Parts Diagrams RR/RS Models
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- Blaze Hutchinson
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1 Parts Diagrams RR/RS Models
2 Table Of Contents Description Page # front fork 1 handlebar, clutch pump, meter (RR Models) 2 handlebar, clutch pump, meter (RS Models) 3 frame, subframe 4 rear shock, swingarm 5 exhaust 6 airbox 7 front wheel 8 rear wheel 9 brakes 10 plastic, seat (RR Models) 11 plastic, seat (RS Models) 12 electrics (RR Models) 13 electrics (RS Models) 14 radiator 15 rear linkage (early production) 16 rear linkage (late production) 17 graphics 18
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5 Pos Part Number Description RR/RS Notes front fork assembly model front fork assembly model fork cap spring support fork spring, 48kg 2 stock setting fork spring, 50kg opt fork spring, 45kg opt fork spring, 42kg opt fork spring tube fork leg, upper fork bushing fork seal fork dust ring inner tube kit top nut fork spring inner tube inner fork tube A inner fork tube B lower fork tube, right fork bushing valve assembly lower fork tube, left lower triple clamp top triple clamp washer top nut fork guard, left model red fork guard, left model black fork guard, right model red fork guard, right model black complete fork leg, left 1 Page 1
6 complete fork leg, right spacer hose guide model red hose guide model black fork guide bolt, axle pinch bolt, fork guard screw, hose guide bolt, fork pinch bolt, stem pinch bolt, fork guide nut, fork guide reflector 2 RS models only Page 1
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9 Pos Part Number Description RR ONLY Notes speedometer main wire harness wire holder screw for meter washer for meter rubber for meter speedometer bracket throttle assembly, includes grips start switch throttle cable top handlebar mount bolt, handlebar, 8x bolt, handlebar clamp, 10x lower handlebar mount handlebar switch assy, left grips, pair banjo bolt 1 same as item clutch hose crush washer clutch pump assembly banjo bolt 1 same as item screw for top cap seal and cap for clutch pump wire holder piston kit for clutch pump spring, adjuster clutch lever adjuster clutch lever only bush, clutch lever screw, clutch lever nutplate screw clip, clutch adjuster bolt nut, clutch lever throttle tube 1 tube only washer spacer bolt, 6x16 2 Page 2
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11 Pos Part Number Description RS Notes speedometer main wire harness wire holder flasher rubber for meter speedometer bracket throttle assembly, includes grips start switch throttle cable top handlebar mount bolt, handlebar, 8x bolt, handlebar clamp, 10x lower handlebar mount handlebar switch assy, left model switch assy, left model grips, pair banjo bolt clutch hose crush washer clutch pump assembly banjo bolt 1 same as item screw for top cap seal and cap for clutch pump push button for meter piston kit for clutch pump spring, adjuster clutch lever adjuster clutch lever only bush, clutch lever screw, clutch lever washer, meter nut, meter clip, clutch adjuster bolt nut, clutch lever throttle tube 1 tube only mirror, right side mirror, left side bolt, 6x16 2 Page 3
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13 Pos Part Number Description RR/RS Notes main frame (RR model) 1 must return steering head main frame (RS model) 1 must return steering head bearing protection, top bearing, steering bearing protection, bottom oring steering lock 1 RS models only footrest, right footrest pin footrest spring footrest washer, 10x21x cotter pin, 3x engine mount bolt footrest, left sliding block fuel tank pad rear subframe model rear subframe model cushion side stand rubber side stand bolt 1 for spring side stand bolt side stand spring skid plate bolt, upper sub frame bolt, lower sub frame bolt, airbox nut, engine mount bolt, tank pad washer, steering stop bolt, steering stop bolt, skid plate bolt, skid plate 1 pan head screw nut clip pad, skid plate tool bag 1 includes tools owners manual model owners manual model Page 4
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15 Pos Part Number Description RR/RS Notes shock assembly upper bushing kit adjustment nut A adjustment nut B bump stop retainer lower clevis seal set A seal set B 1 10 AB shock spring, 5.4 kg 1 stock setting 10 AB shock spring, 5.2 kg opt 10 AB shock spring, 5.6 kg opt 10 AB shock spring, 5.8 kg opt 10 AB shock spring, 6.0 kg opt bolt, shock mount nut, shock mount bolt, sprocket cover bolt, chain block bolt, chain block nut, chain block upper chain guard washer, guard inner chain guard bolt, 5x hose guide swing arm plug master link drive chain, 520x chain adjuster bolt, 8x chain adjuster nut, 8mm spacer 1 Page 5
16 lower chain block spacer swing arm plug bolt, 5x wellnut for frame guards swing arm pivot shaft swing arm 1 does not include bearings bearing, swing arm spacer cup spacer seal swing arm shaft nut spacer sprocket cover chain slider spacer 1 Page 5
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19 Pos Part Number Description RR/RS Notes exhaust header pipe exhaust spring exhaust muffler, spark arrestor spacer rubber bushing spacer, long muffler re pack kit bolt, muffler bolt, muffler nut clip, muffler bolt, header pipe nut clip, header pipe 1 Page 6
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21 Pos Part Number Description RR/RS Notes air boot clamp rear air boot filter box, right air filter hold down bracket filter box, front filter box, rear air filter cage air filter filter pin air filter holder holding washer battery box ground cable bolt, 6x rear mud flap filter box, left carbon canister 1 RS models only, includes hoses catch tank 1 RS models only check valve 1 RS models only rivot, air box holder rivot, filter box spacer, battery box bolt, batter box washer, rear mud flap screw, rear mud flap oring, battery holder airbox assembly 1 does not include air boot (item #2) Page 7
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23 Pos Part Number Description RR/RS Notes front brake rotor 1 does not include items 7 & front hub 1 includes bearings and seals front axle nut front wheel spacer front wheel seal front wheel bearing clip speedometer pick up front spoke, 4x nipple front spoke, 4x rotor bolt, 8x front hub inner spacer front wheel bearing 1 same as item front wheel seal front wheel spacer 1 same as item front axle front axle plug front rim, 21" rim strip front tube, 21" front tire, Pirelli MX extra (80/100x21) 1 RR Model front tire, Pirelli MT21 (90/90x21) 1 RS Model front rim lock nut, 8mm 1 25 AB front wheel assembly, no tire or tube 1 RR/RS Model, includes rotor & bearings Page 8
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25 Pos Part Number Description RR/RS Notes rotor bolt, 8x rear brake rotor rear spoke, 4x nipple rear spoke, 4x rear hub 1 includes bearings and seals rear sprocket, 50t 1 RR Model, standard setting rear sprocket, 52t opt rear sprocket, 48t opt rear sprocket, 45t 1 RS Model, standard setting rear sprocket nut, 8mm rear sprocket bolt rear hub inner spacer rear wheel bearing 1 uses only one of this bearing rear wheel bearing rear wheel seal rear wheel spacer, left rear axle 1 does not include item tensioner block, left rear rim, 18" rim strip rear tube, 18" rear tire, Pirelli MX extra (110/100x18) 1 RR Model rear tire, Pirelli MT21 (130/90x18) 1 RS Model rear rim lock nut, 8mm rear wheel bearing 1 same as item rear wheel seal 1 same as item rear wheel spacer, right tensioner block, right rear axle nut 1 28 AB rear wheel assembly, no tire or tube 1 RR Model, includes rotor, bearings, & sprocket 28 AB rear wheel assembly, no tire or tube 1 RS Model, includes rotor, bearings, & sprocket Page 9
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27 Pos Part Number Description RR/RS Notes rebuild kit, front brake pump front brake pump assembly front brake lever cap, front brake pump screw, brake pump cap crush washer banjo bolt 1 RR model banjo bolt & stop switch 1 RS model front brake hose front hose clip, small front hose clip, large sensor for meter banjo bolt 1 same as item front brake caliper 1 includes brake pads caliper spring piston and seal kit for caliper brake bleeder front brake pad set pin for brake pad pin plug lever cover bolt, caliper mount washer, caliper mount bolt, rear brake pump rear brake pump assembly rebuild kit, rear brake pump cap set, rear brake pump pin, rear brake pump cotter key, rear brake pump kit, lower clevis 1 includes adjustment bolt brake pedal tip 1 Page 10
28 bolt, 5x brake pedal spring cotter pin, 2x pin kit, pump tank kit, lower clevis bearing, 8x22x bushing, rear beake pedal rear brake pedal 1 arm only rear brake pedal assembly 1 includes items 30,31,37, & rear brake pump cap 1 includes cap seal banjo bolt 1 RR model banjo bolt & stop switch 1 RS model rear brake hose banjo bolt 1 same as item rear brake caliper assembly 1 includes mount rear brake pad set brake bleeder piston and seal kit for caliper caliper spring pin plug pin for brake pad 1 Page 10
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31 Pos Part Number Description RR ONLY Notes headlight mask Model headlight mask Model front fender Model front fender Model front fender support spacer tank panel, right Model tank panel, right Model tank panel, left Model tank panel, left Model spacer Model spacer Model petcock frame guard, right frame guard, left inner rear fender side panel, left Model side panel, left Model spacer rear tail light holder rear fender Model rear fender Model seat bracket seat 1 does not include item 17 18a seat cover 1 cover only side panel, right Model side panel, right Model cushion fuel tank spacer seat lock screw fuel cap Model Page 11
32 fuel cap Model fuel line 1 sold per foot fuel tank breather breather fitting fuel tank headlight holder air breather washer, fender Model fender spacer Model screw, special long bolt, 6x bolt, 6x spacer bolt, 6x allen screw, seat bracket spacer, machined screw, special short spacer, rear air intake bolt, 6x screw, tank shroud spacer, inner fender bolt, 6x seal, fuel cap guide, front brake hose screw, front brake hose guide 1 Page 11
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35 Pos Part Number Description RS Notes headlight mask model headlight mask model front fender model front fender model front fender support spacer front brake hose guide tank panel, right model tank panel, right model tank panel, left model tank panel, left model spacer model spacer model petcock frame guard, right frame guard, left inner rear fender side panel, left model side panel, left model spacer rear tail light holder 1 does not include light rear fender model rear fender model seat bracket seat 1 does not include item 17 18a seat cover 1 cover only side panel, right model side panel, right model cushion fuel tank spacer seat lock screw 1 Page 12
36 fuel cap model fuel cap model fuel line 1 sold per foot fuel tank breather breather fitting fuel tank headlight holder air breather washer, fender screw, special long bolt, 6x bolt, 6x spacer bolt, 6x allen screw, seat bracket spacer, rear air intake bolt, 6x screw, tank shroud spacer, inner fender bolt, 6x seal, fuel cap guide, front brake hose nut clip screw, special license plate holder reflector reflector kit 1 includes aluminum bracket spacers and bolts 1 to hold item 49 to rear fender Page 12
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39 Pos Part Number Description RR ONLY Notes headlamp assembly 1 RR Model, includes loom assy spark plug cap regulator wire loom 1 CDI to main loom ignition coil rear wire loom fuse, 10A positive battery cable 1 solinoid to battery rear tail light 1 RR Model starter relay positive battery cable 1 solinoid to main loom block positive battery cable 1 main loom block to starter battery YTX5LBS CDI unit, CDI unit, 400, screw for headlight bulb, 35/35 W bulb, small allen, starter cable bolt, 6x bolt, 6x12 2 Page 13
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41 Pos Part Number Description RS Notes headlamp assembly spark plug cap regulator flasher wire loom 1 CDI to main loom ignition coil rear wire loom 1 RS Model fuse, 10A positive battery cable 1 solinoid to battery rear tail light rear tail light lens starter relay positive battery cable 1 solinoid to main loom block positive battery cable 1 main loom block to starter battery YTX5LBS rear turn signal, right rear turn signal, left front turn signal, right front turn signal, left CDI unit, CDI unit, 400, screw, tail light lens bulb, tail light nut, turnsignal lens, turnsignal 4 lens only screw, 6mm pan head bulb, 35/35 W nut, rear tail light bulb, turn signal allen, starter cable bolt, 6x bolt, 6x12 2 Page 14
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43 Pos Part Number Description RR/RS Notes radiator, right radiator hose hose clamp, 19x radiator hose overflow tube 1 sold per foot radiator cap radiator, left 1 includes cap horn 1 RS Model horn bracket 1 RS Model bolt, 6x12 2 RS Model radiator hose bolt, 6x washer, 6x rubber mount, radiator radiatorat hose radiator guard, right radiator guard, left lower thermo hose A lower thermo hose B thermostat assembly 1 Page 15
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45 Fits: 400 RR ZD3E thru RR ZD3E thru RR ZD3E thru RS ZD3E thru Pos Part Number Description RR/RS Notes nut, 12mm 1 same as item cup washer seal, 25x32x needle bearing, 20x26x wishbone inner bushing bolt lower shock bolt, 10x cup washer seal, 18x24x needle bearing, 18x24x inner bushing nut, 12mm 2 same as item washer, 20x30x inner bushing bolt bolt inner bushing rocker arm swing arm bushing 2 Page 16
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47 Fits: 400 RR ZD3E and on 450 RR ZD3E and on 525 RR ZD3E and on All other RS Models Pos Part Number Description RR/RS Notes nut, 12mm 1 same as item cup washer seal, 25x32x needle bearing, 20x26x wishbone inner bushing bolt lower shock bolt, 10x retainer seal, 16x24x needle bearing, 12x24x needle bearing, 20x26x nut, 12mm 2 same as item inner bushing bolt bolt inner bushing rocker arm swing arm bushing 2 Page 17
48 Graphics Pos Part Number Description RR/RS Notes opt tank panel graphic set only RR/RS (all models) opt tank panel graphic set only RR/RS (all models minus 450 RR race) opt complete graphic set RR opt complete graphic set RR opt complete graphic set RR opt complete graphic set RS opt complete graphic set RS opt complete graphic set RR opt complete graphic set RR opt complete graphic set RR auto opt complete graphic set RR race **** opt complete graphic set RR opt complete graphic set RR auto opt complete graphic set RS opt complete graphic set RS opt AB Front mask graphic RR (all models) opt AB Front mask graphic RS (all models) opt AB Front mask graphic RR 400/450/525 opt AB Front mask graphic RR 450 auto/525 auto opt AB Front mask graphic RS (all models) opt AB Front fender graphic RR/RS (all models) opt AB Front fork guard graphic (set) RR/RS (all models) opt AB Front fork guard graphic (set) RR/RS 400/450/525 opt AB Front fork guard graphic (set) RR 450 auto/525 auto opt AB airbox graphics (set) RR opt AB airbox graphics (set) RR opt AB airbox graphics (set) RR opt AB airbox graphics (set) RS opt AB airbox graphics (set) RS opt AB airbox graphics (set) RR Page 18
49 opt AB airbox graphics (set) RR opt AB airbox graphics (set) RR auto opt AB airbox graphics (set) RR opt AB airbox graphics (set) RR auto opt AB airbox graphics (set) RS opt AB airbox graphics (set) RS opt AB Rear number plate graphics (set) RR/RS (all models) opt AB Rear number plate graphics (set) RR/RS (all models) opt AB Rear fender graphic RR/RS (all models) opt AB Fuel tank graphic (around gas cap) RR/RS (all models) opt AB Fuel tank graphic (around gas cap) RR/RS (all models) ****note 450 RR race model graphics are unique to this model and are only available in a complete set Page 18
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51 Parts Diagrams RR/RS Models (ENGINE) Printed 4/2009
52 Table of Contents Description Page # lower engine case 1 crankshaft, piston 2 counterbalancer 3 cylinder 4 cylinder head 5 valves, rocker arms 6 camshaft, camchain, waterpump 7 oil filters, oil pump 8 carburetor 9 stator, cdi, coil 10 starter motor 11 clutch 12 kickstarter assembly 13 transmission A 14 transmission B 15 shifting mechanism 16
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55 08 09 Beta RR/RS Models Pos Part Number Description Qty Notes engine case set 1 includes parts as listed dowel, 17x14x dowel, 9.8x7x hanger for vent hose bolt, 6x oil drain bolt crush washer plug dowel, 17x19x pressure spring valve piston jet, oil breather pipe bleeder flange locating screw crush washer needle roller oil sight glass 1 seal included oil filler plug oil filler oring locating pin washer screw, 5x screw, 6x bracket for brake pedal spring oring plug, oil screen oil screen oring seal ring outer clutch cover clutch cover gasket center case gasket clutch cover assembly 1 includes outter cover shift shaft seal kickstart shaft seal bolt, clutch cover outter clutch cover seal bolt, 6x bolt, 6x bolt, 6x bolt, 6x bolt, 6x complete engine gasket set 1 Page 1
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57 08 09 Beta RR/RS Models Pos Part Number Description Qty Notes crankshaft crankshaft 1 450, connecting rod set connecting rod set 1 450, engine main bearing drive gear, 32t thrust washer opt thrust washer opt thrust washer opt keyway bolt, 6x oil seal, 30x47x primary gear, 33t nut keyway oil seal, 14x24x circlip nut spring washer piston pin circlip, piston piston kit, 89mm # piston kit, 89mm # piston kit, 89mm # piston kit, 89mm # piston kit, 95mm # piston kit, 95mm # oil scraper ring 1 400, oil scraper ring piston ring, top 1 400, piston ring, top Page 2
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59 08 09 Beta RR/RS Models Pos Part Number Description Qty Notes balancer shaft bearing oil seal 1 Page 3
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61 08 09 Beta RR/RS Models Pos Part Number Description Qty Notes cylinder, 89mm 1 400, cylinder, 95mm base gasket, 0.5mm 1 400, base gasket, 0.8mm dowel bolt, 6x bolt, 6x locating pin crush washer bolt, 6x10 1 Page 4
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63 08 09 Beta RR/RS Models Pos Part Number Description Qty Notes cylinder head USA 1 includes vacuum port head gasket, 89.3mm 1 400, head gasket, 95.3mm tappet cover tappet cover gasket bolt, 6x bolt, 6x bolt, 6x bolt, 6x bolt, 6x valve guide, intake valve guide, exhaust intake boot clamp exhaust flange exhaust flange gasket bolt, 6x crush washer bolt, 6x dowel bolt, 6x crush washer washer water pump cover water pump cover gasket cylinder bolt 4 Page 5
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65 08 09 Beta RR/RS Models Pos Part Number Description Qty Notes intake valve, 35mm exhaust valve, 30mm valve guide seals valve spring kit valve spring keeper valve adjustment screw valve adjustment nut rocker arm shaft, intake rocker arm shaft, exhaust end cap oring washer, aluminum screw, 5x decompression shaft oring spring circlip rocker arm assembly, intake rocker arm assembly, exhaust 1 Page 6
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67 08 09 Beta RR/RS Models Pos Part Number Description Qty Notes cam chain 1 includes master link cam chain guide cam chain guide, lower timing gear, 18t cam chain guide cam chain tensioner gasket cam chain tensioner bushing bolt, 6x bolt, 5x spacer crush washer bolt, 6x camshaft camshaft 1 450, camshaft gear auto decompression shaft bolt, 8x shim washer water pump seal holder camshaft bearing spring for auto decompression oring oring water pump seal cam chain master link locating pin water pump impeller circlip 1 Page 7
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69 08 09 Beta RR/RS Models Pos Part Number Description Qty Notes oil pump shaft oil pump assembly, inner oil pump assembly, outer oil pump drive gear, 26t oil pump cover, outer oil pump cover, inner bolt, 5x bolt, 5x oil filter cover oil filter, long oil filter, short locating pin locating pin banjo bolt banjo bolt crush washer oil pipe oring, oil filter cover oil screen plug oil screen oring, oil screen oring, oil screen plug washer circlip rubber, oil pipe 1 Page 8
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71 08 09 Beta RR/RS Models Pos Part Number Description Qty Notes carburetor assembly RR carburetor assembly RR carburetor assembly RR carburetor assembly RS carburetor assembly RS carburetor cover throttle shaft throttle shaft spring throttle valve arm 1 18 not used throttle valve throttle valve bushing throttle valve plate gasket washer jet needle, OBDTR 1 400, 450, 525 RR jet needle, OBDVT 1 450, 525 RS jet needle, OBDVR opt neddle clip needle holder set needle jet main jet, 170 opt main jet, 172 opt main jet, 175 opt main jet, stock jet main jet, 180 opt main jet, 182 opt main jet, 185 opt main jet, 188 opt main jet, 190 opt pilot jet, 42 1 stock jet pilot jet, 45 opt starter jet, idle air jet, Page 9
72 08 09 Beta RR/RS Models idle air jet, air mixture screw set buffer plate float float arm pin float valve assembly drain screw accelerator pump cover float chamber coil spring starter valve set breather hose set screw, throttle cover drain bolt intermediate lever set link lever spring, link lever spring, intermediate lever carburetor cover washer circlip accelerator pump rod clamp plug opt crush washer opt hose connector engine breather hose idle adjuster set throttle position sensor gasket set, complete 1 Page 9
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75 08 09 Beta RR/RS Models Pos Part Number Description Qty Notes ignition cover ignition cover gasket stator 1 does not include item # flywheel pulser coil cdi unit RR and RS cdi unit 1 400, 525 RR and RS spark plug cap spark plug, DCPR8E support for wire screw, 4x wire loom 1 CDI to main loom ignition coil cable tie opt sold in package of dowel bolt, 6x bolt, 6x bolt, 6x bolt, 5x bolt, 6x bolt, 6x16 2 Page 10
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77 08 09 Beta RR/RS Models Pos Part Number Description Qty Notes starter motor starter motor brush set 1 item not shown intermediate gear, 58t shim circlip reduction gear needle bearing bearing shaft one way clutch hub screw, 6x needle bearing one way clutch freewheel gear bolt, 6x oring 1 Page 11
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79 08 09 Beta RR/RS Models Pos Part Number Description Qty Notes clutch basket inner clutch hub friction disc steel plate, 1.0mm pressure plate clutch spring spring retainer steel plate, 1.4mm clutch push rod half washer shim bolt, 6x needle bearing primary gear, 33t clutch slave cylinder oring fluid injector opt piston kit 1 includes ball and oring bleeder screw bolt, 6x bolt, 6x stepped washer slave cylinder gasket drive sleeve circlip washer needle bearing pressure piece clutch nut locking washer banjo bolt 1 Page 12
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81 08 09 Beta RR/RS Models Pos Part Number Description Qty Notes kickstart lever kickstart lever bolt washer oil seal, 19x30x driving hub kickstarter gear, 39t circlip shim washer intermediate gear, 24t kickstarter spring spring hanger bolt, 6x shim circlip needle bearing bump stop shim ratchet gear spring kickstart ratchet bolt, 6x kickstart shaft 1 Page 13
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83 08 09 Beta RR/RS Models Pos Part Number Description Qty Notes main shaft, 1st, 14t idler gear, 5th, 24t needle bearing shim sliding gear, 3rd/4th, 19/22t circlip shim idler gear, 6th, 26t solid gear, 2nd, 17t shim bearing, bearing, Page 14
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85 08 09 Beta RR/RS Models Pos Part Number Description Qty Notes countershaft idler gear, 2nd, 31t needle bearing shim circlip idler gear, 6th, 21t shim sliding gear, 4th, 26t sliding gear, 3rd, 28t sliding gear, 5th, 23t shim needle bearing idler gear, 1st, 34t shim spacer bushing front sprocket, 15t 1 all RS models front sprocket, 14t 1 all RR models front sprocket, 13t opt sprocket bolt and spring washer oring bearing, special bearing countershaft oil seal, 32x45x7 1 Page 15
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87 08 09 Beta RR/RS Models Pos Part Number Description Qty Notes shift shaft shifter bolt, 6x washer, thick shifter seal, 14x24x needle bearing shift fork, 2nd/4th gear shift shaft assembly 1 includes item 12 and shift fork, 1st/3rd gear shim return spring tensioner spring shift rail pressure spring shift bushing shift locating drum sliding plate screw, 6x bearing detent lever bolt, 5x sleeve detent spring shift rail shift fork, 5th/6th gear shift drum spring guide washer star washer flat head screw washer 1 Page 16
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