plug MlO x joint M &1 691 cyl. screw M6 x oil seal 30x47x7/7,5, crankshaft, magneto

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4 Crankcase Ill. No. Part No. D e s c r i p t i o n Qty crankcase assy dowel 9,8 x dowel 3,8 x plug MlO x joint M & 69 cyl. screw M6 x oil seal 30x47x7/7,5, crankshaft, magneto side oil seal 25x40x7, main shaft ~0 roller bearing 205, main shaft ball bearing 6203, clutch shaft oil separator foam, magneto side oil separator roam, clutch side... 4 oil pump assy. (only single parts are available, see chapter oil pump) lock washer cyl. screw M6 x cyl. scr~w M6 x cyl. screw M6 x ~4 87 cyl. sc~ew M6 x nipple, st r3.ig~. t plug, front Zl30 ball bearing ball bearing shim 40/46,50,5.. as requ shim 40/'6,5/0, as requ shim 40/6,5/0,... as requ shim 34/39,5/0,5... as requ shim 34/39,50, as requ shim 34/39,50, ~. as requ retaining plate counter sunk slot head screw MS x screw M2, kick starter stop sieve cover oil sieve gasket ring

5 [. No. Part No. D e s c r i p t i o n Qty a-ring 3,3-2, cyl. screw M6 x gasket ring C2x hex. screw M2 x plug M2 x,5, magnetic drain dowel 3,8 x stud MlO x 96, magneto side stud MlO x 84, clutch side nut MlO cyp nut MlO nipple assy. without oil line gasket ring C8x cyl. screw MB x stud MB x 6/5, tensioner pulley dowel 9,8 x LOCTITE ;4 (orange), 50 c.c.... as requ LOCTITE 22 (violet) as requ LOCTITE 648 (green), 6 c.c..... as requ.

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7 Oil Pump Ill. No. Part Ho. D e s c r i p t i o n Qty pump housing assy., suction pump shaft needle roller 3 x 5, inner rotor, suction outer rotor, suction needle roller 4 x 25, pump housing, lubrication oil seal x7x inner rotor, lubrication outer rotor, lubrication pump cover washer 0,/7/ as requ needle roller 3 x 2,8. ~ pump gear 27 t LOCTITE 574 (orange), 50 c.c as requ.

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9 Crankshaft, Balancer drive I Piston I Cylinder Ill. No. Part No. D e s c r i p t i o n Qty II l!f Jt'92fl crankshaft assy distance ring 35,2i50/4 ball bearing 6207 shim 35,4/43/0,, shim 35,4/43/0,2 Woodruff key 6 x 9 Woodruff key 4 x 5 balancer drive assy. (replace only both 3 gears together) drive gear with clutch drum assy. (replace only drive gear with clutch drum assy.!). ball bearing 6304 E. 2 counter shaft shim 20,5/30/0, shim 20,5/30/0,5... shim 20,5/30/0, lock washer ,... hex. nut M4x,5.... piston assy. w. rings 94,o mm, standard piston assy. w. rings 94,25 nun, st oversize 2 as requ as requ oil strainer ring assy. 94,0 mm, standard oil strainer ring assy. 94,25 mm, lf:t oversize rectangular ring 94,o mm, standard... rectangular ring 94,25 mm, st oversi=e. rectangular ring 94,0 mm, chrom plated, standard rectangular ring 94,25 mm, chrom plated, st oversize piston pin 22 circlip 22, piston pin gasket, cylinder base cylinder with sleeve assy gasket, clinder head o-ring 32-2 cylinder sleeve crankshaft repair kit LOCTITE 242 (blue) LOCTITE Antiseize 0 g Molykote GN, slide paste 00 g 2 as requ. as requ. as requ.

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11 Transmission Ill. No. Part No. D e s c r i p t i o n Qty transmission assy clutch shaft 3 t bushing 22,Bx24x,7, clutch shaft gear 4th, clutch shaft, 7 t thrust washer 24,2/27,5/2,3, clutch shaft snapring gear 3rd, clutch shaft, 5 t thrust wascher 2,2/27,5/, clutch shaft needle bearing 2x25x3, clutch shaft gear 5th, clutch shaft, 23 t gear 2nd, clutch shaft, 3 t main shaft bushing 23,8x25x9,8, main shaft needle bearing 2x25x3, main shaft gear 2nd, main shaft, 23 t thrust washer 22/30/2,6, main shaft gear 5th, main shaft, 2 t gear 3rd, main shaft, 2 t gear 4th, main shaft, 9 t !&68 thrust washer 20,5/30/, main shaft needle bearing 20x24x2, main shaft 2 235!&73 gear st, main shaft 3 t thrust washer 7,2/30/, main shaft washer NA24, main shaft locking 2il hex. nut M20 x,5 main shaft sprocket 5 t sprocket 4 t. ~ sprocket 6 t sprocket 7 t sprocket 8 t shift shaft with pawl assy spring, pawl o-ring 0-2, distance sleeve

12 Ill. No. Part No. D e s c r i p t i o n Qty washer 4,5/22,5/ J&o spring, transraission actuating lever lever assy., index washer 0,/7/ 3& spring, index '' shift drum assy washer 2,5/2,5/2, shift drum fork, shifting fork, shifting fork, shifting pin, shift fork guide 2 l& shift lever assy. ltl shift lever! folding lever spring.!& Ji bearing screw M6 x rubber shift lever &6 2' 930 cyl. screw M6 x 20. ' LOCTITE 22 (violet) as requ &3 LOCTITE Antiseize 0 g as requ. 49 BP-Energrease LS3. as requ. + These parts are mounted as standard

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14 Clutch, Kick Start Ill. No. Part No. D e s c r i p t i o n Qty thrust washer 20,2353, inner, clutch drum inner race, clutch drum needle bearing 25x29x0, clutch drum 2,, 293 lf90 drive gear with clutch drum assy. (replace only drive gear with clutch drum asey.) plate, clutch, inner pressure plate 2,5 mm, clutch, friction plate,5 mm, clutch driven clutch hub washer NA20, transmission shaft locking hex. nut M8 x,5, transmission shaft spring, clutch (change springs only setwise) 6 2, plate with thrust bearing assy plate, clutch_spring retaining thrust bearing 8x20x8, lock washer screw M5 x 25, hex. head gear assy., 26 t., kick start idler 7 23'/ 62 kick start shaft thrust washer 20,5/30/ snapring, kick start shaft 20x, spring, kick start return ratchet gear, with start gear assy. (replace both gears together thrust washer 22,2/25,5/, kick gear thrust washer 22,5/30/0,5, kick start 927 lf 75 thrust washer 22,5/30/0,5, kick start as reql circlip 9, lever assy., kick start lever, kick start hub, kick start spring, kick start lever ball 7/32", kick start lever dowel tube 6x rubber sleeve, kick start cyl. ~ screw MB x clutch drum...

15 Ill. No. Part No. D e s c r i p t i o n Qty. 33 2~3 340 rivet 5x2. 8, LOCTITE Antiseize 0 g as requ LOCTITE 648 (green), 6 c.c. as requ

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17 5~f. - ~ - Clutcih Cover, Timlne Belt Housing, Timing Belt Cover Ill. No. Part Ho. D e s c r i p t i o n Qty ' II JO ~3~ clutch cover asny gruove pin 3x8 oil seal 35x47x7 oil seal 22x32x7 ball 2 cam assy., clutch r~lease screw M8 x 9,5, clutch adjustment hex. nut MB spring, clutch can: retaining cyl. zcrew M5 x g _, -. "'"',., r,..,,':" a;.. r~turn a. - t.:....[ l. '~ '. ' '.,...;, '... cyl. scrtw M6 x ]... j;( r> ug s l r.: ~ r~h -...!. '-' x, ) ti~id~ ~e~~ to~sing wa~her ":J,<i3 '..:/J (, : rn i nc ~. e -+; ':! ').., er lerj3 ga3ket ri~c ~!9/0,5. ' 7,, I! 0 -ring ~-,.,... 0-rinc. 2,?, S 3 :, rr.m ~yl. ~c.:rew!c x 20. cyl. screw M6 x 50. cyl. screw Mt x 35 clutch cahle SILASTTC 732 HTV 00 g as requ. LOCTITE 242 (blue) as requ

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19 Cylinder Head, Cam Shaft, Valve Cover Ill. No. Part No. D e s c r i p t i o n Qty ! ! itoo Boo ! ! 0! 867 If cylinder head assy needle bushing 22x28x2 cam shaft 26 degrees cam shaft 292 degrees ball bearing 6204 retaining shim 38/46,8/,0 oil seal 30x47x7 locking ring 47x,75 o-ring 8-, 5 distance sleeve 20/30/3. plug screw M6 x,5 stud M8 x 94 stud MB x 9 nut MB stud MB x 58 ~ stud M6 x ~o valve cover assy., intake. valve cover, exhaust oil seal 4x24x7 spring, decompressor decompression shaft assy. groove pin 4x20 plate, decompresser flat spring, decompressor, Taptite-screw M6 x 2 o-ring 07-2,5 lock washer 6 cyl. screw M6 x 20 gasket intake tlange counter sunk screw M6 x 6 rubber socket hose clamp 5! dowe 3, 8 x 5. ~alve guide If

20 Ill. No. Part No. D e s c r i p t i o n Qty. 35 2&5 J&Jao circlip MOLYKOTE GN as requ LOCTITE 22 (violet) as requ 38 2~7 385 SILASTIC 732 RTV aa requ + These parts are mounted as standard

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22 5~ Cam Shaft Drive Ill. No. Part No. D e s c r i p t i o n Qty J J J J OlJ rin~ 7-2,5.... tining pull~y 5 t... lock washer hex. nut ~6 x, distance sleeve 8,4/24/ ten3icner pulley loc~ ~as~e~ 8... hex. nut M ,2/353 pulley 30 ~. washer e,4/32/3 sprinr. ~asher 8. hex. sc~ew ~e x ball bearin~ tensioner excenter ti~in~ b~!t 8~ t LOCTITE 2~2 (clue) 6 c.c... as requ.

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24 Valves, Rocker Arm, Rocker Arm Shatt, Adjustment Screw Ill. No. Part No. D e s c r i p t i o n Qty intake valve 36 mm exhaust valve 30 mm shim 2,2/29,5/.... Ii Ii seal, valve spring, valve. Ii retainer, valve spring,, key half rocker arm assy., intake J&5 rocker arm assy., exhaust adjustment screw assy. M7... Ii hex. nut M ,, rocker arm shaft spring washer 4,3/20/0, thrust washer 4,3/20/0, MOLYKOTE GN, slide paste 00 g... as requ.

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26 Ignition Unit Ill. No. Part No. D e s c r i p t i o n Qty.,2, magneto generator assy. 2V 90W.., stator assy. with magneto flywheel (stator and magneto flywheel must be exchanged only together!) trigger coil assy., for start ignition cyl. screw M6 x lock washer hex. nut MlS x, , ignition coil assy shielded spark plug protector spark plug 2 Champion A6 YC amplifier-box LOCTITE 242 (blue) 6 c.c.. as requ SILASTIC 732 RTV 00 g as requ

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28 Valve, Oil Filter Element, Ignition Cover Ill. No. Part No. D e s c r i p t i 0 n Qty pressure retaining valve guide pin spring l& screw, guide pin oil filter element cover, oil filter plug screw /8-27 NPT ring 60-2, cyl. screw M6 x trigger coil (see chapter ignition unit ) TAPTIT[-screw M6 x cable clamp TAP'l'ITE-s~rew tt.4 x rubber pluc; ignition cover hclder, call~s, inner dowel 9,8 x llo 880 cyl. screw ~6 x holder, :ables, outer cyl screw MC x plug s c rt. r M8 x, SILASTIC 732 RTV, 00 g as requ LOCTITE 242 (blue), 6 c.c. as requ.

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30 5~ Tools, Gasket Set Ill. No. Part No. D e s c r i p t i o n Qty tool kit, owners tool bag wrench 6, int. hex. screw wrench 5, int. hex. screw ring wrench 22/24 mm fork wrench 7/9 mr.i spark plug wrench 8 mm valve clearance feeler gage 0,05 mm fork wrench /3 r.im fork wrench 0/3 r;rn grip for screw driver screw driver blade-flat wrench, clutch adjustment insertion jig, for oil seal , crankshaft nagneto side insertion jig, for oil seal , main shaft insertion jig, for oil seal , crankshaft clutch side insertion jig, for oil seal , kick start shaft insertion jig, for oil seal , deco~pression s~aft insertion jig, for oil seal , oil pump shaft.... ~ insertion jig, for oil seal , cam shaft guide sleeve for oil seal, main shaft guide sleeve for oil seal, oil pump shaft guide bolt for piston pin piston ring spanner, to mount piston in cylinder puller assy. for timing pulley puller assy. for flywheel ring for puller ringhalf for puller puller assy., bearings cyl. screw M8 x puller assy., cam shaft assembly trestle puller plate assy., crankshaft disassembly

31 5& Ill. No. Part No. D e s c r i p t i o n Qty j , puller bell puller ri~g bolt for puller ring pull-in spindle M8 x,5 clutch hub locking tool locating bolt for crankshaft valve spring push insert ring wrench 3/5, for cylinder head nut puller as3y. for bearings, clutch shaft and balancer shaft extractor sleeve for bearing 6304 puller plate, crankcase diaassernbly Silastic 732 RTV, 00g, sealent material Molykote G~, slide paste 00 g. LOCTITE 57~ orange, 50 c.c., sealing material LOCTITE 242 blue 6 c.c., means of securing LOCTITE 648 green, 6 c.c., rneans of securing LOCTITE Antiseize 0 g. gasket set