yamaha y80 service manual · 2015-08-03 · 1. piston and piston ring. 1. ii'i:i;iil.ii!i:i;!~...

$: Yamaha Y80 Service Manual · 2015-08-03 · 1. Piston and piston ring. 1. ii'i:i;iIl.ii!i:i;!~ 0), \1flU1JU{j~1~Ul11u\1n~lJ 1. Omboh dan gelang omboh a. Ring end gap. a. 1~",1!Ji!$
T N

281 HO

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CONTENTS

I. S E R V ICE POI N TS . . .. .. . .. . . .. . . . . .. . .. . . .. .... 1

A. Engine ................................................. 1

1. Piston and piston ring ...... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 2

2. Crankcase disassembly(1) ........................................ 3

3. Crankshaft ................................................... 6

4. Clutch ...................................................... 8

5. Transmission ................................................. 11

6. Shifter 1.2. . .................................................. 12

7. Carburetor ................................................... 14

8. Autolube pump ............................................... 16 9. Air cleaner ................................................... 19

B. Chassis ................................................. 20

1. Fuel filter cup ................................................ 20

2. Front fork ................................................... 21

3. Steering head ................................................. 22

4. Wheel ....................................................... 23

5. Brake shoe ................................................... 25

6. Chain free play ................................................ 25

7. Wheel ru n-out ................................................. 26

C. Electrical .............................................. 26

1. Ignition system ................................................ 26

2. Charging system ............................................... 28 3. Battery ...................................................... 30

4. Inspection ................................................... 31

II. AP PEN D ICE S ...................................... 39

A. Service data ........................................ ·39

B. Cable routing diagram .......................... 48



I w .*iHilEPlT ............................................ ................................ 1

A. ff ItJ •............................................................................... 1

1. ii5:lli;Ji!.ii5:lli;jfi·········.... ................................................................ . ............. 2 2. rlllij!rli*'lia~1JTIlJIJ(1 )......................... ............................................................... 3

3. rlll iilll····················································· ............................................ 6 4. iilI1 -€; ~ ................................................................................................. 8

5. ~ lJ: ~ ..................................................... ············································11

6.~lJ:~1·2························································································12 7. ~ 11::. ~ ................................................................................................. 14 8. iI'<l ;~ * ................................................................................................. 16 9. ~Jlaij!fi!jl~·········· .................................................................................... 19

B .• liE •............................................................................... 20 I .• ~.~~ ................................................. ............................................. W 2. ii1i 3'1. . . . . . . . . . • . . . • • . • . • • • . • . . • . . . • . . . . . . . . . • • . • • • . • . . • . • . . . . • . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 21

3. ,Ii ioJ fii'j···················································· ............................................. 22 4. ~li ioJ '1m ...............•..•...••••.•..•.••.•.........•...•.••...•.••.........•...•..............•.•.•.... 23 5. 1M ~ J;L ....•..•..•..•.......•...•..••.•.•.•......•.•.•.•.•.•.................•..•..•.•..•.•.•.•.•.•.•.•. 25

6. ®! l1f 'm···················································· .............................................. 25 7 .• ~8~·················································· ............................................... ~

c. ~1i[**1t .............................................................................. 26

1. llI; *- * ................................................................................................. 26 2. 1t '1ll: * ................................................................................................. 28

3. ~ '1ll: ;th···················································· ............................................. 30

4.#1 ~ ............................................................ ·.·· ................................ 31

II m IJf.t ~ ......................................................................... 41

A. ~~tt •............................................................................... 41

B .•• ~.m~ .................................................................. ~



• <U '3J ~

(9). 111Gijtltltl~ ......................................................... 1

.i! d n. LfI<H)~tlU~ ........................................................... 1

Gl. {l11{fUH{l:;H111U{lfH'IlJ ...................................................... 2 ~ ~ ~ ~

0/ -d 9910/ ~ d !oJ. fl1JtHl\?l'Um1111'J~ ~\?IVltmmtHI'JU\?I ................ " .......................... 3 _ <l

"'. 1'V'Hn'Um1111'J~ ............................................................. 6 ~ d

&. fl{lVl'lf .................................................................... 8

<\ d 11 &. 1111'J'l .................................................................... .

'v. fllW~lL~I'J~ Gl -1<0 .......................................................... 12 d d

0>. fll11Jl'H\?I[)J ................................................................ 14 "

~. eW1\?1{lJ ................................................................... 16 "

G. I1'HN'fll 111\"1 ................................................................ 19

~. 1nHHl ............................................................... 20

Gl. t'hl'Jmtl~~llIu ............................................................. 20

1- ~,.I -1<0. 'l5m)l~l1Ul ................................................................ 21 d

"'. IWU\?IHl .................................................................. 22

&. 1~{ltl ..................................................................... 23 v

&. flllJL1JJfl ......................................................... ; ........ 25 ",I<\~ v .; ~ ,

'v. fl1'j11l.jU~'i!\?I'j:;I'J:;l1U~'Utl1j'15 ................................................ 25

, " 0>. fl11lJHm1'Utl1{ltl .......................................................... 26

fl. 'rJ~l ................................................................. 26

Gl. 'j::;uU'1l\?l1~ ................................................................ 26 • "". 1:::um)\?I1~ ................................................................ 28

'" I1m)\?I'~ .................................................................. 30

&. fll'im1'1l1fl'l>Jl .............................................................. 31

~ ~ ~. t 'Y'!lJ L \?llJ ............................................................. 43

'JI 1 I "" OJ "" n. ~t)1JfI Uf11'lUfJU ~ ................................................ 43

~. HNUN\lVll\1!~U(;'n tl,rJ ............................................ 48



KANDUNGAN

I . PERKARA PERKHIDMAT AN ............... 1

A. Enjin .................................................... 1

1. Omboh dan gelang omboh .......................................... 2

2. Kotak - engkol tidak terkumpul ..................................... 3

3. Aci - engkol ..................................................... 6

4. Pemindahan ..................................................... 8

5. Pemindahan ..................................................... 11

6. Pengalih 1 ,2 ................................................... 12

7. Kabureta ....................................................... 14

8. Pump autolube .................................................. 16

9. Pembersih udara ................................................. 19

B. Chasis .................................................. 20

1. Penutup penapis bahan api ......................................... 20

2. Depan cabang - palang ............................................. 21

3. Kepala steering .................................................. 22

4. Roda .......................................................... 23

5. Brek kaki ....................................................... 25

6. Rantai berpusing bebas ............................................ 25

7. Roda berpusing .................................................. 26

C. Eletrik ········.·········································26

1. Sistem penyalaan api .. ,', .. ,., .................................... 26

2. Pengujian .......... , , . , ......................................... 28

3. Bateri ......... " ....................... , .................... ,. 30 4. Pemeriksaan ,., ................. , ...... , .............. , ..... , ... 31

II. HUJUNGAN .. , ....................................... 45

A. Dataperkhidmatan ......... , ........ ··,···········45

B. Gambarajah pusingan cable., .............. 48



I. SERVICE POINTS ~. I . *I~~PJT I.

A. Engine

A. ff I1J •

® : 25Nm(2.5m . kg)

r~ ®: 10Nm(1.0· kg)

® : Tightening torque CD : !IIll1l:t.Ji'll CD: mllJutlw"Uu,:ji1tl~lhjw

GJ : Mengetatkan pergelangan

-1-

• OJ 'J.I "'!

m"ll!1B\l PERKARA PERKHIDMATAN

.!! d fI. ! fI'HHtI 'U \?l

A. Enjin



1. Piston and piston ring.

1. ii'i:i;iIl.ii!i:i;!~

0), \1flU1JU{j~1~Ul11u\1n~lJ

1. Omboh dan gelang omboh

a. Ring end gap. a. 1~",1!Ji!

n. 'limil,Jm ULt111tl a. Pemisah hujung gelang 0.15"'-' 0.35 mm

0.15- 0.35l11i*

b. Piston clearance.

b. ii!i!!!W.l'»:

C. Carbon removal

O,G.la--O.C!l(l; lJ.lJ.

Break the old piston ring in two and remove

the carbon deposite in the piston groove with

broken ring.

c . ii/i 'lillJ!l '"' 2!IlWlii2i:>Cil", 211li1, Ice III liIii,$H',J-,<, j":tili"H'ml"lo'Jlr,,",,

fl. flTHll'D~ ~'lJlJl

H'mmltH'lQ\!'lH nlm)fll~U j;'HJ~~i)U u~11,*m'nwQfl 1\1U11 11 m ~ml1 1'111111:101 ?lrHl'Qfl\!1J

C. Pemindahan karbon Patah kan dua gelang omboh yang lama dan

buangkan lebihan karbon pad a alor - alor

omboh dengan gelang yang patah.

'lJ. CJif)~l'h~\1\!1J

b. Pembersihan omboh

•

0.035 ---0.040 mm 0,035 - 0,040 lIIi* o.oGllC6-o.odo lJ.U.

, .. ;; . I '" h"1 ,.' " ' .. 'L. . \



2. Crankcase disassembly(1) 2. IIIl ljiIU1HI';J ;lJT r.Il (11

Lc.n, mHlfl\?1~ml1~ml~11u~l~tHrJu~ (0))

2. Kotak engkol tidak terkumpul

Flywheel holding tool iIU.IiII:;EIJl,

~ G '" '" T ,

l fl1D ~ bi 1'1111l11U1J~ Il

Alat oktuk memegang roda berpusing

Tool No. 90890-01235

Flywheel puller m!ljllial ..

'lUJU'UhL '11uihwni':JUtlU~'Hl Penolak roda berpusing

Tool No. 90890-01189

-3-



-4-

'~ w~

GJ : 50Nm(5 0 . m . kg)

GJ : Tighteni CD: jJjl~:lJliJj n9 torque

(1): fI11lJUUWU€m'1"''''.;i '" GJ ""nil : Mengetarkan pergelangan



Crankcase disassembly(2) aUil!*1la~~JTIl.' (2)

m'Jfl8~ollm111m1~1'h:JLfl~umu~ (\2))

Kotak engkol tidak terkumpul (2)

Crankcase separating tool !I!IOlb" ,HIllIJil,

L f1~ t)~ Ll tJ noUflL 11~ m 1 ~111 D~ l ~fJ ~ enl ~ Alat mengasingkan kolak . engkol

Tool No. 1135

-5-



3, Crankshaft 3, ~ fill

® : Apply grease

GJ : Tightenin

SW-3244-8

A

Ci) : jljl~:i:J)dj g torque

®: ~unil I-----:~~~--

CD: fr:nwnJu 01 "" , '1.HJ.:JUfll?ll'I"lJU

®, lft\llllJ GJ : Mengetalkan

® ' B pergelangan ,--~~- II , ubuh ' SW mlnyak peliein -2540-8

GIl, 1Ylm4JfHH~ln 3, Aci - engkol

6-



a. Small end free play. a. Jl\liiffilQU~

n. llmuilu,~m1'jlll~j a. Hujungan kecil pusingan bebas

b. Crankshaft deflection b. i1llilllltiiiiill'

oj ~" .,i r

"U. 1"lJWfl1I?1"UDltf1fH UHHlJU

b. Membias aci - engkol

\ r1 \ - ~

III" -I~, , , , ,

L ___ J ,~ -r I , , , !... __ ..J

0,03 mm

0.Q3 ~*

1.5"'-'2.0 mm

1.5 - 2.0~*

GH~ --lg"olJ.1J.

c. Correct any misalignment by tapping the ,-------.-----------,

flywheel with a brass hammer and by using a

wedge.

c. 1li!)Il 111!1'11t;>lilj)g~' 111!ll;!, ~A)ij(~tlHIHjij,

*4lE~ "c1ft", 0

n m,J lu"U1111mlm~llmlllJ1~1~lJm'~nJ1~ "', ''II 'II <'I .... ,,' 'j.1lJl flm tJ'JJ f)'l.-nm:j 1 tlIHl ,'j'ji'FI l')j~jJ Wit) n

c. Menbetulkan sibarang salah nyalaan dengan

mengetok rod a yang berpusing dengan tukul L-_________________ ...J

tembaga dan dengan menggunakan suatu baji.

d. Crank width d. i1llli'i1!:

" ".,; -1. fl11lJfl11-l'lJB:jll'H'Il'lJiH'H1m

d. Keluasan engkol

-7 --

mm 48 -0.05 ~*

-0.10 lUJ.



4. Clutch

4.l!l!I'il'fi

CD: 50Nm(5 0 ft~;;;)

& fli1Wft 4. Penggenggam

CD: 50Nm(5.0m· k9)---~

. m.kg) e&~ .. , ~, o ,-

~IC") , /f;) W: CD'T' . Ighening torqu

CD : jljl~:l.JlJj e

CD: m llJmlu'1I€l ,rth_Wl'!l' • CD ~u : Mengetatkan pergelangan

-8-



Flywheel holding tool iI'i~fliI:;EIJOl,

& 0 '" '" ' I

~mt"almmUl,j'"

Alat pemegang roda - bebas

Tool No. 90890·01235

a. Adjustment a. IOOOJ.!:

n. m,Jfu a. Penyesuaian

Measure the gap between the function plate and pressure plate.

;HII ll!:};j!;mWl"QI~HJiiz. F.' a~ F.' '* 0

" " r V 1if\"l!€l~1nj :;-;')-i11.J'lllU 1>11'i;'lDI'.JUa:;-;lllU j)fI

Tentukan pemisah diantara pinggan utama dan pinggan pendesak

b. Checking b. iftlit f1. rn~W1~1'il'i;'lilU

b. Pemeriksaan

Thickness gauge

;~IJ~ot

,nmlUl1tll Sukat penebalan

Wear limit

mlOij!i'JR ~~~ln~m,~n Had pakai

2.7 mm

2.7 lI!i*

-9-

mm 1.6 - 1.95 lI!i* G).\)-Gl·5& lUJ



New:

fi "D,l11~

Baru:

Wear limit:

M flO f.il ~JR

0.05 mm

0.05 ~JIC 0.0& lUJ.

29.9 mm

29.9 ~JIC

\§!lC;.6 lJ olJ •

28.9 mm 28.9

~JIC ~\01~lmm11~f) \§!l~.5 lJ ",lJ 0

Had pakaj:

-10-



5. Transmission 5. !iiH~ lffi

!I!"uu.*,,!t :

il!\- 39/12

il!\= 29/16

24/20

~ -111111 , d .;\

'n~ l'11U,'J cr,G/ G) L'<'J

" , U1UJ t'fm 1>Il5/ Gl\)

, , Hltn TIl~ kud/L<;r)o

39/12 29/16

24/20

Kadar pem' d In ahan gear ~

Perta ma 39/12 Kedua 29/16

~etiga 24120

-

--I

cr. lntJ~ 5. Pemindahan

SD· 20·38·5

® : Apply grease

® : !JQn~

® : Bubuh . _____ -=~ __ ----------------~®A~,~l ~a'~"l~lD~h _ 1 1 mmyak pelicin



6. Shifter 1.2. 6. !Il:;)f;~ 1 . 2

® : Apply grease

®: :lJUH~ ®, 1ri;mil ® : Bubuh minyak pelicin

, , , 'D. fllkH'lmmO

6. Pengalih 1,2

-12-

J10 191~



Reassembling :jlj:~UC

~ Tool No. 90890·01274

(j)~ ~ ~TooINo.90890.01275

CV~ Tool No. 90890·01278

®

1. Crank installer pot

2. Crank installer bolt

3. Crank installer adapter bolt

I) iIIliliJlnl" iIR .. Ii:>

2) Bll.iIl'li'iIR .. ll\ji

3) Bll'iIl'li"Hlll!iH~"I!I\ji

m,Jgnsu Pengumpulan semula

G), fl1J~\?l~m~~fUl'H'n~m'l1it'N t.n. flll1 rirrtio"UfJ ~ l tHn~m'Hi t'H

~. m,irimi"nJru'1mm;moiim 111m

1. Periok pemasang engkol.

2. Pasak pemasang engkol.

3. Pasak penyesuai pemasang engkol.

Wipe both crankcase surfaces with racker thinner and apply

liquid seal to the crankcase(R).

1,,)jjii'iilHlffl>!1'IJ. i81,1': 21~!llJl>ilJt~"'j!j. it1'Eunlib11l

(R)I).J;tmJ:illi~j 0

l i1\?lfld::;~ n{iDL111 Hnr-lrnJ-loUl-l ~1t'JVlunlt1~ u ~1l11~1 tJ~lm Jj~Hiw ~m~~fl9Jml1ifN (R)

Sapu kedua - dua pemukaan kota - engkol dengan "racker

thinner"dan bubuh pemetri yang cair pada kotak - engkol(R)

-13-



7. Carburetor 7. 5"\ it lm 7. Kabureta

Turns out

HlfWDDfl

Pusing keluar

-14 -



a. Pilot air screw(turns out) a. ;.lj lii\!~ur (ME til )

n. an,'liimllmfl n1!jllflflnl

a. Pilot skru udara (pusing keluar)

Turns out ME til

1 _1/2

l1lJWflOf) "J

Pusing keluarl "'-i<!

b. Throttle stop screw. b . /i1llii\"~ r.<.lf:~ iT , 'lJ. i11lj'HfJ~Hnl

b. Skru pemberhenti pendikit

c. Throttle cagle 2 free play c. /i1llii\1Il1li 2l!lJiI!

... t '" ~l ' • fl. ftl tJf1Un.Hitjl-Hlb!l ~ ~J:;:: 11:;::'I1'U~

c. Cable pendikit 2 qosing - bebas

-15 -



8. Autolube pump

8. IS iJJiI'./jj'it* t::. JmHJ1~W-l 8. Pump Autolube

a. Pump cable adjustment a. mmlllla<:JlIIIl!!!

n. lliumu~~'~'m'lfu a. Penyesuai cable pump

If the mark and pin are not in alignment,

adjust cable length until alignment is

achieved.

Imi;::'CfDj;~1;'litiit, iftllflIlH\'[j~j!i:Krn:o lIiJiljt~ h~j

!¥.jiO .tl:o

~n BUt fl~ fHrflll tm [l g:a iJlJ'hi~ fJ ~lu UJI1 m.:J L ~m nw l~hJ 1U fl11lJ tJl1 Glm~ bll>l ~~W m g;,f.:JfJ rjluuu1~~tl,j fll'J

Jika tanda dan pin itu tidak menyala,

sesuaikan panjang cable hingga nyalaan

didapati.

-16-



b. Minimum pump storoke checkig. b. ~,J-jjHTI:;:tl'Jjftl!i'

~. ~J1 ~TImJ'liwl1n«u ~~~f"~n~Ul'f1J b. Memeriksa pukulan pump yang d inima.

1) Set the dial gauge as illustrated. 2) Start the engine and check to see the plunger

stroke. I) ~ II!] 0lt:;E 'F 5)- J!<

2) j@~~ia!Jil\i, ;l/;.#.n!l'j!j!iIDi§!o

0) .r~\1U1U~UD~ln IlDlilrlm ,r~uTI~~lum>'l

Dial gauge 'F5)-J!<

'nuuul1ibtt~ Dial penyukat

Tool No. 90890-01252

1) Pasangkan dial penyukat seperti dalam gambarajah.

2) Hidupkan enjin dan perikda dj ngan memerhatikan

palam pemukul.

c. Adjustment Turning the adjusting bolt counterclockwise increases the plunger stroke.

c. ~JiI'l\1!:

J;...(m'!ilfiilt:IJ Jl';] ;lIj~lI~JiI'l\1!:~%, ;l/I*IlH!j!iIDf~o

n nllJfu l1~U ~rf, n~ tl1rlll1fmi fu

LhJ ~ltfVlf1~Vl1W l '1llJ'l-l1'11 fllt lilli,m 1 ~~m-l ~fl1\J1J 1';; l ~1 ~'W c. Penyesuaian

Buka pasak penyesuai mengikut pusingan jam

tambahkan palam pemukul.

- 17-

Oil pump adjusting stand

'F5)-J!<~ -<\ '" .!l, ~ i'1'PHtmmf)~1?l

Kaki penyesuai pump minyak

Tool No. 90890-01194

1. Adjuster 1. ~'l\1!:lm 1. Penyesuai



d. Air bleeding

The Autolube Pump and delivery lines must be bled on the following

occasions.

II Setting up a new machine out of the crate.

.. Whenever the Autolube tank has run dry.

co Whenever any portion of the Autolube system is disconnected.

d. 1iJI:!I!t

illEl')Ji~ji~'*fOI~imlj;, {£I"jli~"I'i\'i"T, Ii1:JJuUJili:,,:

"1Er,~f~8i", ~MWr*~""'o .. EI !Ii!JirM~'im iii rAJ OiIIim lito

co !3jljJir>j~*MEfEmm\Hil1lij)i1llt""o

~. n1;'I~au if Uflm ~~Jll a~a 1 uri ~ ~~~fl' 'I ~au 11.H H ~n1)\ll ~fl 'IJ ~

.Jj~@mD1H:J~lD$~ .I! '" "" f " • UJOT;H flf)HIlJUlm~~..:J

• , 1'" '"" I • ~lHH'I1U f1J:'f1'W11'W ..:J"Ufl ~'J g;'1JUtltll fllJUl1~\?l

d. Aliran udara Pump autolube itu dan salor penyampai hendaklah dapat

mengalirkan sebagaimana masa - mada dibawah :

.. Pasangkan mesen baru diluar pembungkus.

.. Hendaklah selalu tangke Autolube dalam kekeringan.

.. Hendaklah mana - mana bahagian sistem autolube itu

tidak dicantumkan,

1) Start the engine

2) Remove the pump bleed screw.

3) Pull the pump wire all the way,

4) Keep the oil running out until air

bubbles disappear. ,. , G)) Wll?llfl'Jil..:JtI'Ulll

'") Dfl~~~~mirllHrlJ'I~mmft Gl1) ~'HnrJiflJl~:U~ ,,) J~flu~1I1u111'1Haufln~um~lfm1U11~11hllfu

'I:JiJ~u~mmfl

1) iIOlibi1tlibl1l!

2) iIIlTlj;:1iJI:!l!tOlln

3) ~llIIj;it!l::jHI'J~<m

4) 1iJI:t!lilll, ii!l:~Jil!::fj'!I!t;ii!t!l"!ltm.II:

1) Hidupkan enjin,

2) Anjakkan dkru pengalir pump.

3) Tarik wire pump semuanya.

4) Jaga perjalanan minyak keluar hingga gj

lombong udara hilang.

-18-



9. Air cleaner 9. ~~j~j~fi

5, fntl'lfllflltl

9. Pembersih udara

Clean the element by compressed air.

o • 0"

mmllJ~ ::il1~lmil' mil'il1mfi~1 UnmUlftlJ

Bersihkan serpihan - serpihan dengan mengempiskan udara.

-19-



B. Chassis B .• ~ g 'll. 1 fI'HHl

B. Chasis 1. Fuel filter cup I. !It!.{ 5IIl i!UJ! lit

'" % '" Gl. (11rm~tl>ll"IJml'i"\I

1. Tutup penapis bahan api

-20·-



2. Front fork kll. 145rnhnn'.b 2. Wi Yi. 2. Depan cabang - palang

cb /. (!) /, @.-G):15Nm(1.5m-kg)

G) : 15 Nm (1.5 m-kg)~ ';;:{---,Jfl'»---@ """ ~~ ~

G'l : Tightening torque CD: jljlli'!:t.JMl

, [C/ <i '" Q): fl11lJUU'U'\Jf)\lUBfill1'U't-l

CD : Mengetatkan pergelangan

® : Apply grease ® : JJ~H~ ®: lri;mil ® : Bubuh minyak pelicin

~ ®I-=--~ ~ ®~

C~

-21 -


mailto:@.-G):15Nm


3. Steering head 3. ~Ii ionfi

d 0/

GTI. UeJ'U W1'11'U1Hl

3. Kepala steering

a. Fork freeplay checking a. Wil!i'yO!H*

fl. \?nli)m)1Jfl1'Hfl~md)m~lun:t'J~mj>l "tHYl Himlrnn'b

a. Periksa cabang - palang dengan be bas.

Exhaust ring and steering nut wrench i~ I' AA IJrt "& lfit¥ rtD !l!jt: -8.): tti T

f11j<uwmnW1fl1m ~v LUl ~f1U'Uf)~Ue1U ~ Gelang tempat keluar asap dan perengkuh nut steering

Tool No: 90890-01208

y\

- 22--



4. Wheel 4. Jl[~

Front wheel WI!j!~ ~DYiib Roda depan

G'l : Tightening torque CD : l"'~ 7:J l<!j

Q): ml1Jul-h"!'UD\jWD~~<UW GJ : Mengetatkan pergelangan

® : Apply grease

®: jmn~ ® lri~11il ® : Bubuh minyak . pelicin

" 6. m:rH1 4. Roda

- 23-



Rear wheel Roda belakang

A

-------;1 6202 .

6202Z

37T

Beri gemuk

DD-30-40-8

DK420 99L + Joint

® : Tightening torque ® : Apply grea, ® : !JQn~

®:j~~n~ ____________________________________________ _

~~ 24 -



5. Brake shoe 5. 1M IJJ JiL

• o. jAJl~mf1

5. Brek kaki

Wear limit: 2 mm llHlili'H: 2l1!i*

6. Chain free play 6. \tli lat 'ill

l ' " ",. • 'n. "l5l111'!.H)j;'j~~I~j:t:tJ~l1W~

6. Rantai pusing - bebas

20""'30mm

20-30ll!i* \@O-GIlO lJ.t1.

~\\

J o

-25 -



7. Wheel run· out 7. :;J;:iiiffi8t±l

" " d. m~~hH'\tl

7. Roda berpusing

c. Electrical C. ~1M}k*1f

fl. ,rJrll C. Eletrik

1. Ignition system

1. ~ *- *' @ l"ulJml~~ll'i 1. Sistem penyalaan api

a. Ignition timing adjustment. a. J!I;*iE~fl<JilJlI~

n. nmMl'i a. Tempat penyesuaian nyalaan api.

O.3"'-'O.4mm

O.3-0.4'11!i*

o.Cfl-o.dlJ.ll

-26 -

\ \.

o / I



CD Screw driver ® Point gap becomes large = Timing ad

vances ® Point gap becomes small = Timing

retards

CD OJ!!flll<:'f' ® !!:u"1II!:k:~mjlfjiEB<¥ ® !lliM'1II!'J'~!Jf~iEB<¥

@. 1'Um,

l<;!l. 'HU111D~"ul1th:jlJlf) -- ~m~lu~i1 " , 'II .,. 'li

~. I1U1~"''U1111l'UDV - ~~l ",U~ll1

CD Skru driver

® Celah cantu man menjadi besar = tempat

penyesuaian luas.

® Celah cantu man menjadi kecil = tempat

penyesuaian terencat.

b. Ignition system checking

b. !IIi 1< * a<J1Ill!l' 'U. m1~~mn~lJu~~1yj b. Periksa sistem nyalaan.

c. Igkition coil checking. c. !lli1<**11!1 a<J1Ill!l'

D ~J1~aDu'U~m~nmi~1yj c. Periksa lengkaran nyalaan.

CD Primary coil resistance check

® Secondary coil resistance check

1. M~~liI1I~1lft\J:ta:m: 2. <l:I!lWl!Illi'''fl'JWII'

@. ~J1 ~~DUm1lJ~ll!1'11u'Um'U~m rnJ ~lJ~il t.rl. \?11 1111;'H)lJ mllJ~h'UYI1U "Uu>l'U\?I'Et1 ~)'\'l ~vtl:iJ 1. Periksa penahanan lengkaran utama. 2. Periksa penahanan lengkaran kedua.

Primary coil Sencondary coil

resistance resistance

(Use Q x 1 scale) (Use Q x 100 scale)

1.m ± 10% 6.0kQ ± 20%

,""""J~~Qii 'U ~" fl Wll'] fl m;p1 11'* Q x I "111') 110Ji oX IOO~111')

1.7Q±]O% 6.0kQ ± 20%

6mm

6~* '0 lJ.lJ.

,------fJJ ~,&~e~ ltfj'ITt 1m.

(N'JjjOX IIlU

1.711 +10%

:-k*lk*Ji![tf]'rttlill.

(i',mo XIOOlitl

6.0KO±20%

Penahanan lengkaran utama Penahanan lengkaran kedua (gunaQ x 1 scale) (gunaQ x 100 scale)

1.m ± 10% 6.0 kQ ± 20%

-27 -



2. Charging system

2. Jf.~*

w. '~lJ1Jil~1~ 2. Sistem mengecas

a. Checking the charging current and voltage.

a. ijil!i'1tj!\:j!\:il\

"I'· Y fl. m1~11'iH;lmJm ~Ubij AlA 'VltlWlUi'!::::mllJWlW

a. Periksa aliran kuasa mengecas dan voltage.

Charging current

DAY OFF-ON

O.3~O.5A at )i, Throttle

@ 4.0~5.0A at Frll Throttle

NIGHT OFF-ON O.2-0.3A at)i, Thruttle

@ 2.0~3.0A at Full Throttle

~

- 28-

1) Start the engine and open the throttle

about Yo turns (Key position is ON).

1) iIil!IIJ~!llJiI!!. »'1lIl~f!1IlIi\lIm*,"1/3"o (~in:illillon)

G») ~~!,ft10'HfI.! ~Llft:::;lilfl~Wu~rilJ~ltTw1u

• 'J lmfl~t1'U\iI j&:'JJ1Ul GJ/d. 1€llJ

(~1~'ll~!1Ill~'UB"~11~U'IJ~~111l1W' ON)

1) Hidupkan injin dan buka pendikit

kira Yo besarnya (tempat hendak lah dibuka)

(DC.A)

1tj!\:iiIt 1':1 B OFF-ON

@ 0.3-0.5*, 1i1i*i FlrJiHk 1/4""'

4.0-5.0~·, in*'< ~~ :£:11~ R~

"~i: OFF-ON

@ 0.2-0.3-$:', fi'rj*( r914~lj,£1/ 411#

2.0-3.0'£(" f1~~H~c:l?~fJ!l~

~



mn)~m~u~ ali ran kuasa

nm~lw

i'J~-li'J~ o.GI1--,o.C6A 1u m/& ' i'J

@ ~Wl ~

i • i'J ,.,; &o-&.oA mnn \>U\?ltJ'VI

Siang buka-tutup

@ 0.3· 0.5A pada % pendikit

4.0· 5.0A pad a pendikit yang penoh

• nm~nw Malam

i'J~-,i'J~

@ o . .,-o.",A iw @/d ~Wli'J~

buka-tutup 0.2 . 0.3A pada % pendikit

@ 2.0· 3.0A pada pendikit yang penoh

~ i ' i'J ,.,; 1m. 0 -r;r"oA U '(lW! W1~WllJVI

~ ~ ~

(DC20)

Charging voltage nmj~lm1~i'h

OFF-ON

@ 5.5- 6.5V at % throttle

7.5-B.5V at Full Throttle

i'J~-li'J~ &.&-I>.~ 1fl~11 iw ",/d ~Wltl~

@ 1'j'tl ,.,; d.~ .-".& fl~l1 W ~Wl ~ l~~l1

Jt;!;1110 aliran kuasa voltage

OFF-ON

@ 5.5-6.51*. W#(r~m¥JjJJ:l/4~

7.5-S.51*. jfpj,m ~r,M '"'

buka-tutup 5.5 - 6.5 pada % pendikit

@ 7.5 - B.5V pad a pendikit yang penoh

, - 29-



b. Checking the silicon rectifier. b. tal1l"U!3Jlllll!

'II. m1~11\la"m11~~nilumJa,1,~ b. Periksa pembetul silicon

If the tester needle deflects as illrst

rated in either tests "a" and "b".

The rectifier is considered to be in good

condition. "twA: "8." !J)(: "b" 8(Jil\lldAIFilqlI9i-7T~, 'i{t~,tWo:no0.it;ff

l11iJ,l :R7J~;E: " tnjfE1*J,;1JE1¥;o

11,m nile iJu~, ~Di ,il 1)1 'Du'bJ ~11J1i u a~1 mlJi11u,lJ n ua~ 'II. nmu ua~'11",uJa,1,1"~luam'Hl"ul0",]

®

Jika jarum penguji terbias seperti dalam (i:i) gambarajah dalam menguji "a" dan "b".

Pembetul itu hendaklah berkeadaan baik.

3. Battery 3. lIi!li1l!

Cll. ~llJfllflEa 3. Bateri

a. Battery charging a. lIiI!itll1t:I!

n. nm)~1v1uu~,~o~ a. Mengecas bateri

Charging hours: 10 hours

1t:!!ltl'rOl : 10'J'1tl'

nm~10)5D~ 0)0 'tilJ.

Waltu mengecas: 10 jam

- 30-

Charging current: 0.4 A

1t:I!!!iiff. : 0.4*

m"ua%iiiHtl~ o.~ "ou"Ji Aliran kuasa mengecas: OAA



b. Battery fluid b. i!lllIitlllll!!l ill<

, " "lJ U1ml?lnmJm~m

b. Bateri cair

If you should upset the battery care

lessly, thus causing the battery fluid to

spil, and a dilute sulfuric acid (specific

gravity,l.260).

t.lrl*~t:1'rttifu~t~, -fiTi'f~1tli~'ntiili:£~~1fiW:i1a\:i±I, ~~j,.

1~JE'l'fj'ft, ~u#1JOUfffiil.m~

(ltilil.260), i1?f!IJ1mUilirJilko

lh l'lnrl'J 1 ~ ~t'J~ til tllJLL1J\?U \>1D~~U1111H~1 m iww U1J\?l

L \?rU~l1f)U ih (j ~ ~ lliHf~l m ~fhlJ g;rl\m th-lriflt! (f111lJth:j'j)lrvng; GJ.lffi'Do)

JikaJika anda kurang menjagai bateri,

menyebabkan bateri itu jadi cair dan

melilih, dan mencairkan asid sulfuric

(graviti ketetapannya: 1.260)

4. Inspection

4. "" Jj;

d. 11HIlHfnlh

4. Pemeriksaan

a. Lighting coil

I Tester scale range R x 1

I Standard value I 0.30n ± 1"0%]

a. fl~')jIJllll!1

RX!

O. 30l!:};: ± 10%

R x I

0.300+10%

a. Lengkaran yang menyala

Jarak skil penguji I R x 1

Kilai yang standard 1 0.30n ± 10% 1- 31 -

Dilute sulfuric acid.

(SPECIFIC GRAVITY 0 1.260)

fffi1in~~ (1t:1E : 1.260) %' 0 .. , ,

til m l>1fl1lJ g;(]u tl t1UcHl'U

(mllJ~1:j'1l1mlg; G),\@\)o)

Asid sulfuric cairo (ketetapan graviti; 1.260)

Yellow

M • 11 fi<l \1

Kuning



b. Source coil

Tester scale range R x 10

Standard value 1.39Q ± 10%

R X10

1.39~X± 10%

, ' 'U. fteM~lU~l 0

R x 10

1.39Q± 10%

b. Bahan - bahan yang dilingkar

I Jarak skil pengunji R x 10

Nilai yang standard 1.39Q ± 10%

c. Charge coil

I Tester scale range R x 1

Standard Day (Green· black) 0.15Q ± 10%

value Night (Green/red - black) 0.34Q ± 10%

RX1

O.15Wi:±10%

Q,34Wi:±lO%

. '" . nm~ftU(l'U01/11~~-~l) 0.340 ± 10%

c. Menukar iingkaran

I Jarak skil penguji R x 1

Nilai Suabg (Hijau . Hitam) 0.15Q ± 10%

standard Malam (Hijau/Merah . Hitam) O.34Q ± 10%

- 32-

Green

~

'" L ,\W1 Hijau

Black/White ;\\\/13 ~l/ 'Ul1 Hitam/Putih

Green/Red

~/n

'" l'U01/11~~

Hijau/Merah



d. Main switch

~n Color of lead OFF

B lack/W h ile- Black 0 Red-Black/Red X

Red-Brown X

0- Conlinuiwldenoles 0)

x- No continuity

~~ ~'lJB1mV

~1/'lJl1-~1

ll~1-~1 /ll~1

, l!\>I~-U1~H}

• • O-·WlmWi),,'J (UJ;'I\>1,,'j 0)

x-1~~mdB1

CHECK ON

X X

0 X

X 0

D~ Wl1~ cD ~

0 X X

X 0 X

X X 0

~ w.*~Jl.~7J[J

!!I!\/H-!!I!\

tJ: -!I,UtJ:

/;I.-I;j<

0: iillll!(tl!7),Q)

X : '[';>EX ..

d. Suis besar

OFF

0

X

X

~s pedoman warna

Hitam/Putih - Hitam

Merah - Hitam/Merah Merah - Coklat

o - Berterusan (denotes 0)

X - Tidak berterusan

B/W B R B/R B r

ON

B, Black B: !!I!\ B: ~1 B : Hitam W, White W:S W ~11 W : Putih R, Red R:n R uvn R : Merah Sr : Brown Br: ~ Br:

, Be : Coklat Ulfll\j)

Dg' Dark green Dg: ),;~ " 09 : Hijau pekat

Ch, Dark brown Ch: ;A!I~

Dg: l"lJU1Ufl Ch, Coklat pekat L, Blue Ch:

, : Biru

L : j1f U1WlllHln L G, Green , G : Hijau y, Yellow G:~ L Wll~1-l

0 Y : Kuning p, Pink y: 'lift G l"Utl1 P : Merah jambu

P: Illn y 0 lOJ.JfJB

P 't"lJl'j

- 33-

",'Ii ON

X X

0 X

X 0

Tutup uji buka

0 X X

X 0 X

X X 0



e. Flasher switch

~n Color of lead

Dark green· Brown/White

Brown/White· Dark brown

o - Continuity(denotes 0)

X - No continuity

~ Mm~m~

.; ,. l~mL! n -1.l1~1~ /~11

, . , Ul~l~ /~11-Ulm~L!n

, . O-~tH'W'U,'j (Ut'I~,'j 0)

x--'D';mdfl~

L N R

X X 0

0 X X

L N R

X X 0

0 X X

~ 'j>'j'k.l'l'i3 rJ lj f{=f,<iji.. lJ

i~*,k-f;~/tJ

f'~; / 1'1- ig~f;j;;

. -0: i!l!1\'!(*,,,, 0)

X : "f'illiil'l

e. Suis lampu penyinar

~iS pedoman warna

Hijau pekat . Coklat!putih

Coklat!putih - Coklat pekat



"" Dg B r/\I\ Ch

.... U- -U

~ 0- -n

- 34-

L N R

X X 0 0 X X

L N R

X X 0

0 X X



f. Light switch

~n Color of lead

Green - White

Brown· Blue/Red

Brown· Blue/White

Blue/Red· Blue/White

White· Green/Red

Yellow/White· Blue

0- Continuity (denotes 0)

X - NO continuity

~ J:I"iJtJ~ftltJ

'" L"iJ"U€l-"iJ11

, , , UHll{'J -Wll>lU /ul?n

, , , m~l~ -mml /~11

1f <>< 1f ..", m.111 /"~1-111L111 /~m

'" 'Ul1-l"iJtJtl IU~\I --. , ,

.llOB1 /~n-1l1'111

• • O-(~WHW€l,'j (lU1~.:j 0) , " . x ----llJW1tHl-H)-'l

"" 0

P

~D

OFF P ON

0 X X

X 0 X

X 0 0

X 0 X

X 0 0

X X 0

OFF P ON

0 X X

X 0 X .-

X 0 0

X 0 X

X 0 0

X X 0

Br L/R L1W

~

G W

n-

0

f. ~TIlIlIlll

0: J!l!~;i'i(R7f, 0)

x : /f~J!JH~

.

OFF

o x x x x x

f. Sris lampu menyala

~iS pedoman warna

H ijau - Putih

Coklat - Biru/Merah

Coklat - Beru/Putih

Biru/Merah - Biru/Putih

Putih - Hijau/Merah

Kuning/Putih - Biru

o -Berterusan (denotes 0)


G/R Y/W L

--n

--n n- --n

- 35-

p ON

x x o x o o o x o o x o

Tutup P Buka

0 X X

x 0 X

X 0 0

X 0 X

X 0 0

X X 0



g. Dimmer switch

~on Color of lead

Green· Blue

Blue - Yellow

o -ContinUity (denotes 0)

X - NO continuity

~ ~~fl~m~

.. " I~~fl-llll~ll

d' • ll~ll-Ill~fl~

, . O-~flillfl~ lU~fl~ 0)

x - 'll~flIJfl~

LO HI

0 X

X 0

LO HI

0 X

X 0

G L Y

0::

~"' i!H~"'31j

lci<-Fi

'.!i:-j){

0: iJ!>Il1!(",,,,O)

x : "Fi1!!Il1!

-36 -

g. Suis lampu kabur

~iS pedoman warna

Hijau - Biru

Biru - Kuning

o -Berterusan (denotes 0)


LQ HI

0 X

x 0

LO HI

0 X

X 0



h. Horn switch

~n Color of lead

Pink· Black

0- Continuity (denotes 0)

X - NO continuity

h. 'JJ"illlllllll

0: i'lil.,(,b" 0)

x : /GiJlH~ 'Jj, ~1~U~J

, . O-\?lmwv~ (U'(ftl~ 0)

x - '!l~m~!l~ h. Suis bunyi isyarat

OFF Push

X 0

OFF Ii

x 0

OFF Push

X o

~iS pedoman warna Tutup Tekan

Merah jambu - H itam



i. Neutral switch When the point is pudhed, there should be continuity

i. S!!llilllllllll

Ii A illfllimii U!Y , 110 Hi£lii'I'-i',

ru, fI~~hl':h"l

l~f)fl~~lHI~~O~fWl~1U\?lfl1lJl'im~fl-.lfi'w

i. Suis neutral

X 0

Bila tempat itu ditekan, ia meati berterudan

~

k:1

- 37-

P B

0- ~

~



j. Horn j. ·.!JW\

qj. dq)q)lflJthm1D\O)

j. Pembunyi isvarat

k. Flasher relay

k. 11'l1'l11ruRl",1il~ k. Lampu gilir penyinar

Resistance between X-L About a n

Resistance between case and each terminal

1Mil or more

, , W1111J~1'U111U1~'U11>1 X·L

" , I MQ HH)lJ1f1f)11

I Penahanan antara X - L kira - kira 0 I

Penahanan antara kes dan tiap - tiap terminal

1 M[l atau lebih

1. Battery 1. fi~;1.h , Gl. U'jJrpJl~m

1. Bateri

- 38-

X L

2. Flasher relay 2. M7tmf;\'!!!O:" t.!l. rl'qJtylU1~lm1D~

1.05[2±20%

2. Lampu gilir penyinar



II. APPENDICES

A. Service data Engine

Displacement 79 em'

Bore and stroke 47 x 45.6 mm

Compression ratio 6.6: 1

Piston ring end gap 0.15~0.35 mm

Piston clearance 0.035 ~ 0.040 mm

Crankshaft

Small end free play 1.5~2.0 mm

Crankshaft deflection 0.03 mm

Clutch friction plate wear limit 2.7 mm

Transmission gear ratio

First 39/12 3.250

Second 29/16 1.812

Third 24/20 1.200

Secondary reduction ratio 37/14 12.642)

Chain size & No. of link DK420 99link+joint

Engine oil Exchange 650 em', Total 700 em'

Oil pump minimum stroke O.25~ 0.30 mm

Carburetor

Type VM15SC

Main jet #95

Clip position 3

Float level 23 ± 1 mm

Pilot air screw ,.Y2

Engine idling speed 1 ,250 ~ 1450 r/min

Chassis

Tire size

Front 2.50-17-4PR

Rear 2.50-17-4PR

Tire pressure

Front 1.5 barl1.5 kg/em2)

Rear 2.0 bar(2.0 kg/em2)

Fuel tank capacity 5.3 Q

Autolube oil tank capacity 1.2 Q

- 39 --



Electrical

Ignition timing(B.T.D.C.) 1.8 mm

Spark plug type BP6HS

gap 0.5-0.6 mm

Charging current

Day OAA or more/3,000 r/min

5.0A or less/8,000 r/min

Night 0.2A or more/3,000 r/min

3.0A or less/8,000 r/min

Charging voltage 6.0V or more/3,OOO r/min

8.2V or less/8,000 r/min

Source coil resistance Black/White: 1.39 [2 ± 10%

Charge coil resistance Green:O.15 [2 ± 10%

Green/Red:O.34 [2 ± 10%

Lighting co it resistance Yellow:0.30 [2 ± 10%

Lighting

Head light 6V,25/25W

Tail/brake light 6V,5.3/17W

Flasher light 6V, lOW

Meter light 6V,3W

Auxiliary light 6V,3W

Neutral indicator light 6V,3W

Oil warning light 6V,3W

Ignition coil resistance

Primary winding 1.][2 ± 10% (20°C)

Secondary winding 6.0k[2 ± 20% (20°C)

-40 -



n .

l!Hi!l:!it 79 J1: 7J )j)¥

ru! • hUt 47 x 45.6 "'*

llIl'iIillt 6.6 : 1

;i5ll!:B*"" 0.15 - 0.35'!!;*

;i5ll!:ljt;;l;M! 0.035 - 0.040 "'*

i!liilib

'H"l!IM! 1.5 - 2.0 "'* i!Ii;;m1i!", 0.03 "'*

ifI!!~HllI!'mWiilll!'mH1'H 2.7 '!!;*

!Ii',*HJlliilillt 1I\-Jlliilil 39/12 3.250 1I\=Jlliilil 29/16 1.812 1I\~Jlliilil 24/20 1.200

~*ll",*lt 37/14 (2.6421

1i!.R-tl>l.~iI'tIi: DK420 99 !;til'+tJii!L~

llI!)!Il 3l'!fl!650= *1l,t700c.c

5fa~:ft/J\1T,i 0.25- 0.30",*

"'ltH lI:! II!! VM15SC 3o'jiHL # 95 ?'c'Til'i:ii1i 3

i'l''T*'l' 23± 1"'* ;Ji;Un 1-1/2 fj!!liJllI!",,* 1 ,250 - 1,450 JIi1i/-B-

'i<iIilR-t M' 2.50-17-4PR iI! 2.50-17-4PR

'i<;n~lI!lllll'

M 1.501T/1i:*' iI! 2.001T/1i:*'

It&)!Il*ll'lii':!it 5.30Jt

1O!liJi!l!JilfH)!Il*ll'l§':!it 1.20'1t

~41-



!!l;xJEI>.f (L"~!!l;) 1.8~*

x'IE'" !l:!!re BP6HS

M; 0.5-0.6 ~*

]E~~5i1E

sa o. 4iz::uxl.-.:.t.l/3, OOOr/mi n

5. O'k!'xU -1'- /8, ODOr 1m i n

'5{,L o. 2-tz:l1t!-.:tl:./3, 0001' /mi []

3. O-'t2!'xU -F /8. OOOr/m i 11

"ff.~~~ 6. OikU,J.:./3 ,ODOr/min

8. 21k.l--.JJ:.I8, ODOr /mi n

iIi:;miI~!lID iIi:?l1 i~T:VI'I : 1. 39IKj: -.110%

:;Cili:*~!lIDiIi:'.!l {f.;}: : 0 . 151l).: ± 10%

{f,31<I,f,r: O.34IXX±lO%

fl~'JlI,,~!lIDiIi:?l1 t1't: O.3OfX±10%

fl~ 'Jl :*:1~ 6lk, 25/25}[.

r.l / iIi'I.I;)] m 61*. 5.3/171'L

~7tm 6 ik. lOlL

l,H>!!! 6 17~, 3 Fe

'.~JJm 61*. 3lL

~~i1~maim 6ik, 311

~re~w~m 61k. 3 JiL

!!l;x*l:lI!IiIi:'.!l tJJiI!lJll;l!'! 1.7[1 ± 10% (20°C) o:iI!lJll;l!'! 6.0k[l ± 10% (20°C)

-42 -



~.

. , IfI'H1Hll'lW

. , ~l'f~1"IJtHU1[J:j

J ~ 1 [J eltH ~ fl1.njlJ'li~ '" ~" .. , I'lJUI m~'lfiH'\11 [J:J1Jl1JUJU

, , I fH'J'H'IllJ

~m'Hth~~~ 1 ~~iH ~1J J;1fll'iiO-Hllfl1fl

, 1 ., l'l81lJln Ufll'W:·.J1NaltyIWlHH1JU'91

'm"o "IJ'U 1 WI"IJ D H'JH

Hih 11ri'..J

mllJU\?l'Utmn1 • ~W1

'mi-, ., ,

fl11lJ'Q"IJtl:jrl~I'lIm 'W~\I

i'l111J 't!'IJ ()..) i.l\l~ lUU iJ €I 1 '91~lJ

d.5 '11.'11 •

h,'n:Gl

O.GJa-"-O.Gfla lJ.1J

O.OGllG "'"- 0,060 lllJ.

(;).6 -- ~o lJ.lJ.

o.ocnlJ,lJ

Iq"d lUJ,

r;nG;Gl~ rn.kn&o

louG/(;)b <>u::;:'o!9J

lOTld/k'lo 0. k!loo

o.\;;n&- O.GnolJ,lJ.

(i).Gl/b

G).10&" 0 - Gl&& 0 "HJ'\J /'W iVl

. lB.tto-ro.>rJi-((fi.tl'l1 00 .((o-~w-r;(Y:; .tl'l1.

~.& n.n./'iI~.'Il.lJ.

".0 n.n ./'iI~.'Il.lJ.

a.r.n ~Vl1

Gl,L;u ~Vl1

-43 -



nl1"",",iJ.1v1 ~." lJ .lJ •

~i1"~",Mm" "u11'1 B p" HS

'15!:Wll'l o,a -o.ulJ,1J.

n1l'r.1\~ mn.:J1'U o.d-A 'Yf~illJlilfdll m.OOD ~fltJ /tnl1

&'oA 'H~m'l~HJf1111 ~.ooo ~iltJ /\,nl1 , flm~f1W o.Ig,A l1ltllJ1fHl'Jl/ co.ooa ~fltJ /tnVl

til. 0 A 'H~i)\'lfl[Jfr:hl r:::.ooo ~fltJ /\,nl'1

nmi.""ll'i!'h n.oV 'H~mJ1fHl':hl m.DOO ~iltJ /tnVl ~.~V 111fll'f-tHJfl11! ~.ooo ~iltJ/U'1'1

" " fl11UWll'UVll'U"lHH ftfl ~ [J 111'1-1 '\11 [J ~1/<tJ11 G),Cf$J.') Q ± (;)0%

fl111J Wll'Ul'11Ul<tJ D'l • O,Gl& Q ± 6)0 % L'l.HJ1 • o.(.'[l6 Q ± mo % L'tlV1! HYl'l :

ml1J~1'U'\'l1U"\JtHr1flrlm g:UUhJflflrl [Hlfl1'Y'l L'Ham : a,GIlD Q ± G>O%

,,",11'1

11'i,," " 1 ,~vi, oo,f /oo,f '1Vlvl 111 tJihh'V'lH1 ohm; ,~.~/ ~cl

. " '1V1Yl

1I'1 li'Y'Y1ru " 1,~vi, ~o ",,,,vi"

1'Y'lLlJU1U~ " 1,~vi, ~ -1V1v1

11'i01\l1 "J,.lmil " 1,~1'i", ~ -'l"'1'1

'vJLYl~m~'h'l 1 •• 1'i" , .

" ~ -1,,1,.,1

''t~t~m.nlll1u 1 ,,,1'i", .

" " lVlvl

fl11lJ~lU'YI1'U'lJm 'tlY1(lf) fIlQ VI''Y'l

,"",.J~U~iJ .. ).dQ±~% c·

'\J~nHlYl'1 ~mJiJ $ _0 kQ ±'o/O~'O

-" 44-



II. HUJUNGAN

A. Dataperkhidmatan Enjin

Tidak ditempatkan 79 em ,

Gerek dan pemukol 47 x 45.6 mm

Kadar kepadatan 6.6: 1

Hujung pemisah gelang omboh 0.15~ 0.35 mm

Omboh pembersihan 0.035 ~ 0.040 mm

Aci - engkol

Hujung keeil pusing - bebas 1.5~ 20 mm

Aci - engkol yang terbias 0.03 mm

Pinggan geseran gengam had pakai 2.7 mm

Kadau pemindahan gear

Pertama 39/12 3.250

Kedua 29/16 1.812

Ketiga 24/20 1.200

Kadar penurunan kedua 37/14 (2.642)

Saiz rantai & No. sambungan DK420 99 penyambung + dieantum

Minyak enjin penukaran 650 em', jumlah 700 em'

Pump minyak pukulan minima 0.25~0.30 mm

Kabureta

Jenis VM15SC

Jet utama # 95

Kedudukan elip 3

Paras apungan 23 ± 1 mm

Pilot skru udara 1-1h

Kelajuan biasa enjin 1 ,250 ~ 1,450 r/min

Chasis

Jenis tayar

Depan 2.50-17-4PR

Belakang 2.50-17-4PR

Tekanan tayar

Depan 1.5 bar (15 kg/crrr)

Belakang 2.0 bar (2.0 kg/em2)

Keupayaan tangki bahan api 5.3 £

Keupayaan tangki minyai autolube 1.2 £

~45 -



Eletrik

Tempat menyala (B.T.D.C.) I.B mm

Pemisah janis palam pencucuh BP6HS

0.5- 0.6mm

Mengecas al iran - kuasa

Siang O.4A atau lebih/3.000 min··

5.0A atau kurang/B.OOO r/min

Malam 0.2A atau lebih/3.000 r/min

3.0A atau kurakg/B.OOO r/min

Mengecas voltage 6.0V atau lebih/3.000 r/min

B.2V atau kurang/B.OOO r/min

Pwnahanan bah an lengkaran Hitam/Putih: 1.39n ± 10%

Penahanan mengecas lengkaran Hijau: 0.15n ± 10%

Hij"u/Merah: 0.34n ± 10%

Penahanan menyala lengkaran Kuning: 0.30n ± 10%

Nyalaan lampu

Lampu atas 6V.25/25W

Lampu brake belakang 6V.5.3/17W

Lampu penyinar 6V. lOW

Lampu meter 6V.3W

Lampu besar 6V.3W

Lampu penyuluh neutral 6V.3W

Lampu amaran minyak 6V.3W

Penahanan penyalaan lengkaran

BeUtan utama 1.7n ± 10% (20°C)

Bel itan kedua 6.0kn ± 20% (20°C)

-46 -



-MEMO-

-47 -



B. Cable routing diagram B. IU.lc*j~ri] Ciij. uNwN-:)vn-:)t~tH'f1 tl''V'J B. Gambarajah pusingan cable

11 ® ®

-48-



1. Front brake wire y

2. Throttle wire 1 I. 111UbUHl11U1

3. Throttle wire 2 • 2. 11l1J!11.l 4. Starter wire • 5. Pump wire 3. 1111J!1W 2 6. Speedometer cable

d 7. Air vent pipe 4. 111 Vl1\llll'VI 8. Clamp

11l vitlJ 9. Vacuum pipe 5. 10. Fuel pipe ~ d d

11. Over flow pipe 6. l1lVIJI\llmmllJL1d ,

7. 'VI m ~1Jl V lllJ ~ ~

8. IlIJI1WU ,

9. 'VI tl lJII! II! 1 f11 ff , , ~ ~

10. 'VI tlWlll'WI 'lltll1'l m ,

II. 'VIm~1J1V

I. "iJiIlIl'IJ~~II~ ;" 1. Wire brake depan 2. .1i)jlrUl~~II'~~ 1

2. Wire 1 pendikit 3. fl1j~FllNljl~", 2

4. """hi*l~ '" 3. Wire 2 pendikit 5. *ll~'" 4. Wire pump 6. III Jlli Iialllij ~.~

7. jffi*<~ 5. Wire pump 8. !k'.'r

6 . Cable meter laju 9. . ~~

10. *~·IPHJff 7. Lubang pintu angin II. iiiiViEtr

8. Pengikat

9. Lubang udara kosong

10. Lubang bahan api

11. Lubang kelebihan panas

-49 -



-50 -



1. Clamp 2. Pump wire 3. Wire harness 4. Oil pipe 5. Front brake wire 6. Speedometer cable 7. Pump wire 8. Vacuum pipe 9. Fuel pipe

10. Air vent pipe 11 . Starter wire 12. Clamp 13. Throttle wire 2 14. Band

I. ,",'i'-

2. *'~;1\ 3. m***ll 4. iF.l:Jif 5. "trlliljjl!JI~;1\

6. 'i<))jj ,HI~ III 7. WJI/;1\

8. • ~"8"

9. ~.t4'1if

10. iili",'Iif II. j@jl!Ji!ltI~ ;1\

12. ,",'f-13. 1t,*,rll~;1\ 2

14. t,\'H

• • I. fllJl1WlJ

2. \'11 viJlJ

3. !1lVl'Vn~

" 5. l'I1Vl1J1fll1Wl

6 . !1lViitOlll~mllJl~1

7 . !1l viJlJ ,

8. 'YIll!J!J!!J!lmfl ! 'It .., ij, "'"

9. 'YIllWllJWt 'IllllI'HN ,

10 'YIlli~lJ1VlllJ

d II. !1lVl'lOlll'YI

• • 12. fllJl1WlJ ~

13.!1lVllW 2 d

14. ItlJWOl

1. Pengikat

2. Wire pump

3. Wire keras

4. Lubang minyak

5 . Wire brake depan

B. Cable meter laju

7. Wire pump

8. Lubang udara kosong

9. Lubang bahan api

10. Lubang pintu angin

11. Wire startet

12. Pengikat

13. Wire 2 pendikit

14. Band

-51 -



- 52-



1. Front brake wire 2. Handle switch lead wire (R) 3. Flasher lead wire (R) 4. Flasher lead wire (ll 5. Handle switch lead wire (ll 6. Starter wire 7. Throttle wire 1 8. Front brake wire 9. Front stop switch lead wire

10. Flasher lead wire (R) 11. Pilot lead wire 12. Wire harness 13. Clamp 14. Main switch lead wire 15. Flasher lead wire 16. Handle switch lead wire (l)

17. Speedometer cable 18. Starter wire

1. MilIIJW}JwlmJ;;f~

2. flj1jf,fJfJ!I#le~Cfil

3. r"Jti!t#I'~11\)

4. rx-J7tX[1UJ~Ut::)

5. f I,," rm 1m IIII '" ( ;Ii'! 6. ""j)b!l~j"~"" 7. 1i1i*,r9jli!J:,j~ 1

8. MrlJllwMImJ# 9. ""{"ll:Ii1JI1lJ'Ij;I,~

10. I"Jti!t#I,~(ti)

11. JB-fG :IM¥-Hv'lt 12. j,Wrl ;,}~if,Fi

13. ~.:--(-

14. ±'M~jrMl';ll.Mii

15. 1'1 )\'JMF!H", (ft)

16. fl,"!lIIm'lj;,J,~(;IC)

17. 'i' ilillkj~l!l 18. iI'Q,,!J~II'I;I;

:.... 0 '" .",. ~ d 1 !'flUi'I~m!'fll1ml'f1'Y1'Y1U!JWI'1 1'1111)

3. !'fl~i'I~fl1l1!]!!]!lru 1'1111)

~ 0 ... ,.",. ~ d 9.i

5. !'fl[Ji'I~ml'f1mU!1TVI'Y1U!JWI'1 1'lI1m

6. !'fl Ul'fi'll~'Y1 , 7. !'flU!1W I

:., 0 ....",. 9.i

9. l'flUrl~fl1!'flmUl'f11111ql'111m

10. !'flU\il~rl111!]!!]!ltl! 1'1111)

II. ,m '1~~f)rl

12. !'flm~l~ <\ <\

I]. IllJ11WU

14. l'f.1U\il~rl'lti111i'Ul'f111mln

15. l'fl[J\il~rl'll1!]!!]!lru

1. Wire brake depan

2. Pemegang suis pangkal wire (kanan)

3. Penyinar pangkal wire (kanan)

4. Penyinar pangkal wire (kiri)


6. Wire starter

7. Wire 1 pendikit

8. Wire brake depan

9. Suis berhenti depan pangkal wire

10. Penyinar pangkal wire (kanan)

11. Pilot pangkal wire

12. Wire keras

13. Pengikat

14. Suis utama pangkal wire


16. Pemegang suis pangkal wire (kid)

17, Cable meter laju

18. Wire starter

- S3-



54

® ®



l. Front brake wire 2. Throttle wire 1 " I. m 1Jt1J'!f111Ul

3. Front stop switch lead wire 4. Speedometer cable 5. Pilot lead wire 6. Main switch lead wire 7. Oil pipe

~ 2. 111V!1U i

:.., 0 OJ "" ~ 3. 111V<1~fl1mmV1111'111~<111Ul

~ d d 4. 111VlJl<1mmllJll1

8. Oil tank breather pipe 9. Bridge plate breather pipe 5. 111V<1~fM1'lgll<1

1", C OJ "" OJ

6. 111V<1~fl1ml1m1111'1U!1fl , ~ .

7. 1'111UllJU ! OJ %' ."

8. 1'1m~1J1Vll1flll'l'UiH!lllUllJU , ~ d

9. 1'1m~lJ1V tllflll'l'U1l1 1J'!lll1l1'l!1<1

1. JlljiliIJiliiJj~", 1. Wire brake depan 2. Il)j*,r'j~", 1

2. Wire 1 pendikit 3. Jllj 1<' 11: Ilm Il!l ~ *,~ 4. • jIDJtaf,ijJ$~ 3 . Sui, berhenti de pan pangkal wire 5. ,~il' 1.'" ~ *$

4. Cable meter iaju 6. :E1lm1l!l~~~

7. im~ 5. Pilot pangkai wire 8. 11",1'i il!i '" 'l1f 6. Suis utama pangkal wire 9. tiHRJID#\:~

7. Lubang minyak

8. Lubang angin tangki minyak

9. Pinggan ata, lubang angin



CD @

®

®

~ V' V'

n H 0 (CZl:CD. _? .. :"L7..r_;?i7..7

7 B ®

lID

@----""----&

@,-~f\tI~~

15

- 56-



1. Taillight lead wire 2. Clamp 3, Flasher lead wire 4, Grommet 5, Clamp 6. Grommet 7. Oil level gauge lead wire 8. Wire harness 9. Battery breather pipe

10. Oil pipe 11. Wire harness 12. Grommet 13. High tension cord 14. Clamp 15. Earthwire 16. Bridge plate breather pipe 17. Oil tank breather pipe

1. ~*1iW.*~'it 2. "'+ 3. rlJ7t;f;(t~k;,Jl.

4. ilile1.i'ffilill 5. "'+ 6. i,,;rl.i'lftll!l 7. iiIJ ill: "I-\fl; I,~ 8. '~*IJJ. 9. tD-m:lili:im~tg

10. rm11f 11. i~*IJl

12. i*WTI\ll!I 13. iWim~*Jj! 14. "'+ 15. jHl!:lI,~

16. tim fIX 1m #I: W 17. rm¥ti:iJII~1ff

~ ~ 2.lllJl1UlJ

3. !11~IiI~fhl1'!l!qJlru 4 mSlJllJl1

~ ~ 5 IllJl1UIJ

6 . fl'W lJ! lJ 11 ~ i! '" 01 't: OJ

7. !11~IiI~fl'llmmI1i11~IiIIJU1lJU

, . . I O. 11 SU llJU

II . !11mlJl~

12. mSlJllJl1

13. !11 ~ ~1l lI1U'll'U ~ ~

14. IllJUUIJ

15. !11~~U , " d

16. I1m~1J1~mfl1ft'IJmIJH}!1 l1"lMl

1. Pangkal wire lampu belakang

2. Pengikat

3, Penyinar pangkal wire

4, Grommet

5, Pengikat

6, Grommet

7, Sukat paras minyak pangkal wire

8. Eire keras

g, Lubang angin bateri

10, Pipe minyak

11, Wire keras

12, Grommet

13. Ketegangan tali pengikat yang tinggi

14, Pengikat

15, Wire bumi

16. Pinggan atas lubang angin

17, Lubang angin tangki minyakqq

- 57--



-MEMO-

- 58-



-MEMO-·

-59 -



-MEMO-

- 60--



YAMAH MOTOR CO", IWA.TA, JAPAN

D"

PRINTED IN .JAPAN go. j---l,!J.-, >: I 0

(#' . cp . 5' 1 . -::,,',



yamaha y80 service manual · 2015-08-03 · 1. piston and piston ring. 1. ii'i:i;iil.ii!i:i;!~...

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