YFZ450RSF (1TDG) U.S.A. 1P1TD-110EA

Transcription

1 YFZ450RSF (1TDG) U.S.A. 1P1TD-110EA ( )

2 YFZ450RSF PARTS CATALOGUE 2014 by Yamaha Motor Co., Ltd. 1st edition, October 2014 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. Q TY 2F FRONT FLASHER LIGHT ASSY BULB (6V 18W) 1 4. Applicable colours of graphics are represented in the as shown below. 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 YB(*) YAMAHA BLACK Quantity Column Information Column No. Name Of Q ty Column Destination 1 U.S.A.

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 (5) Model Code Production Code Number of Model Listed in This Parts Catalogue Model Code Production Code No. 1TDG 010 U.S.A. Country (destination) Model Code Production Code No. Country (destination) (3) Model Label Affixing Location (4) Colouring Information Model Code Colouring Type Code Colour Code Colour Name 1TDG J 0033 YAMAHA BLACK YB Abbreviation

6 CONTENTS ENGINE CYLINDER... 1 CRANKSHAFT & PISTON... 3 VALVE... 4 CAMSHAFT & CHAIN... 6 WATER PUMP... 7 RADIATOR & HOSE... 8 OIL PUMP... 9 INTAKE THROTTLE BODY ASSY EXHAUST CRANKCASE CRANKCASE COVER STARTER CLUTCH TRANSMISSION SHIFT CAM & FORK CHASSIS FRAME FRONT FENDER REAR FENDER SIDE COVER REAR ARM REAR SUSPENSION STEERING FRONT SUSPENSION & WHEEL FUEL TANK SEAT FRONT WHEEL FRONT BRAKE CALIPER REAR WHEEL REAR BRAKE CALIPER STEERING HANDLE & CABLE FRONT MASTER CYLINDER STAND & FOOTREST REAR MASTER CYLINDER GUARD GENERATOR STARTING MOTOR HEADLIGHT TAILLIGHT HANDLE SWITCH & LEVER ELECTRICAL GRAPHICS EMBLEM & LABEL INDEX NUMERICAL INDEX... 63

7 FIG. 1 CYLINDER 1 1TD CYLINDER HEAD ASSY 1 2 5TA GUIDE, VALVE TA GUIDE, VALVE BOLT, FLANGE PLUG, STRAIGHT SCREW PIN, DOWEL PIN, DOWEL BOLT, FLANGE GASKET BOLT, FLANGE BOLT, STUD PLUG, SPARK (NGK CR8E) S GASKET, CYLINDER HEAD BOLT, FLANGE WASHER, PLATE S COVER, CYLINDER HEAD BE GUIDE, STOPPER BOLT VY 1111G 00 RUBBER, MOUNT P PIPE, BREATHER TD PIPE, BREATHER A1 CLIP S GASKET, HEAD COVER S CYLINDER S GASKET, CYLINDER PIN, DOWEL BOLT, FLANGE 1 1

8 FIG. 1 CYLINDER 28 1TD PIPE TJ GASKET BOLT, HEXAGON SOCKET HEAD 2 2

9 FIG. 2 CRANKSHAFT & PISTON 1 1TD CRANKSHAFT ASSY P CRANK P CRANK P PIN, CRANK BEARING 1 6 1TD ROD, CONNECTING BEARING P GEAR, DRIVE BEARING P SHAFT P GEAR, BALANCE WEIGHT NUT WASHER, LOCK P WEIGHT SCREW BEARING KEY, WOODRUFF TG PISTON (STD) TG PISTON RING SET (STD) TG PIN, PISTON CIRCLIP 2 3

10 FIG. 3 VALVE 1 5TA VALVE, INTAKE 1 2 5TA VALVE, INTAKE TA VALVE, EXHAUST 2 4 3GM SEAT, VALVE SPRING TJ SPRING, VALVE INNER 3 6 5TJ SPRING, VALVE OUTER 2 7 5BE RETAINER, VALVE SPRING 3 8 4GY RETAINER, VALVE SPRING 2 9 1AA LOCK, VALVE SPRING RETAINER WG LOCK, VALVE SPRING RETAINER M SEAL, VALVE STEM SV SEAL, VALVE STEM LD PAD, ADJUSTING (1.20) 5 UR 3LD PAD, ADJUSTING (1.25) 5 UR 3LD PAD, ADJUSTING (1.30) 5 UR 3LD PAD, ADJUSTING (1.35) 5 UR 3LD PAD, ADJUSTING (1.40) 5 UR 3LD A0 PAD, ADJUSTING (1.45) 5 UR 3LD F0 PAD, ADJUSTING (1.50) 5 UR 3LD H1 PAD, ADJUSTING (1.55) 5 UR 3LD K1 PAD, ADJUSTING (1.60) 5 UR 3LD M1 PAD, ADJUSTING (1.65) 5 UR 3LD R1 PAD, ADJUSTING (1.70) 5 UR 3LD U1 PAD, ADJUSTING (1.75) 5 UR 3LD W1 PAD, ADJUSTING (1.80) 5 UR 3LD Y1 PAD, ADJUSTING (1.85) 5 UR 3LD PAD, ADJUSTING (1.90) 5 UR 4

11 FIG. 3 VALVE 13 3LD PAD, ADJUSTING (1.95) 5 UR 3LD PAD, ADJUSTING (2.00) 5 UR 3LD PAD, ADJUSTING (2.05) 5 UR 3LD PAD, ADJUSTING (2.10) 5 UR 3LD E0 PAD, ADJUSTING (2.15) 5 UR 3LD G0 PAD, ADJUSTING (2.20) 5 UR 3LD J0 PAD, ADJUSTING (2.25) 5 UR 3LD L0 PAD, ADJUSTING (2.30) 5 UR 3LD N0 PAD, ADJUSTING (2.35) 5 UR 3LD T0 PAD, ADJUSTING (2.40) 5 UR 14 3FV LIFTER, VALVE 5 YELLOW 5

12 FIG. 4 CAMSHAFT & CHAIN 1 1TD CAMSHAFT ASSY TD CAMSHAFT ASSY CIRCLIP CHAIN (98XRH M) 1 5 5TA TENSIONER ASSY, CAM CHAIN 1 6 4FM GASKET, TENSIONER CASE BOLT, FLANGE GASKET 1 9 2S DAMPER, CHAIN P DAMPER, CHAIN COLLAR P PLATE, GUIDE STOPPER BOLT, HEXAGON SOCKET HEAD 2 6

13 FIG. 5 WATER PUMP 1 18P IMPELLER SHAFT ASSY CIRCLIP 1 3 4C SEAL, MECHANICAL OIL SEAL BEARING P COVER, HOUSING P GASKET, HOUSING COVER PIN, DOWEL BOLT, FLANGE GASKET 1 7

14 FIG. 6 RADIATOR & HOSE 1 1TD E RADIATOR ASSY 1 2 1TD E BLOWER ASSY 1 3 1PE E PLATE 3 4 1PE E BOLT, BLOWER HOLDING 3 5 1HP E CAP, RADIATOR 1 6 5TG PIPE BOLT, FLANGE O-RING 1 9 1TD E HOSE TD E HOSE CLIP HOSE CLAMP ASSY GROMMET COLLAR BOLT, WITH WASHER 4 8

15 FIG. 7 OIL PUMP 1 18P OIL PUMP ASSY 1 2 5TA ROTOR ASSY PIN, DOWEL CIRCLIP PIN, DOWEL BOLT 2 7 2S SHAFT, IDLE GEAR SCREW P GEAR, OIL PUMP IDLE CIRCLIP WASHER, PLATE P HOUSING, STRAINER P STRAINER, OIL BOLT, HEXAGON SOCKET HEAD PIN, DOWEL P STRAINER 2 2 9

16 FIG. 8 INTAKE 1 18P JOINT, CARBURETOR BOLT HOSE CLAMP ASSY 1 4 5S SENSOR, PRESSURE SCREW, TAPPING HOSE CLAMP ASSY P PLATE P CASE, AIR CLEANER FP SENSOR, AIR TEMPERATURE SCREW, PAN HEAD TD JOINT, AIR CLEANER TJ PIPE GH HOOK TG ELEMENT, AIR CLEANER TG GUIDE P FUNNEL P CAP, CLEANER CASE KM SEAL HOSE CLAMP ASSY P 1442F 00 PROTECTOR RIVET, BLIND WASHER, PLATE D HOLDER, GUIDE ES SEAL V SEAL A1 CLIP WASHER 1 10

17 FIG. 8 INTAKE BOLT, WING P DAMPER P GROMMET COLLAR BOLT, FLANGE P BREATHER ASSY BOLT, FLANGE P 1531A 00 HOSE, BREATHER A6 CLIP P 1532A 00 HOSE, BREATHER A6 CLIP CLIP 1 11

18 FIG. 9 THROTTLE BODY ASSY 1 1 1TD THROTTLE BODY ASSY 1 2 8FP RUBBER, INJECTOR 1 3 3B INJECTOR 1 4 5PS O-RING P DELIVERY PIPE ASSY CC SCREW 2 7 3B THROTTLE SENSOR ASSY 1 8 5JW PLATE 1 9 5YP O-RING SCREW, PAN HEAD LP O-RING S NUT, CABLE ADJUSTING UY GUIDE, CABLE H O-RING FP CLIP P HOSE, AIR P PIPE P HOSE BOLT 3 12

19 FIG. 10 EXHAUST 1 18P PIPE, EXHAUST P PROTECTOR, EXHAUST PIPE WASHER, PLATE SCREW, BIND WASHER, PLAIN 3 6 3VD GASKET, EXHAUST PIPE NUT, FLANGE 2 8 1TD E MUFFLER COMP TD E SPARK ARRESTER ASSY BG E GASKET, SILENCER BOLT, FLANGE TD E GASKET, MUFFLER TD E CAP, SILENCER SCREW TD E PROTECTOR, MUFFLER SCREW, BIND WASHER, PLATE WASHER BE BAND, SILENCER BOLT, FLANGE WASHER, PLATE TD HOSE, BEND CLIP GD AIR INDUCTION SYSTEM ASSY TD E HOSE, BEND A0 CLIP TD AIR CUT VALVE ASSY 1 13

20 FIG. 10 EXHAUST 28 1TD HOSE, BEND CLIP TD F117A 00 STAY BOLT, BUTTON HEAD BOLT, BUTTON HEAD CLAMP 1 14

21 FIG. 11 CRANKCASE 1 18P CRANKCASE ASSY PIN, DOWEL 2 3 2S NOZZLE BUSH, SOLID BOLT BOLT BOLT BOLT BOLT, FLANGE GASKET JT PLATE, BEARING COVER P PLATE, BEARING COVER SCREW, COUNTERSUNK SCREW S PLATE, BEARING COVER S PLATE, STOPPER BOLT, FLANGE PIN, DOWEL O-RING N2 COLLAR PIN, DOWEL CLAMP CLAMP BOLT P HOLDER BOLT, FLANGE GASKET 1 15

22 FIG. 12 CRANKCASE COVER P COVER, CRANKCASE PLUG, STRAIGHT SCREW A3 O-RING PLUG, STRAIGHT SCREW O-RING P PLUG, OIL LEVEL O-RING P GASKET, CRANKCASE COVER PIN, DOWEL BOLT, FLANGE BOLT, FLANGE P COVER P GASKET, COVER PINION PIN, DOWEL BOLT, FLANGE TA HOLDER, CLUTCH CABLE BOLT P COVER, CRANKCASE P GUIDE, CHAIN BOLT P COVER, CRANKCASE OIL SEAL WASHER, PLATE (T=1.0) CIRCLIP TG COVER, GENERATOR P GASKET PIN, DOWEL 2 16

23 FIG. 12 CRANKCASE COVER BOLT, FLANGE BOLT, FLANGE P 1243A 00 HOSE A0 CLIP D ELEMENT ASSY, OIL CLEANER BE COVER, OIL ELEMENT O-RING O-RING BOLT, HEXAGON SOCKET HEAD BOLT SEAT, CHECK BALL BALL E0 SPRING, COMPRESSION P GASKET, CRANKCASE COVER PIN, DOWEL BOLT, FLANGE BOLT, FLANGE CLAMP BOLT, FLANGE TD PIPE, BREATHER WASHER, PLATE BOLT E9 BOLT CLAMP A6 CLIP P CLAMP P COVER 1 17

24 FIG. 12 CRANKCASE COVER P 1541A 00 STAY, CRANKCASE COVER BOLT BE PIPE, WATER O-RING 1 18

25 FIG. 13 STARTER 1 18P DAMPER ASSY BEARING P SHAFT P GEAR, IDLER P GEAR TJ STARTER ONE-WAY ASSY BOLT, HEXAGON SOCKET HEAD 6 19

26 FIG. 14 CLUTCH 1 2S GEAR, PRIMARY DRIVE WASHER, CONICAL SPRING NUT 1 4 1TD PRIMARY DRIVEN GEAR COMP TD BOSS, CLUTCH 1 6 4X PLATE, CLUTCH TD PLATE, CLUTCH VY PLATE, FRICTION 5 9 1TD PLATE, FRICTION TD PLATE, PRESSURE TD SPRING, CLUTCH TD WASHER TD PLATE, PRESSURE TD SCREW, SPRING TD SPRING.,CUSHION TD PLATE, SEAT JG PLATE, CLUTCH 2 1 UR T=1.2 4X PLATE, CLUTCH 2 1 UR T=1.6 1TA PLATE, CLUTCH 2 1 UR T= JG PLATE, CLUTCH 2 1 UR T=1.2 4X PLATE, CLUTCH 2 1 UR T=1.6 1TA PLATE, CLUTCH 2 1 UR T= TA PLATE, THRUST TD ABSORBER WASHER, LOCK NUT TG ROD, PUSH

27 FIG. 14 CLUTCH BEARING L6 WASHER, PLATE CIRCLIP BALL P ROD, PUSH P AXLE, PUSH LEVER P LEVER, PUSH WASHER, PLATE CIRCLIP BEARING OIL SEAL CIRCLIP SPRING, TORSION 1 21

28 FIG. 15 TRANSMISSION BEARING P AXLE, MAIN P GEAR, 5TH PINION (21T) WASHER CIRCLIP P GEAR, 4TH PINION (21T) P GEAR, 3RD PINION (19T) P GEAR, 2ND PINION (15T) BEARING BEARING P DRIVE AXLE ASSY P GEAR, 2ND WHEEL (30T) WASHER CIRCLIP P GEAR, 3RD WHEEL (31T) WASHER, CLAW WASHER, CLAW COLLAR P GEAR, 4TH WHEEL (28T) P GEAR, 5TH WHEEL (23T) P GEAR, 1ST WHEEL (35T) WASHER, PLATE (T=1.0) BEARING OIL SEAL COLLAR O-RING P SPROCKET, DRIVE (14T) 1 22

29 FIG. 15 TRANSMISSION WASHER, PLATE NUT S PLATE, COVER BOLT, FLANGE 2 23

30 FIG. 16 SHIFT CAM & FORK 1 18P CAM, SHIFT BEARING 1 3 2S SEGMENT 1 4 2S STOPPER LEVER ASSY SPRING, TORSION BOLT WASHER, PLATE P FORK, SHIFT P FORK, SHIFT P FORK, SHIFT P BAR, SHIFT FORK GUIDE WG BAR, SHIFT FORK GUIDE P SHIFT SHAFT ASSY SPRING, TORSION E1 WASHER, PLATE PIN, DOWEL OIL SEAL XJ PIN, SHIFT XJ ROLLER, SHIFT LEVER P LEVER, SHIFT XJ PAWL, SHIFTER G5 SPRING, COMPRESSION XJ PIN, PAWL BE GUIDE, SHIFT BOLT P SHIFT PEDAL ASSY YT COVER, SHIFT PEDAL 1 24

31 FIG. 16 SHIFT CAM & FORK BOLT 1 25

32 FIG. 17 FRAME 1 1TD F FRONT FRAME COMP P F REAR FRAME COMP SCREW P 2133H 00 BRKT., BRAKE PIPE RIVET, BLIND (4.8X17 YELLOW) P STAY, ENGINE BOLT WASHER, PLATE BOLT, HEXAGON SOCKET HEAD WASHER, PLATE P STAY, ENGINE P STAY, ENGINE BOLT, FLANGE WASHER, PLATE BOLT, FLANGE NUT, SELF-LOCKING BOLT, FLANGE NUT, SELF-LOCKING P PROTECTOR, ENGINE DAMPER, PLATE BOLT TG TENSIONER BEARING WASHER, PLATE N4 COLLAR BOLT, FLANGE BEARING 1 26

33 FIG. 17 FRAME OIL SEAL OIL SEAL GT HOLDER, BEARING PLUG PLUG P 2111A 00 CAP, MAIN PIPE P CLAMP, WIRE HARNESS P CLAMP, WIRE HARNESS RIVET P REINF., SEAT RAIL KJ DAMPER, SEAT XY DAMPER S2 2177M 00 DAMPER, LOCATING C3 2214F 00 DAMPER XY MOLE YX 2171L 00 MOLE, SIDE COVER HOSE (L18) BOLT, FLANGE COLLAR PE F TOOL KIT NV 2811A 01 GAUGE, AIR 1 27

34 FIG. 18 FRONT FENDER 1 1TD F FRONT FENDER ASSY 1 2 4XV 2177L 01 PLATE, SPRING 2 3 8HG HEAD 4 4 1TD F STAY, FENDER TD F STAY, FENDER XV 2177L 01 PLATE, SPRING GROMMET BOLT 4 28

35 FIG. 19 REAR FENDER 1 1TD F REAR FENDER ASSY P STAY, FENDER BOLT, BUTTON HEAD P STAY, FENDER BOLT, BUTTON HEAD 1 6 4XV 2177L 01 PLATE, SPRING 2 7 8HG HEAD 4 8 1TD PROTECTOR P 2163E 00 COVER, TD 2163F 00 COVER, REAR FENDER TD F FLAP TD 2164F 00 STAY TD 2164H 00 STAY SCREW, BINDING BOLT, BUTTON HEAD COLLAR NUT, SELF-LOCKING WASHER, PLATE TD F FLAP TD 2164G 00 STAY TD 2164J 00 STAY SCREW, BINDING BOLT, BUTTON HEAD COLLAR NUT, SELF-LOCKING WASHER, PLATE BOLT, FLANGE 4 29

36 FIG. 19 REAR FENDER WASHER, PLATE NUT, SELF-LOCKING BOLT, BUTTON HEAD WASHER, PLATE P 2163A 00 COVER, REAR FENDER BOLT 1 30

37 FIG. 20 SIDE COVER 1 18P TANK, RECOVERY BOLT, WITH WASHER S CAP H ELBOW CLIP CLIP CLIP HOSE (L350) M11 CLAMP HOSE (L730) CLAMP M08 CLAMP TD E COVER, RADIATOR RIVET TD F171A 40 COVER, TOP W PAD, SEAT HG HEAD TD F COVER, SIDE TD F COVER, SIDE LJ 2414J 00 DAMPER, PLATE RIVET TD F COVER, SIDE TD F COVER, SIDE XV 2177L 01 PLATE, SPRING COLLAR BOLT,HEX. SOCKET BUTTON BOLT 2 31

38 FIG. 21 REAR ARM 1 18P REAR ARM COMP TG HUB, REAR BEARING OIL SEAL 2 5 5TG SPACER, BEARING 1 6 1S O-RING 2 7 5TG BRACKET, CALIPER COLLAR BOLT, HEXAGON SOCKET HEAD CIRCLIP O-RING O-RING BOLT, HEXAGON SOCKET HEAD WASHER, PLATE TG SEAL, DUST BEARING BUSH, SOLID OIL SEAL (DC ) COLLAR W1 COLLAR X COVER, THRUST YF WASHER PLUG P SHAFT, PIVOT WASHER, PLATE NUT, SELF-LOCKING TD F217A 00 ARM, RELAY 1 32

39 FIG. 21 REAR ARM BEARING OIL SEAL COLLAR BEARING COLLAR OIL SEAL K COVER, THRUST BOLT, FLANGE NUT, SELF-LOCKING BOLT, FLANGE NUT, SELF-LOCKING TD F217F 00 ROD, CONNECTING BEARING COLLAR OIL SEAL K COVER, THRUST BOLT, FLANGE NUT, U WASHER, PLATE P SEAL, GUARD BOLT P GUARD TG GUARD, CHAIN RIVET, BLIND (4.7X16.4 BLACK) WASHER, PLATE BOLT, FLANGE COLLAR 4 33

40 FIG. 21 REAR ARM WASHER, PLATE 4 34

41 FIG. 22 REAR SUSPENSION 1 1TD F SHOCK ABSORBER ASSY, REAR 1 2 1HP F LABEL, WARNING BOLT, FLANGE WASHER, PLATE NUT, U COLLAR BOLT, PIN HOLE HEX WASHER, PLATE PIN, COTTER 1 35

42 FIG. 23 STEERING 1 1TD F COLUMN, STEERING TD F ARM, PITMAN 1 3 1TD ROD, TIE 2 4 1S JOINT, UNIVERSAL S JOINT, UNIVERSAL NUT NUT 2 (RH. THREAD) NUT, CASTLE WASHER PIN, COTTER P HOLDER, HANDLE UPPER P HOLDER, HANDLE UNDER BOLT, FLANGE NUT, SELF-LOCKING WASHER, PLATE S F BEARING, STEERING OIL SEAL PE F BRACKET, STEERING LOWER BOLT, HEXAGON UY WASHER, LOCK R0 COLLAR WASHER, PLATE NUT, SELF-LOCKING PIN, COTTER R6 COLLAR COLLAR 1 36

43 FIG. 24 FRONT SUSPENSION & WHEEL 1 1TD F FRONT LOWER ARM COMP. (LEFT) 1 2 5LP BALL JOINT CIRCLIP 1 4 1TD F FRONT LOWER ARM COMP. (RIGHT) 1 5 5LP BALL JOINT CIRCLIP 1 7 1TD F FRONT UPPER ARM COMP. (LEFT) 1 8 5LP BALL JOINT CIRCLIP TD F FRONT UPPER ARM COMP. (RIGHT) LP BALL JOINT CIRCLIP BUSH, SOLID BUSH, SOLID R3 COLLAR COLLAR COLLAR YT COVER, THRUST YT COVER, THRUST BOLT, FLANGE BOLT, FLANGE WASHER, PLATE WASHER, PLATE NUT, SELF-LOCKING NUT, SELF-LOCKING NIPPLE, GREASE NIPPLE, GREASE 2 37

44 FIG. 24 FRONT SUSPENSION & WHEEL 28 1TD F SHOCK ABSORBER ASSY HP F LABEL, WARNING BOLT, FLANGE NUT, SELF-LOCKING WASHER, PLATE BOLT, FLANGE COLLAR NUT, SELF-LOCKING WASHER, PLATE P STEERING KNUCKLE ASSY (LEFT) P STEERING KNUCKLE ASSY (RIGHT) WASHER NUT, CASTLE PIN, COTTER 4 38

45 FIG. 25 FUEL TANK 1 1TD F FUEL TANK COMP KM CAP ASSY GROMMET H4 COLLAR K6 WASHER, PLATE BOLT, BUTTON HEAD GROMMET K6 WASHER, PLATE J1 COLLAR BOLT, FLANGE HOSE TD F414H 00 DAMPER, PLATE NUT, SPRING P 2247A 00 HOSE DAMPER, PLATE RR DAMPER, RUBBER P FUEL PUMP COMP P BRACKET, FUEL PUMP S O-RING NUT, CROWN P 2464V 00 CASE, CAP P 2467E 00 CAP P PIPE, FUEL

46 FIG. 26 SEAT 1 18P SINGLE SEAT ASSY P 2470F 20.SEAT COVER COMP STOPPER, MAIN STAND DAMPER, SEAT W PAD, SEAT P SPACER P DAMPER, SEAT 2 40

47 FIG. 27 FRONT WHEEL 1 1TD F WHEEL COMP TIRE (AT21X7R10 MS21**TL) 1 MAXXIS VALVE, RIM (TR413) 1 MAXXIS 4 1TD F WHEEL COMP TIRE (AT21X7R10 MS21**TL) 1 MAXXIS VALVE, RIM (TR413) 1 MAXXIS 7 1PE F510D 00 HUB ASSY BOLT, SERRATION 4 9 5LP SPACER, BEARING BEARING BEARING OIL SEAL OIL SEAL NUT, FLANGE WASHER COLLAR WASHER, PLATE R1 COLLAR WASHER, PLATE NUT, CASTLE PIN, COTTER S COVER, PLATE 2 41

48 FIG. 28 FRONT BRAKE CALIPER 1 4XE F582T 11 DISC, BRAKE (LEFT) BOLT 8 3 5TG 2580T 11 CALIPER ASSY (LEFT) 1 4 5TG W PISTON ASSY, CALIPER 1 5 3LC W CALIPER SEAL KIT 1 6 1UY BOOT JD BOOT, CALIPER 1 8 3JD SUPPORT, PAD 1 9 1UY W BLEED SCREW KIT UY BOLT UY WASHER, SPRING JD BOLT JD NUT TG W BRAKE PAD KIT TG PIN, PAD S SHIM, CALIPER TG 2580U 11 CALIPER ASSY (RIGHT) TG W PISTON ASSY, CALIPER LC W CALIPER SEAL KIT UY BOOT JD BOOT, CALIPER JD SUPPORT, PAD UY W BLEED SCREW KIT UY BOLT UY WASHER, SPRING JD BOLT JD NUT 1 42

49 FIG. 28 FRONT BRAKE CALIPER 28 5TG W BRAKE PAD KIT TG PIN, PAD S SHIM, CALIPER BOLT, FLANGE TG 2514A 00 RING, WHEEL SCREW 4 43

50 FIG. 29 REAR WHEEL 1 1TD F REAR WHEEL COMP TIRE (AT20X10R9 MS22**TL) 1 MAXXIS VALVE, RIM (TR413) 1 MAXXIS 4 1TD F REAR WHEEL COMP TIRE (AT20X10R9 MS22**TL) 1 MAXXIS VALVE, RIM (TR413) 1 MAXXIS 7 18P COLLAR, WHEEL BOLT, SERRATION NUT, FLANGE WASHER WASHER, PLATE NUT, CASTLE PIN, COTTER P COLLAR, SPROCKET AXLE TG SPROCKET, DRIVEN (38T) BOLT NUT, SELF-LOCKING TD F BRACKET, DISC COLLAR P AXLE, WHEEL NUT WASHER, CONICAL SPRING BOLT, SET P CIRCLIP O-RING CHAIN (DID520MXV4-98LE) 1 44

51 FIG. 30 REAR BRAKE CALIPER 1 1S3 2582W 20 DISK, REAR BRAKE BOLT 4 3 5TG 2580W 21 CALIPER ASSY, REAR TG W PISTON ASSY, CALIPER 1 5 5TG W CALIPER SEAL KIT 1 6 5TG RUBBER, BUSHING 1 7 5UG BOLT, FITTING 2 8 5TG SHAFT L 1 9 1UY BOOT UY NUT TG ADJUST BOLT LD SPRING, PAD TG W BRAKE PAD KIT DH PIN, PAD UY BOOT SP PIN, SLIDE JD BOOT, CALIPER SP BOLT UY W BLEED SCREW KIT TG SPRING, RETURN A9 BOLT, FLANGE 2 45

52 FIG. 31 STEERING HANDLE & CABLE 1 5D HANDLEBAR COLLAR RIVET, BLIND 1 4 5FU F GRIP P 2622H 00 WEIGHT GROMMET 4 7 1S THROTTLE LEVER ASSY 1 8 1S3 2628F 00.CAP, GEAR 1 9 1S3 2628G 00.GASKET NUT, U NV WASHER NV SPRING NV COLLAR NV 2625K 00.COLLAR OIL SEAL NV WASHER S3 2625G 00.LEVER, THROTTLE SCREW NUT SCREW, PAN HEAD S HOLDER, LEVER LOWER SCREW, PAN HEAD WASHER, SPRING P CABLE, THROTTLE UY COLLAR TG COVER, HANDLE LEVER P CABLE, CLUTCH 1 46

53 FIG. 31 STEERING HANDLE & CABLE 28 1C BOOT, CABLE P WIRE, BRAKE P PROTECTOR, HANDLEBAR BAND, SWITCH CORD CLAMP 1 47

54 FIG. 32 FRONT MASTER CYLINDER 1 5D3 2583T 02 MASTER CYLINDER ASSY 1 2 5D3 W CYLINDER KIT, MASTER 1 3 4TT DIAPHRAGM, RESERVOIR 1 4 5YU CAP, RESERVOIR SCREW, FLAT HEAD 2 6 5MV BRACKET, MASTER CYLINDER 1 7 5MV BOLT, FITTING 2 8 5D LEVER NUT, WITH WASHER D FRONT STOP SWITCH ASSY B4 2589F 30.BOLT, LEVER SCREW, PAN HEAD WASHER, SPRING WASHER, PLATE TD F HOSE, BRAKE TD F HOSE, BRAKE P HOLDER, BRAKE HOSE P HOLDER, BRAKE HOSE BOLT TD F PIPE, BRAKE BOLT, FLANGE NUT GU CIRCLIP BOLT, UNION WASHER, PLATE 6 48

55 FIG. 33 STAND & FOOTREST 1 1TD F FOOTREST BOLT, FLANGE BOLT, FLANGE 1 4 1TD F FOOTREST BOLT, FLANGE BOLT, FLANGE SPRING, TENSION P PEDAL, BRAKE P BOLT WASHER, PLATE CLIP BOLT, SQUARE NUT, SELF-LOCKING 1 49

56 FIG. 34 REAR MASTER CYLINDER 1 1S3 2580E 00 REAR MASTER CYLINDER ASSY 1 2 1S3 W CYLINDER KIT, MASTER 1 3 1AE 2582A 00.JOINT O-RING SCREW, PAN HEAD WASHER, SPRING WASHER, PLATE 1 8 4SS NUT 2 9 2YK JOINT BOLT, BUTTON HEAD P COVER BOLT, BUTTON HEAD PIN, CLEVIS WASHER, PLATE PIN, COTTER TD F HOSE, RESERVOIR CLIP CLIP JJ TANK, RESERVOIR XP CAP, RESERVOIR VN DIAPHRAGM, RESERVOIR VN BUSH,DIAPHRAGM P DAMPER BOLT, WITH WASHER P BRACKET BOLT, FLANGE TD F HOSE, BRAKE 1 50

57 FIG. 34 REAR MASTER CYLINDER WASHER, PLATE BOLT, UNION TD F HOLDER, BRAKE HOSE TD F HOLDER, CABLE BOLT, FLANGE 2 51

58 FIG. 35 GUARD 1 18P 2845N 20 BAR, CARRY FRONT BOLT, FLANGE P 2845R 30 BAR, CARRY REAR GROMMET COLLAR BOLT, FLANGE BOLT, FLANGE 4 8 5TG WASHER, SPECIAL P WASHER, SPECIAL XV 2177L 01 PLATE, SPRING 2 52

59 FIG. 36 GENERATOR 1 18P STATOR ASSY P ROTOR ASSY P CLAMP BOLT, HEXAGON SOCKET HEAD BOLT, HEXAGON SOCKET HEAD BOLT, HEXAGON SOCKET HEAD NUT WASHER, PLATE 1 53

60 FIG. 37 STARTING MOTOR 1 18P MOTOR ASSY P BRUSH SET P BOLT 2 4 4B GASKET 2 5 1FK O-RING 1 6 4XV 8182A 00.NUT P CORD, STARTER MOTOR 1 8 4XV 8182A 00 NUT BOLT, FLANGE 2 54

61 FIG. 38 HEADLIGHT 1 4KB BULB (12V-30/30W) 1 2 5TG HEADLIGHT UNIT ASSY 1 3 5TG RIM, HEADLIGHT COVER TG SOCKET CORD ASSY GROMMET COLLAR BOLT, FLANGE WASHER, PLATE 1 9 4KB BULB (12V-30/30W) TG HEADLIGHT UNIT ASSY TG RIM, HEADLIGHT COVER TG SOCKET CORD ASSY GROMMET COLLAR BOLT, FLANGE WASHER, PLATE 1 55

62 FIG. 39 TAILLIGHT 1 1S TAILLIGHT UNIT ASSY GROMMET COLLAR SCREW, TAPPING P COVER, TAILLIGHT P 8411K 00 PLATE, INSULATOR CLAMP 1 56

63 FIG. 40 HANDLE SWITCH & LEVER 1 1S SWITCH, HANDLE P LEVER HOLDER ASSY (LEFT) 1 3 5TG HOLDER, LEVER TJ LEVER BOLT 1 6 5TA BOLT, ADJUSTING NUT, U 1 8 5HD BOLT, CABLE ADJUSTING 1 9 5KM SWITCH TG HOLDER, LEVER LOWER BOLT TG BRACKET, LEVER D PLATE, GUIDE TG LEVER, BRAKE TG COLLAR, LEVER BOLT, BUTTON HEAD PLUG BOLT, BUTTON HEAD 2 57

64 FIG. 41 ELECTRICAL 1 1 1TD 8591A 00 ENGINE CONTROL UNIT ASSY BOLT, FLANGE P BRACKET, UNIT GROMMET COLLAR BOLT, FLANGE CLAMP P IGNITION COIL ASSY SCREW, TAPPING P PLUG CAP ASSY P BRACKET PLUG A6 NUT, SPRING GROMMET COLLAR PLUG BOLT,HEX. SOCKET BUTTON GB NEUTRAL SWITCH ASSY GASKET YP THERMOSENSOR ASSY GASKET P SENSOR, SPEED D O-RING BOLT BN RECTIFIER & REGULATOR ASSY BOLT, FLANGE P STAY, REGULATOR 1 58

65 FIG. 41 ELECTRICAL GROMMET COLLAR WASHER, PLATE BOLT, FLANGE TD H BATTERY ASSY (YTZ7S) P SEAT, BATTERY P BRACKET, BATTERY BOLT, FLANGE PLUG P COVER, BATTERY D SEAT, BATTERY MP DAMPER HC PLATE, FOOTREST P W WIRE, PLUS LEAD CLAMP P WIRE, MINUS LEAD P WIRE, LEAD P STARTER RELAY ASSY (RC19-084A) BOLT, FLANGE SH MAIN SWITCH ASSY HN CAP, KEY HN NUT, MAIN SWITCH P PILOT LIGHT ASSY P 8361L 00 BRACKET, INDICATOR GROMMET COLLAR WASHER, PLATE 2 59

66 FIG. 41 ELECTRICAL BOLT, BUTTON HEAD TD WIRE HARNESS ASSY D CIRCUIT BREAKER ASSY D THERMO SWITCH ASSY WA DIODE ASSY WP DIODE ASSY P STOP SWITCH ASSY P 8246B 10 COVER TD 2177N 00 DAMPER, LOCATING BOLT, FLANGE TP RELAY ASSY (1TP-00) DM RELAY ASSY (G8HN-1C4T-DJ-Y52) PS SENSOR, LEAN ANGLE BOLT WASHER, PLATE P 8212B 00 BOX, BATTERY GROMMET BOLT, FLANGE COLLAR P 8254E 00 INSULATOR CLAMP RU 8252U 00 COVER CLAMP 2 60

67 FIG. 42 GRAPHICS 1 1TD F GRAPHIC TD F GRAPHIC TD F15A9 50 GRAPHIC TD F165E 20 GRAPHIC, FRONT 1 5 1TD F165F 20 GRAPHIC, FRONT 1 6 1TD F GRAPHIC KN 2836B 10 TUNING FORK MARK 1 8 1TD F165G 20 GRAPHIC, REAR (LH) 1 9 1TD F165H 20 GRAPHIC, REAR (RH) TD F EMBLEM TD F EMBLEM TD F EMBLEM TD F EMBLEM TD F173E 20 GRAPHIC TD F173F 20 GRAPHIC

68 FIG. 43 EMBLEM & LABEL 1 1 4XE F LABEL, WARNING 1 ENGLISH 2 4XE F RIVET 6 3 4XE F WASHER, FENDER MOLD 6 4 1P0 F816L 00 LABEL, WARNING AGE 1 ENGLISH 5 4XE F RIVET 4 6 4XE F WASHER, FENDER MOLD 4 7 1TD F816M U0 LABEL, WARNING TIRE & LOAD 1 ENGLISH 8 4XE F RIVET 4 9 4XE F WASHER, FENDER MOLD C2 F151H 00 LABEL 5 1 ENGLISH 11 4XE F RIVET XE F WASHER, FENDER MOLD TD F415E 00 LABEL, CAUTION 1 ENGLISH 14 3C2 F819R 10 TAG, WARNING P0 F POUCH 1 62

69 NUMERICAL INDEX 1TD VY 1111G TA TA TD P S S S S S TD P P P P P P TG TG TG TD P TA TA TJ TJ GY BE AA WG M SV TA GM FV 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 TD TD TA FM P BE S P P P C P 1243A P TG BE P P TA P S P P P D BE P P FP P TD B P P P FP H LP PS UY S CC P P P P TJ P 1442F P GH TG KM TD V TG D ES P YP P VD P BE GD TJ TD TD TD TD JW P S P 1531A P 1532A P P P JT P S TD P P TG P 1541A P P P TA P P P P P P P P P TJ S TD TA TD VY TD TA X JG TD TD TD P TD TD TG P TD P TD TD TD P P P P P P P P P P P P P S P P YT P S BE XJ XJ XJ XJ S P P P P WG P S P 2111A P P P P P P P 2133H P RR XY P 2163A P 2163E TD 2163F P P TD 2164F TD 2164G TD 2164H TD 2164J TD YX 2171L MP XV 2177L S2 2177M TD 2177N H P S P X K P YF C3 2214F P TG TG P TG P 2247A S P P P P YT LP TD S S GT UY LJ 2414J S P KM P 2464V P 2467E P 2470F P

70 NUMERICAL INDEX 18P KJ P W LP S TG 2514A TG TG P P P P TG D TG TG TG S3 2580E TG 2580T TG 2580U TG 2580W S AE 2582A S3 2582W MV UG D3 2583T YU XP VN TT VN GU MV P P JJ P B4 2589F SP JD JD JD TG JD UY SP DH LD UY UY JD TG UY UY TG TG TG D P NV P 2622H S UY NV S3 2625G NV 2625K S3 2628F S3 2628G NV P P TA P C TG NV P P SS YK P HC P NV 2811A P TG XY KN 2836B HG P 2845N P 2845R D P P P P P P XV 8182A B FK P P P TP DM BN WP WA P P D P P P 8212B D P P S P 8246B SH RU 8252U P GB P P 8254E D HN PS HN TD P TG S TG KM P P 8361L P TJ D TG HD S D TG P 8411K TG TG TG TG KB TG S P YP B FP TD 8591A P P TD E TD E HP E TD E PE E TD E TD E PE E TD E TD E TD E BG E TD E TD E TD E TD F TD F117A P F TD F TD F TD F C2 F151H XE F XE F XE F TD F TD F TD F TD F15A TD F TD F TD F165E TD F165F TD F165G TD F165H TD F TD F TD F171A TD F TD F TD F173E TD F173F TD F TD F TD F TD F TD F TD F217A TD F217F TD F HP F TD F TD F TD F TD F TD F TD F S F TD F TD F PE F TD F TD F414H TD F415E PE F510D TD F TD F TD F XE F582T TD F TD F TD F TD F TD F TD F FU F TD F TD F PE F P0 F816L TD F816M U P0 F C2 F819R TD H D3 W S3 W TG W TG W TG W TG W LC W UY W TG W TG W

71 NUMERICAL INDEX 18P W A E A K L E H J N R R R W N R M M A A A A A E G