SINCE 1889 FLEXIBLEFLYER

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Roy Cobb
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1 SINCE 889 FLEXIBLEFLYER

2 FIG. Cylinder No. Part Number Price Description Quantity Note Head, Cylinder Note :AII parts are inter- * Head, Cylinder changeable between Cylinder Head Gasket Sunray50 and Sunray90, * Cylinder Head Gasket except those noted with Spark Plug E8T or BP7HS Cylinder an asterisk (*) * Cylinder Those marked with asterisk Cylinder Gasket are for 90cc only. I * Cylinder Gasket Bolt, Stud * Bolt, Stud 7 SOD.DO? 0.95 Nut

3 FIG. Crankshaft. Rod No. Part Number Price Description Quantitv I Note Crankshaft Assy. * Crankshaft Assy Bearing * Bearing Left Crank Crank Pin Bearing 5 Connecting Rod 6 Right Crank Key X5X Bearing Oil Seal Oil Seal

4 FIG. Crankshaft. Rod No. Part Number Price Description Quantitv I Note Collar * Collar PistonSet * Piston Set PistonPin * Piston Pin Piston Ring Set * Piston Ring Set Circlip * Circlip

5 FIG. 6 Air Shroud' Fan ~ e. ~ ~5"( ".. V "'".J.,l '"';~~.,8"\,.., \~ CIj o::i> /')", )? / 0 I 7 /'\ '-.. '.:::J Pt l'~'\\' /,/ / ~, '" \'<::::;'" '. " ' ~/ i/,c," /J;, -- / \ < F ) )f,[/ / I " / 'v JY '. /,~- ' '- -- ~:-v <;;, "'./ /~ )/ No. Part Number Price Description Quantity I Note Air Shroud, Cylinder * Air Shroud, Cylinder 50.0r: Red Grommet 50.0y: Yellow Air Shroud, Cylinder 50.0g : Green * Air Shroud, Cylinder Collar 5 Grommet ScrewM6X0-Ep.ln.cD(Black) Screw Tapping ST6.X8-F-h-Ep.Zn.cD(Black * Screw Tapping ST6.X8-F-h-Ep.Zn.c 8 Damper, AirShroud Fan * Fan 0 O-Ring Screw, Washer M6X6-Ep.ln.cC Stop Plate Throttle Cable * Throttle Cable 50.0 *see note.59 Fan Cover Protective Plate Screw Tapping ST.5X6-Ep.ln.cD (Black) Washer 5-Eo.ln.cC

6 FIG. Oil Pump, I I 0 I No. Part Number "' "' I (9- ~ : I "" I I I I ~8 &- 6 ~ ~: : I ', - - ~ 6 J I. ~~ I ~~ J,,-- ~9...~;>'~ ~.. ' '", ",., '" ',-,'" Price Description il Pump Oil Pump Bolt, Breather Gasket O-Ring Gear, Worm Wheel Dowel Pin Clip Oil Tube Clip Oil Tube Clip, Clip 0.8 Screw, M5X6-Ep.Zn. cd (Black) 0.5 Screw, M5X6-Ep.Zn. cd (Black) 7.60 Gear, Pump Drive 0.5 Pin Cx 0.65 Circli Quanti Note 5

7 FIG. 5 Air Cleaner No. Part Number Price Descri tion Quanti Note Reed Valve Assy. " Reed Valve Assy. Reed Valve Reed Valve LimitPlate Screw Mx8-Ep.Zn.cC Washer -A0HV Gasket, Valve Seat Intake Pipe Bolt M6x0-Ep.Zn.cC Clamp 0 Clip AirCleaner Assy. AirCleaner Case AirCleaner Cover Intake Pipe Element, AirCleaner 6 Seal 7 Connecting Tube 8 Screw Screw M6x0-E 6

8 FG.5 Air Cleaner l No. 0 Part Number Price Collar Grommet.5NutPlate Description Quanti Note 7

9 FIG. 6 Exhaust Muffier 5 r, / / " I & """, '... -()-'... -Uo,'} I I No. 5 6 Part Number *seenote Price Descri tion Exhaust pipe Assy. 0.5 Bolt 0.97 Gasket, Exhaust Pipe 0.65 Flange Bolt(M0x) 6.95 Warming Plate. Exhaust pipe ring Quanti Note Note: The exhaust pipe ring is an optionalpart for speed restriction. Q

10 FIG. 7 Crankcase No. Part Number Price Description Left Crankcase Bush, Bear Shock Absorber Gasket, Crankcase Cover Breather Plug *See note Left/Right Crankcase * Left/Right Crankcase Rubber Cap Hose Dowel Pin * Dowel Pin Screw M6x5-Ep.Zn.cC Screw, Pan head M6x0-Ep.Zn.cC Holder Crankcase Cover * Crankcase Cover Crankcase Cover Gasket Left Crankcase Cover Gasket * Left Crankcase Cover Gasket Dowel Pin 9 Quanti 6 Note includes Line & Line 5

11 FIG. 7 Crankcase No. Part Number Price Description Quantity I Note Screw M6x0-Ep.Zn.cC Screw M6x0-Ep.Zn.cC Crankcase Side Cover * Crankcase Side Cover Starting Shaft DowelPin Screw M6x5-Ep.Zn.cC Screw M6x0-Ep.Zn.cC Screw M6x65-Ep.Zn.cC Plug,Oil O-Ring Bolt, Flange AM8x6-Ep.Zn.cD(Black) Washer 0

12 FIG. 8 Slarter No. * * Part Number Price ~~ ~~ /6/ 8 i ) \ ~ C:OJ~~ ~~ 5 '~~l~-/ J 9 ~W@r/ / " j ~~ Descri tion.95 Wheel,Starter.75 Wheel, Starter.95 Bearing.95 Boss, Gear.58 Washer Plate.95 Starter Clutch Assy Clip 8.5 Gear, Idle 9.5 Gear, Idle 6.5 Bearing.59 Shaft, Idle Gear.5 Washer, Plate.55 Plate, Idle Gear 0. Screw M6x0-Ep.Zn.cC.5 Kick Starting Shaft Assy..5 Torsion Spring 0.78 Bush Solid 0.65 Washer Plate 0.89 Circlip Kick Starting Lever 0.7 Bolt M6x5-Ep.Zn.cD(Black) 5.9 Kick Pinion Assv. c..,, I Quanti Note

13 FIG. 9 Transmission. Clutch No. Part Number Price Description Quantity I Note Clutch Assy. * Clutch Assy Gear, Primary Drive Assy. * Gear, Primary Drive Assy Washer 6- OOHV Screw M6x0-Ep.Zn.cC 500: 0.9 Circlip Bearing, Clutch Shaft Oil Seal 7x8x5.5 7 Clutch Carrier Assy. 8 Tension Spring, Clutch Weight 9 Secondary Fixed Sheave Compo 0 Secondary Sliding Sheave Oil Seal O-Ring Guide Pin Spring, Compression 5 Seat, Secondary Spring Nut 7 Clutch Hosing Compo

14 FIG. 9 Transmission. Clutch No. Part Number Price Description Quantitv I Note Nut Bearing * Bearing O-Ring.0x Front PullyAssy. Weight 6 Cam Slider 5 Collar Washer Plate V-Belt * V-Belt ' 8 Sheave Primary Fixed Washer Claw Clutch One Way Washer, Spring Nut M0x.5-Ep.Zn.cC

15 IG.O Transmission 0!s../p s..~o " fj ~A ) 9, Lhd / 8 (D~ 6 No. * * 5 * Part Number Price Descri tion 9.80 Main Axle Compo.5 Main Axle Compo.5 Bearing, Main Axle 8.75 Bearing, Main Axle 0.0 Washer, Plate.7 Washer Conical Spring 6.5 Drive Axle Assy Drive Axle Assy Bearing 8.95 Bearing.67 Oil Seal 0.89 Circlip 0.5 Bolt M6x0-Ep.Zn.cC 0.5 Washer 0.0 Clip 0-Ep.Zn.cC 7.99 Sprocket.5 Lock Plate, Sprocket Quanti Note

16 FIG. Generator No. * Part Number Price Descri tion 7.65 Generator 8.75 Generator Stator Compo Pulse Trigger Oil Seal Screw, Pan Head Screw, Pan Head Screw, Pan Head Washer, Spring Rotor Assy. Washer, Plate -Ep.Zn.cC Nut, Hexagon Mx.5-Ep.Zn.cC, I Screw M6x6-Ep.Zn.cC Wire Quanti Note 5

17 G. Starting Motor No. * Part Number Price 9s.00 Description Starting Motor Assy l Starting Motor Assy. Brush Set O-Ring O-Ring Bolt Cable Screw M6x0-Ep.Zn.cC(Black) Quanti Note 6

18 FIG. Carburetor, , S i, I I - I r.5: : 7 8 I I if 6 m i I: J:ln I :. i I 0 : iijl I 8 9 i I 0 I j : &- -' " -I -..- / "" / I / I Q.7 // " ". If- -' ' ' -' No. Part Number Price Descriotion Quantity Note Carburetor Assy. * Carburetor Assy. Gasket Sprig, ThrottleValve Screw, Pan Head 5 Washer, Plate 6 Valve, Throttle 7 Needle Set 8 Nozzle, Main 9 Seal 0 Jet, Main Pipe Jet, Pilot, AirScrew Set Plug, Drain 5 Screw, Pan Head 6 Washer, Plate 7 Screw, Pan Head 8 Plunger, Starter 9 O-Rina 7

19 FIC., , Curburdor : : '0: - : 5 0 V:', rs: 6 :, 7 -Ef 8 I: I i I ;f.j i I.J:n - ' I : Q : i ':i'! I 0 h : J : ===-f &- / Q I.' / I /, I -..- I 7 // " // I "",- ti_,/' No. Part Number Price Description Quantity Note 0 Throttle Screw Set Needle Valve Set Float Pin Screw, Pan Head Nut, Cable Adjusting 5 Cap, Rubber 8

20 ~'IG. Engine Bracket,.',, No. Part Number Price Description Quantity I Note Connecting Plate Shaft Nut M8-Ep.Zn.cC Connecting Plate BoltAMx0-Ep.Zn.cC Nut M-Ep.Zn.cC Washer -Ep.Zn.cC Oil Tank Bracket 9

21 FIG. 5 Frame j "~ 6 ~. ~,- <~; 5 \ e ~@c. e r ~ /". 8/~7 0 / 9~ 9 9, 8 5 ~.I \j 6 ~7 \(6 ~--- 8 )---0 \-9 8~~ / 56--;~~.>- 6 5/ ~8 No Part Number Price Description 9.0 Frame.80 Bearing.0 Clip 0.89 Seat Front Shock Absorber Rubber.9 Seat Rear Shock Absorber Rubber.65 Engine Set Bolt. Engine Suspension Assy. Engine Setting Bush.75 Engine Set Bolt.95 Nut MOx.5-Ep.Zn.cC 0.65 Bolt AM8x5-Ep.Zn.cC Frame Number Plate Rivet x Plug Rubber, seat. Battery Base.6 Battery cover 0.5 Bolt with Washer (M6x) 0.9 Flange Nut (M6). Battery Pad 0.5 Washer Q-EoZn.cC Quanti 6 Note 0

22 FIG. 5 Frame 8 5 v7 \(6 ~ \;:-8 \j 6.~:O 5 :n h. I e ~ ))@c{ r """"e e ~, ~ 8 0 9~ 9 9 ~...J.~ 8 ~~7 / 7~~ 6 ~.:> 6 5/ "8 No Part Number ! Priee Deseri tion.6 Left Bracket, Rear Fender.6 Right Bracket, Rear Fender.0 Left Bracket, Front Fender.0 Right Bracket, Front Fender 0.69 Bolt (M6x) 0.5 Flange Screw 6.76 SwingArm Sub Assy..6 Bushing Containing Oil 5.56 Swing Arm Spacer.9 Swing Arm Seal Cover.5 Rubber Sleeve 6.68 Swing Arm Set Bolt.5 Flange Self-Lock Nut (M) Nut M8-Ep.Zn.cC Quanti 8 Note

23 FIG. 6 Swing Arm. Footrest 5! No. Part Number Price Description Quantity I Note Arm Suspension, Left Bushing, Arm Suspension Bushing, Containing Oil Bushing, Containing Oil Arm Suspension, Right Waterproof Cover Dustproof Rubber Bolt AMOx.5x50-Ep.Zn.cC Flange Self-lock Nut (M0) Grease Valve M6 Cap, Grease Valve Footrest Assy Flange Bolt (M0x) Fend Bar Assy Flange Screw (M8x) Bolt AM6x-Ep.Zn.cC ij(}, tjc76 5'-0'(') j(" f,t.(r rmf n is( Silt,0/7 ft rj /J /J /- /- IJv/U.ch -

24 FIC.I? Front Ft'nller ] 5 \.~ i ~80 6 8/.~ / 5 No. Part Number Price Description *see note 9.96 Front Fender Bolt with Washer (M6x) *see note.9 Rear Fender Sticker, Warning (Engine Oil) Sticker, Key Sticker, Warning (Y-6) Sticker, Warning (Tire Pressure) Sticker Warning (Passenger) Sticker, Warning (Sandy Beach) Bolt (M6x) Nut M *see note.99 Cover, Handle Bar Screw M6x-Ep.Zn.cC. Nut M5-Ep.Zn.cC Refiector(Red) Left Sticker, Front Fender Right Sticker, Front Fender Left Sticker, Rear Fender Right Sticker, Rear Fender Decals Quanti~ set Note Note: r : Red 57.00y : Yellow 57.00g : Green r: Red 57.00y : Yellow 57.00g : Green. 57.0r : Red 57.0y : Yellow 57.0g : Green. Decals# include line -9 and line 6-9

25 FIG. 8 Seal No Part Number ~ ---6 ~--~ 6?-~ Price Descrition 6.5 Seat.95 Seat Fixed Plate.95 Seat Fixer Seat Lock Assy. Bolt AM6x-Ep.Zn.cC 0.9 Flange Nut (M6).9l Seat Screw Quanti Note

26 FU;. 9 Oil Tank' Fuel Tank' 5 /- ~ ~ 0 7 ~.-- ~~.. ~,{> /-_J ~ No Part Number a 59.05b Price Descri tion 5.99 Oil Tank Assy..9 Oil Tank Cap 0.5 Bolt with Washer (M6x).99 Headproof Pad, Oil tank 9.99 Fuel Tank Assy Fuel Tank Cap 5.78 Fuel Filter Assy. Tube Clip I Tube Clip II.90 Manual Fuel Cup Assy. 0.5 Screw M5x6-Ep.Zn.cC.68 Pad, Fuel Tank.60 Breathe Tube Spring.6 Fuel Pipe.95 Spare Tube Quanti Note 5

27 FIG. 0 SUMI~IIMion ~. ~ 5 / ~ No. Part Number Price Descri tion Quanti Note 50.0Q.95 FrontShockAbsorber * Front Shock Absorber BoltAM0x.5x0-Ep.Zn.cC FlangeSelf-LockNut(M0) RearShockAbsorber Pin 6

28 VIC. Fl'OlIt WI...,.I 5 ~ ~.. Yi{ /l;68 'Ji,. 8/'" / 7 0" ~ '/ 8~ No. 0 *0 * * Part Number 5.00a 7.00a *see note Price Descri tion 8 6 / 0. Valve, Front/Rear Tire. Valve, tire.95 Front Tire 6x Rear Tire 9x7-B 5.75 Front Wheel Rim, Outer 5.5 Front wheel rim (0mm,one piece typ 5.75 Front Wheel Rim, Inner 0.69 Seal (5x).6 Front Brake Drum 0.99 Oil Seal FB57D.8 Inner Spacer.8 Outer Spacer.65 Bearing 600-Z.95 Bearing 600-Z 0.75 Castle Nut M 0.65 Washer xxt 0.5 Cotter Pin.x.5 Rubber Cap, Wheel axles 0.85 Washer 0xx.5t, Wheel Axle 0.69 Bolt AM8x6-Ep.Zn.cC 0.69 Screw (M8x6).95 Flanae Self-Lock Nut (M8 7 Quanti Note Note: Part5.005 includes part of line 6,7,9 & 0.

29 FIC. B,.ur Wh,.d 7~~ \:Yr-- / No. Part Number Price Description Quantity Note a. Valve, tire. The part #5.005, # * a. Valve, tire and # 5.00 may be sub Rear Tire 6x8-7 tituted withpart # * Rear Tire 9x7-B Rear Wheel Rim, Outer * Rear wheel rim (0mm,one piece type /55.0: Price: $.5 Flange self-lock NutM Rear Wheel Rim, Inner Seal (5x) *see note.5 Castle Nut Washer Shaft Connector Rubber Cover BoltAM8x6-Ep.Zn.cC Cotter Pin.x Wheel Axle Washer, Rear 0xx.5t Screw (M8x6) Flange Self-LockNut (M8) 8 8

30 FIG. Front Brake 9 8 I 5,~t@@\ / \ No Part Number 5.00 *see note *see note Price Description 7.95 Front Brake Panel Comp, Left.99 Front Brake Arm, Left Front Brake Indicator, Left 8.0 Front Brake Panel Comp, Right.99 Front Brake Arm, Right Front Brake Indicator, Right 5.99 Front Brake Cam 0.99 \ Front Brake Shoe Compo Spring Dust Seal Front Brake Return Spring Bolt AM5x5-Ep.Zn.cC ~.99IFront Brake Cable Quant" Note. Part 5.00 includes part of line,,7,8,9,0,&.. Part 5.00 includes part of line 5,6,7,8,9,0,&. 9

31 FIG. Hcur Brake ~. No. Part Number Price Description Quantitv I Note Bearing Seat Assy.Rear Brake Oil Seal FB555 B Bearing 6006-Z \. Part line, 5.00 & includes part of Spacer, Bearing Seat Assy Discplate Brake I Bolt AM8x0-Ep.Zn.cC. Part line includes part of Brake Disk Holder, Rear Brake Calipers Assy Supporer Calipier Bolt AM8x6-Ep.ZncC Bolt Flange Self-Lock Nut (M8) Rear Brake Cable Flange Screw (Mx5) Spring Washer (6) Wash (5xx5t) Flange Screw (M8x0) Rear Brake Cover Flange Screw (M8x) 0

32 FIG. Hear Brake No. Part Number Price Description Quantity I Note Shoe, Disk Brake Flange Screw (Mx8) Collar, Rear Brake Adjust Nut, Rear Brake Flange Self-Lock Nut (M8)

33 FIG. 6 Rear Wheel Axle 6Q c= No. Part Number Price Description Quantitv I Note Rear Wheel Axle Right Spacer, Long Left Spacer, Short Rear Sprocket Sprocket Holder, Rear Bolt M8x Washer Washer 6

34 FIG. 7 Chain._, No. 5 6 Part Number Price Descri tion 9.90 Drive Chain Assy..8 Protect Cover 0.65 Flange Screw (M8x).9 Adjuster, Chain Nut M6-Ep.Zn.cC Washer 6-Ep.Zn.cC Quanti Note Note :,Part includes part of line 5 & 6.

35 Frr,. 8 SlPt~ing 0 \J. BY ~~ ~ 5 No Part Number Price Description 9.75 Shaft Assy.,Steering.9 Oil Seal FB87D.9 Oil Seal FB57D.9 Inner Spacer.5 Flange Self-Lock Nut (M).95 Flange Self-Lock Nut (M8).95 Bush Sleeve, Steering Shaft.99 Knuckle, Left.99 Knuckle, Right.99 Castle Flange Nut 0.7 Cotter Pin.0x Steering Tie-Rod Assy..99 Flange Self-Lock Nut (M0).99 Bracket, Steering Shaft Quanti Note 5

36 FIG.9 El~ctrit~alPart!! I ~~, No. Part Number Price Description Quantity I Note Main Wire Assy Battery Lever Holder Assy. Left Plug, Small Rubber Plug, Big Main Switch Assy Screw M5x-Ep.Zn.cC Band ZD00x Safety Switch Bolt AM6x6-Ep.Zn.cC Safety Switch Warning Tag Ignition Coil Assy CDI Unit Assy Rectifier & Regulator ResistorAssy Starting Relay Assy Bolt AM6x0-Ep.Zn.cc 6 -

FIG.0 Tool Box No. Part Number Price Description Quantity I Note 50.00.99 ToolBox 50.00 8.99 Tools 50.00 0.

37 FIG.0 Tool Box No. Part Number Price Description Quantity I Note ToolBox Tools Bolt AM6x-Ep.Zn.cC Owner's Manual Service Manual () [).t;)'o (//70 r-b fa //;0' I I 7

DL601 PARTS MANUAL (T-REX 2001)

DL601 PARTS MANUAL (T-REX 2001) TABLE OF CONTENTS ENGINE ASSEMBLIES: CYLINDER... 2 CRANKSHAFT & PISTON... 4 AIR SHROUD & FAN... 6 OIL PUMP... 8 INTAKE HOUSING & AIR FILTER... 10 CARBURETOR... 11 CRANKCASE...