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1 .0 HANDLEBAR 8759 INSTRUMENT HOUSING 85 SCREW M5X WARNING LIGHT (FOR WD) 3a 894 WARNING LIGHT (FOR 4WD) BOLT M8X THROTTLE CONTROL (WITHOUT STOP SWITCH) 5a 879 THROTTLE CONTROL (WITH STOP SWITCH) HANDLEBAR IGNITION SWITCH WITH KEY HANDLEBAR CLAMP NUT M THROTTLE CABLE (BOTTOM PULL CABLE TYPE) 0a 887 THROTTLE CABLE (TOP PULL CABLE TYPE) 876 SWITCH ASSY 84 GRIP WARNING LIGHT BRACKET WASHER WARNING LIGHT BULB ONLY
2 . HANDLEBAR 8967 INSTRUMENT HOUSING UPPER(FOR MECHANICAL METER) a 8367 INSTRUMENT HOUSING UPPER(FOR LCD METER ) 8760 WARNING LIGHT (FOR WD) a 8984 WARNING LIGHT (FOR 4WD) HAZARD LIGHT SWITCH IGNITION SWITCH WITH KEY METER (MECHANICAL) 5a 8368 METER (LIQUID CRYSTAL DISPLAY) SCREW ST4.X WARNING LIGHT BRACKET INSTRUMENT HOUSING DOWN BOLT M8X WASHER NUT M SWITCH ASSY( FOR 05) a 8300 SWITCH ASSY( 07 BODY) (WITH STOP SWITCH) 3 84 GRIP NUT M THROTTLE CONTROL 5a 834 THROTTLE CONTROL(WITH WD/4WD SWITCH) HANDLEBAR THROTTLE CABLE (FOR BOTOM PULL CABLE TYPE) 7A 887 THROTTLE CABLE (FOR TOP PULL CABLE TYPE) HANDLEBAR CLAMP CUSHION RUBBER RING 8370 WARNING LIGHT BRACKET 8988 RUBBER RING WARNING LIGHT BULB ONLY
3 PDFMAILER.COM Print and send PDF files as s with any application, ad-sponsored and free of charge FUEL TANK REF. No MANCO NO DESCRIPTION FUEL CAP VENT TUBE VENT FITTING FOAM GASKET BOLT M6X60 WASHER 6 MOUNTING BRACKET LEFT FUEL TANK FOAM PAD SPACER MOUNTING PAD FUEL HOSE SCREW M4 WASHER 4 FUEL CONTROL KNOB NUT FUEL VALVE HOSE CLAMP FUEL LINE FUEL FILTER CLAMP MOUNTING BRACKET RIGHT FUEL LINE PIPE FUEL VALVE ASSY FUEL FILTER PAD BOLT M6X FUEL PUMP ASSY HOSE CLAMP FUEL LINE 3 PIPE FUEL HOSE FUEL HOSE FUEL HOSE3 FUEL HOSE COUPLER WASHER 6 Q'TY 9 7
4 3.0 REAR FENDERS 8636 SEAT 868 SPRING LATCH ASSEMBLY RETAINER CLIP 5 87 SCREW ST4.8X BOLT M6X STORAGE BOX COVER STORAGE BOX 8a REAR FENDERS(SI) 8b REAR FENDERS(GN) 8c REAR FENDERS(RE) 8d REAR FENDERS(GN)(07) WASHER BOLT M6X LATCH BRACKET REAR MUD GUARD RIGHT FOOTREST RIGHT (FOR 04) 837 FOOTREST RIGHT( FOR 05) BOLT M6X RUBBER PAD REAR MUD GUARD LEFT FOOTREST LEFT BATTERY MOUNTING PAD PLASTIC PLATE 863 FOOTREST RIGHT ADIABATIC PELLICLE 8633 REAR MUD ADIABATIC PELLICLE A REAR MUD ADIABATIC PELLICLE B SEAT ASSY TOOL FOOTBOARD SUPPORT-RIGHT FOOTBOARD SUPPORT-LEFT REAR COVER( 07)
5 4.0 FRONT BODY&FRAME 8768 FRONT COVER B 830 FRONT COVER( FOR 07) FRONT BODY A 830 FRONT BODY( FOR 07) SIDE COVER LEFT SIDE COVER RIGHT MUD GUARD RIGHT SPRING NUT MUD GUARD LEFT FRONT BODY FOAM SMALL FRONT COVER 87 SCREW ST4.8X6 868 UP BRACKET RADIATOR DOWN BRACKET RADIATOR SPACER RUBBER
6 4. FRONT BODY&FRAME ( FOR 05) 8768 FRONT COVER 8959 FRONT BODY SIDE COVER LEFT SIDE COVER RIGHT MUD GUARD RIGHT NUT M MUD GUARD LEFT FRONT BODY FOAM SMALL FRONT COVER 87 SCREW ST4.8X6 837 UP BRACKET RADIATOR DOWN BRACKET RADIATOR SPACER RUBBER LEFT HEADLIGHT COVER UPPER - ASSM ONLY LEFT HEADLIGHT COVER DOWN - ASSM ONLY LEFT HEADLIGHT COVER - ASSM ONLY HEADLIGHT COVER - ASSM ONLY SCREW ST4.X3 - ASSM ONLY BOLT - ASSM ONLY 8937 NUT M6 839 RIGHT HEADLIGHT COVER UPPER - ASSY ONLY RIGHT HEADLIGHT COVER DOWN - ASSY ONLY RIGHT HEADLIGHT COVER - ASSY ONLY HEADLIGHT COVER - ASSY ONLY CUSHION - ASSY ONLY CUSHION - ASSM ONLY SCREW M5X30 - ASSM ONLY WASHER 5 - ASSM ONLY WASHER 4 - ASSM ONLY CUSHION 3 - ASSM ONLY SCREW ST3.5X3 - ASSM ONLY
7 PDFMAILER.COM Print and send PDF files as s with any application, ad-sponsored and free of charge A-ARM REF. No. MANCO NO DESCRIPTION NUT M0X.5 BOLT M0X.5X55 TIE ROD END A JAM NUT(RIGHT) TIE ROD JAM NUT(LEFT) TIE ROD END B BOLT M0X.5X55 WASHER NUT M0X.5 COTTER PIN BALL JOINT STUD BALL JOINT MOUNTING BRACKET BALL JIONT CUP BOLT M6X NUT M0 COTTER PIN A-ARM LEFT(USED WITH 0408f AND 0408W) A - ARM SHIELD LEFT SCREW M5X A-ARM PIVOT SHAFT TIE ROD ASSY NUT MX.5 BUSHING A-ARM RIGHT(USED WITH 0408f AND 0408W) A - ARM SHIELD RIGHT A-ARM LEFT ( ONLY FOR OLD FRAME 0408) A-ARM RIGHT ( ONLY FOR OLD FRAME 0408) GREASE FITTING ( USE WITH ) A-ARM PIVOT SHAFT( USE WITH ) SPACER( USE WITH ) BUSHING( USE WITH ) WASHER 0( USE WITH ) BOLT M0X5( USE WITH ) Q'TY
8 6.0 SWINGARM ASSY 835 REAR PROPSHAFT ASSY 836 O-RING COUPLING-PROP SHAFT GREASED SWINGARM ASSY SKID PLATE REAR SEAL-SWINGARM PIVOT 7 83 BEARING 8 83 SEAL SWING ARM PIVOT RIGHT THREADED PIVOT 835 NUT M WASHER BOLT MX BOLT M8X CAP SWINGARM PIVOT ROLL PIN SWINGARM PIVOT LEFT SPONGY GASKET
9 7.0 WHEEL FRONT 8330 BOLT M8X SPACER ( NOT FOR 4WD) BEARING SEAL SLEEVE HUB ASSY SHRT 5a 8375 HUB ASSY SHRT (FOR 4WD) WHEEL STUD 8 6a 8345 WHEEL STUD( FOR AL) PLUG PIPE 7a 8346 PLUG PIPE( FOR AL) TIRE FRONT WHEEL FRONT 9a 8977 WHEEL FRONT( FOR AL) WASHER 6 0a 8377 WASHER ( FOR 4WD) 8340 SLOTTED NUT M6X.5 a 8376 SLOTTED NUT ( FOR 4WD) 834 COTTER PIN O-RING HUB CAP -LOBE AWD SCREW M5X LUG NUT M0X LUG WASHER 9 83 BEARING (NOT FOR 4WD) 4
10 8.0 SHOCK ABSORBER REAR 8346 O-RING 79X CUSHION PAD SPACER-BEARING O-RING REAR AXLE UP BOLT M0X.5X NUT M0X SHOCK ABSORBER REAR DOWN BOLT M0X.5X57
11 9.0 WHEEL REAR 8643 WASHER BOLT MX AXLE TUBE AND HITCH ASSEMBLY LEFT RING RETAINER INT SPACER BEARING BALL DBL SEAL RING RETAINER INT SPACER-BEARING SEAL REAR AXLE BOLTS M0X.5X O-RING 8364 HUB BRAKE DISC MACH N UT M0X AXLE CAP COTTER PIN NUT SLOTTED M0X WASHER WHEEL HUB LUG NUT MX.5 8 9a 83 LUG NUT MX.5 ( FOR ALUMINUM WHEELS) TIRE REAR 837 WHEEL STUD MX.5X WHEEL REAR (STANDARD STEEL GLOSS BLACK) a 8978 WHEEL REAR( ALUMINUM) WASHER L BRAKE HOSE COVER LEFT 4a 8650R BRAKE HOSE COVER RIGHT AXLE TUBE AND HITCH ASSEMBLY RIGHT BOLT MX WHEEL WASHER 8
12 0.0 REAR GEAR-BOX 8374 BOLT M8X SEAL 50X70X OUTPUT COVER DOWEL PIN O-RING 76X SHIM SHIM THRUST BUTTON BEARING RING GEAR 8384 VENT 8385 BEARING DRIVE HOUSING OIL PLUG WASHER SEAL 50X70X BUSHING P3X0X PINION SHAFT BEARING 6306ST RETAINER O-RING 79X INPUT COVER BOLT M8X SEAL 5X35X REAR GEARBOX ASSY
13 .0 TRANSMISSION 8399 SEAL 5X47X BOLT M8X MAIN COVER 3a 8304 MAIN COVER( USE WITH HIGH-POWER CLUTCH) DOWEL PIN BEARING 605c INPUT SHAFT 6a 8305 INPUT SHAFT( USE WITH HIGH-POWER CLUTCH) CHAIN GEAR 6T BEARING GEAR,HELICAL 35T 8409 INTERLOCK PIN 840 INTERLOCK BRACKET 3 84 SPRING INTERLOCK PIN 5 85 SCREW M5X SPACER GEAR 3T NEEDLE BEARING THRUST WASHER SNAP RING 849 DOG GEAR 840 SNAP RING 3 84 THRUST WASHER 4 84 SPROCKET 4T NEEDLE BEARING THRUST WASHER SHAFT NEEDLE BEARING GEAR 35T THRUST WASHER SNAP RING ENGAGEMENT THRST WASHER NUT M WASHER
14 . TRANSMISSION (wd) BELLCRANK SNAP RING WASHER VENT TUBE VENT TUBE FITTING SHIFT FORK HIGH/REVERSE SCREW M WASHER GEAR INDICATOR SWITCH GEARCASE,RH 45a 8306 GEARCASE,RH( USE WITH LCD) SEAL 5X47X DIPSTICK BEARING 604C GEAR HELICAL 46T SCREW M6X BEARING RETAINER PLATE SNAP RING BEARING 6305ST PINION SHAFT 0T SHIFT FORK LOW GEAR INDICATOR SWITCH SNAP RING SHIFT ROD LOW SHIFT ROD HIGH/REVERSE THRUST WASHER GEAR SHAFT REAR OUTPUT 63a 830 SHAFT REAR OUTPUTA( USE WITH LCD) THRUST BUTTON SHIM SHIM 67 DOWEL PIN COVER DRAIN SCREW WASHER TRANSMISSION ASSY
15 . TRANSMISSION (wd) OIL PLATE O RING 8X SPROCKET O RING 4X SPEED SENSOR ( USE WITH LCD)
16 .3 TRANSMISSION ( FOR 4WD) 8399 SEAL 5X47X BOLT M8X MAIN COVER 3a 8304 MAIN COVER( USE WITH HIGH-POWER CLUTCH) DOWEL PIN BEARING 605c INPUT SHAFT 6a 8305 INPUT SHAFT( USE WITH HIGH-POWER CLUTCH) CHAIN GEAR 6T BEARING GEAR,HELICAL 35T 8409 INTERLOCK PIN 840 INTERLOCK BRACKET 3 84 SPRING INTERLOCK PIN 5 85 SCREW M5X SPACER GEAR 3T NEEDLE BEARING THRUST WASHER SNAP RING 849 DOG GEAR 840 SNAP RING 3 84 THRUST WASHER 4 84 SPROCKET 4T NEEDLE BEARING THRUST WASHER SHAFT NEEDLE BEARING GEAR 35T THRUST WASHER SNAP RING ENGAGEMENT THRST WASHER NUT M WASHER BELLCRANK
17 .4 TRANSMISSION ( FOR 4WD) SNAP RING WASHER VENT TUBE VENT TUBE FITTING SHIFT FORK HIGH/REVERSE SCREW M WASHER GEAR INDICATOR SWITCH GEARCASE,RH 45a 8306 GEARCASE,RH( USE WITH LCD) SEAL 5X47X DIPSTICK BUSHING BEARING 604C GEAR HELICAL 46T SCREW M6X BEARING RETAINER PLATE SNAP RING BEARING 6305ST PINION SHAFT 0T SHIFT FORK LOW GEAR INDICATOR SWITCH SNAP RING SHIFT ROD LOW SHIFT ROD HIGH/REVERSE THRUST WASHER SPORCKET T SHAFT REAR OUTPUT 63a 830 SHAFT REAR OUTPUTA( USE WITH LCD) THRUST BUTTON SHIM SHIM DOWEL PIN COVER DRAIN SCREW WASHER TRANSMISSION ASSY GEAR O RING 8X.65
18 .5 TRANSMISSION ( FOR 4WD) SPROCKET SHAFT FRONT OUTPUT SPORCKET T CHAIN O RING 4X SPEED SENSOR( USE WITH LCD)
19 .0 SUPPORT BRACKET 8653 BOLT MX WASHER TRANSMISSION MOUNTING BRACKET RIGHT TRANSMISSION MOUNTING BRACKET LEFT BOLT M8X NUT M BOLT M0X TRANSMISSON MOUNTING BRACKET BOTTOM BOLT M8X WASHER0 897 WASHER 846 BOLT M0X.5X NUT M TRANSMISSION MOUNTING BRACKET REAR
20 3.0 SHIFT ROD 8836 LABLE 8779 SHIFTER ASSY MOUNTING KNOB SHIFT LEVER SCREW M6X WASHER BOOT PLASTIC SPHERE GROOVE PIN CENTERING SPRING 8477 DETENT SPRING 8478 DETENT BULLET DOWEL PIN SHIFFER HOUSING O-RING SELECTOR SLIDES HIGH/REVERSE SHIFTER MOUNTING BRACKET 8 87 BOLT M6X SHIFT ROD COUPLER SHIFT ROD END CW 8486 JAM NUT M6 CW SHIFT ROD HIGH/REVERSE SHIFT ROD LOW JAM NUT M6 CCW SHIFT ROD END CCW SELECTOR SLIDES LOW SHIFTER MOUNTING ROD A SHIFTER MOUNTING ROD B
21 4.0 SHOCK ABSORBER FRONT 866 NUT M4X WASHER SPACER RUBBER UPPER PIVOT BALL BOLT M8X NUT M4X LOWER PIVOT BALL SPRING RETAINER SPRING STRUT BUMPER 8499 CLAMP 845 NUT M SPRING RETAINER STRUT BODY LEFT SPINDLE BOLT BEARING GREASE FITTING SEAL SLEEVE STRUT BODY RIGHT FRONT SHOCK ABSORBER ASSEMBLY
22 5.0 STEERING COLUMN 845 NUT M GREASE FITTING 3 85 BUSHING STEERING CLAMP REAR STEERING CLAMP FRONT BOLT STEERING COLUMN ( 68 MM LENGTH) BOLT WASHER BEARING RETAINER 850 BEARING 845 NUT M STEERING COLUMN RETAINER NUT 4 85 COTTER PIN
23 6.0 ELECTRICAL SYSTEM 8697 CDI 857 REVERSE SPEED LIMITER ( FOR MECHANICAL METER) a 8304 REVERSE SPEED LIMITER ( FOR LCD) BATTERY CABLE POSITIVE STARTER RELAY BATTERY BATTERY CABLE GROUND REGULATOR RECTIIFIER WARNING BUZZER ( FOR MECHANICAL METER) HEADLIGHT ASSEMBLY RIGHT( ROUND) TAIL LIGHT 0a 8305 TAIL LIGHT(FOR 07) a 8839 WIRING HARNESS ( FOR 05 AND SPORT 4WD) b 8536 WIRING HARNESS ( FOR 04 WD) c 878 WIRING HARNESS ( FOR 04 4WD) d 8378 WIRING HARNESS ( FOR 07 AND LCD) e 8306 WIRING HARNESS ( FOR 07 AND MECHANICAL METER ) 8537 IGNITON COIL AND WIRE INDIATOR LIGHT WIRING HARNESS ENGINE TEMPERTURE SENSOR HEAD LIGHT BULB ONLY TAIL LIGHT BULB ONLY BATTERY BELL GEAR SENSOR(for 05 and before model) 898 CAPCITOR AMP FUSE AMP FUSE AMP FUSE FLASHER RELAY ASSY F USE BOX HORN FREEZE PROOF DEVICE HEADLIGHT ASSEMBLY ( SQUARE)
24 6. ELECTRICAL SYSTEM 8374 HEADLIGHT ASSEMBLY (SPORT MODEL ONLY CENTER MOUNT) HAZARD LIGHT SWITCH ( ONLY FOR 04) FRONT TURN INDICATOR RIGHT( SPORT MODEL ONLY) FRONT TURN INDICATOR LEFT( SPORT MODEL ONLY) REAR TURN INDICATOR RIGHT( SPORT MODEL ONLY) REVERSE GEAR WARNING( FOR 4WD) FRONT TURN INDICATOR RIGHT( FOR07) FRONT TURN INDICATOR RIGHT( FOR 07) BRAKE SWITCH RESISTANCE
25 7.0 BRAKING SYSTEM 840 MASTER CYLINDER WITH BRAKE LEVER 8560 HAND BRAKE HOSE REAR BRAKE HOSE REAR HAND BRAKE HOSE BRAKE CALIPER LEFT REAR BOLT M0X.5X WASHER NUT M0X WASHER SPACER 8543 REAR BRAKE PADS, SET OF 8667 RETAINING PIN BANJO BOLTS BRAKE CALIPER LEFT FRONT BOLT M8X WASHER WASHER FOOT BRAKE HOSE BOLT M5X NUTM DONKEY PUMP 8550 BOLT M6X BRAKE HOSE CLAMP RESERVOIR FRONT BRAKE DISC BRAKE CALIPER RIGHT FRONT FRONT BRAKE HOSE FRONT BRAKE HOSE BRAKE LINE COUPLER SCREW M5X NUT M BOLT M5X BOLT M5X BRAKE LINE CLAMP SMALL BRAKE LINE CLAMP LARGE RETAINER WASHER BRAKE PEDAL
26 7. BRAKING SYSTEM BOLT M6X FOOT BRAKE MOUNTING PLATE RETURN SPRING SWITCH ASSY.STOP 44 ** BRAKE ASSY FRONT BRAKE PADS, SET OF REAR BRAKE DISC BRAKE CALIPER RIGHT REAR ADIABATIC PELLICKE SERVICE KIT
27 8.0 BUMPER & RACK 8657 BOLT M8X CONNECTIVE BUMPER TRESTLE LEFT BOLT M8X TRESTLE LEFT FRONT FRAME TRESTLE 3 LEFT BOLT M8X REAR FRAME 8577 TRESTLE RIGHT 8578 TRESTLE RIGHT TRESTLE 3 RIGHT NUT M BOLT M6X WASHER WASHER BOLT M8X BOLT M8X FRONT REFLECTOR 8677 REAR REFLECTOR CONNECTION BRACKET SPACER RUBBER PAD RIGHT PROTECT POLE LEFT PROTECT POLE BOLT M8X NUT M8 4
28 8. CROSS BUMPER STYLE REF. No. MANCO NO. DESCRIPTION BOLT M8X0 845 NUT M BUMPER TRESTLE LEFT BOLT M8X TRESTLE LEFT FRONT FRAME TRESTLE 3 LEFT BOLT M8X REAR FRAME 8385 TRESTLE RIGHT TRESTLE RIGHT TRESTLE 3 RIGHT NUT M BOLT M6X PROTECT POLE NUT M BOLTM8X BOLTM8X FRONT REFLECTOR 8677 REAR REFLECTOR 8678 CONNECTION BRACKET BOLT M8X5
29 8. BUMPER & RACK 8309 RIGHT HEADLIGHT HEADLIGHT BRACKET HEADLIGHT BRACKET FRONT COVER PLASTIC BUMPER HEADLIGHT BRACKET BUMPER DOWN BRACKET RADIATOR LEFT COVER LEFT BRACKET LEFT BRACKET AXLE BOX FRONT REFLECTOR HEADLIGHT ADJUSTMENT COVER( LEFT) BOX LOCK SEAL BOX COVER BOX COVER BRACKET BOX COVER LINE BOX COVER BRACKET SERVICE COVER FRONT BUMPER HEADLIGHT ADJUSTMENT COVER( RIGHT) LEFT COVER RIGHT COVER RIGHT BRACKET RIGHT BRACKET RADIATOR RIGHT COVER LOCK HOOK BOLT M8X TRESTLE RIGHT BOLT M6X BOLT M6X SCREW ST4.8X SCREW.TAPPING BOLT M6X BOLT M8X BOLT M8X95
30 8.3 FRONT BUMPER & RACK SNAP RING NUT M BOLT M6X SCREW ST4.8X HOOK SCREW M6X SCREW M6X SCREW ST4.8X SCREW.TAPPING BOLT M8X RUBBER STOPPER 5 87 SCREW ST4.8X NUT M TRESTLE LEFT RUBBER SPACER RUBBER SPACER WASHER BOLT M5X LEFT HEADLIGHT HEAD LIGHT BULB ONLY
31 8.4 REAR RACK REAR RACK BRACKET TRESTLE 3 LEFT BOLT M8X REAR RACK BRACKET BOLT M8X TRESTLE 3 RIGHT REAR RACK BRACKET REAR RACK REAR ARMGUARD REAR TURN LIGHT(LEFT) LEFT REAR TURN LIGHT BRACKET REAR TURN LIGHT(RIGHT) TAIL LIGHT COVER BOLT M8X RIGHT REAR TURN LIGHT BRACKET SCREW ST4.8X SCREW.TAPPING BOLT M8X BOLT M8X REAR REFLECTOR 867 NUT M REAR BUMPER(OPTIONAL ACCESSORY)
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