PARTS CATALOG 2003 G21AY (JR61) U.S.A., CANADA, EUROPE, OTHERS

Transcription

1 PARTS CATALOG 2003 G21AY (JR61) U.S.A., CANADA, EUROPE, OTHERS OCTOBER BJR6-100E1

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3 FOREWARD 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. G21A (JR61) 6. Applicable Serial No. and Color Code 1 Frame Serial No. JR ~ 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 7. Note that the illustrations are for reference in finding parts numbers, not to be used for assembling. When assembling, please use the applicable service manual. 8. The asterisk (*) before a reference number indicates modification items after the first edition. 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 2F FRONT FLASHER LIGHT ASSY BULB (6V-18W) 1 5. Applicable colors of graphics are represented in the REMARKS as shown below. PART DESCRIPTION Q TY REMARKS 2N X5 FUEL TANK COMP. 1 MAXIM RED 3J GRAPHIC, FUEL TANK 1 for MXR

4 CONTENTS ENGINE PAGE PAGE Engine Assembly 5 Transmission 31 ~ 33 Cylinder Head 6 Rear Axle Mount / Wheel 34 Crankshaft / Piston 7 Shifter / Cables 35 Camshaft / Valve 8 Bumper 36 Air Shroud / Fan 9 Body (Front) 37 ~ 38 Intake 10 Body 2 (Rear) 39 Carburetor 11 Body Fitting 40 Exhaust 12 Carrier 41 ~ 42 Crankcase 13 Seat 43 Starter Generator 44 ~ 45 CHASSIS Electrical 1 46 Engine Mount 14 Electrical 2 47 ~ 48 Rear Arm / Suspension 15 Frame 16 Front Suspension / Wheel 17 ~ 18 Steering 19 ~ 20 Fuel Tank 21 Brake 22 ~ 24 Brake 2 25 Brake 3 26 Accelerator 27 Governor 28 Primary Clutch 29 Secondary Sheave 30

5 FIG. 1 ENGINE ASSEMBLY 1 JR ENGINE ASSEMBLY 1 Page 5

6 FIG. 2 CYLINDER HEAD 1 JT HEAD, CYLINDER 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 NGK-BPR4E-S0-00 PLUG, SPARK 1 AP, U.S PLUG, SPARK 1 AP, EUROPE 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 7RH 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 JN6-E DUCT, RIVET 2 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 JT.,CARBURETOR JN6-E CLIP,CAP FITTING D6-00 O-RING BOLT, FLANGE 3 18 JN6-F WIRE, THROTTLE J55-F WIRE, STARTER 1 20 JN6-F NUT CLAMP 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 JN6-E MUFFLER ASSEMBLY 1 2 7KY GASKET, EXHAUST NUT NUT, U-FLANGE 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 A 2 12 JN COVER, CRANKCASE BEARING SEAL, OIL BEARING 1 16 JN GSKT.,CRANKCASE COVER BOLT, FLANGE BOLT, FLANGE EN PLUG, OIL O-RING 1 21 J GAUGE, LEVEL 1 Page 13

14 FIG. 10 ENGINE MOUNT 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 JN6-F REAR ARM COMP. 1 2 JN6-F COVER, RIVET, BLIND RIVET, BLIND 2 5 JN6-F BUSHING, BOLT, FLANGE NUT P BOLT,HEX. W/WASHER (7-FQA) 2 9 JN6-F ROD, CONNECTING ASSY JN6-F BUSHING, BOLT, FLANGE NUT, U-FLANGE WASHER, PLAIN 2 14 JR6-F SHOCK ABSORBER BOLT, FLANGE NUT, U-FLANGE 4 Page 15

16 FIG. 12 FRAME 1 JR6-F FRAME COMP BOLT NUT, HEX WASHER, SPRING WASHER, PLAIN 4 6 JJ3-F722B BAR, TOW 1 Page 16

17 FIG. 13 FRONT SUSPENSION / WHEEL 1 JR6-F FRONT LOWER ARM, LEFT 1 2 JN6-F BUSHING, ARM BUSH, BIMETAL 2 4 JR6-F STRG. KNUCKLE ASSY.,LH. 1 5 JN3-F ARM,KNUCKLE LH BOLT, FLANGE NUT, U-FLANGE PIN, SPLIT 12 9 J SEAL, DUST JR6-F PIN,STRG. KNUCKLE KING 2 SEE NOTE "A" J2-00 WASHER, PLAIN P NUT, U-FLANGE 2 SEE NOTE "A" 13 JR6-F FRONT LOWER ARM, RIGHT 1 14 JR6-F KNUCKLE, STEERING RIGHT BOLT, FLANGE 4 16 JR6-F SHOCK ABSORBER ASSY BOLT BOLT 2 19 JR6-F BRKT. 1 (LH) 1 20 JR6-F BRKT. 2 (RH) 1 21 JR6-F GUIDE WIRE 2 22 J55-G DRUM 2 23 JN6-F BACKING PLATE ASSY (LH) 1 SEE PAGE 26 FOR COMPONENT PARTS 24 JN6-F BACKING PLATE ASSY (RH) 1 SEE PAGE 25 FOR COMPONENT PARTS P BOLT P NUT Y3-00 BEARING 2 Page 17 NOTE "A": The King Pin (Ref #10) was changed from 12mm (old PN JJ3-F ) to 10mm threads (new PN JR6-F ), and the flange nut (Ref #12) was changed from 12mm ( ) to 10mm (9560P-10200). To determine which parts you are working with, measure the thread diameter of your existing components. The old King Pin (JJ3-F ) is not available and has been superceded to JR6-F Be sure to also order the new 10mm flange nut (Ref # 12) to update older units.

18 FIG. 13 FRONT SUSPENSION / WHEEL 28 JR6-F HUB BOLT KNURLED X0-00 BEARING M7-00 COLLAR WASHER NUT, U 2 34 JN6-F COVER, HUB DUST 2 35 JN6-F FR. WHEEL ASSY NUT 8 Page 18

19 FIG. 14 STEERING Page 19 1 JG5-F COLUMN, STEERING 1 2 J ARM, PITMAN 1 3 J PIN, PITMAN SEAL, OIL 1 5 J55-F BOLT Y2-00 BEARING 2 7 J NUT 1 8 J WASHER 1 9 JN3-F COVER, STEERING 1 10 J SEAL, STEERING 1 11 J10-F BOLT NUT, HEX BOLT, FLANGE 4 14 JN3-F HOLDER, HANDLE 1 15 J STEERING SHAFT 1 16 JN3-F WHEEL, STEERING NUT, SELF-LOCKING WASHER, PLAIN 1 19 J ARM, IDLER NUT, NYLON WASHER, TONGUE BOLT, FLANGE 4 23 JN6-F TIE ROD ASSY, RIGHT 1 24 JN6-F TIE ROD ASSY, LEFT 1 25 JN6-F UNIVERSAL JOINT 2 26 JN6-F UNIVERSAL JOINT N NUT, (RH THREAD) 2

20 FIG. 14 STEERING NUT (LH THREAD) NUT, U-FLANGE PIN, SPLIT 4 Page 20

21 FIG. 15 FUEL TANK 1 J55-F TANK, FUEL 1 2 J BODY CAP ASSY 1 3 J GASKET, CAP 1 4 J GROMMET 1 5 J RELEASE VALVE ASSY R FILTER ASSY F GASKET 1 8 J FUEL LEVEL GAUGE ASSY BOLT HEX. HEAD W/WASHER S2-00 WASHER, PLATE P NUT, U FLANGE 2 12 JN6-F FUEL PUMP ASSY JN6-F BOLT, SPECIAL 2 14 JR3-F PIPE JR3-F PIPE, JOINT 1 16 JN6-F PIPE, FUEL 1 17 JN6-F PIPE JR3-F PIPE CLIP CLIP CLAMP CLAMP SPRING COMPRESSION CLIP 1 Page 21

22 FIG. 16 BRAKE 1 J BRAKE ARM COMP BUSH, BIMETAL FORMED 2 3 J PEDAL, BRAKE 1 4 J PARKING PEDAL COMP 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, LINK 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 O-RING 2 41 JR6-F LINK PIN PIN, SPLIT 3 44 JN6-F ROD PIN 2 46 J EQUALIZER, BRAKE PIN NUT NUT, HEX PIN, SPLIT PIN 8 52 JJ3-F WIRE, BRAKE JJ3-F WIRE, BRAKE JR6-F WIRE, BRAKE 3 2 Page 23

24 FIG. 16 BRAKE CIRCLIP E BOLT, FLANGE CLAMP 1 Page 24

25 FIG. 17 BRAKE 2 1 JN6-F BACKING PLATE, (RH) 2 (FOR R/S FRONT & REAR WHEELS ONLY) 2 JN6-F SHOE, BRAKE SET 1 (FOR ONE WHEEL) 3 JN6-F819G REPAIR PARTS KIT 2 4 JG5-F COVER, DUST 2 5 JN6-F722F LEVER ADJUSTER, (RH) 2 Page 25

26 FIG. 18 BRAKE 3 1 JN6-F BACKING PLATE, (LH) 2 (FOR L/S FRONT & REAR WHEELS ONLY) 2 JN6-F SHOE, BRAKE SET 1 (FOR ONE WHEEL) 3 JN6-F819G REPAIR PARTS KIT 2 4 JG5-F COVER, DUST 2 5 JN6-F722E LEVER ADJUSTER, (LH) 2 Page 26

27 FIG. 19 ACCELERATOR 1 JN6-F BRACKET, PEDAL 1 2 J SHAFT, PEDAL 1 3 J ARM, ACCELERATOR PIN, SPRING PIN, SPRING 1 6 J PEDAL, ACCELERATOR BOLT, FLANGE BOLT, RD. HEX NUT, FLANGE BUSH, BIMETAL FORMED O-RING 4 12 JN3-F COVER, PEDAL BOLT, FLANGE SPRING, TENSION 1 15 JJ3-F WIRE, THROTTLE PIN CLIP SPRING, TORSION SPACER BOLT, FLANGE NUT, FLANGE CLAMP T4-00 COLLAR 1 Page 27

28 FIG. 20 GOVERNOR 1 J LEVER, SPEED NUT, HEX BUSH SPRING, TORSION 1 5 J SCREW, ADJUSTING NUT, U-FLANGE 1 7 JN3-G BRACKET BOLT, FLANGE 1 Page 28

29 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 29

30 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 COMP. 1 SEE NOTE "B" 8 JN6-G SECONDARY SPRING SEAT 1 9 JN6-E SHOE, RAMP BOLT, HEX. SOCKET SPRING, TORSION 1 L=135.0mm± 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. NOTE "B": Secondary spring seat comp. Includes: secondary spring seat, shoe ramp and bolts. Page 30

31 FIG. 23 TRANSMISSION 1 1 JR6-G TRANSAXLE ASSEMBLY 1 2 JR3-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 JR6-G SHAFT, INPUT ASSY JN3-G633G SHAFT 1 23 JN3-G GEAR, PRIMARY SEAL, OIL 2 25 JR3-G SHAFT, RR. AXLE JR3-G SHAFT, RR. AXLE CIRCLIP 4 Page 31

32 FIG. 23 TRANSMISSION X2-00. BEARING 2 29 JR3-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 JR6-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 32

33 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) JN3-G SHIM mm (0.070in) JN3-G6344-A0-00. SHIM mm (0.075in) JN3-G6344-B0-00. SHIM mm (0.080in) JN3-G6344-C0-00. SHIM mm (0.085in) JN3-G6344-D0-00. SHIM mm (0.090in) 59 JN3-G GASKET 1 60 ACC-QUICK-GS-KT SEALANT 1 1 Page 33

34 FIG. 24 REAR AXLE MOUNT / WHEEL 1 JR6-F WHEEL ASSY NUT 8 3 J55-G DRUM 2 4 JN6-F COVER, HUB DUST BOLT, FLANGE NUT, FLANGE P BOLT, HEX. HEAD W/WASHER S3-00 WASHER PLAIN 8 Page 34

35 FIG. 25 SHIFTER / CABLES NUT, U 1 2 JJ3-G SHIFT CABLE END ASSY. 1 3 J55-G LEVER, SHIFT JJ3-G WIRE, SHIFT 2 5 JF LEVER, SHIFT PIN WASHER, PLAIN PIN, SPLIT 2 9 JN3-G KNOB, SHIFT 1 10 JN3-G SPRING SET L9-00 WASHER, PLAIN WASHER, PLAIN CIRCLIP (S) SCREW, PANHEAD W/WASHER 2 15 JN3-G BRACKET, SHIFT WIRE BOLT, FLANGE 4 17 JN SWITCH CLAMP 1 19 JJ3-G JOINT 1 Page 35

36 FIG. 26 BUMPER 1 JN3-K FRONT BUMBER COMP. 1 2 JN8-K STAY, FR. BUMPER BOLT, FLANGE BOLT, FLANGE 2 Page 36

37 FIG. 27 BODY 1 JN6-K COWL, FRONT 1 HUNTER GREEN 2 JR6-F FENDER OVER JR6-F FENDER OVER JR6-F STAY, FENDER BOLT, HEX SOCKET RIVET, BLIND 6 7 JN3-K818E CAP, PROTECTOR 2 8 JN6-F EMBLEM, SCREW, OVAL COUNTERSUNK TAP 2 10 JF2-K811G BOLT, COWL FITTING SCREW, BINDING 2 12 JF2-K811V PROTECTOR, JF2-K PLATE, BODY PROTECTOR PLATE, JF2-K PLATE, BODY PROTECTOR JF2-K PLATE, BODY PROTECTOR NUT, SELF-LOCKING JF2-K PLATE, BODY PROTECTOR P NUT, U-FLANGE 2 20 JF2-K811W PROTECTOR JF2-K PLATE, BODY PROTECTOR 1 22 JF2-K811X PROTECTOR JF COVER, HOLE RIVET 4 25 JF2-K PANEL, FRONT 1 SEE NOTE "A" RIVET 3 27 JN3-K815G SEAL, FRONT STORAGE 1 Page 37

38 FIG. 27 BODY 28 JF2-K835E HOLDER, BEVERAGE R6-00 WASHER, PLATE SCREW, TAPPING 2 31 JR6-K LABEL, WARNING JN6-K MAT, MAIN FLOOR JN6-K MAT, MAIN FLOOR JN6-K MAT, MAIN FLOOR RIVET RIVET, BLIND 9 NOTE "A": When replacing "Panel Front JF2-K " you should also replace "Label Warning 1 JR6-K ". Page 38

39 FIG. 28 BODY 2 1 JJ3-K LABEL, WARNING 5 1 SEE NOTE A 2 JN3-K INDICATOR 1 1 SEE NOTE B 3 JJ3-K PANEL, REAR BODY 1 HUNTER GREEN, SEE NOTE "A" 4 JJ3-K PANEL, INTERMEDIATE BODY 1 HUNTER GREEN, SEE NOTE "B" NUT, SPRING NUT, SPRING 4 7 JJ3-K PANEL, BODY SHELL 1 HUNTER GREEN 8 JJ3-K PANEL, BODY SHELL 1 HUNTER GREEN SCREW, COUNTERSUNK RIVET, BLIND BOLT, HEX. W/WASHER R8-00 WASHER, PLATE 8 13 JJ3-K ROD, SEAT STOPPER 1 14 JJ3-K HINGE, SEAT RIVET, BLIND S1-00 WASHER, PLATE 4 17 JJ3-K814H HOOK, BODY LOCK BOLT, HEX. W/WASHER BOLT, HEXAGON SOCKET HEAD GROMMET CLAMP XE-F BUMPER, RUBBER JJ3-K LABEL, WARNING 8 1 SEE NOTE A RIVET, BLIND 4 NOTE "A": When replacing "Panel Rear Body JJ3-K " you must also replace "Label Warning 5 JJ3-K ", and "Label Warning 8 JJ3-K ". NOTE "B": When replacing "Panel Intermediate Body JJ3-K " you must also replace "Indicator 1 JN3-K ". Page 39

40 FIG. 29 BODY FITTING 1 JN6-K SERVICE LID 1 2 JF2-K PLATE, SIDE TRIM 1 3 JF2-K821F PLATE, SIDE TRIM RIVET, BLIND 4 5 JJ3-K REINFORCEMENT JJ3-K PANEL, REAR FENDER JJ3-K PANEL, REAR FENDER RIVET, BLIND 6 9 JF2-K FLAP, FRONT FENDER LEFT 1 10 JF2-K FLAP, FRONT FENDER RIGHT RIVET, BLIND 4 Page 40

41 FIG. 30 CARRIER 1 JJ3-K810F SIDE PANEL COMP. (LH) 1 SEE NOTE "A" 2 JJ3-K810G SIDE PANEL COMP. (RH) 1 3 JJ3-K PANEL, DASH 2 1 SEE NOTE "B" 4 JJ3-K810N REAR STORAGE LID COMP. 1 5 JJ3-K PLATE BOLT, WITH WASHER BOLT, WITH WASHER P NUT, SELF-LOCKING RIVET, BLIND 6 10 JJ3-K821A PAD, BODY MOUNTING JR3-K STOPPER, LOCK 2 12 JJ3-K RING, HOOK BOLT, HEX. W/WASHER NUT, U FLANGE 6 15 JJ3-K BOLT, BOLT, HEX R NUT, HEX JJ3-K BOLT P NUT, U FLANGE 2 20 JJ3-K818N BED, BOX 1 21 JJ3-K SUPPORT RIVET, BLIND 2 23 JJ3-K LOCK ASSY BOLT, FLANGE P NUT, U FLANGE 6 26 JJ3-K818M CAP, PROTECTOR END PIN, CLEVIS 2 Page 41

42 FIG. 30 CARRIER PIN, COTTER 2 29 JJ3-K ROD, INSPECTION LID PIN, COTTER 1 31 JJ3-K PIN, LEVER BOLT, WITH WASHER NUT, SELF-LOCKING 2 34 JJ3-K LABEL, WARNING 4 1 SEE NOTE "A" 35 JJ3-K LABEL, WARNING 6 1 SEE NOTE "B" 36 JJ3-K815H DAMPER, LOCK PLUG 4 38 JR3-K DAMPER 2 39 JJ3-K DAMPER P NUT, SELF-LOCKING 2 41 JR3-K BRACKET, JN3-K LABEL, WARNING 2 1 SEE NOTE "C" 43 JN6-K HOLDER, SPRING, CONICAL N7-00 COLLAR H9-00 WASHER, PLAIN SCREW PAN HEAD 2 48 JN3-K HOLDER 1 1 SEE NOTE "C" 49 JN6-K KT INFORMATION HOLDER KIT 1 SEE NOTE "D" Page 42 NOTE "A": When replacing "Side Panel Comp. (LH) JJ3-K810F-00-00" you must also replace "Label Warning 4 JJ3-K ". NOTE "B": When replacing "Panel Dash 2 JJ3-K " you must also replace "Label Warning 6 JJ3-K ". NOTE "C": When replacing "Holder 1 JN3-K " you must also replace "Label Warning 2 JN3- K ". NOTE "D": Includes 43, 44, 45, 46, 47

43 FIG. 31 SEAT 1 JN6-K CUSHION SEAT 1 2 JN6-K COVER, SEAT 1 3 JN3-K HINGE, SEAT MALE BOLT, HEX WASHER, SPRG SCREW, PAN HEAD TAP P NUT, SELF-LOCKING 12 8 JN6-K REINFORCEMENT JN6-K REINFORCEMENT JJ3-K SEAT ASSY 2 1 SEE NOTE "A" 11 5FU-F111A CAP, MAIN PIPE 2 12 JJ3-K CAP, END 2 13 JR3-K SEAT SUB ASSY, BACK 2 14 JR3-K841G COVER, SEAT BACK JJ3-K COVER, SEAT BACK 2 SEE NOTE "B" BOLT, HEX. W/WASHER 4 17 JJ3-K LABEL, WARNING 2 1 SEE NOTE "B" 18 JJ3-K LABEL, WARNING 3 2 SEE NOTE "A" 19 JJ3-K DAMPER, SEAT SUPPORT 4 NOTE "A": When replacing "Seat Assy 2 JJ3-K " you must also replace "Label Warning 3 JJ3-K ". NOTE "B": When replacing the LS "Cover Seat Back JJ3-K " you must also replace "Label Warning 2 JJ3-K ". Page 43

44 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 44

45 FIG. 32 STARTER GENERATOR 28 JN3-H SPACER 1 29 JN3-H PULLEY NUT, FLANGE SCREW 3 Page 45

46 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 46

47 FIG. 34 ELECTRICAL 2 1 JN3-H SCREW, FITTING 2 2 J55-H PLATE, BATTERY FITTING WASHER, PLAIN NUT, FLANGE 2 5 JR3-H WIRE, PLUS LEAD JR3-H WIRE, MINUS LEAD CLAMP 2 8 JR3-H WIRE, LEAD 1 9 JR6-H WIRE HARNESS ASSY. 1 WITH FUSE 10 JR3-H RELAY ASSY JN6-H HARNESS, WIRE SCREW, HEX. TAPPING 2 13 JF VOLTAGE REGULATOR ASSY BOLT, FLANGE 1 15 JF SWITCH, ACCELERATOR STOP SCREW, PAN HEAD W/WASHER CLAMP 5 18 JR1-H BUZZER 1 19 JN6-H STAY, BUZZER 1 20 * BATTERY - OBTAIN LOCALLY 1 LM (12 V, BCI group 24, CCA: minimum 400A) 21 4U RELAY ASSY JN OIL LEVEL GAUGE BOLT, FLANGE 4 24 JN CLAMP, OIL LEVEL 1 25 JN MAIN SWITCH ASSY. 1 JN MAIN SWITCH ASSY., RANDOM KEY 1 AP 26 J YY KEY, MAIN SWITCH 1 FOR STD. MAIN SWITCH ONLY Page 47

48 FIG. 34 ELECTRICAL 2 27 JN PILOT LAMP A XX. BULB, (12V-3.4W) X FUSE (10A-BLADE) 1 30 JR6-H270X SWITCH, HORN COMP P BOLT, FLANGE NUT, FLANGE LR HORN 1 Page 48