YFM25BY (1P0H) U.S.A. 1H1P0-110E1

Transcription

1 YFM25BY (1P0H) U.S.A. 1H1P0-110E1 ( )

2 YFM25BY PARTS CATALOGUE 2008 by Yamaha Motor Co., Ltd. 1st edition, July 2008 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 Q TY 2F FRONT FLASHER LIGHT ASSY BULB (6V 18W) 1 4. Applicable colours of graphics are represented in the as shown below. PART 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 PDG(*) PASTEL DEEP GREEN 00K0 RTR(*) ROMANTIQUE ROUGE 00TR SMJ(*) BLACK METALLIC J 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. 1P0H 010 U.S.A. Country (destination) Model Code Production Code No. Country (destination) (3) Model Label Affixing Location (4) Colouring Information Model Code 1P0H Colouring Type Code Colour Code Colour Name Abbreviation A 00TR ROMANTIQUE ROUGE RTR B 00K0 PASTEL DEEP GREEN PDG T 0906 BLACK METALLIC J SMJ

6 CONTENTS ENGINE CYLINDER HEAD... 1 CYLINDER... 3 CRANKSHAFT & PISTON... 4 VALVE... 6 CAMSHAFT & CHAIN... 7 INTAKE... 8 OIL PUMP... 9 CARBURETOR EXHAUST CRANKCASE CRANKCASE COVER STARTER STARTER CLUTCH CLUTCH TRANSMISSION MIDDLE DRIVE GEAR DRIVE SELECTOR SHIFT CAM & FORK SHIFT SHAFT CHASSIS FRAME FRONT FENDER REAR FENDER SIDE COVER REAR ARM DRIVE SHAFT REAR SUSPENSION FRONT SUSPENSION & WHEEL STEERING FUEL TANK SEAT FRONT WHEEL FRONT BRAKE CALIPER REAR WHEEL STEERING HANDLE & CABLE FRONT MASTER CYLINDER STAND & FOOTREST GUARD GENERATOR STARTING MOTOR HEADLIGHT TAILLIGHT HANDLE SWITCH & LEVER ELECTRICAL EMBLEM & LABEL INDEX NUMERICAL INDEX... 56

7 FIG. 1 CYLINDER HEAD PART 1 5XG E CYLINDER HEAD ASSY 1 2 5H GUIDE, VALVE CIRCLIP SCREW, HEXAGON GASKET 1 6 5XG E ABSORBER XG E ABSORBER GH GASKET, CYLINDER HEAD PIN, DOWEL PIN, DOWEL GASKET BOLT, FLANGE C3 WASHER, PLATE BOLT G0 WASHER, PLATE XG E BREATHER ASSY XG E PLATE, BREATHER XE PIPE, BREATHER A4 CLIP O-RING BOLT, FLANGE A2 O-RING SCREW, PAN HEAD XG E COVER, CYLINDER HEAD SIDE XG E COVER, CYLINDER HEAD SIDE O-RING BOLT 5 1

8 FIG. 1 CYLINDER HEAD PART 28 3UR E111F 00 PLATE BOLT WASHER, LOCK PLUG, SPARK (NGK DR7EA) 1 2

9 FIG. 2 CYLINDER PART 1 5XG E CYLINDER O-RING 1 3 5VC GASKET, CYLINDER O-RING PIN, DOWEL BOLT 2 3

10 FIG. 3 CRANKSHAFT & PISTON PART 1 5XG E CRANKSHAFT ASSY 1 2 5XG WE CRANK SUB ASSY XG E CRANK UR E PIN, CRANK J3.BEARING 1 6 5XG E ROD, CONNECTING BEARING KEY, WOODRUFF 1 9 4BD Y0 PISTON (STD) 1 4BD PISTON (0.50MM O/S) 1 AP 4BD PISTON (1.00MM O/S) 1 AP 10 5XG E PISTON RING SET (STD) 1 5XG E PISTON RING SET (0.50MM O/S) 1 AP 5XG E PISTON RING SET (1.00MM O/S) 1 AP 11 5XG E PIN, PISTON CIRCLIP XG E GEAR, DRIVE XG E GEAR, BALANCE WEIGHT XG E WEIGHT BEARING KEY, STRAIGHT WASHER, LOCK NUT KEY, WOODRUFF F8 WASHER, PLATE WASHER, SPRING BOLT 1 4

11 FIG. 3 CRANKSHAFT & PISTON PART O-RING CIRCLIP 1 5

12 FIG. 4 VALVE PART 1 5XG E VALVE, INTAKE 1 2 5XG E VALVE, EXHAUST 1 3 4G SEAT, VALVE SPRING 2 4 4G SPRING, VALVE INNER 2 YELLOW 5 4G SPRING, VALVE OUTER 2 YELLOW 6 5H SEAL, VALVE STEM 2 7 4G RETAINER, VALVE SPRING 2 8 4G COTTER, VALVE 4 9 5XG E ARM, VALVE ROCKER UR E SHAFT, ROCKER UR E SHAFT, ROCKER O-RING NX SCREW, VALVE ADJUSTING NUT 2 6

13 FIG. 5 CAMSHAFT & CHAIN PART 1 5XG E CAMSHAFT XG E SPROCKET, CAM CHAIN PIN, DOWEL BOLT C6 WASHER, PLATE BUSH CHAIN (DID25SH 104L) 1 8 3UR E GUIDE, STOPPER XG E GUIDE, STOPPER GC TENSIONER ASSY, CAM CHAIN FM GASKET, TENSIONER CASE BOLT, FLANGE BOLT, HEXAGON WASHER, PLATE 2 7

14 FIG. 6 INTAKE PART 1 1P JOINT, CARBURETOR O-RING BOLT HOSE CLAMP ASSY 1 5 5UH E PIPE 1 6 4XE E CASE, AIR CLEANER JN6 E CLIP, CAP FITTING 3 8 4XE E SEAL 1 9 4XE E CAP, CLEANER CASE XE E SEAL XE E CLIP, DRAIN CLEANER XE E ELEMENT ASSY, AIR CLEANER A PIPE HOSE CLAMP ASSY P0 E JOINT, AIR CLEANER XE E DUCT HOSE CLAMP ASSY HOSE CLAMP ASSY A PIPE XE E442F 10 PROTECTOR P0 2177C 30 PLATE, EPA OFFROAD ATV 1 1 8

15 FIG. 7 OIL PUMP PART 1 5XG E OIL PUMP ASSY 1 2 5XG E GEAR, PUMP DRIVEN PIN, DOWEL 1 4 4BE GASKET, PUMP COVER SCREW, FLAT HEAD Y STRAINER, OIL SPRING, COMPRESSION 1 8 5XG E PLUG, DRAIN O-RING UH E ELEMENT ASSY, OIL CLEANER XG E COVER, OIL ELEMENT A1 O-RING BOLT BOLT 1 9

16 FIG. 8 CARBURETOR PART 1 1P0 E CARBURETOR ASSY P0 1490J 00.NEEDLE SET 1 3 5DM SPRING, DIAPHRAGM 1 4 5GH DIAPHRAGM ASSY 1 5 5DM VALVE, THROTTLE GH RING 1 7 5FU PILOT SCREW SET 1 WHITE SPRING 8 3H WASHER 1 9 3H O-RING G2 1414E 37.JET, MAIN (#93.8) DM HOLDER O-RING PIN, FLOAT P NEEDLE VALVE SET DM O-RING DM NOZZLE, MAIN KM SCREW HX JET, MAIN (# 80) KB PIPE SCREW, PAN HEAD UH 1410A 00.STARTER SET G JET, POWER (# 60) FV PLUG, DRAIN SCREW, PAN HEAD FU E O-RING SCREW, PAN HEAD NUT, CABLE ADJUSTING 1 10

17 FIG. 8 CARBURETOR PART SCREW, PAN HEAD FN SCREW DM FLOAT FU PIPE SCREW, PAN HEAD WASHER, SPRING WASHER GH CLIP KM JET, PILOT (# 17.5) EL 1490H 00.DIAPHRAGM SET FU E GUIDE, CABLE UH THROTTLE SCREW SET XE CLIP UH PIPE T HOSE FU CONNECTOR WASHER DM SCREW W PIPE A TUBE, FLEXIBLE VINYL 1 11

18 FIG. 9 EXHAUST PART 1 1P0 E PIPE, EXHAUST XE E PROTECTOR, EXHAUST PIPE BOLT, FLANGE 2 4 1P0 E NUT, RING 1 5 1P0 E MUFFLER ASSY ND E GASKET, MUFFLER 1 7 4BE GASKET, EXHAUST PIPE BOLT BOLT, FLANGE WASHER, PLATE 2 12

19 FIG. 10 CRANKCASE PART 1 5XG E CRANKCASE ASSY BOLT PIN, DOWEL BOLT PIN, DOWEL SCREW, PAN HEAD SCREW, PAN HEAD SCREW, PAN HEAD SCREW, PAN HEAD BOLT, HEXAGON SOCKET HEAD SCREW, PAN HEAD 1 13

20 FIG. 11 CRANKCASE COVER 1 PART 1 4BD GASKET, CRANKCASE COVER PIN, DOWEL 2 3 5XG E ADAPTOR OIL SEAL Y0 BEARING V WASHER, THRUST SCREW, FLAT HEAD SCREW, PAN HEAD SCREW, PAN HEAD SCREW, PAN HEAD BD GASKET, CRANKCASE COVER PIN, DOWEL SCREW, PAN HEAD XG E COVER, CRANKCASE XG E SPACER, ENGINE MOUNT PIN, DOWEL SCREW, PAN HEAD XG E PROTECTOR, COVER SCREW, BIND BD GASKET, COVER PINION SCREW, PAN HEAD SCREW, PAN HEAD SCREW, PAN HEAD XG E PLUG, OIL LEVEL O-RING X0 BEARING OIL SEAL 1 14

21 FIG. 11 CRANKCASE COVER 1 PART 28 5XG E PLATE, BEARING COVER SCREW, FLAT HEAD 3 15

22 FIG. 12 STARTER PART 1 1P0 E STARTER ASSY 1 2 1P0 E CASE, STARTER 1 3 1P0 E DRUM, SHEAVE 1 4 1P0 E SPRING, STARTER 1 5 1P0 E PAWL, DRIVE 1 6 1P0 E SPRING, FRICTION 1 7 1P0 E SPRING 1 8 1P0 E PLATE, DRIVE 1 9 1P0 E SCREW P0 E WIRE, STARTER P0 E HANDLE, STARTER P0 E COVER SCREW, PAN HEAD XG E PULLEY, STARTER 1 16

23 FIG. 13 STARTER CLUTCH PART 1 1P0 E GEAR, IDLER XG E SHAFT C9 WASHER, PLATE CIRCLIP 2 5 5XG E GEAR, IDLER WASHER, PLATE A STARTER CLUTCH OUTER ASSY SPRING, COMPRESSION 3 9 1J CAP, STARTER CLUTCH SPRING PIN, DOWEL BOLT 3 17

24 FIG. 14 CLUTCH PART 1 5XG E CLUTCH HOUSING COMP V BEARING, ONE WAY 1 3 5XG E RETAINER, BEARING M6 WASHER, PLATE 1 5 5XG E CLUTCH CARRIER ASSY 1 6 5XG E SPRING, CLUTCH WEIGHT F6 WASHER, PLATE WASHER, LOCK NUT XG E PRIMARY DRIVEN GEAR COMP XG E PLATE, THRUST XG E BOSS, CLUTCH XG E PLATE, FRICTION XG E PLATE, CLUTCH XG E PLATE, PRESSURE J7 SPRING, COMPRESSION XG E PLATE, PRESSURE SCREW, WITH WASHER BEARING V PLATE, PUSH WASHER, LOCK NUT PLUG CIRCLIP 1 18

25 FIG. 15 TRANSMISSION PART 1 5XG E MAIN AXLE ASSY W GEAR, 5TH PINION (28T) WASHER CIRCLIP 1 5 5XG E GEAR, 3RD PINION (22T) 1 6 5XG E GEAR, 4TH PINION (25T) 1 7 5XG E GEAR, 2ND PINION (19T) Y6 BEARING OIL SEAL X2 BEARING XG E DRIVE AXLE ASSY XG E GEAR, 2ND WHEEL (34T) P0 E GEAR, 4TH WHEEL (26T) XG E GEAR, 3RD WHEEL (29T) BD GEAR, 5TH WHEEL (23T) WASHER CIRCLIP XG E GEAR, 1ST WHEEL (34T) WASHER CIRCLIP WASHER, PLATE XG E PLATE, BEARING SCREW X2 BEARING 1 19

26 FIG. 16 MIDDLE DRIVE GEAR PART 1 52G Y MIDDLE GEAR COMP YE BEARING W SHIM, THRUST (0.13T) 1 UR 24W SHIM, THRUST (0.15T) 1 UR 24W SHIM, THRUST (0.2T) 1 UR 24W SHIM, THRUST (0.3T) 1 UR 24W SHIM, THRUST (0.4T) 1 UR 24W SHIM, THRUST (0.5T) 1 UR NUT Y3 BEARING G SHIM, PINION (0.1T) 1 UR 52G SHIM, PINION (0.15T) 1 UR 52G SHIM, PINION (0.2T) 1 UR 52G SHIM, PINION (0.3T) 1 UR 52G SHIM, PINION (0.4T) 1 UR 52G SHIM, PINION (0.5T) 1 UR 7 5XG E CLUTCH, DOG G SHIM, (0.15T) 1 UR 52G SHIM, (0.2T) 1 UR 52G SHIM, (0.3T) 1 UR Y0 BEARING NUT NUT XG E SHAFT, MIDDLE DRIVEN XG E SHIM, (1.0T) 1 UR 5XG E SHIM, (1.1T) 1 UR 5XG E SHIM, (1.2T) 1 UR 20

27 FIG. 16 MIDDLE DRIVE GEAR PART 13 5XG E SHIM, (1.3T) 1 UR 5XG E SHIM, (1.4T) 1 UR 5XG E SHIM, (1.5T) 1 UR 5XG E SHIM, (1.6T) 1 UR 5XG E SHIM, (1.7T) 1 UR 5XG E SHIM, (1.8T) 1 UR 5XG E SHIM, (1.9T) 1 UR BEARING P0 E NUT, BEARING XG E YOKE, JOINT F7 WASHER, PLATE NUT XG E HOUSING, BEARING O-RING BOLT WASHER, PLATE XG E FORK, SHIFT A5 SPRING, COMPRESSION BALL XG E BAR, SHIFT FORK GUIDE SPRING, COMPRESSION P0 E CAP, SPRING XG E812A 00 STOPPER SHAFT ASSY XG E SHAFT CIRCLIP XG E LEVER, SHIFT XG E LEVER 1 21

28 FIG. 16 MIDDLE DRIVE GEAR PART BOLT, FLANGE OIL SEAL O-RING 1 22

29 FIG. 17 DRIVE SELECTOR PART 1 1P SHIFTER ASSY 1 2 1P KNOB, SHIFT LEVER RIVET 1 4 5GH BOOT, SEALING 1 5 5GH STOPPER,RUBBER HOSE (L90) 1 7 5ND E PLUG, DRAIN CLIP WASHER PIN, COTTER P0 E KNOB, SHIFTER P0 E LEVER XG E COVER, DUST P0 E SHAFT, RINK J2 WASHER, PLATE O-RING WASHER, PLATE BOLT, FLANGE P3 WASHER, PLATE P2 WASHER, PLATE PLUG, STRAIGHT SCREW BOLT XG E JOINT, ROD WASHER PIN, COTTER XG E COVER, DUST P NUT, ADJUST 1 23

30 FIG. 17 DRIVE SELECTOR PART NUT NUT XG E JOINT, ROD WASHER PIN, COTTER XG E COVER, DUST 1 24

31 FIG. 18 SHIFT CAM & FORK PART 1 52G SHIFT CAM ASSY BEARING 1 3 5XG E SEGMENT PIN, DOWEL PIN, DOWEL SCREW, COUNTERSUNK 1 7 5XG E FORK, SHIFT XG E FORK, SHIFT XG E FORK, SHIFT XG E BAR, SHIFT FORK GUIDE XG E BAR, SHIFT FORK GUIDE

32 FIG. 19 SHIFT SHAFT PART OIL SEAL PIN, DOWEL 1 3 5XG E BOLT, STOPPER 1 4 5XG E SHIFT SHAFT COMP XG E SHIFT LEVER ASSY SPRING, TENSION SPRING, TORSION WASHER, PLATE 2 9 5XG E STOPPER LEVER ASSY SPRING, TORSION W GUIDE V HOLDER, PAWL W SHIFT GUIDE COMP XG E817A 00 ARM, SHIFT XG E PIN, LEVER XG E PIN, JOINT WASHER, PLATE PIN, COTTER XG E STOPPER, SCREW O-RING WASHER, PLATE NUT SPRING, COMPRESSION P SHIFT PEDAL ASSY N COVER, SHIFT PEDAL BOLT 1 26

33 FIG. 20 FRAME PART 1 1P0 F FRAME COMP XE F STAY, ENGINE BOLT, FLANGE A7 BOLT, FLANGE A8 BOLT, FLANGE A9 BOLT, FLANGE NUT, SELF-LOCKING BUSH, SOLID O-RING NIPPLE, GREASE FU F111A 00 CAP, MAIN PIPE P0 F ARM BOLT, FLANGE BOLT, FLANGE P0 F BRACKET, SWITCH BOLT, FLANGE ND F TOOL KIT NV 2811A 01 GAUGE, AIR O-RING 1 27

34 FIG. 21 FRONT FENDER PART 1 1P0 F1500 A0 FRONT FENDER ASSY 1 UR FOR RTR 1P0 F1500 B0 FRONT FENDER ASSY 1 UR FOR PDG 1P0 F1500 C0 FRONT FENDER ASSY 1 UR FOR SMJ BOLT, WITH WASHER SCREW 2 4 5FU F175B 01 TUNING FORK MARK 1 5 5UH F GRILLE, FRONT BOLT, WITH WASHER NUT, SPRING NUT, SPRING RIVET BOLT, WITH WASHER UH F CAP 2 28

35 FIG. 22 REAR FENDER PART 1 1P0 F REAR FENDER ASSY. 1 UR FOR RTR 1P0 F REAR FENDER ASSY. 1 UR FOR PDG 1P0 F REAR FENDER ASSY. 1 UR FOR SMJ BOLT, WITH WASHER BOLT, WITH WASHER A4 CLIP 1 5 5BF 1443E 00 PIPE, DRAIN 1 6 1P0 F COVER, REAR FENDER 1 UR FOR RTR 1P0 F COVER, REAR FENDER 1 UR FOR PDG 1P0 F COVER, REAR FENDER 1 UR FOR SMJ 7 1P0 F DAMPER 1 8 1P0 F CLAMP, DAMPER 2 29

36 FIG. 23 SIDE COVER PART 1 1P0 F171A 00 COVER, TOP 1 UR FOR RTR 1P0 F171A 10 COVER, TOP 1 UR FOR PDG 1P0 F171A 60 COVER, TOP 1 UR FOR SMJ RIVET RIVET 2 30

37 FIG. 24 REAR ARM PART 1 4XE F REAR ARM COMP P0 G REAR AXLE HOUSING COMP XE F151K 00 LABEL 7 1 ENGLISH BOLT, FLANGE NUT, WITH WASHER Y3 BEARING OIL SEAL G COLLAR O-RING XE F SHAFT, PIVOT NUT XE F214H 01 SHAFT, PIVOT PLUG U BOOT, RUBBER CLAMP, HOSE CLAMP, HOSE XE F219X 01 COVER STOPPER, MAIN STAND BOLT, FLANGE BOLT, FLANGE WASHER, PLATE 4 31

38 FIG. 25 DRIVE SHAFT PART 1 4XE G REAR AXLE GEAR CASE ASSY 1 2 4XE G HOUSING, DRIVE SHAFT BOLT, STUD 4 4 4XE G BEARING ASSY OIL SEAL Y9.BEARING 1 7 4XE Y RING GEAR SET Y6.BEARING H9.COLLAR U RETAINER, BEARING O-RING OIL SEAL PLUG, STRAIGHT SCREW GASKET N BREATHER XE G HOUSING, BEARING OIL SEAL Y0.BEARING O-RING BOLT WASHER, PLATE BOLT, FLANGE PLUG, STRAIGHT SCREW XE E SHIM, THRUST(T=0.15MM) 1 UR 4XE E SHIM, THRUST(T=0.30MM) 1 UR 4XE E SHIM, THRUST(T=0.40MM) 1 UR 4XE E SHIM, THRUST(T=0.45MM) 1 UR 32

39 FIG. 25 DRIVE SHAFT PART 24 4XE E SHIM, THRUST(T=0.50MM) 1 UR 4XE E SHIM, THRUST(T=0.60MM) 1 UR 25 4XE G SHIM, THRUST(T=1.0MM) 1 UR 4XE G SHIM, THRUST(T=1.1MM) 1 UR 4XE G SHIM, THRUST(T=1.2MM) 1 UR 4XE G SHIM, THRUST(T=1.3MM) 1 UR 4XE G SHIM, THRUST(T=1.4MM) 1 UR 4XE G SHIM, THRUST(T=1.5MM) 1 UR 4XE G SHIM, THRUST(T=1.6MM) 1 UR 4XE G SHIM, THRUST(T=1.7MM) 1 UR 4XE G SHIM, THRUST(T=1.8MM) 1 UR 4XE G SHIM, THRUST(T=1.9MM) 1 UR 4XE G SHIM, THRUST(T=2.0MM) 1 UR 4XE G SHIM, THRUST(T=2.1MM) 1 UR 4XE G6118 A3.SHIM, THRUST(T=1.35MM) 1 UR 4XE G6118 A4.SHIM, THRUST(T=1.45MM) 1 UR 4XE G6118 A5.SHIM, THRUST(T=1.55MM) 1 UR 26 4XE G SHIM, RING GEAR(T=0.25MM) 1 UR 4XE G SHIM, RING GEAR(T=0.30MM) 1 UR 4XE G SHIM, RING GEAR(T=0.35MM) 1 UR 4XE G SHIM, RING GEAR(T=0.40MM) 1 UR 4XE G SHIM, RING GEAR(T=0.45MM) 1 UR 4XE G SHIM, RING GEAR(T=0.50MM) 1 UR NUT, WITH WASHER O-RING XE G SHAFT, DRIVE CIRCLIP 1 33

40 FIG. 25 DRIVE SHAFT PART 31 4X CROSS JOINT COMP BEARING CIRCLIP CLIP C4 HOSE (L900) 1 34

41 FIG. 26 REAR SUSPENSION PART 1 4XE F SHOCK ABSORBER ASSY, REAR BOLT, FLANGE NUT, SELF-LOCKING PIN, CLEVIS WASHER, PLATE PIN, COTTER 1 7 1W COVER, THRUST

42 FIG. 27 FRONT SUSPENSION & WHEEL PART 1 4XE F FRONT LOWER ARM COMP. (LEFT) 1 2 4XE F BALL JOINT CIRCLIP 1 4 4XE F FRONT LOWER ARM COMP. (RIGHT) 1 5 4XE F BALL JOINT CIRCLIP 1 7 2HR BUSH BOLT, FLANGE NUT, SELF-LOCKING XE F SHOCK ABSORBER ASSY NUT CIRCLIP XE F STEERING KNUCKLE ASSY (LEFT) XE F STEERING KNUCKLE ASSY (RIGHT) NUT, CASTLE PIN, COTTER BOLT NUT, U 4 36

43 FIG. 28 STEERING PART 1 1P0 F COLUMN, STEERING PLUG, TAPER 1 3 8K HOLDER, HANDLE BOLT, FLANGE 4 5 1UY PLANE BEARING, STEERING OIL SEAL 2 7 4XE F BRACKET, STEERING LOWER BOLT 2 9 1UY WASHER, LOCK R0 COLLAR WASHER, PLATE NUT, SELF-LOCKING PIN, COTTER XE F ROD, TIE D9 F JOINT, UNIVERSAL ND F JOINT, UNIVERSAL XE F NUT XE F NUT XE F ROD, TIE D9 F JOINT, UNIVERSAL ND F JOINT, UNIVERSAL XE F NUT XE F NUT NUT, CASTLE PIN, COTTER 4 37

44 FIG. 29 FUEL TANK PART 1 4XE F FUEL TANK COMP KM CAP ASSY 1 3 3JN FUEL COCK ASSY AJ SEAL, COCK SCREW, PAN HEAD 2 6 4X O-RING WASHER, PLATE SCREW GROMMET J1 COLLAR BOLT, WITH WASHER GROMMET WASHER, PLATE COLLAR BOLT, WITH WASHER P PIPE, FUEL A1 CLIP HOSE (L500) BD GROMMET XE F DAMPER, LOCATING XE F414H 00 DAMPER, PLATE

45 FIG. 30 SEAT PART 1 5ND F SINGLE SEAT ASSY 1 2 5ND F470F 01.SEAT COVER COMP XE F DAMPER, SEAT 6 4 4XE F478V 00.SPRING, TORSION 1 5 5ND F LEVER, SEAT 1 39

46 FIG. 31 FRONT WHEEL PART 1 4XE F WHEEL COMP. 1 UR FOR RTR,PDG 4XE F WHEEL COMP. 1 UR FOR SMJ TIRE (AT 22X 7-10, M-905) 1 CHENG SHIN VALVE, RIM (TR413) 1 4 4XE F WHEEL COMP. 1 UR FOR RTR,PDG 4XE F WHEEL COMP. 1 UR FOR SMJ TIRE (AT 22X 7-10, M-905) 1 CHENG SHIN VALVE, RIM (TR413) 1 7 4XE F HUB, FRONT 2 8 1P0 F BOLT 4 9 1UY SPACER, BEARING YX BEARING XM BEARING OIL SEAL OIL SEAL NUT R1 COLLAR WASHER, PLATE NUT, CASTLE PIN, COTTER H 2512A 00 CAP, WHEEL 2 40

47 FIG. 32 FRONT BRAKE CALIPER PART 1 4XE F582T 11 DISC, BRAKE (LEFT) BOLT 8 3 3GD 2580T 01 CALIPER ASSY (LEFT) 1 4 3GD W PISTON ASSY, CALIPER 1 5 3GD W CALIPER SEAL KIT 1 6 1UY W BLEED SCREW KIT 1 7 3GD W BRAKE PAD KIT 1 8 3GD SHIM, CALIPER 1 9 3GD PIN, PAD GD 2580U 01 CALIPER ASSY (RIGHT) GD W PISTON ASSY, CALIPER GD W CALIPER SEAL KIT UY W BLEED SCREW KIT GD W BRAKE PAD KIT GD SHIM, CALIPER GD PIN, PAD BOLT, FLANGE XE F514A 00 RING, WHEEL BOLT, FLANGE 4 41

48 FIG. 33 REAR WHEEL PART 1 4XE F REAR WHEEL COMP. 1 UR FOR RTR,PDG 4XE F REAR WHEEL COMP. 1 UR FOR SMJ TIRE (AT 22X10-10, M-906) 1 CHENG SHIN VALVE, RIM (TR413) 1 DUNLOP 4 5ND F COLLAR, WHEEL 1 5 1P0 F BOLT 4 6 4XE F REAR WHEEL COMP. 1 UR FOR RTR,PDG 4XE F REAR WHEEL COMP. 1 UR FOR SMJ TIRE (AT 22X10-10, M-906) 1 CHENG SHIN VALVE, RIM (TR413) 1 DUNLOP Y0 BEARING OIL SEAL SH COVER, HUB DUST OIL SEAL Y0 BEARING VH F PLATE, BRAKE SHOE VH F CAMSHAFT VH WF BRAKE SHOE SET VH F SPRING, RETURN FU F533A 11 PLATE, INDICATOR BOLT L NUT, SELF-LOCKING P0 F LEVER, CAMSHAFT VH F GASKET VH F BOLT, CALIPER VH F SEAL, CAMSHAFT VH F539F 01 PLATE

49 FIG. 33 REAR WHEEL PART PIN, COTTER SPRING, TENSION XE G RETAINER A4 BOLT, FLANGE P0 F AXLE, WHEEL T0 COLLAR O-RING FU F531E 10 DRUM, BRAKE FU F RING FU F COVER, PLATE FU F SEAL, HUB DUST BOLT, FLANGE FU F537Y 00 SEAL, DUST FU F COLLAR, WHEEL P0 F BOLT NUT FU F WASHER, WHEEL WASHER, PLATE H 2512A 00 CAP, WHEEL NUT, CASTLE PIN, COTTER HOSE (L1050) A0 CLIP CLIP 2 43

50 FIG. 34 STEERING HANDLE & CABLE PART 1 5FU F HANDLEBAR 1 2 5FU F GRIP 2 3 1P0 F PROTECTOR, HANDLEBAR 1 4 1P CABLE, THROTTLE P WIRE, BRAKE SPRING, COMPRESSION PIN E NUT, ADJUSTING 1 9 4KB THROTTLE LEVER ASSY KB 2628F 10.CAP, GEAR NV 2625G 01.LEVER, THROTTLE SCREW SCREW, PAN HEAD NUT, U NUT OIL SEAL NV SPRING KB 2628G 00.GASKET NV WASHER NV WASHER V HOLDER, LEVER LOWER SCREW, PAN HEAD WASHER, PLATE P0 F CABLE, STARTER

51 FIG. 35 FRONT MASTER CYLINDER PART 1 5KM 2583T 01 MASTER CYLINDER ASSY 1 2 8CR W CYLINDER KIT, MASTER 1 3 4L GASKET, DIAPHRAGM 1 4 5JX CAP, RESERVOIR SCREW, FLAT HEAD 2 6 5GH HOLDER 1 7 5EB BOLT 2 8 5KM LEVER NUT, U LP FRONT STOP SWITCH ASSY FK 2589F 00.BOLT, LEVER XE F HOSE, BRAKE XE F HOSE, BRAKE XE F PIPE, BRAKE BOLT, FLANGE WASHER, PLATE BOLT, UNION GU CIRCLIP XE F612K 11 BRKT BOLT WASHER, PLATE XE F587A 01 HOLDER, BRAKE HOSE 2 45

52 FIG. 36 STAND & FOOTREST PART 1 1P0 F BRACKET, FOOTREST BOLT, FLANGE BOLT, FLANGE 2 4 1P0 F BRACKET, FOOTREST BOLT, FLANGE BOLT, FLANGE 2 7 1P0 F PEDAL, BRAKE 1 8 1P0 F COVER P0 F COVER P0 F741A 00 ARM BOLT, FLANGE SCREW WASHER, PLATE NUT, NYLON P0 2637F 10 CABLE, CONTROL SPRING, TENSION WASHER, PLATE PIN, COTTER XE ROD, BRAKE PIN, CLEVIS WASHER PIN, COTTER SPRING, COMPRESSION PIN E NUT, ADJUSTING BOLT NUT 2 46

53 FIG. 37 GUARD PART 1 1P0 F845N 00 BAR, CARRY FRONT 1 2 4XE F CAP BOLT, FLANGE 6 4 1P0 F CARRIER, FRONT BOLT, FLANGE 2 6 1P0 F CARRIER, REAR BOLT, FLANGE 4 8 1P0 F842M 00 COVER BOLT 3 47

54 FIG. 38 GENERATOR PART 1 1P0 H STATOR ASSY 1 2 1P0 H ROTOR ASSY SCREW, PAN HEAD WASHER, PLATE 3 48

55 FIG. 39 STARTING MOTOR PART 1 5XG H STARTING MOTOR ASSY 1 2 3KW H BRUSH SET O-RING 1 4 3KW H BOLT XG H183G 00.CORD COMP O-RING 1 7 1EV STAY, STARTING MOTOR SCREW, PAN HEAD WASHER, SPRING 2 49

56 FIG. 40 HEADLIGHT PART 1 4KB BULB (12V-30/30W) 2 2 5KM LENS ASSY 2 3 5EH SOCKET CORD ASSY SCREW, PAN HEAD 2 5 2GU SPRING, SCREW 2 6 2GU NUT, ADJUSTING A8 NUT, SPRING SCREW, BIND 4 50

57 FIG. 41 TAILLIGHT PART 1 5KM TAILLIGHT UNIT ASSY 1 2 1A BULB (12V-21/5W) 1 3 5KM 8472C 10.LENS, TAILLIGHT WASHER, PLATE NUT, NYLON 2 51

58 FIG. 42 HANDLE SWITCH & LEVER PART 1 5FU LEVER HOLDER ASSY (LEFT) 1 2 1YW HOLDER, LEVER HT LEVER YW LEVER, LOCK 1 5 2XJ HOLDER, LEVER LOWER BOLT NUT, U SCREW, PAN HEAD WASHER, SPRING FA FRONT STOP SWITCH ASSY BOLT NUT LP SWITCH, HANDLE GH LEVER, STARTER UY WASHER, SPECIAL L WASHER, STARTER SCREW, PAN HEAD WASHER, SPRING SCREW, PAN HEAD CLAMP 3 52

59 FIG. 43 ELECTRICAL 1 PART 1 1P C.D.I. UNIT ASSY SCREW, TAPPING CLAMP PLUG 1 5 5GT RECTIFIER & REGULATOR ASSY BOLT WASHER, PLATE 2 8 4XE STARTER RELAY ASSY 1 9 2GH FUSE (20A-BL) BOLT, FLANGE RL RELAY ASSY KJ IGNITION COIL ASSY BOLT BOLT WASHER, PLATE UY PLUG CAP ASSY GB NEUTRAL SWITCH ASSY GASKET KD NEUTRAL SWITCH ASSY WASHER, PLATE XG H WIRE, LEAD P0 H WIRE, MINUS LEAD DM RELAY ASSY (G8HN-1C4T-DJ-Y52) XE H BATTERY ASSY (GS CB14A-A2) P0 H BRACKET, BATTERY TG PAD, BATTERY BOLT, FLANGE 2 53

60 FIG. 43 ELECTRICAL 1 PART 28 1P0 H PIPE, BREATHER P0 H WIRE, PLUS LEAD XE MAIN SWITCH ASSY HN CAP, KEY HN NUT, MAIN SWITCH TE PILOT LIGHT ASSY GH BULB (14V-1.7W) P WIRE HARNESS ASSY CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP XE STOP SWITCH ASSY CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP 1 54

61 FIG. 44 EMBLEM & LABEL 1 PART 1 4XE F LABEL, WARNING 1 ENGLISH 2 1P0 F816L 00 LABEL, WARNING AGE 1 ENGLISH 3 4XE F RIVET XE F WASHER, FENDER MOLD XE F EMBLEM 1 6 4XE F151E 01 LABEL 2 1 ENGLISH 7 3B EMBLEM 3D 1 8 4XE F LABEL, CAUTION S F817J 00 PLATE, ANSI SVIA XE F816M 00 LABEL, WARNING TIRE & LOAD XE F RIVET XE F WASHER, FENDER MOLD XE F EMBLEM P0 F1781 E0 EMBLEM 1 1 FOR RTR,PDG,SMJ 15 1P0 F1782 E0 EMBLEM 2 1 FOR RTR,PDG,SMJ 16 5UH F173B 20 EMBLEM 3D XE F819R 20 TAG, WARNING P0 F POUCH 1 55

62 NUMERICAL INDEX PART PART PART PART PART PART 5H XE GH VC BD Y BD BD G G G G G H NX GC FM BE Y P UH FU P UH 1410A DM DM KM H G2 1414E FU FV W KB FU DM KM G HX DM UH A BF 1443E DM FN BE EL 1490H P0 1490J GH DM XE GH GH H DM T N BD BD BD A J V V V W BD G G G G G G W W W W W W G G G W P N GH P W V P P G GH P0 2177C W U HR UY K UY P BD JN X AJ KM UY H 2512A SH GD 2580T GD 2580U GD GD KM 2583T JX L GU GH FK 2589F GD NV B KB NV 2625G KB 2628F KB 2628G NV P EB P E P0 2637F NV XE NV 2811A U X EV XE DM RL GT TG GH KJ UY XE XE KD GB HN HN P FU YW XJ V GH TE UY HT KM GH L YW LP LP FA KB KM GU GU EH KM A KM 8472C P XG E UR E111F XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E UR E XG E XG E UR E XG E UR E XG E XG E UR E XG E XG E XG E UH E XG E P0 E FU E FU E ND E UH E XE E XE E JN6 E XE E442F XE E XE E XE E P0 E XE E XE E P0 E P0 E XE E P0 E ND E XG E XG E XG E XG E XG E XG E XG E P0 E XG E XG E P0 E P0 E P0 E P0 E P0 E P0 E XG E P0 E P0 E P0 E P0 E P0 E XG E P0 E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E P0 E XG E XG E XG E XE E XE E XE E XE E XE E

63 NUMERICAL INDEX PART PART PART PART PART PART 4XE E XG E XG E XG E XG E P0 E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E XG E812A XG E XG E XG E P0 E XG E XG E817A XG E P0 E XG E XG E P0 E P0 E XG E XG E XG E XG E XG E XG E XG E XG E P0 F FU F111A XE F XE F P0 F P0 F1500 A P0 F1500 B P0 F1500 C XE F151E XE F151K XE F XE F XE F XE F P0 F P0 F P0 F P0 F P0 F P0 F P0 F P0 F P0 F171A P0 F171A P0 F171A UH F173B FU F175B P0 F1781 E P0 F1782 E XE F XE F XE F214H XE F219X XE F XE F XE F XE F XE F XE F XE F P0 F XE F XE F XE F D9 F D9 F ND F XE F XE F XE F414H XE F P0 F ND F470F ND F XE F ND F XE F478V P0 F P0 F XE F XE F XE F XE F514A XE F XE F FU F FU F531E VH F FU F VH F FU F FU F533A VH F P0 F VH F FU F FU F537Y P0 F ND F FU F XE F XE F VH F539F P0 F VH F XE F582T XE F XE F XE F XE F587A VH F FU F P0 F XE F612K FU F P0 F P0 F P0 F741A P0 F P0 F P0 F P0 F ND F P0 F816L XE F816M S F817J P0 F XE F819R UH F UH F P0 F842M P0 F845N XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G6118 A XE G6118 A XE G6118 A XE G XE G XE G XE G P0 G P0 H P0 H XG H KW H KW H XG H183G XE H P0 H P0 H P0 H P0 H XG H CR W GD W GD W UY W GD W XG WE VH WF G Y XE Y A A A A A

64 NUMERICAL INDEX PART PART PART PART PART PART P G C F C F C J P F M J R R G H T C A A A A A J A A A YX Y Y Y X XM X Y Y YE Y J Y Y Y L

65 NUMERICAL INDEX PART PART PART PART PART PART