PARTS CATALOG 2004 G22AZ (JU01) U.S.A., CANADA, EUROPE, OTHERS APRIL 2005

Transcription

1 PARTS CATALOG 2004 G22AZ (JU01) U.S.A., CANADA, EUROPE, OTHERS APRIL 2005

2

3 FOREWORD This Parts Catalogue is related to the parts for the model(s) shown in the frame below. When you are ordering replacement parts, please refer to this Parts Catalogue and quote both part numbers and part names correctly. G22A (JU01) 6. Applicable Serial No. and Color Code 1Vehicle (Frame) Serial No. JU ~ 2Engine Serial No. JU ~ 1. Modifications or additions which have been made after issue of the Parts Catalogue will be announced in the Yamaha Parts News. It is advisable that you make necessary corrections to the Parts Catalogue according to the Yamaha Parts News. 2. Abbreviations The following abbreviations are used in this Parts Catalogue. UR Use specified part number. UN Use as many as needed. AP Alternate parts. LM Local Made (Parts need to be ordered locally) F# Frame Number (Applicable machine number) 3. Parts, which are to be supplied in an assembly, are listed with a dot (.) in front of the part name as shown below. EXAMPLE CARBURETOR ASSY.JET, PILOT.NOZZLE, MAIN 4. Number of component for assembly The numeral appearing to the right of each component part indicates the quantity of parts for each assembly unit. EXAMPLE: PART DESCRIPTION Q TY REMARKS JR CARBURETOR ASSY SCREW, PAN HEAD 2 5. Applicable colors of body panels as well as other relevant information are represented in the REMARKS column as shown below. EXAMPLE: PART DESCRIPTION Q TY REMARKS 7. Note that the illustrations are to be used as a reference for finding part numbers, and not to be used for assembling. When dis-assembling and/or re-assembling, please use the applicable service manual. 8. The asterisk (*) before a reference number indicates modification items after the first edition. JU0-K COWL FRONT 1 Ivory color JN6-F512M-C0-00.HUB-CAP, CHROME 4 With clips

4 CONTENTS ENGINE PAGE PAGE Engine Assembly 5 Secondary Sheave 29 Cylinder Head 6 Transmission 30 ~ 32 Crankshaft / Piston 7 Rear Axle Mount / Wheel 33 Camshaft / Valve 8 Shifter / Cables 34 Air Shroud / Fan 9 Bumper 35 Intake 10 Body (Front) 36 ~ 37 Carburetor 11 Body 2 (Rear) 38 ~ 39 Exhaust 12 Body Fitting 40 Crankcase 13 Carrier 41 Seat 42 CHASSIS Starter Generator 43 ~ 44 Engine Mount 14 Electrical 1 45 Rear Arm / Suspension 15 Electrical 2 46 ~ 47 Frame 16 Optional Hub Caps 48 Front Suspension / Wheel 17 ~ 18 Optional Windshield 49 Steering 19 ~ 20 Optional Sunroof 50 Fuel Tank 21 Optional Light Kit 51 Brake 22 ~ 23 Brake 2 24 Brake 3 25 Accelerator 26 Governor 27 Primary Clutch 28

5 FIG. 1 ENGINE ASSEMBLY 1 JR ENGINE ASSEMBLY 1 Page 5

6 FIG. 2 CYLINDER HEAD 1 JT HEAD, CYLINDER JN GUIDE, INTAKE VALVE 2 3 JT GASKET, CYLINDER HEAD BOLT, FLANGE PIN, DOWEL A BOLT, STUD 2 7 NGK-BPR2E-S0-00 PLUG, SPARK 1 STD, U.S PLUG, SPARK 1 STD, EUROPE (BPR2ES) NGK-BPR4E-S0-00 PLUG, SPARK 1 AP, U.S PLUG, SPARK 1 AP, EUROPE (BPR4ES) 8 JN COVER, CYLINDER HEAD JN JOINT, BREATHER PIPE 1 10 JN COVER, BREATHER 1 11 JN GASKET, BREATHER COVER 1 12 JN GASKET, HEAD COVER BOLT, FLANGE 4 14 JN6-E PIPE, BREATHER BOLT, STUD 2 16 JR ELEMENT CLAMP 2 Page 6

7 FIG. 3 CRANKSHAFT / PISTON 1 JN CRANK SHAFT ASSY. 1 2 JR A0 PISTON, (STD) 1 STD JR PISTON, (0.25mm O/S) 1 AP JR PISTON (0.50mm O/S) 1 AP 3 JR PISTON RING SET, STD. 1 STD JR PISTON RING SET, (0.25mm O/S) 1 AP JR PISTON RING SET, (0.50mm O/S) 1 AP PIN, PISTON CIRCLIP 2 6 JN CONNECTING ROD ASSY 1 7 JN BOLT, CONNECTING ROD 2 8 JN WEIGHT, NUT, HEX WASHER, PLAIN KEY, WOODRUFF 1 Page 7

8 FIG. 4 CAMSHAFT / VALVE 1 JR CAMSHAFT ASSY JN VALVE, INTAKE 1 3 7RH VALVE, EXHAUST 1 4 JN LIFTER, VALVE A9-00 SPRING, COMPRESSION 2 6 J RETAINER, VALVE SPRING 2 7 J COTTER, VALVE 2 8 JN ARM, VALVE ROCKER F SCREW, VALVE ADJUSTING NUT, HEX J SHAFT, ROCKER JR ROD, VALVE PUSH H SEAL, VALVE STEM 1 Page 8

9 FIG. 5 AIR SHROUD / FAN 1 JN CASE, FAN BOLT, FLANGE 5 3 JN COVER, FAN CASE SCREW, PAN HEAD 3 5 JN AIR SHROUD, CYLINDER JR DAMPER AIR SHROUD JN AIR SHROUD, CYLINDER BOLT, FLANGE 2 9 JN6-E DUCT, RIVET 2 Page 9

10 FIG. 6 INTAKE 1 JN JOINT NUT, FLANGE 2 3 JN GASKET BOLT, HEX HEAD W/WASHER PIN, CYL. HEAD W/HOLE CLIP CIRCLIP (E) PIN, CYL. HEAD W/HOLE CLIP 1 10 JN6-E CASE, AIR FILTER 1 11 JN6-E CAP, CASE JN6-E ELEMENT ASSY JN6-E445E FILTER, JN6-E JOINT, CARBURETOR 1 15 JN6-E CLIP, CAP FIT D6-00 O-RING BOLT, FLANGE 3 18 JN6-F WIRE, STARTER 1 19 JN6-F WIRE, THROTTLE 1 20 JN6-F NUT 1 Page 10

11 FIG. 7 CARBURETOR 1 JR CARBURETOR ASSY SCREW, PAN HEAD WASHER 2 4 JN BRACKET J WASHER 1 6 7NJ SCREW, PILOT ADJUSTING A SPRING, PILOT ADJUSTING A0.JET, PILOT 1 (#65.0) 9 JN6-1495H-3B-00.NOZZLE, MAIN A-1414G PIPE, MAIN BLEED G2-1423A-68-A0.JET, MAIN 1 (# 87.5) GASKET, FLOAT CHAMBER 1 13 JN FLOAT GASKET R BOLT, HOLDING 1 16 JN NEEDLE ASSY F PIN, FLOAT WG SCREW, THROTTLE A SPRING, PILOT ADJUSTING SCREW, PAN HEAD WASHER E PLUG, DRAIN A SPRING, PILOT ADJUSTING LV CAP KT PIPE 1 Page 11

12 FIG. 8 EXHAUST 1 JU0-E MUFFLER ASSEMBLY KY GASKET, EXHAUST NUT NUT, SELF LOCKING BOLT, HEX HEAD W/WASHER 2 6 JN6-F BRACKET, MUFFLER 1 Page 12

13 FIG. 9 CRANKCASE 1 JR CRANKCASE ASSY 1 2 JN NOZZLE, JR ELEMENT JR PLATE, BAFFLE SCREW, W/WASHER BEARING SEAL, OIL BEARING PLUG, STRAIGHT SCREW GASKET PIN, DOWEL 2 12 JN COVER, CRANKCASE BEARING SEAL, OIL BEARING 1 16 JN GASKET, CRANKCASE COVER BOLT, FLANGE BOLT, FLANGE EN PLUG, OIL O-RING 1 21 J GAUGE, LEVEL 1 Page 13

14 FIG. 10 ENGINE MOUNT RE 1 JN6-F BRACKET, ENGINE JN6-F BRACKET, ENGINE JN6-F BOLT, ENGINE WASHER, PLAIN P NUT, U-FLANGE BOLT, HEX K6-00 WASHER, PLAIN 4 8 JN6-F DAMPER, JN6-F SPACER 2 10 JN6-F SPACER NUT, U-FLANGE 4 Page 14

15 FIG. 11 REAR ARM / SUSPENSION 1 JU0-F REAR ARM COMP. 1 2 JN6-F COVER, JN6-F211E PANEL, INNER JN6-F211G PANEL, INNER RIVET, BLIND RIVET, BLIND 2 7 JN6-F BUSHING, BOLT, FLANGE NUT P BOLT, HEX. W/WASHER 2 11 JN6-F ROD, CONNECTING 1 12 JN6-F BUSHING, P BOLT, FLANGE P NUT, U-FLANGE WASHER, PLAIN 2 16 JN4-F SHOCK ABSORBER BOLT, FLANGE NUT, U-FLANGE 4 Page 15

16 FIG. 12 FRAME 1 JU0-F FRAME COMP. 1 2 JU0-F254R SUPPORT, BODY MOUNTING BOLT, FLANGE GROMMET 1 Page 16

17 FIG. 13 FRONT SUSPENSION / WHEEL 1 JU0-F FRONT LOWER ARM COMP. 2 FITS LS AND RS BUSHING SOLID 4 FITS LS AND RS 3 2HR BUSH 1 4 FITS LS AND RS COLLAR COVER, BOLT, FLANGE NUT, U-FLANGE BOLT, FLANGE P NUT, U-FLANGE 2 10 JU0-F CUSHION ASSY JU0-F CUSHION ASSY BOLT, FLANGE BOLT, FLANGE PIN, SPLIT 8 15 JU0-F KNUCKLE, STEERING LH BUSH, SOLID NL COVER, THRUST JU0-F ARM, KNUCKLE BOLT, FLANGE 4 20 JU0-F KNUCKLE, STEERING RH SEAL, OIL X0-00 BEARING 2 23 JG5-WF HUB BOLT, KNURLED M7-00 COLLAR Y3-00 BEARING WASHER 2 Page 17

18 FIG. 13 FRONT SUSPENSION / WHEEL NUT,U FLANGE 2 29 JN6-F COVER, HUB DUST 2 30 JN6-F WHEEL ASSY. (KENDA TIRE) 2 JU0-F WHEEL ASSY. (MAXXIS TIRE) NUT NL SPACER P8-00 WASHER, PLAIN 4 Page 18

19 FIG. 14 STEERING 1 JU0-F COLUMN, STEERING P BOLT,FLG. (7-FQA) 4 3 JN3-F HOLDER,HANDLE UPPER 1 4 JU0-F ROD,STRG. 1 5 JN3-F WHEEL,STRG P WASHER PLAIN (7-FQA) NUT,SELF-LOCKING 1 8 JU0-F JT., BOLT,HEX. HEAD W/WASHER 2 10 JU0-F STEERING ASSEMBLY 1 11 JU0-F SEAL 1 12 JU0-F387J RING 1 13 JU0-F CIRCLIP 1 14 JU0-F339Y BEARING 1 15 JU0-F387A GEAR PINION 1 16 JU0-F620A HOUSING COMP JU0-F ROD, TIE 2 18 JU0-F NUT, JU0-F CLAMP 2 20 JU0-F BOOT 2 21 JU0-F387E GEAR, RACK 1 22 JU0-F387F PAD, PRESSURE 1 23 JU0-F387K SPRING, PRESSURE 1 24 JU0-F387G COVER, ADJUST 1 25 JU0-F NUT, JU0-F JT., UNIVERSAL NUT, U FLANGE 2 Page 19

20 FIG. 14 STEERING PIN. SPLIT BOLT, FLG JU0-F HOLDER 1 Page 20

21 FIG. 15 FUEL TANK 1 JN6-F FUEL TANK COMP SCREW, PAN HEAD W/WASHER 4 3 JN3-F FUEL PIPE JOINT C4-00.O-RING 1 5 JN6-F CAP ASSY BOLT, FLANGE SPACER S2-00 WASHER, PLAIN 2 9 JN6-F FUEL PUMP ASSY 1 10 JN6-F BOLT, SPECIAL 2 11 JN6-F PIPE, JN6-F FILTER ASSY JN6-F PIPE, FUEL 1 14 JN6-F PIPE, JN6-F PIPE, CLIP 2 RED CLIP 6 GREEN CLAMP 2 Page 21

22 FIG. 16 BRAKE 1 J BRAKE ARM COMP BUSH, BIMETAL FORMED 2 3 JU PEDAL, BRAKE 1 4 JU PEDAL, PARKING BRAKE BUSH, BIMETAL COLLAR COLLAR BOLT, HEX NUT BOLT, HEX NUT, HEX WASHER, PLAIN 1 13 J SECTOR, PARKING BRAKE BUSH, BIMETAL 1 15 J SEAL, SHAFT WASHER, PLAIN CIRCLIP (E) SPRING, TORSION 1 19 J PAD, PARKING 1 20 J ROD, BRAKE 1 21 J END, ROD NUT, HEX SPRING,TENSION 1 24 J DAMPER, BRAKE 1 25 J PIN, LINK JOINT WASHER, PLAIN CIRCLIP (E) 1 Page 22

23 FIG. 16 BRAKE BUSH, COLLAR SPRING, TORSION G8-00 WASHER, PLATE 2 31 JN3-F PAD, BRAKE PEDAL SPRING,TORSION BOLT, HEX NUT, U-FLANGE 1 35 J M BRACKET, J NAIL, BRAKE BOLT, FLANGE 2 38 J DAMPER, BRAKE F8-00 COLLAR 1 40 JN6-F ROD O-RING PIN PIN, SPLIT 1 44 JN6-F EQUALIZER, BRAKE PIN NUT NUT, HEX JU0-F WIRE, BRAKE JU0-F WIRE, BRAKE CIRCLIP (E) PIN PIN PIN,SPLIT 4 Page 23

24 FIG. 17 BRAKE 2 1 JN6-F BACKING PLATE, (RH) 1 (FOR RIGHT WHEEL ONLY) 2 JN6-F SHOE, BRAKE SET 1 (FOR ONE WHEEL) 3 JG5-F819G REPAIR PARTS KIT 1 4 JG5-F COVER, DUST 1 5 JN6-F722F LEVER ADJUSTER, (RH) 1 Page 24

25 FIG. 18 BRAKE 3 1 JN6-F BACKING PLATE, (LH) 1 (FOR LEFT WHEEL ONLY) 2 JN6-F SHOE, BRAKE SET 1 (FOR ONE WHEEL) 3 JG5-F819G REPAIR PARTS KIT 1 4 JG5-F COVER, DUST 1 5 JN6-F722E LEVER ADJUSTER, (LH) 1 Page 25

26 FIG. 19 ACCELERATOR 1 JN6-F BRKT., PEDAL ACCELERATOR 1 2 J SHAFT, PEDAL1 1 3 J ARM, ACCELERATOR PEDAL PIN, SPRING PIN, SPRING 1 6 JF PEDAL, ACCELERATOR BOLT, FLANGE BOLT, RD. HEX NUT, FLANGE BUSH, BIMETAL FORMED O-RING BOLT, HEX. H SPRING, TENSION 1 14 JN3-F WIRE, THROTTLE PIN, CLEVIS CLIP SPRING, TORSION SPACER BOLT, FLANGE NUT, FLANGE CLAMP T4-00 COLLAR 1 Page 26

27 FIG. 20 GOVERNOR 1 J LEVER, SPEED LIMITER NUT, HEX BUSH SPRING, TORSION 1 5 J SCREW, ADJUSTING P NUT, U-FLANGE 1 7 JN3-G BRACKET BOLT, FLANGE 1 Page 27

28 FIG. 21 PRIMARY CLUTCH JN6-G PRIMARY CLUTCH ASSEMBLY 1 SEE NOTE "A" 1 JN6-G PRIMARY FIXED SHEAVE 1 2 JN6-G PRIMARY SLIDING SHEAVE SEAL, OIL BUSH, BIMETAL FORMED NIPPLE, GREASE PLUG 3 7 JN6-G WEIGHT, BOLT NUT, SELF-LOCKING 3 10 JN6-G SPIDER 1 11 JN6-G COLLAR, ROLLER 3 SEE NOTE "B" SEE NOTE "B" A3-00 PIN, DOWEL 3 13 JN6-G SLIDER 6 14 JU0-G CAP 1 15 JU0-G COVER, DUST BOLT, FLANGE K5-00 WASHER, PLAIN 1 18 JN6-G BOLT 1 19 JN6-G621F SHIM, THRUST 6 20 J55-G BELT 1 NOTE A : Assembly includes all parts except. Numbers 18 and 20 (the main bolt for the Primary Clutch assembly, and the belt). NOTE B : Old style Spider and Collar/Rollers are no longer available. Order Spider/Roller Kit pn JU0-G to upgrade older units (serial number JU and earlier), see Technical Bulletin G Serial number JU and later were manufactured with NEW spider & rollers. Page 28

29 FIG. 21 PRIMARY CLUTCH JN6-G PRIMARY CLUTCH ASSEMBLY 1 SEE NOTE "A" 1 JN6-G PRIMARY FIXED SHEAVE 1 2 JN6-G PRIMARY SLIDING SHEAVE SEAL, OIL BUSH, BIMETAL FORMED NIPPLE, GREASE PLUG 3 7 JN6-G WEIGHT, BOLT NUT, SELF-LOCKING 3 10 JN6-G SPIDER 1 SEE NOTE "B" 11 JN6-G COLLAR, ROLLER 3 SEE NOTE "B" A3-00 PIN, DOWEL 13 JN6-G SLIDER 6 14 JU0-G CAP 1 15 JU0-G COVER, DUST BOLT, FLANGE K5-00 WASHER, PLAIN 18 JN6-G BOLT 19 JN6-G621F SHIM, THRUST 6 20 J55-G BELT 1 NOTE "A": Assembly includes all parts except. Numbers 18 and 20 (the main bolt for the Primary Clutch assembly and the belt.) NOTE "B": Old style Spider and Collar/Rollers are no longer available. Order Spider/Roller Kit pn JU0-G to upgrade older units (serial number JR and earlier), see Technical Bulletin G Serial number JR and later were manufactured with NEW spider & rollers Page 29

30 FIG. 22 SECONDARY SHEAVE 1 JN6-G SECONDARY FIXED SHEAVE 1 2 JN6-G KT SECONDARY SLIDING SHEAVE KIT 1 SEE NOTE "A" 3 JN6-G SECONDARY SLIDING SHEAVE BUSHING, BIMETAL FORMED NIPPLE, GREASE OIL SEAL 2 7 JN6-G SECONDARY SPRING SEAT COMP. 1 SEE NOTE "B" 8 JN6-E SHOE, RAMP BOLT, HEX. SOCKET SPRING, TORSION KEY, WOODRUFF WASHER, PLAIN WASHER, PLAIN NUT, U-FLANGE L=100.5mm± NOTE A : Secondary sheave kit includes: secondary sliding sheave, bushing, oil seals and grease nipple. NOTE "B": Secondary spring seat comp. Includes: secondary spring seat, shoe ramp and bolts. Page 29

31 FIG. 23 TRANSMISSION 1 1 JN6-G TRANSAXLE ASSEMBLY 1 With brake plates 2 JN3-G CASE ASSY 1 3 JN3-G COVER, TRANSMISSION SEAL, OIL Y6-00.BEARING 3 6 JN6-G DIFFERENTIAL ASSY Y4-00.BEARING 1 8 JN6-G BRACKET, BOLT, FLANGE Y0-00.BEARING 2 11 JN3-G633E BAR, PIN, SPLIT BOLT, HEX NUT, HEX BOLT, FLANGE 4 16 JU0-F722H RETAINER 2 17 JN3-G STOPPER 1 18 JU0-F723F WASHER, SPECIAL BOLT, HEX JN3-G COVER, TRANSMISSION JN3-G SHAFT, INPUT ASSY JN3-G633G SHAFT 1 23 JN3-G GEAR, PRIMARY SEAL, OIL 2 25 JN3-G SHAFT, RR. AXLE JN3-G SHAFT, RR. AXLE CIRCLIP 4 Page 30

32 FIG. 23 TRANSMISSION X5-00.BEARING 2 29 JN3-G HUB, RR. AXLE BOLT, KNURLED 8 31 JN3-G BRACKET, NUT, SELF-LOCKING 2 33 JH7-G CAP 1 34 JN6-F BACKING PLATE ASSY. LH 1 35 JN6-F BACKING PLATE ASSY. RH BOLT, HEX NUT, HEX H8-00.WASHER, PLAIN 2 39 JN3-G GEAR, PINION JN3-G GEAR, WHEEL JN3-G GEAR, WHEEL JN3-G GEAR, IDLER H9-00.WASHER, PLAIN J0-00.WASHER, PLAIN CIRCLIP 1 46 JN3-G638A BAR, SHIFT JN6-G638E BAR, SHIFT BOLT, SET SPRING, COMPRESSION BALL CIRCLIP WASHER, PLAIN SEAL, OIL SEAL, OIL 1 Page 31

33 FIG. 23 TRANSMISSION 1 55 JU0-G GOVERNOR BUSHING 1 56 JN3-G COLLAR, GUIDE PIN, DOWEL 2 58 JN3-G SHIM mm (0.030in) JN3-G SHIM mm (0.035in) JN3-G SHIM 1 1.0mm (0.040in) JN3-G SHIM mm (0.045in) JN3-G SHIM mm (0.050in) JN3-G SHIM mm (0.055in) JN3-G SHIM mm (0.060in) JN3-G SHIM mm (0.065in) JN3-G SHIM mm (0.015in) 59 JN3-G GASKET 1 60 ACC-QUICK-GS-KT SEALANT 1 1 Page 32

34 FIG. 24 REAR AXLE MOUNT / WHEEL 1 JN6-F WHEEL ASSY. (KENDA TIRE) 2 JU0-F WHEEL ASSY. (MAXXIS TIRE) NUT 8 3 J55-G DRUM 2 4 JN6-F COVER, HUB DUST P BOLT, FLANGE NUT, FLANGE P BOLT, HEX. W/WASHER (7-FQA) 8 Page 33

35 FIG. 25 SHIFTER / CABLES NUT, U 1 2 JN3-G SHIFT CABLE END ASSY. 1 3 J55-G LEVER, SHIFT JN3-G WIRE, SHIFT 2 5 JF LEVER, SHIFT PIN, CYL. HEAD W/HOLE P WASHER, PLAIN (7-FQA) PIN, SPLIT 2 9 JN3-G KNOB, SHIFT 1 10 JN3-G SPRING SET L9-00 WASHER, PLAIN WASHER, PLAIN CIRCLIP (S) SCREW, PANHEAD W/WASHER 2 15 JN3-G BRACKET, SHIFT WIRE BOLT, FLANGE 4 17 JN SWITCH CLAMP CLAMP 1 Page 34

36 FIG. 26 BUMPER 1 JN3-K FRONT BUMPER COMP. 1 2 JU0-K STAY, FR. BUMPER BOLT, FLANGE P BOLT, FLANGE 2 5 JN3-K STAY, RR. BUMPER JN6-K REAR BUMPER COMP BOLT, FLANGE 2 Page 35

37 FIG. 27 BODY 1 JU0-K COWL, FRONT 1 IVORY JU0-K COWL, FRONT 1 BURGUNDY JU0-K COWL, FRONT 1 HUNTER GRN JU0-K COWL, FRONT 1 CANDY APPLE RED METALLIC JU0-K COWL, FRONT 1 BRILLIANT BLUE METALLIC 2 JN3-K818E CAP, PROTECTOR 2 W/O SUNTOP 3 JU0-F EMBLEM, JU0-K NUT, SPECIAL 2 5 JU0-F CLIP, FRONT COWL 1 6 JF2-K811V PROTECTOR, JU0-K PLATE, BODY PROTECTOR WASHER, PLAIN 10 9 JF2-K PLATE, BODY PROTECTOR JF2-K PLATE, BODY PROTECTOR NUT, SELF-LOCKING JN6-K PLATE, BODY PROTECTOR P NUT, U-FLANGE 4 14 JN6-K PLATE, BODY PROTECTOR JN3-K COVER, HOLE JF2-K PANEL, FRONT RIVET 3 18 JN3-K815G SEAL, FRONT STORAGE 1 19 JN3-K LABEL, WARNING 8 1 JN3-K LABEL, WARNING 8 1 UR, FOR USA SEE NOTE "A" UR, FOR CAN SEE NOTE "A" Page 36

38 FIG. 27 BODY JN3-K LABEL, WARNING 8 1 UR, FOR EUR SEE NOTE "A" 20 JN6-K835E HOLDER, BEVERAGE 1 21 JN3-K835G HOUSING, HOLDER P SCREW, PAN TAP (7-FQA) 6 23 JN6-K PLATE, RIVET, BLIND 2 NOTE A : When replacing Housing Holder JN3-K835G you should also replace Label Warning 8 JN3-K7768-**-00. Page 37

39 FIG. 28 BODY 2 1 JN6-K PANEL, REAR BODY 1 JU0-K PANEL, REAR BODY 1 JU0-K PANEL, REAR BODY 1 JU0-K PANEL, REAR BODY 1 JU0-K PANEL, REAR BODY BOLT, HEX. SOCKET H0-00 WASHER, PLAIN NUT, SPRING 2 5 JN3-K PROTECTOR 2 IVORY SEE NOTE "A" BURGUNDY SEE NOTE "A" HUNTER GREEN SEE NOTE "A" 6 JN3-K INDICATOR, 1 1 SEE NOTE "A" 7 JN3-K SEAL, SEAT 2 8 JN3-K842A SEAL, SEAT PLUG JN6-K824E TRIM, REAR BODY 1 11 JF2-K COVER, REAR FLOOR RIVET BOLT, HEX HEAD W/WASHER G7-00 WASHER, PLAIN R NUT, NYLON (0-FQA) 2 16 JU0-K PANEL, INSPECTION LID OUTER RIVET, BLIND 2 18 JN6-K MAT, MAIN FLOOR JN6-K MAT, MAIN FLOOR JN6-K MAT, MAIN FLOOR 2 1 CANDY APPLE RED METALLIC SEE NOTE "A" BRILLIANT BLUE METALLIC SEE NOTE "A" Page 38

40 FIG. 28 BODY RIVET RIVET, BLIND 9 23 JN6-K PAD, SILENCER JN6-K PAD, SILENCER JN6-H LABEL 1 UR, SEE NOTE "A" 26 JN3-K PLATE, CAUTION 3 1 UR, SEE NOTE "A" 27 JN3-K PLATE, CAUTION 1 1 UR, SEE NOTE "A" 28 JN3-K MAT, BODY SIDE LEFT 1 29 JN3-K MAT, BODY SIDE RIGHT RIVET 10 NOTE "A": When replacing "Panel Rear Body JN6-K or JU0-K8142-**-00" you must also replace "Indicator 1 JN3-K ", "Label JN6-H ", "Plate Caution 3 JN3-K ", and "Plate Caution 1 JN3-K ". Page 39

41 FIG. 29 BODY FITTING 1 JN6-K SERVICE LID, PEDAL 1 2 JU0-K818A PROTECTOR, SIDE PLATE JU0-K818B PROTECTOR, SIDE PLATE JF2-K PLATE, SIDE TRIM JF2-K821F PLATE, SIDE TRIM PLUG RIVET, BLIND RIVET, BLIND RIVET, BLIND 4 10 JF2-K PANEL, REAR FENDER JF2-K PANEL, REAR FENDER JF2-K FLAP, FRONT FENDER LEFT 1 13 JF2-K FLAP, FRONT FENDER RIGHT 1 Page 40

42 FIG. 30 CARRIER 1 JF2-K PAD, BAG SUPPORT 1 2 JN6-K BAND 1 3 J PLATE, ANCHOR BOLT, HEX NUT, SELF LOCKING 1 6 JN6-K LOCK ASSY SCREW, WITH WASHER R WASHER, PLAIN (0-FQA) 4 9 JN3-K HOLDER, 1 1 SEE NOTE "A" 10 JN6-K HOLDER, SCREW, PAN HEAD H9-00 WASHER, PLAIN SPRING, CONICAL N7-00 COLLAR 2 15 JU0-K LABEL, WARNING 2 1 JU0-K LABEL, WARNING 2 1 JU0-K LABEL, WARNING 2 1 UR, FOR USA SEE NOTE "A" UR, FOR CAN SEE NOTE "A" UR, FOR EUR SEE NOTE "A" Page JN6-K SWEATER BASKET BOLT, HEX. SOCKET BUTTON R9-00 WASHER, PLAIN NUT, SELF-LOCKING PLUG 2 21 JN6-W001D SCORECARD HOLDER KIT 1 SEE NOTE "B" NOTE A : When replacing Holder 1 JN3-K you must also replace Label Warning 2 JU0-K7762-**-00. NOTE B : Includes 10, 11, 12, 13, 14

43 FIG. 31 SEAT. PART NUMBER DESCRIPTION QTY REMARKS 1 JN6-K SEAT SUB-ASSY, CUSHION UR IVORY WHITE JU0-K SEAT SUB-ASSY, CUSHION UR TAN 2 JN6-K COVER, SEAT UR IVORY WHITE JU0-K COVER, SEAT UR TAN 3 JF2-K HINGE, SEAT BOLT, FLANGE JN3-K HINGE, SEAT BOLT WASHER, SPRING JN6-K ARM REST JU0-K ARM REST SCREW, TAPPING P NUT JN6-K REINFORCEMENT JN6-K REINFORCEMENT JN3-K SEAT SUB ASSY, BACK UR IVORY WHITE JU0-K SEAT SUB ASSY, BACK UR TAN 15 JN3-K841G COVER, SEAT BACK UR IVORY WHITE JU0-K841G COVER, SEAT BACK UR TAN 16 JN3-K COVER, SEAT BACK BOLT, WITH WASHER J4-00 WASHER, PLATE BOLT, FLANGE G0-00 WASHER, PLATE G6-00 WASHER, PLATE JU0-K SUPPORT, SEAT BACK JN3-K842H RETAINER, SEAT BOLT, FLANGE PLUG Page 42

44 FIG. 32 STARTER GENERATOR 1 JN6-H STARTER GENERATOR 1 2 JN3-H ARMATURE ASSY BEARING 1 (6202 SD) 1 4 J BEARING 2 (6203 SD) 1 5 J HOLDER, BEARING 1 6 JN6-H STATOR ASSY 1 7 JN6-H FIELD COIL ASSY 1 8 J SCREW NUT WASHER, WAVE WASHER, WAVE 4 12 J SCREW J BRACKET, STARTER GENERATOR J BRACKET, STARTER GENERATOR J SCREW NUT WASHER, WAVE WASHER, WAVE 4 19 JN6-H BRUSH HOLDER ASSY 1 20 JF BRUSH 4 21 JN6-H SPRING, BRUSH 4 22 J WIRE, LEAD SCREW, PAN HEAD SCREW, PAN HEAD 4 25 J COVER, BRUSH 4 26 J SCREW WASHER, PLAIN 2 Page 43

45 FIG. 32 STARTER GENERATOR 28 JN3-H SPACER 1 29 JN3-H PULLEY NUT, FLANGE SCREW 3 Page 44

46 FIG. 33 ELECTRICAL 1 1 JN6-H TENSIONER ASSY P BOLT, FLANGE BOLT NUT, FLANGE BOLT, HEX NUT, HEX. 1 7 JN6-H BELT CLAMP 1 9 JR ROTOR ASSY JN T.C.I. UNIT BOLT, FLANGE 2 12 JN WIRE, SUB-LEAD NUT, HEX WASHER, PLAIN KEY, WOODRUFF 1 16 JN PLUG CAP ASSY 1 17 JE SEAL, PLUG CAP 1 18 JN6-H BRACKET, STARTER GENERATOR P BOLT, FLANGE P BOLT, FLANGE BOLT, FLANGE CLAMP WASHER, FINISH U9-00 RIVET 1 Page 45

47 FIG. 34 ELECTRICAL 2 1 JN3-H SCREW, FITTING 2 2 J55-H PLATE, BATTERY FITTING P WASHER, PLAIN (7-FQA) NUT, FLANGE 2 5 JN6-H WIRE, PLUS LEAD 1 6 JN6-H WIRE, MINUS LEAD 1 7 JN6-H WIRE, LEAD 1 8 JN6-H WIRE HARNESS 1 WITH #32 FUSE 9 JR3-H RELAY ASSY JN6-H HARNESS, WIRE SCREW, HEX. T 2 12 JF VOLTAGE REGULATOR BOLT, FLANGE 1 14 JF SWITCH, ACCELERATOR STOP SCREW, PAN HEAD W/WASHER CLAMP 4 17 JR1-H BUZZER 1 18 JN6-H STAY, BUZZER 1 19 * BATTERY ASSY, 12V GROUP 24 1 Obtain Locally, (CCA: minimum 400A) 20 4U RELAY ASSY JN6-H COVER CLAMP BOLT, FLANGE GROMMET 1 25 JN OIL LEVEL GAUGE BOLT, FLANGE 4 27 JN CLAMP, OIL LEVEL 1 Page 46

48 FIG. 34 ELECTRICAL 2 28 JN MAIN SWITCH ASSY. 1 JN MAIN SWITCH ASSY., RANDOM KEY 1 AP 29 J YY KEY, MAIN SWITCH 1 For Std Main Switch Only 30 JN PILOT LAMP ASSY XX.BULB, (12V-3.4W) 1 US Market Only 32 JN6-H FUSE (10A-BLADE) 1 Page 47

49 FIG. 35 OPTIONAL HUB CAPS 1 JN6-F512M-C0-00 HUB-CAP, CHROME 4 Comes with clips 2 JN6-F512M-SM-00 HUB-CAP, BRUSHED ALUMINUM 4 Comes with clips Page 48

50 FIG. 36 OPTIONAL WINDSHIELD. PART NUMBER DESCRIPTION QTY REMARKS 1 JU0-K WINDSHIELD ASSY, SOLID (CLEAR) UR AP JU0-K WINDSHIELD ASSY, SOLID (TINTED) UR AP 2 JU0-K838A RETAINER JU0-K838A RETAINER JU0-K LABEL, WARNING JU0-K WINDSHIELD ASSY, HINGED (CLEAR) UR AP JU0-K WINDSHIELD ASSY, HINGED (SMOKE) UR AP 6 JU0-K838B RETAINER GCA-WSUPP-ER-KT. UPPER, LATCH JU0-K BRACKET, WINDSHIELD (R.H.) JU0-K LABEL, WARNING JN3-K DAMPER, WINDSHIELD Page 49

51 FIG. 37 OPTIONAL SUN ROOF. 1 JU0-K SUN ROOF ASSY UR IVORY JU0-K SUN ROOF ASSY UR TAN 2 JU0-K COVER, SUN ROOF UR IVORY JU0-K COVER, SUN ROOF UR TAN 3 JU0-K SUPPORT, SUN ROOF JU0-K SUPPORT, SUN ROOF JU0-K BOLT, ROOF T2-00. WASHER, PLATE JU0-K NUT, ROOF BOLT J3-00. WASHER, PLATE NUT, SELF-LOCKING J4-00. WASHER, PLATE NUT, CROWN JU0-K834A REINF., HOLDER FOR SUN ROOF 14 JN3-K832F GROMMET, ROOF SUPPORT 2 FOR SUN ROOF WASHER, PLATE FOR SUN ROOF Page 50

52 FIG. 38 OPTIONAL LIGHT KIT Ref. No. Part Number Description Qty Remarks 1 JN6-H430A HEADLIGHT UNIT ASSY UR 2 JN3-H HEADLIGHT UNIT ASSY JN3-H SWITCH, HANDLE E TERMINAL JN6-H CORD, HEADLIGHT JU5-H TAILLIGHT ASSY JU5-H GROMMET CLAMP JU0-H430A HEADLIGHT UNIT ASSY UR 10 5FU-H HEADLIGHT ASSY FU-H BULB, HEADLIGHT (12V-30/30W) FU-H LENS ASSY FU-H SOCKET CORD ASSY JU7-H411T HOLDER, SCREW, PAN HEAD SPRING, SCREW GU NUT, ADJUSTING SCREW, ROUND HEAD NUT, SPRING JU7-H MARK, SIGNAL LAMP JU7-H COVER, SOCKET FU-H HEADLIGHT ASSY FU-H BULB, HEADLIGHT (12V-30/30W) FU-H LENS ASSY FU-H SOCKET CORD ASSY JU7-H411U HOLDER, SCREW, PAN HEAD SPRING, SCREW GU NUT, ADJUSTING Page 51 CONTINUED ON NEXT FRAME

53 FIG. 38 OPTIONAL LIGHT KIT Ref. No. Part Number Description Qty Remarks SCREW, ROUND HEAD NUT, SPRING JU7-H MARK, SIGNAL LAMP JU7-H COVER, SOCKET JU5-H TAILLIGHT ASSY JU5-H GROMMET JU7-H STAY, HEADLIGHT JU7-H STAY, HEADLIGHT SCREW, TAPPING JU0-H SWITCH, HANDLE JU0-H CORD, HEADLIGHT CLAMP X FUSE, (10A-BL) Page 52

54 CONTENTS ENGINE PAGE PAGE Engine Assembly 5 Secondary Sheave 29 Cylinder Head 6 Transmission 30 ~ 32 Crankshaft / Piston 7 Rear Axle Mount / Wheel 33 Camshaft / Valve 8 Shifter / Cables 34 Air Shroud / Fan 9 Bumper 35 Intake 10 Body (Front) 36 ~ 37 Carburetor 11 Body 2 (Rear) 38 ~ 39 Exhaust 12 Body Fitting 40 Crankcase 13 Carrier 41 Seat 42 CHASSIS Starter Generator 43 ~ 44 Engine Mount 14 Electrical 1 45 Rear Arm / Suspension 15 Electrical 2 46 ~ 47 Frame 16 Optional Hub Caps 48 Front Suspension / Wheel 17 ~ 18 Optional Windshield 49 Steering 19 ~ 20 Optional Sunroof 50 Fuel Tank 21 Optional Light Kit 51 ~ 52 Brake 22 ~ 23 Brake 2 24 Brake 3 25 Accelerator 26 Governor 27 Primary Clutch 28