerusakan.
chain guide sprocket spindle [2] for wear or
sprocket if the cam - Camdamage.c hain guide sprocket spindle [2] terhadap
chain guide keausan atau kerusakan.
sprocket is
damaged.
[2]
-– Spindle journals [1]

[1] for
terhadap keausan
abnormal wear ortidak normal
damage.
Crankcase kiri: Crankcase kanan:
atau kerusakan.
[1]
12-25
INSTALLATION
PEMASANGAN
Apply engine
Semprotkan oli oil to the
mesin cam chaingeser
ke permukaan guidecam
sprocket
chain
spindle [1] sliding surface. [1]
guide sprocket spindle [1].
Install the cam chain guide sprocket [2] and spindle to
Pas ang cam chain guide sprocket [2] dan spindle pada
the left crankcase, hold the sprocket and tighten the
left crankc ase, tahan sprocket dan kencangkan spindle
spindle to the specified torque.
Assemble the crankcase (page 12-7).
Rakit crankcase (hal. 12-7)
[2]
12-26
13. RODA DEPAN/SUSPENSI/KEMUDI
LOK ASI KOMPONEN

COMPONENT ....................................
LOCATION 13-2
··························13-2 FORK (GARPU) ......................................... 13-11
FORK·························································

···························13-3 HANDLEBAR
HANDLEBAR (STANG STIR).................... 13-19
············································ 13-19
TROUBLESH OOTING ................................... 13-6 STEERING STEM (POROS KEMUDI) ...... 13-21
TROUBLESHOOTING·································13-6 STEERING STEM ····································· 13-21
RODA DEPAN ................................................ 13-7
FRONT WHEEL···········································13-7
13
13-1
RODA DEPAN/SUSPENSI/KEMUDI
LOKASI KOMPONEN
9 N·m (0,92 kgf·m; 6,6 lbf·ft)
59 N·m (6,0 kgf·m; 44 lbf·ft)
64 N·m (6,5 kgf·m; 47 lbf·ft)
30 N·m (3,1 kgf·m; 22 lbf·ft)
59 N·m (6,0 kgf·m; 44 lbf·ft)
13-2
KETERANGAN SERVIS
UMUM
PERINGATAN
Seringkali menghirup debu brake pad, tidak tergantung dari komposisi bahan, dapat membahayakan kesehatan anda.
• Jangan menghirup partikel-partikel debu.
• Jangan memakai slang udara atau sikat untuk membersihkan susunan rem. Pakailah vacuum cleaner (alat penghisap debu)
yang baik.
• Bab ini meliputi front wheel (roda depan), fork (garpu), handlebar (stang stir) dan steering stem (poros kemudi).
• Sewaktu menservis front wheel, fork, atau steering stem, topanglah sepedamotor dengan dongkrak atau peralatan pendukung
lain.
• Brake disc atau pad yang terkontaminasi mengurangi daya pengereman. Buanglah pads yang terkontaminasi dan bersihkan
disc yang terkontaminasi dengan pembersih gemuk berkualitas tinggi untuk peralatan rem.
• Setelah pemasangan front wheel, periksalah cara kerja rem dengan menjalankan brake lever (handel rem).
• Untuk servis sistem rem, lihat hal. 15-3.
SPESIFIKASI
Satuan: mm
Tekanan udara Pengendara saja 175 kPa (1,75 kgf/cm2, 25 psi) –
ban dingin Pengendara dan pembonceng 175 kPa (1,75 kgf/cm2, 25 psi) –
roda Aksial – 2,0
Garpu Panjang bebas pegas 290,1 284,3
Kebengkokan pipa – 0,2
Fluid garpu yang dianjurkan Fork fluid –
TORSI
TORQUEPENGENCANGAN
VALUES
Mur poros
Front axledepan
nut 59 N.m
59(6,0
N·mk gf.m; 44 lbf.ft)
(6.0 kgf·m, 44 lbf·ft) Mur-U U-nut
Baut
Brakesocket brake disc
disc socket bolt 42 N.m
42(4,3
(4.3 kgf·m, 31 lbf·ft) Baut ALOC,
ALOC ganti dengan with
bolt; replace yangabaru
new one
Mur handlebar
Handlebar postpost
nut 59 N.m
59(6,0
(6.0 kgf·m, 44 lbf·ft) Mur-U U-nut
Sekrup
Handlebarhandlebar
weight weight
screw 9 N.m9(0,92
N·m k(0.92
gf.m;kgf·m,
6,6 lbf.ft)
6.6 lbf·ft) SekrupSLulirthread
SL screw
Baut penjepit
Bottom bridgebottom
pinch bridge
bolt 64 N.m
64(6,5
(6.5 kgf·m, 47 lbf·ft)
Baut
Forksocket forksocket
pipe seat pipe seat
bolt 20 N.m
20(2,0
(2.0 kgf·m, 15 lbf·ft) Oleskan cairan
Apply pengunci
locking agentpada
to theulir
threads
Mur pengunci
Steering stemsteering
lock nutstem - – Utk urutan pengencangan (hal.13-25)
For tightening sequence (page 13-25)
Steering stem top thread - Utk urutan pengencangan (hal.13-25)
Steering stem top thread – For tightening sequence (page 13-25)
13-3
TOOLS
adjustable pin spanner Bearing driver attachment, 32×35 [in Bearing driver attachment, 37×40 [in
07702-0020001 combination with 07749-0010000 ] combination with 07749-0010000 ]
07746-0010100 07746-0010200
Pilot, 12 [ in combination with 07749- Bearing remover shaft, 9×200L Remover head, 12
0010000 ] 07746-0050100 07746-0050300
07746-0040200
Oil seal remover Driver handle, 15×135L Lock nut wrench, 5.7×50
07748-0010001 or equivalent 07749-0010000 07916-3710101
Socket wrench, 32 (octagon) Bearing driver attachment Fork seal driver attachment, 35.2 [ in
07916-KM10000 07946-3710701 combination with 07747-0010100 ]
07947-KA20200
13-4
Oil seal driver, 53,5 Ball race remover, 34,5 Ball race remover, 36×340L
07947-SB00200 07948-4630100 07GMD-KS40100
13-5
TROUBLESHOOTING
Hard steering
Kemudi berat
• Insufficient tire pressure
•• Faulty
Tekanan tireudara ban terlalu rendah
• Ban rusak
• Steering stem lock nut too tight
•• Faulty
Jari-jari roda longgar
steering atau berubah bentuk
head bearing
•• Faulty
Mur penguncian
steering headsteering s tem
bearing terlalu kencang
race
•• Bent
Steering headstem
steering bearing tidak bekerja dengan baik
• Steering
Steers to one head
sidebearing
or does race
nottidak
trackbekerja dengan baik
straight
•• Bent
Steering
frontstem
axle bengkok
• Wheel
Kemudi installedkeincorrectly
menarik satu sisi atau tidak dapat ber jalan lurus
•• Worn
Porosordepan
damaged front wheel bearings
bengkok
•• Bent fork
Roda tidak terpas ang dengan baik
• Bent frame
• Front wheel bearings aus atau rusak
• Faulty steering head bearing
• Fork bengkok
Front wheelbengkok
• Rangka wobbles
•• Loose
Steeringfront axlebearing
head fasteners
tidak bekerja dengan baik
• Bent rim
Roda depan
• Worn bergoyang
or damaged front wheel bearings
• Pengikat poros depan longgar
Front wheel turns hard
•• Front
Pelek bengkok
brake drag
• Front wheel
• Bent front bearings aus atau rusak
axle
• Faulty
Roda depan front wheel
berat perbearings
putarannya
• Rem
Soft depan menyangkut
suspension
•• Low
Poros
tiredepan
pressurebengkok
•• Deteriorated
Front wheel bearings
fork fluid tidak bekerja dengan baik
• Incorrect fork fluid weight
Suspensi lunak
• Insufficient fluid in fork
•
• Weak forkudara
Tekanan springban terlalu rendah
• Fork fluid memburuk kondisinya
Hard suspension
• Berat fork fluid tidak tepat
•• High
Fork tire
fluidpressure
tidak cukup jumlahnya
• Too much fluid in fork
• Fork spring lemah
• Incorrect fork fluid weight
• Bent fork
Suspensi pipes
keras
•• Clogged
Tekananfork udara fluid passage
ban terlalu tinggi
• Terlalu banyak
Suspension noisyfluida di dalam fork
•• Bent
Beratfork
forkslider
fluid tidak tepat
•• Insufficient
Fork pipes fluid
bengkokin fork
•• Loose
Lintasanforkfork
fasteners
fluid tersumbat
Suspensi berisik
• Fork slider bengkok
• Fork fluid tidak cukup jumlahnya
• Pengikat fork longgar
13-6
FRONT WHEEL (RODA DEPAN)
Support the motorcycle
Topanglah sepedamotorusingdengan
a jack or other adjustable
dongkrak atau
support. pendukung lain yang dapat disetel.
peralatan
Remove/install thesebagai
Lepaskan/pasang following:berikut:
-– Speedometer
Speedometercable cable[1][1]
-– O-ring
O-ring[2][2]
-– Mur
Axleporos [3]
nut [3]
-– Front
Frontaxle
axle(poros
[4] depan) [4]
-– Front
Frontwheel
wheel(roda
[5] depan) [5]
-– Side
Sidecollar
collar[6][6]
-– Speedometer
Speedometergearbox gearbox[7][7]
TORSI:
TORQUE:
MUR
AXLEPOROS
NUT 59 N.m
59 N·m (6.0(6,0 kgf.m;
kgf·m, 44 lbf.ft)
44 lbf·ft)
•• Replace
Gantilah the
speedometer
speedometer cable
cableO-ring
O-ringdengan
with a yang
new
baru.
one.
•• Apply
Berikan gemuk
grease to pada front axle,
the front axle, speedometer
speedometer gear
gear
and
dan speedometer
speedometercable
cable O-ring.
O-ring.
•• Check
Periksathe brake
cara operation
kerja after pemasangan.
rem setelah installation.
* : 3 g ke gigi-gigi gear
: 0.5 – 1.0 g ke permukaan dalam gear
[4]
[5]
[6]
[3] 59 N·m (6,0 kgf·m; 44 lbf·ft)
* Tepatkan alur speedometer

gearbox dengan boss pada
fork leg.
[1]
Tepatkan speedometer gear tabs Lepaskan tab sementara

dengan alur wheel hub. mendorongnya dan lepaskan
speedometer cable.
[7] [2]
13-7
Remove/install thesebagai
Lepaskan/pasang following:berikut:
– Left/right dust seals [1]/[2]
- Dust seals kiri/kanan [1]/[2]
-– Baut-baut
Socket bolts [3] [3]
socket
– Brake disc
- Brake disc [4] [4]
-– Wheel
Left/right wheel
bearing bearingkiri/kanan
(6201U) (6201U) [5]/[6]
[5]/[6]
– Distance collar [7]
- Distance c ollar [7]
• Replace the socket bolts, bearings and dust seals
• with
Gantilah baut-baut soc ket, bearings dan dust seals
new ones.
dengan yang
• Apply grease to baru.
the dust seal lips, bearing cavities
• and
Berikan gemuk
distance collar.pada bibir-bibir dust seal dan
rongga-rongga bearing.
TORQUE:
TORSI:
BRAKE
BAUT DISC
SOCKET 42 N·m (4.3(4,3
42 N.m kgf·m, 31 lbf·ft)
kgf.m; 31 lbf.ft)
SOCKET
BRAKE DISCBOLT
For wheel
Untuk bearing replacement
penggantian (page
wheel bearing (hal.13-9).
13-9).
Kencangkan baut dalam pola

[3] 42 N·m (4,3 kgf·m; 31 lbf·ft) bersilangan dalam 2 atau 3 langkah
[2]
[7]
[4]
[6]
[5]
[1]
Pasang dust seal kiri sampai ia telah Pasang dust seal kanan sampai ia rata
duduk sepenuhnya. dengan permukaan ujung roda.
[1]
[2]
13-8
PELEPASAN BEARING
BEARING REMOVAL
Install
Pas ang the bearing
bearing remover
remov er headhead into thebearing
ke dalam bearing[1].
[1].
From
Dari sisithe opposite pasang
berlawanan, side, install
bearingtheremover
bearingshaft
remover
dan [2] [3]
shaft and
dorong drivekeluar
bearing the bearing out ofhub.
dari wheel the wheel hub.
Remove the
Lepaskan distance
distance collar
collar danand drivekeluar
dorong out the other
bearing
bearing.
yang lain.
TOOLS:
TOOLS:
[2]Bearing
[2] Bearing remover
remover head,12
head, m m 07746-0050300
07746-0050300
12 mm remover shaft,
[3] Bearing 07746-0050100
[3] Bearing remover shaft 07746-0050100
[1]
[1]
[3] [2]
PEMASANGAN BEARING
BEARING INSTALLATION
Isilah
Packsemua rongga
all bearing bearing dengan
[1] cavities gemuk.
with grease.
[3] [2]
Jangan
Never memasang
install the old Dorong
Drive inmasuk
a new bearing kanan
right (brake discbaru
side) (sisi brake
bearing dis c)
squarely
ke mbali bearings secara tegaklurus dengan sisinya yang tertutup
bearings. Once the with its sealed side facing up until it is fully seated.
lama. Se kali bearings menghadap ke atas sampai ia duduk sepenuhnya.
bearings have been
telah dikeluarkan,
removed, the
bearings harus TOOLS:
TOOLS:
bearings
diganti must
dengan be
yang
replaced withbaru.new
[2]
[2] Driver
Driver 07749-0010000
07749-0010000
ones. [3]
[3] Attachment, 32x x3535
Attachment, 32 mmmm 07749-0010100
07746-0010100
[4]
[4] Pilot, 12 mm
Pilot, 12 mm 07746-0040200
07746-0040200
[1] [4]
Apply
Pas ang thin coat of
distance grease
collar [1]. to the distance collar [1] and
install it. [1] [2]
Dorong mas uk bearing kiri baru [2] secara tegaklurus
Drive insisinya
dengan a newyang
left bearing
tertutup [2] squarely ke
menghadap withatas.
its sealed
side facing up.
TOOLS:
TOOLS:
Driver 07749-0010000
Driver
Attachment, 32 x 35 mm 07749-0010000
07746-0010100
Attachment,
Pilot, 12 mm 32 x 35 mm 07746-0010100
07746-0040200
Pilot, 12 mm 07746-0040200
13-9
INSPECTION
PEMERIKSAAN
AXLE(POROS)
AXLE
Place the axle
Letakkan axle on V-blocks
pada and measure
V-blocks the runout
dan ukur with
keolengan
a dial indicator.
dengan sebuah dial indicator.
SERVICE
BATAS LIMIT: 0,2
SERVIS: 0.2 mm
mm (0.01 in)
Actual runout
Keolengan is 1/2 of the
sebenarnya total ½
adalah indicator reading. total
dari pembacaan
indicator.
WHEEL
WHEELBEARING
BEARING(BANTALAN RODA)
Turn the
Putar inner
inner race
race of each
dari bearinging
masing-mas withbearing
your finger,
denganthe
bearingbearing
jari-jari, should harus
turn smoothly
berputarand quietly.
dengan halus dan tanpa
Also check that the bearing outer race fits tightly in the
suara.
Gantilah bearings hub. periksa bahwa bearing outer race duduk dengan
Juga
dalam pasangan. erat pada hub.
Replace the Remove and discard the bearings if the races do not
bearings in pairs. turn smoothly,
Lepaskan quietly, or bearings
dan buanglah if they fit loosely in the hub.
jika races-nya tidak
berputar dengan halus, tanpa suara, atau jika mereka
duduk dengan longgar pada hub.
WHEEL
WHEELRIM
RIM(PELEK RODA)
Periksa
Check keolengan
the wheel rim wheel rim dengan
runout meletakkan
by placing the wheelwheel
on a
pada sebuah
turning stand.turning stand (alat pegangan roda untuk
penyetelan jari-jari).
Spin the wheel by hand and read the runout using a dial
indicator.
Putar wheel dengan tangan dan baca keolengan
Actual menggunakan
dengan runout is 1/2 the total
dial indicator
indic ator. reading.
Keolengan sebenarnya adalah ½ dari pembacaan total
SERVICE LIMIT:
indicator.
Axial: 2.0 mm (0.08 in)
BATAS SERVIS: 2.0 mm (0.08 in)
Radial:
Aksial: 2,0 mm
Radial: 2,0 mm
13-10
FORK (GARPU)
PELEPASAN
REMOVAL
Remove front
Lepaskan the front fender
fender B (page
B (hal. 3-11).3-11).
[1]
Gantunglah
Support thefront
front Lepaskan
Remove the baut-baut pemasangan
brake caliper mountingbrake
boltscaliper dan
and brake
brake
brakecaliper
caliperdengan
with a brake c aliper
caliper from dari fork leg
the right forkkanan (hal.15-12).
leg (page 15-12).
piece ofseutas
wire sokawat
that
se hingganot
ia tidak Remove baut-baut
Lepaskan the bottompenjepit
bridge upper pinch bolts
atas bottom [1].[1].
bridge
it does hang
menggantung pada Loosen thebaut-baut
Longgarkan bottom bridge
penjepitlower pinch
bawah bolts
bottom [2] and
bridge [2]
from the front brake
front brake hose. remove
dan the fork
lepaskan forklegs
legs[3].
(kaki garpu) [3].
hose.
Jangan memelintir
Do not twist the
brake hose.
brake hose.
[3]
[2]
PEMBONGK ARAN
DISASSEMBLY
Hold the
Tahan forkfork slider
slider [1] [1] in a catok
dalam vice with soft jaws
dengan or alunak
rahang shop
towel.
atau dengan dibungkus kain lap. [1] [2]
Loosen the baut
Longgarkan fork socket
socket bolt
fork[2]
[2]but do not
tetapi remove
jangan yet.
lepaskan
dulu.
Put the suitable

Letakkan suitabletool
tool[1](perkakas
on the spring
yangseat [2]. [1] pada
c ocok)
spring seat [2]. [1]
To prevent loss of Press the spring seat into the fork pipe using a suitable
Untuk mencdo
tension, egahnot tool and
Dorong hydraulic
masuk press,
spring s eatthen removefork
ke dalam thepipe
stopper ring
dengan [2]
hilangnya
compress tegangan,
the fork [3] using a smallsuitable
menggunakan screwdriver.
tool dan hydraulic press,
jangan me nekan
spring morefork
than kemudian lepaskan stopper ring [3] dengan
spring lebih dari
necessary. The
yang diperlukan.
menggunakan obeng kecil.
spring seat is under
Spring seat berada di
spring
bawahpressure.
tekanan
Use care
spring. when
Berhati-
removing the fork
hatilah sewaktu [3]
assembly from
melepaskan the
fork
hydraulic
assemblypress.
dari
hydraulic press.
Remove spring
Lepaskan the spring
seat seat [1], O-ring
[1], O-ring [2] spring
[2] dan and spring [3]
[3] dari
from
fork the[4].
pipe fork pipe [4]. [4] [1]
Remove the
Lepaskan O-ringdari
ke O-ring fromspring
the spring
seat. seat.
[2]
[3]
13-11
Tuangkan fork
Pour out the forkfluid
fluid (minyak garpu)
by pumping keluar
the fork pipe dengan
several
times.
memompa fork pipe beberapa kali.
Lepaskan bautsocket
Remove the soc ketbolt
[1] [1]
danand
sealin washer
sealing [2]. [2].
washer
[2]
[1]
Remove the
Lepaskan forkfork piston
piston [1] and
[1] dan rebound
rebound spring
spring [2] from
[2] dari fork
[3] [1]
the [3].
pipe fork pipe [3].
[2]
Tarik keluar
Pull the forkfork
pipepipe [1] dari
[1] out fromfork
theslider [2]. [2].
fork slider
[2]
[1]
13-12
Remove the
Lepaskan dustdust
sealseal
[1]. [1].
[1]
Remove the
Lepaskan oil seal
oil seal stopper
stopper ringring
[1]. [1].
[1]
Remove the
Lepaskan oil seal
oil seal [1] usingmenggunakan
[1] dengan the special tool.
special tool.
[2]
TOOL:
TOOL:
[2]
[2]Oil
Oilseal
sealremover 07748-0010001
remover 07748-0010001 or equivalent
atau sejenisnya
[1]
Remove the
Lepaskan backback-up
-up ringring [1] from
[1] dari fork sthe fork slider.
lider.
[1]
13-13
INSPECTION
PEMERIKSAAN
FORKSPRING
FORK SPRING
Measure the bebas
Ukur panjang fork spring [1] free[1].
fork spring length.
SERVICE
BATAS LIMIT: 284,3
SERVIS: 284.3 mm
mm (11.19 in) [1]
FORKPIPE/SLIDER/PISTON
FORK PIPE/SLIDER/PISTON
Check the
Periksa forkfork pipe
pipe [1],[1], fork
fork slider[2][2]dan
slider andfork
fork piston
piston [3]
[3]
for scoretanda-tanda
mark, and excessive [2]
terhadap gerusan, or danabnormal
keausanwear.
berlebihan
atau
Checktidak
thenormal.
fork piston ring [4] for wear or damage.
Periksa fork piston spring
Check the rebound [5] for
ring [4] fatigue or
terhadap damage.atau
keausan
kerusakan.
Replace the components if necessary.
Periksa rebound spring [5] terhadap kelelahan atau
kerusakan.
Gantilah komponen-komponen bila perlu. [1]
[5]
[3] [4]
Place thefork
Letakkan forkpipe
pipepada
on V-block
V-blockand
danmeasure the runout.
ukur keolengan.
Actual runout
Keolengan is 1/2 the adalah
sebenarnya total indicator
½ dari reading.
pembacaan total
indicator.
FORK
FORKPIPE
PIPEBUSHING/BACK-UP
BUSHING/BACK-UPRING
RING
Visuallyguide
Periksa inspect the guide
bushing [1] bushing
secara [1] in the
visual di fork slider.
dalam fork
Replace the fork slider as an assembly if there is
slider. [1]
excessive
Ganti fork scoring or scratching,
slider sebagai sebuahor assembly
if the teflonjika
is worn
ada
so that
gerus an the
ataucopper
goresansurface appearsatau
berlebihan, on more than 3/4
jika teflon of
telah
the entire surface. [2]
aus sehingga permukaan tembaga tampak pada lebih
dari ¾ dari
Check theseluruh
back-up permukaan.
ring [2]; replace it if there is any
distortion at the points
Periksa bac k-up ring [2], [3] indicated
ganti jikabyada arrows on the
perubahan
figure.
bentuk pada titik-titik [3] yang ditunjukkan oleh anak-
anak panah pada gambar.
[3]
13-14
PERAKITAN
FORK PIPE FORK PISTON STOPPER RING
FORK PISTON RING
DUST SEAL
STOPPER RING
OIL SEAL
BACK-UP RING SPRING

SEAT
FORK SLIDER
O-RING
SOCKET BOLT
20 N·m
(2,0 kgf·m; 15 lbf·ft)
FORK SPRING
SEALING WASHER REBOUND SPRING
Sebelum perakitan,wash
Before assembly, cucilah semua
all parts parts
with highdengan cairan
flash point or
non-flammable
pelarut solvent
yang tidak dapatand wipe them
terbakar atau dry.
mempunyai titik [1]
api tinggi
Install dan
the s eka mereka
back-up ring [1] sinto
ampai
the kering.
fork slider [2].
Pas ang back-up ring [1] ke dalam fork slider [2].
[2]
Apply fork
Berikan forkfluid
fluidtopada
the lip of oil
bibir a new
sealoil seal
baru [1].
[1].
[2]
Install Drive the
seal Dorong
the oil seal
Pasang oil seal
masuk oil into
sealthe
ke fork slider
dalam using
fork the dengan
slider special
dengan
with its sisi yang side
marked tools until it is fully
ada menggunakan specseated.
ial tools sampai ia duduk
tandanya me nghadap
facing up. sepenuhnya. [3]
ke atas. TOOLS:
TOOLS:
[2] Driver 07749-0010000
[2]
[3]Driver
Attachment, 37 × 40 mm 07749-0010000
07746-0010200
[3] Attachment, 37 x 40 mm 07746-0010200
[1]
13-15
Pas ang the
Install oil seal s topper
oil seal ringring
stopper [1][1]
keinto
dalam
the alur stopper
stopper ring
ring padaon
groove fork
theslider.
fork slider. [2]
Apply fork
Berikan forkfluid
fluidtopada
a new dust
bibir seal
dust lip.baru.
seal
DoJ angan Install
the dust Pas
not tapmengetuk angthe
dustdust
s ealseal [2] until itiaisduduk
[2] sampai fully seated.
sepenuhnya.
bibirseal
dustlip
seal terlalu
too hard.
keras.
[1]
Install
Pas angthe
forkfork
pipepipe [1] dalam
[1] ke into thefork
forkslider
slider[2].
[2].
[2]
[1]
Pasang forkthe
Install piston
fork Jika forkfork
If the piston ringring
piston [1] telah dilepaskan
[1] was removeddari forkthe
from piston
fork
ring dengan
piston sisiwith
ring yang
its [2], pasang
piston fork piston
[2], install a newring
forkbaru pada
piston alur
ring to fork piston.
the fork piston
ada potongannya [1]
cut-out side facing groove.
menghadap ke
down.
bawah.
[2]
Pastik
Makeansure
bahwa the Pas
thatfork ang the
Install rebound spring
rebound [1] [1]
spring dan fork
and piston
fork [2][2]
piston keinto
dalam
the
piston
fork ringring
piston telahis fork
forkpipe.
pipe. [2]
duduk pada alurnya.
seated in the
groove.
[1]
13-16
Bersihkan
Clean the ulir bautbolt
socket socket [1] dan
[1] threads andberikan cairan
apply locking
pengunci
agent to pada ulir-ulir
the bolt baut.
threads. [2]
Pas angand
Install dantighten
kencangkan baut bolt
the socket socket
[2] [2]
withdengan
a new sealing
washerbaru
washer to the forkfork
pada piston.
piston.
[1]
Tuangkan jumlah fork

Pour the specified fluid yang
amount ditentukan ke
of recommended dalam
fork fluid
intopipe.
fork the fork pipe.
KAPASITAS
FORK FLUID FORK FLUID:
CAPACITY:
3
63,5 ± 1,0 cm 3
63.5 ± 1.0 cm (2.15 ± 0.03 US oz, 2.24 ± 0.04 Imp oz)
Pompa fork pipe beberapa kali untuk mengeluarkan
Pump the fork pipe several times to remove trapped air
udara yang
from the terperangkap
lower darifork
portion of the bagian
pipe. bawah dari fork
pipe.
Pastikan
Be sure level Tekan
the oilbahwa fork leg
Compress the sepenuhnya
fork leg fully dan
and ukur tinggi
measure permukaan
the fluid level
permuk aaninolithe
is same adalah
both fluid
fromdari
thebagian atasfork
top of the forkpipe.
pipe.
sama tingginya di
forks.
dalam kedua forks. TINGGI PERMUKAAN
FORK FLUID LEVEL: FORK73 mmFLUID:
(2.9 in) 73 m m
73 mm
Tarik fork fork

Pull the pipepipe
[1] ke atasand
[1] up daninstall
pasang
the fork
fork sspring
pring [2]
with its sisa
dengan tapered
yangside [3] facing
meruncing [3]down.
menghadap ke bawah. [1] [5]
Coat aO-ring
Lapisi new O-ring [4] dengan
baru [4] with forkfork
fluidfluid
and dan
installpasang
it into the
ke
groove
dalam in the
alur springspring
di dalam seat [5].
seat [5].
[4]
[2]
[3]
13-17
Tempatkan
Set the forkfork assembly,
assembly, spring
spring seatseat [1] dan
[1] and stopper
stopper ring
[2] onto
ring the hydraulic
[2] pada hydraulic press. [3]
Letakkan suitabletool
Put the suitable tool[3]
[3]on
pada
the spring
spring sseat.
eat.
Untuk menghindari
To prevent loss of Dorong masuk
Press the spring spring seatthe
seat into ke fork
dalam
pipefork
untilpipe sampai
the stopper
hilangnya tegangan,
tension, do not ringstopper
alur groove ring
is visible.
tampak. [2]
jangan tekan
compress thefork
fork
springmore
lebih dari Install
Pas ang the stopper
stopper ringring
ke into the alur
dalam stopper ring groove
stopper on
ring pada
spring than
yang diperlukan. the pipe.
fork fork pipe.
necessary.
[1] [2]
Hold the
Tahan forkfork slider
slider [1][1]pada
in a catok
vise with soft jaws
dengan or a lunak
rahang shop
towel.
atau dibalut dengan kain lap. [1]
Tighten the fork
Kencangkan bautsocket boltfork
socket [2] to[2]thedengan
specified torque.
tors i yang
ditentukan.
[2]
INSTALLATION
PEMASANGAN
Install
Pas angthe
forkfork
pipepipe [1] dalam
[1] ke into thesteering
steeringstem
stem[2].
[2].
[3]
Align the lubang
Tepatkan upper pinch
baut bolt hole atas
penjepit [3] with
[3] the groove
dengan [4][4]
alur of
the fork
dari fork pipe
pipe seperti
as shown.diperlihatkan.
[4]
[1] [2]
Install
Pas angthe bottom
baut bridge
penjepit atasupper pinch
bottom bolts
bridge [1].[1].
Tighten the bottom
Kencangkan bridgeatas/bawah
baut penjepit upper/lowerbottom
pinch bolts [2][2]
bridge to [1]
the specified
dengan torque.
TORQUE:
TORSI: 64 64
N.m N·m
(6,5(6.5 kgf·m,
lbf.ft)
Install
s ebagai berikut:
- –Front fender
Front fender B (hal. 3-11)
B (page 3-11)
- –Brake caliper (hal. 15-12)
Brake caliper (page 15-12)
[2]
13-18
HANDLEBAR
Remove
Lepaskanthe following:
[2]
- Handlebar rear cover (hal. 3-6)
– Handlebar rear cover (page 3-6)
- Main
– Mainpipe
pipecover
cover(hal. 3-15)
(page 3-15)
Lepaskanthe
Release yang berikutfrom
following darithe
handlebar clamps
handlebar [1] [1]:
clamps
- Front brak e hose [2]
– Front brake
- Throttle cablehose
[3] [2]
– Throttle cablecable
- Speedometer [3] [4]
– Speedometer cable [4]
Remove
- Masterthe following:
cylinder [5], holder [6] dan baut-baut [7]
-– Sekrup-sekrup
Master cylinder[8][5],dan handlebar
holder [6] andweights [9]
bolts [7]
–- Throttle
Screwspipe [10]handlebar weights [9]
[8] and
–- Handlebar grip[10]
Throttle pipe [11] [1]
– Handlebar
- Mur grip [11]
[12], collars [13] dan baut [14] [3]
– Nut [12], collars
- Handlebar post [15][13] and bolt [14]
– Handlebar post [15]
TORSI :
HANDLEBAR
WEIGHT SCREW 9 N·m (0.92 kgf·m, 6.6 lbf·ft)
HANDLEBAR
POST NUT 59 N·m (6.0 kgf·m, 44 lbf·ft)
• For handlebar post/handlebar grip installation (page
• Untuk
13-20).pemasangan handlebar post/handlebar grip
• (hal.
Route13-20)
the hose and cables properly (page 1-14).
• Alurkan hose dan cables dengan benar (hal. 1-14).
Kencangkan baut atas dulu,

Tepatkan ujung dari master kemudian baru baut bawah
cylinder dengan tanda titik
pada handlebar.
[10]
[8] 9 N·m (0,92 kgf·m; 6,6 lbf·ft)
[6]
[7]
Tempatkan holder dengan tanda
"UP" menghadap ke atas.
[15]
[11]
[9]
[5]
[12] 59 N·m (6,0 kgf·m; 44 lbf·ft)
[14]
[13]
13-19
PEMASANGAN HANDLEBAR
HANDLEBAR POST POST
INSTALLATION
Install
Pas ang the handlebarpost
handlebar post [1] onto
padathes teering
steering stem
while aligning
sementara the bolt holes.
mentepatkan lubang-lubang baut. [1]
[5] [3]
Rear
Rearcollar Install
taller Pas
is lebih
collar ang the front
front collar
collar [2],[2], rear
rear collar
collar [3],[3], bolt[4]
baut [4]dan
andmur
nut
tinggithe
than daripada front [5].
front collar. [5].
collar. Kencangkan mur dengan tors i yang ditentukan
Tighten the nut to the specified torque while holding the
sementara
bolt. menahan baut.
TORSI: 59 59
N·m kgf.m; 44 44
kgf·m, lbf.ft)
lbf·ft)
[2]
[4]
PEMASANGAN HANDLEBAR
HANDLEBAR GRIP GRIP
INSTALLATION
If the
Jika handlebar
handlebar gripgrip [1] were
[1] dilepas removed,
kan, berikan apply
HondaHonda
Bond
ABond
atauAsor equivalent
ejenisnya to the
pada insidedalam
bagian of the grip
dari and
griptodan
the [1]
cleanpermukaan
pada surfaces ofbersih
the left handlebar
dari [2]. [2].
left handlebar
Wait 3 3
Tunggu –5 minutes
–5 and pas
menit dan install
angthe grip.
grip.
Allow the adhesive
Biarkan Rotate
lem Putar the
grip griplem
agar for tersebar
even application
merata. of the adhesive.
mengering selama
to dry for 1
1 hour
jam sebelum
before using.
memakainya.
[2]
PENGGANTIAN HANDLEBAR
HANDLEBAR INNER WEIGHTINNER WEIGHT
REPLACEMENT
Push the
Dorong retainertab
retainer tab[1]
[1] melalui
through lubang
the handlebar hole [2]
handlebar [1]
with a screwdriver
dengan obeng atau or punch.
pons.
Temporarily
minyak Untuk
Apply lubricant
Semprotkan install
sementara pasangthe handlebar and sekrup,
handlebar weight dan screw,
pelumas
spray melalui
through then remove
the kemudian the inner
lepaskan innerweight assembly
weight [3][3]
assembly by dengan
turning
lubang handle
handlebar holebar the handlebar
to memutar weight.
handlebar weight.
kepada rubber
the rubber foruntuk
easy
mempermudah
removal.
pelepasannya.
[3]
[2]
Lepaskan
Remove thesekrup
screw [1],
[1],handlebar
handlebarweight
weight[2]
[2] dan
and rubber
cushions[3]
cushions [3]dari
from the weight
inner inner weight
[4]. [4]. [4]
Buanglah retainer
Discard the [5].[5].
retainer
Check that
Periksa the condition
keadaan of the
dari rubber rubber cushions,
cushions, replace
ganti mereka bila [5]
them if necessary.
perlu.
Install
Pas ang the rubber
rubber cushions
c ushions and
dan a new baru
retainer retainer onto
pada the
inner
inner weight.
weight.
Install
Pas ang the handlebar
handlebar weight
weight padaonto
innertheweight
inner dengan
weight [1]
aligning its boss
mentepatkan with groove
boss-nya each other.
pada alurnya.
Install
Pas angthe handlebar
s ekrup weight
handlebar screw.
weight.
[3]
[2]
13-20
Masukkan innerweight
Insert the inner weight assembly
assembly [1] into[1] ke dalam
the handlebar.
handlebar.
Turn the inner weight and hook the retainer tab [2] with [1] [3]
[2]
Putar inner
the hole [3]weight dan kaitkan retainer tab [2] dengan
in the handlebar.
lubang [3] pada handlebar.
Remove the handlebar weight screw [4] and handlebar
weight [5].sekrup handlebar weight [4] dan handlebar
Lepaskan
weight [5].
[5] [4]
STEERING STEM
PELEPASAN
REMOVAL
Remove the
Lepaskan following:
sebagai berikut:
- –Fork (hal. 13-11) [1]
Fork (page 13-11)
- –Handlebar
Handlebar (hal. 13-19)
(page 13-19)
Tahan
Loosentop thethread dengan
steering menggunakan
stem lock pinthespanner
nut [1] using socket
dan longgarkan
wrench [2]. mur pengunc i steering stem [1] dengan
menggunakan socket wrenc h.
TOOLS:
TOOLS:
[2] Socket wrench 07916-KM10000 [3] [2]
[2] Pin spanner 07702-0020001
Remove
[3] Socketthe steering stem lock nut07916-KM10000
wrench [1] and lock washer
[3].
Lepaskan mur pengunci s teering stem.
Hati-hati agarnot
Be careful to Tahan
tidak steering
Hold the stem
steering dan
stem andlonggarkan
loosen thetop
top thread
thread [1]
menjatuhkan steering dengan
drop the steering menggunakan
using the stem socket.stem socket.
stem. [2]
stem.
TOOL:
TOOL:
[2]
[2]Steering
Steering stem
stemsocket
socket 07916-3710101
07916-3710101
[1]
Hati-hati agarnot
tidak Remove upper bearing
the upper innerinner
bearing race race
[1] dan
[1] up per upper
and steel
menjatuhkan steering balls
drop the steering steel(23
ballsbola)
(23 balls) [2] while holding
[2] sementara menahathe steering stem
n steering stem [1]
stemstem
dan upper steel [3].
and upper [3].
balls.
steel balls. [2]
[3]
13-21
Hati-hati agar not
tidak Remove the steerin g stem
steering [1][1]
stem danandlower
lowersteel
steel balls
balls (29
menjatuhkan steering bola)
drop the steering balls)[2].
[2].
stemstem
dan lower steel [1]
and lower
steel balls.
balls.
[2]
STEERING STEM
PENGGANTIAN BEARINGS
STEERING STEM
REPLACEMENT
BEARINGS
•• Selalu
Alwaysganti
replace
steelthe steel
balls danballs andsebagai
races races as a set.
sebuah
set. the steering stem (page 13-21).
Remove [1]
Lepaskan
Remove steering
the upper stem (hal. 13-21).
bearing outer race [1] using the
Lepaskan upper bearing outer rac e [1] dengan
following tool.
menggunakan tool sebagai berikut.
TOOL:
TOOL:
[2] Ball race remover 07GMD-KS40100
[2] Ball race r emover 07GMD-KS40100
[2]
Lepaskan
Remove the lower
lowerbearing
bearing outer
outer race [1]
[1] using
dengan
the
menggunakan tools sebagai berikut.
following tools.
TOOLS:
TOOLS:
[2] [3]
[2]Ball
Ball race
race rremover,
emover, 34,5
34.5 mm
mm 07948-4630100
07948-4630100
[3]
[3]Ball
Ball race
racerremover
emover 07GMD-KS40100
07GMD-KS40100
[2]
[1]
Remove dust
Lepaskan the dust
sealseal [1] lower
[1] dari from the lowerinner
bearing bearing
raceinner
[2].
[2]
race [2].
Lepaskan lower bearing inner race dengan pahat atau
Remove [3]
tool sejenisthesementara
lower bearing inner race
berhati-hati agarwith a merusak
tidak chisel or
equivalent
stem [3]. tool being careful not to damage the stem
[3].
[1]
13-22
Pas ang alower
Install bearing
new lower inner inner
bearing race race
baru [1]
[1]using
dengan
the
menggunakan
following tool tool
and berikut dan
hydraulic hydraulic press.
press. [1]
TOOL:
TOOL:
[2]
[2]For k seal
Fork seal driver
driver attachment, 07947-KA20200
attachment, 07947-KA20200
35,2
35.2mm
mm
[2]
Berikan
Apply gemuk
greasedenganwith bahan
extremetahan pressure
tekanan sangat agent
tinggi (dianjurkan: EXCELIGHT
(recommended: EXCELIGHT EP2 EP2 yang dibuat oleh
manufactured by
KYODOYUSHI,
KYODO YUSHI, japanatau
J apan or Shell
Shell ALVANIA
ALVANIAEP2 EP2 or
atau
sejenisnya)
equivalent) pada bibir
to a new dust
dust sealseal
[1] lipbaru
then [1] kemudian
install it to the
lower bearing
pasang innerbearing
pada lower race. inner race.
[1]
Dorong
Drive amasuk upper
new upper bearing
bearing outer
outer racerace baru
[1] into the[1]head
ke
dalam headthe
pipe using pipe dengantools.
following menggunakan tools sebagai [2]
berikut.
TOOLS:
TOOLS:
[2] Driver 07749-0010000
[2]
[3]Driver
Bearing driver attachment 07749-0010000
07946-3710701 [3]
[3] Bearing driver attachment 07946-3710701
[1]
Dorong
Drive amasuk lower
new lower bearing
bearing outer
outer racerace baru
[1] into the[1]head
ke
dalam headthe
pipe using pipe dengan
following menggunakan tool sebagai
tool. [1]
berikut.
TOOL:
TOOL:
[2] Oil seal driver 53.5 mm 07947-SB00200
[2] Oil seal driver 53,5 mm 07947-SB00200
Install the steering stem (page 13-24).
Pas ang steering s tem (hal. 13-24).
[2]
13-23
INSTALLATION
PEMASANGAN
For steering
Untuk stem bearing
penggantian steeringreplacement (page
stem bearing (hal.13-22).
13-22). LOCK NUT
: gemuk dengan bahan tahan tekanan TOP THREAD LOCK WASHER

sangat tinggi (di anjurkan: EXCELIGHT EP2
yang di buat oleh KYODO YUSHI, japan
atau Shell ALVANIA EP2 atau sejenisnya) UPPER BEARING (23)
: Berikan minimum 3 g masing-masing ke
UPPER INNER
lower/upper races dan bibir dust seal
RACE
UPPER OUTER RACE
LOWER OUTER RACE
LOWER BEARING (29)
LOWER INNER RACE

STEERING STEM
DUST SEAL
Berikan
Apply 3 gggemuk dengan
of grease bahan
with tahan pressure
extreme tekanan san gat
agent
(recommended:
EXCELIGHT EP2 EP2 manufactured by
yang dibuat oleh [1]
KYODOYUSHI,
KYODO YUSHI,Japanjapanatau
or Shell
Shell ALVANIA
ALVANIAEP2EP2a tau
or
equivalent)
sej to thelower
eni snya) pada lowerbearing
bearingraces.
races.
Ganti bearing
Replace Attach the
races Pasang
the bearing steel
steel balls
balls (29bola)
(29 balls)[1]
[1] pada
to thelower
lower bearing
danand
races ballsballs
sebagai outerrace.
as a outer race.
sebuah set.
set.
Hati-hati Insert the steering stem

tidakto Masukkan
agar not
Be careful stem [2]
[2]into thesteering
pada steering head
head pipe,
menjatuhkan
drop the steering being careful
steering dengan not toagar
berhati-hati droptidak
the steel balls.
menjatuhkan steel balls.
stemstem
dan lower steel
and lower
steelballs.
balls.
[2]
Berikan
Apply 3 gggemuk dengan
of grease bahan
with tahan pressure
extreme tekanan san gat
agent
(recommended: [1]
EXCELIGHT EP2 EP2 manufactured by
yang dibuat oleh
KYODOYUSHI,
KYODO YUSHI,Japan
japanatau
or Shell
Shell ALVANIA
ALVANIAEP2EP2a tau
or
equivalent)
sej to theupper
eni snya) pada upperbearing
bearingraces
races[1].
[1].
Gantilah
Replace the be aring Pasang
bearing Install the
steelsteel
b allsballs
(23 (23
bo la)balls) [2] onto
[2] pada thebearing
upper upper
racesraces dan balls
and balls bearing
as a outer outer race.
race.
sebagai sebuah set.
set. [2]
Hati-hati agar tidak Pasang upper bearing inner race pada stem.
Be careful not to Install the upper bearing inner race onto the stem.
menjatuhkan steering
drop
stem danthe steering
upper steel
stem and balls.
upper
steel balls.
13-24
Install
Pas ang the
top top thread
thread [1]. [1].
Hold the
Tahan steering
steering stem
stem dan and tighten thestem
kencangkan stem top
top thread
thread [2]
to the initial
sampai ke torque
torsi using the special tool.awal dengan
pengencangan
menggunakan special tool.
TOOL:
[2] Steering stem socket
TOOL: 07916-3710101
[2] Steering stem socket 07916-3710101 [1]
Putar
Turn steering stem stem
the steering dari ujung-ke-ujung beberapa
lock-to-lock several timeskali
to
seat mendudukkan
untuk the bearing. bearing.
Longgarkan top thread [1] sama sekali. C

o
m [1]
p
l
e
t
e
l
y loosen the top thread [1].
Tahan steering
Hold the stem
steering dan
stem kencangkan
and tighten thestem
stem top
top thread
thread
[1]dengan
[1] to the specified
torsi yangtorque using the
ditentukan special
dengan tool.
menggunakan [2]
spec ial tool.
TOOL:
TOOL:
[2] Steering stem socket 07916-3710101
[2] Steering stem socket 07916-3710101
TORQUE:
TORSI: 2.5 N·m
2,5 N.m (0.25
(0,25 kgf·m,
kgf.m; 1,8 1.8 lbf·ft)
lbf.ft) [1]
13-25
Turn the
Putar top top thread
thread [1] [1] counterclockwise
berlawanan about jam
arah jarum 45°
degrees. kira-kira 45o.
sebanyak
[1]
45°
Tahan
Install top
the thread dengan
lock washer [3] menggunakan
by aligning its pin
tab spanner
with the
groove
dan of the steering
kencangkan stem. steering stem [1] dengan
mur pengunci [1]
torsi yang ditentukan dengan menggunakan sock et
Tighten the steering stem lock nut [1] to the specified
wrench.
torque.
TOOLS:
TOOLS:
[2] Pin spanner 07702-0020001
[2] Socket wrench 07916-KM10000
[3] Socket wrench 07916-KM10000 [3]
Tepatkan [2]
TORQUE:
TORSI: 83 83
N.mN·m
(8,5(8.5 kgf·m,
lbf.ft)
Turnsteering
Putar the steering
stemstem lock-to-lock
beberapa several
kali dari times.
ujung-ke-ujung.
Pas tikansure
Make bahwa steering stem
the steering stem moves
bergerak denganwithout
smoothly halus
play or
tanpa binding. atau mengikat.
kelonggaran
Install
s ebagai berikut:
- –Fork (hal.
Fork (page 13-18)
13-18)
- –Handlebar
Handlebar (hal. 13-19)
(page 13-19)
13-26
14. RODA BELAKANG/REM/SUSPENSI
LOK ASI KOMPONEN ................................ 14-2 REAR BR AKE PEDAL LOCK ARM .......... 14-17
COMPONENT LOCATION ··························14-2 REAR BRAKE PEDAL LOCK ARM ········· 14-17
KETERANGAN SERVIS ............................ 14-3 SWINGARM................................................ 14-18
SERVICE INFORMATION ···························14-3 SWINGARM ·············································· 14-18
TROUBLESHOOTING ............................... 14-5 SHOCK ABSORBER ................................. 14-22
TROUBLESHOOTING·································14-5 SHOCK ABSORBER ································ 14-22
RODA BELAKANG .................................... 14-6 BRAKE PEDAL .......................................... 14-23
REAR WHEEL ·············································14-6 BRAKE PEDAL ········································· 14-23
REM BELAKANG ....................................... 14-14
REAR BRAKE ···········································14-14
14
14-1
LOKASI KOMPONEN
REAR WHEEL/BRAKE/SUSPENSION
39 N·m (4,0 kgf·m; 29 lbf·ft)
59 N·m (6,0 kgf·m; 44 lbf·ft)
22 N·m (2,2 kgf·m; 16 lbf·ft)
24 N·m (2,4 kgf·ml; 18 lbf·ft)
14-2
KETERANGAN SERVIS
UMUM
PERINGATAN
yang baik.
• Bab ini meliputi servis dari rear wheel (roda belakang), rear brake (rem belakang), swingarm (lengan ayun), shock absorber
(peredam kejut) dan brake pedal (pedal rem).
• Brake drum atau shoe yang terkontaminasi mengurangi daya pengereman. Buanglah shoes yang terkontaminasi dan bersihkan
drum yang terkontaminasi dengan pembersih gemuk berkualitas tinggi untuk peralatan rem.
• Sewaktu menservis rear wheel dan suspensi, letakkan sepedamotor pada centerstand-nya.
• Pakailah baut dan mur pengganti yang asli Honda saja untuk semua engsel suspensi dan titik-titik pemasangan.
SPESIFIKASI
Satuan : mm
Tekanan udara Pengemudi saja 225 kPa (2,25 kgf/cm2; 33 psi) –
ban dingin Pengemudi dan pembonceng 280 kPa (2,80 kgf/cm2; 41 psi) –
roda Aksial – 2,0
Jarak wheel hub-ke-pelek roda 6,0 ± 1,0 –
Rantai roda Size – link RK 420SL – 102RJ –
DID 420AD – 102RB –
Kekenduran 30 – 40 –
Jarak main bebas pedal rem 20 – 30 –
Jarak main bebas rear brake pedal lock arm 1,0 – 2,0 –
TORSI
TORQUEPENGENCANGAN
VALUES
Mur
Rearporos
axle belakang
nut 5959N·m
N.m(6.0
(6,0 kgf.m;4444lbf·ft)
kgf·m, lbf.ft) U-nut Mur-U
Jari-jari belakang 3,2 N.m (0,33 kgf.m; 2,4 lbf.ft)
Driven sprocket nut 32 N·m (3.3 kgf·m, 24 lbf·ft) U-nut
Mur driven s procket 32 N.m (3,3 kgf.m; 24 lbf.ft) Mur-U
Driven flange stud bolt – See page 14-11
Baut stud driven flange - Lihat hal. 14-11
Rear brake stopper arm nut 22 N·m (2.2 kgf·m, 16 lbf·ft)
Mur rear brake stopper arm 22 N.m (2,2 kgf.m; 16 lbf.ft)
Rear
Mur brake
rear arm
brake nut
arm 1010N·m
N.m(1.0
(1,0kgf·m,
kgf.m;77lbf·ft)
lbf.ft) U-nut Mur-U
Shock
Mur pemasabsorber
anganupper
atas smounting nut
hock absorber 2424N·m
N.m(2.4
(2,4kgf·m,
kgf.m;1818lbf·ft)
lbf.ft)
Shock
Mur topiabsorber lowerbawah
pemasangan mounting capabsorber
s hock nut 2424N·m
N.m(2.4
(2,4kgf·m,
kgf.m;1818lbf·ft)
lbf.ft)
Swingarm pivot
Mur engsel swingarm nut 3939N·m
N.m(4.0
(4,0kgf·m,
kgf.m;2929lbf·ft)
lbf.ft)
Rearengsel
Baut brake rear
pedalbrake
lock pedal
arm pivot
lockbolt
arm 1212N·m
N.m(1.2
(1,2kgf·m,
kgf.m;9 9
lbf·ft)
lbf.ft)
14-3
TOOLS
Bearing driver attachment, 32×35 [in Bearing driver attachment, 37×40 [in Pilot, 12 [ in combination with 07749-
combination with 07749-0010000 ] combination with 07749-0010000 ] 0010000 ]
07746-0010100 07746-0010200 07746-0040200
Pilot, 17 [ in combination with 07749- Bearing remover shaft, 9×200L Remover head, 12
0010000 ] 07746-0050100 07746-0050300
07746-0040400
Driver handle, 15×135L

07749-0010000
14-4
TROUBLESHOOTING
Rear wheel wobbles
Roda belakang bergoyang
• Bent rim
•• Worn
Rim (pelek) bengkok
wheel bearings
• Wheel
• Faulty tirebearings (bantalan roda) aus
•• Improperly
Jari-jari roda longgaraxle
tightened ataufasteners
berubah bentuk
•• Faulty
Ban rusak
swingarm pivot bushings
•• Insufficient tire pressure
Pengikat poros tidak dikencangkan dengan baik
•
Soft suspension bushings tidak bekerja dengan baik
Swingarm pivot
•• Weak
Tekanan udara
shock ban terlalu
absorber rendah
springs
• Oil leakage
Suspensi lunak from damper unit
• Low tire pressure
• Shock absorber springs lemah
• Kebocoran
Stiff suspension oli dari damper unit
•• Bent shockudara
Tekanan absorber damper
ban terlalu rod
rendah
• Damaged swingarm pivot bushings
Suspensi kaku pivot
• Bent swingarm
•• High
Shocktireabsorber
pressuredamper rod bengkok
•• Damaged
Swingarmshockpivot bushings rusak
absorber bushings
• Swingarm pivot bengkok
Steers to one side or does not track straight
•• Bent
Tekanan udara ban terlalu tinggi
rear axle
•• Bent
Shock absorber bushings rusak
frame
• Damaged
Menarik ke satuswingarm pivot
sisi atau bushing
tidak dapat berjalan lurus
•• Axle
Rearalignment/chain adjustment
axle (poros belakang) not equal on both sides
bengkok
• Rangka
Poor brake bengkok
performance
•• Improper
Swingarm brake
pivotadjustment
bushing rusak
•• Worn brake axle/penyetelan
Penjajaran linings rantai tidak sama antara kedua sisi
• Contaminated brake linings
Unjuk
• Wornkerja
brakeremcambur uk
•
• Worn brake drumkurang baik
Penyetelan rem
•• Brake
Brakearm serrations
linings aus improperly engaged
•• Worn
Brakebrake shoes
linings at cam contact faces
terkontaminasi
• Brake c am aus
• Brake drum aus
• Gerigi brak e arm tidak mengait dengan baik
• Brake s hoes aus pada permukaan kontak c am
14-5
REAR WHEEL (RODA BELAKANG)
PELEPASAN
REMOVAL
Support the
Letakkan motorcyclepada
sepedamotor with centers
its centerstand.
tand-nya. [3]
Remove the
Lepaskan murbrake adjusting
penyetelan nut[1],
rem [1],spring
spring[2]
[2] dan
and joint
pin[3].
pin [3].
[1] [2]
Remove the
Lepaskan following:
sebagai berikut:
[2] [1]
- –Cotter pin [1]
Cotter pin [1] [3]
- –Mur [2][2]
Nut
- –Was her [3][3]
Washer
- –Rubber
Rubber washer
washer [4][4]
Lepaskan
Remove thebautbolt
[5] [5]
danand
bebaskan
release stopper arm [6]
the stopper armdari
[6]
brake
from panel.
the brake panel.
[4]
[5] [6]
Loosen the mur

Longgarkan axleporos
nut [1].
[1]. [6]
Loosen both drive chain adjuster [7] [1]/[5]
Longgarkan kedua mur pengunci drivelock
chainnuts [2] and
adjuster [2]
adjusters
dan [3]. [3].
adjusters
Push the
Dorong rear
rear wheelkeforward
wheel depanand
danrelease
lepaskanthedrive
drive chain
chain
[4]. roda) [4].
(rantai
Remove the
Lepaskan following:
sebagai berikut:
- –Mur
Rear axle
poros nut
belakang
- –Rear
Rearaxle
axle(poros
[5] belakang)
- –Adjuster
Adjuster plates
plates [6][6]
- –Rear
Rear wheel
wheel
- –Right
Right side
side collar
collar [7][7]
[4] [2] [3]

Lepaskan brake
Remove the panel
brake assembly
panel [1] [1]
assembly dari right
from thewheel
right
hub. [1]
wheel hub.
14-6
Remove the
Lepaskan sideside collar
c ollar darifrom the left side.
sisi kiri. [1]
INSPECTION
PEMERIKSAAN
AXLE
AXLE (POROS)
Set the rear axle in V-blocks.
Tempatkan rearaxle
Turn the rear axleand
pada V-blocks
measure . runout using a dial
the
Putar rear axle dan ukur keolengan dengan
indicator.
menggunakan
Actual runout dial indicator.
is 1/2 the total indicator reading.
Keolengan sebenarnya adalah ½ dari pembacaan total
indicator.
WHEEL
WHEELBEARING
BEARINGDAN
ANDDRIVEN
DRIVENFLANGE
FLANGEBEARING
BEARING
Putar inner
Turn the race
inner dari
race masing-mas
of each bearinging
withbearing dengan
your finger.
jari-jari.
The bearings should turn smoothly and quietly.
Also check
Bearings thatberputar
harus the bearing
denganouter racedan
halus fitstanpa
tightlysuara.
in the
wheelperiksa
Juga hub or bahwa
driven flange.
bearing outer race duduk dengan
erat pada wheel hub atau driven flange.
Replace the Replace the bearings if the inner race does not turn
Gantilah bearings
bearings smoothlybearings
in pairs. Gantilah and quietly, or if the
jika inner raceouter
tidakrace fit loosely
berputar dengan in
dalam pasangan. halus
the wheel
dan hub or driven
tanpa suara,flange.
atau jika outer race duduk
dengan longgar di dalam wheel hub atau driven flange.
WHEEL
WHEELRIM RIM(PELEK RODA)
Periksa keolengan
Check the rim runoutrimbydengan
placing menempatkan
the wheel in a wheel
truing
(roda)
stand.pada sebuah truing stand.
Putar
Spin wheel dengan
the wheel pelan,
slowly, anddanreadbac a keolengan
the dengan
runout using a dial
menggunakan
indicator. dial indicator.
Actual runout
Keolengan is 1/2 the adlaah
sebenarnya total indicator
½ dari reading.
pembacaan total
indiator.
SERVICE LIMITS:
BATAS SERVIS:
Radial: 2.0 mm (0.08 in)
Radial:
Axial: 2,0
2.0mmmm (0.08 in)
Aksial: 2,0 mm
14-7
DISASSEMBLY
PEMBONGK ARAN
Remove the
Lepaskan dustdust
sealseal
[1]. [1]. [2]
Loosen themur-mur
Longgarkan driven sprocket nuts [2]. [2].
driven sprocket
[1]
Remove the
Lepaskan driven
driven flange
flange [3] from
[3] dari the lefthub.
left wheel wheel hub.
[3]
Gantilah dampe
Replace r Lepaskan
the damper
Remove the rubbers
damper [1] dan
rubbers O-ring
[1] and [2] [2].
O-ring
rubbers sebagai [1]
damper rubbers as
sebuaha set.
set.
[2]
Remove the
Lepaskan nuts [1]
mur-mur [1]and
dandriven
driven sprocket
sprock et [2].
[2]. [1]
[2]
14-8
PENGGANTIAN WHEEL
WHEEL BEARING BEARING
REPLACEMENT
Replace the wheel
Gantilah wheel Install
Pas ang the bearing
bearing remover
remov er headhead
ke into the wheel
dalam wheel bearing
bearing
bearings
bearingsindalam
pairs. [1].
[1]. [2] [3]
Do notpasangan.
reuse the From
Dari sisiopposite sidepasang
berlawanan install bearing
the bearing remover
remover shaftshaft
dan
Jangan memakai
old bearings. and drive
dorong the bearing
bearing out wheel
keluar dari of the wheel
hub. hub.
ke mbali bearings Remove the
Keluarkan distance
distance collar
collar dan and drivekeluar
dorong out the other
bearing
lama. bearing.
yang lain.
TOOLS:
TOOLS:
[2]Bearing
[2] Bearing remover
remover head,12
head, m m 07746-0050300
07746-0050300
12 mm
[1]
[1]
[3] [2]
Isilah
Packsemua rongga-rongga
all bearing [1] cavities bearing [1] dengan gemuk.
with grease.
[3] [2]
Dorong
Drive inmasuk
a newbearing kanan squarely
right bearing baru secara
with tegaklurus
its sealed
dengan sisinya
side facing yang
up until it is tertutup menghadap ke atas
fully seated.
sampai ia telah duduk sepenuhnya.
TOOLS:
TOOLS:
[2] Driver 07749-0010000
[2]
[3]Driver
Attachment, 37 x 40 mm 07749-0010000
07746-0010200
[3]
[4]Attachment,
Pilot, 12 mm37 x 40 mm 07746-0010200
07746-0040200
[4] Pilot, 12 mm 07746-0040200
[1] [4]
Apply
Pas ang thin coat collar
distance of grease
[1]. to the distance collar [1] and
install it.
Dorong mas uk bearing kiri baru [2] secara tegaklurus
Drive insisinya
dengan a newyang
left tertutup
bearing [2] squarely ke
menghadap with its sealed
atas. [1]
side facing up. [2]
TOOLS:
TOOLS:
Driver 07749-0010000
Driver
Attachment, 32 x 35 mm 07749-0010000
07746-0010100
Pilot, 12 mm 32 x 35 mm
Attachment, 07746-0040200
07746-0010100
Pilot, 12 mm 07746-0040200
14-9
PENGGANTIAN
DRIVEN FLANGEDRIVEN FLANGE
BEARING BEARING
REPLACEMENT
Remove the
Lepaskan driven
driven flange
flange collar
collar [1]. [1].
[1]
Drive out
Dorong the driven flange bearing [1].
keluar
[1]
IsiPack all bearing

semua rongga [1] cavities
bearing [1] with grease.
dengan gemuk.
[2]
Install
Pas ang adriven
new driven
flange flange
bearingbearing squarely
baru secara with its
tegaklurus
sealed sisinya
dengan side facing
yangup.
tertutup menghadap ke atas.
TOOLS:
TOOLS:
[2]Driver
[2] Driver 07749-0010000
07749-0010000
[3]Attachment,
[3] Attachment,37
37xx40
40mm
mm 07746-0010200
07746-0010200
[4]Pilot,
[4] Pilot,17
17mm
mm 07746-0040400
07746-0040400
[1] [3]/[4]
Pas ang the

Install driven flange
driven collar
flange [1] [1]
collar ke into
dalam
the driven
driven flange
flange
bearing
bearing[2].
[2]. [2]
[1]
14-10
PERAKITAN
RIGHT WHEEL BEARING (6301U)
O-RING
DAMPER RUBBER
DISTANCE COLLAR
DUST SEAL
DRIVEN FLANGE
DRIVEN
SPROCKET (38T)
DRIVEN FLANGE
COLLAR
LEFT WHEEL BEARING (6201U)
DRIVEN FLANGE BEARING (6203U) 32 N·m (3,3 kgf·m; 24 lbf·ft)
DRIVEN
DRIVENFLANGEFLANGESTUDSTUDBOLTBOLT
Oleskan cairan agent
Apply locking pengunci
to thepada ulirflange
driven baut stud
stud bolt
driven
[1]
flange [1] ifjika
threads thebaut-baut
stud boltsstud
are dilepaskan.
removed. 12,7 ± 0,5 mm
Pas ang and
Install dantighten
kenc angkan bautflange
the driven s tud stud
driven
bolt flange
to the
dengan torsi
torque.
TORSI: 20 N.m
TORQUE: (2,0(2.0
20 N·m kgf.m; 15 15
kgf·m, lbf.ft)
lbf·ft)
Setelah memasang
After installing baut-baut
the stud stud,
bolts, check thatperiksa bahwa
the height from
ketinggian dari to
the bolt head kepala baut sampai
the driven ke permukaan
flange surface is within
driven flange adalah sesuai dengan s pesifikasi.
specification.
[1]
PER AKITAN
ASSEMBLY
Install
Pas ang the damper
damper rubbers
rubbers [1] dalam
[1] ke into thewheel
wheelhub.
hub.
[1]
Apply grease to a new O-ring [2] and
Berikan gemuk pada O-ring baru [2] dan pasanginstall it into the
ke
groove of the wheel hub.
dalam alur dari wheel hub.
[2]
14-11
Pas ang the
Install driven flange
driven pada
flange to wheel hub.hub.
the wheel
[2]
Install
Pas ang the driven
driven sprocket
sprocket [1] and
[1] dan nuts [2].
mur-mur [2]. [3]
Tighten the mur-mur
Kencangkan nuts to the specified
dengan torsitorque.
yang ditentukan.
TORQUE:
TORSI: 32 32
N.mN·m
(3,3(3.3 kgf·m,
lbf.ft)
Berikan gemuktopada
Apply grease bibir-bibir
a new dust sealdust
[3] lips baru
sealand [3] dan
install it to
pasang pada
the driven driven
flange untilflange s ampai
it is flush ia driven
with the rata dengan
flange
permukaan ujung driven flange.
end surface.
[1]
PEMASANGAN
INSTALLATION
Pas ang the
Install s ideside
collar [1] ke
collar [1] dalam
into thedriv en flange.
driven flange.
[1][1]
Jagalah
Do notagar gemuk Pas
get grease ang the
Install brake panel
brake assembly
panel [1] ke
assembly [1] dalam
into thewheel
wheelhub.
hub.
tidak mengenai [1]
on the brake brake
drum
drum ataupower
or stopping daya
pengereman akan
will be reduced.
berkurang.
Place therear
Letakkan rearwheel
wheeldibetween the swingarm.
dalam swingarm. [2]/[5]
[3] [4]
Install
Pas ang the drive
drive chain
c hain [1] [1] overdriv
di atas theendriven sprocket.
sprocket.
Apply grease
Berikan gemukto the permukaan
pada rear axle [2]rear
surface.
axle [2].
Install
s ebagai berikut:
- –Left adjuster
Left adjuster plate
plate
- –Rear
Rear axle
axle
- –Right
Rightside collar
side [3][3]
collar
- –Right
Rightadjuster
adjusterplate [4][4]
plate
- –Mur rearaxle
Rear axlenut
[5] [5]
[1] [2] [3]
14-12
Pas ang the
Install stopper armarm
stopper [1] ke
[1]brake
to thepanel
brakedengan
panel baut [2],
with bolt
[5] [6]
[2], rubber
rubber washer
was her [3], washer
[3], washer [4]mur
[4] dan and [5].
nut [5].
[4]
Tighten the mur
Kencangkan nut to the specified
dengan torque.
TORQUE:
TORSI: 22 N·m
22 N.m (2,2(2.2 kgf·m,
lbf.ft)
Pakailah
Install a cotter pin baru
new cotter pin [6].
[3]
[2] [1]
Pas ang the

Install joint pin
joint pin[1]
[1] ke
intodalam brake
the brake arm,arm,
thenkemudian
install the
[1]
pasang
spring spring [2], rod
[2], brake brake
androd dan murnut
adjusting penyetelan
[3]. [3].
Adjust
Setel the drive chain
kekenduran drive slack
chain (page 4-11).
(hal. 4-11).
Adjust
Setel themain
jarak brakebebas
pedalpedal
freeplay
rem(page 4-15).
(hal. 4-16).
Pas ang c hain case (hal. 3-18).
[3] [2]
REAR BRAKE (REM BELAKANG)

Lepaskan rearrear
Remove the wheel (hal.(page
wheel 14-6).14-6).
PEMERIKSAAN
INSPECTION
Measure
Ukur the rear
D.D. rear brake
brake drum I.D.
drum.
BATAS SERVIS:
111.0 mm
mm (4.37 in)
Pas ang the
Install rearrear
wheel (hal.
wheel 14-12).
(page 14-12).
DISASSEMBLY
PEMBONGK ARAN
Remove the
Lepaskan brake
brake shoes
shoes [1] and
[1] dan springs
springs [2]. [2]. [2]
• • Selalu
Alwaysganti brakthe
replace e shoes
brakesebagai
shoes assebuah
a set. set.
• • Jika
Whenbrake
the brake dipakai
shoesshoes arekembali,
reused, tandai
mark allsemua
parts
beforesebelum
parts disassembly so they can be
pembongkaran installedmereka
sehingga in their
original
dapat locations.
dipas ang pada lokasi mereka semula.
[1]
14-13
Remove the
Lepaskan murnut
[1],[1],
bautbolt
[2][2]
danand brake
brak arm
e arm [3].[3].
[1]
Remove the
Lepaskan indicator
indicator plate
plate [4] [4].
[3]
[4] [2]
Lepaskan felt felt
Remove the sealseal
[1] [1]
danand
brake
brakecamcam[2][2]
dari brake
from the
panel. [2]
brake panel.
Periksa keadaan dari felt seal, gantilah bila perlu.
Check the condition of the felt seal, replace it if
necessary.
[1]
PERAKITAN
BRAKE ARM BOLT *1: Berikan 0.2 – 0.3 g gemuk

*2: Gear oil
INDICATOR PLATE
FELT SEAL *2
*1
BRAKE CAM
NUT
10 N·m (1,0 kgf·m; 7 lbf·ft)
*1
ANCHOR PIN
BRAKE SHOES
SPRINGS
BRAKE PANEL
14-14
Berikan 0,2 –– 0.3
Apply 0.2 0,3 g gemuk
of greasepada
to brake panel
the brake anchor
panel pin
anchor
[1]. [1]
pin [1].
Apply 0.2
Berikan 0,2– –
0.30,3
g ofggrease
gemuktopada
the brake cam [2] luncur
permukaan sliding
brake camand
surface [2] brake
dan daerah
shoes kontak
contactbrake
area. shoes.
Install
Pas ang the brake
brake camcam into thebrak
ke dalam brake panel.
e panel.
[2]
Apply gear gear

Semprotkan oil to oil
theke
feltfelt
seal [1] [1]
seal anddan
install it onto
pasang the
pada
[1]
brakepanel.
brake panel.
Install
Pas ang the indicator
indicator plate[1][1]pada
plate on thebrake
brakeccam aligning
am dengan
[1]
its wide toothgigi
mentepatkan withyang
the wide
lebar groove on the
dengan alurbrake
lebarcam.
pada
brake cam.
Tepatkan
Pas ang the

Install brakbrake
e armarm
[1] dengan mentepatkan
[1] aligning the punch tanda-tanda
marks of the
titik pada brake [2] Tepatkan
brake arm andarm dan
brake brake cam.
cam.
Install
Pas ang the
bautbrake
brakearmarmbolt
[2] [2]
danand
murnut [3].
[3].
Tighten the mur
Kencangkan nut to the specified
dengan torque.
torsi yang ditentukan. [1]
TORQUE:
TORSI: 10 N·m
10 N.m (1,0(1.0 kgf·m,
kgf.m; 7 lbf·ft)
7 lbf.ft)
[3]
14-15
Jikabrake
If the shoe s Pas
brakeshoes angthe
Install brake shoes
brake [1] [1]
shoes danand
springs [2].[2].
springs
dipakai kembalil, [2]
are reused, the
shoesand Install the rear wheel (page 14-12).
springs Pas ang rear wheel (hal. 14-12).
dan springs
shoes
harus
must ditempatkan
be placed
kembali pada lok asi
back in their original
mere ka semula.
locations.
[1]
REAR BRAKE PEDAL LOCK ARM

Remove the
Lepaskan swingarm
swingarm (hal.(page 14-17).
14-18).
Release the
Lepaskan rearrear brake
brak pedal
e pedal lockcable
lock cableclip
clip[1]
[1] dari
fromrear
the
rear brake
brake pedal pedal lock[2]
lock arm arm [2] asdiperlihatkan.
seperti shown.
[2] [1]
Remove the
Lepaskan following:
- –Pivot bolt [1]
Pivot bolt [1]
- –Rear
Rearbrake
brakepedal lock
pedal arm
lock [2][2]
arm
- –Collar [3][3]
Collar
Berikan
Apply the Pemasangan
gemuktopada
grease Installation is inadalah dalam
of removal. dari
pivot baut
bolt engsel dan pelepasan.
and collar
daerah luncur ollar. TORQUE:
slidingc area.
TORSI:
REAR BRAKE 12 N·m (1.2 kgf·m, 9 lbf·ft)
BAUT ENGSEL
PEDAL LOCK
REAR
ARMBRAKE
PIVOT BOLT
PEDAL LOCK ARM 12 N.m (1,2 kgf.m; 9 lbf.ft)
[3] [1]
14-16
SWINGARM (LENGAN AYUN)
PELEPASAN
REMOVAL
Support sepedamotor
Letakkan the motorcyclepada
its centerstand. [1]
Remove the
Lepaskan following:
sebagai berikut:
- –Passenger
Drive chain coverholders
footpeg (hal. 3-18)
(page 3-18)
- –Rear wheel (hal.
Passenger 14-6)holders (page 3-18)
footpeg
– Rear wheel
Hati-hati agar tidak Lepaskan kaitan(page 14-6) light switc h spring [1] dari
dari brake
membengkokkan pedal rem [2].
Be careful
ujung springnot to Unhook the brake light switch spring [1] from the brake
lebih
bendyang
dari spring end pedal [2].
the diperlukan.
more than
necessary.
[2]
Lepaskan kaitan
Unhook the dari pedal
brake brake pedal
return return
springspring [1] dari
[1] from the
[1]
swingarm.
swingarm.
Lepaskan
Remove the mur-mur topi absorber
rear shock pemas angan
lower bawah s hock
mounting cap
nuts [1] and
absorber washers
belakang [2]. washers [2].
[1] dan
[3]
Release both
Lepaskan shock
kedua absorber
tempat [3] lower mounts
pemasangan bawahfrom the
s hock
swingarm
absorber [3]studs.
dari swingarm studs.
[1]/[2]
Remove the
Lepaskan following:
sebagai berikut:
[1] [2]
- –Mur engsel
Pivot nut [1]
[1]
- –Baut engsel
Pivot [2]
bolt [2]
- –Swingarm
Swingarm[3][3]
[3]
14-17
DISASSEMBLY/INSPECTION
PEMBONGK ARAN/PEMER IKSAAN
Check the
Periksa drive
drive chain
chain slider[1]
s lider [1] terhadap
for wear or damage.atau
keausan [4]/[5]
kerusakan.
Release the drive chain slider bosses[2] from the holes
Lepaskan
[3] on the slots [2] dari chain slider dari hooks [3] dari
swingarm. [2]/[3]
swingarm.
Remove the drive chain slider by releasing the slots [4]
Lepaskan drive [5]
from the hooks chain slider
on the dengan melepaskan slots
swingarm.
[4] dari chain case guides [5].
[1]
Remove the
Lepaskan following:
- –Cotter
Cotterpinpin
[1][1]
- –Mur [2][2]
Nut
- –Was her [3][3]
Washer
- –Spring
Spring washer
washer[4] [4]
- –Baut
Bolt[5][5]
- –Stopper
Stopper arm [6] [6]
arm
[1]
[2]/[3]/[4]/[5]
Periksa pivot
Check the pivotbushings
bushings [1] terhadap
[1] for keausan atau
wear or damage.
kerusakan.
Check the swingarm for cracks or damage.
Periksa swingarm terhadap retak-retak atau kerusakan.
[1]
ASSEMBLY
PERAK ITAN
Pasang stopper arm Install
s ebagai berikut:
dengan sisinya yang [1] Sisi datar
Install the stopper - –Stopper arm
Stopper arm [1][1]
datar menghadap ke - –Baut
arm with its flat
dalam side
seperti Bolt[2][2]
facing inside as
diperlihatkan. - –Spring
Spring washer
washer[3] [3] sisi dalam
shown. - –Was her [4][4]
Washer
- –Mur [5][5]
Nut [3]
[4]
Kencangkan mur
Tighten the nut dengan
to the specifiedtors i yang
torque ditentukan
while holding the
sementara
bolt. menahan baut.
TORSI: 22 N.m
TORQUE: (2,2(2.2
22 N·m kgf.m; 16 16
kgf·m, lbf.ft)
lbf·ft)
Pas ang ac otter
Install pin baru
new cotter pin[6].
[6].
[6] [2]/[3]/[4]/[5] [5] [2]
14-18
Pas ang the
Install drive c hain
drive slider
chain [1] dengan
slider mentepatkan
[1] to the slots
swingarm while [1]
aligning
pada its slots with
sisi belakanag the hooks
dengan chainand its guide.
case bosses with the Tepatkan
holes.
Pas ang slots pada sisi depan dengan hooks pada
Install the front side slots to the hooks on the swingarm.
swingarm.
Tepatkan
INSTALLATION
PEMASANGAN
Route the
Alurkan drivdrive chaindan
e chain andpasang
install the swingarm
swingarm keinto the
dalam [1]
frame.
rangka.
Insert
Pas angthe
bautpivot bolt [1]
engsel [1] dari
fromsisi
thekiri.
left side.
Install
Pas angthemurpivot nut [1]
engsel [1]topada
the pivot
bautbolt and temporarily
engsel dan untuk
tighten it. kencangkan.
sementara
[1]
Hook thetempat
Kaitkan rear shock absorber [1]
pemasangan lower shock
bawah mountsabsorber
onto the
swingarm[1]
belakang studs,
padathen install the
swingarm washers
s tuds, [2] and
kemudian lower
pasang [1]
mounting
washers [2]cap
dannuts [3]. topi pemasangan bawah [3].
mur-mur
Temporarily
Untuk tighten the
sementara rear shock mur-mur
kencangkan absorber lower
topi
mounting capbawah
pemasangan nuts. shock absorber belakang.
[2]/[3]
14-19
Hook the
Kaitkan brake
brake pedalreturn
pedal returnspring
spring [1]
[1] to the swingarm
pada swingarm
[1]
as shown.
BRAKE ROD
HOLE SIDE
SWINGARM
SLOT SIDE
Hati-hati agarnot
Be careful Hook the
to Kaitkan
tidak brake
brake lightswitch
light switchspring
spring[1]
[1] pada
to the brake
brake pedal
bendmembengkokkan
the spring end [2][2]dengan
securely as shown.
aman seperti diperlihatkan.
ujung spring [1]
more lebih
than
dari yang necessary.
diperlukan.
[2]
Pas angthe
Install rearrear
wheel (hal.
wheel 14-12).
(page 14-12).
Retract
Tarik the centerstand
centerstand carefully
dengan hati-hati ke and
atas, support the
dan dukung
motorcycle securely,
sepedamotor then tighten
dengan kokoh, kemudianthekenc
swingarm
angkanpivot
mur
nut [1]swingarm
engsel to the specified torque.
TORQUE:
TORSI: 39 39
N.mN·m
(4,0(4.0 kgf·m,
kgf.m, 29 29 lbf·ft)
lbf.ft)
[1]
14-20
Support thesepedamotor
Topanglah motorcycle securely,
denganthen tightenkemudian
kokoh, the both [1]
rear shock absorber
kencangkan kedua mur lower
topimounting cap nuts
pemasangan bawah[1] stohock
the
specifiedbelakang
absorber torque. [1] dengan torsi yang ditentukan.
TORSI: 24 24
TORQUE: N.mN·m
(2,4(2.4
kgf.m; 18 18
kgf·m, lbf.ft)
lbf·ft)
Letakkan
Support sepedamotor
the motorcyclepada
its centerstand.
Pas ang the
Install passenger footpeg
passenger holders
footpeg (hal.(page
holders 3-18).
3-18).
SHOCK ABSORBER
REMOVAL
PELEPASAN
Support sepedamotor
Letakkan the motorcyclepada
its centerstand. SISI KIRI DIPERLIHATKAN: [1]/[2]
Remove the
Lepaskan body
body cover
cover (hal.(page
3-13).3-13).
Remove the
Lepaskan murshock absorber upper
pemasangan atas mounting nut [1] and
shock absorber [1]
twodua
dan washers [2]. [2].
washers
Remove the
Lepaskan murshock absorber lower
topi pemasangan mounting
bawah shockcap nut [3]
absorber
and washer [4], then remove the shock absorber
[3] dan washer [4], dan lepaskan shock absorber [5].
[5].
[5] [3]/[4]
PEMERIKSAAN
INSPECTION
Visually inspect
Do not disassemble Periksalah shoc k the shock secara
absorber absorber for terhadap
visual wear or [1]
the shock absorber. keausan
damage.atau kerusakan.
Replace the shock
Check the following:
absorbers as a set. Periksa sebagai berikut:
-–Perubahan bentuk
Deformation atau
or oil kebocoran oli
leakage
-–Bushings [1] terhadap keausan atau kerusakan
Bushings [1] for wear or damage
- Damper rod [2] terhadap kebengkokan atau kerusakan
Check the smooth damper operation.
Periksa kehalusan kerjanya damper.
14-21
PEMASANGAN
INSTALLATION
Install
Pas angthe shock
shock absorber
absorber [1][1]dan
anddua
twowashers
washers[2]
[2] pada
onto SISI KIRI DIPERLIHATKAN:
the frame.
rangka.
Pas ang and
Install dantighten
kencangkan murmounting
the upper pemas angan
nut [3]atas [3]
to the [2]
dengan torsi
torque.
TORSI:
TORQUE: 24 24
N.m (2,4
N·m kgf.m;
(2.4 1818
kgf·m, lbf.ft)
lbf·ft)
Pas angthe
Install washer
washer [4][4]dan
andmur
lowertopi pemasangan
mounting cap nutbawah
[5].
[5].
Tighten the lower mounting cap nut to the specified
Kencangkan
torque. mur topi pemasangan bawah dengan torsi
yang ditentukan.
Install the body cover (page 3-13).
Pas ang body cover (hal. 3-13).
[1]
[3]
[4]/[5]
BRAKE PEDAL
PELEPASAN
REMOVAL
Lepaskan
following:
- Chain case (hal. 3-18) [4]
– Passenger footpeg holder (page 3-18)
Letakkan sepedamotor pada sidestand.
Support the motorcycle with its sidestand.
Lepaskan mur penyetel brake pedal [1], brake rod [2],
Remove the brake pedal adjusting nut [1], brake rod [2],
spring
spring[3]
[3]dan
andjoint
jointpin
pin[4]
[4]dari
frombrake arm. arm.
the brake
[2]
[3]
[1]
Jangan not to Lepaskan

membongkar
Be careful Unhook the kaitan brake
brake lightlight switch
switch spring
spring [1] dari
[1] from brake
the brake [1]
shock absorber.
bend the spring end pedal
pedal[2].
[2].
Gantilah shock
more
absorbers than
sebagai
necessary.
sebuah set.
[2]
14-22
Lepaskan
Remove brake pedal
the brake return
pedal spring
return [1]. [1].
spring
[1]
Lepaskan
Remove the centerstand spring
centerstand [1][1]dan
spring andspring
spring retainer
retainer
plate [2]
plate[2][2].
[1]
Lepaskan
Remove cotter pin [1].
the cotter pin [1]. [1] [3]
Remove centerstand
Lepaskan the centerstand [2] brake
[2] dan and brake
pedalpedal [3] by
[3] dengan
menarik
pulling keluar
out thecenterstand
centerstandpivot
pivot[4].
[4].
[2]
[4]
Lepaskan
Remove cotter pin [1],
the cotter washer
pin [1], [2], [2],
washer danand
pisahkan brake
separate the
[2] [1] [3]
brake
rod rod brake
[3] dari [3] from the brake
pedal [4]. pedal [4].
[4]
14-23
Lepaskan duatwo
Remove the bautbolts
[1]. [1].
Remove the main stand hook stay [2], spring retainer [2]/[4]
Lepaskan main stand hook stay [2], spring retainer plate
plate [3] and bush [4].
[3] dan bush [4]
[1]
[3]
PEMASANGAN
INSTALLATION
Install
Pas ang the spring
spring retainer
retainer plate
plate [3],bush
[3], bush[4],
[4],main
main stand
stand [4] [2]
hookstay
hook stay[2]
[2]dan
andkencangkan
tightend thekedua
two bolts [1][1]
baut ondithe frame
Rangka [1]
[5]seperti
[5] as shown.
di perlihatkan.
[4]
[5]
[3]
Connect the
Hubungkan brake
brake rodrod
[1][1]
ketobrake
the brake
pedal pedal [2], then
[2], kemudian
[3] [4] [1]
install the
pasang washer
washer [3] and
[3] dan a new
c otter cotter[4].
pin baru pin [4].
[2]
Apply grease
Berikan gemuk topadathepermukaan
centerstandluncur
pivot centerstand
[1] sliding
[1]
surface.
pivot [1].
Install
Pas the brake
ang brake pedal
pedal [2], [2], centerstand
centerstand [3] and
[3] dan centerstand
centerstand
pivot pivot to the frame.
ke rangka.
[3] [2]
14-24
Masukkan
Insert the centers tand pivot
centerstand pivot [1]
[1] sementara mentepatkan
while aligning its cut-out [1]
potongan padanya dengan stopper dari rangka.
with the frame.
Secure the
Amankan centerstand
centerstand pivot
pivot with acotter
dengan new cotter pin [2].
pin baru [2].
Tepatkan
[2]
Pas angthe
Install spring retainerspring
centerstand plate [1]
[1] indengan mentepatkan
the shown direction. sisi pendek
lubang dengan boss pada rangka.
Long side [1]
Hook the
Kaitkan brakepedal
brake pedalreturn
return spring
spring [1] in the shown
sesuai arah
direction.
penunjuk.
[1]
SWINGARM BRAKE ROD

SLOT SIDE HOLE SIDE
14-25
Hati-hati agarnot
Be careful tidak Hook the
to Kaitkan brakelight
brake lightswitch
switchspring
spring [1]
[1] dengan
to the brake pedal
kokoh ke
bendmembengkokkan [2] securely
the spring end brake asseperti
shown.diperlihatkan. [1]
pedal [2]
ujung spring
more lebih
than
dari yang necessary.
diperlukan.
[2]
Install
Pas angthe jointpin
joint pin[1]
[1] ke
intodalam
the brake arm,arm,
brake thenkinstall
emudianthe
[1]
spring [2],
pasang brake
spring [2],rod [3] rod
brake and[3]
adjusting
dan murnut [4].
penyetel [4].
Install
sebagai berikut:
- –Exhaust
Exhaustpipe/muffler (hal.
pipe/muffler 3-20)
(page 3-20)
- –Chain c ase
Chain case(hal. 3-18)
(page 3-18)
Setel jarak
Adjust the main
brakebebas
pedalbrake pedal
freeplay (hal.
(page 4-15).
4-15).
[3]
[2]
[4]
14-26
15. REM HIDRAULIK
COMPONENT
LOK LOCATION
ASI KOMPONEN ··························15-2
.................................. 15-2 BRAKEPAD/DISC
BRAKE PAD/DISC.....................................
······································ 15-7
15-7

···························15-3 MASTER
MASTER CYLINDER
CYLINDER................................. 15-9
·································· 15-9
TROUBLESHOOTING ................................. 15-4 BRAKE C ALIPER ...................................... 15-12

TROUBLESHOOTING·································15-4 BRAKE CALIPER ····································· 15-12
PENGGANTIAN BRAKE FLUID/
BRAKE
AIR FLUID REPLACEMENT/
BLEEDING ............................................ 15-5
AIR BLEEDING ···········································15-5
15
15-1
REM HIDRAULIK
LOKASI KOMPONEN
HYDRAULIC BRAKE
34 N·m (3,5 kgf·m; 25 lbf·ft)
30 N·m (3,1 kgf·m; 22 lbf·ft)
34 N·m (3,5 kgf·m; 25 lbf·ft)
15-2
REM HIDRAULIK
KETERANGAN SERVIS
UMUM
PERINGATAN
yang baik.
Spilled brake
Brake fluid fluid will
(minyak severely
rem) yang damage
tertumpah instrument lenses and kerusakan
akan menimbulkan painted surfaces. It is also
par ah pada harmful
lensa to some
instrumen danrubber parts. yang
permukaan Be careful
dicat.
whenever you remove
Ia juga merusak the reservoir
beberapa cap; Hati-hati
parts karet. make sure the frontanda
sewaktu reservoir is horizontal
melepaskan first. cap, pastikan bahwa front r eservoir pada
reservoir
posisi ho risontal dulu.
• A contaminated brake disc or pad reduces stopping power. Discard contaminated pads and clean a contaminated disc with a
high quality brake
• Brake disc atau pad degreasing agent. nasi mengurangi daya pengereman. Buanglah pads yang terkontami nasi dan bersihkan
yang terkontami
• Check the brake system by applying the brake lever after the air bleeding.
disc yang terkontaminasi dengan pembersih gemuk berkualitas ti nggi untuk pera latan rem.
• Never allow contaminants (dirt, water, etc.) to get into an open reservoir.
• • Once
Peri ksa
the sistem remsystem
hydraulic dengan menarik
has brake lever
been opened, or if(handel
the brake rem) setelah
feels air the
spongy, bleeding
system (membuang uda ra palsu).
must be bled.
• Jagalah agar bahan-bahan pengotor (kotoran, air, dsb.) tidak memasuki reservoir yang terbuka.
• Always use fresh DOT 3 or DOT 4 brake fluid from a sealed container when servicing the system. Do not mix different types of
• fluid,
Sekali sistem
they may hidraulik telah dibuka, atau jika rem terasa seperti sepons, si stem har us di air bleed.
not be compatible.
• • Always
Sel alu check
pakai the
DOT 3 atau
brake DOT 4before
operation brakeriding (minyak
fluid the rem) dari kemasan yang belum per nah dibuka sebelumnya sewaktu
motorcycle.
menservis sistem. Jangan mencampurkan bermacam-macam merek fluid, mereka tidak cocok satu sama lain.
• Sel alu periksa cara kerja rem sebelum mengendarai sepedamotor.
SPESIFIKASI
Satuan: mm
Minyak rem yang ditentukan DOT 3 or 4 –
Brake disc Tebal 3,3 – 3,7 3,0
Master cylinder D.D. cylinder 11,000 – 11,043 11,055
D.L. piston 10,957 – 10,984 10,945
Caliper D.D. cylinder 33,96 – 34,01 34,02
D.L. piston 33,878 – 33,928 33,87
TORSI PENGENCANGAN
TORQUE VALUES
Brake caliper bleed va lve 5,4 N.m (0,55 kgf.m; 4,0 l bf.ft)
Brake caliper
Sekrup bleed valve
brake master cyli nder reservoir cap 5.4 N·m
1,5 (0.55 kgf·m,kgf.m;
N.m (0,15 4.0 lbf·ft)
1,1 l bf.ft)
Brake
Brakepad pin cylinder reservoir cap screw
master 17 N.m
1.5 N·m (0.15(1,7 kgf.m;
kgf·m, 1.1 13 l bf.ft)
lbf·ft)
Baut
Brake engsel front brake lever
pad pin 1 N.m
17 N·m (1.7 (0,10
kgf·m,kgf.m; 0,7 lbf.ft)
13 lbf·ft)
Mur
Frontengsel
brakefront
leverbrake
pivotlever
bolt 1 N·m5,9 N.mkgf·m,
(0.10 (0,60 0.7
kgf.m; 4,4 l bf.ft)
lbf·ft)
Sekrup front brake
Front brake light nut
lever pivot switch 1,2 (0.60
5.9 N·m N.m (0,12
kgf·m,kgf.m; 0,9 l bf.ft)
4.4 lbf·ft)
Brake hose oil bolt
Front brake light switch screw 34 N.m (3,5 kgf.m; 25
1.2 N·m (0.12 kgf·m, 0.9 lbf·ft) l bf.ft)
Baut
Brake pemasangan
hose oil boltbrake caliper 34 N·m (3.5 kgf·m, 25 lbf·ft) bf.ft)
30 N.m (3,1 kgf.m; 22 l Baut ALOC; ganti dengan yang baru
Brake
Brakecaliper
calipertorque
mountingpin bolt 22 (3.1
30 N·m N.mkgf·m,
(2,2 kgf.m; 16 l bf.ft)
22 lbf·ft) ALOC bolt; replace with a new one
Brake caliper pin 17 N.m (1,7 kgf.m; 13 l bf.ft)
Brake caliper torque pin 22 N·m (2.2 kgf·m, 16 lbf·ft)
Baut penjepit brake hose 12 N.m (1,2 kgf.m; 9 l bf.ft) Baut ALOC; ganti dengan yang baru
Brake caliper pin 17 N·m (1.7 kgf·m, 13 lbf·ft)
Brake hose clamp bolt 12 N·m (1.2 kgf·m, 9 lbf·ft) ALOC bolt; replace with a new one
15-3
REM HIDRAULIK
TOOL
Snap ring pliers
07914-SA50001
TROUBLESHOOTING
Brake lever
Brake lever terasa
soft or lunak
spongy atau seperti sepons
•• AirAda
in the hydraulic
udara system
di dalam sistem hidraulik
• Leaking hydraulic system
• Ada kebocoran pada sistem hidraulik
• Worn caliper piston seal
• Caliper piston seal aus.
• Worn brake pad/disc
•• Caliper
Brakenotpad/disc
slidingaus.
properly
•• Worn
Caliper tidakcylinder
master meluncur dengan
piston cupsbenar
•• LowMaster
brakecylinder piston cups aus
fluid level
•• Clogged
Tinggi permukaan brake fluid terlalu rendah
brake fluid passage
•• Contaminated
Jalan lintaranbrakebrakepad/disc
fluid tersumbat
•• Contaminated
Brake pad/disc caliper
terkontaminasi
•• Contaminated master cylinder
Caliper terkontaminasi
•• Warped/deformed brake disc i
Master cylinder terkontaminas
• Sticking/worn caliper piston
• Brake disc berubah bentuk melengkung
• Sticking/worn master piston
• Caliper piston macet/aus
• Bent brake lever
• Master piston macet/aus
Brake
• Brakeleverlev
harder bengkok
• Sticking/worn caliper piston
Brake levernot
• Caliper keras
sliding properly
•• Clogged/restricted
Caliper piston macet/aus
brake fluid passage
•• Sticking/worn
Caliper tidakmaster piston
meluncur dengan benar
•• Bent brake
Jalan lever brake fluid tersumbat/terhambat
lintasan
• Master
Brake drag piston macet/aus
•• Contaminated
Brake lev er bengkok
brake disc/pad
• Warped/deformed
Tahanan pada rem brake disc
• Caliper not sliding properly
• Brake disc/pad terkontaminasi
• Sticking caliper piston
• Brake disc berubah
• Sticking/worn bentuk melengkung
master piston
•• Clogged/restricted
Caliper tidak meluncurbrake dengan benar
hose joint
• Caliper piston macet
• Master piston macet/aus
• Brake hose joint tersumbat/terhambat
15-4
REM HIDRAULIK
BRAKE FLUID REPLACEMENT/AIR
PENGGANTIAN BRAKE FLUID/
BLEEDING
AIR BLEEDING (MEMBUANG UDARA PALSU)
Spilledrem
Minyak fluidyang
can tertumpah
damage painted, plastic, parts
dapat merusak or rubber
yang
parts.terbuat
dicat, Place dari
a rag overatau
plastik these parts
karet. whenever
Letakkan the
kain lap
system isparts
menutupi serviced.
ini setiap kali sis tem diserv is.
•• Jagalah
Do not allow
agar foreign material
benda-benda to enter
as ing tidak the system
memasuki
when filling
sistem the reservoir.
sewaktu mengisi reservoir.
• When using a commercially available brake bleeder,
• Jika memakai alat brak e bleeder yang dapat dibeli
follow the manufacturer’s operating instructions.
di pasaran, ikuti petunjuk pemakaian pabrik
BRAKE FLUID DRAINING
pembuatnya.
Remove the ARKAN
MENGELU handlebar BRAKE
top cover (page
FLUID3-4).
Turn the handlebar
Lepaskan handlebar top
to the left (hal.
cover until 3-4).
the reservoir is level
before removing the reservoir cap [1]. [2]
Putar
Removehandlebar (stang
the screws [2], stir) ke kiri
reservoir cap, settingres
sampai ervoir
plate [3]
and diaphragm
mendatar [4].melepaskan reservoir cap [1].
sebelum
Lepaskan s ekrup-sekrup [2], reservoir cap, setting plate
[3] dan diaphragm [4].
[1]
[3]
[4]
Connect a bleed
Sambungkan hose
bleed [1] to
hose the bleed
(slang valve [2]. [1] ke
pembuangan)
bleed valve [2]. [2]
Loosen the bleed valve and pump the brake lever until
no more fluid
Longgarkan flows
bleed out of
valve danthepompa
bleed valve.
brake lever (handel
rem) sampai
Tighten fluid tidak
the bleed valve.mengalir keluar lagi dari bleed
valve.
Kencangkan bleed valve.
[1]
BRAKE FLUID
PENGISIAN FILLING/AIR
BRAKE BLEEDING
FLUID/AIR BLEEDING
Do not mix different Fillreservoir
Jangan Isi the reservoir
sampai to ke
thebirai
casting ledge[1]
tuangan [1]dengan
with DOT 3 or
DOT 3 [1]
types DOTDOT
of fluid. They atau
mencampurkan 4 brake
4 fluid
brakefrom a sealed
fluid container.
dari kemas an yang belum
are not compatible. pernah dibuka sebelumnya.
bermacam-macam
mereka fluid. Mereka
tidak cocok satu sama
lain.
15-5
REM HIDRAULIK
Hubungkan alat brake bleeder
Connect a commercially [1] yang
available brakedapat dibeli
bleeder di
[1] to [1]
pasaran pada
the bleed bleed
valve [2]. valve [2]. [2]
Operate the
Jalankan brakebrake bleeder
bleeder danand loosen the
longgarkan bleed
bleed valve.
valve.
• • Periksa tinggi permukaan fluid berulangkali
Check the fluid level often when bleeding to prevent sewaktu
bleeding
air from untuk
being mencegah
pumped intodipompanya
the system.masuk udara
• keWhen
dalamusingsistem.a brake bleeding tool, follow the
• Jika menggunakan
manufacturer’s sebuahinstruction.
operating brake bleeding tool, ikuti
• petunjuk
If air is pemakaian
entering thepabrik
bleeder from around the bleed
pembuatnya.
• Jikavalve threads,
udara seal thebleeder
memasuki threadsdariwithsekitar
teflon tape.
ulir bleed
valve, rapatkan ulir dengan pita teflon.
After bleeding the air completely, tighten the bleed
valve to the
Setelah specified torque.
membuang udara palsu seluruhnya,
kencangkan bleed
TORQUE: 5.4 N·mvalve
(0.55dengan
kgf·m, torsi yang ditentukan.
4.0 lbf·ft)
If aalat
Jika brake bleeder
brake bleederis tidak
not available, use the prosedur
tersedia, jalankan following
procedure:
sebagai berikut:
Isilah reservoir sampai ke birai tuangan dengan DOT 3
Do not mix different Fill the reservoir to the casting ledge with DOT 3 or
Jangan atau DOT 4 brake fluid dari kemas an yang belum
typesmencampurkan
of fluid. They DOT 4 brake fluid from the sealed container.
are not compatible.
pernah dibuka sebelumnya.
bermacam-macam Pump up the system pressure with the brake lever until
merek fluid, Mereka Pompalah tekanan
lever resistance sistem dengan brake lever sampai
is felt.
tidak cocok satu sama terasa ada tahanan pada lever.
lain.
Hubungkan
Connect a bleed hose [1] [1] to
pada
the bleed
bleed valve
valve [2] and
dan
buanglah
bleed theudara
system palsu dari sistem sebagai berikut:
as follows: [2]
1. Pencet brake lever. Buka bleed valve ½ putaran dan
Do not release the 1. Squeeze the brake lever. Open the bleed valve 1/2
tutuplah.
brake lever until the turn and close it.
Jangan melepaskan brake lever s ampai bleed valve
bleed valve has
2. Release
telah ditutup. the brake lever slowly and wait several
been closed.
seconds after
2. Lepaskan it reaches
brake lever the end of its travel.
pelan-pelan dan tunggu
beberapa detik 1sampai
Repeat steps ia mencapai
and 2 until akhir
air bubbles dodari
not appear in
thepergerakannya.
bleed hose.
After bleeding
Ulangi langkah 1the danair completely,
2 sampai tighten udara
gelembung the bleed
tidak
valve tolagi
tampak thedispecified torque.
dalam bleed hose.
TORQUE: membuang
Setelah 5.4 N·m (0.55 kgf·m,
udara 4.0palsu
lbf·ft) semuanya,
kencangkan bleed v alve dengan torsi yang ditentukan. [1]
TORSI: 5,4 N.m (0,55

Fill the reservoir to thekgf.m;
casting4,0 lbf.ft)
ledge [1] with DOT 3 or
[1]
DOT 4 brake fluid from a sealed container.
Isi reservoir sampai ke birai tuangan [1] dengan DOT 3
atau DOT 4 brake fluid dari kemas an yang belum
pernah dibuka sebelumnya.
15-6
REM HIDRAULIK
Pas ang the
Install diaphragm [1],[1],
diaphragm setting
settingplate
plate[2]
[2]dan
and reservoir
cap[3].
cap [3]. [4]
Install
Pas ang and
dantighten the screws
kencangkan [4] to the specified
sekrup-sekrup torque.
[4] dengan torsi
yang ditentukan.
Install the handlebar top cover (page 3-4).
Pas ang handlebar top cover (hal. 3-4).
[3]
[2]
[1]
BRAKE PAD/DISC
PENGGANTIAN BRAKE PAD
BRAKE PAD REPLACEMENT
Periksa
Check brake Dorong
the tinggi Push the masuk caliper
caliper piston
piston all sama sekaliin keto dalam
the way allow
permukaan
fluid level brake
in the untuk memungkinkan
installation pemasangan
of new brake pads. brake pads baru.
fluidreservoir
be rulang-ulang
as this
oleh causes
operation karena
pekerjaan ini
the level to rise.
menye babkan
naiknya permukaan.
Lepaskan padpad
Remove the pin [1], O-ring
pin [1], [2] dan
O-ring brake
[2] and pads
brake [3]. [3].
pads
[1]/[2] [3]
Selalu replace
Always Install
the Pas
ganti brake ang new brake
brake pads
pads [1] into
baru the dalam
[1] ke brake caliper
brake so their
caliper
pads dalam pasangan [2] [3]
brake pads ends seatujung-ujung
in pairs sehingga against the mereka
retainer duduk
[2] and terhadap
bracket pin bolt A
retainer
to untuk
ensurememastikan [3].
even disc [2] dan bracket pin bolt A [3].
tekanan pressure.
disc yang
merata.
[1]
15-7
REM HIDRAULIK
Berikan gemukgrease
Apply silicon silikontopada O-ring
a new baru
O-ring [1] [1]
anddan pasang
install it to
pada padpin
the pad pin[2].
[2]. [2]
Pas ang the

Install padpad
pin sementara menekan
pin while pushing thepads
padsterhadap
against pad
pad
spring.
spring.
[1]
Kencangkan
Tighten the pad pin [1] to
dengan torsi yang
the specified ditentukan.
torque.
TORSI:
TORQUE: 17 17
N.m (1,7(1.7
N·m kgf.m; 13 13
kgf·m, lbf.ft)
lbf·ft)
Jalankan brake lever untuk mendudukkan caliper
Operate the brake lever to seat the caliper pistons
pistons terhadap pads.
against the pads.
[1]
PEMERIKSAAN BRAKE DISC
BRAKE DISC INSPECTION
Periksalah brake the
Visually inspect discbrake
secara visual
disc terhadap
for damage orkerusakan
cracks.
atau retak-retak.
Measure the brake disc thickness at several points.
Ukur tebal brake dis c pada beberapa titik.
Ukur keolengan
Measure brake
the brake disc
disc dengan
runout withalat dialindicator.
a dial indicator.
BATAS
SERVICESERVIS:
LIMIT: 0,30
0.30 mm
mm (0.012 in)
Periksa wheel bearings terhadap kelonggaran
Check the wheel bearings for excessive play, if the
berlebihan, jika keolengan melampaui batas serv is.
runout exceeds the service limit.
Ganti brake
Replace thedisc jikadisc
brake bearings
if the adalah normal.
bearings are normal.
Untuk penggantian
For brake brake disc(page
disc replacement (hal. 15-7).
13-8).
15-8
REM HIDRAULIK
MASTER CYLINDER
Drain the brake
Keluarkan brake fluid
fluid (page 15-5).
(hal. 15-5).
Remove the
Lepaskan handlebar
handlebar rearrear cover
cover (page
(hal. 3-6).3-6).
Se waktu
When melepaskan
removing the Remove the
Lepaskan oil oil
boltbolt[1],[1],brake
brakehose
hose [2]
[2] dan
and sealing
oilbolt,
oil bolt,cover
tutupilah
the washers[3].
washers [3].
ujung
end dari hose untuk Lepaskan baut-baut
bolts [4],[4], holder
[5] [5]
anddan master cylinder
of the hose to
menc egah Remove the holder master cylinder [6].
prevent [6].
kontaminasi. Install the removed parts indalam
the urutan
reverseterbalik
orderdariof
contamination. Pas ang parts yang dilepaskan
removal.
pelepas an.
•• Replace
Gantilah the
sealing
sealingwaswasher
her dengan yangones.
with new baru.
TORSI:
TORQUE:
OIL
OILBOLT
BOLT 34 34
N·m N.m
(3.5(3,5 kgf.m;
kgf·m, 25 lbf.ft)
25 lbf·ft)
Isi sistem hidraulik dan jalankan air bleeding (hal. 15-5).
Fill and air bleed the hydraulic system (page 15-5).
Tepatkan ujung dari

master cylinder dengan
tanda titik pada handlebar.
[4] [5] Kencangkan upper
bolt dulu, kemudian
baru lower bolt.
Tempatkan holder
dengan tanda "UP"
[3] menghadap ke atas.
Tempatkan brake
hose eyelet
terhadap stopper.
[2]
[1] 34 N·m (3,5 kgf·m; 25 lbf·ft)

[6]
15-9
REM HIDRAULIK
Remove/install theyang
Lepaskan/pasang following
berikutfromdari
the mas
master
ter cylinder
body[1]:
body [1]:
- –Mur engsel brake [8]
Brake lever pivotlevnut
er [2],
[2], bolt
baut[3][3]and
danbrake
brak elever
lever[4]
[4]
- –Sekrup [5] dan brake light switch
Screw [5] and brake light switch [6] [6]
- –Boot [7][7]
Boot
Lepaskan/pasang
Remove/install thes nap
snapring ring [8] dengan
[8] using themenggunakan
special tool.
spec ial tool.
TOOL:
TOOL:
[9] Snap
[9] Snap ring
ring pliers
pliers 07914-SA50001
07914-SA50001 [9]
Remove/install thewasher
Lepaskan/pasang washer[10],[10],master
master piston
piston [11]
[11] dan
and
spring[12].
spring [12].
•• Pertahankan
Keep the piston, piston, cups[13],
cups [13],spring,
spring,snap
snap ring
ring dan
and
boot
boot assebagai
a set; do sebuah set, jangan
not substitute menggantikan
individual parts.
• parts
Whentersendiri.
installing the cups, do not allow the lips to turn
• Sewaktu
inside out.memasang cups, jagalah agar bibir-bibir
• tidak berputar
Be sure that snapsebelah
ring isdalam
firmlydiseated
luar. in the groove.
•• Pastikan
Apply brake bahwa fluidsnap
to the ring dudukpiston
spring, dengancupskokoh
and
master
pada piston.
alurnya.
•• Oleskan
Apply 0.1brake
g of silicone grease
fluid pada to thepiston
spring, pivot bolt
cups sliding
dan
surfacepiston.
master and brake lever contact area with piston.
• Berikan
Fill the brake0,1fluid
g gemuk s ilikon
and bleed thepada permukaan
hydraulic systemluncur
(page
pivot
15-5). bolt dan daerah kontak brake lever dengan
piston.
TORQUE:
Isi PIVOT
brake BOLT
fluid dan jalankan 1 N·mair bleeding
(0.10 kgf·m, pada sistem
0.7 lbf·ft)
hidraulik
PIVOT(hal.
NUT15-5). 5.9 N·m (0.60 kgf·m, 4.4 lbf·ft)
TORSI:
BRAKE LIGHT
BAUT
SWITCH ENGSEL
SCREW 1 N.m
1.2 N·m(0,10
(0.12kgf.m;
kgf·m,0,7
0.9lbf.ft)
lbf·ft)
MUR ENGSEL 5,9 N.m (0,60 kgf.m; 4,4 lbf.ft)
SEKRUP BRAKE 1,2 N.m (0,12 kgf.m; 4,4 lbf.ft)
LIGHT SWITCH
[1] *
[3] 1 N·m (0,10 kgf·m; 0,7 lbf·ft)
[12] [6]
[13]
[10]
[7]
[11]
[8] [5]
1,2 N·m (0,12 kgf·m;
[2] 5,9 N·m (0,60 kgf·m; 4,4 lbf·ft) 0,9 lbf·ft)
[4]
*: Berikan 0,1 g gemuk silikon. Tepatkan switch boss dengan lubang.
15-10
REM HIDRAULIK
INSPECTION
PEMERIKSAAN
Check piston
Periksa the piston
cups cups [1] for wear,
[1] terhadap deterioration
keausan, pemburukan or
damage.
kondisi atau kerusakan. [3]
Check the
Periksa spring
spring [2] for fatigue
[2] terhadap or damage.
kelelahan atau kerusakan.
Check the
Periksa master cylinder
permukaan dalam[3]master
inner surface and[3]
cylinder master
dan
piston [4] outer
permukaan surfacepiston
luar master for scratches or damage.
[4] terhadap goresan atau
kerusakan. [1]
[2]
[4]
Measure
Ukur D.D. the master
master cylinder I.D.
cy linder
BATAS SERVIS:
11.055 mm (0.4352 in)
Ukur D.L. master
Measure piston
the master piston O.D.
BATAS
SERVICE LIMIT: 10.945 mm
SERVIS: 10,945 mm (0.4309 in)
15-11
REM HIDRAULIK
BRAKE CALIPER
Jagalah
Avoid agar fluid
spilling Drain the brake
Keluarkan brake fluid
fluid(page 15-5).
(hal. 15-5).
ontidak tertumpah
painted, di
plastic,
atas or
parts yangparts.
dicat, Remove/install thesebagai
Lepaskan/pasang following:
berikut:
rubber
atau
Place terbuattowel
a shop dari -– OilOilbolt
bolt [1], brake hose [2]dan
[1], brake hose [2] andsealing
sealingwashers
washers[3][3]
plastik atau karet. -– Baut-baut
over these parts Mountingpemasangan
bolts [4] [4]
Letakk an kain lap
whenever the -– Brake
Brakec aliper
caliper[5][5]
menutupi parts ini
system is kali
setiap serviced.
sistem TORSI:
TORQUE:
diservis. BAUT PEMASANGAN 30 N.m (3,1 kgf.m; 22 lbf.ft)
BRAKE CALIPER
BRAKE CALIPER
MOUNTING BOLT 30 N·m (3.1 kgf·m, 22 lbf·ft)
OIL BOLT
OIL BOLT 34 N.m
34 N·m (3.5(3,5 kgf.m;
kgf·m, 25 lbf.ft)
25 lbf·ft)
•• Gantilah
Replace baut-baut
the brakepemasangan brake caliper
caliper mounting dan
bolts and
ssealing
ealing washers
washersdengan yang
with new baru.
ones.
Filldengan
Isi the brake fluid fluid
brake and bleed the hydraulic
dan jalankan system (page
air bleeding pada 15-5).
sis tem hidraulik (hal. 15-5).
[5]
[4] 30 N·m (3,1 kgf·m; 22 lbf·ft)
[2]
[1] 34 N·m (3,5 kgf·m, 25 lbf·ft) [3]
15-12
REM HIDRAULIK
Remove the
Lepaskan yang following fromcaliper
berik ut dari the caliper
bodybody
[1]. [1]:
- Brake pads (hal. 15-7) [5]
– Brake pads (page 15-7)
- –Caliper bracket
Caliper bracket [2][2]
- –Bracket pin boots
Bracket pin boots [3][3]
- –Pad
Padspring
spring[4][4]
Letakkan kain lap
Place a shop toweldi atas
over piston [5]. [5].
the piston
J angan menggunakan
Do not use high Tempatkan
Position thecaliper
caliper body
bodydengan
with thepis piston
ton menghadap
facing down ke
udara bertekanan bawah dansmallberikan
pressure air or bring and apply squirts semburan
of air pressure kecil udara
to the dari
fluid inlet
tinggi atau membawa kompressor kepada fluid inlet (lubang pemasuk an fluid)
the nozzle
nozzle too close
terlalu dekat to remove the piston.
topada
the inlet.
inlet. untuk mengeluarkan piston.
Remove the dust seal [6]/piston seal [7].
Lepaskan dust seal [6]/piston seal [7].
Install
Pas the removed
ang parts parts in
terbalik of
removal.
pelepasan.
•• Apply brake
Berikan brakefluid to pada
fluid the caliper
caliper piston
piston and piston
dan piston
seal.
seal.
•• Apply silicone
Berikan gemukgreasesilikonto pada
the bracket
permukaan pin luncur
sliding
surface
bracketand
pin dust seal.seal.
dan dust
•• Replace
Gantilahthepispiston
ton sealsealdan
anddust
dust seal
seal with new yang
dengan ones as a set.
baru sebagai sebuah set.
[3]
5,4 N·m (0,55 kgf·m; 4,0 lbf·ft)
[6]
[7]
[2]
[3] [5]
Pasang caliper piston dengan

ujungnya yang terbuka
[1] [4] menghadap ke brake pads.
PEMERIKSAAN
INSPECTION
Periksa caliper
Check the cylinders
caliper terhadap
cylinders gerusan,
for scoring, goresan
scratches or
atau kerus akan.
damage.
Ukur D.D. caliper
Measure cy linder.
the caliper cylinder I.D.
BATAS SERVIS:
34.02 mm (1.340 in)
Periksa
Check the pistons terhadap
pistons for scoring,gerusan,
scratches goresan atau
or damage.
kerusakan.
Measure the caliper piston O.D.
Ukur D.L. caliper piston.
15-13
CATATAN
16. BATERAI/SISTEM PENGISIAN
LOK ASI SISTEM

SYSTEM .......................................... 16-2
LOCATION···································16-2 BATERAI
BATTERY........................................................
···················································· 16-6
16-6
DIAGRAM SISTEM ......................................

SYSTEM DIAGRAM 16-2
····································16-2 PEMERIKSAAN SISTEM
CHARGING SYSTEM PENGISIAN ..........
INSPECTION ·········· 16-7
16-7
KETERANGAN SERVIS .............................. 16-3 KUMPAR AN PENGISIAN ALTERNATOR.... 16-8
SERVICE INFORMATION ···························16-3 ALTERNATOR CHARGING COIL ·············· 16-8
TROUBLESHOOTING ................................. 16-5 REGULATOR/RECTIFIER ............................. 16-8
TROUBLESHOOTING·································16-5 REGULATOR/RECTIFIER ·························· 16-8
16
16-1
BATERAI/SISTEM PENGISIAN
LOKASI SISTEM
BATTERY/CHARGING SYSTEM
REGULATOR/
RECTIFIER
MAIN FUSE 15 A
BATTERY
ALTERNATOR
DIAGRAM SISTEM
To IGNITION G: Green (hijau)
SWITCH R: Red (merah)
W: White (putih)
MAIN FUSE 15 A Y: Yellow (kuning)
G R
Y R/Y R W G G G
ALTERNATOR
BATTERY
REGULATOR/RECTIFIER
To LIGHTING SWITCH
16-2
KETERANGAN
SERVICE SERVIS
INFORMATION
GENERAL
UMUM
! PERINGATAN
• Baterai mengeluarkan gas yang dapat meledak, jauhkan percikan bunga api, lidah api dan rokok. Sediakan ventilasi yang
‚Ä¢The battery gives off explosive gases; keep sparks, flames and cigarettes away. Provide adequate ventilation when charg-
memadai
ing. pada waktu charging (pengisian muatan listrik).
• ‚Ä¢The
Bateraibattery
mengandung
containsasam sulfat
sulfuric acid (electrolyte).
(electrolyte). Kontak
Contactdengan
with skinkulit atau may
or eyes matacause
dapatsevere
mengakibatkan
burns. Wearluka bakar parah.
protective clothing
Kenakan
and a face pakaian
shield.pelindung dan pelindung muka.
- Jika
‚ÄìIfelectrolyte
electrolytemengenai kulit, skin,
gets on your bilas flush
dengan
withair.
water.
- Jika
‚ÄìIfelectrolyte
electrolytemengenai mata,
gets in your bilasflush
eyes, dengan
withair selama
water for atsekurangnya 15 menit
least 15 minutes anddan
callminta bantuan
a physician dokter dengan segera.
immediately.
• ‚Ä¢Electrolyte
Electrolyte beracun
is poisonous.
- Jika
‚ÄìIftertelan, minumlah
swallowed, drink sejumlah besar air
large quantities of atau
watersusu danand
or milk mintalah bantuan
call your local Rumah Sakit atau
Poison Control dokter
Center ordengan
a call a segera.
physician imme-
diately.
CATATAN
•‚Ä¢Always
Selalu putarturn ignition
OFF the switch
ignitionke switch
OFF sebelum melepaskan sambungan
before disconnecting any electrical sebuah komponen listrik.
component.
•‚Ä¢Some
Beberapa komponen
electrical listrik dapat
components mayrusak jika terminal
be damaged atau connectors
if terminals or connectors dihubungkan atau dilepaskan
are connected sementara
or disconnected ignition
while switch
the ignition
pada posisi
switch is ONON dan ada
position andlistrik
currentyangis mengalir.
present.
• Model ini dil engkapi dengan sebuah maintenance free (MF) battery (baterai bebas perawatan). Ingatlah hal-hal berikut ini
‚Ä¢This model comes with a maintenance free (MF) battery. Remember the following about MF batteries.
mengenai MF batteries.
‚ÄìUse only the electrolyte that comes with the battery.
- Hanya
‚ÄìUsepakaiall of electr olyte yang datang dengan baterai.
the electrolyte.
- Pakailah
‚ÄìSeal the semuabatteryelectr olyte.
properly.
- Tutuplah sil baterai dengan
‚ÄìNever open the seals after rapat-rapat.
installation.
-‚Ä¢For
Jangan sekali-kali
extended membuka
storage, removesil setelah pemasangan.
the battery, give it a full charge, and store it in a cool, dry space. For maximum service life,
• charge
Untuk penyimpanan
the stored battery jangka lama,
every twolepaskan
weeks. baterai, berikan muatan listrik penuh, dan simpanlah di tempat keri ng yang teduh.
Untuk
‚Ä¢For a mendapatkan
battery remaining umurinpemakaian maksimum,disconnect
a stored motorcycle, isi baterai the
yang disimpan
negative dengan
battery muatan
cable from listrik setiap terminal.
the battery dua minggu.
•‚Ä¢The
Ji ka baterai
maintenancetetap terpasang
free (MF) pada batterysepedamotor yang disimpan,
must be replaced lepaskanthe
when it reaches kabel
endnegatif bater ailife.
of its service dari terminal baterai.
•‚Ä¢The
Maintenance
battery can fr ee be
battery
damagedharus ifdiganti jika ia telah
overcharged mencapai akhiror
or undercharged, dari umur
if left to pemakai
discharge annya.
for long period. These same conditions
• contribute
Baterai dapat to shortening
rusak ji kathe "life span" of
overcharged (dithe battery.
berikan Evenlistrik
muatan underberlebihan)
normal use,atau the performance
underchargedof(muatan the battery deteriorates
listrik after 2
yang diberikan
‚Äì
kur 3 years.
ang) , atau bila dibiarkan ber kurang muatannya untuk jangka waktu lama. Kondisi yang sama ini berperan dalam
‚Ä¢Battery
memperpendekvoltage may “jangkarecover waktuafterkehi
battery
dupan” charging,
sebuahbutbaterai.
under heavy
Bahkan load, the battery
dalam pemakai voltage will dropunjuk
an normal, quickly and baterai
kerja eventually akandie
out. For thissetelah
memburuk reason, 2 –the charging system is often suspected as the problem. Battery overcharge often results from problems in
3 tahun.
• the battery
Voltase itself,
baterai which
dapat may appear
membaik setelahto baterai
be an overcharging
diberikan muatansymptom.
listrik, Iftetapi
one of the battery
di bawah beban cells is shorted
berat, voltase and battery
baterai akanvoltage
turun
does
dengan notcepat
increase,dan the regulator/rectifier
akhirnya akan mati. Inil supplies excess voltage
ah sebabnya mengapa to sistem
the battery. Underseringkal
pengisian these conditions,
i dicurigai the electrolyte
sebagai penyebablevel
goes down quickly.
persoal annya. Namun seringkali battery overcharge diakibatkan ol eh persoalan di dalam baterai sendi ri , yang mungkin akan
‚Ä¢Before
tampak troubleshooting
sebagai gejala the charging system,
overcharging. Jika salahcheck for sel
satu proper
bateruse and maintenance
ai ada hubungan si ngkat of thedan
battery. Check
voltase if thetidak
baterai battery
naik,is
frequently under heavy load, such as having the turn signal and brake lights on for long
regulator/rectifier memasok voltase berlebihan kepada baterai. Di bawah kondisi-kondisi ini, tinggi permukaan electrolyte akan periods of time without riding the
motorcycle.
tur un dengan cepat.
‚Ä¢The battery will self-discharge when the motorcycle is not in use. For this reason, charge the battery every two weeks to prevent
• Sebelum men-troubleshooting sistem pengisian, periksalah terhadap penggunaan yang wajar dan perawatan dari baterai.
sulfation from occurring.
Periksachecking
‚Ä¢When apakah baterai seri ngkali
the charging di bawah
system, always beban
followberat, sepertiinapabila
the steps lampu besar dan
the troubleshooting (page l ampu belakang menyala untuk jangka
16-5).
waktu
‚Ä¢For lama tanpa
alternator mengendarai
service (page 11-5). sepedamotor .
• Baterai akan berkurang sendiri muatan listriknya apabila sepedamotor ti dak dipakai. Oleh karena i ni, berikan muatan listrik
kepada bater ai setiap dua minggu untuk mencegah ter jadinya sulfation.
• SewaktuCHARGING
BATTERY memeriksa sistem pengisian, selalu ikuti langkah- langkah pada peta aliran troubleshooting (hal. 16-5).
• Untuk servis alternator ( hal. 11- 3) .
‚Ä¢Turn power ON/OFF at the charger, not at the battery terminal.
‚Ä¢For battery charging, do not exceed the charging current and time specified on the battery. Using excessive current or
BATTERY
extending CHARGING
the charging (PENGISIAN
time may damage MUATAN theLISTRIK
battery. BATERAI)
•‚Ä¢Quick chargingdaya
Hidup/matikan should only
listrik padabe done in an
charger, emergency;
jangan slow charging
pada terminal baterai. is preferred.
• Untuk pengisian muatan l istr ik baterai, jangan melampaui arus pengisian dan waktu yang ditentukan pada baterai. Penggunaan
arus listrik yang berlebihan atau waktu pengisian yang terlalu l ama dapat merusak baterai.
BATTERY
• Quick chargingTESTING (pengisian muatan l istrik dengan cepat) hanya boleh dilakukan dalam keadaan darurat, lebih baik jalankan slow
Referchartoging
the(pengisian
instruction of thel istr
muatan Operation
ik denganManual
pelan). for the recommended battery tester for details about battery testing. The
recommended battery tester puts a "load" on the battery so that the actual battery condition during load can be measured.
BATTERY TESTING
Recommended battery tester: BM-210 or BATTERY MATE or equivalent
Bacal ah petunjuk pemakai an di dal am Operati on Manual dari battery tester yang dianjurkan untuk detil- detail mengenai
pengetesan bater ai. Battery tester yang di anj urkan mel etakkan “beban” pada bater ai sehingga kondisi baterai sebenarnya dari
beban dapat di ukur.
Batt ery tester yang dianjurkan: BM- 210 atau BATTERY MATE atau sejenisnya
16-3
SPESIFIKASI
BAGIAN SPESIFIKASI
Baterai Kapasitas 12 V ‚Äì 3,0 Ah
Kebocoran arus listrik Makasimum 0,1 mA.
Voltase Terisi penuh 13,0 ‚Äì 13,2 V
(20¬×C) Perlu diisi kembali Below 12,4 V
Arus pengisian Normal 0,3 A/5 ‚Äì 10 jam
(20¬×C) Cepat 3,0 A/0,5 jam
Alternator Kapasitas 0,170 kW/5,000 min-1 (rpm)
Tahanan coil pengisian (20¬×C) 0,2 ‚Äì 1,0 Œ©
16-4
TROUBLESHOOTING
BATERAI
BATTERYRUSAK ATAU LEMAH
IS DAMAGED OR WEAK
1. BATTERY
1. TEST TEST
BATERAI
Remove the battery
Lepaskan (page
baterai (hal.16-7).
16-6)
Check the battery
Periksa condition
kondisi baterai using
denganthememakai
recommended
battery tester yang dianjurkan (hal. 16-6).
battery tester (page 16-7).
BATTERY TESTER YANG DIANJURKAN: BM- 210 atau BATTERY MATE atau sejenisnya
RECOMMENDED BATTERY TESTER:BM-210 or BATTERY MATE or equivalent
Apakah baterai dalam kondisi baik?
Is the battery in good condition?
YA - LANJUTKAN DENG AN LANGKAH 2
YES ‚ÄìGO TO STEP 2.
TIDAK - Baterai tidak bekerj a dengan bai k
NO ‚ÄìFaulty battery
2. TEST KEBOCORAN ARUS LISTRIK
2. CURRENT LEAKAGE TEST
Pasang baterai (hal. 16-6).
Install the battery (page 16-7).
Periksa kebocoran arus listrik bater ai (hal. 16-7).
Check the battery current leakage (page 16-8).
Apakah kebocoran arus listrik di bawah 0,1 mA?
Is the current leakage below 0.1 mA?
YES YA‚ÄìGO-TO LANJUTKAN
STEP 4. DENG AN LANGKAH 4
NO TIDAK
‚ÄìGO-TO
LANJUTKAN
STEP 3. DENG AN LANGKAH 3
3. TEST KEBOCORAN
3. CURRENT LEAKAGE ARUS LISTRIK
TEST TANPA REG ULATO R/RECTIFIER TERSAMBUNG
WITHOUT
REGULATOR/RECTIFIER CONNECTED
Lepaskan regulator/rectifier connector dan periksa kembali kebocoran ar us li stri k baterai.
Disconnect
Apakahthe regulator/rectifier
kebocoran arus listrikconnector
di bawah and
0,1 mA?
recheck the battery current leakage.
YA - Regulato r/rectifier tidak bekerja den gan baik
Is the current leakage below 0.1 mA?
TIDAK -
YES • ‚ÄìFaulty regulator/rectifier
Hubu ngan singkat pada wire harness
NO • ‚ÄìIgnition
‚Ä¢Shorted wire
switch harness
tidak bekerja dengan baik
‚Ä¢Faulty ignition switch
4. PEMERIKSAAN KUMPARAN PENGISIAN ALTERNATOR
4. ALTERNATOR CHARGING COIL INSPECTION
Periksa kumpar an pengisi an alter nator (hal. 16-8).
Check the alternator charging coil (page 16-9). o
Apakah tahanan kum paran pengisian alternat or antara 0,2 – 1,0 ohm (20 C)?
Is the alternator charging coil resistance within
YA1.0 Œ©
0.2 ‚Äì - LANJUTKAN
(20¬×C/68¬×F)? DENG AN LANGKAH 5.
YES TIDAK
‚ÄìGO-TO Kumparan
STEP 5.pen gisian tidak beker ja dengan baik
5. NO PEMERIKSAAN VOLTASE
‚ÄìFaulty charging coil PENG ISIAN
Ukur dan
5. CHARGING catat voltase
VOLTAGE baterai dengan menggunakan digita l multimeter (hal. 16-6)
INSPECTION
Hi dupkan
Measure mesin. the battery voltage using a
and record
digitalUkur
multimeter
voltase(page 16-7).
pengisian (hal . 16-7).
Start the engine.
Bandingkan hasil pengukuran dengan hasil dari perhitungan berikut ini .
Measure the charging voltage (page 16-8).
STANDARD: VB Yang Diukur < VP Yang Diukur < 15,5 V
Compare the measurements to result of the
• VB
following = Voltase Baterai (hal. 16-6)
calculation.
• VP = Voltase Pengisian
STANDARD:Measured BV < Measured CV < 15.5 V
‚Ä¢BVApakah voltase
= Battery pengisian
Voltage (page yang
16-7) diukur sesuai dengan standard untuk voltase?
‚Ä¢CVYA = Charging Voltage
- Baterai r usak
Is the measured
TIDAK chargingDENG
- LANJUTKAN voltage within the
AN LANGKAH 6.
standard voltage?
6. PEMERIKSAAN SISTEM REGULATO R/RECTIFIER
YES ‚ÄìFaulty battery
Periksa voltase dan tahanan pada regulator/rectifier connectors (hal. 16-8).
NO ‚ÄìGO TO STEP 6.
Apakah hasil dari pemerik saan voltase dan tahanan adalah benar?
6. REGULATOR/RECTIFIER SYSTEM INSPECTION
YA - Regulato r/rectifier tidak bekerja den gan baik.
Check the voltage and resistance at the regulator/
TIDAK
rectifier -
connectors (page 16-9).
•
Are the results of terbuka
Ran gkaian checked padavoltage
kawat yang
andbersangkutan
•
resistance Kontak l onggar atau buruk dari terminal yang bersangkutan
correct?
• Hub ungan singkat pada wire harness
YES ‚ÄìFaulty regulator/rectifier
16-5
‚Äì
BATTERY
• ‚Ä¢Always
Selalu putar
turn ignition switch switch
the ignition ke OFFOFFsebelum
before
melepaskan baterai.
removing the battery. [1] [2] [3]
Unlock
Buka and open dan
penguncian the naikkan
seat. seat.
Remove trim
Lepaskan the trim clip dan
clip [1] [1] battery
and battery
covercover [2] while
[2] sementara
releasing
melepas kanthehook
hook[3][3] dan
and tabs [4]
[4] from
dari the slots
slots [5][5] of
dari
the luggage
luggage box. box.
[4]
[5]
Selalu
Always Remove baut
lepaskan Lepaskan
disconnect the bolt [1] and
[1] dan disconnect
lepaskan the negative
kabel negatif (-) [2]. (‚Äì)
terminal negatif Tarik [5] [3] [1] [2]
the negative cablepositive
[2]. terminal cov er ke belakang.
terminaldulu. Pull back baut
first. Lepaskan the positive
[3] dan terminal
lepaskancover.
kabel pos itif (+) [4].
Remove the bolt [3] and disconnect the positive (+)
Keluarkan
cable [4]. baterai [5] dari luggage box.
Pemasangan
Remove the batteryadalah dalam
[5] out of theurutan
luggage terbalik
box. dari
pelepas an.
• Hubungkan kabel positif (+) ke baterai dulu,
‚Ä¢Connect the positive (+) cable to the battery first,
kemudian hubungkan kabel negatif (-).
then connect the negative (‚Äì) cable.
[4]
PEMERIKSAAN VOLTASE
VOLTAGE INSPECTION
Measure
Ukur voltasthe battery dengan
e baterai voltage menggunakan
using a commercially
s ebuah
available
digital digital multimeter.
multimeter yang dapat dibeli di pas aran.
VOLTASE (20o C):
VOLTAGE
Bermuatan (20¬×C/68¬×F):
penuh: 13,0 – 13,2 V
Fullydisetrum
Perlu charged:kembali:
13.0 ‚ÄìDi13.2 V 12,4 V
bawah
Needs charging:Below 12.4 V
CATATAN: (‚Ä (+)
• Sewaktu mengukur voltase baterai setelah
disetrum,
‚Ä¢When diamkanthedulu
measuring s ampai
battery sekurangnya
voltage 30
after charging,
menit,
leave itatau hasil 30
for least yang akuratortidak
minutes, dapat diperoleh
the accurate results
oleh
cannotkarena voltasebecause
be obtained baterai the
berfluktuasi tepat
battery voltage
setelah
fluctuatesdisetrum.
just after charging.
BATTERY TESTING
PENGETESAN BATERAI
Refer to the instructions that are appropriate to the
Bac alah petunjuk pemakaian untuk peralatan
battery testing equipment available to you.
pengetesan baterai yang akan anda pakai.
TOOL:
TOOL:
Battery
Batterytester
tester BATTERY
BM-210, BM-210, MATE
BATTERY
atau sejenisnya. MATE or equiva-
lent
16-6
CHARGING SYSTEM INSPECTION
TEST KEBOCORAN
CURRENT ARUS
LEAKAGE LISTRIK
TEST
Lepaskan battery
Remove the cover
battery (hal.(page
cover 16-6).16-7).
Putar
Turn ignition switch ke
the ignition OFF dan
switch OFFlepaskan kabel negatif
and disconnect the
(-)negative
[1] dari baterai.
(‚Äì) cable [1] from the battery.
Hubungkan
Connect thejarum ammeterpengetesan
(+) probe (+) to theamperemeter
negative cableke
kabel negatif dan
and ammeter jarum
(‚Äì) probe pengetesan
to the battery (-) amperemeter
(‚Äì) terminal. ke (+)
With the(-)ignition
terminal baterai.switch OFF, check for current leakage. (‚Ä
Dengan ignition s witch pada OFF, periksalah terhadap
kebocoran arus lis trik.
‚Ä¢When measuring current using a tester, set it to a
CATATAN:high range, and then bring the range down to an
• Jikaappropriate
mengukur level.arus
Current flow
listrik higher menggunakan
dengan than the range
selected
tester, may blow
pasang padathedaerah
fuse injangkauan
the tester. tinggi dulu,
‚Ä¢While measuringturunkan
dan kemudian current, do not turn
daerah jangkthe ignition
auan ke
switch ON,
bawah A sudden
ke tingkat surge
yang lebihof current
s esuai.may blowarus
Aliran the [1]
fuse inyang
listrik the tester.
lebih tinggi daripada daerah jangkauan
yang dipilih dapat memutuskan sekring di dalam
SPECIFIED
tester. CURRENT 0.1 mA max.
LEAKAGE:
• Sewaktu mengukur arus listrik, jangan memutar
If ignition
current switch
leakagekeexceeds
ON. Lonjakan arus listrik
the specified yanga
value,
tiba-tiba
shorted dapat
circuit memutuskan
is the sekring di dalam tes ter.
probable cause.
Locate the short by disconnecting connections one by
KEBOCORAN ARUS LISTRIK YANG
one and measuring the current.
DIPERBOLEHKAN: maksimum 0,1 mA
Jika kebocoran VOLTAGE

CHARGING arus listrik melampaui nilai yang
INSPECTION
ditentukan, kemungkinan penyebabnya adalah s ebuah
hubungan singkat.
Carilah lokas i hubungan singkat dengan melepaskan
hubungan-hubungan satu demi satu dan mengukur
besarnya arus listrik.
PEMERIKSAAN VOLTASE PENGISIAN

Jangan lepaskan Lepaskan battery
Remove the cover
battery (hal.(page
cover 16-6).16-7).
baterai atau salah
satu kabel pada CATATAN:
sistem pengisian Pas tikansure
Make bahwa the baterai
battery is berada dalam
in good kondisibefore
condition baik
tanpa sebe lumnya sebelum
performingmenjalankan pemeriksaan ini.
this inspection.
memutar ignition Panaskan mesin ke suhu operas i normal. (‚Ä (+)
Do switch ke OFF.
not disconnect Warm upmesin
Matikan the engine
dan tohubungkan
normal operating temperature.
multimeter seperti
Kegagalan
the battery oruntuk
any Stop the engine and connect the multimeter as shown.
diperlihatkan.
mematuhi tindakan
cable in the
pengamanan ini
CATATAN:
charging system Untuk mencegah terjadinya hubungan singkat, yakinlah
dapat merusak teste r To prevent a short, make absolutely certainatau
which are
without first dengan benar yang mana adalah terminal kabel
atau komponen2 the positive and negative terminals or cables.
switching OFF the
listrik. positif dan negatif.
ignition switch. Connect a tachometer according to its
Failure to follow this Hubungkan tachometer
manufacturer‚Äôs sesuai dengan petunjuk pabrik
instructions.
precaution can pembuatnya.
damage the tester Restart the
Hidupkan mesinengine.
kembali.
or electrical Measure
Ukur the pada
voltase voltage on the multimeter
multimeter s ewaktu when
mesinthe engine
berputar
-1-1
components. runs5.000
pada at 5,000
menitmin (rpm).
(rpm).
STANDARD:
STANDARD:
Measured
VB BV <<Measured
yang diukur CV < 15.5
VP yang diukur V V
< 15,5
• VB
‚Ä¢BV = Battery
= Voltase Voltage
Baterai (hal.(page
16-6) 16-7)
‚Ä¢CV
• VP = Charging
= Voltase Voltage
Pengisian
16-7
ALTERNATOR CHARGING COIL
(KUMPARAN PENGISIAN ALTERNATOR)
INSPECTION
PEMERIKSAAN
Remove the left crankcase rear cover (page 3-17).
Disconnect
Lepaskan leftthe alternatorrear
c rankcase 2Pcover
connector
(hal. [1].
3-17).
Check the resistance between
Lepaskan alternator 2P connector [1]. the White and Green
wire terminals of the alternator side.
Periksa tahanan antara terminal2 kawat Putih dan Hijau
STANDARD:
pada 0.2 ‚Äì 1.0 Œ© (at 20¬×C/68¬×F)
sisi alternator.
Replace the0,2stator o
STANDARD: – 1,0 ?if (pada
the 20resistance
C) is out of
specification.
Gantilah stator jika tahanan di luar spes ifikasi.
For stator removal (page 11-5).
Untuk
Installpelepasan stator (hal.
the left crankcase rear11-5).
cover (page 3-17).
Pas ang left crankcas e rear cover (hal. 3-17).
[1]
[1]
REGULATOR/RECTIFIER
SYSTEM INSPECTION
PEMERIKSAAN SISTEM
Remove the
Lepaskan right
right body
body cover
cover (page
(hal. 3-13).
3-13).
Turn the
Putar ignition
ignition switch
switch OFF.
ke OFF.
Disconnectregulator/rectifier
Lepaskan the regulator/rectifier
6P 6P connector
c onnector [1],[1],dan
and
check it for loose contact or corroded terminals.
periksa terhadap kontak longgar atau terminal2 yang
berkarat.
If the charging voltage reading (page 16-8) is out of the
specification, inspect the regulator/rectifier 6P
Jika pembacaan voltase pengisian (hal. 16-7) diluar
connector terminals (wire harness side) as follows:
spesifikasi, periksalah regulator/rectifier 6P connector
terminals Item(sisi wire harness) sebagai berikut:
Terminal Specification
Battery charging Red/yellow (+) Battery voltage
Bagian Terminal Spesifikasi
line and Ground (‚Äì) should appear
Saluran Merah/kuning (+) Voltas e
Charging coil line White and 0.2 ‚Äì 1.0 ‚Ñ¶
pengisian dan Massa (-) baterai harus
Green (at 20¬×C/
baterai tampak
68¬×F) [1]
Saluranline
Ground Putih
Greendan
andHijau 0,2 – 1,0 ?
Continuityo
kumparan Ground (pada 20
should existC)
pengisian
IfSaluran
all components Hijau of thedan
charging
Massasystem is normal
Harus ada and
there
massa are no loose connections at the kontinuitas
regulator/rectifier
6P connector, replace the regulator/rectifier unit.
Jika semua komponen dari sistem pengisian adalah
Install thedan
normal righttidak
body cover
ada (page 3-13). longgar pada
hubungan
regulator/rectifier 6P connector, gantilah
regulator/rectifier unit.
Pasang right body cover (hal. 3-13).
16-8
Lepaskan right
Remove the body
right c over
body (hal.
cover 3-13).
(page 3-13).
[3] [5]
Putar
the ignition ke OFF.
switch OFF. [4]
Lepaskan regulator/rectifier
Disconnect 6P c onnector
the regulator/rectifier [1]. [1].
6P connector
Lepaskan
Remove the keduatwo baut
bolts [2],
[2], terminal massa [3] and
ground terminal dan
regulator/rectifier[4].
regulator/rectifier [4].
Tempatkan
Set theterminal Installation is inadalah
ground Pemasangan the reverse orderurutan
dalam of removal.
terbalik dari
massa pada stoppe
terminal r pelepas an.
on the
stopper[5].
[5].
[2] [1]
16-9
CATATAN
17. SISTEM PENGAPIAN
LOK ASI SISTEM........................................ 17-2 SYSTEM SAAN

PEMERIK LOCATION ··································
SISTEM PENGAPIAN ...... 17-5 17-2
DIAGRAM SISTEM .................................... 17-2 IGNITION COIL ............................................

SYSTEM DIAGRAM ····································17-7
17-2
KETER ANGAN SERVIS ............................ 17-3 WAKTU PEN

SERVICE GAPIAN .................................. 17-8
INFORMATION··························· 17-3
TROU BLESHOOTING ............................... 17-4
TROUBLESHOOTING ································ 17-4
IGNITION SYSTEM INSPECTION ·············· 17-5
IGNITION COIL ··········································· 17-7
IGNITION TIMING ······································· 17-8
17
17-1
SISTEM PENGAPIAN
LOKASI SISTEM
IGNITION SYSTEM
MAIN FUSE 15 A REGULATOR/

RECTIFIER
IGNITION SWITCH
BATTERY
IGNITION COIL
SPARK PLUG ECM

CKP SENSOR SIDESTAND SWITCH
DIAGRAM SISTEM
IGNITION SWITCH
Bl: Black
Bu: Blue
MAIN FUSE G: Green
15 A Bl/Bu
P: Pink
G R R: Red
Bl/Bu
W: White
Y: Yellow
R/Y G R
IGNITION
COIL
BATTERY
SPARK
PLUG
P/Bu
REGULATOR/RECTIFIER
G/W
G
W/Y Bu/Y G
UP
SIDESTAND
CKP SWITCH
SENSOR
G
ECM
17-2
SISTEM PENGAPIAN
KETERANGAN SERVIS
UMUM
• ECM dapat rusak jika dijatuhkan. Juga jika connector dilepaskan sewaktu arus listrik mengalir.
• Voltase yang berlebihan dapat merus ak module. Selalu putar ignition switch ke OFF sebelum menservis .
• Pakailah
‚Ä¢The ECM busimay bedengan
damaged derajat panas yang
if dropped. Also iftepat. Pemakaian
the connector busi denganwhen
is disconnected derajat panas
current yang tidak tepat dapat merusak
is flowing.
mesin.
‚Ä¢The excessive voltage may damage the module. Always turn off the ignition switch before servicing.
• Beberapa
‚Ä¢Use komponen
spark plug listrik dapat
of the correct heat rusak
range.jika terminals
Using atau with
spark plug connec tors disambung
an incorrect atau can
heat range dilepaskan
damagesambungannya
the engine. sementara
ignition switch pada posisi ON dan ada arus listrik yang mengalir.
‚Ä¢Some electrical components may be damaged if terminals or connectors are connected or disconnected while the ignition
• Sewaktu menservis sistem pengapian, selalu ikuti langkah2 pada troubleshooting (hal. 17-4).
switch is ON position and current is present.
• Transistorized ignition system menggunakan sebuah ignition timing system yang diatur oleh listrik. Ignition timing (waktu
‚Ä¢When servicing the ignition system, always follow the steps in the troubleshooting (page 17-4).
pengapian)
‚Ä¢The tidak dapat
transistorized disetel.
ignition system uses an electrically controlled ignition timing system. No adjustments can be made to the
• ignition timing. ignition timing mengikuti putaran mes in. TP sensor memberikan sinyal kepada ECM untuk mengimbangi
ECM mengatur
ignition
‚Ä¢The ECM timing s esuai
varies dengan
ignition timingpembukaan
according throttle.
to the engine speed. The TP sensor signals the ECM to compensate the ignition
• timing
Ignition system to
according yang
the tidak
throttlebekerja dengan baik seringkali disebabkan oleh sambungan yang buruk atau connectors yang
opening.
‚Ä¢Aberkarat. Periksalah
faulty ignition sambungan2
system is often ini sebelum
related melanjutkan.
to poorly connected or corroded connectors. Check those connections before
• proceeding.
Untuk servis CKP sensor (hal. 11-5).
• Untuk
‚Ä¢For CKP servis ECM
sensor (hal. 6-41).
service (page 11-5).
‚Ä¢Forketerangan
Untuk ECM service 6-42). s witch (hal.
(pageignition
tentang
‚Ä¢For ignition switch information (page 17-3).
SPESIFIKASI
BAGIAN SPESIFIKASI
Busi Standard CPR6EA ‚Äì 9S (NGK), U20EPR9S (DENSO)
Untuk berkendaraan lama pada kecepatan tinggi CPR7EA ‚Äì 9S (NGK), U22EPR9S (DENSO)
Jarak renggang busi 0,80 ‚Äì 0,90 mm
Voltase puncak ignition coil Minimum 100 V
Voltase puncak CKP sensor Minimum 0,7 V
Waktu pengapian 10¬× BTDC pada putaran stasioner
TORSI PENGENCANGAN
TORQUE VALUE
Timing hole cap 1,5 N.m (0,15 kgf.m; 1,1 lbf.ft)
Timing hole cap 1.5 N¬²m (0.15 kgf¬²m, 1.1
lbf¬²ft.)
TOOLS
Imrie diagnostic tester (model 625) Test probe Timing cap wrench
atau Peak voltage adaptor 07ZAJ-RDJA110 07709-0010001
07HGJ-0020100
with commercially available digital mul-

timeter (impedance 10 MŒ©/DCV
minimum)
17-3
SISTEM PENGAPIAN
TROUBLESHOOTING
•‚Ä¢Inspect
Periksa yang the following
berikut inibefore diagnosing
sebelum the system.
mendiagnosa sistem.
‚ÄìTurn
- Putar the ignition
ignition switch
switch ke ON and
ON dan check
periksa the MIL
kedipan MILblinks
(hal.(page
6-13).6-13).
‚ÄìFaulty
- Bus spark plug
i tidak bekerja dengan baik
‚ÄìLoose
- Spark plugspark plug cap
cap longgar or spark
atau plug wire
sambungan connection
k abel busi longgar.
‚ÄìWater
- Air mas uk got into the
ke dalam spark
spark plug
plug capcap (Leaking the
(Kebocoran ignition
pada coilsekunder
voltase secondary voltage)
coil pengapian)
‚Ä¢If there is no spark at cylinder, temporarily exchange the ignition
• J ika tidak ada perc ikan bunga api pada cylinder, untuk sementara gantilah coil with a known-good one andignition
ignition coil dengan performcoil
thelain
spark test.
yang If there
diketahui
is spark, the original ignition coil is faulty.
berada dalam kondisi baik dan jalankan test percikan bunga api. Jika ada percikan bunga api, berarti ignition coil semula tidak
‚Ä¢"Initial voltage" of the ignition primary coil is the battery voltage with the ignition switch turned ON.
bekerja dengan baik.
• “Voltase awal” dari kumparan primer pengapian adalah voltase baterai sewaktu ignition switch diputar ke ON.
Tidak ada percikan bunga api pada busi
UNUSUAL CONDITION PROBABLE CAUSE (Check in numerical order)
Voltase primer Tidak ada voltase awal sewaktu igni- 1. Rangkaian terbuka atau connector longgar pada kawat hitam/
ignition coil tion switch diputar ke ON. (Kom- biru.
ponen listrik lain adalah normal) 2. Sambungan longgar atau buruk dari terminal kawat primer ig-
nition coil atau rangkaian terbuka pada kumparan primer.
Voltase awal adalah normal tetapi ia 1. Sambungan2 peak voltage adaptor tidak benar. (Sistem ada-
turun dengan 2-4 V sewaktu mesin lah normal jika voltase yang diukur lebih tinggi dari spesifikasi
diputar dengan sambungan terbalik.))
2. Muatan listrik baterai kurang. (Voltase turun banyak sewaktu
mesin distart.)
3. Sambungan longgar atau buruk atau rangkaian terbuka pada
kawat hijau dari ECM
4. Sambungan longgar atau buruk atau rangkaian terbuka pada
kawat Merah muda/biru antara ignition coil dan ECM.
5. Ada hubungan singkat di dalam kumparan primer ignition coil.
6. CKP sensor tidak bekerja dengan baik.(Ukur voltase puncak.)
7. ECM tidak bekerja dengan baik (jika No.1 s/dgn. 6 di atas
adalah normal).
Voltase awal adalah normal tetapi 1. Sambungan2 peak voltage adaptor tidak benar. (Sistem ada-
tidak ada voltase puncak sewaktu lah normal jika voltase yang diukur adalah lebih tinggi dari
mesin diputar. spesifikasi dengan sambungan terbalik.)
2. Peak voltage adaptor tidak bekerja dengan baik.
3. Rangkaian terbuka atau sambungan buruk pada kawat Hijau/
putih atau Hijau dari sidestand switch
4. Sidestand switch tidak bekerja dengan baik.
5. ECM tidak bekerja dengan baik (jika No. 1 s/dgn. 4 di atas
adalah normal).
Voltase awal adalah normal tetapi 1. Impedansi multimeter terlalu rendah, di bawah 10 MW/DCV.
voltase puncak lebih rendah daripa- 2. Kecepatan pemutaran mesin terlalu pelan. (Muatan baterai
da nilai standard. kurang.)
3. Sampling timing (pengaturan waktu pengambilan contoh) dari
tester dan pulsa yang diukur tidak sinkron. (Sistem adalah
normal jika voltase yang diukur sedikitnya sekali di atas
voltase standard.)
4. ECM tidak bekerja dengan baik (jika No.1 s/dgn. 3 di atas
adalah normal).
Voltase awal dan voltase puncak 1. Busi tidak bekerja dengan baik atau ada kebocoran arus
adalah normal tetapi tidak ada perci- sekunder pada ignition coil.
kan bunga api. 2. Ignition coil tidak bekerja dengan baik.
CKP sensor Voltase puncak lebih rendah daripa- 1. Impedansi multimeter terlalu rendah, di bawah 10 MW/DCV.
da nilai standard. 2. Kecepatan pemutaran mesin terlalu pelan. (Muatan baterai
kurang.)
3. Sampling timing (pengaturan waktu pengambilan contoh) dari
tester dan pulsa yang diukur tidak sinkron. (Sistem adalah
normal jika voltase yang diukur sedikitnya sekali di atas
voltase standard.)
4. CKP sensor tidak bekerja dengan baik (jika No. 1 s/dgn. 3 di
atas adalah normal).
Tidak ada voltase puncak. 1. Peak voltage adaptor tidak bekerja dengan baik.
2. CKP sensor tidak bekerja dengan baik.
17-4
SISTEM PENGAPIAN
PEMERIKSAAN IGNITION
IGNITION SYSTEM SYSTEM
INSPECTION
(SISTEM PENGAPIAN)
‚Ä¢If there is no spark at the spark plug, check all
CATATAN:
• J ika
connections for loose
tidak ada percikan bungaor api
poorpadacontact before
busi, periksa
measuring
s emua the peak terhadap
sambungan voltage. kontak longgar atau
‚Ä¢Use commercially
buruk sebelum available
mengukur digital
voltase multimeter with
puncak.
an impedance
• Pakailah digitalof 10 M‚Ñ¶/DCV dengan
multimeter minimum. impedansi
‚Ä¢The
minimumdisplay value yang
10 M? /DCV differs depending
dapat upon the
dibeli di pasaran.
internal impedance of the multimeter.
• Nilai tayangan berbeda tergantung pada impedansi
‚Ä¢If the imrie diagnostic tester (model 625) is used,
internal dari multimeter.
follow the manufacturer‚Äôs instructions.
• J ika Imrie diagnostic tester (model 625) yang dipakai,
Connect the peak
ikuti petunjuk voltagepabrik
pemakaian adaptor [1] to the digital
pembuatnya.
multimeter [2], or use the Imrie diagnostic tester. [2]
Hubungkan peak voltage adaptor [1] pada digital
multimeter
TOOLS: [2], atau pakailah Imrie diagnostic tester.
TOOLS:
Imrie diagnostic tester (model 625) or
Imrie
Peakdiagnostic tester (model 625)07HGJ-0020100
voltage adaptor
atau withPeak voltage adaptor
commercially available digital07HGJ-0020100
multimeter
dengan digital 10multimeter
(impedance yang dapat dibeli di
M‚Ñ¶/DCV minimum)
pasaran (impedansi minimum 10 M? /DCV)
[1]
VOLTASE
IGNITIONPUNC
COILAK KUMPARAN
PRIMARY PEAK
PRIMER
VOLTAGEIGNITION COIL
CATATAN:
• ‚Ä¢Check
Periksa all semua
systemsambungan
connections sistem sebelum
before performing
menjalankan
this inspection. pemeriksaan ini. Connectors
Loose connectors yang
can cause
longgar dapat
incorrect menyebabkan pembacaan yang salah.
readings.
• ‚Ä¢Check
Periksalahcylinder
kompressicompression and periksa
c ylinder dan check that the
bahwa
spark
busi plug
telah is installed
dipasang correctly.
dengan benar.
Support sepedamotor
Letakkan the motorcyclepadawith centerstand-nya.
its centerstand.
[1]
Disconnect
Lepaskan the plug
spark sparkcapplug
[1]cap
dari[1] from the spark plug.
busi.
Connect a known
Sambungkan busi good spark diketahui
[2] yang plug [2] toberada
the spark plug
dalam
cap and ground the spark plug to the cylinder
keadaan baik pada s park plug c ap dan hubungkan busi head as
kedone in a spark
massa pada test.
cylinder head seperti dilakukan pada
test percikan bunga api busi.
[2]
17-5
SISTEM PENGAPIAN
Lepaskan rightright
Remove the lower sideside
lower cover (hal.(page
cover 3-12).3-12).
DoJangan lepaskan Dengan
not disconnect With the kawat primer
ignition coil primary ignition coil tersambung,
wire connected, connect [1]
kawatthe
primer ignition
ignition coil hubungkan peak voltage
the peak voltage adaptor adaptor
or Imrieatau Imrie
tester to tester pada
the ignition
coil. terminal
primary wire. coil primary terminal
primer ignition[1]coil
and [1]ground.
dan massa.
TOOLS:
TOOLS:
Imrie
Imriediagnostic
diagnostictester
tester(model
(model625)
625) or
atau
PeakPeak voltage
voltage adaptor
adaptor 07HGJ-0020100
07HGJ-0020100
dengan digital multimavailable
with commercially eter (impedansi minimum(im-
digital multimeter 10
M? pedance
/DCV) yang dapat dibeli di
10 M‚Ñ¶/DCV minimum)pasaran
HUBUNGAN:
CONNECTION:
Terminal Merah m uda/biru (+) – Massa badan (-)
Pink/blue terminal (+) ‚Äì Body ground (‚Äì)
Putar ignition switch ke ON.
Turn the
Periksa ignition
voltase switch
awal padaON.
waktu ini.
Check baterai
Voltase the initial voltage
harus at this time.
diukur.
Thevoltase
Jika battery awal
voltage should
tidak dapatbediukur,
measured.
ikuti pemeriksaan
If the initial voltage cannot be
pada tabel troubleshooting (hal. 17-4). measured, follow the
ECM
checks in the troubleshooting table (page 17-4).
Jangan menyentuh Tarik sidestand ke atas. P/Bu
Avoid
busitouching
dan jarumthe Retract the sidestand.
Tekan brake lever sepenuhnya. (+)
spark plug and Squeeze the brake lever fully. Bl/Bu
pentegesan tester Putar mesin dengan starter motor dan ukur voltase
tester
agar tidakprobes
terkena to Crank the engine with the starter motor measure the
puncak primer ignition coil. From
prevent electric ignition coil primary peak voltage. (‚Ä
kejutan lis trik. IGNITION
shock. VOLTASE PUNCAK: minimum 100 V
PEAK SWITCH
VOLTAGE:
Jika voltase 100 V minimum
puncak tidak normal, bacalah
troubleshooting pada hal. 17-4.
If the peak voltage is abnormal, refer to the IGNITION
troubleshooting
Pas ondilepaskan
ang parts yang page 17-4.dalam urutan terbalik dari COIL
pelepas an.
Install the removed parts in the reverse order of
removal.
VOLTASE PUNC AK
CKP SENSOR CKPVOLTAGE
PEAK SENSOR
CATATAN:
• ‚Ä¢Check
Periksa kompressi cylinder dan and
cylinder compression perikscheck
a bahwa
that busi
the
telah dipasang
spark dengan benar.
plug is installed correctly.
Lepaskan rightright
Remove the body cover
body (hal.(page
cover 3-13).3-13).
Putar
Turnignition switch
the ignition ke “OFF”.
switch "OFF".
Lepaskan
DisconnectECM
the33P
ECM connector (Hitam)
33P (Black) [1]. [1].
connector
Connect the Imrie
Hubungkan Imrie diagnostic
diagnostic tester
testeror peak
atau voltage
jarum
pengetesan peaktovoltage
adaptor probes the ECMadaptor ke terminal
33P connector ECM 33P
terminals.
connector.
TOOLS:
Imrie diagnostic tester (model 625) or
TOOLS:
Peakdiagnostic
Imrie voltage adaptor 07HGJ-0020100
tester (model 625) atau
with voltage
Peak commercially
adaptor available digital multimeter
07HGJ-0020100
(impedance 10 M‚Ñ¶/DCV minimum)
dengan digital multim eter (impedansi minimum 10
Test
M? probe
/DCV) 07ZAJ-RDJA110
yang dapat dibeli di pasaran [1]
CONNECTION: Blue/yellow (+) ‚Äì White/yellow (‚Äì)
HUBUNGAN: Biru/kuning ECM 33P CONNECTOR (HITAM)
Turn the ignition switch ON.(+) – Putih/kuning (-) (Sisi kawat / terminal betina)
Putar ignition
Retract switch ke ON.
the sidestand.
Tarik sidestandbrake
Squeeze the lever fully.
ke atas.
Crankbrake
Tekan the engine with the starter motor and measure
lever sepenuhnya. Bu/Y
the CKP
Putar sensor
mesin peak voltage.
dengan starter motor dan ukur voltase
puncak
PEAK CKP s ensor.0.7 V minimum
VOLTAGE:
W/Y
VOLTASE
If the peakPUNCAK: minimumat0,7
voltage measured theVECM connector is
Jika voltase punc ak yang diukur padaat ECM
abnormal, measure the peak voltage the CKP sensor
connector
wire normal,
tidak connectors.
ukurlah voltase puncak pada connectors
kawat CKP sensor.
17-6
SISTEM PENGAPIAN
Lepaskan left cleft
Remove the rankcase rearrear
crankcase cover (hal.(page
cover 3-17).3-17).
[2] [1]
Turn ignition
switch OFF.
ke OFF.
Disconnect
Lepaskan the CKP
connector kawatsensor wire (White/yellow)
(Putih/kuning) CKP sensor
connector
[1] dan c[1] and (Blue/yellow)
onnector (Biru/kuning) connector [2], then
[2], kemudian
connect the
hubungkan peak
peak voltage
voltage tester
tester or adaptor
atau probes to
jarum pengetesan
the connector
adaptor pada terminals
connectorof the CKP sensor
terminals padaside.
sisi CKP
sens or.
CONNECTION: Blue/yellow (+) ‚Äì White/yellow (‚Äì)
HUBUNGAN: Biru/kuning (+) – Putih/kuning (-)
In the same manner as at the ECM 33P (Black)
connector,
Dengan carameasure the peak
sama seperti voltage
pada ECM and compare
33P it to
connector
the voltage
(Hitam), ukurmeasured at the ECM
voltas e puncak dan 33P connector.
bandingkan dengan
voltase
‚Ä¢If yang diukurvoltage
the peak pada ECM 33P connector.
measured at the ECM is
• Jika voltas e punc ak yang diukuratpada
abnormal and the one measured the CKP
ECMsensor
tidak
normal dan yang diukur pada CKP sensorcircuit
is normal, the wire harness has an open adalah or
loose connection.
normal, maka wire harness mempunyai rangkaian
‚Ä¢If the peak voltage of the CKP sensor side is lower
terbuka atau sambungan longgar.
than standard value, follow the checks described in
• Jika voltase puncak pada sisi CKP sensor lebih PV
the troubleshooting on page 17-4.
rendah daripada nilai standard, ikuti pemeriksaan (‚Ä
If the
yangCKP sensorpada
diuraikan is faulty, replace the
troubleshooting CKP
pada hal.sensor
17-4. (+)
(page 11-5).
Jika CKP
Install thesensor tidakparts
removed bekerjain dengan baik, order
the reverse gantilahof
CKP sensor (hal. 11-5). W/Y Bu/Y
removal.
CKP
pelepas an.
SENSOR
IGNITION COIL
Remove the
Lepaskan following:
sebagai berikut: [2] [1] [3]/[4]
- ‚Äì
Main pipe cover
Main pipe cover(hal. 3-15)
(page 3-15)
- ‚Äì
Spark plug
Spark cap
plug cap(hal. 4-7)4-7)
(page
Lepaskan
Disconnectconnector kawat
the ignition coil (Biru/kuning) ignition
wire (Blue/yellow) coil [1]
connector
[1] and
dan (Pink/blue)
connector (Merahconnector
muda/biru)[2]. [2].
Remove the
Lepaskan bolts [3],
baut-baut [3],spacers
spacers[4][4]and
danignition
ignitioncoil
coil[5].
[5].
dalam of removal.
terbalik dari
pelepas an.
[5]
IGNITION TIMING (WAKTU PENGAPIAN)

Panaskan
Warm up mes in.
the engine.
[1]
Stop the
Matikan engine
mesin dan and remove
lepaskan the hole
timing timing
caphole cap [1]
[1] dengan
using the special
menggunakan tool.tool.
special
TOOL:
TOOL:
Timingcap
Timing capwrench
wrench 07709-0010001
07709-0010001
17-7
SISTEM PENGAPIAN
Hubungkan
Connect a tachometer.
[3]
Bacalah Read
petunjuk
the Hubungkan
Connect thetiming light
timing [1][1]
light pada kabel
to the busi.
spark plug wire.
pabrik pembuat untuk
manufacturer‚Äôs
pengoperasian timing Hidupkan
Start the mesin
enginedan
andbiarkan berputar stasioner.
let it idle.
instructions for
light. -1
timing light PUTARAN STASIONER:
IDLE SPEED:1,400 ¬± 100 min±-1 100
1.400 m enit (rpm)
(rpm)
operation. [2]
Waktu pengapian
The ignition timingadalah tepatif jika
is correct tanda
the "F" “F”[2]
mark [2]on
pada
the
flywheel
flywheelbertepatan
aligns withdengan takik penunjuk
the index notch [3] [3]
onpada
the left
left
crankcase
crankcasecover.
cover.
[1]
Berikan oli mesin

Apply engine oil pada O-ring
to a new baru[1].
O-ring [1].
[2]
Install and tighten the timing hole cap [2] to the
Pas ang dan kencangkan timing hole cap [2] dengan
specified torque.
TORQUE: 1.5 N¬²m (0.15 kgf¬²m, 1.1 lbf¬²ft)
TORSI: 1,5 N.m (0,15 kgf.m;1,1 lbf.ft)
[1]
17-8
18. ELECTRIC STARTER SYSTEM
LOK ASI SISTEM..........................................

SYSTEM LOCATION···································18-2 18-2 TROUBLESHOOTING
TROUBLESHOOTING...............................
································18-4
18-4
DIAGRAM SISTEM ......................................

SYSTEM DIAGRAM 18-2
····································18-2 STARTER
STARTER MOTOR.....................................
MOTOR ·····································18-6
18-6
KETER ANGAN SERVIS .............................. 18-3 STARTER RELAY ...................................... 18-10
SERVICE INFORMATION ···························18-3 STARTER RELAY····································· 18-10
18
18-1
ELECTRIC STARTER SYSTEM
LOKASI SISTEM
SUB FUSE 10 A
STARTER SWITCH
MAIN FUSE 15 A
FRONT BRAKE
LIGHT SWITCH ECM
STARTER
RELAY
IGNITION SWITCH
RESISTOR
BATTERY
STARTER MOTOR
SIDESTAND SWITCH REAR BRAKE LIGHT SWITCH
DIAGRAM DIAGRAM
MAIN FUSE SUB FUSE Bl: Black
15 A 10 A G: Green
R R/Y Bl/R P: Pink
R: Red
IGNITION W: White
Bl
STARTER SWITCH Y: Yellow
RELAY
FRONT BRAKE REAR BRAKE

LIGHT SWITCH LIGHT SWITCH
G R
SIDESTAND
SWITCH
BATTERY G/Y
G/W G
UP
G/Y P
R/W
Y/R G/Y
RESISTOR
G/Y
STARTER
STARTER
MOTOR
SWITCH
ECM
18-2
KETERANGAN SERVIS
SERVICE INFORMATION
GENERAL
UMUM
•• Alwaysputar
Selalu turn the ignition
ignition switchke
switch "OFF"
“OFF”before servicing
sebelum the starter
menservis motor.
starter The motor
motor. Motorcould
dapatsuddenly start, causing
dihidupkan dengan serious injury.
tiba-tiba, dan
• A weak batteryluka-luka
menyebabkan may be unable
parah. to turn the starter motor quickly enough, or supply adequate ignition current.
•• The starter
Baterai yangmotor
lemahcan be serviced
mungkin with the memutar
tid ak mampu engine installed
starter in the frame.
motor dengan cukup cepat, atau memberikan arus pengapian yang
• When
mencukupi. checking the starter system, always follow the steps in the troubleshooting (page 18-4).
•• If the current
Starter is keptdiservis
motor dapat flowingdengan
throughmesin
the starter motorpada
terpasang to turn it while the engine is not cranking over, the starter motor may be
rangka.
damaged.
• Sewaktu memeriksa sistem starter, selalu ikuti langkah-langkah pada troubleshooting (h al. 18-4 ).
• Refer to the following component information.
• Jika arus listrik
– Ignition switchdibiarkan mengalir melalui starter motor untu k memutarnya sedangkan mesin ti dak berputar, starter motor
(page 19-12)
mungkin
– Starterakanswitchrusak.
(page 19-14)
• Bacalah
– Brakeinformasi tentang
light switches komponen
(page 19-17) berikut:
- – Ig nition switch
Sidestand switch(hal. 19-12)
(page 19-18)
- Starter switch (hal. 19-12)
- Brake light switches (hal. 19-15)
- Sidestand switch (hal. 19-17)
SPESIFIKASI
Satuan: mm
Panjang sikat starter motor 7,0 3,5
TORSI
TORQUEPENGENCANGAN
VALUES
Sekrup starter motor cable 2 N.m (0,20 kgf.m; 1,5 lbf.ft)
Starter motor cable screw
Sekrup starter motor case
2 N·m (0.20 kgf·m, 1.5 lbf·ft)
4,2 N.m (0,43 kgf.m; 3,1 lbf.ft)
Starter motor case screw 4.2 N·m (0.43 kgf·m, 3.1 lbf·ft)
TOOL
Test probe
07ZAJ-RDJA110
18-3
TROUBLESHOOTING
Start er mmotor
Starter otor tidak
doesberputar
not turn
1.1.Pemeriksaan
Standard Inspection
Standard
Check
Periksa for following:
terhadap yang beri kut:
– Battery
- Kondisi condition
bater ai
– ing
- Sekr Burned
putusfuse
Are hal-hal
Apakah the above items
di atas in good
dalam condition?
kondisi baik?
– GO TO STEP
YA YES- LANJUTKAN 2.
DENGAN L ANGKAH 2
NO – Replace or repair the malfunction
TIDAK - G anti atau perbaiki parts yang part(s). den gan baik.
tidak berfungsi
2.2.Cara
Starter
kerjaRelay Operation
Starter Relay
Putar ignition switch ke “O N”.
Retract the sidestand and squeeze the brake lever fully.
Nai kkan sidestand ke atas dan tarik br ake lever sepen uhnya.
Push the starter switch.
TekanYoustarter
shouldswitch.
hear the relay "CLICK" when the starter switch is depressed.
Relay har us berbu nyi “ KLIK” sewaktu starter switch di tekan.
Is the "CLICK" heard?
Apakah
YESsuara– GO“KLIK” terdengar?
TO STEP 3.
YA NO - LANJUTKAN DENGAN
– GO TO STEP 5. L ANGKAH 3
TIDAK - LANJUTKAN
3. Starter DENGAN
Relay Continuity L ANGKAH 5
Inspection
3.Pem eriksaan
Check Kontinuitas
the starter relay forStarter Relay
continuity (page 18-11).
Periksa starter
Is there relay terhadap kontinuitas (hal. 18-11).
continuity?
Apakah
YESada– kontinuitas?
GO TO STEP 4.
YA NO - LANJUTKAN DENGAN
– Faulty starter relay. L ANGKAH 4
TIDAK - Starter
4. Starter Motorrelay ti dak bekerja dengan baik.
Inspection
Apply batteryStart
4. Pemeriksaan voltage to the starter motor directly and check the operation.
er Motor
Doesvoltase
Teruskan the starter motor
batera turn?ke starter motor dan periksa cara kerjanya.
i langsung
YESstart
Apakah • m
– er Open
otor circuit in Red wire between the starter relay and battery.
berputar?
• Open circuit in Red/white wire between the starter relay and starter motor.
YA -
NO – Faulty
• Rangkaian starter
ter buka padamotor.
kawat Merah antara starter relay dan baterai.
• Rangkaian
5. ter buka
Starter Relay Coil pada
Circuitkawat Merah/putih antara starter relay dan starter motor.
Inspection
TIDAK - Starterthe
Disconnect motor tidak
starter bekerja
relay dengan baik.
5P connector.
5. Pemeriksaan Ra ngkaian
Retract the sidestand andStarter
squeeze Relay
the Coil
brake lever fully.
Push the
Lepaskan starter
starter r elayswitch andector.
5 P conn measure the battery voltage between the starter relay 5P connector terminal of
Putarthe wire harness
ignition switch ke side.
“O N”.
TarikCONNECTION:
side stand ke ata s da n tekan
Yellow/red (+)br–ake lever sepenu
Green/white (–)hnya.
Tekan starter switch dan ukur voltase baterai antara starter relay 5P connector terminal pada sisi wire harness.
Does the battery voltage exist?
HUBUNG
YES AN: Kuning/merah
– Intermittent (+) – Hijau/putih (-)
failure.
Apakah
NO ada– voltase
• Loose batera i? connected connector.
or poorly
YA • Open circuit in Green/white wire between the starter relay and sidestand switch.
- Keg agal an ter putus-putus.
• Open circuit in Yellow/Red wire between the starter switch and starter relay.
TIDAK - • Open circuit in Green wire between the sidestand switch and ground.
• • Open
Connector circuitatau
longgar in Green/yellow wire between
tersambung dengan buruk.the brake light switch and starter switch.
• • Open
Rangkaian circuitpada
terbuka in Black
kawatwire between antara
Hijau/putih the ignition switch
starter relayand
danbrake light switches.
sidestand switch.
• • Faulty
Rangkaian starter
terbuka padaswitch (page
kawat 19-14).
Kuning/Merah antara starter switch dan starter re lay
• • Faulty
Rangkaian sidestand
terbuka switch Hijau
pada kawat (pageantara
19-18)sidestand switch dan massa.
• Faulty brake light switches (page 19-17)
• Rangkaian terbuka pada kawat Hijau/kuning antara brake light switch da n starter switch.
• Rangkaian terbuka pada kawat Hitam antara ignition switch dan brake light switches.
• Starter switch tida k bekerja dengan baik (hal. 19-12).
• Sidestand switch tidak bekerja d engan baik (hal. 19-17).
• Brake light switches tidak bekerja dengan baik (hal. 19-15).
18-4
Starter
Starter motor
motor berputar,
turns, buttetapi mesindoes
the engine tidaknot
mau hidup
start
•• Rangkaian
Open circuit or poor
terbuka connection
atau hubunganin buruk
Green/yellow wire Hijau/kuning
pada kawat between the brake
antaralight switches
brake and ECM.
light switches dan ECM.
Starter motor
Starter motor memutar
turns engine mesin slowly
dengan pelan
•• Voltas
Low battery voltage.
e baterai rendah
•• Battery
Poorly terminal
connected battery
cable terminal dengan
ters ambung cable. buruk
• Poorly connected starter motor cable.
• Starter motor cable ters ambung dengan buruk
• Faulty starter motor.
•• Starter
Poorly motor tidak battery
connected bekerjaground
dengancable.
baik
• Kabel massa baterai tersambung dengan buruk
Starter motor turns, but engine does not turn
Starter motor
• Starter motorberputar,
is runningtetapi mesin tidak berputar
backwards.
• Starter
– Casemotor berputar
assembled terbalik
improperly.
- Case dirakit dengan
– Terminals tidakimproperly.
connected benar
- • Terminal tersambung
Faulty starter dengan
clutch (page tidak benar
11-10).
•Starter
Starter clutc h tidak bekerja dengan
relay "CLICK", but engine does baiknot
(hal.turn
11-10).
• Crankshaft
Starter does not“KLIK”,
r elay berbunyi turn duetetapi
to engine problems.
mesin tidak berputar
•• Crankshaft
Faulty starter clutch
tidak .(page
berputar 11-10)
akibat persoalan pada mesin.
• Starter clutc h tidak bekerja dengan baik (hal. 11-10).
18-5
STARTER MOTOR
PELEPASAN
REMOVAL
Lepas kan the
Remove rightright
bodybody
cover (hal.(page
cover 3-13).3-13).
[2] [3]
Lepas kan clutch
Release cov er
the clutch outletoutlet
cover duct duct
boss boss
[1] dari
[1] clamp [2]
from the
clamp
dari [2] of
rangka thelepaskan
dan frame and disconnect
starter thec starter
motor 2P onnector motor
[3].
2P connector [3].
[1]
Lepas kan baut-baut
Remove the bolts [1]
[1] dan
andstarter
startermotor
motor[2] [2]
darifrom
mesin.
the
[2]
engine.
[1]
Remove
Lepas kan the O-ring
O-ring [1]. [1].
[1]
DISASSEMBLY
PEMBONGK ARAN
Pull off
Tarik thedust
lepas dustcov
cover [1].
er [1]. [4]/[5] [2]/[3]
Remove the
Lepaskan screw
sekrup [2] [2]
danand starter
starter motor
motor cable
cable [3].[3].
Remove the
Lepaskan screw
sekrup [4] [4]
danand ground
kabel massacable
[5]. [5].
[1]
18-6
Lepaskan sekrup-sekrup
Remove the [1] dan
screws [1] and starter
starter motor
motor casecase
[2]. [2].
Lepaskan
following:
- Armature [3]
– Armature [3]
- Bracket [4]
– Bracket [4]
- –Springs
Springs[5][5]
- –Gasket [6]
Gasket [6]
[1] [2]
[3]
[5]
[6]
[4]
PEMERIKSAAN
INSPECTION
BRUSH
BRUSH
Inspect brus
Periksa the brushes for damage
hes (s ikat-sikat) and measure
terhadap the brush
kerusakan dan
length.
ukur panjang brush.
BATAS SERVIS:
SERVICE LIMIT: 3,5
3.5 mm
mm (0.14 in)
18-7
ARMATURE
ARMATURE
Do not use
Jangan Inspect commutator
emery Periksa
memakai the commutator
bars bars [1] ofarmature
[1] dari the armature for
terhadap
or sandatau
emery paper discoloration.
on perubahan
kertas warna. [1]
amplas pada
the commutator.
Bars discolored
commutator. Lempengan in pairs
yang indicate
berubah shorted
warna coils.pasangan
dalam
menunjukkan adanya kumparan yang ada hubungan
singkat.
Periksa terhadap
Check for continuitykontinuitas antara
between each pair masing-masing
of commutator
KONTINUITAS:
bars.
pasangan lempengan commutator.
Thereada
Harus should be continuity.
kontinuitas.
Periksa terhadap
Check for continuitykontinuitas antara
between each masing-masing
commutator bar and
lempengan commutator dan armature shaft.
armature shaft. TIDAK KONTINUITAS:
Thereboleh
Tidak should
adabekontinuitas.
no continuity.
ASSEMBLY
PERAK ITAN
Install the
Pasang springs
springs [1]dalam
[1] di in the brush
brush holders
holders [2]
[2].
[2]
[1]
18-8
Pasang
Install thearmature
armature [1] ke the
[1] into dalam brac
bracket ket holding
while sementara
the
menahan brushes [2].
brushes [2]. [1]
[2]
Kumparan dapat Install agasket

Pasang new gasket [1]pada
baru [1] onto bracket
the bracket[2]. [2]. [2] [4]
rusak
The jik a magnet
coil may be Install the
Pasang bracket
bracket danand armature
armature [3] [3]
padato the
motormotor
case case
[4]
menarik
damagedarmature
if the [4] while holding
sementara the bracket
memegang side armature
bracket shaft tightly.
side armature shaft
terhadap
magnet c ase.
pulls the dengan erat.
armature against
the case.
[3]
[1]
Install the
Pasang two sekrup
kedua starter starter
motor case screws
motor [1].
case [1].
[1]
Tempatkan kabel
Set the ground cablemassa [1] pada
[1] onto starter
the starter motor
motor case
case as
[1]/[2] To be butted
seperti
shown.diperlihatkan.
Pasang sekrup
Install the [2].[2].
screw
Tighten the ketiga
Kencangkan three starter
sekrup motor
starter case
motorscrews to the
case dengan
specified
torsi torque.
yang ditentukan.
TORQUE:
TORSI: 4,24.2
N.mN·m (0.43
(0,43 kgf·m,
lbf.ft)
Pasang starter
Install the motor
starter motorc able [3] [3]
cable dan kencangkan
and tighten the sekrup
screw [3]/[4]
[4]
[4]dengan torsi yangtorque.
to the specified ditentukan.
TORSI: 2 N.m
TORQUE: (0,20
2 N·m kgf.m;
(0.20 1,51.5
kgf·m, lbf.ft)
lbf·ft)
Tarik dust
Put the cover
dust [5] kembali
cover [5] back pada
in the posisi yang sesuai.
appropriate position. [5]
18-9
INSTALLATION
PEMASANGAN
Coat a O-ring
Lumasi new O-ring
baru [1]
[1] with engine
dengan oli oil and install
mesin it into
dan pasang
the starter
pada motormotor.
alur starter groove.
[1]
Pasang starter
Install the motor
starter [1] dan
motor baut-baut
[1] and bolts [2][2]topada mesin.
the engine.
[1]
Tighten the bolts.
Kencangkan baut-baut.
[2]
Sambungkan
Connect the starter
starter motor
motor2P2Pconnec tor [1]
connector [1]dan
andpasang
install
[3] [1]
the clutch
clutch covercover
outletoutlet
duct duct
bossboss [2]dalam
[2] ke into the clamp
clamp [3][3] of
dari
the frame.
rangka.
Install the
Pasang right
right body
body cover
cover (page
(hal. 3-13).
3-13).
[2]
STARTER RELAY
Remove the
Lepaskan battery
battery cover
cover (hal.(page
16-6).16-7).
[3] [2]
Remove the
Lepaskan starter
starter relay
relay [1] from
[1] dari stay the
[2]. stay [2].
Disconnect
Lepaskan the starter
starter relay
relay 5P 5P connector
connector [3]. [3].
Installation is in the reverse
Pemasangan adalah dalam urutan order of removal.
terbalik dari
pelepas an.
[1]
18-10
OPERATION INSPECTION
PEMERIKSAAN CARA KERJA
Remove the
Lepaskan battery
battery cover
cover (hal.(page
16-6).16-7).
[1]
Turn the ignition switch
Putar ignition switch ke “ON”. "ON".
Retract
Tarik the sidestand
sidestand ke and
atassqueeze the brake
dan tekan braklever fully.
e lever
Push the starter switch.
sepenuhnya.
The system
Tekan starter is normal
switc h. if the starter relay [1] clicks.
Sistem adalah normal
If you don’t hear the relay jika"CLICK",
s tarter inspect
relay [1]
the berbunyi
“KLIK”.
following:
Jika relay tidak berbunyi “KLIK”, periks alah s ebagai
– Starter relay coil circuit (page 18-12)
berikut:
– Battery (page 16-7)
- Rangkaian starter relay coil (hal. 18-12)
- IfBaterai
you hear the16-6)
(hal. relay "CLICK", but starter does not turn,
inspect the starter relay continuity (page 18-11).
Jika relay berbunyi “KLIK”, tetapi starter tidak berputar,
periksalah kontinuitas starter relay (hal. 18-11).
STARTER RELAY
PEMERIKSAAN CONTINUITY
KONTINUITAS STARTER
INSPECTION
RELAY
Remove the
Lepaskan starter
starter relay
relay [1] (page
[1] (hal. 18-10).
18-10).
Connect a fully
Hubungkan charged
kawat positif12 V battery
baterai 12Vpositive wire to the
yang bermuatan
relay switch
penuh terminal
pada relay A and
switch negative
terminal A wire
dan to the terminal
kawat negatif
B. terminal B.
pada
Check for
terhadap at the terminal C and
pada terminal
terminal C D.
dan
terminal D.
There should be continuity between the C and D
Harus ada kontinuitas
terminals while the antara terminals
battery C dan D sewaktu
is connected, and no
baterai dihubungkan,
continuity dan tidak
when the battery ada kontinuitas sewaktu
is disconnected.
baterai dilepaskan. A C
B D
[1]
A B C D
18-11
STARTER RELAY
PEMERIKSAAN COIL CIRCUIT
RANGKAIAN
INSPECTION
KUMPAR AN STAR TER RELAY
Remove the
Lepaskan battery
battery cover
cover (hal.(page
16-6).16-7). [3] [2]
Lepaskan starter relay [1] darifrom
Remove the starter relay [1] stay the
[2]. stay [2].
Lepaskan starter relay 5P connec tor [3]. [3].
Disconnect the starter relay 5P connector
Turn ignition
switch "ON".
ke “ON”.
Retract the sidestand and squeeze the brake lever fully.
Tarik sidestand ke atas dan tekan brak e lever
Measure the voltage between the starter relay 5P
sepenuhnya.
connector of the wire harness side while pressing and
Ukur voltase antara starter relay 5P c onnector pada sisi
holding the starter switch.
wire harness sementara menekan dan menahan starter
CONNECTION: Yellow/red (+) – Green/white (–)
switch.
If the battery Kuning/merah
HUBUNGAN: voltage appears
(+)only when the (-)
– Hijau/putih ignition
switch is "ON" and starter switch is pressed, the circuit
Jika voltase baterai hanya tampak sewaktu ignition
is normal.
[1]
switch pada “ON” dan starter switch ditekan, maka
rangkaian adalah normal.
SIDESTAND
SWITCH
G
BRAKE LIGHT
SWITCHES
G/W
Y/R G/Y Bl
From
IGNITION
[3] STARTER SWITCH SWITCH
INHIBITOR LINE
SALURAN INHIBITOR
(STARTER
(STARTER MOTOR
MOTOR TURNS, BUT
BERPUTAR, THE
TETAPI
ENGINE
MESIN DOES
TIDAK NOT
MAU START)
HIDUP)
Remove the
Lepaskan rightright
bodybody cover
cover (hal.(page
3-13).3-13).
Turn ignition
switch "OFF".
ke “OFF”.
Disconnect the ECM
Lepaskan ECM 33P connector33P (Black) connector
(Hitam) [1]. [1].
Turn ignition
switch "ON".
ke “ON”.
Squeeze the brake lever fully.
Tekan brake lever sepenuhnya.
Measure the voltage between the ECM 33P connector
Ukur voltase antara ECM 33P connector pada sisi wire
of the wire harness side and ground.
harness dan massa.
TOOL:
TOOL:
CONNECTION:
HUBUNGAN: Green/yellow
Hijau/kuning (+) (+) – Ground
– Massa (-) (–)
Jika voltas
If the e baterai
battery voltagetampak, rangkaian
appears, adalah
the circuit normal.
is normal. [1]
ECM 33P CONNECTOR (HITAM)

(sisi kawat/terminal betina)
G/Y
18-12
19. LAMPU/METER/SAKELAR
SYSTEM
LOK LOCATION···································19-2
ASI SISTEM.......................................... 19-2 IGNITION SWITCH
IGNITION SWITCH····································
.................................... 19-10

···························19-3 HANDLEBAR
HANDLEBAR SWITCH ES.........................
SWITCHES ························ 19-12
PEMERIKSAAN RANGKAIAN
LIGHTING CIRCUIT INSPECTION ·············19-4 BRAKE
BRAKE LIGHT
LIGHT SWITCH
SWITCH............................ 19-13
··························· 19-13
PENERAN GAN ............................................ 19-4
HORN (KLAKSON) .................................... 19-14
HEADLIGHT/FRONT
LAMPU BESAR/LAMPU TURN SEIN SIGNAL
DEPAN ...... 19-5 HORN ························································ 19-14
LIGHT ··························································19-5
RELAY LAMPU SEIN ................................ 19-15
LAMPU KOMB INASI BELAKANG.............. 19-6 TURN SIGNAL LIGHT RELAY ················· 19-15
REAR COMBINATION LIGHT ····················19-6 SIDESTAND SWITCH ................................ 19-16
SPEEDOMETER .......................................... 19-7 SIDESTAND SWITCH ······························· 19-15
SPEEDOMETER··········································19-7 RESISTOR .................................................. 19-17
FUEL METER /FUEL LEVEL SENSOR ....... 19-9 RESISTOR ················································ 19-17
FUEL METER/FUEL LEVEL SENSOR ·······19-9
19
19-1
LAMPU/METER/SAKELAR
LOKASI SISTEM
LIGHTS/METERS/SWITCHES
FRONT BRAKE
LIGHTING SWITCH
LIGHT SWITCH
STARTER SWITCH
SPEEDOMETER
TURN SIGNAL FUEL LEVEL SENSOR

LIGHT RELAY
IGNITION SWITCH
MAIN FUSE 15A
SUB FUSE 10A
DIMMER
SWITCH
HORN SWITCH
TURN SIGNAL
LIGHT SWITCH
RESISTOR
HORN
REAR BRAKE LIGHT

SWITCH
SIDESTAND SWITCH
19-2
LAMPU/METER/SAKELAR
KETERANGAN SERVIS
SERVICE INFORMATION
GENERAL
UMUM
•• Check
Periksa thekondisi
batterybaterai
condition beforemenjalankan
sebelum performing any inspection
ses uatu thataan
pemeriks requires proper battery
yang memerlukan voltage.
voltase baterai yang memadai.
•• ATest
continuity test can
kontinuitas be dijalankan
dapat made with dengan
the switches installed
switches onang
terpas thepada
motorcycle.
sepedamotor.
•• Route
Alurkanthekawat
wires dan
andkabel
cablesdengan
properly aftersetelah
benar servicing each component
menserv (page 1-14).
is masing-masing komponen (hal. 1-14).
•• The following color codes are used throughout
Kode warna berikut ini dipakai di dalam bab ini. this section.
BuBu: Blue
: Blue (biru) G:GGreen
: Green (hijau) Lg: Light Green W: White
Lg: Light Green (hijau muda) W: White (putih)
Bl Bl: Black(hitam)
: Black Gr:
GrGray
: Gray (abu-abu) O: Orange O : OrangeY: Yellow
(jingga) Y : Yellow (kuning)
Br Br: Brown(coklat) Lb:
: Brown Light
Lb: Blue
Light Blue (biruR:muda)
Red R : Red (merah)
SPESIFIKASI
BAGIAN SPESIFIKASI
Bola lampu Lampu besar 12 V – 32/32 W
Lampu senja 12 V – 5 W
Lampu rem/belakang 12 V – 18/5 W
Lampu sein depan 12 V – 10 W x 2
Lampu sein belakang 12 V – 10 W x 2
Lampu instrumen 12 V – 1,7 W x 2
Lampu indicator tidak bekerjanya 12 V – 1,7 W
PGM-FI (MIL)
Indicator lampu jauh 12 V – 1,7 W
Indicator lampu sein 12 V – 3,4 W x 2
Sekring Sekring utama 15 A x 1
Sekring tambahan 10 A x 1
Tahanan fuel level sensor (20°C) Penuh 6 – 10 Ω
Kosong 90 – 100 Ω
Tahanan resistor (20°C) 9,5 – 10,5 Ω
TORQUE
TORSI VALUES
PENGENCANGAN
Ignitionpemasangan
Sekrup switch mounting screw
ignition switch 9 N·m
9 N.m (0.92
(0,92 kgf·m,
lbf.ft) BautALOC bolt:
ALOC: replace
ganti withyang
dengan a new one.
baru.
Key socket
Baut shutter key
socket bolt
shutter 5,1 5.1
N.mN·m (0.52
(0,52 kgf·m,
lbf.ft) BautALOC bolt:
ALOC: replace
ganti withyang
dengan a new one.
baru.
TOOL
Test probe
07ZAJ-RDJA110
19-3
LAMPU/METER/SAKELAR
LIGHTING SYSTEM
RANGKAIAN
PENERANGAN
HEADLIGHT LIGHT DOES NOT COME
PADA, ATAU LAMPU BESAR LEMAH
Pemeriksaan standar
Periksa berikut ini:
– Terbakar atau watt bohlam lampu tidak disesuai
dengan spesifikasi
– Koneksi putus
– Sakelar lampu
– Sakelar lampu besar
Jika bagian-bagian di atas normal, periksa sebagai
berikut:
Pemeriksaan sirkuit lampu
– Handlebar front cover (hal.3-5)
– Right body cover (hal. 3-13)
– Left crank case rear cover (hal. 3-17)
[2]
Lepaskan regulator/rectifier 6P (Putih) connector [1].
Putar sakelar lampu [3] ke HL dan sakelar lampu besar
[4] ke posisi Hi position.
Periksa sambungan antara lampu besar 9P (Putih)
connector [2] dan regulator/rectifier 6P (Putih)
connector [1] terminal.
CONNECTION: BLUE – YELLOW
Jika tersambung, periksa berikut ini:
[1]
[2]
[1]
[4] [3]
19-4
LAMPU/METER/SAKELAR
Lepaskan alternator 2P (Putih) connector.
Periksa sambungan antara regulator/rectifier 6P (Putih)
connector [1] dan alternator 2P (Putih) connector [2].
[1]
HUBUNGAN: PUTIH – PUTIH
[2]
Pemeriksaan Massa
Periksa sambungan antara lampu besar 9P (Putih)
[1]
connector [1] dan massa.
HUBUNGAN: HIJAU – MASSA

Jika ada sambungan, periksa coil lampu/charging coil
(hal. 16-9).
19-5
LAMPU/METER/SAKELAR
POSISI LAMPU/LAMPU SENJA TIDAK
MENYALA
Nyalakan mesin.
Periksa lampu berikut:
– Posisi lampu
– Posisi senja
Jika salah satu lampu di atas tidak menyala, periksa
bola lampu.
Jika bola lampu normal, periksa kabel terkait untuk
koneksi buruk, terbuka atau sirkuit pendek.
Jika semua bagian di atas tidak menyala, periksa
sebagai berikut:
[1]
– Front top cover (hal. 3-10)
– Right body cover (hal. 3-13)
– Regulator/rectifier 6P (putih) connector [1].
Putar sakelar lampu [3] ke posisi TL.
Periksa sambungan antara tregulator/rectifier 6P (putih)
connector [1] dan posisi lampu 3P (putih) connector [2]
terminal.
HUBUNGAN: KUNING – KUNING
jika tidak ada sambungan, periksa berikut ini.
Periksa sambungan antara posisi lampu 3P (Putih)
connector [2] terminal dan massa. [2]
HUBUNGAN: YELLOW – MASSA [2]
Jika tidak ada sambungan, sirkuit normal.

Jika sambungan ada ganti regulator / rectifier dengan
yang baru dan periksa kembali.
[3]
[1]
19-6
LAMPU/METER/SAKELAR
HEADLIGHT/FRONT TURN SIGNAL
LIGHT
(LAMPU BESAR/LAMPU SEIN DEPAN)
BULB REPLACEMENT
PENGGANTIAN
HEADLIGHT BOLA LAMPU
Remove the (LAMPU
HEADLIGHT handlebarBESAR)front cover (page 3-5).
[3]
Pull off the dust cover [1] from the headlight unit.
Lepaskan handlebar front cover (hal. 3-5).
Slightly push the headlight bulb socket [2] and turn it
Tarik lepas dust covthen
counterclockwise, er [1]pull
dariout the bulbunit.
headlight socket from the
headlight
Tekan unit.
headlight bulb socket [2] sedikit dan putar
Remove thearah
berlawanan headlight
jarum bulbjam,[3] from the tarik
kemudian headlight unit.
keluar bulb [4]
Install dari
socket a new headlight
headlight unit.bulb by aligning the tab with the
Lepaskan
groove of headlight
the headlight bulb (bola lampu besar) [3] dari
unit.
headlight
Align theunit.
tabs of the headlight bulb socket with the slots
Pasang
of the headlight
headlight bulb unit, baru
then dengan
push thementepatkan
headlight bulbtab
dengan
socket alur
and dari
turn headlight
it clockwise. unit.
Tepatkan dustdari
Install thetabs cover headlight
with its TOPbulb mark [4] dengan
socket slots
facing up.
dari headlight unit, kemudian tekan headlight bulb
Install dan
socket the handlebar
putar searah front cover
jarum (page 3-5).
jam. [1] [2]
Pasang dus t cover dengan tanda TOP [4] menghadap
ke atas.
POSITION LIGHT
Pasang handlebar front cover (hal. 3-5).
Turn the position
POSITION light bulb SENJA)
LIGHT (LAMPU socket [1] counterclockwise
and remove it from the position light unit. [2]
Putar
Remove the position
position light bulblight bulb
socket [1] berlawanan
[2] from arah
the bulb socket.
jarum jam dan lepas kan dari position light unit.
Install a new position light bulb into the bulb socket.
Lepaskan position light bulb (bola lampu s enja) [2] dari
Install
bulb the position light bulb socket into the turn signal
socket.
light unit by turning it clockwise.
Pasang position light bulb baru ke dalam bulb socket.
Pasang pos ition light bulb sock et ke dalam turn signal
light unit dengan memutarnya searah jarum jam.
[1]
FRONT TURN SIGNAL LIGHT

RemoveTURN
FRONT the handlebar front cover
SIGNAL LIGHT (pageSEIN
(LAMPU 3-5). DEPAN)
Turn thehandlebar
Lepaskan front turn frontsignal light3-5).
cover (hal. bulb socket [1]
counterclockwise and remove it from the headlight unit.
Putar
Remove frontthe
turnfront
signal
turnlight bulblight
signal bulb[1]
s ocket berlawanan
from the bulb
arah jarum
socket. jam dan lepaskan dari headlight unit.
Lepaskan front turn signal light bulb dari bulb socket.
Install a new turn signal light bulb into the bulb socket.
Pasang turn signal light bulb baru ke dalam bulb socket.
• Use only the amber bulb.
• Hanya pakai bulb berwarna kuning.
Install the turn signal light bulb socket into the headlight
Pasang
unit by turning
turn signal light bulb socket ke dalam headlight
it clockwise.
unit dengan memutarnya searah jarum jam.
Install the handlebar front cover (page 3-5).
Pasang handlebar front cover (hal. 3-5).
[1] [2]
19-7
LAMPU/METER/SAKELAR
REAR COMBINATION LIGHT
PENGGANTIAN BULB
BULB REPLACEMENT
BRAKE/TAIL
BRAKE/TAILLIGHT
LIGHT(LAMPU REM/BELAKANG)
Remove the
Be careful not to Lepaskan screws [1] and
sekrup-sekrup covers
[1] dan [2]. [2].
covers [5] [4]
damage the covers [2]
Remove the tail light lens [3] by releasing the tab [4]
Hati-hati agar lens. Lepaskan tail light lens [3] dengan melepaskan tab [4]
and tidak
from
merusak c overs dan dari the[5]slot
slot [5]rear
dari of the rear combination
combination light unit.
light unit.
lens.
[3] [1]
Tekan
Slightlybrake/tail
push the light
brake/tail [1] bulb
bulb light sedikit dan turn
[1] and putar
it
berlawanan arah jarum
counterclockwise, jam, kemudian
then remove the bulb lepaskan
from the bulb
dari
socket.
bulb socket.
Install abulb
Pasang newbaru
bulbdalam
in the urutan
reverseterbalik
order of removal.
dari pelepasan.
[1]
REAR
REARTURN
TURNSIGNAL
SIGNALLIGHT
LIGHT(LAMPU SEIN
BELAKANG)
Remove the
Lepaskan rearrear combination
combination lightlight
unitunit
(hal.(page
19-7).19-9).
Turn bulb
Putar the bulb
socksocket [1] counterclockwise
et [1] berlawanan andjam
arah jarum remove
dan
it, then pull out the bulb [2] from the bulb socket.
lepaskan, kemudian tarik keluar bulb [2] dari bulb
Install a new bulb in the reverse order of removal.
socket.
Pasang only baru
• Usebulb dalam bulb.
the amber urutan terbalik dari pelepasan.
• Install
Hanya the rear bulb
pakai combination light
berwarna unit (page 19-9).
kuning.
Pasang rear combination light unit (hal. 19-7).
[2] [1]
19-8
LAMPU/METER/SAKELAR
REAR COMBINATION LIGHT UNIT
REAR COMB INATION LIGHT UNIT
Remove the
Lepaskan tail body
covercover (page 3-13).
(hal. 3-12). [6] [1]/[2]
Remove the two bolts [1]
Lepaskan kedua baut [1] dan andcollars
collars[2].
[2].
Slightly rear
Angkat pull up the rear combination
c ombination light unit light
[3] unit [3] and
sedikit dan
release the grommet [4] from the boss [5]
lepaskan grommet [4] dari boss [5] dari rear fender of the rear
fender.
(s pakbor belakang)
Pull the rear combination light unit backward and
Tarik rear combination light unit ke belakang dan
disconnect the brake/tail light 6P connector [6].
lepaskan brake/taillight 6P c onnector [6].
Route the wire Install the removed parts in the reverse order of
Alurkan wire Pasang parts yang dilepaskan dalam urutan terbalik dari
harness
harnessproperly
dengan removal.
pelepas an.
benar(page 1-14).
(hal. 1-14).
[5] [3] [4]
SPEEDOMETER
PENGGANTIAN BULB
BULB REPLACEMENT
Lepaskan
Remove the handlebar
handlebar frontfront (hal.(page
cover
cover 3-5).3-5).
Pull out
Tarik the bulb
keluar bulb socket
socket[1]
[1]dari
fromspeedometer.
the speedometer. [2]
Remove the
Lepaskan bulb
bulb [2][2] from
dari the socket
socket and replace
dan ganti denganityang
with
a new one.
baru.
Pemasangan
the reverse orderurutan terbalik dari
of removal.
pelepas an.
[1]
Remove the
Lepaskan handlebar
handlebar rearrear cover
cover (hal.(page
3-6). 3-6). [2]
Disconnect
Lepaskan the following
connectors connectors [1]:
[1] berikut: [3] [1]
- –Dimmer
Dimmer switch
s witch 3P3P connector
connec tor
- –Turn
Turn signal
signal switch
switch 3P3P (Merah)
(Red) connector
connector
- –Horn
Horn switch
switch 3P3P (Hitam)
(Black) connector
connector
- –Starter
Starter switch
s witch 3P3P (Hitam)
(Black) connector
connector
– Light switch 4p (Natural) connector
Lepaskan ketiga sekrup [2] dan speedometer [3] dari
Remove
rear the three
handlebar coverscrews
[4]. [2] and speedometer [3] from
the rear handlebar cover [4].
Installation
[4]
19-9
LAMPU/METER/SAKELAR
- Turn signal light relay [1]
–- Bulb
Turnsockets
signal light[2] relay [1]
– Bulb sockets [2]
- Sekrup-sekrup terminal [3] dan terminal2 kawat [4]
– Terminal
- Sekrup wirescrews
band [3]
[5] and
dan wire terminalssub
speedometer [4] harness [6]
– Wire band
- Meter lens [7] screw [5] and
dengan speedometerdari
melepaskannya subtabs
harness
[8] dari
[6] case [9]
meter
– Meterplate
- Meter lens [10]
[7] by releasing it from the tabs [8] of the
meter
- Dua case [9]
sekrup/washers [11] dan speedometer [12]
– Metercase
- Meter plate [10]
– Two screws/washers [11] and speedometer [12]
Perak
– Meteritan case adalah dalam urutan terbalik dari
pembongkaran.
Assembly
• Hati-hati is inagar
the reverse
jangan order of disassembly.
meninggalkan sidik jari pada
• Be careful
meter panel.not to put fingerprints on the meter panel.
•• Route
Alurkan the speedometer
speedometersub harness
sub as shown. seperti
harness
diperlihatkan.
[7]
[8]
[9]
[10]
[12]
[11]
[2]
[6]
[4]
[5] [3]
[1]
METER LIGHT (Bl, G)
RIGHT TURN SIGNAL LEFT TURN SIGNAL
INDICATOR (Lb, G) INDICATOR (O, G)
MIL (Bl, W/bu) HIGH BEAM INDICATOR

(Bu, G)
FUEL METER WIRE (Y/W)

FUEL METER WIRE (Bl)
FUEL METER WIRE (G)
19-10
LAMPU/METER/SAKELAR
FUEL METER/FUEL LEVEL SENSOR
PEMERIKSAAN SISTEM
SYSTEM INSPECTION
SEWAKTU BAHAN
WHEN FUEL BAKAR
IS ABOUT HAMPIR
FULL PENUH DOES
BUT NEEDLE
NOT MOVE
TETAPI JARUM TIDAK BERGERAK
Before performing
Sebelum menjalankan thepemeriksaan
system inspection,
sistem, check the
periksalah [1]
following:
sebagai berikut:
- –Kondisi baterai
Battery condition
- –Sekring
Burnedputus
fuse
- –Cara kerja
Horn horn (klakson)
operation
Lepaskan
Remove the
fuelfuel
pumppump cover
c over (hal.(page
6-30).6-23).
Lepaskan
Disconnect
fuelthe fuel pump
pump [1]. [1].
5P connector
5P connector
Hubungkan singkat connector
Short the connector terminals of the wirepada
terminals sisi side
harness wire
with thedengan
harness wire [2].wire [2].
jumper jumper
HUBUNGAN: Kuning/Putih
CONNECTION: – Hijau
Yellow/White – Green
Jangan
Do biarkan
not leave the Putar
the ignition ke ON,
switch ON,periksa
checkapakah jarum
if the fuel fuel
meter
terminals
terminals meter
needle bergerak
moves toke"F".
“F”.
tersambung dengan
connected with Jarum akan moves
The needle bergerak
if thejika
system circuit issistem
rangkaian normal.adalah
jumper wire untuk FUEL METER
jumper wire for normal.
In that case, check the fuel level sensor (page 19-11).
wak tu lama, oleha
long time,akan
as it Dalam hal itu, periksalah fuel lev el sensor (hal. 19-9).
karena If the needle does not move, check the following:
causes damage to
menyebabkan Jika jarum tidak bergerak, periks alah s ebagai berikut:
the fuel
kerusakan meter.
pada fuel – Yellow/white wire between the fuel pump/fuel level
- Kawat Kuning/putih antara fuel pump/fuel level
me ter. sensor and speedometer for open or short circuit
sensor dan speedometer terhadap rangkaian terbuka
– Black wire between the speedometer 6P connector
atau hubungan singkat.
and fuel meter for open circuit
-– Kawat
GreenHitam antara speedometer
wire between 6P connector
the fuel pump/fuel dan
level sensor
fuel meter terhadap rangkaian terbuka. Y/W Bl
and ground for open circuit G
- Kawat Hijau antara fuel pump/fuel level sens or dan
If massa
the wire is normal,
terhadap replace
rangkaian the speedometer panel
terbuka.
with a new one, and recheck. Dari
Jika kawat adalah normal, gantilah speedometer panel Bl IGNITION
dengan yang baru, dan periks a ulang. SWITCH
Y/W
[1] [2]
FUEL LEVEL SENSOR

FUEL LEVEL SENSOR
Remove the
Lepaskan fuelfuel
levellevel sensor
sensor [1] (page
[1] (hal. 19-12).
19-10).
Measure
Ukur tahanantheantara
resistance between
connector the pada
terminals connector
posisi
terminals at the float upper (full) and lower (empty)
upper (penuh) dan lower (kosong) dari pelampung.
positions.
HUBUNGAN: A–B PENUH
(20°C/68°F)
POSISI PELAMPUNG PENUH KOSONG
6 – 10 Ω 90 – 100 Ω A
Replace the fuel level sensor if it is out of specification.

Gantilah fuel level sensor jika ia tidak sesuai dengan B
KOSONG
spesifikasi. [1]
19-11
LAMPU/METER/SAKELAR
FUEL LEVEL SENSOR REMOVAL/
INSTALLATION
FUEL LEVEL SENSOR
Remove the
Lepaskan fuel fuel
pumppumpunitunit
(hal.(page
6-29).6-29). [1] Black Red
Disconnect
Lepaskan fuelthelevel
fuel sensor
level sensor wire (Red,(Merah,
wire connectors Black)
connectors
Hitam) [1]. [1].
Release kawat2
Lepaskan the wires [2] [2]
darifrom
guidesthe[3]guides [3]pump
dari fuel of theunit.
fuel
pump unit.
[3] [2]
Remove the
Lepaskan fuelfuel levelsens
level sensor [1] by
or [1] releasing
dengan the three
melepaskan
hookshooks
ketiga [2] from
[2] the
darislots
slots[3]
[3]ofpada
the fuel
fuel pump
pump unit
unit [4].
[4]. [4]
dalam of the removal.
terbalik dari
pelepas an.
[3]
[2]
[1]
IGNITION SWITCH
REMOVAL
PELEPASAN
Remove the
Lepaskan steering
steering stemstem
(hal.(page 13-21).
13-21).
Disconnect
Lepaskan the ignition
ignition switch 4P switch 4P connector
connector [1] and
[1] dan lepaskan
release the
connector connector
dari guide [2] from
padathe guide [2] of the frame.
rangka. [1]
[2]
19-12
LAMPU/METER/SAKELAR
Remove the
Lepaskan twosscrews
kedua [1]dan
ekrup [1] andignition
ignitionswitc
switch [2].
h [2].
[2]
[1]
INSTALLATION
PEMASANGAN
Set the ignition
Tempatkan switch
ignition [1] [1]
switch in position.
pada posisinya.
[1]
Install dan
Pasang and kencangkan
tighten newsekrup-s
screwsekrup
[2] tobaru
the[2]specified
dengan
torque.
TORQUE:
TORSI: 9 N·m
9 N.m (0.92
(0,92 kgf·m,
lbf.ft)
[2]
Tempatkan
Set the ignition switch
ignition switc4P connector
h 4P [1] the
[1] into
connector ke dalam
guide
[2] of[2]
guide thedari
frame and dan
rangka connect it.
hubungkan.
Install the
Pasang steering
steering stem
s tem (page
(hal. 13-24).
13-24). [1]
[2]
KEY SHUTTER
KEY SHUTTER
Remove the
Lepaskan ignition
ignition switch
switch (hal.(page 19-12).
19-10). [3]
Remove the
Lepaskan bautsocket
socketbolt
[1] [1]
danand
keykey shutter
shutter [2] [2]
darifrom the
ignition
ignition
switch [3].switch [3].
Blow the
Tiuplah key shutter
daerah cover area
key shutter withdengan
cover compressed
udaraair.
dari
kompressor.
Install the key shutter assembly onto the ignition switch.
Pasang
Install and tighten assembly
k ey shutter pada ignition
a new socket bolt to switch.
the specified
torque.
Pasang dan kencangkan sebuah baut socket baru
dengan
TORQUE: torsi5.1
yang
N·mditentukan.
(0.52 kgf·m, 3.8 lbf·ft)
TORSI: 5,1ignition
Install the N.m (0,52 kgf.m;
switch 3,8
(page lbf.ft)
19-13).
Pasang ignition switch (hal. 19-11). [2] [1]
19-13
LAMPU/METER/SAKELAR
INSPECTION
PEMERIKSAAN
Remove the
Lepaskan frontfront
covercover
(hal.(page
3-10).3-10).
Disconnect the ignition switch
Lepaskan ignition switch 4P connector 4P connector [1] and
[1] dan lepaskan
release the connector from the
connector dari guide [2] pada rangka. guide [2] of the frame.
Check for
terhadap at the terminals
pada ofterminals
the switchpada
side [1]
connectorpada
connector in eachsisiswitch
switchposition.
pada masing-masing posisi
Continuity should exist between the color coded wires
switch.
as follows:
Harus ada kontinuitas antara kawat-kawat dengan kode
warna sebagai berikut.
[2]
IGNITION
IGNITION SWITCH
SWITCH
BAT1 VO1 BAT2 VO2
ON
OFF
LOCK
COLOR R Bl/Bu Bl/R Bl
HANDLEBAR SWITCHES
RIGHT HANDLEBAR
PEMERIKSAAN SWITCH
RIGHT HANDLEBAR
INSPECTION
SWITCH
Remove the
Lepaskan handlebar
handlebar frontfront cover
cover (hal.(page
3-5). 3-5).
Disconnect the starter switch 3P (Black) connector [1] [2]
Lepaskan starter switch 3P connector (Hitam) [1].
and lighting switch 4p (Natural0 connector) [2].
Periksa terhadap kontinuitas antara terminals dari
Check for continuity between the terminals of the starter
starter switch connector pada masing-mas ing posisi
switch connector and lighting switch connector in each
switch.
switch position.
Harus ada kontinuitas
Continuity should existantara kawat-kawat
between the colordengan kode
coded wires
as follows:
[1]
LIGHTING SWITCH
STARTER SWITCH
19-14
LAMPU/METER/SAKELAR
LEFT HANDLEBAR
PEMERIKSAAN RIGHTSWITCH
HANDLEBAR
INSPECTION
SWITCH
Remove the
Lepaskan handlebar
cover (hal.(page
3-5). 3-5). [1]
Disconnect the following:
Lepaskan starter switch 3P connector (Hitam) [1]. [3]
– Dimmer
Periksa switch 3P
terhadap connectorantara
kontinuitas [1] terminals dari
– Turn signal light switch 3P (Red)
starter switch connector pada masing-masconnectoring
[2] posisi
– Horn switch 3P (Black) connector [3]
switch.
Check for continuity between the wire terminals of the
Harus adaswitch,
dimmer kontinuitas antaralight
turn signal kawat-kawat
switch anddengan kode
horn switch
connector in each switch position.
Continuity should exist between the color coded wires
as follows:
[2]
DIMMER SWITCH HORN SWITCH
TURN SIGNAL
LIGHT SWITCH
DIMMER SWITCH HORN SWITCH TURN SIGNAL LIGHT SWITCH
HL Lo Hi Ho BAT WR W WL
LO FREE R
(N) PUSH N
HI COLOR Lg Bl L
WARNA Y W Bu WARNA Lb Gr O
BRAKE LIGHT SWITCH

FRONT
DEPAN
Remove the
Lepaskan handlebar
cover (hal.(page
3-5). 3-5).
Disconnect the brake
front brake [1]
Lepaskan front light light
switchswitch
wirewire connectors
connectors [1]
[1] periksa
dan and check for continuity
terhadap of the
kontinuitas switch
pada sisiside.
switch.
Thereada
Harus should be continuity
kontinuitas denganwithfrontthe frontlever
brake brake lever
ditekan,
squeezed, and there should be no continuity
dan tidak boleh ada kontinuitas sewaktu front brake when the
frontdilepaskan.
lever brake lever is released.
19-15
LAMPU/METER/SAKELAR
REAR G
BELAKAN
Remove the
Lepaskan rightright
bodybody cover
cover (hal.(page
3-13).3-13).
Disconnect
Lepaskan thebrake
rear rear brake light switch
light switch 2P connector
2P connector [1]
[1] dan
and check for continuity at the wire connector
periksa terhadap kontinuitas pada connector terminals terminals
of thepada
kawat switch
sisiside.
switch.
There should be continuity
Harus ada kontinuitas denganwithrearthe rearpedal
brake brake pedal
ditekan,
pushed, and there should be no continuity
dan tidak boleh ada kontinuitas s ewaktu rear brake when the
rear brake pedal is released.
pedal dilepaskan.
[1]
HORN (KLAKSON)
REMOVAL
PELEPASAN
Remove the
Lepaskan frontfront cover
cover (hal.(page
3-10).3-10). [5]
Disconnect thewire
horn wire connectors [1] from [3]
Lepaskan horn connectors [1] dari horn [2]. the horn
[2].
- Remove
Baut [3] the following:
- –Collar
Bolt [4]
[3]
- –Dua Collar
rubbers[4] [5]
- –HornTwo rubbers [5]
– Horn
[4]
[2]
[1]
[2]
INSPECTION
PEMERIKSAAN
Remove the front cover (page 3-10).
[1]
Lepaskan front cover (hal. 3-10).
Disconnect the horn wire connectors [1] from the horn
[2].
Lepaskan horn wire connectors [1] dari horn [2].
Connect a sebuah
Hubungkan 12 V battery
baterai[3] 12
to the
V [3]horn terminals.
ke horn terminals.
The adalah
Horn horn is normal
normal ifjika
it sounds whensewaktu
ia berbunyi the 12 Vbaterai
battery12
is
Vconnected
dihubungkanto the
ke horn terminals.
horn terminals.
[2] [3]
19-16
LAMPU/METER/SAKELAR
TURN SIGNAL LIGHT RELAY
(RELAY LAMPU SEIN)
INSPECTION
PEMERIKSAAN
Before performing the inspection, check the following:
– Battery
Sebelum condition pemeriksaan, periksalah sebagai
menjalankan
– Burned
berikut: out bulb or non-specified wattage
-– Kondisi
Burned baterai
fuse
– Ignition switch
- Bola lampu putus and atau
turn signal light switch
dari ukuran function
watt yang tidak
– Loose connector
sesuai spesifikasi
– Horn operation
- Sekring putus
-Remove
Fungsithe handlebar
ignition switchfront
dancover (pageswitc
turn signal 3-5).h
- Connector longgar
Disconnect the turn signal light relay 2P connector [1]
-from
Cara
thekerja
relay.horn
Lepaskan
Short thehandlebar
turn signalfront relay(hal.
lightcover 3-5).
2P connector terminals
of the wireturn
Lepaskan harness
signalside with
light a jumper
relay wire [2]. [1] dari
2P connector
relay. [1]
Turn the ignition switch ON.
Hubungkan singkat turn signal light relay 2P connector [2]
Check the
terminals turnsisi
pada signal
wirelight by turning
harness denganthejumper
switchwire
ON.[2]. [1]
If theignition
Putar light comes
switchon,
ke the
ON.turn signal light relay is faulty
or connector has poor connection.
Periksa turn signal light dengan memutar switc h ke ON.
If the light does not come on, the wire harness is
Jika lampu sein menyala, turn signal light relay tidak
broken. O
bekerja dengan baik atau connector tersambung dengan Bl Gr
buruk. Lb
Jika lampu sein tidak menyala, wire harness putus. IGNITION G
SWITCH G
TURN SIGNAL
LIGHT SWITCH
SIDESTAND SWITCH
Remove the
Lepaskan left crankcase
left crankcase rearrear cover
cover (hal.(page
3-17).3-17). [3]
Release the
Lepaskan wire
kawat [1][1]dari
from the clamp
clamp [2]. [2].
Disconnect
Lepaskan the sidestand
sidestand switch 3Pswitch 3P (Green)
connector connector
(Hijau) [3].
[3].
[1] [2]
19-17
LAMPU/METER/SAKELAR
Lepaskan bautbolt
Remove the [1] [1]
danand sidestand
s idestand [2].[2].
switch
switch
Align
Pasang
Install the switch sementara
sidestandswitch
sidestand mentepatkan
while aligning its groove
alurnya
with thedengan
spring spring
pin. pin.
Pasang dan kencangkan baut sidestand switch.
Install and tighten the sidestand switch bolt.
Amankan kawat sidestand switch dengan clamp.
Route the wire Secure the sidestand switch wire with the clamp.
Alurkan
harness wire
properly Sambungkan sidestand switch 3P connector (Hijau).
harness dengan Connect the sidestand switch 3P (Green) connector.
(page 1-14).
Pasang left crankcase rear cover (hal. 3-17).
benar (hal. 1-14). Install the left crankcase rear cover (page 3-17).
CATATAN:
• Jangan memakai kembali sidestand switch yang
• rusak.
Do not reuse the broken sidestand switch.
• Remove the sidestand switch before retightening the
• Lepaskan sidestand switch s ebelum mengencangkan
sidestand pivot nut.
kembali mur engsel s idestand. [1] [2]
PEMERIKSAAN
INSPECTION
Lepaskan
Remove the
rightright
bodybody (hal.(page
cover
cover 3-13).3-13).
Putar
Turn ignition
the ignition ke “OFF”.
switch
switch "OFF".
Disconnect
Lepaskan ECMthe33P
ECMconnector
(Hitam) [1]. [1].
[1]
Check terhadap
Periksa for continuity between
kontinuitas theECM
antara ECM33P33P (Black)
connector
connector
(Hitam) of thesisi
[1] pada wire harness
wire side
harness and
dan ground.
massa.
[1]
TOOL:
TOOL:
Test
Testprobe
probe 07ZAJ-RDJA110
07ZAJ-RDJA110
HUBUNGAN: Hijau/putih – Massa
CONNECTION: Green/white – Ground
Harus ada kontinuitas dengan sidestand tertarik ke atas
There
[2], danshould be continuity
tidak boleh with the sidestand
ada kontinuitas retracted
sewaktu sides tand
[1], and there
diturunkan [3]. should be no continuity with the sidestand
applied [2].
Jika tidak ada kontinuitas sewaktu sidestand ditarik ke
If there is no continuity with the sidestand retracted, the
atas, maka wire harnes s putus atau sidestand switch
wire harness is broken or the sidestand switch is faulty.
rusak.
[2]

Green/
White
19-18
LAMPU/METER/SAKELAR
RESISTOR
INSPECTION
PEMERIKSAAN
Remove the
cover (hal.(page
3-10).3-10). [1]
Disconnect
Lepaskan the resistor
resistor wire (Pink)
wire connector connector
(Merah muda)[1].
[1].
Measure
Ukur tahanan theantara
resistance
terminalbetween the muda)
kawat (Merah wire (Pink)
pada
terminal
sis of dan
i resistor the resistor
massa. side and ground.
STANDARD:9,5
STANDARD: 9.5––10,5
10.5ohm
Ω (20°C/68°F)
O
(20 C)
If the
Jika nilaimeasured value
yang diukur jauh is far beyond
melampaui the standard,
standard, gantilah
replace the resistor.
resistor.
RESISTOR
Remove the
cover (hal.(page
3-10).3-10). [1]
[2]
Disconnect the resistor wire
Lepaskan resistor wire connector(Pink) connector
(Merah muda)[1].
[1].
Remove the
Lepaskan bautbolt
[2] [2]
danand resistor
resistor [3].[3].
Installation is reverse
Pemasangan adalah order of removal.
dalam urutan terbalik dari
pelepas an.
[3]
19-19
CATATAN
20. DIAGRAM LISTRIK
DIAGRAM LISTRIK ·····································20-2
20
20-1
WIRING DIAGRAM
20-2
BATTERY STARTER
12V 3.0AH RELAY
IGNITION SWITCH REAR BRAKE O2
R
LIGHT SWITCH SENSOR
R/Y
RESISTOR
LIGHTING STARTER FRONT BRAKE 10ǡ9 5P
VO2
BAT2
VO1
BAT1
SWITCH GRAY SWITCH Gr LIGHT SWICH SUB MAIN
PINK P FRAME FUSE FUSE
GROUND 10A 15A
BAT
ST
TL
C1
HL
C1
LIGHT GREEN Lg REGULATOR/
Bl
R
R
R
Bl
Bl
Bl/R
RECTIFIER
R/Y
Y/R
LIGHT BLUE Lb
Bl/R
Bl/Bu
R/W
G/Y
G/W
ORANGE O
DIAGRAM LISTRIK
3P
BROWN
4P
Br Bl 4P 3P 1P
Bl MINI WPC 6P
Bl
Y
Y
Bl
P
Y
R
Br
G
W
Y/R
Bl
G/Y
Bl
G/Y
G
R/Y
R/Y
Y/R
Bl/R
Bu/R
G/W
G/Y
Bl/R
Bl/O
G/Bl
Bl/Bu
MOTOR
STARTER
2P 3P
MINI
DIAGRAM LISTRIK
Y/R
G/W
R/Y
Bl/R
ALTERNATOR
P
RIGHT FRONT Lb
SENSOR
TURN SIGNAL LIGHT G
CKP
12V 10W
L 2P
TURN SIGNAL Gr
LIGHT RELAY Bl
RIGHT REAR
G
R/W
MIL W/Bu 9P MINI TURN SIGNAL LIGHT
12V 1.7W Bl
12V 10W
2P
Bl Lb
METER G G G G
LIGHT G/Y G/Y 6P MINI
Bl
R/W
12V 1.7W x 2 Br Br Lb Lb
G Y Y G G G
W/Bu W/Bu G/Y G/Y G/Y
Br Br Y
Bu O O
HIGH BEAM
INDICATOR G BRAKE/TAIL LIGHT
12V 1.7W 12V 18W/5W
Lb
R
G G
TURN SIGNAL G 6P MINI O
LIGHT L
O Bl Bl
INDICATOR Lb Lb LEFT REAR
12V 3.4W x 2 TURN SIGNAL LIGHT
Bl O O 12V 10W
FUEL METER Y/R Y/R
Y/W Y/W Y/W
G
Bu Bu Bu
HEADLIGHT G G G
12V 32W/32W W W W
Lb Lb
G
O
G
O
W
P/G
W/Y
P/Bu
Bu/Y
Bl/Bu
Bl/Bu
POSITION LIGHT G
12V 5W Y 2P
9P MINI WPC 2P
Bl
Y Y
LEFT FRONT
G
G
G
Br
Y/W
G/W
G
W
TURN SIGNAL LIGHT

Bl/Bu
W/Y
O G G
Bu/Y
12V 10W
3P MINI 5P INJECTOR
3P
MINI WPC
G
Y
Y
G
G
O
G
Y
W
Bl
Br
Gr
Lb
G
Lg
Lg
Bu
Bu
Bu
Y/R
Y/R
P/G
G/Y
Y/R
G/Bl
Bl/R
Bl/O
G/O
W/Y
G/Bl
Br/R
Lg/Y
G/O
Bl/R
G/O
G/W
Lg/R
Gr/R
Br/R
Bu/R
Bu/Y
P/Bu
Y/Bu
Lg/Y
Gr/R
Lg/R
G/W
Y/Bu
Bl/Bu
Bl/Bu
W/Bu
Gr/Bu
Gr/Bu
4P 33P 4P 5P
3P 3P 2P WPC WPC WPC WPC 2P
R Bl R Bl Bl Bl WPC
FL
TA
LG
O2
PB
TO
SG
INJ
DLC
IGP
PG1
PCP
SCS
THR
PG2
VCC
PCM
HI
M
HL
IGPLS
LO
TA
PB
WARN
WL
HO
SG
K-LINE
ST-SW
WR
BAT
THR
VCC
IACV 1A
IACV 1B
IACV 2A
IACV 2B
UP
STOP SW
IACV 2B
IACV 2A
IACV 1B
IACV 1A
FUEL PUMP UNIT
SSTAND SW
DIMMER TURN SIGNAL HORN SENSOR UNIT EOT SIDESTAND
SWITCH LIGHT SWITCH HORN
ECM IACV SENSOR SWITCH IGNITION COIL
SWITCH
TURN SIGNAL LIGHT STARTER

IGNITION SWITCH LIGHTING SWITCH DIMMER SWITCH SWITCH HORN SWITCH SWITCH
BAT1 VO1 BAT2 VO2 HL C1 C1 TL HL Lo Hi WR W WL Ho BAT ST BAT
ON Lo R FREE FREE
Bl BLACK
OFF (N) N PUSH PUSH Y YELLOW
(N) Bu BLUE
LOCK Hi L COLOR Lg Bl COLOR Y/R G/Y G GREEN
COLOR R Bl/Bu Bl/R
R RED
Bl COLOR Y W Bu COLOR Lb Gr O
(N) W WHITE
COLOR COMB : GROUND/MARKING
COLOR Bu/R Y Y Br
21. TROUBLESHOOTING
ENGINE
MESIN DOES
TID NOTHSTART
AK MAU IDUP ATAU OR IS PERFORMA BURUK PADA
HARDDIHIDUPKAN
SULIT TO START········································21-2
.................................... 21-2 KECEPAT AN TINGGI .................................. 21-6
MESIN
ENGINEKEKURANG AN TENAGA
LACKS POWER ............... 21-3
···························21-3 PENGENDALIAN BURUK ........................... 21-7
PERFORMA BURUK PADA

POOR PERFORMANCE AT LOW AND
KECEPAT AN R ENDAH DAN
IDLE SPEED················································21-5
PADA PUTARAN STASIONER ................... 21-5
POOR PERFORMANCE AT
HIGH SPEED ···············································21-6
POOR HANDLING·······································21-7
21
21-1
MESIN TIDAK MAU HIDUP ATAU SULIT DIHIDUPKAN
TROUBLESHOOTING
1.1. Pemeriksaan
Spark Plug Inspection
Busi
Remove dan
Lepaskan and periksa
inspect spark plug4-7)
busi (hal. (page 4-7).
Is the spark
Apakah plug inkeadaan
busi dalam good condition?
baik?
NO -– • Incorrect spark plug heat range
TIDAK
• Incorrect
• Derajat panas sparktepat
busi tidak plug gap
• Dirty air cleaner
• Jarak renggang busi tidak tepat
• YES – GOkotor
Air cleaner TO STEP 2.
2. YA
Spark -Test
Perform
2. Test sparkbunga
percikan test using the same procedure as ignition coil primary peak voltage inspection (page 17-5).
api busi
Is there good spark?
Jalankan test percikan bunga api busi dengan menggunakan prosedur sama seperti pada pemeriksaan
voltase
NO punc – • akFaulty
primer ignition
spark plugcoil (hal. 17-5).
• Broken or shorted
Apakah ada percikan bunga api spark
yang plug wire
baik?
• Loose or disconnected ignition system wires
TIDAK - • Faulty igniting switch
• Busi tidak • bekerja
Faulty ignition
dengancoil
baik
• Kabel busi • Faulty ECMada hubungan singkat
patah atau
• Kawat-kawat • Faulty
sistemCKP sensor longgar atau terlepas
pengapian
• YES
Ignition switch tidak
– GO TO STEP 3. bekerja dengan baik
• Ignition coil tidak bekerja dengan baik
3. Fuel Pump Inspection
• ECM tidak bekerja dengan baik
• Check
CKP sfor operation
ensor of the fuel
tidak bekerja pumpbaik
dengan and inspect the fuel flow (page 6-29).
Is the fuel
YA pump unit DENGAN
- LANJUTKAN normal? LANGKAH 3
NO – Faulty
3. Pemeriksaan fuel
Fuel pump unit
Pump
YES terhadap
Periksa – GO TOcara
STEP 4. fuel pump dan periksa fuel flow (hal. 6-29).
kerja
4. Apakah
PGM-FIfuel
System Inspection
pump unit normal?
Check -the
TIDAK PGM-FI
Fuel pumpsystem (page
unit tidak 6-5).dengan baik.
bekerja
Is the PGM-FI
YA systemDENGAN
- LANJUTKAN normal? LANGKAH 4.
NO – Faulty PGM-FI system
4. Pemeriksaan PGM-FI System
Periksa PGM-FI s ystem (hal. 6-5).
5. Cylinder Compression
Apakah PG M-FI system normal?
Test cylinder compression (page 8-6).
TIDAK - PGM-FI system tidak bekerja dengan baik.
Is the compression as specified?
NO – • Valve stuck open
5. Kompressi• Cylinder
Worn cylinder and piston rings
• Damaged
Test kompressi cylinder cylinder head gasket
(hal. 8-6).
• Seized valve
Apakah kompressi
• Impropersesuai
valvedengan
timing spesifikasi?
TIDAK
YES -– GO TO STEP 6.
• Valve macet terbuka
6. Engine Starting Condition
• Cylinder dan piston rings aus
• Start by following
Kerusakan pada normal
cylinderprocedure.
head gasket
• Does
Valvethe
macet
engine start then stops?
• Valve timing tidak tepat\
YES – • Leaking insulator or intake manifold
YA - LANJUTKAN DENGAN
• Improper ignition LANGKAH
timing 6.
(Faulty ECM or CKP sensor)
• Contaminated fuel
6. Kondisi Penghidupan Mesin
• Clogged IACV passage
Hidupkan mesin dengan pros edur normal.
Apakah mesin hidup kemudian mati?
YA -
• Ada kebocoran pada insulator atau intake manifold
• Ignition timing tidak tepat (ECM atau CKP sens or tidak bekerja dengan baik)
• Bahan bakar terkontaminasi
• Jalan lintas an IACV tersumbat
21-2
MESIN KEKURANGAN TENAGA
1. Pemeriksaan Dr ive Train (Peralatan Penggerak)
Naikkan roda lepas tanah dan putar dengan tangan.
Apakah roda berputar dengan bebas?
TIDAK -
ENGINE LACKS POWER
• Rem menyangkut
• Kerusakan pada secondary reduction sys tem
1. Drive Train
• Wheel Inspection
bearings aus atau rusak
YA wheel
Raise - LANJ UTKAN
off the DENGAN
ground LANGKAH
and spin 2
it by hand.
2.
DoesPemeriksaan
the wheel spin Tekanan
freelNO Udar a Ban
Periksa tekanan udara ban (hal. 4-20).
• Brake dragging
• Damaged
Apakah tekanan udara secondary reduction
ban terlalu rendah?system
YA - • Worn or damaged wheel bearings
YES• Pentil
– GOban TO
tidakSTEPbekerja
2. dengan baik
• Ban bocor
2. Tire Pressure Inspection
Check tire pressure (page 4-19).
3. Pemeriksaan Dr ive Train (Peralatan Penggerak)
Are the tire pressures low?
Periksa drive train.
YES – • Faulty tire valve
Apakah drive train normal?
• Punctured tire
TIDAK -
• Drive– belt
NO GO kotor
TO STEP atau 3.tidak bekerja dengan baik
•
3. Drive Train Inspection tidak bekerja dengan baik
Drive pulley kotor atau
• Driven pulley kotor atau tidak bekerja dengan baik
Check
• Clutch theshoes/clutch
drive train. outer aus
• the
Is Adadrive train
additive di normal?
dalam oli mesin
YA - LANJ UTKAN DENGAN LANGKAH 4.
NO – • Fouled or faulty drive belt
4. Pemeriksaan • Fouled
Performaor faulty drive pulley
Mesin
• Fouled
Berakselerasilah or faulty
dengan driven pulley
ringan.
• Worn clutch shoes/clutch outer
Apakah putar an mesin
• Additive naik?oil
in engine
TIDAK -
YES – GO TO
• Air cleaner STEP 4.
kotor
•
4. Engine Performance terhambat
Aliran bahan bakar Inspection
• Exhaust system tersumbat.
Accelerate lightly.
YA - LANJ UTKAN DENGAN LANGKAH 5.
Does the engine speed increase?
5. Pemeriksaan Busi
NO
Lepas kan– • danDirty air cleaner
periksa busi (hal. 4-7)
• Restricted fuel flow
Apakah busi kotor atau
• Clogged berubah
exhaust system warna?
YA -
YES
• Busi–jarang
GO TO STEP 5.
diservis
• Derajat
5. Spark Plugpanas busi tidak tepat
Inspection
• Jarak renggang busi tidak tepat
Remove and inspect spark plug (page 4-7).
TIDAK
Is - LANJUTKAN
the spark plug fouledDENGAN LANGKAH 6
or discolored?
6. YES
Pemeriksaan
– • PlugsOli Mesin
not serviced frequently enough
Periksa tinggi permukaan
• Incorrect sparkoliplug
danheat
kondisinya
range (hal. 4-9)
Apakah oli • mesin
Incorrect sparkkondisi
dalam plug gap
baik?
NO
• Permukaan oli terlalu tinggi
6. Engine Oil Inspection
• Permukaan oli terlalu rendah
• Oli terkontaminasi
Check oil level and condition (page 4-9).
Is
YAthe engine oilUTKAN
- LANJ in good condition?
DENGAN LANGKAH 7
7. NO – • OilIgnition
Pemeriksaan level tooTiming
high (Waktu Pengapian)
• Oilpengapian
Periksa waktu level too low
(hal. 17-8).
• Contaminated oil
Apakah waktu pengapian sesuai dengan spesifikasi?
YES
• ECM tidak
7. Ignition bekerja
Timing dengan baik
Inspection
• CKP sensor tidak bekerja dengan baik
Check ignition timing (page 17-7).
YA - LANJ UTKAN DENGAN LANGKAH 8
21-3
8. Is the ignitionKompressi
Pemeriksaan timing as specified?
Cylinder
NO – test
Jalankan • Faulty ECM cylinder (hal. 8-6).
kompressi
• Faulty CKP sensor
Apakah kompressi seperti ditentukan?
TIDAK -
8. Cylinder
• Valv eCompression
macet terbukaInspection
• Cylinder
Test dan piston rings
cylinder compression (pageaus.
8-6).
•
Is the compression as specified? gasket
Kerusakan pada cylinder head
• Valv e timing tidak benar
NO – • renggang
• Jarak Valve stuck
klepopen
tidak benar
• Valv e• macet.
Worn cylinder and piston rings
• Damaged cylinder head gasket
• Decompressor tidak bekerja dengan baik
• Improper valve timing
YA - •LANJ
Improper
UTKAN valve
DENGANclearance
LANGKAH 9
• Seized valve
9. Pemeriksaan Fuel Pump
• Faulty decompressor
Periksa aliran
YES – GO TO bahan
STEPbakar
9. (hal. 6-5).
Apakah
9. Fuel PumpfuelInspection
pump unit normal?
TIDAK the
Inspect - Fuel
fuelpump unit tidak
flow (page 6-5).bekerja dengan baik
YAthe fuel
Is - LANJ
pumpUTKAN DENGAN LANGKAH 10
unit normal?
10.NO Pemeriksaan
– Faulty fuelPGM-FI System
pump unit
Periksa–PGM-FI
YES GO TO system (hal. 6-5)
STEP 10.
Apakah System
10. PGM-FI PGM-FI Inspection
system normal?
TIDAK the
Check - PGM-FI
PGM-FI system
system tidak
(pagebekerja
6-5). dengan baik
Is
YAthe PGM-FI
- LANJsystem
UTKANnormal?
DENGAN LANGKAH 11
11.NO Pemeriksaan
– Faulty PGM-FI system
Pelumasan
YES – GO
Lepaskan TO STEP
cylinder head11.
cover dan periks a pelumasan.
11. Lubrication Inspection
Apakah valve train (peralatan penggerak klep) dilumasi dengan benar?
Remove
TIDAK - the cylinder head cover and inspect lubrication.
Is• theJalan
valve lintasan oli tersumbat
train lubricated properly?
• Lubang oli tersumbat
NO – • Clogged oil passage
• Oil pump tidak bekerja dengan baik
• Clogged oil orifice
• Oil strainer
• Faulty screen jarang diservis
oil pump
YA - •LANJ
Oil UTKAN
strainer screen
DENGANnotLANGKAH
serviced frequently
12. enough
12.YES Pemeriksaan
– GO TO STEP 12.
Overheating
12. Overheating Inspection
Periksa terhadap overheating pada mesin.
Check for engine overheating.
Apakah mesin mengalami overheating?
Is
YAthe engine
- overheating?
YES• Pembangunan karbon
– • Excessive carbonyangbuild-up in combustion
berlebihan chamber
di dalam ruang pembakaran
• Pemakaian
• Use bahan
of poorbakar
quality fuel
berkualitas buruk
• Jenis• bahan
Wrong typeyang
bakar of fuel
salah
13.
13.Engine Knocking Inspection
Pemeriksaan Engine Knocking
Accelerate or run at
Berakselerasilah atauhigh speed.pada kecepatan tinggi.
jalankan
Is there knocking?
Apakah ada knocking?
YES – • Worn piston and cylinder
YA -
• Wrong type of fuel
• Piston dan cylinder aus.
• Excessive carbon build-up in combustion chamber
• Jenis• bahan bakar
Ignition tidak
timing toosesuai
advance (Faulty ECM or CKP sensor)
• Pembangunan karbon berlebihan pada ruang pembakaran
POOR PERFORMANCE AT LOW AND IDLE SPEED
• Waktu pengapian terlalu maju (ECM atau CKP sensor tidak bekerja dengan baik)
1. Spark Plug Inspection
Remove and inspect the spark plug (page 4-7).
21-4
PERFORMA BURUK PADA
Is the spark plug KECEPATAN RENDAH
in good condition?
NO – • Plug not serviced frequently enough
DAN PADA PUTARAN STASIONER
• Incorrect spark plug heat range
• Incorrect
1. Pemeriksaan Busi spark plug gap
YES – GO
Lepas kan danTO STEP
periks 2. i (hal. 4-7).
a bus
2. Ignition
Apakah Timing Inspection
busi dalam kondisi baik?
Check
TIDAK theignition timing (page 17-7).
• Busi kurangtiming
Is the ignition mendapatkan perawatan
as specified?
• Derajat panas busi tidak sesuai
NO – • Faulty ECM
• Jarak •renggang
Faulty CKPbusisensor
tidak tepat
YA - •LANJUTKAN
Improper valve timing LANGKAH 2
DENGAN
2. YES – GO TO
Pemeriksaan STEPPengapian
Waktu 3.
3. Fuel Pump
Periksa Inspection
waktu pengapian (hal. 17-8)
Inspect
Apakahthe fuel flow
waktu (page 6-29).
pengapian sesuai dengan spesifikasi?
Is the
TIDAK -fuel pump unit normal?
NO• ECM – Faulty fuel pump
tidak bekerja unit baik
dengan
• CKP sens or
YES – GO TO STEP 4.tidak bekerja dengan baik
• Valve timing tidak sesuai
4. PGM-FI System Inspection
Check the PGM-FI system (page 6-5).
3. Pemeriksaan Fuel Pump
Is the PGM-FI system normal?
Periksa aliran bahan bakar (hal. 6-29)
Apakah fuel pump unit normal?
TIDAK - Fuel pump unit tidak bekerja dengan baik
5. IACV Inspection
Check the IACV (page 6-37).
4. Pemeriksaan PGM-FI System
Is the IACV normal?
Periksa– PGM-FI
NO • FaultySystem
IACV (hal. 6-5)
• Clogged
Apakah PGM-FI IACVnormal?
system passage
YES
TIDAK –- GO TO STEP
PGM-FI 6. tidak bekerja dengan baik
system
6. Throttle
YA -Body InsulatorDENGAN
LANJUTKAN Leaking LANGKAH
Inspection5.
5. Check for leaksIACV

Pemeriksaan at the throttle body insulator.
Are there leaks?
Periksalah IACV (hal. 6-36).
YES
Apakah – IACV
• Loose throttle body insulator
normal?
• Damaged throttle body insulator
TIDAK -
POOR PERFORMANCE AT HIGH SPEED
• IACV tidak bekerja dengan baik
• Jalan lintasan IACV tersumbat
1. Ignition Timing Inspection
Check the LANJUTKAN
YA - ignition timingDENGAN LANGKAH 6.
(page 17-7).
6. Is
Pemeriksaan
the ignitionKebocoran Throttle Body Insulator
timing as specified?
Periksa– terhadap
NO • Faultykebocoran
ECM pada throttle body insulator.
• Faulty
Apakah ada kebocoran? CKP sensor
• Improper valve timing
YA -
YES – GO TO STEP
• Throttle body 2. longgar
ins ulator
• Ada
2. Fuel Pump kerusakan pada throttle body insulator
Inspection
Inspect the fuel flow (page 6-29).
In the fuel pump unit operation normal?
NO – Faulty fuel pump unit
3. PGM-FI System Inspection
Check the PGM-FI system (page 6-5).
21-5
PERFORMA IsBURUK
the PGM-FI system normal?
PADA KECEPATAN TINGGI
1. Pemeriksaan Waktu Pengapian
Periksa waktu pengapian (hal. 17-8).
4. Valve Timing Inspection
Apakah waktu pengapian sesuai dengan spesifikasi?
Check the valve timing (page 8-8).
TIDAK -
Is
• the
ECMvalve
tidaktiming
bekerjacorrect?
dengan baik
• CKP sensorsprocket
NO – Cam not installed
tidak bekerja denganproperly.
baik
• Valve timing tidak
YES – GO TO STEP 5. tepat
5. YA
Valve - LANJUTKAN
Spring InspectionDENGAN LANGKAH 2.
2. Pemeriksaan
Check Fuel Pump
valve springs (page 8-15).
Periksa
Is aliranspring
the valve bahanfree
bakar (hal. as
length 6-29).
specified?
Apakah– fuel
NO Faultypump
valveunit bekerja dengan normal?
spring
TIDAK –- GO
YES Fuel
TOpump unit
STEP 6. tidak bekerja dengan baik.
YA - LANJUTKAN
6. Camshaft Inspection DENGAN LANGKAH 3.
3. Remove
Pemeriksaan PGM-FI
and inspect System
the camshaft (page 8-9).
Is the cam PGM-FI
Periksalah lobe height as specified?
system (hal. 6-5).
NO
Apakah– PGM-FI
Faulty camshaft
system norm al?
TIDAK - PGM-FI system tidak bekerja dengan baik
POOR HANDLING
4. Pemeriksaan Valve Tim ing
Steering is heavy
• Steering top thread
Periksa valve timingtoo tight tertib klep) (hal. 8-8).
(waktu
• Damaged steering head bearings
Apakah valve
• Insufficient timing tepat?
tire pressure
TIDAK
Either wheel - Cam s procket tidak dipasang dengan benar.
is wobbling
• Excessive
YA wheel
- LANJUTKANbearingDENGAN
play LANGKAH 5.
• Bent rim
5.• Improperly
Pemeriksaan Valvewheel
installed Springhub
• Excessively worn swingarm pivot bushings
Periksa valve springs (hal. 8-15).
• Bent frame
Apakah panjang bebas valve spring sesuai spesifikasi?
Motorcycle pulled to one side
TIDAK
• Front and- rear
Valve s pringnot
wheels tidak bekerja dengan baik .
aligned
• Bent fork
• Bent swingarm
6.• Faulty shock absorber
Pemeriksaan Camshaft
• Bent axle
Lepask
• Bent an dan periksa camshaft (hal. 8-9).
frame
• Incorrect axle alignment
Apakah tinggi cam lobe (chain adjustment
(bubungan) not equal
sesuai denganon spesifikasi?
both sides)
TIDAK - Camshaft tidak bekerja dengan baik.
21-6

BPR REVO AT - KWZG - 3 Juli 2010 PDF

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BPR REVO AT - KWZG - 3 Juli 2010 PDF

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1.

SPESIFIKASI SISTEM BAHAN BAKAR (Programmed Fuel Injection)

SPESIFIKASI CYLINDER HEAD/VALVES

SPESIFIKASI DRIVE PULLEY/DRIVEN PULLEY/CLUTCH

SPESIFIKASI ALTERNATOR/STARTER CLUTCH

SPESIFIKASI RODA BELAKANG/REM/SUSPENSI

SPESIFIKASI REM HIDRAULIK

SPESIFIKASI BATERAI/SISTEM PENGISIAN LISTRIK/ALTERNATOR

SPESIFIKASI SISTEM ELECTRIC STARTER

SPESIFIKASI LAMPU/ INSTRUMEN/ SAKELAR

SISTEM BAHAN BAKAR (Programmed Fuel Injection)

SISTEM STARTER LISTRIK

FRONT BRAKE LIGHT SWITCH WIRE

FRONT BRAKE LIGHT

LIGHTING SWITCH 4P HEADLIGHT 9P

FRONT BRAKE HOSE

FRONT BRAKE HOSE

SPEEDOMETER SUB HARNESS

EOT SENSOR WIRE

FRONT BRAKE HOSE

REAR BRAKE PEDAL

MAIN WIRE HARNESS

FRONT BRAKE HOSE

THROTTLE CABLE IGNITION SWITCH

AIR INLET CLUTCH COVER

IGNITION COIL WIRES

FUEL FEED HOSE

STARTER MOTOR CABLE 2P CONNECTOR

O2 SENSOR 1P CONNECTOR (HITAM)

FUEL FEED HOSE

CRANKCASE BREATHER HOSE

EOT SENSOR 2P CONNECTOR

Posisi standard kickstarter pedal :

IGNITION COIL STAY REAR BRAKE PEDAL LOCK CABLE

IGNITION COIL WIRE IACV 4P CONNECTOR (HITAM)

SPARK PLUG WIRE

STARTER MOTOR CABLE

STARTER MOTOR CABLE 2P CONNECTOR

BATTERY NEGATIVE (-) TERMINAL

SUB FUSE 10A

FUEL PUMP 5P CONNECTOR

FUEL FEED HOSE

FUEL PUMP WIRE

FRAME GROUND POINT

BATTERY SUB HARNESS REGULATOR/

MAIN WIRE MAIN WIRE HARNESS

BRAKE/TAIL LIGHT 6P CONNECTOR

REAR BRAKE LIGHT SWITCH

Sisi panjang Arah penempatan centerstand spring:

MAIN WIRE HARNESS FRAME PIPE

MAIN WIRE HARNESS

MAIN WIRE HARNESS

LEFT FRONT TURN RIGHT FRONT TURN

LEFT REAR TURN SIGNAL LIGHT WIRE

MAIN WIRE HARNESS BRAKE/TAIL LIGHT 6P CONNECTOR

CRANKCASE BREATHER HOSE

THREE-WAY C ATALYTIC CONVERTER (KATALISATOR PENGUB AH DENGAN TIGA-JALAN)

ENGINE OIL COOLER

MAIN SUB IGNITION

W/Y W/Y Bl/Bu

R: Red (Merah) CKP

KETERANGAN SERVIS ................................ 3-3 BODY COVER .......................................... 3-13

LOWER SIDE COVER