YZ450FD (33DD) CANADA YZ450F (33DE) EUROPE YZ450F (33DF) JAPAN YZ450FD (33DG) OCEANIA,SOUTH AFRICA 1M33D-100E1

Transcription

1 YZ450FD () CANADA YZ450F () EUROPE YZ450F () JAPAN YZ450FD () OCEANIA,SOUTH AFRICA 1M33D-100E1 ( )

2 YZ450FD/YZ450F PARTS CATALOGUE 2012 by Yamaha Motor Co., Ltd. 1st edition, June 2012 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

3 FOREWORD This Parts Catalogue is related to the parts for the model(s) on the cover page. When you are ordering replacement parts, please refer to this Parts Catalogue and quote both part numbers and part names correctly. 6. The asterisk (*) before a reference number indicates modified items after the first edition. 1. Modifications or additions which have been made after the issue of the Parts Catalogue will be announced in the Parts News. It is advisable that you make the necessary corrections to the Parts Catalogue according to the Parts News. 2. Abbreviations The following abbreviations are used in this Parts Catalogue. UR Use specified parts number. UN Use as many as needed. AP Alternate Parts LM Locally Made (Parts need to be ordered locally) F# Frame No. (Applicable machine No.) O/S Over Size 3. The number of components for assembly Parts, which are to be supplied in an assembly, are listed with a dot (.) in front of the part name as shown below. The numeral appearing to the right of each component part indicates the quantity of parts for each assembly unit. PART DESCRIPTION Q TY 2F FRONT FLASHER LIGHT ASSY BULB (6V 18W) 1 4. Applicable colours of graphics are represented in the as shown below. PART DESCRIPTION Q TY 2N X5 FUEL TANK COMP. 2 MXR 3J GRAPHIC, FUEL TANK 1 FOR MXR 5. Note that the illustrations for reference in finding parts numbers are not to be used for assembling. When assembling, please use the applicable service manual.

4 FOREWORD 7. Applicable Serial No. Engine Serial No. Frame Serial No. 8. Applicable Colour Code (The (*) mark shows Model colour.) Abbreviation Colour Name Colour Code DPBSE(*) DEEP PURPLISH BLUE SOLID E 0583 PWS1(*) PURPLISH WHITE SOLID

5 MODEL LABEL (1) A label called Model Label is affixed in the location as indicated in (3) below. When using this parts catalogue, please be sure to cross reference the model code production code No. in the catalogue with the model code production code No. indicated on the Model Label affixed onto the product concerned. (2) Model Label Indication (3) Model Label Affixing Location (4) Colouring Information Model Code Colouring Type Code Colour Code Colour Name Abbreviation A 0583 DEEP PURPLISH BLUE SOLID E DPBSE B 0206 PURPLISH WHITE SOLID 1 PWS1 A 0583 DEEP PURPLISH BLUE SOLID E DPBSE B 0206 PURPLISH WHITE SOLID 1 PWS1 A 0583 DEEP PURPLISH BLUE SOLID E DPBSE B 0206 PURPLISH WHITE SOLID 1 PWS1 A 0583 DEEP PURPLISH BLUE SOLID E DPBSE B 0206 PURPLISH WHITE SOLID 1 PWS1 (5) Model Code Production Code Number of Model Listed in This Parts Catalogue Model Code Production Code No. Country (destination) 020 CANADA 010 AUSTRIA BELGIUM CZECHO DENMARK FINLAND FRANCE GERMANY GREECE HUNGARY IRELAND ITALY NETHERLANDS NORWAY POLAND PORTUGAL SLOVAKIA SLOVENIA SPAIN SWEDEN SWITZERLAND UNITED KINGDOM 010 JAPAN 010 AUSTRALIA NEW ZEALAND Model Code Production Code No. Country (destination) 010 SOUTH AFRICA

6 CONTENTS ENGINE CYLINDER... 1 CRANKSHAFT & PISTON... 3 VALVE... 4 CAMSHAFT & CHAIN... 6 WATER PUMP... 7 RADIATOR & HOSE... 8 OIL PUMP... 9 OIL CLEANER INTAKE INTAKE EXHAUST CRANKCASE CRANKCASE COVER STARTER CLUTCH TRANSMISSION SHIFT CAM & FORK SHIFT SHAFT CHASSIS FRAME FENDER SIDE COVER REAR ARM REAR SUSPENSION STEERING FRONT FORK FUEL TANK SEAT FRONT WHEEL FRONT BRAKE CALIPER REAR WHEEL REAR BRAKE CALIPER STEERING HANDLE & CABLE FRONT MASTER CYLINDER STAND & FOOTREST REAR MASTER CYLINDER GENERATOR HANDLE SWITCH & LEVER ELECTRICAL ALTERNATE FOR CHASSIS INDEX NUMERICAL INDEX... 56

7 FIG. 1 CYLINDER PART DESCRIPTION 1 33D CYLINDER HEAD ASSY PS GUIDE, VALVE PS GUIDE, VALVE BOLT, FLANGE PLUG, STRAIGHT SCREW PIN, DOWEL PIN, DOWEL BOLT, FLANGE GASKET BOLT, FLANGE GASKET BOLT, STUD PLUG, SPARK (NGK R CR8E) STD PLUG, SPARK (NGK R CR8E) 1 STD PLUG, SPARK (NGK R CR9E) AP PLUG, SPARK (NGK R CR9E) 1 AP 14 33D GASKET, CYLINDER HEAD PIN, DOWEL BOLT, FLANGE WASHER, PLATE BOLT, FLANGE D COVER, CYLINDER HEAD BE GUIDE, STOPPER D GASKET, HEAD COVER PIPE, BREATHER D PIPE, BREATHER A4 CLIP

8 FIG. 1 CYLINDER PART DESCRIPTION 25 5UM 1119E 00 BOLT, COVER HEAD D 1119E 00 BOLT, COVER HEAD D CYLINDER D GASKET, CYLINDER PIN, DOWEL BOLT, FLANGE

9 FIG. 2 CRANKSHAFT & PISTON PART DESCRIPTION 1 33D CRANKSHAFT ASSY D CRANK D CRANK TG PIN, CRANK BEARING D ROD, CONNECTING BEARING D GEAR, DRIVE D SHAFT BEARING S GEAR, BALANCE WEIGHT NUT WASHER, LOCK D WEIGHT SCREW D WEIGHT KEY, STRAIGHT NUT WASHER, LOCK KEY, WOODRUFF D 116A0 00 PISTON ASSY D PISTON (STD) D PISTON RING SET (STD) D PIN, PISTON CIRCLIP

10 FIG. 3 VALVE PART DESCRIPTION 1 33D VALVE, INTAKE D VALVE, EXHAUST D SEAT, VALVE SPRING D SEAT, VALVE SPRING D SPRING, VALVE INNER D SPRING, VALVE OUTER D RETAINER, VALVE SPRING LD RETAINER, VALVE SPRING LD COTTER, VALVE Y SEAL, VALVE STEM LD PAD, ADJUSTING (1.20) UR 3LD PAD, ADJUSTING (1.25) UR 3LD PAD, ADJUSTING (1.30) UR 3LD PAD, ADJUSTING (1.35) UR 3LD PAD, ADJUSTING (1.40) UR 3LD A0 PAD, ADJUSTING (1.45) UR 3LD F0 PAD, ADJUSTING (1.50) UR 3LD H1 PAD, ADJUSTING (1.55) UR 3LD K1 PAD, ADJUSTING (1.60) UR 3LD M1 PAD, ADJUSTING (1.65) UR 3LD R1 PAD, ADJUSTING (1.70) UR 3LD U1 PAD, ADJUSTING (1.75) UR 3LD W1 PAD, ADJUSTING (1.80) UR 3LD Y1 PAD, ADJUSTING (1.85) UR 3LD PAD, ADJUSTING (1.90) UR 3LD PAD, ADJUSTING (1.95) UR 3LD PAD, ADJUSTING (2.00) UR 4

11 FIG. 3 VALVE PART DESCRIPTION 11 3LD PAD, ADJUSTING (2.05) UR 3LD PAD, ADJUSTING (2.10) UR 3LD E0 PAD, ADJUSTING (2.15) UR 3LD G0 PAD, ADJUSTING (2.20) UR 3LD J0 PAD, ADJUSTING (2.25) UR 3LD L0 PAD, ADJUSTING (2.30) UR 3LD N0 PAD, ADJUSTING (2.35) UR 3LD T0 PAD, ADJUSTING (2.40) UR 12 4C LIFTER, VALVE YELLOW 13 5EB LIFTER, VALVE YELLOW 5

12 FIG. 4 CAMSHAFT & CHAIN PART DESCRIPTION 1 33D CAMSHAFT ASSY D CAMSHAFT ASSY CIRCLIP CHAIN TA TENSIONER ASSY, CAM CHAIN EL BOLT EL GASKET FM GASKET, TENSIONER CASE BOLT, FLANGE GASKET D DAMPER, CHAIN D DAMPER, CHAIN D PLATE, GUIDE STOPPER BOLT, FLANGE

13 FIG. 5 WATER PUMP PART DESCRIPTION 1 5GR SHAFT, IMPELLER DJ IMPELLER, WATER PUMP WASHER, PLATE OIL SEAL OIL SEAL (SD HS) BEARING D COVER, HOUSING D GASKET, HOUSING COVER PIN, DOWEL BOLT, FLANGE BOLT, FLANGE GASKET BE PIPE, WATER O-RING

14 FIG. 6 RADIATOR & HOSE PART DESCRIPTION 1 33D JOINT O-RING BOLT, FLANGE D PIPE BOLT, FLANGE O-RING D 1240A 00 RADIATOR ASSY D RADIATOR COMP SL CAP, RADIATOR D DAMPER, RADIATOR A TUBE, FLEXIBLE VINYL A2 CLIP D HOSE D HOSE D HOSE D HOSE HOSE CLAMP ASSY HOSE CLAMP ASSY HOSE CLAMP ASSY HOSE CLAMP ASSY GROMMET COLLAR BOLT, FLANGE WASHER, PLATE BOLT, WITH WASHER

15 FIG. 7 OIL PUMP PART DESCRIPTION 1 2S OIL PUMP ASSY TA ROTOR ASSY PIN, DOWEL CIRCLIP PIN, DOWEL BOLT S SHAFT, IDLE GEAR SCREW S GEAR, OIL PUMP IDLE CIRCLIP WASHER, PLATE S HOUSING, STRAINER BE STRAINER, OIL BOLT, FLANGE PIN, DOWEL

16 FIG. 8 OIL CLEANER PART DESCRIPTION 1 5D ELEMENT ASSY, OIL CLEANER D COVER, OIL ELEMENT O-RING BOLT, FLANGE BOLT, FLANGE

17 FIG. 9 INTAKE PART DESCRIPTION 1 33D JOINT, CARBURETOR BOLT HOSE CLAMP ASSY D COVER D WASHER D HOSE TJ CLIP D BOLT HOSE CLAMP ASSY D JOINT D PLATE D SEAL D HOLDER, GUIDE BOLT,HEX. SOCKET BUTTON WASHER, PLATE D 1441G 00 BINDER D COVER COLLAR D COLLAR D COLLAR SCREW, TAPPING FP SENSOR, AIR TEMPERATURE SCREW, TAPPING TJ PIPE D 1443E 00 PIPE, DRAIN CLIP D 1441B 00 NET

18 FIG. 9 INTAKE PART DESCRIPTION 28 33D ELEMENT, AIR CLEANER D ELEMENT, AIR CLEANER D GUIDE D COVER SUB ASSY BOLT, FLANGE D DUCT UR FOR DPBSE 33D DUCT UR FOR PWS NUT D DAMPER COLLAR BOLT, HEXAGON SOCKET HEAD D 1443A 00 DUCT UR FOR DPBSE 33D 1443A 10 DUCT UR FOR PWS NUT D DAMPER COLLAR BOLT, HEXAGON SOCKET HEAD BOLT, FLANGE D 2173E 50 GRAPHIC UR FOR DPBSE 33D 2173E 60 GRAPHIC UR FOR PWS D 2173F 50 GRAPHIC UR FOR DPBSE 33D 2173F 60 GRAPHIC UR FOR PWS1 12

19 FIG. 10 INTAKE 2 PART DESCRIPTION 1 33D THROTTLE BODY ASSY D PIPE D SCREW, ROD D PLUNGER, STARTER D SCREW, PAN HEAD D PIPE D CLIP D O-RING D SCREW TJ CLIP B INJECTOR PS O-RING GASKET D THROTTLE SENSOR ASSY C SENSOR, PRESSURE

20 FIG. 11 EXHAUST PART DESCRIPTION 1 33D PIPE, EXHAUST D GASKET, EXHAUST PIPE NUT, FLANGE D EXHAUST PIPE ASSY PH GASKET, MUFFLER D DAMPER, MUFFLER D BAND, SILENCER BOLT, FLG.(SMALL HEAD) BOLT, FLANGE WASHER, PLATE VY DAMPER, MUFFLER COLLAR D SILENCER ASSY 1 33D E0 SILENCER ASSY D 1476F 10.REINF., RIVET, BLIND D 1466G 10.BODY, SILENCER S2 1469A 10.FIBER S2 1469E 00.FIBER S2 1469F 00.FIBER GL GASKET, MUFFLER BOLT, WITH WASHER GL BAND, SILENCER BOLT, FLG.(SMALL HEAD)

21 FIG. 12 CRANKCASE PART DESCRIPTION 1 33D CRANKCASE ASSY PIN, DOWEL D NOZZLE O-RING BOLT, HEXAGON SOCKET HEAD BOLT, HEXAGON SOCKET HEAD BOLT, HEXAGON SOCKET HEAD BOLT, HEXAGON SOCKET HEAD D COVER, CRANKCASE S GUIDE, CHAIN BOLT, FLANGE GASKET BOLT, FLANGE GASKET JT PLATE, BEARING COVER P PLATE, BEARING COVER SCREW, COUNTERSUNK SCREW S PLATE, BEARING COVER D PLATE, STOPPER BOLT, FLANGE COLLAR Y GAUGE, LEVEL XC HOLDER BOLT, FLANGE BOLT, FLANGE GASKET

22 FIG. 12 CRANKCASE PART DESCRIPTION 28 33D HOLDER, CLUTCH CABLE BOLT, FLANGE

23 FIG. 13 CRANKCASE COVER 1 PART DESCRIPTION 1 33D COVER, CRANKCASE PLUG, STRAIGHT SCREW A3 O-RING PLUG, STRAIGHT SCREW O-RING Y PLUG, OIL O-RING D GASKET, CRANKCASE COVER PIN, DOWEL BOLT, FLANGE BOLT, FLANGE GASKET S HOLDER D COVER, CRANKCASE OIL SEAL WASHER, PLATE (T=1.0) CIRCLIP D GASKET, CRANKCASE COVER PIN, DOWEL BOLT, FLANGE BOLT, FLANGE D COVER, GENERATOR D GASKET BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE SEAT, CHECK BALL

24 FIG. 13 CRANKCASE COVER 1 PART DESCRIPTION BALL E0 SPRING, COMPRESSION

25 FIG. 14 STARTER PART DESCRIPTION 1 2S KICK SHAFT ASSY WASHER, PLATE (T=0.5) CIRCLIP S WHEEL, RATCHET A2.SPRING, COMPRESSION P7.WASHER, PLATE CIRCLIP GR GUIDE, SPRING B0.SPRING, TORSION H4 WASHER, PLATE Y GUIDE, RATCHET WHEEL NX STOPPER BOLT OIL SEAL TA GEAR, KICK IDLE WASHER, PLATE (T=0.5) CIRCLIP D KICK CRANK ASSY D BOSS, KICK CRANK A5.SPRING, COMPRESSION BALL SCREW, COUNTERSUNK O-RING BOLT, HEXAGON SOCKET HEAD WASHER, PLATE

26 FIG. 15 CLUTCH PART DESCRIPTION 1 2S GEAR, PRIMARY DRIVE WASHER, CONICAL SPRING NUT XD PRIMARY DRIVEN GEAR COMP TA BOSS, CLUTCH S PLATE, PRESSURE B PLATE, CLUTCH TA PLATE, FRICTION E4 SPRING, COMPRESSION SCREW, WITH WASHER XD PLATE, THRUST WASHER, CONICAL SPRING NUT D ROD, PUSH BEARING CIRCLIP BALL S ROD, PUSH D PUSH LEVER COMP BEARING OIL SEAL CIRCLIP

27 FIG. 16 TRANSMISSION PART DESCRIPTION BEARING S AXLE,MAIN(14T) S GEAR, 5TH PINION(21T) K0 WASHER, PLATE (T=1.0) CIRCLIP D GEAR, 3RD PINION (18T) S GEAR, 4TH PINION (22T) COLLAR S GEAR, 2ND PINION(15T) WASHER BEARING BEARING D DRIVE AXLE ASSY S GEAR, 1ST WHEEL(27T) COLLAR E7 WASHER, PLATE D GEAR, 5TH WHEEL (20T) CIRCLIP WASHER S GEAR, 3RD WHEEL(23T) K0 WASHER, PLATE (T=1.0) CIRCLIP S GEAR, 4TH WHEEL(24T) WASHER S GEAR, 2ND WHEEL(23T) COLLAR A5 BEARING

28 FIG. 16 TRANSMISSION PART DESCRIPTION OIL SEAL F COLLAR O-RING E SPROCKET, DRIVE (13T) WASHER, LOCK NUT S PLATE, COVER BOLT, FLANGE

29 FIG. 17 SHIFT CAM & FORK PART DESCRIPTION 1 33D CAM, SHIFT BEARING BEARING D STOPPER LEVER ASSY SPRING, TORSION SCREW, WITH WASHER D SPACER D FORK, SHIFT D FORK, SHIFT TG FORK, SHIFT

30 FIG. 18 SHIFT SHAFT PART DESCRIPTION 1 1C SEGMENT D SHIFT SHAFT ASSY P LEVER, SHIFT F4 COLLAR SPRING, TORSION E1 WASHER, PLATE PIN, DOWEL S SHIFT PEDAL ASSY BOLT, FLANGE OIL SEAL XJ PIN, SHIFT XJ ROLLER, SHIFT LEVER XJ PAWL, SHIFTER G5 SPRING, COMPRESSION XJ PIN, PAWL TJ GUIDE, SHIFT BOLT

31 FIG. 19 FRAME PART DESCRIPTION 1 33D FRONT FRAME COMP D BRACKET, FOOTREST D BRACKET, FOOTREST SCREW D REAR FRAME COMP BOLT, FLANGE BOLT, FLANGE X TENSIONER V BUSH WASHER, PLATE COLLAR BOLT, FLANGE D 2117F 00 COVER SCREW, PAN HEAD N15 WASHER, PLATE COLLAR GROMMET JD TENSIONER BEARING N4 COLLAR BOLT, FLANGE NUT, SELF-LOCKING WASHER, PLATE BOLT, FLANGE NUT WASHER, PLATE D BRACKET, FRONT LOWER

32 FIG. 19 FRAME PART DESCRIPTION BOLT, FLANGE XC PLATE, PATCH BOLT, FLANGE NUT WASHER, PLATE BOLT, FLANGE D BRACKET, REAR UPPER D BRACKET, REAR UPPER BOLT, FLANGE D PROTECTOR, ENGINE BOLT, WITH WASHER D 2147E 00 GUARD, ENGINE BOLT, WITH WASHER D 2116M 00 BRACKET SCREW, COUNTERSUNK D HOLDER, CLUTCH CABLE BOLT, BUTTON HEAD D 2194U 00 STAY, IGNITION COIL BOLT, FLANGE D 2116J 00 BRACKET BOLT, FLANGE CLAMP D SEAL ET WRENCH, HEXAGON TA 2814F 00 BOX, SPARK PLUG P 2467E 00 CAP P 2464V 00 CASE, CAP

33 FIG. 19 FRAME PART DESCRIPTION 55 33D 2814A 00 WIRE, HOOK D DAMPER, LOCATING D DAMPER, LOCATING D DAMPER, LOCATING

34 FIG. 20 FENDER PART DESCRIPTION 1 17D FENDER, FRONT UR FOR DPBSE 17D FENDER, FRONT UR FOR PWS COLLAR BOLT, FLANGE WASHER, PLATE FB 2415E 02 LABEL, CAUTION 1 3FB 2415E C1 LABEL, CAUTION 1 JAPANESE 6 3FB 2415E 12 LABEL, CAUTION 1 7 4SR 2416E 00 LABEL, CAUTION CANADA D REAR FENDER COMP BOLT, FLANGE BOLT, FLANGE D GUARD, FLAP SCREW, TAPPING C5 2411B 20 EMBLEM PA 2118K 00 LABEL, CAUTION 1 1 5PA 2118K 20 LABEL, CAUTION PA 2118K 10 LABEL, CAUTION PG 2816R 00 LABEL, WARNING GENERAL INFO. 1 28

35 FIG. 21 SIDE COVER PART DESCRIPTION 1 33D SIDE COVER ASSY D COLLAR BE COLLAR D 2172S 00.INSULATOR D 2172P 00.SEAT D 2174P 00.SEAT D 2174G 40 GRAPHIC UR FOR DPBSE 33D 2174G 50 GRAPHIC UR FOR PWS1 8 33D SIDE COVER ASSY D COLLAR BE COLLAR XC GROMMET D GROMMET D 2174A 00.INSULATOR, SIDE COVER D 2174T 00.INSULATOR, SIDE COVER D 2173S 00.INSULATOR D 2174S 00.INSULATOR D 2173P 00.SEAT D 2175P 00.SEAT D 2174H 40 GRAPHIC UR FOR DPBSE 33D 2174H 50 GRAPHIC UR FOR PWS BOLT, FLANGE BOLT, WITH WASHER D SIDE COVER ASSY UR FOR DPBSE 33D SIDE COVER ASSY UR FOR PWS1 23 5PA COLLAR D COLLAR

36 FIG. 21 SIDE COVER PART DESCRIPTION COLLAR PW 2413B 00 EMBLEM D SIDE COVER ASSY UR FOR DPBSE 33D SIDE COVER ASSY UR FOR PWS1 28 5PA COLLAR D COLLAR COLLAR PW 2413B 00 EMBLEM BOLT, FLANGE BOLT, FLANGE D 2172A 00 PANEL

37 FIG. 22 REAR ARM PART DESCRIPTION 1 33D REAR ARM COMP BEARING BEARING OIL SEAL OIL SEAL COLLAR S COLLAR P SEAL, GUARD C SCREW, S SUPPORT, CHAIN S COVER, THRUST BOLT, FLANGE NUT, FLANGE BOLT, FLANGE D SHAFT, PIVOT NUT, SELF-LOCKING WASHER, PLATE D 2217A 00 ARM, RELAY BEARING OIL SEAL COLLAR WASHER WASHER, PLATE D 2217F 00 ROD, CONNECTING BEARING OIL SEAL COLLAR

38 FIG. 22 REAR ARM PART DESCRIPTION 28 5XC SHAFT P SHAFT WASHER, PLATE NUT, SELF-LOCKING RV A0 LABEL, TIRE RV B0 LABEL, TIRE 1 32

39 FIG. 23 REAR SUSPENSION PART DESCRIPTION 1 33D B0 SHOCK ABSORBER ASSY, REAR 1 UR FOR DPBSE 33D F0 SHOCK ABSORBER ASSY, REAR 1 UR FOR PWS1 33D SHOCK ABSORBER ASSY, REAR 1 1 UR FOR DPBSE 33D D0 SHOCK ABSORBER ASSY, REAR 1 1 UR FOR PWS1 33D A0 SHOCK ABSORBER ASSY, REAR 1 UR FOR DPBSE 33D E0 SHOCK ABSORBER ASSY, REAR 1 UR FOR PWS1 2 33D DAMPER SUB ASSY 1 33D DAMPER SUB ASSY D DAMPER SUB ASSY L0..CAP, AIR VALVE JX BUSH, SHOCK ABSORBER LOWER DH CIRCLIP D GUIDE, SPRING D SEAT, SPRING UPPER AA LABEL, WARNING 1 4AA LABEL, WARNING 1 1 4AA LABEL, WARNING D SPRING (K=56N/MM) 1 UR FOR DPBSE 33D D0.SPRING (K=56N/MM) 1 UR FOR PWS1 33D SPRING (K=54N/MM) UR FOR DPBSE 33D C0.SPRING (K=54N/MM) UR FOR PWS D GUIDE, SPRING D GUIDE, SPRING C COLLAR, DISTANCE JE SEAL, DUST EW SEAL, RING UN BEARING

40 FIG. 23 REAR SUSPENSION PART DESCRIPTION 16 5MV BUSH C L1.COLLAR, DISTANCE NY SEAL, DUST XE BOLT NUT, U FLANGE WASHER NY BOLT NUT, SELF-LOCKING

41 FIG. 24 STEERING PART DESCRIPTION BEARING D GUIDE, CABLE BOLT, FLANGE COLLAR BEARING D COVER, BALL RACE NUT K9 WASHER, PLATE (T1.0) D CROWN, HANDLE NUT P HOLDER, HANDLE UPPER D HOLDER, HANDLE LOWER WASHER NUT, U FLANGE YU 2143A 00 CAP BOLT, FLANGE D PLATE, NUMBER BOLT, FLANGE D PROTECTOR D 2339R 00 GRAPHIC SET, FOR PWS1 35

42 FIG. 25 FRONT FORK PART DESCRIPTION 1 33D FRONT FORK ASSY (L.H) 1 33D FRONT FORK ASSY (L.H) D TUBE, OUTER (RIGHT) D RING, SNAP D INNER TUBE COMP XE L0.PISTON, FRONT FORK XE L0.METAL, SLIDE XC WASHER, OIL SEAL D OIL SEAL XE L0.RING, SNAP XE L0.SEAL, DUST D CYLINDER COMP., FRONT FORK 1 33D CYLINDER COMP., FRONT FORK C L0..O-RING C L0..SEAT, SPRING UPPER 1 17D SEAT, SPRING UPPER D 2316A 20.VALVE COMP. 1 33D 2316A 30.VALVE COMP C L0..O-RING C N0..O-RING C P0..O-RING C R0..O-RING AE O-RING C L0..AIR VALVE COMP D D0.SPRING, FRONT FORK(K=4.6N/MM) XC BOLT, CAP HH L0..GASKET

43 FIG. 25 FRONT FORK PART DESCRIPTION GASKET D FRONT FORK ASSY (R.H) 1 33D FRONT FORK ASSY (R.H) D TUBE, OUTER (RIGHT) D RING, SNAP D INNER TUBE COMP XE L0.PISTON, FRONT FORK XE L0.METAL, SLIDE XC WASHER, OIL SEAL D OIL SEAL XE L0.RING, SNAP XE L0.SEAL, DUST D CYLINDER COMP., FRONT FORK 1 33D CYLINDER COMP., FRONT FORK C L0..O-RING C L0..SEAT, SPRING UPPER 1 17D SEAT, SPRING UPPER D 2316A 20.VALVE COMP. 1 33D 2316A 30.VALVE COMP C L0..O-RING C N0..O-RING C P0..O-RING C R0..O-RING AE O-RING C L0..AIR VALVE COMP D D0.SPRING, FRONT FORK(K=4.6N/MM) XC BOLT, CAP

44 FIG. 25 FRONT FORK PART DESCRIPTION 47 2HH L0..GASKET GASKET D UNDER BRACKET COMP BOLT, FLANGE D 2315J 50 PROTECTOR UR FOR DPBSE 17D 2315J H0 PROTECTOR UR FOR PWS D 2315H 50 PROTECTOR UR FOR DPBSE 17D 2315H H0 PROTECTOR UR FOR PWS BOLT D CLAMP D CLAMP BOLT, FLANGE

45 FIG. 26 FUEL TANK PART DESCRIPTION 1 33D FUEL TANK COMP NY CAP ASSY HOSE (L30) XJ PIPE JOINT ASSY HOSE D HOLDER, DAMPER COLLAR GROMMET BOLT,HEX. SOCKET BUTTON D 2419A 00 HOLDER BOLT,HEX. SOCKET BUTTON BOLT, FLANGE COLLAR GROMMET D FUEL PUMP COMP D O-RING D BRACKET, FUEL PUMP D BRACKET, FUEL TANK SCREW, BINDING BOLT, HEXAGON SOCKET HEAD D PIPE, FUEL D CLAMP EW 2412F 00 BRACKET, SEAT SCREW, FLAT HEAD D COVER D DAMPER RIVET

46 FIG. 26 FUEL TANK PART DESCRIPTION 28 33D TANK SIDE COVER ASSY UR FOR DPBSE 33D TANK SIDE COVER ASSY UR FOR PWS COLLAR XC COLLAR D TANK SIDE COVER ASSY UR FOR DPBSE 33D TANK SIDE COVER ASSY UR FOR PWS COLLAR XC COLLAR BOLT, FLANGE

47 FIG. 27 SEAT PART DESCRIPTION 1 33D SINGLE SEAT ASSY UR FOR DPBSE 33D A0 SINGLE SEAT ASSY UR FOR PWS1 2 33D 2470F 50.SEAT COVER COMP UR FOR DPBSE 33D 2470F A0.SEAT COVER COMP UR FOR PWS1 41

48 FIG. 28 FRONT WHEEL PART DESCRIPTION 1 5NY HUB, FRONT BEARING NY SPACER, BEARING OIL SEAL RIM ( ) D 2531B 00.EMBLEM, WHEEL NY SPOKE SET, FRONT NY SPOKE, INNER A NIPPLE, SPOKE TIRE (80/ M MX51FG) 1 1 DUNLOP * TIRE (80/ R MST) 1 LM PIRELLI * TIRE(80/ M M601) 1 LM BRIDGESTONE TUBE (80/ M/C TR4) 1 1 DUNLOP * TUBE (80/100-21) 1 LM PIRELLI * TUBE (80/ M/C TR4) 1 LM BRIDGESTONE BAND, RIM (22-21) 1 1 DUNLOP * BAND, RIM (80/100-21) 1 LM PIRELLI * BAND,RIM ( ) 1 LM BRIDGESTONE 13 5SF SPACER, BEAD XC G0 AXLE, WHEEL XC G0 COLLAR, WHEEL XC G0 COLLAR, WHEEL NUT

49 FIG. 29 FRONT BRAKE CALIPER PART DESCRIPTION 1 5XC 2581T G0 DISK BRAKE ASSY SCREW, COUNTERSUNK XC 2580T G0 CALIPER ASSY (LEFT) XC W PISTON ASSY, CALIPER KM W CALIPER SEAL KIT DH SUPPORT, PAD UY W BLEED SCREW KIT XC W BRAKE PAD KIT DH PIN, PAD DH PLUG SP BOLT SP PIN, SLIDE JD BOOT, CALIPER UY BOOT XC G0.RETAINER, CALIPER BOLT, FLANGE

50 FIG. 30 REAR WHEEL PART DESCRIPTION 1 17D HUB, REAR D SPACER, BEARING BEARING OIL SEAL CIRCLIP D SPROCKET, DRIVEN (48T) 1 STD 17D SPROCKET, DRIVEN (49T) STD 17D SPROCKET, DRIVEN (47T) AP 17D SPROCKET, DRIVEN (50T) AP 17D SPROCKET, DRIVEN (51T) AP 17D SPROCKET, DRIVEN (52T) AP 17D SPROCKET, DRIVEN (49T) 1 AP 17D SPROCKET, DRIVEN (48T) AP BOLT NUT, SELF-LOCKING WASHER, PLATE P SPOKE SET, REAR P SPOKE, INNER P SPOKE, OUTER ET NIPPLE, SPOKE RIM ( ) D 2531B 00.EMBLEM, WHEEL TIRE (120/ M MX51) 1 1 DUNLOP * TIRE (110/ M NHS) 1 LM PIRELLI * TIRE (110/ M M602) 1 LM BRIDGESTONE TUBE (110/90-19 M/C TR4) 1 1 DUNLOP * TUBE (110/90-19) 1 LM PIRELLI 44

51 FIG. 30 REAR WHEEL PART DESCRIPTION 17 * TUBE (110/90-19 M/C TR4) 1 LM BRIDGESTONE BAND, RIM (2.5-19) 1 1 DUNLOP * BAND, RIM ( ) 1 LM METZELER * BAND, RIM ( ) 1 LM BRIDGESTONE 19 3JE SPACER, BEAD XM DAMPER GROMMET D 2530S 00 COLLAR ASSY D PULLER, CHAIN D PULLER, CHAIN BOLT NUT D AXLE, WHEEL NUT, SELF-LOCKING WASHER, PLATE Y CHAIN (DID520DMA2-114LL) 1 1 9Y CHAIN (DID520DMA2 SDH 114LL) 1 1 UR FOR DPBSE 9Y CHAIN (DID520DMA2-114LL) 1 1 UR FOR PWS JOINT, CHAIN(DID520DM G&B-RJ) JOINT,CHAIN (DID 520DM-RJ) 1 1 UR FOR DPBSE JOINT, CHAIN(DID520DM G&B-RJ) 1 1 UR FOR PWS1 45

52 FIG. 31 REAR BRAKE CALIPER PART DESCRIPTION 1 2S2 2582W 70 DISK, REAR BRAKE BOLT, FLANGE D 2580W 01 CALIPER ASSY, REAR D 2580W 11 CALIPER ASSY, REAR UN W PISTON ASSY, CALIPER UN W CALIPER SEAL KIT DH SUPPORT, PAD UY SCREW, BLEED UY CAP C3 W BRAKE PAD KIT C3 W0046 B0.BRAKE PAD KIT UN SHIM, CALIPER UN SHIM, CALIPER UN INSULATOR, HEAT CR PIN, PAD DH PLUG DH PIN, SLIDE JD BOOT, CALIPER UN PIN, SLIDE UY BOOT UN RETAINER D PROTECTOR, DISK BRAKE BOLT, FLANGE D PROTECTOR BOLT, FLANGE BOLT, FLANGE

53 FIG. 32 STEERING HANDLE & CABLE PART DESCRIPTION 1 17D H0 HANDLEBAR GY GRIP TJ C0 GRIP ASSY GY GRIP (RIGHT) Y RING, LEAF BE CAP, GRIP UPPER BE CAP, GRIP UNDER SCREW, PAN HEAD SF COVER, CAP GRIP D THROTTLE CABLE ASSY D CABLE, CLUTCH P BOOT, CABLE N2 COLLAR D PROTECTOR, HANDLEBAR D H0 COVER, HAND UPPER

54 FIG. 33 FRONT MASTER CYLINDER PART DESCRIPTION 1 17D HOSE, BRAKE GASKET BOLT, UNION XC W MASTER CYLINDER SUB ASSY XC W CYLINDER KIT, MASTER XC G0.DIAPHRAGM, RESERVOIR XC G0.CAP, RESERVOIR SCREW, FLAT HEAD CG SEPARATOR ASSY XC G0.FLOAT, RESERVOIR CG 2585G 00.CIRCLIP XC L0 LEVER MV 2589F 00 BOLT, LEVER NUT, WITH WASHER MV BRACKET, MASTER CYLINDER MV BOLT, FITTING XC G0 COVER, HANDLE LEVER

55 FIG. 34 STAND & FOOTREST PART DESCRIPTION 1 33D PEDAL, BRAKE D BOLT O-RING CLIP SPRING, TENSION PIN, CLEVIS WASHER, PLATE PIN, COTTER D FOOTREST D FOOTREST SPRING, TORSION SPRING, TORSION PIN, CLEVIS WASHER, PLATE PIN, COTTER P STAND, SIDE

56 FIG. 35 REAR MASTER CYLINDER PART DESCRIPTION 1 33D 2583V 00 RR. MASTER CYLINDER ASSY UN W CYLINDER KIT, MASTER UN NUT UN JOINT UN CAP, RESERVOIR UN 2585B 00.PLATE, DIAPHRAGM UN DIAPHRAGM, RESERVOIR UN BOLT CG SEPARATOR ASSY CG 2585G 00.CIRCLIP BOLT,HEX. SOCKET BUTTON XC L0 HOSE, BRAKE BOLT, UNION GASKET C HOLDER, BRAKE HOSE SCREW, PAN HEAD C HOLDER, BRAKE HOSE SCREW, PAN HEAD

57 FIG. 36 GENERATOR PART DESCRIPTION 1 33D STATOR ASSY D ROTOR ASSY D CLAMP SCREW BOLT, HEXAGON SOCKET HEAD NUT E1 WASHER, PLATE

58 FIG. 37 HANDLE SWITCH & LEVER PART DESCRIPTION 1 17D HOLDER, LEVER D LEVER BOLT LP NUT, LENS FITTING D BOLT, ADJUSTING NUT BOLT P COVER, HANDLE LEVER D HOLDER, LEVER LOWER BOLT, FLANGE D SWITCH, HANDLE

59 FIG. 38 ELECTRICAL 1 PART DESCRIPTION 1 33D 8591A 70 ENGINE CONTROL UNIT ASSY 1 33D 8591A 40 ENGINE CONTROL UNIT ASSY 1 33D 8591A 50 ENGINE CONTROL UNIT ASSY 1 33D 8591A 60 ENGINE CONTROL UNIT ASSY BOLT, BUTTON HEAD COLLAR GROMMET WASHER, PLATE D IGNITION COIL ASSY D TUBE, CORD GROMMET D PLUG CAP ASSY BOLT, BUTTON HEAD D HOSE, VACUUM SENSING CLIP BOLT, BUTTON HEAD P THERMO UNIT GASKET C SENSOR, PRESSURE D PLATE BOLT, FLANGE D RECTIFIER & REGULATOR ASSY BOLT, FLANGE D CONDENSER, SMOOTHING D WIRE HARNESS ASSY D CONNECTOR CLAMP

60 FIG. 38 ELECTRICAL 1 PART DESCRIPTION CLAMP Y CLAMP CLAMP CLAMP CLAMP CLAMP

61 FIG. 39 ALTERNATE FOR CHASSIS PART DESCRIPTION 1 33D SPRING (K=52N/MM) AP BLUE 33D SPRING (K=54N/MM) 1 AP BLUE 33D SPRING (K=56N/MM) AP BLUE 33D SPRING (K=58N/MM) AP BLUE 33D B0 SPRING (K=52N/MM) AP RED 33D C0 SPRING (K=54N/MM) 1 AP RED 33D D0 SPRING (K=56N/MM) AP RED 33D E0 SPRING (K=58N/MM) AP RED 2 33D SPRING, FRONT FORK(K=4.5N/MM) AP 33D SPRING, FRONT FORK(K=4.6N/MM) AP 33D SPRING, FRONT FORK(K=4.7N/MM) AP 55

62 NUMERICAL INDEX PART PART PART PART PART PART 33D PS PS D D D D D 1119E UM 1119E D D D D D D D D S D D D D D TG D 116A D D D D D LD LD Y D D C EB LD LD LD LD LD LD A LD F LD H LD K LD M LD R LD U LD W LD Y LD LD LD LD LD LD E LD G LD J LD L LD N LD T D D TA FM EL EL D BE D D D 1240A D D D DJ GR D SL D D Y BE D D D D S TA S S BE S D D D D D D B D D D TJ PS D D D D D D D TJ D 1441B D 1441G D D D D D 1443A D 1443A D 1443E D D D D D D D D D D D D D D D D 1466G S2 1469A S2 1469E S2 1469F PH GL D VY D D E D 1476F D GL D D XC D Y Y S JT P S D D D D D D D D S D D TA GR NX S Y S XD XD TA B S D S TA D S D S S S S S S D D S S S D S P D TJ XJ D XJ XJ XJ C D D TG D D D D D 2116J D 2116M D 2117F PA 2118K PA 2118K PA 2118K D D D D D YU 2143A D D XC D D 2147E D D D D RV A RV B D D XC D D 2172A D 2172P D 2172S D D D 2173E D 2173E D 2173F D 2173F D 2173P D 2173S D D PA D BE XC D 2174A D 2174G D 2174G D 2174H D 2174H D 2174P D 2174S D 2174T D 2175P D 2194U D XC P S D P

63 NUMERICAL INDEX PART PART PART PART PART PART 5UN X JD D 2217A D 2217F V MV S D D A D B D D D E D F D D D D D D D D B D C D D D E D D D JX D NY XE C C L AA AA AA EW JE NY UN C D D D D D XC D XE L D D D D D D D C L XE L D XC AE C L D XE L HH L D 2315H D 2315H H D 2315J D 2315J H D 2316A D 2316A D D D XE L DH L C L C N C P C R C L D D D 2339R D D P D D D D D D D D D D C5 2411B EW 2412F D PW 2413B D FB 2415E FB 2415E FB 2415E C SR 2416E D D D D D 2419A D XJ D D NY P 2464V D P 2467E D 2470F D 2470F A D D A NY NY NY XC G XC G XC G A NY P D 2530S D D D 2531B XM D D D JE SF ET P P D D D D D D CG D XC 2580T G D 2580W D 2580W XC 2581T G UY UY UN UN S2 2582W MV D 2583V XC G UN XC G XC G UN XC G UN 2585B CG 2585G MV D XC L C C MV 2589F UN UN DH SP DH JD DH DH CR SP DH UY D H D D H TJ C GY GY Y BE BE SF D D D P P XC G D D UN UN UN P D D D D 2814A TA 2814F ET PG 2816R D D D D D D D D D C D D D D P D XC L D LP D FP D 8591A D 8591A D 8591A D 8591A XC W UN W XC W C3 W