Parts & Accessories 21C4 LIMITED EDITION

Transcription

1 Parts & Accessories 21C4 LIMITED EDITION

2 21C4 PARTS CATALOGUE INDIA YAMAHA MOTOR PVT. LTD. 1st edition, August 2009 All rights reserved. Any reprinting or unauthorized use without the written permission of INDIA YAMAHA MOTOR PVT. LTD. is expressly prohibited. Printed in INDIA

3 This Parts Catalogue is related to the parts in use for the YAMAHA - 21C4 When you are ordering replacement parts for 21C4 refer to this Parts Catalogue and quote both part numbers and part names correctly. 1. Modifications or additions which have been made after issue of the Parts Catalogue will be announced in the Service Actions. It is advisible that according to the Service Action you make necessary corrections tothe Parts Catalogue on hand to keep it up-to-date. FOREWORD Abbreviate Colour Name Colour Code 0390 Bluish White Cocktail 1 BWC1 2. Indication of No. of constituent parts for assembly. The numeral appearing to the right of each constituent part under the description indicates the quantity of such parts for each individual assembly unit. EXAMPLE Part No. Description Qty 21C-E CRANK SHAFT ASSY. 1 21C-H BATTERY ASSY HOSE 1 21C-E CYLINDER HEAD 1 NOTICE The description and illustration in this Parts Catalogue may not necessarily match with the physical appearance of the parts. INDIA YAMAHA MOTOR PVT. LTD. reserves the right to carry out modifications on the vehicle, parts or accessories, as may be considered necessary, without being obliged to update this Parts Catalogue immediately. No part of this Publication may be reproduced without written permission of INDIA YAMAHA MOTOR PVT. LTD. 3. Applicable Serial No. and Color Code 1 Frame Serial No 2 Frame Serial No XXX Mfr Code 21C Model Code 21C Model Code X Prod No Code xxxxxx Serial No. 4 Varient Code X Month Code X Year Code X Factory Code xxxxxx Serial No 1

4 1. Parts number Structure 1) Common parts number XXX-XXXXX-XX-XX Example 21C-H Meter Assy. Model Function code Major classification # E--F--H Design Serial number Design Revision Change Modification Color Codes Painted Parts eg:- 21C Major classification Engine Chassis Electrical YMC number Local number E F H? Revision Design Further Design change eg:- 1X/P0 2X/P1 3X/P2 Note:- 1) 'WE' indicates Kit Assy. fixed by service for market. 2) 'XE' indicates Sub Assy. & individual Parts not serviceable fixed by manufacturing. Note:- Only Colored parts are 12 digit in Catalog - Rest are 10 Digits(Non-Coloured Parts) 2) Standard parts number /Regular parts number Standard parts number ; 9XX-XXXXXXX Type of Parts Ex:- 947XX=Plug spark 932XX="O" Ring 985XX=Screw pan head Regular parts number ; 9XXXX-XXXXX Category Code Ex:- 901XX=Bolt and Nut 902XX=Washer and Rivet 903XX=Bush and Collor 904XX=Hose and Clamp 905XX=Springand spacer

5 CONTENTS ENGINE CYLINDER... 2 CRANKSHAFT/PISTON... 3 VALVE... 4 CAMSHAFT/CHAIN... 5 OIL PUMP... 7 INTAKE... 8 CARBURETTOR... 9 EXHAUST CRANKCASE CRANKCASE COVER STARTER CLUTCH CLUTCH TRANSMISSION SHIFT CAM FORK SHIFT SHAFT CHASSIS FRAME FENDER SIDE COVER REAR ARM. & SUSPENSION STEERING FRONT FORK FUEL TANK FUEL TANK SEAT FRONT WHEEL FRONT BRAKE CALIPER REAR WHEEL STEERING HANDLE & CABLE FRONT MASTER CYLINDER STAND FOOTREST STAND FOOTREST GENERATOR STARTER MOTOR FLASHER LIGHT METER HEAD LIGHT TAIL LIGHT HANDLE SWITCH & LEVER ELECTRICAL ELECTRICAL KICK STARTER (OPTIONL) NUMERICAL INDEX

6 FIG. 1 (1) CYLINDER PART PART NAME REMARKS 1 21C-E HEAD, CYLINDER BOLT, FLANGE GASKET BOLT, STUD C-E COVER, CYLINDER HEAD C-E PLATE, BREATHER C-E GASKET, BREATHER COVER BOLT O-RING PIN, DOWEL C-E GASKET, HEAD COVER BOLT C-E COVER, CYLINDER HEAD SIDE C-E GASKET BOLT GASKET BOLT, FLANGE PLUG, SPARK (NGK CPR8EA) C-E GASKET, CYLINDER HEAD PIN, DOWEL BOLT, HEXAGON SOCKET HEAD C-E CYLINDER C-E GASKET, CYLINDER C-E DUCT BOLT C-E DAMPER, DUCT C-E ABSORBER C-E ABSORBER C-E ABSORBER 1 2 2

7 FIG. 2 (1I0) CRANKSHAFT & PISTON PART PART NAME REMARKS 1 21C-E CRANKSHAFT ASSY C-E PIN, CRANK 1 1 Not Serviceable X0.BEARING 1 Not Serviceable 4 21C-E ROD, CONNECTING 1 Not Serviceable 5 21C-E CRANK 2 1 Not Serviceable YC BEARING KEY, WOODRUFF C-E PISTON (STD) 1 21C-E PISTON (0.50MM O/S) 1 21C-E PISTON (1.00MM O/S) C-E PIN, PISTON CIRCLIP C-E PISTON RING SET (STD) 1 21C-E PISTON RING SET (0.50MM O/S) 1 21C-E PISTON RING SET (1.00MM O/S) C-E GEAR, DRIVE C-E WEIGHT C-E GEAR, BALANCE WEIGHT C-E BOSS, BUFFER WASHER, PLATE WASHER, CLAW SPRING, COMPRESSION PIN, DOWEL J0 COLLAR O-RING O-RING BEARING XL BEARING KEY, STRAIGHT WASHER, LOCK NUT 1 3

8 FIG. 3 (1M0) VALVE PART PART NAME REMARKS 1 21C-E VALVE, INTAKE C-E VALVE, EXHAUST C-E SEAL, VALVE STEM C-E SEAT, VALVE SPRING C-E SPRING, VALVE INNER F COTTER, VALVE C RETAINER, VALVE SPRING C-E ARM, VALVE ROCKER C SCREW, VALVE ADJUSTING NUT C-E SHAFT, ROCKER BOLT 2 4

9 FIG. 4 (1N0) CAMSHAFT & CHAIN PART PART NAME REMARKS 1 21C-E CAMSHAFT ASSY PIN, DOWEL Y1 BEARING C-E111F-00 PLATE C-E DECOMPRESSION ASSY C-E CAM, DECOMPRESSION BOLT, FLANGE CHAIN C-E GUIDE, STOPPER C-E GUIDE, STOPPER LS-E COLLAR BOLT, FLANGE C-E TENSIONER ASSY, CAM CHAIN MX-E GASKET, TENSIONER CASE BOLT, FLANGE C-E STOPPER BOLT, FLANGE 2 5

10 FIG. 5 (2C0) OIL PUMP PART PART NAME REMARKS 1 21C-E OIL PUMP ASSY BOLT,HEX. SOCKET BUTTON PLUG, STRAIGHT SCREW GASKET 1 5 4LS-E STRAINER, OIL C-E ELEMENT ASSY, OIL CLEANER C-E COVER, OIL ELEMENT BOLT, FLANGE BOLT, FLANGE C-E GASKET, ELEMENT COVER C-E COVER, PUMP GEAR BOLT, FLANGE 2 6

11 FIG. 6 (2J0) INTAKE PART PART NAME REMARKS 1 21C-E JOINT, CARBURETOR C-E JT., CARBURETOR O-RING HOSE CLAMP ASSY WASHER, PLATE BOLT C-E JOINT C-E HOSE, VACUUM SENSING CLIP C-E CASE, AIR CLEANER C-E CAP, CLEANER CASE C-E ELEMENT ASSY, AIR CLEANER C-E JOINT, AIR CLEANER C-E SEAL SCREW, PAN HEAD WITH WASHER P-E443E-00 PIPE, DRAIN CLIP C-E RESONATOR C-E PIPE, JOINT HOSE CLAMP ASSY NUT, SPRING COLLAR BOLT, FLANGE C-E PIPE, BREATHER CLIP C-E PIPE C-E GASKET BOLT 2 7

12 FIG. 6 (2J0) INTAKE PART PART NAME REMARKS 29 21C-E HOSE, BEND C-E HOSE, BEND CLIP CLIP C-E AIR INDUCTION SYSTEM ASSY BOLT, FLANGE C-E449E-00 COVER, AIR CLEANER CLAMP CLAMP 1 8

13 FIG. 7 (2K0) CARBURETOR PART PART NAME REMARKS 1 21C-E CARBURETOR ASSY YY NEEDLE ASSY C-1410A-00.STARTER SET C PILOT SCREW SET C-1490J-10.NEEDLE SET C THROTTLE SCREW SET 1 7 3G2-1423A-73.JET, MAIN (#112.5) C-1414M-41.NOZZLE, MAIN 1 9 1NT JET, PILOT (# 15) GH RING SCREW, PAN HEAD B FLOAT O-RING PIN, FLOAT SCREW, PAN HEAD F CLIP, PIPE YP O-RING F CLIP F WASHER K WASHER A SEAL WASHER, SPRING NUT KM SCREW C PLUG, DRAIN LW NET, FILTER C COVER, DIAPHRAGM C VALVE ASSY 1 9

14 FIG. 7 (2K0) CARBURETOR PART PART NAME REMARKS 29 21C SPRING C DIAPHRAGM C O-RING C-1496A-00.HOLDER, NEEDEL JET C HOSE C THROTTLE SENSOR ASSY C SCREW C-1410E-00.HOSE 1 10

15 TO : All Dealers Model 21C1,2,3,4,5,6 & 45S1,2 3,4 PART INFORMATION Date: 06 December 2012 IYM Parts: 345 Subject Commonisation Carburetor 21C-E with Models 21C1,2,3,4,5,6 & 45S1,2 3,4 PI 345 Background Carburetor (21C-E ) has been discontinued with immediate effect used on Models 21C1,2,3,4,5,6 & 45S1,2 3,4 due to discontinuation of its Production As as result the Old carburetor (21C-E ) will be substituted with Kit Carburetor 21C-WE ( consisting of Carb -21C-E & Throttle cable 21C-F )-Please refer Annexure -1 The reason of change was necessitated to use additionally the Throttle cable since in Old Carb the Throttle cable length is less by ~34mm Note ;Both throttle cable Parts 21C-F length(102mm) & 21C-F length(136mm) will continue to be serviced by SPD for market to cater to the use of respective carburetors changes Notes:1) Please update your Parts Catalogues for future Parts ordering 2) Please place your order for Spares thru Parts Division in usual manner You are most earnestly requested to please explain, the above to your SERVICE, SALES, & SPARE PARTS TEAM. Please do not hesitate to seek any clarification from our visiting IYM FIELD TEAM.. FPLobo Parts Division INDIA YAMAHA MOTOR PVT.LTD. CC:ZBH / ZSM / RBH / RSM / SALES EXECUTIVE / SERVICE EXECUTIVE / PARTS MANAGERS :YAMAHA POINT(YP)/AUTHORISED SERVICE POINT(ASP) 19/6 Mathura Road- Faridabad

16 Part 21C-E s/s Kit Carb - 21C-WE (consisting Carb 21C-E Throttle cable 21C-F ) Annexure -1 Models 21C1,2,3,4,5,6/45S1,2,3,4

17 FIG. 8 (2N0) EXHAUST PART PART NAME REMARKS 1 21C-E MUFFLER COMP C-E PROTECTOR, MUFFLER C-E CAP GROMMET COLLAR BOLT,HEX. SOCKET BUTTON BOLT,HEX. SOCKET BUTTON WASHER, PLATE C-E NUT P-E DAMPER, MUFFLER C-E GASKET, EXHAUST PIPE NUT, FLANGE WASHER, PLATE BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE F0 WASHER, PLATE 1 11

18 FIG. 9 (2R0) CRANKCASE PART PART NAME REMARKS 1 21C-E CRANKCASE C-E CRANKCASE C-E NOZZLE PIN, DOWEL BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE 5 21C4 13

19 FIG. 10 (2S0) CRANKCASE COVER 1 PART PART NAME REMARKS 1 21C-E HOLDER, CLUTCH CABLE BOLT P-E COVER, CRANKCASE C-E GASKET, CRANKCASE COVER PIN, DOWEL BOLT, FLANGE BOLT, FLANGE P-E GASKET PLUG, STRAIGHT SCREW O-RING PLUG, STRAIGHT SCREW A4 O-RING C-E COVER, CHAIN CASE BOLT, FLANGE C9 COLLAR GROMMET C-E542A-00 DAMPER C-E COVER, CRANKCASE C-E GASKET, CRANKCASE COVER PIN, DOWEL BOLT, FLANGE C-E PLUG, OIL LEVEL O-RING OIL SEAL 1 13

20 FIG. 11 (2V0) STARTER CLUTCH PART PART NAME REMARKS 1 21C-E SPACER G4 WASHER, PLATE CIRCLIP PLUG C-E GEAR C-E SHAFT E8 WASHER, PLATE CIRCLIP C-E GEAR X3 BEARING WASHER, PLATE C-E STARTER CLUTCH OUTER ASSY BOLT 3 14

21 FIG. 12 (2X0) CLUTCH PART PART NAME REMARKS 1 21C-E GEAR, PRIMARY DRIVE C-E KEY, FEATHER WASHER, PLATE NUT C-E PRIMARY DRIVEN GEAR COMP C-E PLATE, THRUST C-E BOSS, CLUTCH C-E PLATE, FRICTION C-E PLATE, FRICTION C-E PLATE, CLUTCH C-E PLATE, PRESSURE C-E SPRING, CLUTCH C-E SCREW, SPRING C-E PLATE, PUSH C-E ROD, PUSH C1-E WASHER C1-E NUT, ADJUSTING C WASHER, LOCK NUT WASHER, CONICAL SPRING C-E PUSH LEVER ASSY C SPRING, RETURN C-E ROD, PUSH BALL Y9 BEARING OIL SEAL CIRCLIP 1 15

22 FIG. 13 (2Z0) TRANSMISSION PART PART NAME REMARKS 1 21C-E AXLE, MAIN (14T) C-E GEAR, 4TH PINION (22T) WASHER CIRCLIP C-E GEAR, 3RD PINION (22T) C-E GEAR, 5TH PINION (24T) C-E GEAR, 2ND PINION (19T) Y6 BEARING Y4 BEARING C-E PLATE, COVER SCREW, PAN HEAD C-E DRIVE AXLE ASSY C-E GEAR, 2ND WHEEL (34T) WASHER, PLATE CIRCLIP C-E GEAR, 5TH WHEEL (21T) C-E GEAR, 3RD WHEEL (29T) WASHER C-E GEAR, 4TH WHEEL (23T) G4 WASHER, PLATE C-E COLLAR C-E GEAR, 1ST WHEEL (38T) XR BEARING X1 BEARING OIL SEAL SPROCKET, DRIVE (14T) LS-E HOLDER, SPROCKET BOLT, FLANGE 1 16

23 PART INFORMATION Date: 01 September 2011 TO : All Dealers IYM Parts: 306 PI 306 Model Subject All FZ,FAZER SZ series Serviceability as a spare Main Axle assy With immediate effect the Main Axle assy will be serviceable for subject models- Please refer Annexure -1,2,3 Note As a result of above, the Individual parts comprising the Main Axle assy will not be serviceable anymore Notes: 1) Please update your Parts Catalogues FZ,FAZER & SZ series for future Parts ordering 2) Please place your order for Spares thru Parts Division in usual manner You are most earnestly requested to please explain, the above to your SERVICE, SALES, & SPARE PARTS TEAM. Please do not hesitate to seek any clarification from our visiting IYM FIELD TEAM. F P Lobo Parts Division INDIA YAMAHA MOTOR PVT.LTD. 19/6 Mathura Road- ffaridabad CC:ZBH / ZSM / RBH / RSM / SALES EXECUTIVE / SERVICE EXECUTIVE / PARTS MANAGERS :YAMAHA POINT(YP)/AUTHORISED SERVICE POINT(ASP)

24 Annexure -2 Appl models 21C1,2,3,4,5,9/45S1,2,3,,4 21C-E

25 FIG. 14 (3J0) SHIFT CAM & FORK PART PART NAME REMARKS 1 21C-E SHIFT CAM ASSY C-E FORK, SHIFT C-E FORK, SHIFT C-E FORK, SHIFT C-E BAR, SHIFT FORK GUIDE C-E BAR, SHIFT FORK GUIDE SPRING, COMPRESSION 4 17

26 FIG. 15 (3K0) SHIFT SHAFT PART PART NAME REMARKS 1 3C1-E STOPPER LEVER ASSY BOLT C-E SPRING C-E SHIFT SHAFT ASSY SPRING, TORSION CIRCLIP PIN, DOWEL OIL SEAL C-E SHIFT PEDAL ASSY P-E COVER, SHIFT PEDAL PIN, COTTER WASHER WASHER, PLATE BOLT 1 19

27 FIG. 16 (3M0) FRAME PART PART NAME REMARKS 1 21C-F FRAME COMP C-F STAY, ENGINE BOLT, FLANGE NUT C-F STAY, ENGINE BOLT, FLANGE BOLT, FLANGE NUT BOLT, FLANGE BOLT, FLANGE C-F PROTECTOR, FOOT REST BOLT, FLANGE BOLT, FLANGE A5 WASHER, PLATE NUT, FLANGE P-E DAMPER, MUFFLER COLLAR YY-H JOINT, HOSE C-F DAMPER C-F TOOL KIT 1 19

28 PART INFORMATION TO : All Dealers Date: 11 April 2012 IYM Parts:334 PI 334 Model Subject All FZ Models Commonisation of Frame All FZ models In order to have a single variety of Frame usage for All FZ models, commonisation has been done with immediate effect Please refer Annexure -1 As a result of the commonisation the Frame(21C-F ) used in Models 21C1,2,3,4,5,6,9,A & when defective will be replaced by a Kit -21C-WF (consisting Frame 21C-F & Main stand 45S-F ).Accordingly supersession done in system for part ordering Notes: 1) Reason for Kit is that the Main Stand(21C-F ) used in the earlier mentioned FZ models is not compatible for fitment 2) However the Individual Parts sale Main Stand 21C-F , Frame 21C-F & Main Stand 45S-F will be available for repair. Notes:1) Please update your Parts Catalogue FZ for future Parts ordering 2) Please place your order for Spares thru Parts Division in usual manner You are most earnestly requested to please explain, the above to your SERVICE, SALES, & SPARE PARTS TEAM. Please do not hesitate to seek any clarification from our visiting IYM FIELD TEAM. F P Lobo Parts Division INDIA YAMAHA MOTOR PVT.LTD. 19/6 Mathura Road- ffaridabad CC:ZBH / ZSM / RBH / RSM / SALES EXECUTIVE / SERVICE EXECUTIVE / PARTS MANAGERS :YAMAHA POINT(YP)/AUTHORISED SERVICE POINT(ASP)

29 Annexure -1 Appl Models 21C1,2,3,4,5,6,9,A 9A To be replaced as a Kit-21C-WF (consisting of Frame 21C-F & Main stand 45S-F )

30 FIG. 17 (3Q0) FENDER PART PART NAME REMARKS 1 21C-XF X FENDER, FRONT - BMC 1 BMC FOR BWC C5 COLLAR GROMMET BOLT, HEXAGON WASHER, PLATE SCREW, BINDING C-F FENDER, REAR C-F COVER, REAR FENDER BOLT COLLAR NUT, SPRING C-F177G-00 BOX, BATTERY C-F DAMPER LS-F PAD, SEAT BOLT, WITH WASHER C-F SEAL C-F16A2-00 SEAL, TS-F PLATE, LICENSE SCREW,WITH WASHER NUT WASHER, PLATE 2 20

31 FIG. 18 (3U0) SIDE COVER PART PART NAME REMARKS 1 21C-XF P1 COVER, SIDE 1 - YB 1 S8 FOR BWC1 21C-XF P1 COVER, SIDE 1 - SILVER 1 MBL2 FOR BWC1 1 45S-XF P0 COVER, SIDE C-F172A-00-P1 PANEL NUT, SPRING SCREW, TRUSS HEAD TAPPING S-XF P0 COVER, SIDE 2 1 S8 FOR BWC1 6 21C-F172F-00-P1 PANEL 2 1 MBL2 FOR BWC NUT, SPRING SCREW, TRUSS HEAD TAPPING C-F DAMPER DG-F DAMPER, LOCATING C-XF P2 COVER, SIDE 3 - BMC 1 BMC FOR BWC C-XF P2 COVER, SIDE 4 - BMC 1 BMC FOR BWC NUT, SPRING SCREW, TRUSS HEAD TAPPING C-XF17C-50-P2 COVER, SIDE 5 - BMC 1 BMC FOR BWC1 16 5TS-F836B-02.TUNING FORK MARK SCREW, TRUSS HEAD TAPPING SCREW, PAN HEAD BOLT, WITH WASHER BOLT, BUTTON HEAD WASHER, PLATE GROMMET 2 21

32 FIG. 19 (4A0) REAR ARM & SUSPENSION PART PART NAME REMARKS 1 21C-WF REAR ARM COMP C-F BUSH OIL SEAL Y5.BEARING C-F SHAFT, PIVOT P-F COVER, THRUST NUT, U WASHER, PLATE C-F SEAL, GUARD J9 COLLAR A3 WASHER, PLATE BOLT, HEXAGON C-F REAR FENDER COMP S1 COLLAR BOLT, FLANGE C-F SHOCK ABSORBER ASSY, REAR COLLAR BOLT, FLANGE BOLT, FLANGE NUT, U H1 WASHER, PLATE 2 22

33 FIG. 20 (4H0) STEERING PART PART NAME REMARKS 1 5KA-F RACE, BALL KA-F RACE, BALL KA-F RACE, BALL LS-F341E-10 RETAINER, BALL BEARING 1 5 4LS-F341E-00 RETAINER, BALL BEARING 1 6 5YY-F COVER, BALL RACE NUT WASHER, CLAW WASHER, PLATE C-F CROWN, HANDLE BOLT, FLANGE T0 WASHER, PLATE NUT, CROWN C-F HOLDER, HANDLE UPPER BOLT, FLG.(SMALL HEAD) C-F STAY, HEADLIGHT C-F317J-00 DAMPER BOLT, FLANGE 2 23

34 PART INFORMATION Date: 19 December 2012 TO : All Dealers PI 346 IYM Parts: 346 Model Subject FZ,Fazer,SZ series Implementation Modified Race Brg FZ,Fazer,SZ series Based on Market situation ti of Race Brg getting defective in FZ,Fazer F,SZ bikes we have now introduced modified Race Brg (Earlier the Race Brgs being used was of 5KA parts) Accordingly a Kit is being offered as: Kit Race Brg RACE, BALL 1 RACE, BALL 2 RACE, BALL 3 21CWF Consisting of 21CF CF CF RACE, BALL 4 21CF REATAINER BALL BEARING 4LSF341E0000 REATAINER BALL BEARING 4LSF341E1000 Note : 1)The Above Kit will be exclusive for subject models & its individual Race Brgs will also be available for replacement 2) In bikes where 5KA Race Brgs are fitted & if become defective, then please replace as set with above 21C Race brgs 3) Kit Race Brg (5KAW ) & individual Race brgs(5ka) will continue to be serviced for other Yamaha models other than above Notes:1) Please update your Parts Catalogue 21C/45S for future Parts ordering 2) Please place your order for Spares thru Parts Division in usual manner You are most earnestly requested to please explain, the above to your SERVICE, SALES, & SPARE PARTS TEAM. Please do not hesitate to seek any clarification from our visiting IYM FIELD TEAM. FPLobo Parts Division INDIA YAMAHA MOTOR PVT.LTD. CC:ZBH / ZSM / RBH / RSM / SALES EXECUTIVE / SERVICE EXECUTIVE / PARTS MANAGERS :YAMAHA POINT(YP)/AUTHORISED SERVICE POINT(ASP) 19/6 Mathura Road- Faridabad

35 FIG. 21 (4K0) FRONT FORK PART PART NAME REMARKS 1 21C-F FRONT FORK ASSY C-F FRONT FORK ASSY (L.H) C-F TUBE, OUTER (LEFT) C-F GASKET C-F BOLT, CAP C-F SPACER C-F WASHER, SPRING UPPER C-F SPRING, FRONT FORK C-F BOLT, HEXAGON SOCKET HEAD C-F GASKET C-F SPINDLE, TAPER EB SEAL, DUST C-F RING, SNAP EB OIL SEAL C-F WASHER, OIL SEAL FM METAL, SLIDE C-F CYLINDER COMP., FRONT FORK C-F INNER TUBE COMP C-F FRONT FORK ASSY (R.H) C-F TUBE, OUTER (RIGHT) C-F GASKET C-F BOLT, CAP C-F SPACER C-F WASHER, SPRING UPPER C-F SPRING, FRONT FORK C-F BOLT, HEXAGON SOCKET HEAD C-F GASKET C-F SPINDLE, TAPER 1 24

36 FIG. 21 (4K0) FRONT FORK PART PART NAME REMARKS 29 4EB SEAL, DUST C-F RING, SNAP EB OIL SEAL C-F WASHER, OIL SEAL FM METAL, SLIDE C-F CYLINDER COMP., FRONT FORK C-F INNER TUBE COMP C-F UNDER BRACKET COMP YY-F SEAL, DUST KA-F RACE, BALL C-F BOLT

37 PART INFORMATION Date:22 June 2010 TO : All Dealers IYM Parts:0276 PI 0276 Model Subject FZ/FAZER series Serviceability Race Bearing Kit Models FZ/Fazer series For the benefit of Customers owning FZ & Fazer bikes the Race Bearing Kit being presently used in our 110 cc & 125 cc bikes can also be used in 150cc bikes FZ & Fazer series Applicable Models : FZ /FAZER series Part Number for Ordering 1) 5KA-W RACE BEARING KIT Notes: 1) Please update your Parts Catalogues FZ/Fazer series for future Parts ordering 2) Please place your order for Spares thru Parts Division in usual manner You are most earnestly requested to please explain, the above to your SERVICE, SALES, & SPARE PARTS TEAM. Please do not hesitate to seek any clarification from our visiting IYM FIELD TEAM..F P Lobo Parts Division INDIA YAMAHA MOTOR PVT.LTD. 19/6 Mathura Road- ffaridabad CC:ZBH / ZSM / RBH / RSM / SALES EXECUTIVE / SERVICE EXECUTIVE / PARTS MANAGERS :YAMAHA POINT(YP)/AUTHORISED SERVICE POINT(ASP)

38 FIG. 22 (4S0) FUEL TANK PART PART NAME REMARKS 1 21C-F FUEL TANK COMP C-F DAMPER, LOCATING C-F DAMPER, LOCATING C-F DAMPER, LOCATING CLAMP COLLAR H6 COLLAR C-F BRACKET, FUEL TANK A3 WASHER, PLATE BOLT, FLANGE BOLT, FLANGE C-F MOLD, FUEL TANK C-XF17D-50-P2 COVER, TOP -BMC C-F414A-00 COVER, FILLER C-F PIPE, OVERFLOW C-F P0 PLATE, CAP SCREW, WITH WASHER NUT C-WF CAP ASSY WITH LOCK C-F FUEL COCK ASSY UU-F SEAL, COCK SCREW UU-F CUP, FILTER UU-F GASKET UU-F NET, FILTER UU-F O-RING SCREW, PAN HEAD UU-F LEVER, COCK 1 26

39 FIG. 022 (4S0) FUEL TANK PART PART NAME REMARKS 29 4UU-F VALVE SCREW WASHER, PLATE C-F PIPE, FUEL A3 CLIP A3 CLIP C-F411G-00 HOOK, SIDE COVER C-F411J-00 DAMPER, SIDE COVER BOLT, FLANGE C-F AIR SHROUD COLLAR BOLT, FLANGE

40 FIG. 23 (4S1) FUEL TANK 2 PART PART NAME REMARKS 1 21C-XF412-A0-P4 TANK SIDE COVER 1 1 FOR BWC1 2 21C-XF413-A0-P4 TANK SIDE COVER 2 1 FOR BWC1 3 21C-F414H-00 DAMPER, PLATE GROMMET BOLT,HEX. SOCKET BUTTON WASHER, PLATE NUT, SPRING SCREW, WITH WASHER NUT C-XF P3 SCOOP & GUIDE AIR 1 - BMC 1 BMC FOR BWC1 11 5TS-F413B-00.EMBLEM C-XF13A-50-P3 SCOOP & GUIDE AIR 2 -BMC 1 BMC FOR BWC1 13 5TS-F413B-00.EMBLEM SCREW, TRUSS HEAD TAPPING NUT, SPRING SCREW, PAN HEAD NUT, SPRING C-F STAY BOLT, FLANGE BOLT, HEX. SOCKET BUTTON 2 28

41 FIG. 24 (4U0) SEAT PART PART NAME REMARKS 1 21C-F DOUBLE SEAT ASSY P-F PAD, SEAT C-F PAD, SEAT P-H BAND, BATTERY C-F SEAT LOCK ASSY BOLT, FLANGE C-F478E-00 CABLE, SEAT LOCK C-WF ROTOR SUB ASSY WITH KEY C-F117K-00 STAY, LOCK C-F472T-00 COVER, SEAT LOCK SCREW, WITH WASHER C-F HANDLE, SEAT BOLT, FLANGE C-F479T-00 BOOT, HANDLE SEAT C-F479U-00 BOOT, HANDLE SEAT C-F479V-00 BOOT, HANDLE SEAT

42 FIG. 25 (4W0) FRONT WHEEL PART PART NAME REMARKS 1 21C-XF P0 CAST WHEEL, FRONT 1 FOR BWC1 2 21C-F510C-00 COLLAR ASSY OIL SEAL YH BEARING TIRE (100/80-17 MC 52P) 1 MRF VALVE, RIM TR C-F COLLAR, WHEEL C-F AXLE, WHEEL NUT, SELF-LOCKING M6 WASHER, PLATE 1 30

43 FIG. 26 (4X0) FRONT BRAKE CALIPER PART PART NAME REMARKS 1 21C-F582U-00 DISK, BRAKE (RIGHT) BOLT,HEX. SOCKET BUTTON 5 3 5YY-F580U-00 CALIPER ASSY (RIGHT) 1 4 5US-W CALIPER SEAL KIT 1 5 5US-F SPRING, RETURN 1 6 5US-W BLEED SCREW KIT 1 7 5US-W BRAKE PAD KIT 1 8 5US-F PIN US-F SHIM, CALIPER US-W CLIP US-W INSULATOR US-W DUST COVER BOLT, FLANGE 2 31

44 FIG. 27 (4Y0) REAR WHEEL PART PART NAME REMARKS 1 21C-XF P0 CAST WHEEL, REAR C-F530S-00 COLLAR ASSY YH BEARING OIL SEAL C-F DAMPER 4 6 5US-F PLATE, BRAKE SHOE 1 7 5YY-WF BRAKE SHOE KIT SPRING, TENSION SPRING, TENSION YY-F CAMSHAFT C-F LEVER, CAMSHAFT BOLT NUT L-F533A-00 PLATE, INDICATOR P-F CLUTCH, HUB Y5 BEARING P-F COLLAR, WHEEL OIL SEAL C-F SPROCKET, DRIVEN (40T) BOLT, STUD NUT, SELF-LOCKING C-F COLLAR, WHEEL TIRE (140/60-17 MC 63P) VALVE, RIM TR C-F BAR, TENSION BOLT NUT CLIP 2 32

45 FIG. 27 (4Y0) REAR WHEEL PART PART NAME REMARKS BOLT NUT WASHER C-F AXLE, WHEEL C-F COLLAR, WHEEL NUT, SELF-LOCKING WASHER, PLATE B5128 CHAIN C-F PULLER, CHAIN C-F END WASHER, PLATE NUT 4 33

46 FIG. 28 (5B0) STEERING HANDLE & CABLE PART PART NAME REMARKS 1 21C-F HANDLEBAR C-F CABLE, THROTTLE C-F CABLE, CLUTCH 1 4 4TL-F COVER, HANDLE LEVER BOLT NUT C-F CABLE, STARTER C-F GRIP C-F GRIP ASSY C-F620B-00 END GRIP ASSY 2 34

47 FIG. 29 (5C0) FRONT MASTER CYLINDER PART PART NAME REMARKS 1 21C-F HOLDER, BRAKE HOSE BOLT, FLANGE C-F HOLDER, BRAKE HOSE C-F HOLDER, CABLE C-F HOSE, BRAKE BOLT, UNION WASHER, PLATE S-F583T-00 MASTER CYLINDER ASSY 1 9 5US-W CYLINDER KIT, MASTER US GASKET, DIAPHRAGM US CAP, RESERVOIR SCREW, FLAT HEAD YY-F BRACKET, MASTER CYLINDER BOLT, FLANGE S-H FRONT STOP SWITCH ASSY YY-H LEVER BOLT NUT, SELF-LOCKING 1 35

48 FIG. 30 (5F0) STAND & FOOTREST PART PART NAME REMARKS 1 35B-F FOOTREST C-F P0 BRACKET, FOOTREST 1 1 S8 FOR BWC B9 SPRING, TORSION PIN PIN, COTTER C-F COVER, FOOTREST SCREW, PAN HEAD BOLT C SHAFT WASHER, PLATE C-F DAMPER, FOOTREST C-F PLATE BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE WASHER, PLATE B-F FOOTREST C-F P0 BRACKET, FOOTREST 2 1 S8 FOR BWC B0 SPRING, TORSION PIN PIN, COTTER C-F COVER, FOOTREST SCREW, PAN HEAD BOLT C-F144G-00 STAY, STOP SWITCH BOLT, FLANGE C-F PEDAL, BRAKE SPRING, TENSION 1 36

49 FIG. 30 (5F0) STAND & FOOTREST PART PART NAME REMARKS 29 21C SHAFT WASHER, PLATE C-F DAMPER, FOOTREST C-F PLATE BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE WASHER, PLATE 3 37

50 FIG. 31 (5F1) STAND & FOOTREST 2 PART PART NAME REMARKS 1 21C-F STAND, MAIN COLLAR SPRING, TENSION C-F STOPPER, MAIN STAND NUT, U FLANGE BOLT, FLANGE C-F ROD, BRAKE PIN, COTTER WASHER PIN, CLEVIS SPRING, COMPRESSION PIN NUT C-F STAND, SIDE SPRING, TENSION HOSE BOLT COLLAR J1 WASHER, PLATE NUT, SELF-LOCKING C-F BRACKET, SIDE STAND BOLT, FLANGE P-F FOOTREST, REAR P-F FOOTREST, REAR PIN PIN, COTTER SPRING, COMPRESSION BALL B-F WASHER, SPECIAL 2 38

51 FIG. 32 (8A0) GENERATOR PART PART NAME REMARKS 1 21C-H ROTOR ASSY C-H STATOR ASSY BOLT BOLT NUT, FLANGE H1 WASHER, PLATE 1 39

52 FIG. 33 (8C0) STARTING MOTOR PART PART NAME REMARKS 1 21C-H STARTING MOTOR ASSY C-H BRUSH HOLDER ASSY C-H181E-00.BRUSH COMP C-H BRUSH SET C-H183G-00.CORD COMP C-WH FASTENER KIT C-WH BEARING KIT C-WH SEALING KIT BOLT 2 40

53 FIG. 34 (8F0) FLASHER LIGHT PART PART NAME REMARKS 1 21C-H FRONT FLASHER LIGHT ASSY C-H BULB, FLASHER (12V-10W) P-H STAY, FLASHER C-H331E-00.CORD ASSY P-H PLATE P-H213A-00.SCREW, FITTING P-H SCREW, LENS FITTING P-H SCREW, FITTING C-H FRONT FLASHER LIGHT ASSY C-H BULB, FLASHER (12V-10W) P-H STAY, FLASHER C-H332E-00.CORD ASSY P-H PLATE P-H213A-00.SCREW, FITTING P-H SCREW, LENS FITTING P-H SCREW, FITTING C-H REAR FLASHER LIGHT ASSY C-H BULB, FLASHER (12V-10W) P-H STAY, FLASHER C-H355M-00.CORD ASSY P-H PLATE P-H213A-00.SCREW, FITTING P-H SCREW, LENS FITTING P-H SCREW, FITTING C-H REAR FLASHER LIGHT ASSY C-H BULB, FLASHER (12V-10W) P-H STAY, FLASHER C-H334E-00.CORD ASS Y 1 41

54 FIG. 034 (8F0) FLASHER LIGHT PART PART NAME REMARKS 29 20P-H PLATE P-H213A-00.SCREW, FITTING P-H SCREW, LENS FITTING P-H SCREW, FITTING YY-H STAY, FLASHER

55 FIG. 35 (8G0) METER PART PART NAME REMARKS 1 21C-H METER ASSY GROMMET SCREW, ROUND TAPPING C-F STAY, PLATE 1 5 5US-F PLATE, NUMBER BOLT, WITH WASHER C-H SENSOR, UNIT CLAMP C-F WINDSHIELD C-F SEAL GROMMET BOLT,HEX. SOCKET BUTTON C-F83E0-00 STAY ASSY., BOLT, WITH WASHER P-F836B-00 TUNING FORK MARK 1 43

56 FIG. 36 (8H0) HEADLIGHT PART PART NAME REMARKS 1 21C-H HEADLIGHT ASSY C-H BULB (12V-35/35W) C-H BULB (12V-5W) C-H COVER COMP C-H CORD ASSY GROMMET D4 COLLAR BOLT, FLANGE BOLT, WITH WASHER C-F COVER, UPPER 1 1 YB FOR BWC SCREW, TAPPING C-F P2 COVER, OUTER 1 1 S8 FOR BWC C-F P2 COVER, OUTER 2 1 S8 FOR BWC C-H DAMPER BOLT,HEX. SOCKET BUTTON BOLT,HEX. SOCKET BUTTON E8 COLLAR A4 NUT, SPRING 4 44

57 FIG. 37 (8J0) TAILLIGHT PART PART NAME REMARKS 1 21C-H TAILLIGHT UNIT ASSY C-H BULB (12V-21/5W) C-H LENS, TAILLIGHT C-H GASKET, TAIL LENS SCREW, TAPPING SCREW, TAPPING WASHER, PLATE GROMMET 2 45

58 FIG. 38 (8T0) HANDLE SWITCH & LEVER PART PART NAME REMARKS 1 21C-F REAR VIEW MIRROR ASSY (LEFT) C-F REAR VIEW MIRROR ASSY (RIGHT) C-H SWITCH, HANDLE C-H SWITCH, HANDLE 3 (RIGHT) 1 5 5YY-H HOLDER, LEVER C-H LEVER L-H BOLT, LEVER NUT, NYLON M BOLT, WITH WASHER WASHER, PLATE L-H BAND, SWITCH CORD 2 46

59 FIG. 39 (8V0) ELECTRICAL 1 PART PART NAME REMARKS 1 21C-H IGNITION COIL ASSY BOLT, FLANGE P-H PLUG CAP ASSY C-H BATTERY ASSY (MINDA MLX-5LE) HOSE C-H WIRE, PLUS LEAD C-H WIRE, MINUS LEAD 1 8 5YY-H BAND, BATTERY 1 9 1S4-H RECTIFIER & REGULATOR ASSY NUT, SELF U-FLANGE BOLT, FLANGE COLLAR WASHER, PLATE C-H WIRE HARNESS ASSY C-H COVER, CONNECTER C-H252U-00 COVER C-H FUSE HOLDER ASSY C-H HOLDER, FUSE C-H BAND C-H FUSE (15A) CLAMP CLAMP 1 47

60 FIG. 40 (8W0) ELECTRICAL 2 PART PART NAME REMARKS 1 21C-H C.D.I. UNIT ASSY C-H NEUTRAL SWITCH ASSY GASKET C-H STOP SWITCH ASSY C-H RELAY C-W STARTER RELAY ASSY NUT, FLANGE C-H MAIN SWITCH STEERING LOCK SCREW C-H SWITCH C-XH MAIN SW. STRG. LOCK SUB ASSY. 1 AP 12 21C-H FLASHER RELAY ASSY KA-H HORN BOLT, FLANGE C-H SENDER ASSY BOLT, WITH WASHER US-H REFLECTOR ASSY NUT, FLANGE 1 48

61 FIG. 41 (9A9) PARTS OPTION (KICK STARTER) PART PART NAME REMARKS 1 21C-E AXLE, KICK C-E GEAR, KICK WASHER, CONICAL SPRING WASHER, PLATE (T=0.5) CIRCLIP C-E WHEEL, RATCHET C-E SPRING P7 WASHER, PLATE CIRCLIP H4 WASHER, PLATE C-E GUIDE, SPRING C-E SPRING, KICK CIRCLIP C-E GUIDE, RATCHET WHEEL BOLT C-E GEAR, KICK IDLE G4 WASHER, PLATE C-E KICK CRANK ASSY NUT OIL SEAL C-F SPRING, RETURN C-F721A-00 GUIDE, PLATE BOLT, FLANGE PIN, COTTER 1 49

62 INDEX-21C4 PART NO PART NO PART NO PART NO PART NO PART NO 1NT S4-H P-E443E P-E P-E P-E P-F P-F P-F P-F P-F P-F P-F836B P-H P-H P-H P-H P-H P-H213A P-H213A P-H213A P-H213A P-H P-H P-H P-H P-H P-H P-H P-H P-H P-H P-H P-H P-H C C C C C-1410A C-1410E C C C C C C C C-1490J C C-1496A C C C C C C C-E C-E111F C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E449E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E542A C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-F C-F117K C-F C-F C-F C-F144G C-F C-F C-F C-F C-F C-F16A C-F C-F C-F172A-00-P C-F172F-00-P C-F177G C-F C-F C-F i

63 INDEX-21C4 PART NO PART NO PART NO PART NO PART NO PART NO 21C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F P C-F C-F P C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F317J C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F411G C-F411J C-F C-F414A C-F414H C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F P C-F472T C-F C-F C-F C-F C-F478E C-F479T C-F479U C-F479V C-F510C C-F C-F C-F530S C-F C-F C-F C-F C-F C-F C-F C-F C-F582U C-F C-F C-F C-F C-F620B C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F721A C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F C-F P C-F P C-F C-F C-F C-F83E C-H C-H C-H C-H C-H C-H C-H C-H C-H C-H C-H C-H C-H C-H252U C-H C-H C-H C-H C-H C-H C-H C-H C-H C-H C-H C-H331E C-H C-H332E C-H C-H C-H334E C-H C-H C-H355M C-H C-H C-H C-H C-H C-H C-H C-H C-H C-H C-H C-H C-H C-H C-H C-H C-WF C-WF C-WF C-XF P C-XF13A-50-P C-XF X C-XF P C-XF P C-XF17C-60-P C-XF17D-50-P C-XF412-A0-P C-XF413-A0-P C-XF P C-XF P C-XH F F F F A B-F B-F B-F L-F533A L-H L-H C1-E C1-E C1-E G2-1423A P-E P-E S-F583T S-H S-XF P S-XF P EB EB EB EB FM ii

64 INDEX-21C4 PART NO PART NO PART NO PART NO PART NO PART NO 4FM KM LS-E LS-E LS-E LS-F341E LS-F341E LS-F TL-F UU-F UU-F UU-F UU-F UU-F UU-F UU-F DG-F GH HK KA-F KA-F KA-F KA-F KA-H LW LW MX-E TS-F TS-F413B TS-F413B TS-F836B US US US-F US-F US-F US-F US-F US-H US-W US-W US-W US-W US-W US-W US-W YP YY-F YY-F YY-F YY-F580U YY-F YY-H YY-H YY-H YY-H YY-H YY-WF K A A A H A F J E H H M H P G G G T J C C D E S H J iii