ORIGINAL PARTS TRi 204
CONTENTS PAGE Cycle part: Part : Frame 2 Part 2: Steering 4 Part 3: Front wheel 6 Part 4: Swing arm 8 Part 5: Rear wheel 0 Part 6: Plastics 2 Part 7: Admission 4 Part 8: Cooler 6 Part 9: Exhaust 8 Part 0: Other elements 20 Motor part: Part : Crankcase 22 Part 2: Cylinder 24 Part 3: Ignition 26 Part 4: Gear/clutch system 28 Part 5: Kickstart set 30 Electric part: Part : Electric injection system 32 Part 2: Light installation 34 Ossa engineering tools 36 Ossa stickers 37 CONTENTS
8 9 6 0 2 3 4 5 4 3 5 6 7 6 2 7 CYCLE PART 8 9 20 26 22 23 4 2 20 25 24 2
REF CODE NAME QUANTITY 08302BG TORX M8x30 2 2 5000022 FOOTREST KIT 3 5002 FOOTREST SCREW 2 4 05608CA TORX M5X6 2 5 0508LA NUT CLIP M5 0 6 052008BB TORX M5x20 4 7 05208CA TORX M5x2 2 8 52203023 ECU SUPPORT 9 05208BB TORX M5X2 0 524003023 ECU HEATSHIELD PROTECTOR 523003052 ECU SUPPORT BELT 2 945002 BREATHER HOSE 3 3500202 BREATHER PIPE 4 940002 FUEL TANK CAP 5 224000TD O-RING 22x4 6 32004QB STEERING BEARING 7 0000023 FRAME 8 30000402 FRAME TRIMS SET 9 50300402 AIR BOX FILTER FOAM 20 08242HA SCREW M8x24 8 2 05608AA SCREW M5x6 8 22 05208AA TORX M5x2 3 23 08452CA TORX M8x45 24 460002 CRANKCASE RUBBER PROTECTOR 25 450002 ENGINE PROTECTOR PLATE 26 0802HA-R ENGINE-FRAME SPECIAL SCREW CYCLE PART 3
6 5 2 4 3 7 CYCLE PART 2 9 8 23 0 F. FORK MAINTENANCE KIT 22 2 2 CLUTCH PUMP MAINTENANCE KIT 5 4 3 20 9 8 7 6 4
REF CODE NAME QUANTITY 2520002 HANDLEBAR GRIPS 2 250002 HANDLEBAR 3 0630YA HANDLEBAR CLAMP PIN 2 4 2530002 HANDLEBAR CLAMP SET 5 2600002 UPPER CLAMP 6 20000022 FRONT FORK 7 2099002 F. FORK MAINTENANCE KIT 8 06200AA TORX 6X20 INOX. 7 9 27000022 LOWER CLAMP 0 260002 STEERING AXLE 20420NA UPPER CLAMP WASHER 2 372500TA STEERING O-RING 3 32004QB STEERING BEARING 2 4 90500402 STEERING BEARING DUST COVER 5 2620002 STEERING NUT 6 2630002 TOP NUT STEERING STEM 7 25650022 HANDLE THROTLE 8 2552002 HYDRAULIC CLUTCH RACORD 9 045NH WASHER 2 20 2550002 CLUTCH LINE 2 2546002 CLUTCH PUMP MAINTENANCE KIT 22 25400024 CLUTCH LEVER / PUMP KIT 23 25420024 CLUTCH LEVER CYCLE PART 2 5
6 7 8 9 0 5 2 4 CYCLE PART 3 3 2 3 20 9 8 7 6 5 4 KIT REPARACION CTO. FRENO DEL. FRONT BRAKE REPAIR KIT VORNE BREMSE REPARATURSATZ REVISIE SET VOORREMKLAW KIT DU MAINTENANCE FREIN AVANT 6
REF CODE NAME QUANTITY 855HA FRONT WHEEL SCREW 2 7400002 FRONT BRAKE PADS 3 72000024 FRONT BRAKE CALIPER 4 73000024 FRONT BRAKE LINE 5 70000024 FRONT WHEEL BRAKE KIT 6 7000024 FRONT WHEEL MASTER CYLINDER 7 73200024 FRONT WHEEL BRAKE LEVER 8 5300022 FRONT WHEEL SPOKES KIT, BLACK 28 9 50002 FRONT RIM 0 5600002 FRONT TYRE 50000022 FRONT WHEEL SET 2 500002 FRONT WHEEL SHAFT 3 7499002 REPAIR KIT FRONT BRAKE SET 4 5620002 FRONT INNER TUBE 5 560002 TYRE CLAMP 6 565002 FRONT RIMSTRIP 7 254209PA FRONT HUB BEARINGS 8 520002 FRONT HUB 9 5400002 FRONT WHEEL BRAKE DISK 20 0620AA SCREW 4 CYCLE PART 3 7
5 6 7 2 3 8 4 9 0 32 33 34 35 36 37 CYCLE PART 4 38 39 4 4 40 42 43 28 5 4 6 3 2 27 3 29 7 30 26 25 24 23 22 3 2 20 9 8 8
REF CODE NAME QUANTITY REF CODE NAME QUANTITY 40000022 SWING ARM 2 7750002 REAR BRAKE CALIPER SCREW 3 687OB FRICTION BEARING 3 4 62505NI WASHER 3 5 05208BB TORX M5X2 2 6 90300402 CHAIN GUIDE 7 90250402 CHAIN PROTECTOR 8 043800FB TAPPING SCREW 2 9 420002 SWING ARM SHAFT BUSH 2 0 4805DA SWING ARM SHAFT SPECIAL SCREW 2 030900FB TORX ST 3,9X9,5 2 2 90350402 CHAIN PROTECTION PLATE 3 202604SH SEALING 2 4 20232.5OB FRICTION BEARING 2 5 20235OA FRICTION BEARING 2 6 0620AA TORX M6X2 7 0502AA SCREW 8 3000002 REAR SHOCK ABSORBER OHLINS 9 062802NA WASHER 20 202805NI WASHER 2 32000024 ROCKER ARM 22 20236.5OB FRICTION BEARING 2 23 32300024 ROCKER ARM - FRAME SHAFT 24 60000WF SEEGER 2 25 32200024 ROCKER ARM SHAFT 26 33000024 LINKER ASSY 2 27 0402HA SHOCK ABSORBER LOWER SCREW 28 02KG NUT M0 29 05608BB TORX M5x6 3 30 530002 SIDE STAND SPRING 3 525002 SIDE STAND 32 060400TA O-RING 6x4 33 550002 SIDE STAND STOP BLOCK 34 540002 SIDE STAND BUSH GUIDE 35 05XB THREADED RIVET M5 3 36 520002 SIDE STAND SUPPORT 37 0802BA SCREW M8x0 38 4450002 CHAIN TENSOR SET 39 4460002 CHAIN TENSOR SPRING 40 60000WD SEEGER 4 06200AA TORX M6X20 2 42 062402NA WASHER 2 43 682OB FRICTION BEARING 4 CYCLE PART 4 9
27 28 29 30 2 3 4 KIT REPARACION CTO. FRENO TRASERO REPAIR KIT REAR BRAKE SET REPARATUR SATZ HINTEN REVISIE SET ACHTER REMKLAUW 25 26 5 6 24 7 8 9 0 2 CYCLE PART 5 23 22 2 8 20 9 7 6 5 4 3 0
REF CODE NAME QUANTITY REF CODE NAME QUANTITY 60000022 REAR WHEEL SET 2 6600002 REAR TYRE 3 600022 REAR RIM 4 6300022 REAR WHEEL SPOKES SET, BLACK 28 5 6200022 REAR HUB 6 7999002 REPAIR KIT REAR BRAKE SET 7 254209PA BEARING 2 8 082KK M8 NUT 4 9 08242HA SCREW M8x24 4 0 6020002 REAR WHEEL SHAFT ASSEMBLY 25: CHAIN SET 4400063 250 / 280 / 300: 4400024 2 25: 65040063 SPROKET Z48 250 / 280 / 300: SPROKET Z42 6500002 3 60400022 REAR WHEEL SPACER 4 20402PA BEARING 5 6042002 REAR WHEEL SPACER 6 6020002 TUBELESS VALVE 7 0620AB DISC BRAKE SCREWS 4 8 7800002 REAR BRAKE LINE 9 7600002 REAR BRAKE MASTER CYLINDER 20 7820002 REAR BRAKE PEDAL 2 7830002 REAR BRAKE PEDAL BUSHING 22 0508KA M5 NUT 23 05208AA TORX M5x2 24 2402BA SCREW M2x40 25 6030002 REAR WHEEL TENSOR PLATE 26 6400002 REAR BRAKE DISK 27 7500002 REAR BRAKE SET 28 700002 LOCK SET 29 7700002 REAR BRAKE CALIPER 30 7900002 REAR BRAKE PADS SET CYCLE PART 5
2 3 4 5 6 7 9 32 8 8 0 2 3 CYCLE PART 6 29 30 3 4 5 6 28 27 26 25 24 23 22 2 20 9 8 7 2
REF CODE NAME QUANTITY REF CODE NAME QUANTITY 05608AA M5x6 TORX SCREW 3 2 6200302 BUSHING 3 3 6300302 SILENTBLOCK 3 4 020402 HEADLIGHT RACING MASK 5 0900YF PLASTIC CLAMP 6 05208BB SCREW 7 50004022 AIR BOX COVER 8 05608CA M5x6 SCREW 4 9 600004023 REAR FENDER 0 050808BB TORX M5X8 3 0508KB NUT 2 606004023 SPECIAL SQUARE NUT 3 3 909004023 EXHAUST PROTECTOR, CENTER 4 042XA RIVET 6 5 040805NA WASHER 6 6 90800402 EXHAUST PROTECTOR, LEFT 7 05208AA TORX M5x2 2 8 90200402 REAR SPROCKET PROTECTOR 9 90850402 LATERAL HEAT SHIELD 20 9050402 REAR DISC PROTECTOR 2 05008AA TORX M5x0 2 22 90700402 EXHAUST PROTECTOR, RIGHT 23 800004023 SEAT BASE 24 8000402 SEAT BASE HEAT SHIELD 25 08302BG TORX M8x30 26 08602BG TORX M8x60 27 7255002 FRONT DISC COVER WASHER 28 9000402 FRONT DISC COVER 29 2650002 FRONT FENDER SUPPORT PLATE 30 0620AA TORX M6X2 4 3 20000402 FRONT FENDER 32 050808AB TORX M5X8 2 CYCLE PART 6 3
2 3 4 5 6 8 CYCLE PART 7 9 7 8 7 3 6 5 4 2 4 0 9
REF CODE NAME QUANTITY 93400023 AIR FILTER SCREW 2 93500023 AIR FILTER FOAM 3 93300023 AIR FILTER HOUSING 4 92500302 AIR TEMPERATURE SENSOR 5 50000402 AIRBOX 6 50200402 AIR FILTER MANIFOLD 7 9400202 RADIATOR SILENTBLOCK 8 9050002 THROTTLE CABLE 9 9000202 REED BLOCK ASSY 0 325009VA CLAMP 05608DA SCREW 4 2 9000002 THROTTLE BODY ASSY 3 304509VA CLAMP 4 505504024 CABLE SUPPORT 5 92600302 AIR PRESSURE SENSOR 6 05400FA TORX. 40X4 2 7 9420002 PRESSURE SENSOR INTAKE HOSE 8 505004024 AIRBOX CAP 9 93000023 AIR FILTER CYCLE PART 7 5
2 9 CYCLE PART 8 8 3 4 7 6 5 6
REF CODE NAME QUANTITY 80002 RADIATOR 2 800002 RADIATOR + FAN SET 3 2308UA CLAMP 4 57200202 WATER PUMP HOSE 5 94000202 RADIATOR SUPPORT PLATE 6 9400202 SILENTBLOCK 2 7 9000302 FAN 8 830002 CYLINDER WATER HOSE 9 208UA CLAMP 3 CYCLE PART 8 7
2 3 4 5 CYCLE PART 9 0 9 8 7 6 8
REF CODE NAME QUANTITY 25: EXHAUST ASSEMBLY 96500063 250 / 280 / 300: 9650002 2 0508LA NUT CLIP M5 3 9670052 CATALYTIC CONVERSOR 42.5 4 950002 BEND EXHAUST GASKET 5 052008AA M5x20 SCREW 3 6 25: HEADER PIPE 9600063 250 / 280 / 300: 960002 7 9620002 HEADER PIPE SPRING 8 96750052 CATALYTIC CONVERSOR 32.25 9 08402AA TORX M8x40 0 082KG M8 NUT CYCLE PART 9 9
2 3 4 5 6 7 CYCLE PART 0 8 4 9 3 2 0 20
REF CODE NAME QUANTITY 000402 HEADLIGHT MASK 2 05608AA M5x6 TORX SCREW 2 3 6200302 BUSHING 2 4 6300302 SILENTBLOCK 2 5 6000302 MULTIFUNCTION SUPPORT PLATE 6 60002 REAR VIEW MIRROR 2 7 60000402 HOMOLOGATED REAR FENDER 8 06604NG SUPPORT WASHER 4 9 700004022 NUMBER PLATE SUPPORT 0 32500302 REAR CATADIOPTRIC 05000FA HEADLIGHT SCREWS 4 2 200302 LAMP SUPPORT 2 3 2200302 HEADLIGHT ADJUSTING SPRING 4 053508AA HEADLIGHT ADJUSTING SCREW CYCLE PART 0 2
4 5 6 7 8 9 3 0 2 2 MOTOR PART 5 3 4 24 6 23 22 2 20 9 8 7 22
REF CODE NAME QUANTITY 25: NEEDLE BEARING 5208QA 250 / 280 / 300: 82222QA 2 25: CRANKSHAFT 300002064 250 / 280 / 300: 300002023 3 00002024 CRANKCASE 4 0802OA FRICTION BEARING 5 08009.5OB FRICTION BEARING 6 945002 CRANKCASE BREATHER HOSE 7 550002023 WATER PUMP ASSY 8 240OA FRICTION BEARING 9 052008AA M5x20 SCREW 3 0 5700202 CYLINDER WATER HOSE 208UA CLAMP 2 2 320000WC SEEGER Ø32 3 20320PA BEARING 4 25422PA BEARING 5 7600202 KICKSTART PEDAL STOP 6 4200002 REAR ENGINE CENTERING BUSHING 2 7 3500202 BREATHER PIPE 8 33500202 CRANKSHAFT BEARING POS. SCREW 9 2802NF WASHER 20 3000202 OIL DRAINING BOLT 2 05095NF WASHER 22 050608AA M5x6 SCREW 23 02540HB WASHER 24 33000202 WOODRUFF KEY 0x3,7x3 MOTOR PART 23
3 4 5 6 7 8 9 2 0 2 3 4 MOTOR PART 2 24 5 COMPLETE ENGINE GASKET SET 6 23 22 2 4 9 8 7 24
REF CODE NAME QUANTITY REF CODE NAME QUANTITY 25: SPARK PLUG 630002063 250 / 280 / 300: SPARK PLUG 63000202 2 052508AA M5x25 TORX 8 3 055NF WASHER 8 4 0845NF WASHER 5 5 25: CYLINDER HEAD ASSY 600002063 250: 600002074 280: 600002024 300: 600002044 6 044078TA O-RING NBR 7 05608BB M5x6 SCREW 2 8 920002 INJECTOR CAP 9 408UC CLAMP 2 0 950002 FUEL LINE 90002 INJECTOR 2 930002 INJECTOR GASKET 3 25: CYLINDER 650002064 250: 650002074 280: 65000202 300: 650002044 4 25 / 250 / 300: CYLINDER WATER HOSE NECK 65502024 280: - 5 25 / 250 / 300: WASHER 4208NE 280: - 6 95300202 CYLINDER GASKET 7 95350202 EXHAUST GASKET 8 65200202 EXHAUST MANIFOLD 9 05208AA M5x2 TORX 3 20 0845NF WASHER 5 2 08302AA M8x30 TORX 4 22 25: 660002063--A 660002063--B 250: 660002074--A 660002074--B 280: 66000202--A 66000202--B 300: 660002042--A 660002042--B 23 25: 632278TB PISTON A ASSY PISTON B ASSY PISTON A ASSY PISTON B ASSY PISTON A ASSY PISTON B ASSY PISTON A ASSY PISTON B ASSY O-RING NBR 250 / 280 / 300: 822778TB 24 95000202 COMPLETE ENGINE GASKET SET MOTOR PART 2 25
8 9 0 6 7 2 5 3 4 2 MOTOR PART 3 3 4 4 6 5 26
REF CODE NAME QUANTITY 052008AA M5x20 TORX 5 2 73000302 IGNITION COVER 3 0402AB M0x40 SCREW 4 05208AA TORX M5x2 INOX 2 5 7000302 ACG SET 6 7200302 STATOR WIRES SUPPORT PLATE 7 05608BB M5x6 TORX 6 8 05608AE M5x6 TORX 3 9 340002023 INNER CRANKSHAFT COVER 0 95700202 INNER CRANKSHAFT COVER GASKET 34200202 INNER CRANKSHAFT COVER INSERT 2 332002023 WASHER 28X34X0,8 3 343002023 BEARING 4 253207SB SEALING 2 5 052508AF M5X25 TORX 3 6 02540HB WASHER 0x25x4 MOTOR PART 3 27
4 5 6 7 8 9 0 3 2 MOTOR PART 4 34 35 5 4 3 2 33 3 32 6 7 8 30 29 28 27 26 25 24 23 22 2 20 9 28
REF CODE NAME QUANTITY REF CODE NAME QUANTITY 250000WA SEEGER Ø25 2 4300202 COUNTERSHAFT SPROCKET 3 304008SB SEAL FOR GEAR OUTPUT SHAFT 4 4500202 SHIFT SEAL BUSHING 5 25500TA O-RING NBR 2 6 400002024 GEAR TRANSMISSION ASSY 7 06008DB SCREW 5 8 230002022 CLUTCH DISCS SET 9 2400202 PRESSURE PLATE 0 243002024 CLUTCH SPRING SUPPORT PLATE 6002023 CLUTCH NUT LOCKER 2 04007BC M4x0 SCREW 8 3 242002024 CLUTCH SPRING 4 24400202 CLUTCH RELEASE ARM 8 5 8200202 GEAR FORK st-4th 6 82300202 GEAR FORK 5th-6th 7 060KI M6 NUT 8 4400202 SHIFT SHAFT ADJUSTING SPRING 9 850202 SHIFT SHAFT SPRING 20 02405NA WASHER 2 8300202 GEAR SELECTOR SPRING 22 8000202 SHIFT SHAFT ASSY 23 8200202 GEAR SELECTOR 2 24 0560NA WASHER 25 052508AA M5x25 TORX 26 22405NA WASHER 27 2805NA WASHER 28 84000202 SHIFT DRUM ASSY 29 052008AA M5x20 TORX 30 8500202 GEAR PEDAL 3 22005SB GEAR SHAFT OIL SEAL 32 400008024 PREASSEMBLED AND ADJUSTED GEARBOX 33 8300202 FORK SHAFT 2 34 82200202 GEAR FORK 2nd-3rd 35 60002024 PRIMARY SHAFT LOCKER SHAFT MOTOR PART 4 29
8 9 0 7 2 6 5 4 3 2 MOTOR PART 5 4 3 7 6 5 2 20 9 8 28 23 27 26 25 24 23 22 30
REF CODE NAME QUANTITY REF CODE NAME QUANTITY 2600202 BEARING PLATE 2 73002RA BEARING 3 262002024 CLUTCH PUMP PISTON 4 263002024 CLUTCH PISTON SPRING 5 26400202 CLUTCH PISTON SPRING GUIDE 6 25500TC O-RING NBR 2 7 95200202 CLUTCH COVER GASKET 8 2802NF WASHER 9 300202 OIL DRAINING BOLT 0 25300202 OIL WINDOW 7400202 KICKSTART PEDAL 2 052508AA M5x25 TORX 4 3 053008AA M5x30 TORX 2 4 74400202 KICKSTART BALL 5 74300202 KICKSTART PEDAL SPRING 6 05208AA M5x2 TORX 2 7 74200202 KICKSTART PEDAL BUSHING 2 8 7002022 KICKSTART SHAFT 9 82404SA SEALING NBR 8x24x4 20 250002024 CLUTCH COVER 2 84005NA WASHER 22 0520MA CENTERING PING 23 7500202 KICKSTART SHAFT CLIP 2 24 7400202 PEDAL KICKSTART SPRING 25 7300202 KICKSTART SPRING BUSHING 26 7300202 KICKSTART GEAR 27 73200202 FRICTION KICKSTART SPRING 28 22405NA WASHER MOTOR PART 5 3
7 8 9 0 2 DIAGNOSTIC KIT 6 3 5 ELECTRIC PART 4 3 2 7 5 6 8 4 32
REF CODE NAME QUANTITY 9000302 ELECTRIC FAN 2 92500302 INTAKE AIR TEMPERATURE SENSOR 3 7000302 ACG SET 4 50200302 SPARK PLUG CAP 5 50000302 IGNITION COIL 6 5000302 REGULATOR 7 99000302 DIAGNOSTICS KIT TR280i 8 52000302 ECU 9 900302 FAN RELAY 0 92000302 ENGINE COOLANT TEMPERATURE SENSOR 92600302 AIR PRESSURE SENSOR 2 6003024 EASY START SYSTEM 3 0003024 MAIN HARNESS 4 24000302 LIGHT HORN SWITCH 5 9000002 THROTTLE BODY ASSY 6 8500302 FUEL LEVEL SENSOR 7 90002 INJECTOR 8 85000302 FUEL PUMP ASSY ELECTRIC PART 33
9 0 8 ELECTRIC PART 2 7 6 5 4 2 3 3 2 34
REF CODE NAME QUANTITY 2000302 LIGHT WIRING 2 23000302 INDICATOR A 2 3 23500302 INDICATOR B 2 4 30003052 TAIL LIGHT 5 2000302 LAMP 6 800302 ENGINE STOP SWITCH 7 23600302 TURN BOX 8 62000302 HORN 9 60000302 TRAILTECH MULTIFUNCTION 0 04007BC SCREW 2 24000302 LIGHT HORN SWITCH 2 2003024 RACING LIGHT HARNESS 3 0206FB SCREW 2 ELECTRIC PART 2 35
OSSA ENGINEERING TOOLS CLUTCH SPRING CENTERING TOOL FLYWHEEL PULLER 0009602 ENGINE STAND PRIMARY SHAFT BEARING DRIVER CRANCKSHAFT REMOOVAL TOOL SET 4999602 OSSA WORKSHOP KIT 36
STICKERS 00005024 COMPLETE DECAL KIT TRi 204 65005064 25 SWING ARM STICKERS 65005074 250 SWING ARM STICKERS 65005024 280 SWING ARM STICKERS 65005044 300 SWING ARM STICKERS 37