Spare parts catalogue S2R1000 U.S.A. DUCATIMONSTER

Transcription

1 Spare parts catalogue S2R000 U.S.A. MONSTER

2

3 GENERAL INFORMATION The present spare parts order exactly the right spare parts When ordering specify: ) the part's code number followed by its description; quantity needed; 2) the motorcycle's serial number, stamped on the steering head. Reference to right and left apply to the vehicle in terms of its direction of move-ment. Spare parts drawings are general and do not represent the part. The contents of this catalogue are general and can undergo changes without prior notice. VALIDITY f.m. d.m. f.m.m. d.m.m. LIST CAL CDN Until V.I.N. From V.I.N. Up to engine number From engine number California Canada Ducati Motor Holding S.p.A. Commercial and Administation Office: Via A. Cavalieri Ducati n Bologna, Italy Telefono Fax Internet

4 PAINTS Paint Code "Rosso Anniversary " "Nero Lucido " "Trasparente" (PPG) (PPG) (PPG)

5 page CONTENTS a 00b 00c a WORKSHOP SERVICE TOOLS WORKSHOP SERVICE TOOLS DDS TESTER WORKSHOP SERVICE TOOLS GEARCHANGE CONTROL GEARBOX CLUTCH CLUTCH-SIDE CRANKCASE COVER CONNECTING RODS CYLINDERS - PISTONS TIMING SYSTEM FILTERS AND OIL PUMP CRANKCASE HALVES ALTERNATOR-SIDE CRANKCASE COVER ELECTRIC STARTING AND IGNITION CYLINDER HEAD : TIMING SYSTEM VERTICAL CYLINDER HEAD HORIZONTAL CYLINDER HEAD INTAKE MANIFOLDS STANDS ELECTRICAL SYSTEM BATTERY SUPPORT FUEL TANK AIR INTAKE - OIL BREATHER OIL COOLER EXHAUST SYSTEM FRAME INSTRUMENT PANEL GEARCHANGE LEVER - FOOTREST REAR FOOTRESTS FRONT FORKS HANDLEBAR AND CONTROLS FRONT BRAKE REAR BRAKE CLUTCH CONTROL REAR SUSPENSION SWINGARM AND DRIVE CHAIN FRONT AND REAR WHEELS REAR WHEEL AXLE HEADLIGHT NUMBER PLATE HOLDER - TAIL LIGHT FUEL SYSTEM SEAT HEADLIGHT FAIRING EVAPORATIVE EMISSIONS CANISTER DATA PLATE POSITIONS 3

6 DRAWING 00 WORKSHOP SERVICE TOOLS

7 DRAWING 00 WORKSHOP SERVICE TOOLS NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY Wrench for holding timing belt rollers ring nuts Head nuts holder wrench Head mounting base Degree wheel Degree wheel holder tool for ignition advance check Exhaust valve guide punch tool Punch tool to extract valve guide Intake valve guide punch tool Tool to drive valve seal ring ø A Torque wrench for timing belt Crankshaft gear holder wrench for tightening nut Punch tool for driving exhaust valve seat Valve lift gauge Punch tool for driving intake valve seat Fork feeler gauge 0. mm Fork feeler gauge 0,2 mm Fork feeler gauge 0.3 mm Timing belt control gauge Tool to hold crankshaft in TDC position Spacer for checking lower valve shim Flywheel Wrench Crankcases assembling cap Plate for positioning gear engagement fork Conversion kit for 2V belts tensioning tool T.D.C. control gauge Drive roller puller Rocker shaft extractor Wrench to hold cluch housing drum steady Sleeve for installing clutch bell gear Extractor for primary drive gear Pin for assembling rocker arms Belt roller timing of two-valva head Wrench for camshaft pulley ring nut adjustment Tool for assembling closing rocker and spring Half-rings mounting punch tool Torque wrench for timing belt Roller cage fitting tool on primary shaft 5

8 DRAWING 00a WORKSHOP SERVICE TOOLS

9 DRAWING 00a WORKSHOP SERVICE TOOLS NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY Tool for overhauling SHOWA forks - assembling seal ring Wrench for front wheel spindle Tool for assembling chain Stopper for assembling the rocker needle bearings Frame/engine mount Stopper for driving the half bearing of the steering head base Wrench for adjusting the eccentric hub Wrench for assembling the steering head cap Tool for assembling the steering head bearings Tool for balancing rear wheel 7

10 DRAWING 00b DDS TESTER

11 DRAWING 00b DDS TESTER NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY DDS (Ducati Diagnosis System) + manifold vacuum meter. kit Belt tensioning kit Sensor Bracket Battery Feeder DDS manual (USB) Memory card reader Main cable Fuse Software DDS CD (USB) Cable extension Black case with sponge rubber Amperometer plier Battery charger 9

12 DRAWING 00c WORKSHOP SERVICE TOOLS

13 DRAWING 00c WORKSHOP SERVICE TOOLS NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Fuel pressure line HS A Fuel pressure line ST/SS/M A Oil pressure line A Fitting - cylinder compression M A Fitting - cylinder compression M A Cable Volt PF DUC Main cable (MARELLI) A Oil pressure fitting A Cable for supplementary tests A Red clamp cable A Black clamp cable A Temperature probe Battery connection adapter A Electric lighter connection adapter (ST) A Battery connection adapter A Red case with sponge rubber T sticker RH/LH side (USB) Adaptor Depressure sensor A Pressure sensor Feeder Depressure/pressure line Union Pressure kit C Cable for potentiometer adjustement

14 DRAWING 002 GEARCHANGE CONTROL

15 DRAWING 002 GEARCHANGE CONTROL NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Return spring A Washer A Special screw A Gear stopper assembly A Gasket th B Switch A Special screw Gasket Gear selector spring Ball A st,4th-2nd,3rd gear selector fork A 5th,6th gear selector fork Fork pin A Shim th Circlip A Needle retaining ring (square cross-section) A Pin A Complete gearbox drum Shim th A Shim th A Fork return spring Shim th Shim th A Ring A Nut A Gearbox drum control fork Gearchange lever pin A Pin with gearchange lever Gearchange lever return spring A Screw A Washer B Screw A Washer A Centering ring A Stopper plate Shim th Shim th

16 DRAWING 003 GEARBOX

17 DRAWING 003 GEARBOX NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY Shim th B Gearbox main shaft Shim th A Needle bearing A Driving gear 5th sp A Grooved washer th Snap ring A Driving gear 3rd/4th sp A Driving gear 6th sp B Driving gear 2nd sp E Shim th A Front sprocket w/rubber protection Z= A Spacer A O-ring A Spacer th. 3, A Grooved washer th Needle bearing B Driven gear st sp Shim th A Driven gear 5th sp A Driven gear 4th sp A Driven gear 3rd sp A Driven gear 6th sp B Driven gear 2nd sp A Gearbox lay shaft Shim th A Complete main shaft A Gearbox lay shaft A Needle bearing A Seal ring A Lock washer A Nut 5

18 DRAWING 004 CLUTCH

19 DRAWING 004 CLUTCH NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY Clutch spring A Retainer A Clutch control pin B Screw A Lock washer B Rubber pad B Plate holder hub A Clutch plates set B Lock washer B Clutch drum Screw B Pressure plate A Clutch housing A Bearing A O-ring A Seal ring B Clutch/crankshaft gears pair A Bearing A Circlip - spacer A Bearing Spacer A Piston assembly A Bush Pin B Nut A O-ring A O-ring B Screw A Clutch control rod O-ring B Spacer O-ring 7

20 DRAWING 005 CLUTCH-SIDE CRANKCASE COVER

21 DRAWING 005 CLUTCH-SIDE CRANKCASE COVER NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY AD Clutch protection cover A Screw A Screw A Oil level sight glass B Screw A Cover clutch side A Clutch cover gasket Bush A Seal ring A Shim th A Circlip A O-ring A Locating bush O-Ring A Complete cap A Switch A Gasket th A Ring Fluid sealant B Screw B Screw A Washer B Screw A Spacer A Holder A Cap A Gasket th. 9

22 DRAWING 006 CONNECTING RODS

23 DRAWING 006 CONNECTING RODS NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Crankshaft (items included) A Special screw A Nut A Special screw A Connecting rods pair A Bush Pin AB Half-bearing (BLUE) AC Half-bearing (YELLOW) A Special screw A Woodruff key A Shim th B Shim th H Shim th K Shim th. 2, L Shim th. 2, M Shim th N Shim th C Shim th D Shim th. 2, E Shim th. 2, F Shim th. 2, G Shim th I Shim th J Shim th A Lock washer Nut A Spring washer 2

24 DRAWING 007 CYLINDERS - PISTONS

25 DRAWING 007 CYLINDERS - PISTONS NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Piston rings set A Piston pin circlip A Piston pin AB Vertical cylinder-piston fit A Head-cylinder gaskets set A Cylinder-crankcase gasket th A Bush AB Horizontal cylinder-piston fit A Complete piston A Head-cylinder gasket A Bush A Vibration damper pad 4 23

26 DRAWING 008 TIMING SYSTEM

27 DRAWING 008 TIMING SYSTEM NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY AB Vertical timing belt cover (BLACK) B Screw B Screw AB Horizontal timing belt cover (BLACK) A Woodruff key A Fixed tensioner assembly A Screw A Complete vertical cylinder tensioner roller A Lay shaft B Timing gears pair A Lock washer Hexagon nut A Spacer A Snap ring A Timing belt roller Z A Belt roller separating washer A Spacer A Elastic-stop ring nut A Timing drive toothed belt 2 25

28 DRAWING 009 FILTERS AND OIL PUMP

29 DRAWING 009 FILTERS AND OIL PUMP NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Complete oil pump A Thermistor A Gasket th A O-ring A Bypass cap A Cap A Aluminium gasket B Screw A Washer B Screw A Washer A Pump drive gear A Bush A Bypass spring Locating bush A Gasket A Oil drain plug with magnet A Gasket th., A Oil filter A Oil filter cartridge A Nipple A O-ring A Cap A Snap ring A Circlip Reduction bush A Cap A Gasket th A Bypass valve A Bypass spring 27

30 DRAWING 00 CRANKCASE HALVES

31 DRAWING 00 CRANKCASE HALVES NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Complete half-crankcases pair Seal ring Needle bearing A Snap ring Fluid sealant A Stud bolt for fastening head cylinder A Special washer A Nut A Bearing Screw A Keep plate A Bearing A Seal ring A Spacer B Screw A Seal ring Bearing Circlip A Aluminium gasket A Bearing A Bearing holder bush Washer A Locating dowel B Screw Bearing A Bearing B Screw A O-ring A Bearing A Bearing holder bush B Screw A Bush B Breather valve O-ring A Nipple A Screw A Aluminium gasket th., A Bush A Special screw 29

32 DRAWING 0 ALTERNATOR-SIDE CRANKCASE COVER

33 DRAWING 0 ALTERNATOR-SIDE CRANKCASE COVER NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Stator "KOKUSAN" Circlip A Bearing AE Chain cover B Screw B Screw A Oil level sight glass f.m.m A O-ring A Cover B Screw Seal ring A Sensor B Screw A Screw Fluid sealant B Screw B Screw A Locating bush A Generator cover A Bracket B Screw A Gasket th.0, AA Gasket th.0, AB Gasket th., A O-ring B Screw A Washer A Holder A Spring washer A Spacer A Cap d.m.m A Aluminium gasket d.m.m A Rotor 3

34 DRAWING 02 ELECTRIC STARTING AND IGNITION

35 DRAWING 02 ELECTRIC STARTING AND IGNITION NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Complete starter motor A Spring washer A Nut A Starter motor gasket A Screw A Starter motor sprocket A Circlip A Intermediate gear pin A Washer A Intermediate gear assembly Circlip B Screw A Flange A Locating pin A Check ring B Ignition flywheel Washer C Inner ring A Needle bearing A Electric starter driven gear A Starter clutch A Flexible bush A Screw 33

36 DRAWING 03 CYLINDER HEAD : TIMING SYSTEM

37 DRAWING 03 CYLINDER HEAD : TIMING SYSTEM NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Elastic-stop ring nut A Washer A Timing belt roller A Screw A Vertical belt inner cover A Horizontal belt inner cover A Seal ring A Woodruff key A Vertical head camshaft B Screw A O-ring A Side cap A Aluminium gasket A Screw B Screw A Horizontal head camshaft A Stud bolt A Stud bolt A Flange A Special washer 2 35

38 DRAWING 04 VERTICAL CYLINDER HEAD

39 DRAWING 04 VERTICAL CYLINDER HEAD NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY AB Complete vertical head B Intake valve seat BB Oversize intake valve seat BC Oversize intake valve seat B Exhaust valve seat BB Oversize exhaust valve seat BC Oversize exhaust valve seat C Intake valve guide CA Intake valve guide magg. 0, CB Intake valve guide magg. 0, CC Intake valve guide magg. 0, B Exhaust valve guide BA Exhaust valve guide magg. 0, BB Exhaust valve guide magg. 0, BC Exhaust valve guide magg. 0, A Valve seal A Closing rocker spring Shim th Shim th Shim th Shim th Shim th A Shim th A O-ring B Valve cover B Screw Shim Spring A Opening rocker A Rocker shaft A Closing rocker See table E Split rings See table A O-ring A Exhaust valve A Intake valve A Gasket A Screw A Vibration damper pad B Screw A Ring A Washer A Spacer 37

40 DRAWING 05 HORIZONTAL CYLINDER HEAD

41 DRAWING 05 HORIZONTAL CYLINDER HEAD NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY AB Complete horizontal head B Exhaust valve guide BA Exhaust valve guide magg. 0, BB Exhaust valve guide magg. 0, BC Exhaust valve guide magg. 0, C Intake valve guide CA Intake valve guide magg. 0, CB Intake valve guide magg. 0, CC Intake valve guide magg. 0, B Intake valve seat BB Oversize intake valve seat BC Oversize intake valve seat B Exhaust valve seat BB Oversize exhaust valve seat BC Oversize exhaust valve seat A Exhaust valve A Intake valve Shim th Shim th Shim th Shim th Shim th A Shim th A Closing rocker spring A Rocker shaft A O-ring B Valve cover B Screw See table E Split rings See table A Opening rocker A Closing rocker Spring Shim A Valve seal A Gasket A Vibration damper pad A Intake valve cover A Rubber cap Snap ring A Spacer A O-Ring A Aluminium gasket A Ring nut A Holder sensor A Sensor A Screw A O-ring 4 39

42 DRAWING 06 INTAKE MANIFOLDS

43 DRAWING 06 INTAKE MANIFOLDS NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Feed unit assembly A Nut A Clamp A Hose B Hose guide A Stepper motor B Intake duct A Hose guide B Screw A Injector A Potentiometer 4

44 DRAWING 07 STANDS

45 DRAWING 07 STANDS NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY C Plate A Screw A Side stand A Screw A Switch A Inner spring A Complete spring A Plate A Pivot A Nut A Shim th..8 43

46 DRAWING 08 ELECTRICAL SYSTEM

47 DRAWING 08 ELECTRICAL SYSTEM NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Injection control unit B Screw B Electric wiring A Relay End section D Sticker schema fusibili A Screw A Voltage rectifier B Screw B Screw A Hose guide A Nut A Spark plug B Horn (BLACK) A Fuse 40A C Coil B Plate A Screw B Nut A Insert A Spark plug cable (L.H.) A Hose guide Hose guide A Hose guide A Washer A Case cover A Fuse 3A A Fuse 7.5A A Fuse 5A A Fuse 30A A Fuse 20A A Fuse B Screw B Washer A Spark plug cable (R.H.) N0 Washer 45

48 DRAWING 09 BATTERY SUPPORT

49 DRAWING 09 BATTERY SUPPORT NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Spring washer A Nut A Solenoid starter - starter motor cable A Remote switch A Pin B Nut A Rubber pad B Special screw B Bracket A Vibration damper B Battery box mount A Battery carpet A Screw C Battery A Spring hook B Screw A Rubber cap A Guide ring A Spring washer A Hose guide A Battery breather pipe 47

50 DRAWING 020 FUEL TANK

51 DRAWING 020 FUEL TANK NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY CJ Tank (RED/WHITE STRIP) CK Tank (BLACK/WHITE STRIP) A Sticker "" A Pad E Screw B Hook A Split pin 7 80C Shim A Bush A Plate B Screw D Pin B Screw B Screw E Screw A Tank cap A White strip A Washer A Panel (BLACK) B Bracket A Gasket A Washer B Kit sticker (for RED, BLACK) 49

52 DRAWING 02 AIR INTAKE - OIL BREATHER

53 DRAWING 02 AIR INTAKE - OIL BREATHER NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Filter/fuel tank outlet pipe A Filter element B Filter case cover B Stud bolt B Screw B Air filter box A Tube A Washer A Pin A Rubber pad B Hook Spring pin A Oil breather tank A Breather pipe A Clamp B Spacer A Screw A Clamp A Pressure pick-up point 5

54 DRAWING 022 OIL COOLER

55 DRAWING 022 OIL COOLER NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY B Ring A Spacer A Oil return pipe A Nipple B Screw B Vibration damper B Screw C Retainer A Oil cooler A Aluminium gasket th A Oil delivery pipe 53

56 DRAWING 023 EXHAUST SYSTEM

57 DRAWING 023 EXHAUST SYSTEM NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY Exhaust gasket A Lambda sensor B Presilencer A Vertical head exhaust pipe D Top RH silencer (REMUS) (REMUS) A Top RH silencer (TERMIGNONI) A Vertical head exhaust pipe A Horizontal head exhaust pipe A Exhaust guard A Clamp D Bottom Rh silencer (REMUS) (REMUS) A Bottom Rh silencer (TERMIGNONI) A Exhaust guard B Screw B Washer C Spacer C Screw A Cap A Gasket th A Nut A Bracket B Screw A Rubber pad A Holder A Vibration damper pad A Spacer B Screw B Screw A Stud bolt B Screw B Spacer A Washer B Screw A Rubber pad A Clamp A Nut A Gasket 55

58 DRAWING 024 FRAME

59 DRAWING 024 FRAME NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY CB Frame (BLACK) CF Frame (RED) A Rubber pad A Spacer B Rubber pad A Nylon washer A Wrench with Transponder A R.H. body panel (CARBON) B Nut A Clamp A Wrench without Transponder A Locks kit A L.H. body panel (CARBON) A Special screw A Rod A Screw BA Front mudguard (RED) BT Front mudguard (BLACK) A Nut A Cap A Screw A Washer A Sticker " MONSTER S2R000" A Insert A Nut A Cover B Antenna A Plate A Key-operated switch B Special screw 2 57

60 DRAWING 025 INSTRUMENT PANEL

61 DRAWING 025 INSTRUMENT PANEL NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY C Complete instrument panel (speedometer - miles) C Special screw A Screw A Sensor A Frame (METALLIC DARK GREY) A Nut C Vibration damper pad 4 59

62 DRAWING 026 GEARCHANGE LEVER - FOOTREST

63 DRAWING 026 GEARCHANGE LEVER - FOOTREST NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A R.H. protection B Screw A Foot peg (front) (R.H.) A Spring A Ring B Pin B R.H. foot peg holder plate AB Special screw A Vibration damper B Washer A Spacer AB Special screw A L.H. protection A Foot peg (front) (L.H.) A Pin A Rubber pad A Gearchange lever A Bush A Washer A Nut A Ball joint B Screw AB Nut A Gearbox transmission rod Nut A Ball joint B Gearchange control lever A L.H. foot peg holder plate A O-ring 2 6

64 DRAWING 026a REAR FOOTRESTS

65 DRAWING 026a REAR FOOTRESTS NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Ring A R.H. protection B Screw A Foot peg (rear) (R.H.) A Plate N Ball B Spring B Pin A Rear L.H. foot peg holder plate A L.H. protection A Foot peg (rear) (L.H.) A Rear R.H. foot peg holder plate A Screw 4 63

66 DRAWING 027 FRONT FORKS

67 DRAWING 027 FRONT FORKS NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A R.H. fork leg assembly A Centering ring A Damper tube A L.H. fork leg assembly A Special washer A Spring A Spring coupling A Coupling A Rubber cush drive hub A Complete cap A Snap ring A R.H. clamp B Screw A L.H. Clamp A Adjusting screw A Special washer A Complete R.H. slider A Dust seal A Seal ring A Check ring A Bush A Stanchion tube A Bush A Complete L.H. slider A Ring A Reflector 2 65

68 DRAWING 028 HANDLEBAR AND CONTROLS

69 DRAWING 028 HANDLEBAR AND CONTROLS NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Nut B Special screw C Steering head base A Washer A Seal ring A Bearing B Screw A Rear-view mirror (R.H.) A Rear-view mirror (L.H.) B Screw A Mudflap A Ring nut A Stud bolt A L.H. switch A Bush A Handlebar B Screw A Bush Cap A Throttle control B Counterweight B Screw A Steering head B Bracket B R.H. switch A Throttle control transmission Screw B Screw B Cover A Spring pin B Screw B Screw 2 67

70 DRAWING 029 FRONT BRAKE

71 DRAWING 029 FRONT BRAKE NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Front brake pump A Lever with dowel A Spare lever pin A Spare pins and spring A Microswitch B Screw A R.H. brake caliper A Gasket th A Spare bleed union A Plate AB Special screw A Dust seal A Tube Spare cap A Complete oil tank A Hose guide A Screw Vibration damper pad B Screw A Bracket A Spare union B Plate A Caliper pump pipe (METAL PLAITED) B Screw A Pads pair A L.H. brake caliper C Fairlead Nut A Special screw 69

72 DRAWING 030 REAR BRAKE

73 DRAWING 030 REAR BRAKE NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Rear brake pump A Spare union A Dust cover A Complete oil tank A Cap A Tube A Hose guide A Rear brake line (METAL PLAITED) AB Special screw A Gasket th A Rear brake caliper A Pads pair B Spare pins and spring A Spare bleed union A Dust seal A Screw B Screw C Screw A Spring washer A Washer B Screw E Speed sensor A Spacer B Adjuster rod A Fork A Bush B Switch A Washer A Nut B Brake control lever A Rubber pad A Adjusting screw A Return spring A Circlip AB Pin A Washer A Pin A Clamp B Screw A O-ring A Special nut A Washer 7

74 DRAWING 03 CLUTCH CONTROL

75 DRAWING 03 CLUTCH CONTROL NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Clutch drive pump A Clutch control lever A Spare lever pin A Bracket A Spare union B Screw A Screw Vibration damper pad C Bracket B Screw A Cap A Complete oil tank Nut A Hose guide A Tube AB Special screw A Gasket th A Clutch control pipe (METAL PLAITED) A Special screw A Bleed A Dust seal A Microswitch 73

76 DRAWING 032 REAR SUSPENSION

77 DRAWING 032 REAR SUSPENSION NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Rocker assembly A Seal ring A Needle bearing A Bush B Screw A Shock absorber B Screw A Spacer A Spacer A Screw A Screw B Special nut A Ball joint B Nut A Ball joint A Tie rod B L.H. nut A Spacer A Cap B Nut 75

78 DRAWING 033 SWINGARM AND DRIVE CHAIN

79 DRAWING 033 SWINGARM AND DRIVE CHAIN NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Special screw A Vibration damper A Chain adjustment sticker A Snap ring A Swingarm A Clamp A Nut B Screw A Chain sliding shoe A Swingarm pivot A Chain guard A Mudflap B Screw C Pin B Shim th B Shim th B Shim th A Chain (04 Links) C Final drive kit A Washer 2 77

80 DRAWING 034 FRONT AND REAR WHEELS

81 DRAWING 034 FRONT AND REAR WHEELS NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY C Nut A Special washer A Valve A Screw A Front brake disc Seal ring AB Wheel rim (rear) (BLACK) A Bearing A Spacer (internal) AB Wheel rim (front) (BLACK) C Front wheel spindle A Clip B Nut A Washer B Spacer 79

82 DRAWING 035 REAR WHEEL AXLE

83 DRAWING 035 REAR WHEEL AXLE NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Clip C Nut A Washer AB Nut C Rear sprocket flange A Washer A Bush A Bush A Rubber cush drive hub C Ring gear D Pin A Spacer A Hub B Screw A Washer A O-Ring A Caliper holder plate A Circlip B Screw A Rear brake disc 8

84 DRAWING 036 HEADLIGHT

85 DRAWING 036 HEADLIGHT NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Complete headlight Bulb B Screw A Washer Fairlead rubber ring B Screw D Headlight holder A Bracket (R.H.) A Turn indicator A Cup Bulb 55/60W A Rubber pad B Spacer A Hose guide Bulb 4W A Turn indicator B Nut A Screw A Retainer A Bracket (L.H.) 83

86 DRAWING 037 NUMBER PLATE HOLDER - TAIL LIGHT

87 DRAWING 037 NUMBER PLATE HOLDER - TAIL LIGHT NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Number plate holder Hose guide A Tail lamp A Cup A Tail lamp A Cup A Vibration damper pad A Spacer B Nut A Turn indicator B Electric wiring A Holder A Reflector A Turn indicator Bulb B Nut B Nut C Washer A Reflector A Plate B Screw A Two-light bulb 2V 5/2W Bulb B Screw A Protection A Plate 85

88 DRAWING 038 FUEL SYSTEM

89 DRAWING 038 FUEL SYSTEM NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Screw A Quick-coupling union A Flange A Thermistor A O-ring A O-ring A collar A Clamps kit A collar A Filter 87

90 DRAWING 039 SEAT

91 DRAWING 039 SEAT NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY BJ Cover (RED/WHITE STRIP) BK Cover (BLACK/WHITE STRIP) A Helmet anti-theft wire A Rubber pad A Threaded insert B L.H. plate D Seat A Cover B Special screw F Owner's manual A Spring washer B Screw B Plate B Screw B Tool bag B R.H. plate A White strip A Flexible cable B Screw A Seat lock A Mudflap B Nut A Washer B Screw 2 89

92 DRAWING 040 HEADLIGHT FAIRING

93 DRAWING 040 HEADLIGHT FAIRING NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY Vibration damper pad A Screw A Insert AJ Headlight fairing (RED/WHITE STRIP) AK Headlight fairing (BLACK/WHITE STRIP) A Windshield A Washer A Screw B Screw B Nut A White strip 9

94 DRAWING 04 EVAPORATIVE EMISSIONS CANISTER

95 DRAWING 04 EVAPORATIVE EMISSIONS CANISTER NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Union A Gasket B Canister filter A Shunt valve A Union/filter pipe B Tube A Tube A Tube A Fuel pipe A Hose guide A Clamp A Hose guide B Hose guide A Bracket A Plate A Rubber pad B Spacer A Screw A Nut B Screw A Hose guide A Union Aluminium gasket A Breather pipe A Spacer 2 93

96 DRAWING 042 DATA PLATE POSITIONS

97 DRAWING 042 DATA PLATE POSITIONS NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY NOTES NO. CODE NO. DESCRIPTION VALIDITY Q.TY A Sticker A Label A Sticker A Sticker 95

98 INDEX CODE No. Drwg. POS. N. CODE No. Drwg. POS. N. CODE No. Drwg. POS. N. CODE No. Drwg. POS. N. CODE No. Drwg. POS. N B A A A C A A A A B A A B B AB B A AC B A a A B A A A A A A A B A A AB B A AB B A A A A A A A A A A B A A A A B A A B A A A A A A A A AD A B A A A A A A A A 03 6 A

99 INDEX CODE No. Drwg. POS. N. CODE No. Drwg. POS. N. CODE No. Drwg. POS. N. CODE No. Drwg. POS. N. CODE No. Drwg. POS. N AB AB BB A A AB AB BC A A A B BC A A A B A A A B BA C A A AE BA A C A A BB A A A A BB A A B A BC A A A A BC A A A A C A A A A 026a C A A A A 026a CA A A A A CA A A A A CB A C A A CB A A A A CC A C B A CC A B A A B A A B A B A A A A BB A B A B BB A A A A BC A A A A BC A A A A B B A A A B A A A A BB A D A B

100 INDEX CODE No. Drwg. POS. N. CODE No. Drwg. POS. N. CODE No. Drwg. POS. N. CODE No. Drwg. POS. N. CODE No. Drwg. POS. N A B A 00c A A A 026a B A 00c A A A 026a A A 00c A A A A A A A CB A A A A CF A A A B AJ A A CJ A AK A A CK A A A E A A A A A A A A A A A A A A C B A A A A A 00c A A A A A 00c A C A BA A A A A BT A A AB A A A A AB B A B A B A A A A B B A BJ A A 00c A A BK A A 00c A B D A A 00c A D A A A 00c A A A A A 00c A D A A A 00c A A A A A A 00c A A A C

101 INDEX CODE No. Drwg. POS. N. CODE No. Drwg. POS. N. CODE No. Drwg. POS. N. CODE No. Drwg. POS. N. CODE No. Drwg. POS. N A A A A A B C A N A A A A A A A A A A A A A A A A B A A A E A A A A E A A A A A A A A A A A A A A A A A B A A A A A A A A A B B C A A B B A A A B A A A A A A A A A A A A A A A A B A A B A A A A C A A A A A A B A A A A A 00c A B A A B A E A B A A A A A A A A D