GTS150. Dune Buggy MINIMUM RECOMMENDED OPERATOR AGE: FOR OFF-ROAD USE ONLY. 10th letter in VIN: D-G
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- Cuthbert Lewis
- 5 years ago
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1 0-06 GTS50 0th letter in VIN: D-G Dune Buggy MINIMUM RECOMMENDED OPERATOR AGE: 6 FOR OFF-ROAD USE ONLY This vehicle is designed and manufactured for off-road use only. USA only: It does not conform to Federal Motor Vehicle Safety Standards, and in regards to operation on public streets, roads, or highways is illegal.
2 FIG. CYLINDER HEAD ASSY
3 PARTS MANUAL CYLINDER HEAD ASSY. REF NO. PART NO. DESCRIPTION REGD NO. M CYLINDER HEAD SPARK PLUG (C7HSA NGK) M CYLINDER HEAD GASKET M CARBURETOR INSULATOR GASKET 5 M CARBURETOR INSULATOR 6 M PIPE COMP. IN 7 M INSULATOR BAND 8 M HEAD COVER GASKET 9 M O-RING 7X 0 M BREATHER TUBE M STUD BOLT M6X8 M STUD BOLT M6X50 M50-B FLANGE BOLT M6X KAS NUT FLANGE M6-ZN. D 5 M CYLINDER HEAD COVER COMP. 6 M DOWEL PIN 0X6 7 M CYLINDER HEAD BOLT FLANGE M6X00 8 M N INTAKE VALVE 9 M VALVE STEM SEAL 0 M VALVE SPRING OUTER SEAT M VALVE OUTER, INNER SPRING M VALVE SPRING RETAINER M VALVE COTTER M N EXHAUST VALVE 5 M C CYLINDER HEAD ASSY** **does not include valve cover/hardware, intake/hardware, and spark plug
4 FIG. CYLINDER Ref No Part No Description QTY M Head, Cylinder - 50cc M Gasket, Cyl Head Low er - 50cc KAT Bolt, M6 x.00 x FHCS M Pin, M0 x 6 Dow el 5 M Tensioner, Cam Chain - 50cc 6 M Gasket, Cam Chain Tensioner - 50cc 7 M Asm, Cam Chain Tensioner - 50cc
5 PARTS MANUAL FIG. CRANKCASE ASSY. () CRANKCASE ASSY.() REF NO. PART NO. DESCRIPTION M R CRANKCASE COVER COMP. M CRANKCASE COVER GASKET M CAP TAPPET ADJUSTING HOLE M OIL FILTING SCREEN 5 M OIL FILTING SCREEN SPRING 6 M OIL LEVEL GAUGE 7 M AC GENERATOR CORD CLAMPER 8 M OIL SEAL 9.8X0X5 9 M O-RING 0.8X 0 M O-RING 8X M DOWEL PIN 8X KAT FLANGE BOLT M6X8 M FLANGE BOLT M6X95 M FLANGE BOLT M6X00 5 M FLANGE BOLT M6X0 6 M FLANGE BOLT M6X5 7 M FLANGE BOLT M6X OH HEX BOLT M5X-ZN.D REGD NO.
6 FIG. ENGINE CRANKCASE Ref No Part No Description QTY 77 Housing, Crankcase RH - 50cc 78 Bushing, Engine Hanger - 50cc M Gasket, Crankcase - 50cc 80 Housing, Crankcase LH - 50cc Grommet 6 8 Bolt, M0 x.5 x 5 FHCS 7 8 Washer, M0. x 8 x. Flat 8 8 Cover, Small Left 9 8 O-Ring, M08 x Pin 85 O-Ring, M6 x.8 M Seal, M9.8 x 0 x 5 86 Bolt, M6 x.00 x 8 FHCS Ref No Part No Description QTY 87 Pin, M0 x Dow el 5 M Bolt, M x.5 Special 6 M Washer, M Flat 7 M Seal, M0 x x 6 8 M Tensioner, Cam Chain - 50cc 9 M Pin, M8 x Dow el 0 M Stud, M8 x.5 x 95.5 M Stud, M8 x.5 x 87.5 M Washer, M8 Flat M Nut, M8 x.5 Flange Head M Bolt, M6 x.00 x 50 FHCS 5 M Spacer, Oil - 50cc 6 M Bolt, M6 x.00 x FHCS
7 FIG.5 PARTS MANUAL CRANKSHAFT CON'ROD & PISTON ASSY CRANKSHAFT CON'ROD & PISTON ASSY. REF NO. PART NO. DESCRIPTION REGD NO. M N CRANKSHAFT & CONROD ASSY. M NUT MX.5 M WASHER -9HV -0HV M LOCKING NUT (left hand thread) 5 M WASHER 6 M KICK DRIVE GEAR 7 M M NUT M 9 M WOODRUFF KEY 0 M PISTON PIN CLIP M PISTON PIN M PISTON M PISTON RING SET 5
8 PARTS MANUAL FIG.6 CAMSHAFT ASSY CAMSHAFT ASSY. REF NO. PART NO. DESCRIPTION REGD NO. M TAPPET ADJUSTING NUT M TAPPET ADJUSTING SCREW M VALVE ROCKER ARM M EX ROCKER ARM SHAFT 5 M CAMSHAFT CHAIN 6 M N CAMSHAFT COMP. 6T 7 M IN ROCK ARM SHAFT COMP. 8 M STOPPER PLATE COMP. 9 M DOWEL PIN 0X6 0 M N CAMSHAFT HOLDER 6
9 FIG.7 PARTS MANUAL LEFT COVER ASSY. LEFT COVER ASSY. REF NO. PART NO. DESCRIPTION REGD NO. M N COVER L M L COVER GASKET FLANGE BOLT M6X0 8 7
10 PARTS MANUAL FIG.8 FAN COVER AND SHROUD ASSY FAN COVER AND SHROUD ASSY. REF NO. PART NO. DESCRIPTION REGD NO. M FAN COVER COMP. M STARTER CABLE CLAMPER M CARBURETOR COOLING DUCT M LOWER SHROUD 5 M LOWER SHROUD SEAL 6 M UPPER SHROUD COMP. 7 M HIGH TENSION CORD CLIP 8 M UPPER SHROUD SEAL 9 M SCREW ST.8X6-F 6 0 M BOLT M6X SCREW ST.5 -F DUST COVER 8
11 FIG.9 PARTS MANUAL OIL PUMP ASSY. 5 OIL PUMP ASSY. REF NO. PART NO. DESCRIPTION REGD NO. M CHAIN OIL PUMP M NUT FLANGE M6 M SPROCKET OIL PUMP DRIVEN M BOLT M6X5 5 M OIL PUMP SUB ASSY. 9
12 PARTS MANUAL FIG.0 DRIVEN PULLEY AND CLUTCH SUBASSY. DRIVEN PULLEY AND CLUTCH SUBASSY. REF NO. PART NO. DESCRIPTION REGD NO. M M M CLUTCH ASSY. OUTER DRIVE BELT DRIVEN PULLEY ASSY. 0
13 PARTS MANUAL FIG. ELECTRIC SYSTEM ELECTRIC SYSTEM REF NO. PART NO. DESCRIPTION REGD NO. M STATOR COMP. M FLYWHEEL COMP. M COOLING FAN COMP. M FLANGE BOLT M6x8
14 FIG. PARTS MANUAL ELECTRIC STARTER ASSY. 5 ELECTRIC STARTER ASSY. REF NO. PART NO. DESCRIPTION REGD NO. M FLANGE STARTING CLUTCH M STARTER REDUCTION GEAR SHAFT M STARTER REDUCTION GEAR M FLANGE BOLT M6X6 5 M STARTER MOTOR ASSY.
15 PARTS MANUAL FIG. DRIVE PULLEY SUBASSY. DRIVE PULLEY SUBASSY. REF NO. PART NO. DESCRIPTION REGD NO. M MOVABLE DRIVE PULLEY ASSY. M ROLLER 6
16 FIG.5 TRANSMISSION Ref No Part No Description QTY 97 Housing, Outer Transmission - 50cc 98 Gear, Pri Drive - 50cc 99 Gear, Sec Drive - 50cc 00 Asm, Shift Gear Cluster F/N/R - 50cc 5 0 Gear, Final Drive Shaft 6 0 Asm, Shift Selector - 50cc 7 0 Paw l, Shift Selector - 50cc 8 0 Rod, Shift Paw l - 50cc 9 05 Shaft, Shifter Cam - 50cc 0 M Gasket, Transmission Case - 50cc M Tube, Transmission Vent 08 Nipple, Vent Tube - 50cc Large 09 Ball, Shift Indent - 50cc 0 Spring, Shift Indent - 50cc 5 Gasket, Shift Indent - 50cc 6 Bolt, Shift Indent - 50cc 7 50 Nipple, Vent Tube - 50cc Small 8 Bolt, Drain/Fill Plug - 50cc 9 Gasket, Trans Drain Plug - 50cc Ref No Part No Description QTY 0 96 Bolt, M6 x.00 x FHCS 5 Washer, M6 Flat 87 Pin, M0 x Dow el 6 Spacer, M5 Inner Gear 900-E60-KAT Bearing, 60 5 x 5 x E60-KAT Bearing, 60 7 x 0 x E60-KAT Bearing, 60 0 x 7 x 7 06 Circlip, M Bearing, 60 5 x x 9 50 Bearing, RNA905 0 x x Bushing, Shock Absorbing - 50C 8 Seal, M0 x 0 x Bearing, Sealed CC 5 Washer, M X X.5 Flat 9 Circlip, M5 5 0 Circlip, M5 6 Clamp, Wire 7 5 Bolt, M6 x.00 x 0 FHCS Oil Seal, Shifter Cam - 50CC
17 FIG.6 FRAME
18 FIG.6 REF NO. PART NO. FRAME GROUP DESCRIPTION REGD. NO F FB C.B.C. CROSS BAR Flat Black F CANOPY TOP F FB C.B.C. BAR CAGE Flat Black F HORN F (color code) HOOD, UPPER -(Red, FB, BL, ORG, CM) F TUBE SEAT Φ5 8 F SOCKET BOLT M8X.5X55 8 F R-WASHER 6 F SOCKET BOLT M8X.5X50 F LOCKING FLANGE NUT M8 F Front Side Reflector F FB FR. HOOD, LOWER F FOAM PADDING F SCREW BOLT, M5X6 6 F RUBBER FOOT PLATE F HEADLIGHT UNIT F FLANGE BOLT M8 x.5 x 50 F NUT M8 F FLANGE BOLT M6X 6 F BANJO BOLT M0x 6 F BRAKE HOSE ASSY. L. " F BRAKE HOSE ASSY. R. " F BRAKE HOSE ASSY. RR. 75" F THROTTLE CABLE COMP. F Forward/Reverse Cable F-N-R F PARKING BRAKE CABLE COMP. F PAN SCREW, M6X5 F HEADLIGHT RUBBER MOUNT F FRONT BLINKER/MIRROR MOUNT F REAR BLINKER MOUNT F COPPER CRUSH WASHER, BRAKE LINE F GRIP, HANDLEBAR F LEFT SIDE MIRROR F RIGHT SIDE MIRROR F FB SIDE ARM BARS Flat Black F TUBE SEAT SIDE ARM BARS F SS LEFT FRONT FENDER F SS RIGHT FRONT FENDER F S LF FENDER BRACKET PIN STRUT MOUNT F S RF FENDER BRACKET PIN STRUT MOUNT F SS FRONT LEFT TURN SIGNAL F SS FRONT RIGHT TURN SIGNAL F SS REAR LEFT TURN SIGNAL F SS REAR RIGHT TURN SIGNAL
19 FIG.7 STEERING SHAFT ASSEMBLY
20 FIG.7 STEEERING SHAFT ASSEMBLY REF NO. PART NO. DESCRIPTION REGD. NO F STEERING BOLT COVER F BOLT STRAP M6x F SPINDLE BRACKET F STEERING WHEEL F STEERING SHAFT F BEARING NK0/6 F SPECIAL WASHER Φ0 F CIRCLIP Φ0 F BOLT M8x5 F LOCKING WASHER Φ8 F STEERING KNUCKLE F STEERING GEAR F FLANGE BOLT M8x.5x5 F ROUND NUT M6x.5 F STEERING BALL JOINT F NUT M0 F BALL JOINT DUST COVER. L. F GTS TIE ROD 5.5" F ROD END F FLAT WASHER Φ0 F LOCKING WASHER Φ0 F CASTLE NUT M0 F COTTER PIN Φx5 F TILT STEERING HOUSING F STEERING GEAR BRACKET F LOCKING FLANGE NUT. M8 8 F THROTTLE PEDAL BOLT M8x.5x5 F THROTTLE PEDAL RETURN SPRING, L F FLANGE BOLT M8x.5x0 F NUT M8 F THROTTLE PEDAL COMP. F PAN SCREW M5x5 F FLAT WASHER Φ5 F NYLON LOCK NUT M5 F BRAKE PEDAL COMP F PIN 6x F SPINDLE PIN F COTTER PIN X F BRAKE LAMP SWITCH ASSY. F PAN SCREW Mx6 F PEDAL BUSH F BRAKE PEDAL RETURN SPRING, R F BRAKE PEDAL BOLT M8x.5x F MASTER CYLINDER F BOLT-WASHER M8x.5x5 F THROTTLE PEDAL PAD F BRAKER PEDAL PAD F MASTER CYLINDER BRACKET F ADJUSTING KNOB F TILT STEERING BOLT F TILT STEERING LOCKING BUSH F COLLAR
21 FIG.8 SUSPENSION ARM ASSY
22 FIG.8 SUSPENSION ARM ASSEMBLY. REF NO. PART NO. DESCRIPTION REGD. NO F GTS STRUT AND SPINDLE SUPPORT, R (PIN FENDER MOUNT) F FLANGE BOLT M8x.5x05 F UPPER SUSPENSION ARM COLLAR F UPPER SUSPENSION ARM BUSHING F SLV UPPER SUSPENSION ARM F LOCKING FLANGE NUT. M8 F LOCKING FLANGE NUT. M ( cotter pin) F BALL HEAD DUST SEAL F BALL HEAD SPACER F GTS STRUT AND SPINDLE SUPPORT, L (PIN MOUNT FENDER) F BOLT STRAP M8x F LOWER SUSPENSION ARM COLLAR F BOLT STRAP M6x F FRONT TIRE & WHEEL, RIGHT 9x7-8 F PAD SET. FR. BRAKE CALIPER F FRONT BRAKE CALIPER. L F FRONT DISC BRAKE F DUST SEAL 7x5-7 F BEARING 60-Z F TIRE BOLT M0x.5x 8 F B FRONT WHEEL HUB F BEARING 60-Z F LOCKING FLANGE NUT M0 8 F FRONT TIRE 9x7-8 F FRONT WHEEL 8" STEEL BLACK F LOCKING FLANGE NUT M0 6 F CASTLE NUT M F COTTER PIN Φx0 F FR. HUB COVER. F FLANGE BOLT M0x.5x0 F FRONT BRAKE CALIPER. R F CUSHION ASSY. FR L=5 F FLANGE BOLT M0x.5x80 F LOWER SUSPENSION ARM DUST CAP 8 F LOWER SUSPENSION ARM BUSHING 8 F O-RING Φ.x.65 8 F SLV LOWER SUSPENSION ARM ASSY. F FRONT TIRE & WHEEL, LEFT 9X7-8 F ACORN NUT M
23 FIG FB Rear Rack 9 9
24 FIG.9 REAR CARGO RACK / SEAT BELTS / SEATS REF NO. PART NO. DESCRIPTION REGD. NO F TUBE SEAT Φ5 F FB RACK SUPPORT ARM FLAT BLACK F FLANGE BOLT M8X.5X0 F LOCKING FLANGE NUT. M8 F FUEL TANK CAP F FB FUEL TANK F FLANGE BOLT M8X.5X50 F TANK COLLAR. F RUBBER MOUNT F FLAT WASHER Φ8 F NYLON LOCKING FLANGE NUT M8 6 F AUTO FUEL COCK ASSY. F FUEL TUBE # F VACUUM TUBE F FUEL TUBE # F FUEL FILTER F SAFETY BELT COMP. F NUT M8 F R SEAT COMP. R F L SEAT COMP.L F SPECIAL BOLT, M7/6 x8 F WASHER BELT Φ 9 F BELT NUT M7/6 9 F SEAT RALL SET. F TAIL LIGHT BULB. W/5W V F TAIL LIGHT F LOCKING NYLON NUT, M6 F BOLT SHARP M8X.5X0
25 FIG Shift Disc REAR UPPER SWINGARM REF NO. PART NO. DESCRIPTION REGD. NO F LOCKING FLANGE NUT. M F WASHER. ENGINE MOUNT LINK F CUSHION. ENGINE MOUNT LINK F SPACER. ENGINE MOUNT LINK F COLLAR. ENGINE MOUNT LINK F WASHER. FLAT Φ F NUT M F ENGINE MOUNT BOLT PLATE F LOCKING FLANGE NUT. M0 F BOLT-WASHER M6x F LOCKING NYLON NUT. M6 F BOLT-WASHER M0x.5x5 F COLLAR. ENGINE MOUNT BOLT PLATE F SCREW. PAN M6x55 F COVER. ELECTRIC ASS'Y. F REAR SWING ARM ASS'Y. UPPER F BOLT-WASHER Mx.5x60 F LOCKING FLANGE NUT. M F SWING ARM DOG BONE F BUSH. CON' ROD 8 F SPACER. CON' ROD F BOLT-WASHER M8x.5x6 F BOLT-WASHER M0x.5x95 F COLLAR. ENGINE MOUNT F SHIFTER ASSEMBLY
26 FIG. ENGINE / MUFFLER / AIR CLEANER 0 5 ENGINE / MUFFLER / AIR CLEANER REF NO. PART NO. DESCRIPTION REGD. NO F AIR CLEANER CLAMP F AIR CLEANER ASSY. F CARBURETOR F N ENGINE, 50CC (non oil cooler) F- 507 MUFFLER SUPPORT (BOLT ) F BOLT, M6X F LOCKING WASHER Φ6 F MUFFLER COMP. EX F-7 SIDE CASE BOOT F MUFFLER JOINT NUT, M6 F-9 M EX. PIPE GASKET F AIR CLEANER ELEMENT
27 FIG
28 FIG. REAR SWING ARM REF NO. PART NO. DESCRIPTION REGD. NO F FLANGE BOLT M0x.5x0 F LOCKING FLANGE NUT M0 F CUSHION ASSY. RR F BOLT STRAP M8x.5x00 F L REAR FENDER BRACKET, L (PIN MOUNT) F LOCKING NYLON NUT M6 F FLANGE BOLT M6x.5x0 F FLANGE BOLT M6x6 F ALLEN BOLT M8x.5x F R REAR FENDER BRACKET, R (PIN MOUNT) F SWING ARM BUSHING F SWING ARM COLLAR F RR. BRAKE PAD SET F CALIPER ASSY. RR F-6 85 LOWER CHAIN GUARD (88 UPPER GUARD) F BATTERY COVER F BATTERY BAND F BATTERY LOWER CUSHION F BATTERY (GTX9-BX) F RR. LOWER SWING ARM COMP. F LOCKING FLANGE NUT M F SWING ARM CUSHION BUSHING F FLANGE BOLT Mx.5x60 F R-(color code) R. REAR FENDER -(Red, FB, BL, ORG, CM) F L-(color code) L. REAR FENDER -(Red, FB, BL, ORG, CM) F BOLT, M6X6 F NUT, M6
29 FIG. REAR HOUSING
30 FIG. REAR HOUSING REF NO. PART NO. DESCRIPTION REGD. NO F BOLT-WASHER M8x.5x F DISC. RR. BRAKE F LOCK FLANGE NUT. M8 F B-N REAR AXLE F N CHAIN O-RING DRIVE 50X5 F REAR SPROCKET T F BOLT-WASHER M8x.5x7 F DUST SEAL 50X-7 F COMP. HOUSING RR. AXLE BRG F BEARING 606 F BEARING BASE F BOLT-WASHER M8x.5x0 6 F DUST SEAL X0-7 F BOLT. TIRE M0x.5x 8 F B HUB. REAR AXLE F TIRE. RR x0-0 F RIM. RR 0" BLACK F LUG NUT. M0 8 F REAR TIRE/WHEEL ASSY., RIGHT F WASHER 6 F CASTLE NUT. M6 F COTTER PIN. X0 F COVER. RR. HUB F REAR TIRE /WHEEL ASSY., LEFT F MASTER LINK, CHAIN F FLANGE BOLT M8X.5X5 F DUST SEAL X8-7 F ROUND NUT M0X.5 F KEEPER F CIRCLIP Φ6 F REAR AXLE BEARING HOUSING F MAGNETIC CONTACT F Pan Screw Mx8
31 FIG. ELECTRICALS
32 FIG. ELECTRICALS REF NO. PART NO. DESCRIPTION REGD. NO F SWITCH PANEL COVER F ENGINE STOP BUTTON F KEY SWITCH F WIRE HARNESS. F POSITIVE/NEGATIVE CABLES F BOLT M6x0 F NYLON LOCKING NUT M6 F GTS REGULATE RECTIFIER COMP. F STARTING RELAY F C.D.I. UNIT COMP. F NYLON LOCKING NUT M5 F ROUND HEAD BOLT M5x5 F IGNITION COIL COMP. F SPEEDOMETER F SPEEDOMETER SENSOR F SCREW, MX0 (GB88) F SPRING WASHER, (GB9) F FLAT WASHER, (GB97.) F NUT, M (GB670) F BOLT, M6X0 (GB5787) F NUT, M6 (GB687) F HEADLIGHT SWITCH
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