XT660R (5VKM) AUSTRALIA XT660R (5VKM) NEW ZEALAND 1M5VK-710E1

Transcription

1 XT660R (5VKM) TRALIA XT660R (5VKM) NEW ZEALAND 1M5VK-710E1 ( )

2 XT660R PARTS CATALOGUE 2013 by MBK Industrie 1st edition, May 2013 All rights reserved. Any reprinting or unauthorized use without the written permission of MBK Industrie is expressly prohibited. Printed in France.

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 DPBSE(*) DEEP PURPLISH BLUE SOLID E 0583 MBL2 MAT BLACK Quantity Column Information Column No. Name Of Q ty Column Destination 1

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. 5VKM 010 Country (destination) TRALIA NEW ZEALAND Model Code Production Code No. Country (destination) (3) Model Label Affixing Location (4) Colouring Information Model Code Colouring Type Code Colour Code Colour Name Abbreviation 5VKM A 0583 DEEP PURPLISH BLUE SOLID E DPBSE

6 CONTENTS ENGINE CYLINDER HEAD... 1 CYLINDER... 2 CRANKSHAFT & PISTON... 3 VALVE... 4 CAMSHAFT & CHAIN... 5 WATER PUMP... 6 RADIATOR & HOSE... 7 OIL PUMP... 8 INTAKE INTAKE EXHT CRANKCASE CRANKCASE COVER STARTER CLUTCH CLUTCH TRANSMISSION SHIFT CAM & FORK SHIFT SHAFT CHASSIS FRAME FENDER SIDE COVER REAR ARM REAR 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 COWLING GENERATOR FLASHER LIGHT METER HEADLIGHT TAILLIGHT HANDLE SWITCH & LEVER ELECTRICAL ELECTRICAL INDEX NUMERICAL INDEX... 62

7 FIG. 1 CYLINDER HEAD PART 1 5VK E CYLINDER HEAD ASSY 1 2 3D GUIDE, VALVE BOLT, STUD 4 4 5VK GASKET, CYLINDER HEAD BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE BOLT J9 WASHER, PLATE X09 PLUG, SPARK (NGK CR7E) X00 PIN, DOWEL VK E COVER, CYLINDER HEAD SIDE X00 O-RING BOLT, FLANGE CLAMP VK E COVER, CYLINDER HEAD SIDE X00 O-RING BOLT 8 1

8 FIG. 2 CYLINDER PART 1 5VK CYLINDER VK GASKET, CYLINDER BOLT, FLANGE BOLT, FLANGE A4 WASHER, PLATE BOLT CLAMP 1 2

9 FIG. 3 CRANKSHAFT & PISTON PART 1 5VK E CRANKSHAFT ASSY 1 2 5VK E CRANK SUB ASSY VK E CRANK VK PIN, CRANK BEARING 1 6 5VK ROD, CONNECTING KEY, WOODRUFF WASHER, PLATE NUT Y0 BEARING VK PISTON (STD) VK PISTON RING SET (STD) VK PIN, PISTON CIRCLIP X00 WASHER, PLATE VK E GEAR, DRIVE VK E GEAR, BALANCE WEIGHT VK E WEIGHT YJ BEARING YH BEARING OIL SEAL KEY, STRAIGHT NUT X00 WASHER, LOCK 1 3

10 FIG. 4 VALVE PART 1 5VK VALVE, INTAKE 2 2 5VK VALVE, EXHT 2 3 5VK SPRING, VALVE INNER 4 4 3YF SEAT, VALVE SPRING 4 5 5H SEAL, VALVE STEM 4 6 3YF RETAINER, VALVE SPRING 4 7 4G LOCK, VALVE SPRING RETAINER 8 8 5VK E ARM, VALVE ROCKER 1 9 5VK E ARM, VALVE ROCKER VK SHAFT, ROCKER BP SCREW, VALVE ADJUSTING NUT 4 4

11 FIG. 5 CAMSHAFT & CHAIN PART 1 5VK E CAMSHAFT ASSY BEARING 1 3 5VK PIN, DECOMPRESSION LEVER 1 4 5VK LEVER, DECOMPRESSION SPRING 1 5 5VK DECOMPRESSION ASSY 1 6 5VK E111F 00 PLATE BOLT, FLANGE BOLT, FLANGE CHAIN (98XRH M) VK E GUIDE, STOPPER VK GUIDE, STOPPER X09 BOLT, WITH WASHER VK E TENSIONER ASSY, CAM CHAIN BOLT DW GASKET, TENSIONER CASE 1 5

12 FIG. 6 WATER PUMP PART 1 5VK E GEAR, DRIVE 1 2 5VK IMPELLER SHAFT ASSY 1 3 5VK COVER, HOUSING O-RING BEARING 1 6 5VK HOUSING, WATER PUMP BOLT, FLANGE OIL SEAL 1 9 5VK SEAL, MECHANICAL WASHER, PLATE VK GASKET, HOUSING COVER GASKET PIN, DOWEL VK GEAR, IMPELLER SHAFT CIRCLIP VK E JOINT BOLT X00 O-RING VK PIPE X00 O-RING BOLT VK E HOSE X03 HOSE CLAMP ASSY BOLT 3 6

13 FIG. 7 RADIATOR & HOSE PART 1 5VK THERMOSTAT ASSY 1 2 5VK E COVER, THERMOSTAT BOLT, FLANGE X00 O-RING 1 5 5VK E HOSE X04 HOSE CLAMP ASSY X04 HOSE CLAMP ASSY 1 8 5VK E RADIATOR COMP 1 9 5VK E BLOWER ASSY VK E CAP, RADIATOR TAPPING SCREW TAPPING SCREW VK E STOPPER VK E STOPPER BOLT, FLANGE VK E PROTECTOR VK E HOSE X04 HOSE CLAMP ASSY X04 HOSE CLAMP ASSY GROMMET COLLAR BOLT WASHER, PLATE FK DAMPER 1 7

14 FIG. 8 OIL PUMP PART 1 5VK E OIL PUMP ASSY 1 2 5LP GASKET, PUMP COVER X00 O-RING BOLT, BUTTON HEAD 3 5 3AJ GEAR, PUMP DRIVEN X00 CIRCLIP 1 7 5VK E COVER, PUMP VK E COVER, PUMP GEAR BOLT VK WE STRAINER COMP VK E SEAL, OIL STRAINER BOLT PLUG, STRAIGHT SCREW GASKET VK E PIPE, DELIVERY X00 O-RING X ELEMENT ASSY, OIL CLEANER WK COVER, OIL ELEMENT X01 O-RING X01 O-RING BOLT BOLT SCREW 1 (M5 BOLT) X00 GASKET 1 (M5 WASHER) 25 5VK PIPE, DELIVERY BOLT, UNION BOLT, UNION 1 8

15 FIG. 8 OIL PUMP PART X01 GASKET VK PIPE, DELIVERY BOLT, UNION X00 GASKET BOLT SEAT, CHECK BALL BALL X01 SPRING, COMPRESSION VK HOSE, OIL X00 O-RING X00 PIN, DOWEL BOLT VK HOSE, OIL X00 O-RING BOLT X01 HOSE CLIP 1 9

16 FIG. 9 INTAKE PART 1 5VK E JOINT, CARBURETOR HOSE CLAMP ASSY 2 3 5VK E CASE, AIR CLEANER VK E JOINT, AIR CLEANER VK E441A 00 COVER, CLEANER CASE VK E SEAL M SCREW, TAPPING VK E ELEMENT, AIR CLEANER 1 9 5VK E DUCT VK E441E 00 COVER, CLEANER CASE VK E SEAL VK F FLAP VK H PAD, BATTERY VK H SEAT, BATTERY VK E443E 00 PIPE, DRAIN CLIP PLUG LW E443E 00 PIPE, DRAIN CLIP CLIP VK E BREATHER VK E PIPE, BREATHER CLIP CLIP VK E CHAMBER, AIR HOSE CLAMP ASSY GROMMET 1 10

17 FIG. 9 INTAKE PART 28 5VK E243A 20 HOSE HOSE CLIP CLIP CLIP VK E HOSE A2 CLIP CLIP VK HOSE, VACUUM SENSING CLIP BOLT, FLANGE BOLT, FLANGE H4 COLLAR GROMMET K6 WASHER, PLATE BOLT, FLANGE COLLAR GROMMET NUT, FLANGE VK PIPE, FUEL

18 FIG. 10 INTAKE 2 PART 1 5VK THROTTLE BODY ASSY 1 2 5VK DELIVERY PIPE ASSY GASKET SCREW, PAN HEAD 2 5 8CC SCREW B ADJUST SCREW SET 1 7 5VK SPRING, ADJUST SCREW 1 8 5VK INJECTOR 1 9 5PS O-RING P THROTTLE SENSOR ASSY 1 12

19 FIG. 11 EXHT PART 1 5VK E PIPE, EXHT JX BAND, MUFFLER 1 3 4FU GASKET, MUFFLER BOLT, FLANGE 1 5 5VK E PROTECTOR, EXHT PIPE BOLT,HEX. SOCKET BUTTON 2 7 1B9 8592A 00 SENSOR, OXYGEN 1 8 5VK E PIPE, EXHT VK E MUFFLER VK W PROTECTOR, MUFFLER VK E PROTECTOR, MUFFLER VK E DAMPER, MUFFLER EL GASKET, MUFFLER BOLT, FLG.(SMALL HEAD) GROMMET COLLAR SCREW W DAMPER, LOCATING VK E MUFFLER VK W PROTECTOR, MUFFLER VK E PROTECTOR, MUFFLER VK E DAMPER, MUFFLER EL GASKET, MUFFLER BOLT, FLG.(SMALL HEAD) GROMMET COLLAR SCREW 4 13

20 FIG. 11 EXHT PART 28 22W DAMPER, LOCATING E2 BOLT NUT YF GASKET, EXHT PIPE VK PIPE VK GASKET BOLT VK HOSE, BEND CLIP VK AIR INDUCTION SYSTEM ASSY VK E HOSE, BEND CLIP A0 CLIP CLAMP CLAMP 1 14

21 FIG. 12 CRANKCASE PART 1 5VK E CRANKCASE ASSY PIN, DOWEL X00.PIN, DOWEL X01.O-RING BOLT BOLT BOLT BOLT BOLT BOLT X00 CLAMP CLAMP VK E PIPE, BREATHER CLIP CLIP VK E PLATE, BEARING COVER BOLT PIN, DOWEL 2 15

22 FIG. 13 CRANKCASE COVER 1 PART 1 5VK WE CRANKCASE COVER ASSY VK E GASKET, CRANKCASE COVER PIN, DOWEL BOLT BOLT BOLT BOLT X00 O-RING PIN, DOWEL X00 PLUG, STRAIGHT SCREW X00 O-RING X00 PLUG, STRAIGHT SCREW X00 O-RING BOLT X00 CLAMP VK E COVER, CRANKCASE VK E GUIDE, CHAIN BOLT VK E COVER, CRANKCASE VK E GASKET, CRANKCASE COVER PIN, DOWEL BOLT VK E HOLDER, CLUTCH CABLE OIL SEAL VK E HOLDER BOLT VK E COVER, OIL PUMP 1 16

23 FIG. 13 CRANKCASE COVER 1 PART 28 5VK E GASKET X00 PIN, DOWEL BOLT, FLANGE VK WE GENERATOR COVER ASSY X00 PIN, DOWEL BOLT BOLT VK GASKET

24 FIG. 14 STARTER CLUTCH PART 1 5VK E GEAR C7 BEARING X01 WASHER, PLATE 1 4 5VK E SHAFT VK E GEAR, IDLER VK E DAMPER ASSY X18 WASHER, PLATE 2 8 5VK STARTER ONE-WAY ASSY BOLT X18 WASHER, PLATE SX MOTOR ASSY VJ GEAR, STARTING MOTOR CIRCLIP AJ BRUSH SET FK O-RING AJ ARMATURE ASSY AJ WASHER KIT H GASKET G CAP XV 8182A 00 NUT VK CORD, STARTER MOTOR BOLT, FLANGE VK H WIRE, MINUS LEAD VK E BRACKET GROMMET 1 18

25 FIG. 15 CLUTCH PART 1 5VK E GEAR, PRIMARY DRIVE KEY, STRAIGHT WASHER X00 WASHER, LOCK NUT 1 6 5VK E PRIMARY DRIVEN GEAR COMP VK E BOSS, CLUTCH 1 8 5VK E PLATE, PRESSURE BEARING VK E PLATE, CLUTCH U PLATE, FRICTION X00 SPRING, COMPRESSION BOLT, WITH WASHER VK E PLATE, THRUST VK PLATE, FRICTION VK E SPRING.,CUSHION VK E PLATE, SEAT TA PLATE, FRICTION X01 WASHER, LOCK NUT XV ROD, PUSH VK PUSH LEVER ASSY X00 SPRING, TORSION VK E AXLE, PUSH LEVER X19 WASHER, PLATE CIRCLIP BEARING 1 19

26 FIG. 15 CLUTCH PART OIL SEAL BEARING X17 WASHER, PLATE X00 CIRCLIP 1 20

27 FIG. 16 TRANSMISSION PART 1 5VK E MAIN AXLE ASSY 1 2 5VK E GEAR, 4TH PINION (22T) X00 WASHER CIRCLIP 3 5 5VK E GEAR, 3RD PINION (20T) 1 6 5VK E GEAR, 5TH PINION (26T) COLLAR X00 WASHER WASHER VK E GEAR, 2ND PINION (16T) XA BEARING XL BEARING VK E AXLE, DRIVE VK E GEAR, 2ND WHEEL (26T) WASHER CIRCLIP VK E GEAR, 5TH WHEEL (20T) VK E GEAR, 3RD WHEEL (23T) X00 WASHER CIRCLIP VK E GEAR, 4TH WHEEL (20T) VK E GEAR, 1ST WHEEL (30T) G4 WASHER, PLATE CIRCLIP X4 BEARING COLLAR X00 O-RING 1 21

28 FIG. 16 TRANSMISSION PART OIL SEAL VK E PLATE, COVER X26 BOLT XM BEARING VK E SPROCKET, DRIVE (15T) X00 WASHER, LOCK NUT 1 22

29 FIG. 17 SHIFT CAM & FORK PART 1 5VK E SHIFT CAM ASSY X00.SPRING, COMPRESSION 1 3 5VK E POINT, NEUTRAL 1 4 5VK E PLATE, SIDE X05.SCREW 1 6 5VK E FORK, SHIFT VK E FORK, SHIFT VK E FORK, SHIFT VK E HANGER, SPRING HOOK, SPRING JW STOPPER LEVER ASSY VK STOPPER, SCREW BEARING OIL SEAL (SD HS) CIRCLIP X06 WASHER, PLATE X00 CIRCLIP X01 WASHER, PLATE X05 WASHER, PLATE VK E BOSS

30 FIG. 18 SHIFT SHAFT PART 1 5VK SHIFT SHAFT ASSY 1 2 5VK E SHIFT PEDAL ASSY 1 3 5VK E COVER, SHIFT PEDAL BOLT 1 24

31 FIG. 19 FRAME PART 1 5VK F FRAME COMP BOLT, FLANGE GASKET 1 4 5VK F NET, FILTER GASKET 1 6 5VK F STAY, ENGINE BOLT, FLANGE NUT 4 9 5VK F STAY, ENGINE BOLT, FLANGE NUT BOLT, WASHER BASED NUT VK F ENGINE BRACKET COMP VK STAY, MUFFLER BOLT, FLG.(SMALL HEAD) X TENSIONER V TENSIONER V BUSH COLLAR H0 WASHER, PLATE BOLT, FLANGE BOLT NUT, U WASHER VK PLUG, OIL LEVEL O-RING 1 25

32 FIG. 19 FRAME PART CLIP CLIP CLIP VK DAMPER 2 26

33 FIG. 20 FENDER PART 1 5VK F FENDER, FRONT 1 (DPBSE) X7 COLLAR L0 COLLAR BOLT, WITH WASHER 4 5 5VK F FENDER, FRONT VK F STAY BOLT, WITH WASHER BOLT, HEXAGON 2 9 5VK REFLECTOR ASSY VK FRONT REFLECTOR ASSY VK F FENDER, REAR DM DAMPER BOLT, FLANGE NUT, SPRING SCREW, TAPPING PLUG VK F BRACKET, LICENSE BOLT, WITH WASHER NUT, SPRING BOLT, FLANGE COLLAR VK F COVER, REAR FENDER 1 (DPBSE) RIVET VK F160E 00 BOX VK DAMPER BOLT COLLAR 2 27

34 FIG. 20 FENDER PART 28 1T PAD, SEAT CLAMP XV BAND, TOOL YX BAND, TOOL VK DAMPER S F153A 00 EMBLEM, YAMAHA 1 28

35 FIG. 21 SIDE COVER PART 1 5VK F COVER, SIDE SCREW, WITH WASHER COLLAR GROMMET 1 5 5VK F COVER, SIDE SCREW, WITH WASHER GROMMET 2 8 5VK F TANK, RECOVERY M9 COLLAR BOLT, FLANGE VK CAP H ELBOW HOSE CLIP HOSE CLIP CLAMP CLAMP 1 29

36 FIG. 22 REAR ARM PART 1 5VK F REAR ARM COMP BEARING BUSH, SOLID OIL SEAL (DC ) X 2219X 00 COVER OIL SEAL ( ) 2 7 5VK BUSH VK BUSH VK F SEAL, GUARD BOLT, FLANGE COLLAR VK F217A 00 ARM, RELAY BEARING OIL SEAL R5 COLLAR COLLAR COLLAR VK F217F 00 ROD, CONNECTING VK BOLT F6 WASHER, PLATE NUT, SELF-LOCKING BEARING OIL SEAL W0 COLLAR BOLT NUT, U J1 WASHER, PLATE 1 30

37 FIG. 22 REAR ARM PART WASHER, PLATE VK F CASE, CHAIN BOLT, WITH WASHER VJ SHAFT, PIVOT NUT, SELF-LOCKING PLUG RIVET VK F LABEL, TIRE 1 31

38 FIG. 23 REAR SUSPENSION PART 1 5VK SHOCK ABSORBER ASSY, REAR 1 2 4AA LABEL, WARNING BOLT NUT, U 1 5 5VK F WASHER

39 FIG. 24 STEERING PART BEARING 1 2 5VK GUIDE, CABLE BOLT, FLANGE 1 4 5VK F PROTECTOR NUT, SPRING BOLT, WITH WASHER BOLT,HEX. SOCKET BUTTON Y6 BEARING 1 9 1W COVER, BALL RACE NUT WASHER, PLATE YF WASHER, SPECIAL NUT, CROWN T0 WASHER, PLATE VK F HANDLE CROWN COMP BOLT, FLANGE VK F317E 00 STAY VK F317F 00 STAY VK GUIDE, CABLE BOLT, FLANGE VK F HOLDER, HANDLE UPPER VK F HOLDER, HANDLE LOWER WASHER, PLATE VK F317M 00 STAY NUT, U FLANGE CLAMP BOLT 4 33

40 FIG. 24 STEERING PART PLUG VK F CLAMP BOLT 2 34

41 FIG. 25 FRONT FORK PART 1 5VK FRONT FORK ASSY (L.H) 1 2 5VK TUBE, OUTER (L.H) 1 3 4V L0.RING, SNAP 1 4 4DA L0.OIL SEAL 1 5 5EB METAL, SLIDE DA L0.SEAL, DUST 1 7 4V L0.WASHER, OIL SEAL 1 8 5VK INNER TUBE COMP YR SPINDLE, TAPER VK CYLINDER COMP., FRONT FORK VK SPRING, FRONT FORK LR WASHER, SPRING UPPER WM SPACER TJ BOLT, CAP V L0.O-RING L0.GASKET D BOLT, HEXAGON SOCKET HEAD 1 (KAYABA MODEL) 18 5VK FRONT FORK ASSY (R.H) VK TUBE, OUTER (R.H) V L0.RING, SNAP DA L0.OIL SEAL EB METAL, SLIDE DA L0.SEAL, DUST V L0.WASHER, OIL SEAL VK INNER TUBE COMP YR SPINDLE, TAPER VK CYLINDER COMP., FRONT FORK 1 35

42 FIG. 25 FRONT FORK PART 28 5VK SPRING, FRONT FORK LR WASHER, SPRING UPPER WM SPACER TJ BOLT, CAP V L0.O-RING L0.GASKET D BOLT, HEXAGON SOCKET HEAD 1 (KAYABA MODEL) BOLT D UNDER BRACKET COMP BOLT, FLANGE VK 2334G 20 BRACKET VK 2334H 20 BRACKET

43 FIG. 26 FUEL TANK PART 1 5VK F P0 FUEL TANK COMP. 1 MBL2 FOR DPBSE 2 5VK F BRACKET, FUEL PUMP B O-RING BOLT 6 5 5VK CAP ASSY 1 6 3TB DAMPER, LOCATING VK DAMPER, LOCATING VK F WASHER, SPECIAL BOLT, FLANGE VK DAMPER, LOCATING VK F137W 01 SCOOP, AIR 1 1 (DPBSE) 12 5VK MOLE VK 2414H 00 DAMPER, PLATE VK 2414K 00 DAMPER, PLATE BOLT,HEX. SOCKET BUTTON VK F137X 01 SCOOP, AIR 2 1 (DPBSE) 17 5VK MOLE VK 2414H 00 DAMPER, PLATE BOLT,HEX. SOCKET BUTTON VK F137Y 00 GUIDE, AIR VK DAMPER GROMMET RIVET VK 2416F 00 INSULATOR, FUEL TANK VK F413B 01 EMBLEM VK F413B 01 EMBLEM VK F137C 80 GRAPHIC, SCOOP AIR SET

44 FIG. 26 FUEL TANK PART 28 5VK F137D 80 GRAPHIC, SCOOP AIR SET WW F LABEL, WARNING VK FUEL PUMP COMP. 1 38

45 FIG. 27 SEAT PART 1 5VK F SEMI-DOUBLE SEAT ASSY 1 FOR DPBSE (BLUE/B 2 5VK COVER, SEAT 1 (BLUE/BLACK) 3 4HM BRACKET, SEAT NUT 1 5 5VK DAMPER, SEAT 1 6 4BP SEAT LOCK ASSY 1 7 5VK F PLATE NUT, FLANGE 2 9 5VK F478E 00 CABLE, SEAT LOCK TV W ROTOR SET BOLT, FLANGE VK F478X 00 BRACKET, SEAT LOCK VK DAMPER, SEAT VL F PAD, SEAT VK F474A 10 ASSIST, GRIP VK F474W 10 ASSIST,GRIP X02 BOLT, HEXAGON SOCKET HEAD X06 BOLT, HEXAGON SOCKET HEAD VK F TOOL KIT VK F TOOL, SPECIAL VK F MANUAL,OWNER'S 1 39

46 FIG. 28 FRONT WHEEL PART 1 5VK HUB, FRONT 1 2 5VK SPACER, BEARING BEARING OIL SEAL FLANGE, SPACER X01 RIM ( ) 1 7 5VK F SPOKE SET, FRONT 1 8 * TIRE (90/90-21M/C 54S) 1 LM AP METZELER TO * TIRE (90/90-21M/C 54T) 1 LM UR MICHELIN SI 9 * TUBE ( 21 ) 1 LM AP * TUBE 1 LM UR 10 * BAND, RIM (21) 1 LM AP * BAND, RIM ( ) 1 LM UR MICHELIN 11 3HT BALANCER, WHEEL (15G) VK F COLLAR, WHEEL VK AXLE, WHEEL VK F COLLAR, WHEEL 1 40

47 FIG. 29 FRONT BRAKE CALIPER PART 1 5VK F581T 00 DISK BRAKE ASSY BOLT,HEX. SOCKET BUTTON 6 3 5VK F580T 00 CALIPER ASSY (LEFT) 1 (BREMBO) 4 5VK W BRAKE PAD KIT 1 (BREMBO) 5 5VK F PIN, PAD 1 (BREMBO) 6 5VK F SUPPORT, PAD 1 (BREMBO) 7 5DS F CAP 1 (BREMBO) 8 5SE F SCREW, BLEED 1 (BREMBO) 9 5DS F BOOT, CALIPER 1 (BREMBO) BOLT, FLANGE 2 41

48 FIG. 30 REAR WHEEL PART 1 5VK HUB, REAR SPACER BEARING OIL SEAL 1 5 5VK CLUTCH, HUB BEARING 1 7 1VJ COLLAR, WHEEL OIL SEAL BOLT, STUD VK SPROCKET, DRIVEN (45T) NUT, U FLANGE Y DAMPER VK F SPOKE SET, REAR X00 RIM ( ) 1 15 * TIRE (130/80-17 M/C 65S) 1 LM AP METZELER TO * TIRE (130/80-17 M/C 65T) 1 LM UR MICHELIN SI 16 * TUBE ( 21 ) 1 LM AP PIRELLI * TUBE 1 LM UR 17 * BAND, RIM (21) 1 LM AP * BAND, RIM ( ) 1 LM UR MICHELIN 18 3HT BALANCER, WHEEL (15G) B6110 CHAIN AJ AXLE, WHEEL UF PULLER, CHAIN VK F END WASHER, PLATE NUT 4 42

49 FIG. 30 REAR WHEEL PART COLLAR COLLAR T3 WASHER, PLATE T2 WASHER, PLATE NUT, U FLANGE 1 43

50 FIG. 31 REAR BRAKE CALIPER PART 1 5VK F582W 00 DISK, REAR BRAKE BOLT 6 3 5VK F580W 00 CALIPER ASSY, REAR 2 1 (BREMBO) 4 5VK W BRAKE PAD KIT 2 1 (BREMBO) 5 5VK F PIN, PAD 1 (BREMBO) 6 5VK F SUPPORT, PAD 1 (BREMBO) 7 5DS F CAP 1 (BREMBO) 8 5SE F SCREW, BLEED 1 (BREMBO) 9 5DS F BOOT, CALIPER 1 (BREMBO) 10 5CH F PROTECTOR BOLT,HEX. SOCKET BUTTON COLLAR 1 44

51 FIG. 32 STEERING HANDLE & CABLE PART 1 5VK HANDLE COMP YR GRIP ASSY 1 3 4YR GRIP (LEFT) 1 4 4JH END, GRIP BOLT 2 6 5VK F CABLE, THROTTLE VK F CABLE, THROTTLE E BOOT, CABLE 1 9 5VK F CABLE, CLUTCH CLAMP CLAMP VK F REAR VIEW MIRROR ASSY (LEFT) VK F REAR VIEW MIRROR ASSY (RIGHT) 1 45

52 FIG. 33 FRONT MASTER CYLINDER PART 1 5VK W MASTER CYLINDER SUB ASSY 1 2 3XP W CYLINDER KIT, MASTER SCREW, FLAT HEAD 2 4 3GM W RESERVOIR CAP SET U DIAPHRAGM, RESERVOIR 1 6 5CG SEPARATOR ASSY 1 7 5VK LEVER BOLT NUT, U SPRING, COMPRESSION VK FRONT STOP SWITCH ASSY A BRACKET, MASTER CYLINDER BOLT WASHER, PLATE VK F HOSE, BRAKE X03 BOLT, UNION X03 WASHER, PLATE 4 46

53 FIG. 34 STAND & FOOTREST PART 1 5VK F FOOTREST VK F BRACKET, FOOTREST X00 SPRING, TORSION X01 PIN, CLEVIS PIN, COTTER BOLT, FLANGE 2 7 5VK F FOOTREST VK F BRACKET, FOOTREST X01 SPRING, TORSION X01 PIN, CLEVIS PIN, COTTER BOLT, FLANGE VK F STAND, SIDE BOLT, FLANGE COLLAR J1 WASHER, PLATE NUT, U SPRING, TENSION VK F741L 10 BRACKET VK F FOOTREST, REAR X02 SPRING, COMPRESSION X00 BALL VK F WASHER, SPECIAL VK F BOLT, FOOTREST NUT, U FLANGE X37 COLLAR VK F742L 10 BRACKET

54 FIG. 34 STAND & FOOTREST PART 28 5VK F FOOTREST, REAR X02 SPRING, COMPRESSION X00 BALL VK F WASHER, SPECIAL VK F BOLT, FOOTREST NUT, U FLANGE X37 COLLAR BOLT, HEXAGON SOCKET HEAD 4 48

55 FIG. 35 REAR MASTER CYLINDER PART 1 5VK F PEDAL, BRAKE SPRING, TENSION 1 3 5VK 2583V 00 RR. MASTER CYLINDER ASSY BN W CYLINDER KIT, MASTER O-RING 1 6 2VN CIRCLIP 1 7 4ML 2582A 50.JOINT 1 8 2YK JOINT 1 9 4SS NUT KW PIN, BRAKE ROD JJ TANK, RESERVOIR PX CAP, RESERVOIR VN DIAPHRAGM, RESERVOIR VN BUSH,DIAPHRAGM VK HOSE, RESERVOIR CLIP BOLT, WITH WASHER VK F117M 10 COVER G6 BOLT PIN, CLEVIS WASHER, PLATE PIN, COTTER VK F HOSE, BRAKE X03 BOLT, UNION X03 WASHER, PLATE VK F HOLDER, BRAKE HOSE BOLT, FLANGE 2 49

56 FIG. 35 REAR MASTER CYLINDER PART 28 5VK F117F 10 COVER SCREW 2 50

57 FIG. 36 COWLING 1 PART 1 5VK F BODY, COWLING 1 (DPBSE) NUT, SPRING SCREW, WITH WASHER 4 4 5VK F WINDSHIELD 1 (BLACK) SCREW, ROUND HEAD NUT 4 7 5VK 2837K 00 DAMPER

58 FIG. 37 GENERATOR PART 1 5VK STATOR ASSY 1 2 5VK ROTOR ASSY BOLT, BUTTON HEAD BOLT X08 WASHER, PLATE 2 52

59 FIG. 38 FLASHER LIGHT PART 1 5VK H FRONT FLASHER LIGHT ASSY VK H333A 00.LENS COMP VK H BULB, FLASHER (12V/10W) 1 4 5VK H SCREW, LENS FITTING CLAMP 1 6 5VK H FRONT FLASHER LIGHT ASSY VK H333A 00.LENS COMP VK H BULB, FLASHER (12V/10W) 1 9 5VK H SCREW, LENS FITTING CLAMP BOLT, BUTTON HEAD VK H REAR FLASHER LIGHT ASSY VK H333A 00.LENS COMP VK H BULB, FLASHER (12V/10W) VK H SCREW, LENS FITTING VK H REAR FLASHER LIGHT ASSY VK H333A 00.LENS COMP VK H BULB, FLASHER (12V/10W) VK H SCREW, LENS FITTING BOLT NUT, U WASHER, PLATE COLLAR VK WASHER, SPECIAL VK PLUG, BLIND 2 53

60 FIG. 39 METER PART 1 5VK METER ASSY 1 (km/h MODEL) SCREW, TAPPING GROMMET 3 4 5VK H BRACKET, METER BOLT, BUTTON HEAD CLAMP 1 54

61 FIG. 40 HEADLIGHT PART 1 5VK H410A 12 HEADLIGHT UNIT COMP VK H BULB, HEADLIGHT 1 H4-12V 55/60W 3 5VK H HOLDER BULB 1 4 3WW H BULB (12V-5W) 1 5 5VK H COVER, SOCKET 1 6 5VK H CORD ASSY NUT, SPRING 2 8 5VK H SPRING, SCREW BOLT WASHER, PLATE VK H NUT, ADJUSTING VK H STAY, HEADLIGHT BOLT, BUTTON HEAD G0 COLLAR GROMMET GROMMET VK H CORD, HEADLIGHT 1 55

62 FIG. 41 TAILLIGHT PART 1 5VK H TAILLIGHT UNIT ASSY 1 2 5VK H LENS, TAILLIGHT 1 3 5VK H LENS, LICENCE LIGHT 1 4 5VK H BULB (BAY15D 12V-21/5W) 1 5 5VK H SOCKET CORD ASSY 1 6 5SE H SCREW, LENS FITTING GROMMET G0 COLLAR WASHER, PLATE NUT, SELF U-FLANGE NC H REAR REFLECTOR ASSY NUT, U FLANGE 1 56

63 FIG. 42 HANDLE SWITCH & LEVER PART 1 1LN HOLDER, LEVER G HOLDER, LEVER LOWER FY LEVER BOLT NUT, U BOLT BOLT NUT 1 9 5VK SWITCH VK SWITCH, HANDLE SCREW, PAN HEAD SCREW, PAN HEAD VK SWITCH, HANDLE SCREW, PAN HEAD WASHER, PLATE SCREW, PAN HEAD SCREW, PAN HEAD CLAMP 2 57

64 FIG. 43 ELECTRICAL 1 PART BOLT, WITH WASHER 2 2 4GV IGNITION COIL ASSY NUT BOLT WASHER, PLATE 1 6 5VK HOLDER, COIL FITTING 1 7 5VK PLUG CAP ASSY 1 8 5SL RECTIFIER & REGULATOR ASSY BOLT, FLANGE FL BATTERY ASSY (GT9B-4) VK H WIRE, PLUS LEAD VK W MAIN SW. IMMOBILIZER KIT VK 8591A 11.ENGINE CONTROL UNIT ASSY VS 8255P 00.IMMOBILIZER. UNIT COMP SL SCREW SL BLANK KEY 1 AP BOLT VK STOP SWITCH ASSY CLAMP VK H WIRE HARNESS ASSY JJ FUSE (7.5A-BL) JJ FUSE (10A-BL) JJ FUSE (20A-BL) CLAMP CLAMP CLAMP CLAMP 1 58

65 FIG. 43 ELECTRICAL 1 PART 28 1UA BAND 12 59

66 FIG. 44 ELECTRICAL 2 PART 1 1AE NEUTRAL SWITCH ASSY X00 O-RING BOLT, HEXAGON SOCKET HEAD 2 4 5PS THERMOSENSOR ASSY X01 GASKET 1 6 5PS SENSOR, PRESSURE 1 7 5VK PLATE NUT, FLANGE 2 9 5VU SENSOR, AIR TEMPRATURE CA GROMMET LP SENSOR, SPEED D O-RING BOLT RT SWITCH, SIDE STAND CLAMP BOLT NUT, U SV STARTER RELAY ASSY (RC19-015) AE FUSE (30A-BL) BOLT, FLANGE VK RELAY ASSY (5VK-40) JJ RELAY ASSY (5JJ-20) JJ HOLDER, RELAY S5 H SENSOR, LEAN ANGLE BOLT A2 WASHER, PLATE VK F BRACKET, SWITCH 1 60

67 FIG. 44 ELECTRICAL 2 PART BOLT, FLANGE GY FLASHER RELAY ASSY VK H HORN BOLT, FLANGE 1 61

68 NUMERICAL INDEX PART PART PART PART PART PART 3D VK VK VK VK VK VK VK VK VK VK YF YF G H VK VK BP DW VK VK VK VK VK VK VK VK VK VK VK VK VK VK VK AJ LP X WK VK VK VK VK VK VK VK PS CC CA B VK YF EL FU JX VK VK VK VK VK VK VJ VK U TA VK VK XV VK VK JW YX XV VK VK VK VK H VK VK VK VK VJ V X V X 2219X VK AA VK VK VK TJ WM EB VK VK VK DA L DA L V L LR V L L VK YR D V L D VK 2334G VK 2334H VK W YF VK 2414H VK 2414K VK 2416F W TB VK VK B VK HM VK VK T VK BP VK VK VK VK Y VK VJ AJ UF HT VK CG ML 2582A VK 2583V PX VN U VN VN A JJ VK VK YR YR JH E SS YK KW VK DM VK VK 2837K D VK VK AJ AJ VK XV 8182A H FK AJ G SX SV JJ VK JJ SL FL SL AE JJ JJ JJ GV VK VK PS VK SL VK AE VS 8255P RT UA LN G VK VK GY VK VK LP FY VK VK VK VK FK VK VK PS P VU VK 8591A B9 8592A VK E VK E111F VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E243A VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E441A VK E441E VK E LW E443E VK E443E VK E VK E

69 NUMERICAL INDEX PART PART PART PART PART PART 5VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK E VK F VK F117F VK F117M VK F VK F VK F137C VK F137D VK F137W VK F137X VK F137Y VK F VK F VK F S F153A VK F WW F VK F VK F160E VK F VK F VK F VK F VK F VK F VK F VK F VK F VK F VK F VK F VK F217A VK F217F VK F VK F VK F317E VK F317F VK F317M VK F VK F VK F VK F VK F VK F P VK F413B VK F VK F VL F VK F474A VK F474W VK F VK F478E VK F478X VK F VK F VK F VK F VK F VK F580T VK F580W VK F581T SE F DS F VK F582W VK F VK F VK F DS F VK F VK F VK F VK F VK F VK F VK F VK F VK F VK F VK F VK F VK F VK F VK F741L VK F VK F VK F742L VK F VK F VK F CH F VK F VK F VK F VK F VK F VK H VK H VK H VK H S5 H VK H VK H VK H VK H VK H VK H VK H333A VK H VK H VK H VK H410A VK H VK H VK H VK H VK H WW H VK H VK H VK H VK H VK H VK H SE H VK H VK H NC H XP W BN W VK W VK W VK W TV W GM W VK W VK W VK WE VK WE VK WE X E G X X X X

70 NUMERICAL INDEX PART PART PART PART PART PART A X K H X X J A J X X X X X F T T X G T X X X X X X X X X X X M G X X H L W R X X X X X X X X X X A A X X X X X X X X X X X X X X X X X X X X X X X X

71 NUMERICAL INDEX PART PART PART PART PART PART XL XM XA X YH YJ Y C Y X X X X X X X B X M