YFM35GY (5WHH) U.S.A. 1H5WH-110E1

Transcription

1 YFM35GY (5WHH) U.S.A. 1H5WH-110E1 ( )

2 YFM35GY PARTS CATALOGUE 2008 by Yamaha Motor Co., Ltd. 1st edition, July 2008 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.

3 FOREWORD This Parts Catalogue is related to the parts for the model(s) on the cover page. When you are ordering replacement parts, please refer to this Parts Catalogue and quote both part numbers and part names correctly. 6. The asterisk (*) before a reference number indicates modified items after the first edition. 1. Modifications or additions which have been made after the issue of the Parts Catalogue will be announced in the Parts News. It is advisable that you make the necessary corrections to the Parts Catalogue according to the Parts News. 2. Abbreviations The following abbreviations are used in this Parts Catalogue. UR Use specified parts number. UN Use as many as needed. AP Alternate Parts LM Locally Made (Parts need to be ordered locally) F# Frame No. (Applicable machine No.) O/S Over Size 3. The number of components for assembly Parts, which are to be supplied in an assembly, are listed with a dot (.) in front of the part name as shown below. The numeral appearing to the right of each component part indicates the quantity of parts for each assembly unit. Q TY 2F FRONT FLASHER LIGHT ASSY BULB (6V 18W) 1 4. Applicable colours of graphics are represented in the as shown below. Q TY 2N X5 FUEL TANK COMP. 2 MXR 3J GRAPHIC, FUEL TANK 1 FOR MXR 5. Note that the illustrations for reference in finding parts numbers are not to be used for assembling. When assembling, please use the applicable service manual.

4 FOREWORD 7. Applicable Serial No. Engine Serial No. Frame Serial No. 8. Applicable Colour Code (The (*) mark shows Model colour.) Abbreviation Colour Name Colour Code PDG(*) PASTEL DEEP GREEN 00K0 RTR(*) ROMANTIQUE ROUGE 00TR SMJ(*) BLACK METALLIC J Quantity Column Information Column No. Name Of Q ty Column Destination 1 U.S.A.

5 MODEL LABEL (1) A label called Model Label is affixed in the location as indicated in (3) below. When using this parts catalogue, please be sure to cross reference the model code production code No. in the catalogue with the model code production code No. indicated on the Model Label affixed onto the product concerned. (2) Model Label Indication (5) Model Code Production Code Number of Model Listed in This Parts Catalogue Model Code Production Code No. 5WHH 010 U.S.A. Country (destination) Model Code Production Code No. Country (destination) (3) Model Label Affixing Location (4) Colouring Information Model Code 5WHH Colouring Type Code Colour Code Colour Name Abbreviation A 00TR ROMANTIQUE ROUGE RTR B 00K0 PASTEL DEEP GREEN PDG T 0906 BLACK METALLIC J SMJ

6 CONTENTS ENGINE CYLINDER HEAD... 1 CYLINDER... 3 CRANKSHAFT & PISTON... 4 VALVE... 6 CAMSHAFT & CHAIN... 7 OIL PUMP... 8 INTAKE... 9 CARBURETOR EXHAUST CRANKCASE CRANKCASE COVER STARTER STARTER CLUTCH CLUTCH TRANSMISSION MIDDLE DRIVE GEAR SHIFT SHAFT CHASSIS FRAME FRONT FENDER REAR FENDER SIDE COVER REAR ARM DRIVE SHAFT REAR SUSPENSION FRONT SUSPENSION & WHEEL STEERING FUEL TANK SEAT FRONT WHEEL FRONT BRAKE CALIPER REAR WHEEL STEERING HANDLE & CABLE FRONT MASTER CYLINDER STAND & FOOTREST GUARD GENERATOR STARTING MOTOR METER HEADLIGHT TAILLIGHT HANDLE SWITCH & LEVER ELECTRICAL EMBLEM & LABEL ALTERNATE PARTS ALTERNATE FOR METER INDEX NUMERICAL INDEX... 61

7 FIG. 1 CYLINDER HEAD 1 5YT CYLINDER HEAD ASSY 1 2 3Y GUIDE, VALVE CIRCLIP BOLT, FLANGE GASKET BOLT, STUD 2 7 3Y ABSORBER Y1 1111F 00 PLATE BOLT WASHER, LOCK UY GASKET, CYLINDER HEAD PIN, DOWEL GASKET BOLT, FLANGE BOLT, FLANGE WASHER, PLATE BOLT WU BREATHER ASSY KB PLATE, BREATHER BOLT, FLANGE C2 E PIPE, BREATHER A4 CLIP CLAMP O-RING BOLT NL COVER, CYLINDER HEAD SIDE NL COVER, CYLINDER HEAD SIDE 3 1 1

8 FIG. 1 CYLINDER HEAD O-RING BOLT PLUG, SPARK (NGK DR8EA) 1 2

9 FIG. 2 CYLINDER 1 4X ABSORBER YT CYLINDER O-RING COLLAR O-RING PIN, DOWEL BOLT 1 8 4KB GASKET, CYLINDER 1 3

10 FIG. 3 CRANKSHAFT & PISTON 1 5UH CRANKSHAFT ASSY 1 2 5UH W CRANK SUB ASSY UH W CRANK SUB ASSY X PIN, CRANK P5.BEARING 1 6 5UH ROD, CONNECTING WASHER 2 8 5UH GEAR, DRIVE SPRING, COMPRESSION PIN, DOWEL UH WASHER, BEARING COVER CIRCLIP KEY, WOODRUFF WASHER, PLATE BOLT BEARING UH SPACER KM SEAL, CRANK UH C0 PISTON (STD) 1 5UH PISTON (0.50MM O/S) 1 AP 5UH PISTON (1.00MM O/S) 1 AP 20 4GB PISTON RING SET (STD) 1 4GB PISTON RING SET (0.50MM O/S) 1 AP 4GB PISTON RING SET (1.00MM O/S) 1 AP CIRCLIP V PIN, PISTON CIRCLIP 1 4

11 FIG. 3 CRANKSHAFT & PISTON 24 5UH WEIGHT BEARING BEARING UH GEAR, BALANCE WEIGHT KEY, STRAIGHT WASHER, LOCK NUT 1 5

12 FIG. 4 VALVE 1 1UY VALVE, INTAKE 1 2 1UY VALVE, EXHAUST 1 3 3Y SEAT, VALVE SPRING U SPRING, VALVE INNER 2 5 1UY SPRING, VALVE OUTER 2 6 M SEAL, VALVE STEM 2 7 3Y RETAINER, VALVE SPRING 2 8 1J COTTER, VALVE 4 9 3GD ARM, VALVE ROCKER WASHER, WAVE SH SHAFT, ROCKER O-RING G SCREW, VALVE ADJUSTING G NUT, LOCK 2 6

13 FIG. 5 CAMSHAFT & CHAIN 1 5UH CAMSHAFT ASSY O-RING PIN, DOWEL BEARING 1 NIHONSEIKO BEARING 1 6 5UH SPROCKET, CAM CHAIN BOLT WASHER, PLATE 1 9 4KB PLATE, BREATHER CHAIN (92RH M) UH GUIDE, STOPPER UH GUIDE, STOPPER G TENSIONER ASSY, CAM CHAIN G PLUG G GASKET GD GASKET, TENSIONER CASE BOLT, FLANGE BOLT WASHER, PLATE 2 7

14 FIG. 6 OIL PUMP 1 5UH OIL PUMP ASSY 1 2 5UH GASKET, PUMP COVER BOLT, FLANGE 3 4 5UH COVER, PUMP GEAR BOLT, FLANGE 2 6 5UH STRAINER, OIL BOLT, FLANGE BALL A7 SPRING, COMPRESSION UH 1319K 00 PLATE GH ELEMENT ASSY, OIL CLEANER BOLT, UNION S JOINT GASKET UH E ELEMENT, OIL COOLER UH E BLOWER ASSY UH E HOSE, OIL D5 E HOSE, OIL O-RING UH E BOLT UH E CLIP GROMMET COLLAR WASHER BOLT, FLANGE 4 8

15 FIG. 7 INTAKE 1 5UH JOINT, CARBURETOR O-RING BOLT WASHER, PLATE HOSE CLAMP ASSY 1 6 5UH E PIPE W PIPE A TUBE, FLEXIBLE VINYL 1 9 5UH E CASE, AIR CLEANER UH E GUIDE UH E PLATE,ELEMENT FITTING UH E ELEMENT, AIR CLEANER UH E CAP, CLEANER CASE UH E SEAL UH E CLIP, CAP FITTING UH E PIPE, DRAIN UH E PLUG, DRAIN UH E CLIP, DRAIN CLEANER ND E442F 00 PROTECTOR UH E JOINT, AIR CLEANER ND E DUCT HOSE CLAMP ASSY HOSE CLAMP ASSY A PIPE HOSE CLAMP ASSY UH 2177C 30 PLATE, EPA OFFROAD ATV 1 1 9

16 FIG. 8 CARBURETOR 1 5UH E CARBURETOR ASSY UH 1490J 10.NEEDLE SET 1 3 5DM SPRING, DIAPHRAGM 1 4 5GH DIAPHRAGM ASSY 1 5 5DM VALVE, THROTTLE GH RING 1 7 5UH PILOT SCREW SET 1 WHITE SPRING 8 3H WASHER 1 9 3H O-RING G2 1423E 51.JET, MAIN (#128.8) DM HOLDER O-RING PIN, FLOAT SV NEEDLE VALVE SET DM O-RING DM NOZZLE, MAIN KM SCREW HX JET, MAIN (# 80) KB PIPE SCREW, PAN HEAD UH 1410A 00.STARTER SET G2 1423A 62.JET, MAIN (#57.5) FV PLUG, DRAIN SCREW, PAN HEAD FU E O-RING SCREW, PAN HEAD NUT, CABLE ADJUSTING 1 10

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

18 FIG. 9 EXHAUST 1 5UH E PIPE, EXHAUST UH E NUT, RING 1 3 5UH E477R 00 BAND UH E PROTECTOR, EXHAUST PIPE 1 5 5UH E477T 00 BAND UH E477K 01 PLATE BOLT, FLANGE BOLT, FLANGE NUT GD GASKET, EXHAUST PIPE UH E MUFFLER ND E PIPE, OUTLET ND E BOLT, MUFFLER UH E PROTECTOR, MUFFLER ND E BAND, SILENCER UH E PROTECTOR, MUFFLER UH E477T 00 BAND P BOLT, FLANGE UH E COLLAR ND E GASKET, MUFFLER ND E BAND, MUFFLER ND E BOLT ND E WASHER BOLT, FLANGE WASHER, PLATE ND E DAMPER, MUFFLER COLLAR 2 12

19 FIG. 10 CRANKCASE 1 5WH CRANKCASE ASSY PIN, DOWEL BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE WASHER, PLATE 1 8 5GH PLATE, BEARING COVER BOLT, FLANGE K PLATE, BEARING COVER SCREW, COUNTERSUNK PLUG, STRAIGHT SCREW GASKET UH HOUSING, BEARING BEARING OIL SEAL WV PLATE, BEARING COVER BOLT, FLANGE BOLT, FLANGE PIN, DOWEL GH PLUG, BLIND BOLT, FLANGE WASHER, PLATE 2 13

20 FIG. 11 CRANKCASE COVER 1 1 5UH COVER, CRANKCASE BEARING OIL SEAL 1 4 5UH PLATE BOLT 2 6 5UH GASKET, CRANKCASE COVER PIN, DOWEL BOLT, FLANGE BOLT, FLANGE CLAMP PLUG, STRAIGHT SCREW O-RING PLUG, OIL LEVEL O-RING UH CRANKCASE COVER ASSY UH COVER, CRANKCASE UH SEAL, CRANKCASE BOLT, FLANGE UH COVER, CRANKCASE GROMMET KM PLUG, DRAIN UH SEAL, CRANKCASE BOLT, FLANGE DAMPER UH SPACER, ENGINE MOUNT UH E DUCT, AIR BF 1443E 00 PIPE, DRAIN 1 14

21 FIG. 11 CRANKCASE COVER A4 CLIP ND E SEAL, AIR DUCT ND E DUCT, AIR UH E SEAL, AIR DUCT HOSE CLAMP ASSY RIVET RIVET CLAMP BOLT, FLANGE 1 15

22 FIG. 12 STARTER 1 5UH STARTER ASSY V PAWL, DRIVE 1 3 5UH SPRING, STARTER V SPRING, FRICTION V SPRING V WIRE, STARTER NUT, FLANGE 1 8 3X HANDLE, STARTER V COVER UH PLATE, DRIVE W DRUM, SHEAVE BOLT, HEXAGON SOCKET HEAD KM PULLEY, STARTER O-RING 1 16

23 FIG. 13 STARTER CLUTCH 1 5UH GEAR, IDLER VJ SHAFT UH GEAR, IDLER WASHER, PLATE 1 5 5KM STARTER ONE-WAY ASSY BOLT 3 17

24 FIG. 14 CLUTCH 1 5UH CLUTCH HOUSING COMP UH CLUTCH CARRIER ASSY 1 3 5UH SPRING, CLUTCH WEIGHT UH HOUSING, BEARING BEARING OIL SEAL CIRCLIP CIRCLIP BEARING CIRCLIP GH BEARING, ONE WAY NUT UH GASKET, COVER PINION BOLT, FLANGE UH PRIMARY SLIDING SHEAVE COMP OIL SEAL WV WEIGHT UH CAM WV SLIDER WV SPACER O-RING UH STOPPER SCREW, PAN HEAD R9 WASHER, PLATE UH COLLAR UH V-BELT UH SHEAVE, PRIMARY FIXED 1 18

25 FIG. 14 CLUTCH T7 WASHER, PLATE NUT UH SECONDARY FIXED SHEAVE COMP UH SECONDARY SLIDING SHEAVE OIL SEAL O-RING CW PIN, GUIDE A0 SPRING, COMPRESSION UH SEAT, SECONDARY SPRING UH SEAT,SPRING NUT NUT 1 19

26 FIG. 15 TRANSMISSION 1 5UH SHAFT, SECONDARY BEARING BEARING 1 4 5UH COLLAR OIL SEAL 1 6 5UH AXLE, DRIVE 1 7 5UH GEAR, MIDDLE DRIVE (21T) 1 8 5UH GEAR, HIGH WHEEL (35T) WASHER, PLATE UH SPROCKET, DRIVEN (26T) WASHER, PLATE F2 BEARING WASHER, PLATE UH CLUTCH, DOG O-RING O-RING BEARING BEARING CHAIN (23RH302-34ASM) UH SHAFT CIRCLIP UH GEAR, MIDDLE DRIVEN (41T) PIN, DOWEL CIRCLIP BEARING 1 20

27 FIG. 16 MIDDLE DRIVE GEAR 1 5UH HOUSING, BEARING BEARING H PLATE, BEARING COVER SCREW 4 5 5KM SHIM, PINION (0.1T) 1 UR 5KM SHIM, PINION (0.15T) 1 UR 5KM SHIM, PINION (0.2T) 1 UR 5KM SHIM, PINION (0.3T) 1 UR 5KM SHIM, PINION (0.4T) 1 UR 5KM SHIM, PINION (0.5T) 1 UR 5KM SHIM, PINION (0.55T) 1 UR 5KM SHIM, PINION (0.6T) 1 UR NUT BOLT, FLANGE 4 8 5UH PINION SET 1 9 5GH HOUSING, BEARING BEARING NUT BEARING OIL SEAL UH YOKE, JOINT R6 WASHER, PLATE NUT O-RING GH SHIM, PINION (0.1T) 2 UR 5GH SHIM, PINION (0.15T) 2 UR 5GH SHIM, PINION (0.2T) 2 UR 21

28 FIG. 16 MIDDLE DRIVE GEAR 18 5GH SHIM, PINION (0.3T) 2 UR 5GH SHIM, PINION (0.4T) 2 UR 5GH SHIM, PINION (0.5T) 2 UR 5GH SHIM, PINION (0.6T) 2 UR BOLT, WITH WASHER 4 22

29 FIG. 17 SHIFT SHAFT 1 5UH SHIFT SHAFT COMP OIL SEAL WASHER, PLATE (T=1.0) CIRCLIP 1 5 5UH FORK, SHIFT A BAR, SHIFT FORK GUIDE BALL SPRING, COMPRESSION BOLT, FLANGE GASKET SH LEVER B COLLAR G5 WASHER, PLATE SPRING, TORSION UH LEVER WASHER, PLATE BOLT, FLANGE UH ROD, SHIFT NUT NUT UH SHIFTER ASSY TE KNOB, SHIFT LEVER RIVET GH BOOT, SEALING GH STOPPER,RUBBER HOSE (L90) ND E PLUG, DRAIN 1 23

30 FIG. 17 SHIFT SHAFT A2 CLIP 1 24

31 FIG. 18 FRAME 1 5UH F FRAME COMP UH F STAY, ENGINE UH E DAMPER, ENGINE MOUNT BOLT, FLANGE BOLT, FLANGE NUT, U FLANGE 1 7 5ND F DAMPER UH F STAY, ENGINE UH E DAMPER, ENGINE MOUNT BOLT, FLANGE BOLT, FLANGE ND F DAMPER BOLT, FLANGE NUT, U FLANGE UH E DAMPER, ENGINE MOUNT ND F DAMPER BOLT, FLANGE NUT, U FLANGE YN BEARING OIL SEAL OIL SEAL GU HOLDER, BEARING ND F STAY, MUFFLER ND F ARM BOLT, FLANGE UH F PROTECTOR BOLT, FLANGE 2 25

32 FIG. 18 FRAME GROMMET ND F TOOL KIT NV 2811A 01 GAUGE, AIR O-RING ND F147A 02 GUARD, ENGINE BOLT 8 26

33 FIG. 19 FRONT FENDER 1 5UH F1500 G0 FRONT FENDER ASSY 1 UR FOR RTR 5UH F1500 H0 FRONT FENDER ASSY 1 UR FOR PDG 5UH F1500 K0 FRONT FENDER ASSY 1 UR FOR SMJ 2 5UH F GRILLE, FRONT 1 3 5FU F175B 01 TUNING FORK MARK NUT, SPRING BOLT, WITH WASHER RIVET NUT, SPRING 2 8 5UH F CAP BOLT, WITH WASHER 2 27

34 FIG. 20 REAR FENDER 1 37S F REAR FENDER ASSY. 1 UR FOR RTR 5ND F1600 W1 REAR FENDER ASSY. 1 UR FOR PDG 5ND F1600 S1 REAR FENDER ASSY. 1 UR FOR SMJ PLUG BOLT, WITH WASHER BOLT, WITH WASHER 2 5 5BF 1443E 00 PIPE, DRAIN A4 CLIP 1 7 5ND F163A 02 COVER, REAR FENDER ND F163E 00 COVER, REAR FENDER ND F PROTECTOR ND F163F 00 COVER, REAR FENDER

35 FIG. 21 SIDE COVER 1 5UH F171A 00 COVER, TOP 1 UR FOR RTR 5UH F171A 10 COVER, TOP 1 UR FOR PDG 5UH F171A 70 COVER, TOP 1 UR FOR SMJ 2 5ND F174M 00 CLOTH, PROTECTOR SCREW A0 NUT, SPRING BOLT, HEXAGON SOCKET HEAD 2 29

36 FIG. 22 REAR ARM 1 3C2 F REAR ARM COMP TE G REAR AXLE HOUSING COMP BOLT, FLANGE NUT, WITH WASHER 4 5 5ND F BUSH BOLT, FLANGE NUT, SELF-LOCKING 2 8 5ND F BOOT, RUBBER SPRING, TENSION CLAMP, HOSE XE F219X 01 COVER STOPPER, MAIN STAND BOLT, FLANGE ND F151K 00 LABEL 7 1 ENGLISH 15 5ND F HOOK BOLT, FLANGE 3 30

37 FIG. 23 DRIVE SHAFT 1 5ND G REAR AXLE GEAR CASE ASSY 1 2 5ND G HOUSING, DRIVE SHAFT BOLT, STUD 4 4 4XE G BEARING ASSY OIL SEAL Y9.BEARING 1 7 5GT Y RING GEAR SET Y6.BEARING H9.COLLAR U RETAINER, BEARING O-RING OIL SEAL PLUG, STRAIGHT SCREW GASKET N BREATHER ND G HOUSING, BEARING OIL SEAL Y0.BEARING O-RING BOLT WASHER, PLATE BOLT, FLANGE FU G STOPPER, RING GEAR PLUG, STRAIGHT SCREW XE E SHIM, THRUST(T=0.15MM) 1 UR 4XE E SHIM, THRUST(T=0.30MM) 1 UR 4XE E SHIM, THRUST(T=0.40MM) 1 UR 31

38 FIG. 23 DRIVE SHAFT 25 4XE E SHIM, THRUST(T=0.45MM) 1 UR 4XE E SHIM, THRUST(T=0.50MM) 1 UR 4XE E SHIM, THRUST(T=0.60MM) 1 UR 26 4XE G SHIM, THRUST(T=1.0MM) 1 UR 4XE G SHIM, THRUST(T=1.1MM) 1 UR 4XE G SHIM, THRUST(T=1.2MM) 1 UR 4XE G SHIM, THRUST(T=1.3MM) 1 UR 4XE G SHIM, THRUST(T=1.4MM) 1 UR 4XE G SHIM, THRUST(T=1.5MM) 1 UR 4XE G SHIM, THRUST(T=1.6MM) 1 UR 4XE G SHIM, THRUST(T=1.7MM) 1 UR 4XE G SHIM, THRUST(T=1.8MM) 1 UR 4XE G SHIM, THRUST(T=1.9MM) 1 UR 4XE G SHIM, THRUST(T=2.0MM) 1 UR 4XE G SHIM, THRUST(T=2.1MM) 1 UR 27 4XE G SHIM, RING GEAR(T=0.25MM) 1 UR 4XE G SHIM, RING GEAR(T=0.30MM) 1 UR 4XE G SHIM, RING GEAR(T=0.35MM) 1 UR 4XE G SHIM, RING GEAR(T=0.40MM) 1 UR 4XE G SHIM, RING GEAR(T=0.45MM) 1 UR 4XE G SHIM, RING GEAR(T=0.50MM) 1 UR 28 5FU G SHIM, RING GEAR(T=0.10MM) 1 UR 5FU G SHIM, RING GEAR(T=0.15MM) 1 UR 5FU G SHIM, RING GEAR(T=0.20MM) 1 UR 5FU G SHIM, RING GEAR(T=0.30MM) 1 UR 5FU G SHIM, RING GEAR(T=0.40MM) 1 UR 5FU G SHIM, RING GEAR(T=0.50MM) 1 UR 32

39 FIG. 23 DRIVE SHAFT O-RING ND G SHAFT, DRIVE CIRCLIP HN CROSS JOINT COMP BEARING CIRCLIP HR SPIDER BEARING CIRCLIP NUT, WITH WASHER WASHER, PLATE HOSE (L1050) CLIP 1 33

40 FIG. 24 REAR SUSPENSION 1 5UH F SHOCK ABSORBER ASSY, REAR BOLT, FLANGE NUT, SELF-LOCKING PIN, CLEVIS 1 5 1W COVER, THRUST WASHER, PLATE PIN, COTTER 1 34

41 FIG. 25 FRONT SUSPENSION & WHEEL 1 5ND F FRONT UPPER ARM COMP. (LEFT) 1 2 5FU F BALL JOINT CIRCLIP 1 4 5ND F FRONT UPPER ARM COMP. (RIGHT) 1 5 5FU F BALL JOINT CIRCLIP NUT, CASTLE PIN, COTTER 4 9 5ND F357A 01 ARM,FR. LWR. LH ND F358A 01 ARM,FR. LWR. RH HR BUSH BOLT, FLANGE NUT, SELF-LOCKING UH F SHOCK ABSORBER ASSY NUT, SELF-LOCKING BOLT, FLANGE 4 35

42 FIG. 26 STEERING 1 5ND F COLUMN, STEERING ND F ARM, PITMAN 1 3 8K HOLDER, HANDLE BOLT, FLANGE PLUG, TAPER 1 6 1UY PLANE BEARING, STEERING OIL SEAL 2 8 5ND F BRACKET, STEERING LOWER BOLT UY WASHER, LOCK R0 COLLAR WASHER, PLATE NUT, SELF-LOCKING PIN, COTTER ND F ROD, TIE D9 F JOINT, UNIVERSAL ND F JOINT, UNIVERSAL XE F NUT XE F NUT NUT, CASTLE PIN, COTTER 4 36

43 FIG. 27 FUEL TANK 1 5UH F FUEL TANK COMP KM CAP ASSY 1 3 5KM FUEL COCK ASSY AC VALVE PACKING 1 5 3AJ SEAL, COCK SCREW, PAN HEAD 2 7 4X O-RING 1 8 5GH LEVER, COCK SCREW, FLAT HEAD WASHER, PLATE SCREW GROMMET J1 COLLAR BOLT, WITH WASHER GROMMET WASHER, PLATE COLLAR BOLT, WITH WASHER UH PIPE, FUEL A1 CLIP C5 HOSE (L400) UH F414H 01 DAMPER, PLATE

44 FIG. 28 SEAT 1 5ND F SINGLE SEAT ASSY 1 2 5ND F470F 01.SEAT COVER COMP XE F DAMPER, SEAT 6 4 4XE F478V 00.SPRING, TORSION 1 5 5ND F LEVER, SEAT 1 38

45 FIG. 29 FRONT WHEEL 1 5ND F WHEEL COMP. 1 UR FOR RTR,PDG 5ND F WHEEL COMP. 1 UR FOR SMJ TIRE (AT25X8-12 M979) 1 CHENG SHIN VALVE, RIM (TR413) NUT 4 5 5GT 2512A 00 CAP, WHEEL 1 6 5HA AXLE, WHEEL 2 7 5ND F STEERING KNUCKLE ASSY (LEFT) Y2.BEARING OIL SEAL OIL SEAL SPACER FU F BALL JOINT CIRCLIP ND F HUB, FRONT BOLT, SERRATION O-RING WASHER, PLATE NUT, CASTLE PIN, COTTER ND F WHEEL COMP. 1 UR FOR RTR,PDG 5ND F WHEEL COMP. 1 UR FOR SMJ TIRE (AT25X8-12 M979) 1 CHENG SHIN VALVE, RIM (TR413) NUT GT 2512A 00 CAP, WHEEL ND F STEERING KNUCKLE ASSY (RIGHT) 1 39

46 FIG. 29 FRONT WHEEL Y2.BEARING OIL SEAL OIL SEAL SPACER FU F BALL JOINT CIRCLIP ND F HUB, FRONT BOLT, SERRATION O-RING WASHER, PLATE NUT, CASTLE PIN, COTTER ND F514A 00 RING, WHEEL BOLT, FLANGE 4 40

47 FIG. 30 FRONT BRAKE CALIPER 1 5ND F582T 00 DISC, BRAKE (LEFT) BOLT 4 3 5ND F582T 00 DISC, BRAKE (LEFT) BOLT 4 5 3GD 2580T 01 CALIPER ASSY (LEFT) 1 6 3GD W PISTON ASSY, CALIPER 1 7 3GD W CALIPER SEAL KIT 1 8 1UY W BLEED SCREW KIT 1 9 3GD W BRAKE PAD KIT GD SHIM, CALIPER GD PIN, PAD GD 2580U 01 CALIPER ASSY (RIGHT) GD W PISTON ASSY, CALIPER GD W CALIPER SEAL KIT UY W BLEED SCREW KIT GD W BRAKE PAD KIT GD SHIM, CALIPER GD PIN, PAD BOLT, FLANGE 4 41

48 FIG. 31 REAR WHEEL 1 5ND F REAR WHEEL COMP. 1 UR FOR RTR,PDG 5ND F REAR WHEEL COMP. 1 UR FOR SMJ TIRE (AT25X10-12 M980) 1 CHENG SHIN VALVE, RIM (TR413) 1 4 5ND F REAR WHEEL COMP. 1 UR FOR RTR,PDG 5ND F REAR WHEEL COMP. 1 UR FOR SMJ TIRE (AT25X10-12 M980) 1 CHENG SHIN VALVE, RIM (TR413) 1 7 5ND F COLLAR, WHEEL 1 8 1P0 F BOLT NUT Y0 BEARING SH COVER, HUB DUST OIL SEAL Y0 BEARING OIL SEAL NUT VH F PLATE, BRAKE SHOE VH F CAMSHAFT VH WF BRAKE SHOE SET VH F SPRING, RETURN VH F533A 01 PLATE, INDICATOR BOLT L NUT, SELF-LOCKING VH F LEVER, CAMSHAFT VH F GASKET VH F BOLT, CALIPER 1 42

49 FIG. 31 REAR WHEEL 26 5VH F SEAL, CAMSHAFT VH F539F 01 PLATE PIN, COTTER SPRING, TENSION FU F COVER, PLATE FU F SEAL, HUB DUST BOLT, FLANGE FU F537Y 00 SEAL, DUST XE G RETAINER A4 BOLT, FLANGE TE F AXLE, WHEEL T0 COLLAR O-RING FU F531E 10 DRUM, BRAKE FU F RING FU F COLLAR, WHEEL P0 F BOLT FU F WASHER, WHEEL WASHER, PLATE NUT, CASTLE PIN, COTTER GT 2512A 00 CAP, WHEEL BOLT, FLANGE WASHER, PLATE HOSE (L1150) A0 CLIP 1 43

50 FIG. 32 STEERING HANDLE & CABLE 1 5FU F HANDLEBAR 1 2 5FU F GRIP 2 3 5ND F PROTECTOR, HANDLEBAR 1 4 4KB THROTTLE LEVER ASSY 1 5 4KB 2628F 10.CAP, GEAR 1 6 1NV 2625G 01.LEVER, THROTTLE SCREW SCREW, PAN HEAD NUT, U NUT OIL SEAL NV SPRING KB 2628G 00.GASKET NV WASHER NV WASHER V HOLDER, LEVER LOWER SCREW, PAN HEAD WASHER, PLATE GH CABLE, THROTTLE VH F CABLE, STARTER TE WIRE, BRAKE E NUT, ADJUSTING SPRING, COMPRESSION PIN 1 44

51 FIG. 33 FRONT MASTER CYLINDER 1 5KM 2583T 01 MASTER CYLINDER ASSY 1 2 8CR W CYLINDER KIT, MASTER 1 3 4L GASKET, DIAPHRAGM 1 4 5JX CAP, RESERVOIR SCREW, FLAT HEAD 2 6 5GH HOLDER 1 7 5EB BOLT 2 8 5KM LEVER NUT, U LP FRONT STOP SWITCH ASSY FK 2589F 00.BOLT, LEVER ND F HOSE, BRAKE GU CIRCLIP ND F HOSE, BRAKE ND F PIPE, BRAKE ND F HOLDER, BRAKE HOSE BOLT, FLANGE ND F BAND BOLT, FLANGE BOLT, UNION WASHER, PLATE BOLT, FLANGE 1 45

52 FIG. 34 STAND & FOOTREST 1 5ND F BAR, FOOTREST BOLT, FLANGE 4 3 5TE F BRACKET, FOOTREST BOLT, FLANGE 3 5 5TE F PEDAL, BRAKE NUT BOLT CIRCLIP WASHER, PLATE E NUT, ADJUSTING SPRING, COMPRESSION PIN PIN, CLEVIS WASHER, PLATE PIN, COTTER ND F COVER ND F COVER ND F PLATE UH F741A 10 ARM U9 RIVET, BLIND BOLT SCREW WASHER, PLATE NUT, NYLON TE CABLE, BRAKE GH 2637F 10 CABLE, CONTROL UH F PROTECTOR 1 46

53 FIG. 34 STAND & FOOTREST BOLT, WITH WASHER SPRING, TENSION UH F PLATE U1 RIVET,BLIND 1 47

54 FIG. 35 GUARD 1 5UH F845N 00 BAR, CARRY FRONT 1 2 4XE F CAP BOLT, FLANGE 4 4 5ND F CARRIER, FRONT BOLT, FLANGE 4 6 5TE F CARRIER, REAR BOLT, FLANGE BOLT, WITH WASHER 2 48

55 FIG. 36 GENERATOR 1 5UH STATOR ASSY SCREW, PAN HEAD WASHER, PLATE BOLT 2 5 5UH ROTOR ASSY 1 49

56 FIG. 37 STARTING MOTOR 1 3HE MOTOR ASSY 1 2 3HE BRUSH HOLDER ASSY 1 3 3HE ARMATURE ASSY 1 4 3AJ WASHER KIT 1 5 3HE FRONT BRACKET ASSY 1 6 3HE BOLT H GASKET 2 8 1FK O-RING 1 9 3XF CORD, STARTER MOTOR G CAP XV 8182A 00 NUT BOLT, FLANGE 2 50

57 FIG. 38 METER 1 5UH F BRACKET, SUPPORT BOLT, WITH WASHER 2 3 5UH F837L 00 PANEL, CONSOLE NUT, SPRING 4 51

58 FIG. 39 HEADLIGHT 1 4KB BULB (12V-30/30W) 2 2 5KM LENS ASSY 2 3 5EH SOCKET CORD ASSY SCREW, PAN HEAD 2 5 2GU SPRING, SCREW 2 6 2GU NUT, ADJUSTING A8 NUT, SPRING SCREW, BIND 4 52

59 FIG. 40 TAILLIGHT 1 5KM TAILLIGHT UNIT ASSY 1 2 1A BULB (12V-21/5W) 1 3 5KM 8472C 10.LENS, TAILLIGHT WASHER, PLATE NUT, NYLON 2 53

60 FIG. 41 HANDLE SWITCH & LEVER 1 1YW HOLDER, LEVER HT LEVER YW LEVER, LOCK 1 4 2XJ HOLDER, LEVER LOWER BOLT NUT, U SCREW, PAN HEAD WASHER, SPRING 2 9 3FA FRONT STOP SWITCH ASSY BOLT NUT LP SWITCH, HANDLE GH LEVER, STARTER UY WASHER, SPECIAL L WASHER, STARTER SCREW, PAN HEAD WASHER, SPRING SCREW, PAN HEAD 2 54

61 FIG. 42 ELECTRICAL 1 1 5UH C.D.I. UNIT ASSY SCREW, TAPPING CLAMP PLUG 1 5 3GB NEUTRAL SWITCH ASSY GASKET 2 7 5KM IGNITION COIL ASSY BOLT 1 9 5UH H SPACER BOLT WASHER, PLATE UY PLUG CAP ASSY GB THERMO UNIT WASHER, PLATE GT RECTIFIER & REGULATOR ASSY BOLT, FLANGE TE H BATTERY ASSY(YUASA YTX14AH) TE H BRACKET, BATTERY PAD, BATTERY ND H COVER, LEAD WIRE BOLT, FLANGE SCREW, TAPPING TE H WIRE, PLUS LEAD UH H WIRE, MINUS LEAD TE PILOT LIGHT ASSY GH BULB (14V-1.7W) KB PILOT LIGHT ASSY 1 RED (OIL) 55

62 FIG. 42 ELECTRICAL GH BULB (14V-1.7W) PLUG PLUG 1 AP 31 4SV STARTER RELAY ASSY AE FUSE (30A-BL) BOLT, FLANGE CLAMP KM MAIN SWITCH ASSY 1 AP 5LP MAIN SWITCH ASSY HN NUT, MAIN SWITCH HN CAP, KEY KB STOP SWITCH ASSY WH WIRE HARNESS ASSY 1 5WH WIRE HARNESS ASSY 1 AP 40 3D CIRCUIT BREAKER ASSY D THERMO SWITCH ASSY JJ FUSE (15A-BL) JJ FUSE (10A-BL) WP DIODE ASSY U RELAY ASSY DM RELAY ASSY (G8HN-1C4T-DJ-Y52) CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP 2 56

63 FIG. 42 ELECTRICAL CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP FU H TERMINAL ASSY 1 AP 68 5FU H191B 10.NUT FU H COVER, CONNECTER 1 AP 57

64 FIG. 43 EMBLEM & LABEL 1 1 4XE F LABEL, WARNING 1 ENGLISH 2 1P0 F816L 00 LABEL, WARNING AGE 1 ENGLISH 3 4XE F RIVET XE F WASHER, FENDER MOLD TE F151E 00 LABEL 2 1 ENGLISH 6 5ND F LABEL, CAUTION 1 ENGLISH 7 3B EMBLEM 3D S F817J 00 PLATE, ANSI SVIA 1 9 5FU F816M 00 LABEL, WARNING TIRE & LOAD 1 ENGLISH 10 4XE F RIVET XE F WASHER, FENDER MOLD ND F EMBLEM UH F1781 K0 EMBLEM UH F1782 K0 EMBLEM UH F173B 20 EMBLEM 3D XE F819R 20 TAG, WARNING P0 F POUCH 1 58

65 FIG. 44 ALTERNATE FOR METER BOLT, WITH WASHER 2 2 5UH W SPEEDOMETER KIT 1 AP 3 4WV HOUSING, TACHOMETER GEAR 1 4 4WV GEAR, DRIVE 1 5 4WV GEAR, DRIVEN V HOUSING, TACHOMETER GEAR 1 7 4SH SPEEDOMETER ASSY 1 MILE/H 8 4SH SOCKET, METER 1 9 4R BULB (12V-3.4W T10) GM BULB (12V-1.7W) M34.WASHER, PLATE BUSH, SOLID OIL SEAL O-RING O-RING BOLT, FLANGE SCREW, PAN HEAD UH F834L 00.BRKT., METER UH F837L 11.PANEL, CONSOLE SCREW, PAN HEAD UH H252R 00.DAMPER M DAMPER X WASHER, SPECIAL CLIP VH H SPEEDOMETER CABLE ASSY O-RING SCREW, PAN HEAD 1 59

66 FIG. 44 ALTERNATE FOR METER CLAMP 1 AP 60

67 NUMERICAL INDEX 5YT Y1 1111F Y X Y KB WU KB UY NL NL YT KB UH KM UH UH UH UH GB GB GB UH C V UH UH UH X UY U UY Y Y J UY M GD SH G G UH UH G GD G G UH UH S UH 1319K UH UH UH UH GH UH UH UH SV UH 1410A DM DM KM H FU FV W KB FU DM KM HX G2 1423A G2 1423E DM UH A BF 1443E DM FN GD EL 1490H UH 1490J GH DM XE GH GH H DM T WH UH UH UH UH KM N UH WV K H GH GH UH UH UH UH UH UH UH UH UH VJ KM UH UH W V UH KM V V X V V UH UH UH UH GH UH UH UH UH UH UH UH UH GH KM GH KM GH KM GH KM GH KM GH KM GH KM KM GH UH UH UH UH UH UH WV UH UH UH UH WV WV UH CW UH UH UH WV V WV WV UH UH GH TE UH SH UH UH A GH UH 2177C W HR UY K GU UY UH KM X AC GH AJ KM GT 2512A HA SH GD 2580T GD 2580U GD GD KM 2583T JX L GU GH FK 2589F GD NV B KB NV 2625G KB 2628F KB 2628G NV GH EB TE E TE GH 2637F NV NV 2811A HN U HR UH UH AJ XF HE XV 8182A HE HE H FK HE G HE SV DM U GT WP AE JJ JJ D KM UY KM LP KB GB D HN HN WH WH YW XJ V GH GM R X

68 NUMERICAL INDEX M TE KB SH SH GB UY HT KM GH L YW LP LP FA KB KM GU GU EH KM A KM 8472C UH C2 E UH E UH E D5 E UH E UH E UH E UH E FU E FU E UH E ND E UH E UH E UH E UH E ND E442F ND E UH E UH E UH E UH E UH E UH E UH E UH E UH E UH E UH E ND E ND E UH E ND E UH E ND E ND E ND E UH E ND E UH E477K UH E477R UH E477T ND E UH E UH E ND E ND E UH E XE E XE E XE E XE E XE E XE E UH F UH F UH F XE F ND F ND F147A ND F ND F UH F1500 G UH F1500 H UH F1500 K TE F151E ND F151K XE F XE F XE F ND F S F ND F1600 S ND F1600 W ND F163A ND F163E ND F163F ND F UH F171A UH F171A UH F171A UH F173B ND F174M FU F175B UH F1781 K UH F1782 K C2 F ND F ND F XE F219X UH F UH F ND F UH F ND F ND F ND F FU F ND F ND F357A ND F358A ND F ND F ND F XE F XE F D9 F ND F ND F UH F UH F414H ND F470F ND F XE F ND F XE F478V ND F TE F ND F ND F ND F ND F514A ND F ND F FU F FU F531E VH F FU F VH F FU F VH F533A VH F VH F VH F FU F FU F537Y TE F ND F FU F ND F ND F VH F539F P0 F VH F ND F582T ND F ND F ND F ND F VH F UH F FU F ND F FU F VH F TE F TE F UH F741A ND F UH F ND F ND F ND F UH F ND F P0 F816L FU F816M S F817J P0 F XE F819R UH F UH F UH F834L UH F837L UH F837L UH F845N ND F ND G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G XE G ND G ND G FU G FU G FU G FU G FU G FU G FU G ND G XE G TE G UH H FU H191B FU H TE H TE H UH H ND H TE H UH H252R FU H VH H CR W GD W GD W UY W GD W UH W UH W UH W VH WF GT Y A

69 NUMERICAL INDEX A A R M G R T U U B J R H T C A A A A A A A A Y Y