PARTS CATALOG 2003 G22AY (JU01) U.S.A., CANADA, EUROPE, OTHERS

Transcription

1 PARTS CATALOG 2003 G22AY (JU01) U.S.A., CANADA, EUROPE, OTHERS SEPTEMBER BJU0-100E1

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, CYL INDER 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 JR 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 JR6-2179R PLATE, EPA / CALIF. 1 UR, U.S. MODEL 10 JN6-E DUCT, RIVET UH-2111F LABEL, EMISSION 1 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, THROTTLE 1 19 JN6-F WIRE, STARTER 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 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-F217G ROD, CONNECTING 1 12 JN6-F BUSHING, BOLT, FLANGE 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 NUT 8 Page 18

19 FIG. 14 STEERING 1 JU0-F COLUMN, STEERING P BOLT,FLG. (7-FQA) 4 3 JN3-F HOLDER,HANDLE UPPER 2 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-F BEARING 1 15 JU0-F387A GEAR PINION 1 16 JU0-F582M BEARING 1 17 JU0-F HOUSING MAIN JU0-F ROD, TIE 2 19 JU0-F NUT, JU0-F CLAMP 2 21 JU0-F BOOT 2 22 JU0-F BRG., INSERT JU0-F387E GEAR, RACK 1 24 JU0-F387F PAD, PRESSURE 1 25 JU0-F387K SPRING, PRESSURE 1 26 JU0-F387G COVER, ADJUST 1 27 JU0-F NUT, 2 1 Page 19

20 FIG. 14 STEERING 28 JU0-F JT., UNIVERSAL NUT. U FLANGE PIN. SPLIT BOLT, FLG. 4 Page 20

21 FIG. 15 FUEL TANK 1 JN6-F FUEL TANK COMP SCREW, PAN HEAD WASHER, LOCK WASHER, PLAIN 4 5 JN3-F FUEL PIPE JOINT C4-00.O-RING 1 7 JN6-F CAP ASSY BOLT, FLANGE SPACER 2 10 JN6-F FUEL PUMP ASSY 1 11 JN6-F BOLT, SPECIAL 2 12 JN6-F PIPE, JN6-F FILTER ASSY JN6-F PIPE, FUEL 1 15 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, L INK JOINT WASHER, PLAIN CIRCLIP (E) 1 Page 22

23 FIG. 16 BRAKE BUSH SPRING, TORSION 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 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 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). Page 28

29 FIG. 22 SECONDARY SHEAVE 1 JN6-G SECONDARY FIXED SHEAVE 1 2 JN6-W001C SECONDARY SLIDING SHEAVE KIT 1 SEE NOTE "A" 3 JN6-G SECONDARY SLIDING SHEAVE BUSHING, BIMETAL FORMED SEAL, OIL NIPPLE, GREASE 1 7 JN6-G SECONDARY SPRING SEAT 1 8 JN6-E SHOE, RAMP BOLT, HEX. SOCKET SPRING, TORSION 1 L=100.5mm± KEY, WOODRUFF WASHER, PLAIN WASHER, PLAIN NUT, U-FLANGE 1 NOTE A : Secondary sheave kit includes: secondary sliding sheave, bushing, oil seals and grease nipple. Page 29

30 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

31 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

32 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

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

34 FIG. 25 SHIFTER / CABLES NUT, U 1 2 JN3-G CABLE, SHIFT 2 3 J55-G LEVER, SHIFT JF LEVER, SHIFT PIN, CYL. HEAD W/HOLE WASHER, PLAIN PIN, SPLIT 2 8 JN3-G KNOB, SHIFT 1 9 JN3-G SPRING SET L9-00 WASHER, PLAIN WASHER, PLAIN CIRCLIP (S) SCREW, PANHEAD WASHER, LOCK WASHER 2 16 JN3-G BRACKET, SHIFT WIRE BOLT, FLANGE 4 18 JN SWITCH CLAMP CLAMP 1 Page 34

35 FIG. 26 BUMPER 1 JN3-K FRONT BUMPER COMP. 1 2 JU0-K STAY, FR. BUMPER BOLT, FLANGE P BOLT, FLANGE 2 5 JN6-K REAR BUMPER COMP. 1 6 JN3-K STAY, RR. BUMPER BOLT, FLANGE 2 Page 35

36 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 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

37 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 SCREW, PAN HEAD 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

38 FIG. 28 BODY 2 1 JN6-K PANEL, REAR BODY 1 IVORY SEE NOTE "A" JU0-K PANEL, REAR BODY 1 JU0-K PANEL, REAR BODY 1 JU0-K PANEL, REAR BODY 1 JU0-K PANEL, REAR BODY 1 BURGUNDY SEE NOTE "A" HUNTER GREEN SEE NOTE "A" CANDY APPLE RED METALLIC SEE NOTE "A" BRILLIANT BLUE METALLIC SEE NOTE "A" BOLT, HEX. SOCKET H0-00 WASHER, PLAIN NUT, SPRING 2 5 JN3-K PROTECTOR 2 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 NUT, SELF LOCK 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 Page 38

39 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

40 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 1 5 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

41 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 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

42 FIG. 31 SEAT 1 JN6-K CUSHION SEAT 1 2 JN6-K COVER, SEAT JF2-K HINGE, SEAT FEMALE BOLT, FLANGE 4 5 JN3-K HINGE, SEAT MALE BOLT, HEX. SOCKET BUTTON WASHER, SPRG. 4 8 JN6-K ARM REST JU0-K ARMREST SCREW, P/H TAPPING P NUT, U-FLANGE JN6-K REINFORCEMENT JN6-K REINFORCEMENT JN3-K BACK, SEAT SUB JN3-K841G COVER, SEAT BACK JN3-K COVER, SEAT BACK BOLT, HEX. W/WASHER J4-00 WASHER, PLAIN BOLT, FLANGE G0-00 WASHER, PLAIN G6-00 WASHER, PLAIN 4 22 JU0-K SUPPORT, SEAT BACK 1 23 JN3-K842H RETAINER, SEAT BOLT, FLANGE 4 Page 42

43 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 JF BRUSH HOLDER ASSY 1 20 JF BRUSH 4 21 J 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

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

45 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 BOLT, FLANGE BOLT, FLANGE CLAMP WASHER, FINISH U9-00 RIVET 1 Page 45

46 FIG. 34 ELECTRICAL 2 1 JN3-H SCREW, FITTING 2 2 J55-H PLATE, BATTERY FITTING WASHER, PLAIN 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 #33 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. 1 LM (12 V, BCI group 24, 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

47 FIG. 34 ELECTRICAL 2 28 JN MAIN SWITCH ASSY. 1 US Market Only JN MAIN SWITCH ASSY., RANDOM KEY 1 AP 29 J YY KEY, MAIN SWITCH 1 30 JN PILOT LAMP ASSY XX.BULB, (12V-3.4W) 1 US Market Only 32 42X FUSE (10A-BLADE) 1 Page 47

48 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 3 JG5-F512N CLIP, HUB CAP 3 Page 48

49 FIG. 36 OPTIONAL WINDSHIELD 1 JU0-K WINDSHIELD ASSY., SOLID (CLEAR) 1 UR, AP JU0-K WINDSHIELD ASSY., SOLID (TINTED) 1 UR, AP 2 JU0-K WINDSHIELD, SOLID (CLEAR) 1 UR JU0-K WINDSHIELD, SOLID (TINTED) 1 UR 3 JU0-K838C HOLDER SHIELD 2 4 JU0-K722A FASTENER, JU0-K WINDSHIELD ASSY., HINGED (CLEAR) 1 UR, AP JU0-K WINDSHIELD ASSY., HINGED (TINTED) 1 UR, AP 6 JU0-K WINDSHIELD, HINGED (CLEAR) 1 UR JU0-K WINDSHIELD, HINGED (TINTED) 1 UR 7 JU0-K722E SLIDE LATCH 2 8 JN3-K DAMPER, WINDSHIELD 6 9 JU0-K838A RETAINER JU0-K BRACKET, W/S 3 Page 49

50 FIG. 37 OPTIONAL SUN ROOF 1 JU0-K SUN ROOF ASSY 1 2 JU0-K COVER, SUNROOF 1 3 JU0-K SUPPORT, ROOF JU0-K SUPPORT, ROOF JU0-K BOLT, ROOF T2-00.WASHER, PLAIN 16 7 JU0-K NUT, ROOF BOLT, HEX J3-00.WASHER, PLAIN NUT, SELF LOCKING J4-00.WASHER, PLAIN NUT, CAP 2 13 JU0-K834A REINF., HOLDER WASHER, PLATE 2 15 JN3-K832F GROMMET, ROOF 2 Page 50

51 FIG. 38 OPTIONAL LIGHT KIT 1 JN6-H430A HEAD LIGHT UNIT COMP. 1 2 JN3-H HEAD LIGHT UNIT ASSY. 1 INCLUDES RH/LH HEADLIGHTS 3 JN3-H SWITCH, HANDLE BULLET, PLUG 2 5 JN6-H CORD, HEAD LIGHT 1 6 JN3-H TAIL LIGHT ASSY 2 7 JN3-H GROMMET,TAIL LAMP CLAMP 20 Page 51

52 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