YZF-R15 1CK1. Parts & Accessories

Transcription

1 YZF-R15 Parts & Accessories

2 YZF-R15 () PARTS CATALOGUE INDIA YAMAHA MOTOR PVT. LTD. 1st edition, September 2011 All rights reserved. Any reprinting or unauthorized use without the written permission of INDIA YAMAHA MOTOR PVT. LTD. is expressly prohibited. Printed in INDIA

3 This Parts Catalogue is related to the parts in use for the YAMAHA - When you are ordering replacement parts for refer to this Parts Catalogue and quote both part numbers and part names correctly. 1. Modifications or additions which have been made after issue of the Parts Catalogue will be announced in the Service Actions. It is advisible that according to the Service Action you make necessary corrections tothe Parts Catalogue on hand to keep it up-to-date. FOREWORD Colour Code Colour Name Abbreviation 1115 DEEP PURPLISH BLUE MET 1 DPBMY 0390 BLACK METALLICX SMX 0121 VIVID RED COCKTAIL1 VRC1 2. Indication of No. of constituent parts for assembly. The numeral appearing to the right of each constituent part under the description indicates the quantity of such parts for each individual assembly unit. EXAMPLE Part No. Description Qty 1CK-WE CRANK SHAFT ASSY. 1 38B-H BATTERY ASSY HOSE 1 38B-E CYLINDER HEAD 1 NOTICE The description and illustration in this Parts Catalogue may not necessarily match with the physical appearance of the parts. INDIA YAMAHA MOTOR PVT. LTD. reserves the right to carry out modifications on the vehicle, parts or accessories, as may be considered necessary, without being obliged to update this Parts Catalogue immediately. No part of this Publication may be reproduced without written permission of INDIA YAMAHA MOTOR PVT. LTD. Spare Parts Division 3. Applicable Serial No. and Color Code 1 Frame Serial No 2 Frame Serial No XXX Mfr Code Model Code Model Code X Prod No Code xxxxxx Serial No. 1 Varient Code X Month Code X Year Code X Factory Code xxxxxx Serial No 1

4 1. Parts number Structure 1) Common parts number XXX-XXXXX-XX-XX Example 1CK-E Model Function code Major classification # E--F--H Design Serial number Design Revision Change Modification Color Codes Painted Parts eg:- 1CK Major classification Engine Chassis Electrical YMC number Local number E F H Revision Design Further Design change eg:- 1X/P0 2X/P1 3X/P2 Note:- 1) 'WE'indicates Kit Assy. fixed by service for market. 2) 'XE' indicatessub Assy. & individual Parts not serviceable fixed by manufacturing. Note:- Only Colored parts are 12 digit in Catalog - Rest are 10 Digits(Non-Coloured Parts) 2) Standard parts number /Regular parts number Standard parts number ; 9XX-XXXXXXX Type of Parts Ex:- 947XX=Plug spark 932XX="O" Ring 985XX=Screw pan head Regular parts number ; 9XXXX-XXXXX Category Code Ex:- 901XX=Bolt and Nut 902XX=Washer and Rivet 903XX=Bush and Collor 904XX=Hose and Clamp 905XX=Springand spacer

5 CONTENTS ENGINE CYLINDER... 2 CRANKSHAFT/PISTON... 3 VALVE... 4 CAMSHAFT/CHAIN... 5 WATER PUMP... 6 RADIATOR & HOSE... 7 OIL PUMP... 8 INTAKE... 9 EXHAUST CRANKCASE CRANKCASE COVER STARTER CLUTCH CLUTCH TRANSMISSION SHIFT CAM FORK SHIFT SHAFT CHASSIS FRAME FENDER SIDE COVER REAR ARM. & 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 LEG SHIELD WINDSHIELD GENERATOR STARTER MOTOR FLASHER LIGHT METER HEAD LIGHT TAIL LIGHT HANDLE SWITCH & LEVER ELECTRICAL ELECTRICAL NUMERICAL INDEX

6 FIG. 1 (1) CYLINDER PART PART NAME REMARKS 1 38B-E CYLINDER HEAD ASSY 1 2 1S7-E GUIDE, VALVE SCREW, HEXAGON GASKET BOLT, STUD B-E COVER, CYLINDER HEAD PIN, DOWEL 1 8 5YP-1482K-00 PLATE B-E AIR CUT VALVE ASSY B-E REED VALVE ASSY BOLT, FLANGE BOLT, FLANGE GASKET B-E GASKET, HEAD COVER O-RING BOLT, FLANGE WASHER, PLATE PLUG, SPARK (NGK CR8E) CK-E GASKET, CYLINDER HEAD PIN, DOWEL PIN, DOWEL BOLT C1-E CYLINDER B-E GASKET, CYLINDER SCREW, HEXAGON GASKET 2

7 PART INFORMATION TO : All Dealers Date: 01 April 2013 PI 351 Model Subject 20P, 38B & 1CK series(r15) IYM Parts: 351 Replacement of Air Cut Valve Assy & Reed Valve Assyin Market-20P,38B&1CK series Background :1) To ensure that the Engine Performance is maintained due to either Air Cut Valve Assy or Reed Valve Assy becoming defective, Design recommends to replace OLD air cut valve or reed valve,assy in customer bike in SET(KIT) of NEW air cut valve & reed valve.assy-please refer Annexure -1 2) Accordingly SPD has fixed a Kit as shown in below table: A) Air Cut Off Valve Kit Air & Reed Valve assy 38BE s/s 1S7WE consisting i 1S7E S7E B) Reed Valve Assy Kit Air & Reed Valve assy 38BE s/s 1S7WE consisting 1S7E S7E Notes: 1) Please update your Parts Catalogue 20P, 38B &1CK for future Parts ordering 2) Please place your order for Spares thru Parts Division in usual manner 3) Air Cut of Valve-1S7E & Reed Valve assy 1S7E will also not be serviced individually & in case of failure of any part the same will also be replaced as Kit 1S7WE You are most earnestly requested to please explain, the above to your SERVICE, SALES, & SPARE PARTS TEAM. Please do not hesitate to seek any clarification from our visiting IYM FIELD TEAM. Parts Division INDIA YAMAHA MOTOR PVT.LTD. CC:ZBH / ZSM / RBH / RSM / SALES EXECUTIVE / SERVICE EXECUTIVE / PARTS MANAGERS :YAMAHA POINT(YP)/AUTHORISED SERVICE POINT(ASP) 19/6 Mathura Road- Faridabad

8 Annexure -1 Models-20P,38B& 1CKI series A) Air Cut Off Valve Kit Air & Reed Valve assy 38BE s/s 1S7WE consisting 1S7E S7E B) Reed Valve Assy Kit Air & Reed Valve assy 38BE s/s 1S7WE consisting 1S7E S7E

9 FIG. 2 (1I0) CRANKSHAFT & PISTON PART PART NAME REMARKS 1 1CK-E CRANKSHAFT ASSY X7 BEARING KEY, WOODRUFF 1 4 3C1-E PISTON (STD) B-E PIN, PISTON CIRCLIP 2 7 3C PISTON RING SET (STD) B-E GEAR, DRIVE C-E BOSS, BUFFER WASHER, PLATE WASHER, CLAW B-E SPRING C-E ROLLER B-E WEIGHT C-E GEAR, BALANCE WEIGHT COLLAR O-RING O-RING YD BEARING XS BEARING KEY, STRAIGHT WASHER, LOCK NUT 1 3

10 FIG. 3 (1M0) VALVE PART PART NAME REMARKS 1 5YP-E VALVE, INTAKE 2 2 5YP-E VALVE, EXHAUST B-E SEAL, VALVE STEM B-E SPRING, VALVE INNER 4 5 1WG COTTER, VALVE 8 6 5YP RETAINER, VALVE SPRING B-E SEAT, VALVE SPRING B-E ARM, VALVE ROCKER 1 9 3C SCREW, VALVE ADJUSTING NUT B-E ARM, VALVE ROCKER C SCREW, VALVE ADJUSTING NUT YP-E SHAFT, ROCKER 2 2 4

11 FIG. 4 (1N0) CAMSHAFT & CHAIN PART PART NAME REMARKS 1 38B-E CAMSHAFT ASSY Y0.BEARING O-RING X7 BEARING B-E DECOMPRESSION ASSY 1 6 5YP-E CAM, DECOMPRESSION 1 7 5YP-E BOLT B-E111F-00 PLATE BOLT, FLANGE A8096 CHAIN B-E GUIDE, STOPPER B-E GUIDE, STOPPER SCREW B-E COLLAR B-E COVER, CHAIN B-E TENSIONER ASSY, CAM CHAIN CK-E GASKET, TENSIONER CASE B-E HOLDER, CLUTCH CABLE BOLT 2 5

12 FIG. 5 (1Q0) WATER PUMP PART PART NAME REMARKS 1 38B-E COVER, HOUSING OIL SEAL B-E GASKET, HOUSING COVER B-E COVER, CYLINDER HEAD SIDE B-E GASKET, CYLINDER HEAD SIDE O-RING B-E IMPELLER SHAFT ASSY B-E PLATE 9 38B-E PLATE Y5 BEARING BOLT, FLANGE BOLT, FLANGE B-E STAY BOLT, FLANGE BOLT, FLANGE O-RING 1 1 6

13 FIG. 6 (1R0) RADIATOR & HOSE PART PART NAME REMARKS 1 1CK-E THERMOSTAT B-E COVER, THERMOSTAT BOLT, FLANGE B-E240A-00 RADIATOR ASSY 1 5 5YP-E BLOWER ASSY 1 6 5YP-E BOLT, BLOWER HOLDING 2 7 5YP-E NUT ST-E CAP, RADIATOR GROMMET BOLT, FLANGE WASHER, PLATE W3 COLLAR GROMMET CK-E246A-00 COVER P-E COVER, RADIATOR P-E PIPE HOSE CLAMP ASSY P-E PIPE HOSE CLAMP ASSY HOSE CLIP 2 7

14 FIG. 7 (2C0) OIL PUMP PART PART NAME REMARKS 1 38B-E OIL PUMP ASSY SCREW, PAN HEAD B-E PLUG, DRAIN B-E STRAINER, OIL SPRING, COMPRESSION O-RING B-E ELEMENT ASSY, OIL CLEANER B-E GEAR, PUMP DRIVE B-E COVER, OIL ELEMENT BOLT, FLANGE BOLT, FLANGE O-RING B-E COVER, PUMP GEAR BOLT, FLANGE 2 8

15 FIG. 8 (2J0) INTAKE PART PART NAME REMARKS 1 38B-E MANIFOLD B-E GASKET, MANIFOLD B-E HOSE, VACUUM SENSING CLIP GASKET B-E JOINT, CARBURETOR O-RING BOLT, FLANGE 2 9 3C INJECTOR ASSY CA O-RING C PIPE, FUEL BOLT, FLANGE CK-E THROTTLE BODY ASSY JW AIR SCREW SET S5-1410H-00.FUEL CUT SOLENOID VALVE S SCREW B-E BAND P-E CASE, AIR CLEANER P-E CAP, CLEANER CASE P-E ELEMENT ASSY, AIR CLEANER P-E JOINT, AIR CLEANER C1-E SEAL SCREW, TAPPING P-E443E-00 PIPE, DRAIN CLIP P-E PIPE, JOINT CLIP P-E PIPE P-E441J-00 PIPE, SILENCER PLUG 1 9

16 FIG. 8 (2J0) INTAKE PART PART NAME REMARKS CLIP NUT, SPRING BOLT, WITH WASHER P-E PIPE, BREATHER CLIP P-E HOSE, BEND CLIP CLIP HOSE CLAMP ASSY P-E RESONATOR S1 COLLAR BOLT, HEXAGON P-E HOSE, BEND WAY P-E HOSE, BEND CLIP 1 10

17 FIG. 9 (2N0) EXHAUST PART PART NAME REMARKS 1 1CK-E MUFFLER COMP CK-E PROTECTOR, MUFFLER CK-E PROTECTOR, MUFFLER M01 NUT, SPRING GROMMET COLLAR BOLT,HEX. SOCKET BUTTON 3 8 1CK-E CAP WASHER, PLAIN BOLT WASHER, PLATE BOLT, HEX GROMMET C-E GASKET, EXHAUST PIPE NUT, FLANGE BOLT, FLANGE WASHER, PLATE BOLT, FLANGE

18 FIG. 10 (2R0) CRANKCASE PART PART NAME REMARKS 1 38B-E CRANKCASE ASSY PIN, DOWEL BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE 1 12

19 FIG. 11 (2S0) CRANKCASE COVER 1 PART PART NAME REMARKS 1 38B-E COVER, CRANKCASE CK-E GASKET, CRANKCASE COVER PIN, DOWEL BOLT, FLANGE PLUG, STRAIGHT SCREW O-RING PLUG, STRAIGHT SCREW O-RING B-E COVER, CHAIN CASE BOLT, FLANGE CK-E COVER, CRANKCASE CK-E GASKET, CRANKCASE COVER PIN, DOWEL BOLT, FLANGE BOLT, FLANGE B-E PLUG, OIL LEVEL O-RING OIL SEAL BOLT, FLANGE 1 13

20 FIG. 12 (2V0) STARTER CLUTCH PART PART NAME REMARKS 1 1CK-E GEAR B-E SHAFT E8 WASHER, PLATE CIRCLIP B-E WHEEL, STARTER X3 BEARING WASHER, PLATE B-E STARTER CLUTCH OUTER ASSY BOLT 3 14

21 FIG. 13 (2X0) CLUTCH PART PART NAME REMARKS 1 38B-E GEAR, PRIMARY DRIVE B-E KEY, FEATHER WASHER, PLATE NUT 1 5 1CK-E PRIMARY DRIVEN GEAR COMP C-E PLATE, THRUST C-E BOSS, CLUTCH B-E PLATE, FRICTION C-E PLATE, FRICTION C-E PLATE, CLUTCH B-E PLATE, PRESSURE C-E SPRING, CLUTCH C-E SCREW, SPRING C-E PLATE, PUSH C-E ROD, PUSH B-E WASHER C1-E NUT, ADJUSTING C-E WASHER, LOCK NUT B-E PUSH LEVER ASSY CK-E SPRING, RETURN B-E ROD, PUSH BALL Y9 BEARING OIL SEAL CIRCLIP WASHER, CONICAL SPRING 1 15

22 FIG. 14 (2Z0) TRANSMISSION PART PART NAME REMARKS 1 38B-E MAIN AXLE COMP XX BEARING YE BEARING B-E PLATE, COVER SCREW, PAN HEAD 2 6 1CK-E DRIVE AXLE ASSY B-E GEAR, 1ST WHEEL (34T) B-E COLLAR B-E GEAR, 5TH WHEEL (22T) WASHER CIRCLIP B-E GEAR, 4TH WHEEL (24T) B-E GEAR, 3RD WHEEL (30T) B-E GEAR, 6TH WHEEL (21T) B-E GEAR, 2ND WHEEL (30T) WASHER, PLATE F4 WASHER, PLATE YN BEARING Y6 BEARING OIL SEAL SPROCKET, DRIVE (15T) LS-E HOLDER, SPROCKET BOLT, FLANGE 1 16

23 FIG. 15 (3J0) SHIFT CAM & FORK PART PART NAME REMARKS 1 1CK-E SHIFT CAM ASSY B-E FORK, SHIFT B-E FORK, SHIFT B-E FORK, SHIFT B-E BAR, SHIFT FORK GUIDE SPRING, COMPRESSION 2 17

24 FIG. 16 (3K0) SHIFT SHAFT PART PART NAME REMARKS 1 21C-E STOPPER LEVER ASSY BOLT B-E SPRING B-E SHIFT SHAFT ASSY SPRING, TORSION CIRCLIP PIN, DOWEL OIL SEAL P-E PEDAL, SHIFT P-E COVER, SHIFT PEDAL P-E ROD, SHIFT WASHER PIN, COTTER P-E ARM, SHIFT BOLT 1 18

25 FIG. 17 (3M0) FRAME PART PART NAME REMARKS 1 1CK-F FRAME COMP BOLT, FLANGE BOLT, FLANGE NUT P-F BRACKET, UNDER BOLT, FLANGE P-F MUD GUARD P-F CLAMP 1 9 1CK-F117G-00 PROTECTOR CK-F TOOL KIT CK-F POUCH 1 19

26 PART INFORMATION Date:24 September2011 TO : All Dealers IYM Parts: 321 PI 321 Model Subject R15- Non Servicing of Pouch The Pouch used for the Tool kit will not be serviced anymore as this is already available as a Tool Kit Please see Annexure -1 Notes: 1) Please update your Parts Catalogues for future Parts ordering 2) Please place your order for Spares thru Parts Division in usual manner You are most earnestly requested to please explain, the above to your SERVICE, SALES, & SPARE PARTS TEAM. Please do not hesitate to seek any clarification from our visiting IYM FIELD TEAM F P Lobo Parts Division INDIA YAMAHA MOTOR PVT.LTD. 19/6 Mathura Road- ffaridabad CC:ZBH / ZSM / RBH / RSM / SALES EXECUTIVE / SERVICE EXECUTIVE / PARTS MANAGERS :YAMAHA POINT(YP)/AUTHORISED SERVICE POINT(ASP)

27 Annexure -1 Model - Not Serviceable

28 FIG. 18 (3Q0) FENDER PART PART NAME REMARKS 1 1CK-F X FENDER, FRONT -DPBMY 1 FOR DPBMY 1CK-F X FENDER, FRONT -SMX 1 FOR SMX 1CK-F X FENDER, FRONT -VRC1 1 FOR VRC C8 COLLAR GROMMET BOLT,HEX. SOCKET BUTTON GROMMET BOLT, WITH WASHER 2 7 1CK-F FENDER, REAR BOLT 2 9 5TS-F PLATE, LICENSE SCREW,WITH WASHER NUT WASHER, PLATE CK-F REAR STAY COMP CK-F GUARD, MUD SCREW, TAPPING G0 COLLAR NUT, SELF-LOCKING CK-F160E-00 BOX GROMMET 1 20

29 FIG. 19 (3U0) SIDE COVER PART PART NAME REMARKS 1 1CK-F COVER, SIDE CK-F COVER, SIDE SCREW, WITH WASHER GROMMET RIVET NUT, SPRING BOLT,HEX. SOCKET BUTTON P-F TANK, RECOVERY BOLT P-F CAP P-F ELBOW HOSE HOSE CLIP P-F CLAMP, HOSE CK-XF P0 COVER, SIDE 3 -DPBMY 1 UR FOR DPBMY 1CK-XF P1 COVER, SIDE 3 -DBNM8 FOR SMX 1 UR DBNM8 FOR SMX 1CK-XF P2 COVER, SIDE 3 -BWC1 FOR VRC1 1 UR BWC1 FOR VRC1 17 1CK-XF P0 COVER, SIDE 4 -DPBMY 1 UR FOR DPBMY 1CK-XF P1 COVER, SIDE 4 -DBNM8 FOR SMX 1 UR DBNM8 FOR SMX 1CK-XF P2 COVER, SIDE 4 -BWC1 FOR VRC1 1 UR BWC1 FOR VRC SCREW, WITH WASHER RIVET NUT, SPRING CK-XF17C-00-P0 COVER, SIDE 5 -DPBMY 1 UR FOR DPBMY 1CK-XF17C-10-P1 COVER, SIDE 5 -DBNM8 FOR SMX 1 UR DBNM8 FOR SMX 1CK-XF17C-20-P2 COVER, SIDE 5 -BWC1 FOR VRC1 1 UR BWC1 FOR VRC P-F836B-00.TUNING FORK MARK SCREW, WITH WASHER 2 21

30 FIG. 19 (3U0) SIDE COVER PART PART NAME REMARKS 24 1CK-F171X-00-P0 COVER, SIDE 6 -DPBMY 1 FOR DPBMY 1CK-F171X-00-P1 COVER, SIDE 6 -DBNM8 FOR SMX 1 DBNM8 FOR SMX 1CK-F171X-00-P2 COVER, SIDE 6 -BWC1 FOR VRC1 1 BWC1 FOR VRC DAMPER, PLATE SCREW, TRUSS HEAD TAPPING 2 22

31 FIG. 20 (4A0) REAR ARM & SUSPENSION PART PART NAME REMARKS 1 1CK-F REAR ARM COMP Y5 BEARING P-F BUSH 1 4 1CK-F COVER, THRUST P-F SHAFT, PIVOT NUT, FLANGE 1 7 1CK-F SEAL, GUARD COLLAR BOLT, FLANGE CK-F217A-00 ARM, RELAY BEARING COLLAR BOLT, FLANGE CK-F217F-00 ROD, CONNECTING NUT OIL SEAL CK-F CASE, CHAIN G0 COLLAR BOLT, FLANGE CK-F219X-00 COVER CK-F REAR FENDER COMP BOLT,HEX. SOCKET BUTTON CK-F164F-00 STAY BOLT, BUTTON HEAD COLLAR H0 COLLAR CK-F STAY, REAR CK-F STAY, REAR 1 23

32 FIG. 20 (4A0) REAR ARM & SUSPENSION PART PART NAME REMARKS BOLT, FLANGE CK-F PROTECTOR, CHAIN BOLT, FLANGE COLLAR CK-F SHOCK ABSORBER ASSY, REAR 1 24

33 FIG. 21 (4H0) STEERING PART PART NAME REMARKS 1 5BP-F BEARING, STEERING UPPER RACE, BALL RACE, BALL TL-2341E-00 RETAINER, BALL BEARING (16) P-F COVER, BALL RACE NUT WASHER, PLATE P-F WASHER, SPECIAL P-F CROWN, HANDLE BOLT BOLT, FLANGE WASHER 1 25

34 FIG. 22 (4K0) FRONT FORK PART PART NAME REMARKS 1 1CK-F FRONT FORK ASSY 1 2 1CK-F FRONT FORK ASSY (L.H) 1 3 1CK-F TUBE, OUTER (LEFT) P-F METAL, SLIDE P-F OIL SEAL P-F RING, SNAP P-F SEAL, DUST P-F INNER TUBE COMP P-F CYLINDER COMP., FRONT FORK P-F SPRING, REBOUND P-F RING, PISTON P-F SPINDLE, TAPER C-F GASKET C-F BOLT, HEXAGON SOCKET HEAD P-F SPRING, FRONT FORK P-F WASHER, SPRING UPPER P-F SPACER P-F BOLT, CAP P-F GASKET CK-F WASHER CK-F FRONT FORK ASSY (R.H) CK-F TUBE, OUTER (RIGHT) P-F METAL, SLIDE P-F OIL SEAL P-F RING, SNAP P-F SEAL, DUST P-F INNER TUBE COMP P-F CYLINDER COMP., FRONT FORK P-F SPRING, REBOUND P-F RING, PISTON 1 26

35 FIG. 22 (4K0) FRONT FORK PART PART NAME REMARKS 31 20P-F SPINDLE, TAPER C-F GASKET C-F BOLT, HEXAGON SOCKET HEAD P-F SPRING, FRONT FORK P-F WASHER, SPRING UPPER P-F SPACER P-F BOLT, CAP P-F GASKET CK-F WASHER P-F UNDER BRACKET COMP P-F BOLT BP-F BEARING, STEERING LOWER YY-F SEAL, DUST 1 27

36 FIG. 23 (4S0) FUEL TANK PART PART NAME REMARKS 1 1CK-XF41A-00-P0 FUEL TANK COMP. -DPBMY 1 UR FOR DPBMY 1CK-XF41A-10-P1 FUEL TANK COMP. -SMX 1 UR FOR SMX 1CK-XF41A-20-P4 FUEL TANK COMP. -VRC1 1 UR FOR VRC1 2 5YY-F413B-00.EMBLEM P-F BRACKET, FUEL TANK P-F411F-00 PLATE, FITTING COLLAR GROMMET BOLT, WITH WASHER BOLT, HEXAGON SOCKET HEAD GROMMET BOLT, HEXAGON SOCKET HEAD COLLAR P-F MOLD, FUEL TANK D-WF CAP ASSY WITH LOCK BOLT, HEXAGON SOCKET HEAD BOLT C1-E FUEL PUMP COMP B-F BRACKET, FUEL PUMP P-F O-RING BOLT, BUTTON HEAD P-F PIPE CLAMP CLIP 1 28

37 TO : All Dealers PART INFORMATION Kindly share & implement the contents of this Part information with all your branches and YBCs.& stockiest Date: 09/07/2015 Model 1CK series(r15 Ver 2.0) Subject Serviceability of Filter (Fuel Pump) & Clip 3C1-E PI 384 This is to inform that SPG will be servicing Filter-3C1-E with immediate effect- Please refer figure This part is a child part fitted in Fuel Pump 3C1-E C1-E Filter 3C1-F Clip 3C1-E Fuel Pump Complete Notes: Please place your order for Spare Parts in usual manner. You are most earnestly requested to explain, the above to your SERVICE, SALES, & SPARE PARTS TEAM. Please do not hesitate to seek any clarification from our visiting IYM & YMIS FIELD TEAM. Parts Technical Information Spare Part Group INDIA YAMAHA MOTOR PVT.LTD. CC:ZBH / ZSM / RBH / RSM / SALES EXECUTIVE / SERVICE EXECUTIVE / PARTS MANAGERS :YAMAHA POINT(YP)/AUTHORISED SERVICE POINT(ASP) A-3,Industrial Area,Noida,Dadri Road,Surajpur ,Distt Gautam Budhnagar-(UP)

38 FIG. 24 (4U0) SEAT PART PART NAME REMARKS 1 1CK-F SINGLE SEAT ASSY P-F PAD, SEAT BOLT, BUTTON HEAD 2 4 1CK-F TANDEM SEAT ASSY 1 5 4LS-F PAD, SEAT C-F PAD, SEAT P-F SEAT LOCK ASSY NUT, FLANGE 2 9 1CK-F478E-00 CABLE, SEAT LOCK CK-WF47E-00 SEAT LOCK ASSY CK-F117K-00 STAY, LOCK SCREW, PAN HEAD SCREW, PAN HEAD NUT,SPRING 2 29

39 FIG. 25 (4W0) FRONT WHEEL PART PART NAME REMARKS 1 1CK-F CAST WHEEL, FRONT 1 UR FOR DPBMY 1CK-XF CAST WHEEL, FRONT 1 UR FOR SMX 1CK-XF CAST WHEEL, FRONT 1 UR FOR VRC1 2 1CK-F510C-00 COLLAR ASSY OIL SEAL YH BEARING TIRE (90/90-21 M/C 54S) VALVE, RIM TR MT BALANCER, WHEEL (10G) 1 UN 5MT BALANCER, WHEEL (20G) 1 UN 5MT BALANCER, WHEEL (30G) 1 UN 8 1CK-F COLLAR, WHEEL 1 9 1CK-F AXLE, WHEEL NUT, SELF-LOCKING 1 30

40 FIG. 26 (4X0) FRONT BRAKE CALIPER PART PART NAME REMARKS 1 1CK-F582U-00 DISK, BRAKE (RIGHT) BOLT,HEX. SOCKET BUTTON 5 3 1CK-F580U-00 CALIPER ASSY (RIGHT) 1 4 3C1-W PISTON ASSY, CALIPER 1 5 3C1-W CALIPER SEAL KIT 1 6 4C9-W BLEED SCREW KIT 1 7 5YP-F BOOT YP-F BOOT, CALIPER 1 9 5YP-F CLIP P0-F SUPPORT, PAD YP-F PIN, PAD C1-W BRAKE PAD KIT YP-F CLIP, PAD BOLT, FLANGE 2 31

41 FIG. 27 (4Y0) REAR WHEEL PART PART NAME REMARKS 1 1CK-F CAST WHEEL, REAR -DPBMY 1 UR FOR DPBMY 1CK-F CAST WHEEL, REAR -SMX 1 UR FOR SMX 1CK-F CAST WHEEL, REAR -VRC1 1 UR FOR VRC1 2 1CK-F530S-00 COLLAR ASSY YH BEARING B-F DAMPER OIL SEAL P-F CLUTCH, HUB 1 YB Y5 BEARING OIL SEAL 1 9 1CK-F COLLAR, WHEEL CK-F SPROCKET, DRIVEN (47T) BOLT, STUD NUT, SELF-LOCKING TIRE VALVE, RIM TR MT BALANCER, WHEEL (10G) 1 UN 5MT BALANCER, WHEEL (20G) 1 UN 5MT BALANCER, WHEEL (30G) 1 UN 16 1CK-F AXLE, WHEEL CK-F COLLAR, SPROCKET AXLE CK-F COLLAR, WHEEL NUT, SELF-LOCKING WASHER, PLATE CK-F PULLER, CHAIN BOLT NUT, FLANGE E5132 CHAIN E5021.JOINT, CHAIN CK F531B 00 EMBLEM, WHEEL 2 UR FOR VRC1 26 1CK F531B 10 EMBLEM, WHEEL 2 UR FOR SMX 32

42 FIG. 28 (4Z0) REAR BRAKE CALIPER PART PART NAME REMARKS 1 1CK-F582W-00 DISK, REAR BRAKE BOLT 5 3 1CK-F580W-00 CALIPER ASSY, REAR 2 1 UR 2PB-F580W-00 CALIPER ASSY, REAR 2 1 UR 4 4S3-W PISTON ASSY, CALIPER 1 5 3GD-W CALIPER SEAL KIT 1 6 4S3-F SUPPORT, PAD 1 7 4S3-W BLEED SCREW KIT 1 8 3SP-F PIN, SLIDE P-W BRAKE PAD KIT 2 1 UR 4S3-W BRAKE PAD KIT 2 1 UR 33

43 FIG. 29 (5B0) STEERING HANDLE & CABLE PART PART NAME REMARKS 1 20P-F HANDLEBAR (LEFT) P-F HANDLEBAR (RIGHT) BOLT BOLT P-F CAP, BOLT 2 6 1CK-F GRIP ASSY P-F GRIP P-F END, GRIP P-F STOPPER P-F622H-00 WEIGHT P-F622F-00 DAMPER, LOCATING BOLT CK-F CABLE, THROTTLE CK-F CABLE, THROTTLE P-F GUIDE, WIRE SCREW, PAN HEAD P-F CABLE, CLUTCH P-F COVER, HANDLE LEVER COLLAR 1 34

44 FIG. 30 (5C0) FRONT MASTER CYLINDER PART PART NAME REMARKS 1 20P-F HOSE, BRAKE CK-F583T-00 MASTER CYLINDER ASSY 1 3 5P0-W CYLINDER KIT, MASTER 1 4 3RW-F DIAPHRAGM, RESERVOIR 1 5 3C1-F CAP, RESERVOIR Y-2589H-00.SCREW 2 7 3RW-F BRACKET, MASTER CYLINDER 1 8 3C1-F BUSH,DIAPHRAGM B-H LEVER BOLT NUT, U CK-H FRONT STOP SWITCH ASSY PLUG BOLT, FLANGE BOLT, UNION WASHER, PLATE CK-F HOLDER, BRAKE HOSE BOLT, FLANGE P-F HOLDER, BRAKE HOSE BAND, SWITCH CORD 1 35

45 FIG. 31 (5F0) STAND & FOOTREST PART PART NAME REMARKS 1 20P-F STAND, SIDE SPRING, TENSION A7 BOLT, FLANGE COLLAR WASHER, PLATE NUT, U HOSE (L70) P-F BRACKET P-F FOOTREST P-F FOOTREST B9 SPRING, TORSION PIN, CLEVIS PIN, COTTER P-F BOLT PIN BOLT, HEXAGON SOCKET HEAD WASHER, PLATE BOLT, HEXAGON SOCKET HEAD P-F PLATE BOLT, BUTTON HEAD P-F BRACKET P-F FOOTREST P-F FOOTREST B0 SPRING, TORSION PIN, CLEVIS PIN, COTTER P-F BOLT PIN BOLT, HEXAGON SOCKET HEAD WASHER, PLATE 1 36

46 FIG. 31 (5F0) STAND & FOOTREST PART PART NAME REMARKS 31 1CK-F PEDAL, BRAKE P-E COVER, SHIFT PEDAL SPRING, TENSION HOSE CK-F144G-00 STAY, STOP SWITCH BOLT, BUTTON HEAD BOLT, HEXAGON SOCKET HEAD P-F PLATE H8 COLLAR BOLT, BUTTON HEAD P-F FOOTREST, REAR P-F FOOTREST, REAR SPRING, COMPRESSION BALL PIN, CLEVIS PIN, COTTER CK-F741L-00 BRACKET CK-F742L-00 BRACKET BOLT, FLANGE COLLAR P-E DAMPER, MUFFLER 1 37

47 FIG. 32 (5G0) REAR MASTER CYLINDER PART PART NAME REMARKS 1 1CK-F583V-00 RR. MASTER CYLINDER ASSY P-W CYLINDER KIT, MASTER NUT 2 4 2YK-F JOINT 1 5 4ML-F582A-50.JOINT 1 6 2VN-F CIRCLIP O-RING P-F TANK, RESERVOIR C-F CAP, RESERVOIR P-F585B-00.PLATE, DIAPHRAGM P-F DIAPHRAGM, RESERVOIR SCREW, FLAT HEAD CLIP CK-F HOSE, RESERVOIR FV-F589A-00.COVER, DUST TT-F PIN PIN, CLEVIS WASHER, PLATE PIN, COTTER BOLT, BUTTON HEAD BOLT, WITH WASHER CK HOSE, BRAKE BOLT, UNION WASHER, PLATE CLAMP 2 38

48 FIG. 33 (5M0) LEG SHIELD PART PART NAME REMARKS CLAMP P-F P0 COVER, UNDER -SMX FOR DPBMY 1 SMX FOR DPBMY 20P-F P2 COVER, UNDER -DBNM8 FOR SMX 1 DBNM8 FOR SMX 20P-F P3 COVER, UNDER -BWC1 FOR VRC1 1 BWC1 FOR VRC1 3 20P-F P0 COVER, UNDER 2 -SMX FOR DPBMY 1 SMX FOR DPBMY 20P-F P2 COVER, UNDER 2 -DBNM8 FOR SMX 1 DBNM8 FOR SMX 20P-F P3 COVER, UNDER 2 - BWC1 FOR VRC1 1 BWC1 FOR VRC BOLT,HEX. SOCKET BUTTON GROMMET C2 COLLAR GROMMET P-F COLLAR NUT, SPRING C-F831U-00 STAY, SIDE P-F832U-00 STAY, SIDE CK-XF83D-00 PANEL, INNER 3 -DPBMY 1 UR FOR DPBMY 1CK-XF83D-10-P0 PANEL, INNER 3 -DBNM8 FOR SMX 1 UR DBNM8 FOR SMX 1CK-XF83D-30-1X PANEL, INNER 3 -BWC1 FOR VRC1 1 UR BWC1 FOR VRC SCREW, TRUSS HEAD TAPPING P-F GROMMET GROMMET BOLT,HEX. SOCKET BUTTON WASHER, PLATE 4 39

49 FIG. 34 (5M3) WINDSHIELD PART PART NAME REMARKS 1 1CK-F WINDSHIELD P-F836R-00 PANEL, INNER SCREW, ROUND HEAD NUT DAMPER, PLATE 2 6 1CK-XF P0 PANEL ASSY -DPBMY 1 UR FOR DPBMY 1CK-XF P1 PANEL ASSY -SMX 1 UR FOR SMX 1CK-XF P4 PANEL ASSY -VRC1 1 UR FOR VRC NUT, SPRING CLAMP CLAMP P-F STAY BOLT,HEX. SOCKET BUTTON GROMMET P-F REAR VIEW MIRROR ASSY (LEFT) P-F REAR VIEW MIRROR ASSY (RIGHT) P-F PLATE, RUBBER P-F PLATE, RUBBER BOLT C2 COLLAR P-F BRACKET, LICENSE P-F CAP, BOLT US-F PLATE, NUMBER SCREW,WITH WASHER CK-XF11E-00-P0 COVER 7 -DPBMY 1 UR FOR DPBMY 1CK-XF11E-10-P1 COVER 7 -SMX 1 UR FOR SMX 1CK-XF11E-20-P2 COVER 7 -VRC1 1 UR FOR VRC1 24 1CK-XF11F-00-P0 COVER 8 -DPBMY 1 UR FOR DPBMY 1CK-XF11F-10-P1 COVER 8 -SMX 1 UR FOR SMX 1CK-XF11F-20-P2 COVER 8 -VRC1 1 UR FOR VRC1 40

50 FIG. 34 (5M3) WINDSHIELD PART PART NAME REMARKS BOLT,HEX. SOCKET BUTTON C2 COLLAR GROMMET WASHER, PLATE BOLT,HEX. SOCKET BUTTON CK-XF P0 PANEL COMP 1 -DPBMY 1 UR FOR DPBMY 1CK-XF P1 PANEL COMP 1 -SMX 1 UR FOR SMX 1CK-XF P2 PANEL COMP 1 -VRC1 1 UR FOR VRC1 31 1CK-XF83G-00-P0 PANEL COMP 2 -DPBMY 1 UR FOR DPBMY 1CK-XF83G-10-P1 PANEL COMP 2 -SMX 1 UR FOR SMX 31 1CK-XF83G-20-P2 PANEL COMP 2 -VRC1 1 UR FOR VRC SCREW, TRUSS HEAD TAPPING NUT, SPRING BOLT,HEX. SOCKET BUTTON WASHER, PLATE P-F837L-00 PANEL, CONSOLE P-F837M-00 PANEL, CONSOLE BOLT,HEX. SOCKET BUTTON C4 COLLAR 2 41

51 FIG. 35 (8A0) GENERATOR PART PART NAME REMARKS 1 3C1-H ROTOR ASSY 1 2 3C1-H STATOR ASSY BOLT BOLT NUT, FLANGE WASHER, PLATE 1 42

52 FIG. 36 (8C0) STARTING MOTOR PART PART NAME REMARKS 1 38B-H STARTING MOTOR ASSY 1 2 3AY-H BRUSH SET 1 3 5D7-8183G-00.CORD COMP S7-H GASKET 1 5 3AY-H SCREW O-RING 1 43

53 FIG. 37 (8F0) FLASHER LIGHT PART PART NAME REMARKS 1 1CK-H FRONT FLASHER LIGHT ASSY B-H331A-00.LENS COMP P-H BULB, FLASHER (12V-10W) P-H STAY, FLASHER CK-H331E-00.CORD ASSY P-H PLATE P-H213A-00.SCREW, FITTING P-H SCREW, LENS FITTING P-H SCREW, FITTING CK-H FRONT FLASHER LIGHT ASSY B-H332A-00.LENS COMP P-H BULB, FLASHER (12V-10W) P-H STAY, FLASHER CK-H332E-00.CORD ASSY P-H PLATE P-H213A-00.SCREW, FITTING P-H SCREW, LENS FITTING P-H SCREW, FITTING YY-H STAY, FLASHER CK-H REAR FLASHER LIGHT ASSY B-H334A-00.LENS COMP P-H BULB, FLASHER (12V-10W) P-H STAY, FLASHER CK-H333E-00.CORD ASS'Y P-H PLATE P-H213A-00.SCREW, FITTING P-H SCREW, LENS FITTING P-H SCREW, FITTING CK-H REAR FLASHER LIGHT ASSY B-H333A-00.LENS COMP

54 FIG. 37 (8F0) FLASHER LIGHT PART PART NAME REMARKS 31 20P-H STAY, FLASHER CK-H334E-00.CORD ASS'Y P-H PLATE P-H213A-00.SCREW, FITTING P-H SCREW, LENS FITTING P-H SCREW, FITTING P-H BULB, FLASHER (12V-10W) YY-H STAY, FLASHER

55 FIG. 38 (8G0) METER PART PART NAME REMARKS 1 1CK-H METER ASSY WASHER, PLATE SCREW, TRUSS HEAD TAPPING GROMMET P-H DAMPER 1 6 1CK-H SENSOR, SPEED 1 7 1CK-H CLAMP BOLT, FLANGE 1 9 1CK-H CLAMP BOLT, FLANGE 1 46

56 FIG. 39 (8H0) HEADLIGHT PART PART NAME REMARKS 1 20P-H HEADLIGHT ASSY P-H BULB (12V-35/35W) P-H BULB (12V-5W) P-H CAP P-H COVER P-H COVER P-H COVER, SOCKET P-H CORD ASSY P-H DAMPER, HEADLIGHT SCREW, TRUSS HEAD TAPPING NUT, SPRING GROMMET WASHER, PLATE SCREW, TRUSS HEAD TAPPING CK-H CORD, HEADLIGHT 1 47

57 FIG. 40 (8J0) TAILLIGHT PART PART NAME REMARKS 1 1CK-H TAILLIGHT UNIT ASSY SCREW, TRUSS HEAD TAPPING GROMMET 2 4 1CK-H LICENCE LIGHT ASSY 1 5 1CK-H SCREW 2 6 1CK-H CORD, LICENCE LIGHT 1 7 1CK-H BULB (12V-5W) SCREW, BIND NUT 1 48

58 FIG. 41 (8T0) HANDLE SWITCH & LEVER PART PART NAME REMARKS 1 20P-H SWITCH, HANDLE CK-H SWITCH, HANDLE P-H HOLDER, LEVER P-H LEVER P-H BOLT, LEVER P-H331B-00 NUT, SPRING P-H BOLT P-H BOLT, CABLE ADJUSTING P-H NUT, ADJUSTING YX SWITCH SCREW, FLAT HEAD 1 49

59 FIG. 42 (8V0) ELECTRICAL 1 PART PART NAME REMARKS 1 1P5-H IGNITION COIL ASSY BOLT P-H PLUG CAP ASSY P-H BATTERY ASSY (GS YTZ 5S MF) 1 5 1CK-H PAD, BATTERY P-F811G-00 BAND 1 7 1CK-H WIRE, PLUS LEAD 1 8 1CK-H WIRE, SUB LEAD 1 9 1CK-H WIRE, MINUS LEAD C-H MAIN SWITCH STEERING LOCK SCREW CK-H STOP SWITCH ASSY CK-H WIRE HARNESS ASSY P-XH MAIN SW. STRG. LOCK SUB ASSY 1 AP 50

60 FIG. 43 (8W0) ELECTRICAL 2 51 PART PART NAME REMARKS 1 1CK-H591A-00 ENGINE CONTROL UNIT ASSY 1 2 1CK-H BAND C-H NEUTRAL SWITCH ASSY GASKET B-H THERMOSENSOR ASSY GASKET 1 7 2S5-H RECTIFIER & REGULATOR ASSY BOLT, FLANGE 2 9 1CK-H PLATE, RECTIFIER FITTING BOLT, FLANGE CK-H STARTER RELAY ASSY P-H FUSE (20A) BOLT B SENSOR, LEAN ANGLE SCREW, TAPPING A2 WASHER, PLATE CK-H RELAY ASSY CLAMP CLAMP CK-H COVER, CONNECTER P-H246B-00 COVER BOLT, WITH WASHER CK-H PROTECTER, WIRE HARNESS CLAMP TS-H FLASHER RELAY ASSY CK-H HORN CK-H HORN BOLT, FLANGE US-H REFLECTOR ASSY NUT, U WASHER, PLATE 1

61 PART NO PART NO PART NO PART NO PART NO PART NO 10B CK CK-E CK-E CK-E CK-E CK-E246A CK-E CK-E CK-E CK-E CK-E CK-E CK-E CK-E CK-E CK-E CK-E CK-E CK-F CK-F117G CK-F117K CK-F144G CK-F X CK-F X CK-F X CK-F160E CK-F CK-F CK-F CK-F CK-F CK-F164F CK-F CK-F CK-F171X-00-P CK-F171X-00-P CK-F171X-00-P CK-F CK-F CK-F CK-F CK-F CK-F217A CK-F217F CK-F219X CK-F CK-F CK-F CK-F CK-F CK-F CK-F CK-F CK-F CK-F CK-F CK-F478E CK-F510C CK-F CK-F CK-F CK-F530S CK-F CK-F CK-F CK-F CK-F CK-F CK-F CK-F580U CK-F580W CK-F582U CK-F582W CK-F583T CK-F583V CK-F CK-F CK-F CK-F CK-F CK-F CK-F741L CK-F742L CK-F CK-F CK-F CK-H CK-H CK-H CK-H CK-H CK-H CK-H CK-H CK-H CK-H CK-H333E CK-H CK-H334E CK-H CK-H CK-H CK-H CK-H CK-H CK-H CK-H CK-H CK-H CK-H CK-H CK-H CK-H CK-H CK-H591A CK-WF47E CK-XF11E-00-P CK-XF11E-10-P CK-XF11E-20-P CK-XF11F-00-P CK-XF11F-10-P CK-XF11F-20-P CK-XF P CK-XF17C-10-P CK-XF17C-20-P CK-XF41A-00-P CK-XF41A-10-P CK-XF41A-20-P CK-XF CK-XF CK-XF CK-XF CK-XF P CK-XF P CK-XF P CK-XF P CK-XF P CK-XF P CK-XF83D CK-XF83D-10-P CK-XF83D-30-1X CK-XF83G-00-P CK-XF83G-10-P CK-XF83G-20-P P5-H S S7-E S7-H WG P-E P-E441J P-E443E P-E P-E P-E P-E P-E P-E P-E P-E P-E P-E P-E P-E P-E P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F411F P-F P-F P-F P-F P-F P-F P-F P-F P-F585B P-F P-F P-F P-F P-F P-F622F P-F622H P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F P-F811G P-F P-F832U P-F P-F836B P-F836R P-F837L P-F837M P-F P P-F P P-F P P-F P P-F P P-F P P-F P-F P-H P-H P-H P-H P-H P-H213A P-H213A P-H213A P-H213A P-H P-H246B P-H P-H P-H P-H P-H P-H P-H P-H P-H P-H331B P-H P-H P-H P-H P-H i

62 PART NO PART NO PART NO PART NO PART NO PART NO 20P-H P-H P-H P-H P-H P-H P-H P-H P-H P-H P-H P-H P-H P-H P-H P-H P-H P-H P-H P-W P-W P-XH C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-E C-F C-F C-F C-F C-F C-H PB-F580W S5-1410H S5-H VN-F YK-F Y-2589H B-E B-E111F B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E240A B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-E B-F B-H B-H B-H AY-H AY-H C C C C C C1-E C1-E C1-E C1-E C1-E C1-F C1-F C1-H C1-H C1-W C1-W C1-W FV-F589A GD-W RW-F RW-F SP-F YX C9-W LS-E LS-F ML-F582A S3-F S3-W S3-W S3-W TT-F B-E B-E B-E B-E B-E B-F B-H331A B-H332A B-H333A B-H334A C-F C-F831U C-H D-WF BP-F BP-F CA D7-8183G JW MT MT MT MT MT MT P0-F P0-W ST-E TL-2341E TS-F TS-H US-F US-H YP YP-1482K YP-E YP-E YP-E YP-E YP-E YP-E YP-E YP-E YP-F YP-F YP-F YP-F YP-F YY-F YY-F413B YY-H YY-H A A E F ii

63 PART NO PART NO PART NO PART NO PART NO PART NO W C C C C C G G H H S B B Y X YN XX Y YD YE XS Y YH YH X Y X Y Y A E E iii