Drawing A Crankcase, Cylinder 1
Drawing A Crankcase, Cylinder Reference Item number Qty Description 1 4140 021 0300 1 Crankcase 2 9639 003 1230 2 Oil seal12x22x7 3 9503 003 0242 2 Grooved ball bearing 6201 4 4140 036 0300 2 Washer 5 4140 030 0401 1 Crankshaft (25.2005) 6 4140 029 2300 1 Cylinder gasket 7 4140 021 2500 1 Engine pan 8 4140 020 1202 1 Cylinder with piston Ø 34 mm 10-14 9 4140 020 1200 1 Cylinder with piston Ø 34 mm (23.2003) 10-14 10 4140 030 2000 1 Piston Ø 34 mm 11-13 11 4137 034 3000 2 Piston ring Ø 34x1.5 mm 12 9463 650 0807 2 Snap ring 8x0.7 13 4137 034 1500 1 Piston pin 8x5x22 14 9075 478 4268 4 Pan head self-tapping screw IS-D5x60 17 4140 190 2010 1 Driver (2,4-6) 18, 19 18 0000 998 0612 2 Torsion spring (2,4-6) 19 4133 195 7201 2 Pawl (2,4-6) 20 0000 400 7000 1 Spark plug NGK BPMR7A 20 1110 400 7005 1 Spark plug Bosch WSR 6 F 21 0783 830 2000 1 Tube of sealant Dirko HT red (B) 4140 007 1050 1 Set of gaskets 2, 6 (1) KM 55, (2) KM 55 C-E, (3) KM 55 R, (4) KM 55 RC-E, (5) KM 55 RC-E DZ, (6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z 2
Drawing B Rewind starter 3
Drawing B Rewind starter Reference Item number Qty Description 8 0000 190 3404 1 Starter grip ElastoStart Ø 3 mm (B) 9, 10 0000 930 2208 1 Starter rope Ø 3 mm x 30.5 m (A,B) 10 0000 195 7000 1 Cap (B) (1) KM 55, (2) KM 55 C-E, (3) KM 55 R, (4) KM 55 RC-E, (5) KM 55 RC-E DZ, (6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z 4
Drawing C Rewind starter ErgoStart 5
Drawing C Rewind starter ErgoStart Reference Item number Qty Description 1 4140 190 4010 1 Rewind starter (2,4-6) 2-12 2 4140 190 0601 1 Rewind spring (2,4-6) 3 4140 195 0410 1 Rope rotor (2,4-6) 4 4140 195 3400 1 Starter grip (2,4-6) 5 4137 195 8200 1 Starter rope Ø 2.7x910 mm (2,4-6) 6 4116 195 7200 1 Pawl (2,4-6) 7 0000 958 0923 1 Washer (2,4-6) 8 1118 195 3500 1 Spring (2,4-6) 9 4140 190 0710 1 Spring housing (2,4-6) 10 4140 195 2010 1 Carrier (2,4-6) 11 9307 021 0120 1 Washer 5.3 (2,4-6) 12 9022 399 0950 1 Spline screw IS-M5x10 (2,4-6) 14 4140 967 1520 1 Model plate KM 55 RC (4-6) 15 0000 951 1100 3 Screw IS-D5x20 (2,4-6) 16 4140 084 6801 1 Spacer (2,4-6) 17 0000 967 4208 1 Tag Easy2Start (5,6) USA, CDN (1) KM 55, (2) KM 55 C-E, (3) KM 55 R, (4) KM 55 RC-E, (5) KM 55 RC-E DZ, (6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z 6
Drawing D Muffler 7
Drawing D Muffler Reference Item number Qty Description 2 4140 140 0610 1 Muffler (6,8) USA, AUS, CDN 3 3 4140 140 6903 1 Stub with screen (6,8) USA, AUS, CDN 5 4140 140 0605 1 Muffler (6,8) USA, AUS, CDN (23.2003) 6 6 4140 140 6900 1 Stub with screen (6,8) USA, AUS, CDN (23.2003) 7 4140 149 0602 1 Exhaust gasket (1-4,6,8) 8 9075 478 4268 2 Pan head self-tapping screw IS-D5x60 (1-4,6,8) 9 0783 830 2000 1 Tube of sealant Dirko HT red (B) (1-4,6,8) 4140 007 1050 1 Set of gaskets (1-4,6,8) 7 (1) KM 55, (2) KM 55 C-E, (3) KM 55 R, (4) KM 55 RC-E, (5) KM 55 RC-E DZ, (6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z 8
Drawing E Muffler Cat. 9
Drawing E Muffler Cat. Reference Item number Qty Description (1) KM 55, (2) KM 55 C-E, (3) KM 55 R, (4) KM 55 RC-E, (5) KM 55 RC-E DZ, (6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z 10
Drawing F Ignition system, Clutch 11
Drawing F Ignition system, Clutch Reference Item number Qty Description 1 4140 400 1200 1 Flywheel (25.2005) 2 4140 162 8900 1 Washer 3 4140 162 9101 1 Spacer sleeve 4 4140 160 2005 1 Clutch 2, 5, 6 5 4140 162 7900 2 Tension spring 6 1 Cup spring 31.7x20.4x0.4 (D) 7 4140 160 2903 1 Clutch drum 8 4140 400 1305 1 Ignition module 9 4140 431 2100 1 Connector tag 10 9075 478 3023 2 Pan head self-tapping screw IS-D4x22 (1) KM 55, (2) KM 55 C-E, (3) KM 55 R, (4) KM 55 RC-E, (5) KM 55 RC-E DZ, (6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z 12
Drawing G Engine housing (Bike handle) 13
Drawing G Engine housing (Bike handle) Reference Item number Qty Description (1) KM 55, (2) KM 55 C-E, (3) KM 55 R, (4) KM 55 RC-E, (5) KM 55 RC-E DZ, (6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z 14
Drawing H Engine housing (Loop handle) 15
Drawing H Engine housing (Loop handle) Reference Item number Qty Description 1 4140 020 3000 1 Engine housing (3-8) 2 4140 080 1600 1 Shroud (3-8) 3 4 9075 478 4159 4 Pan head self-tapping screw IS-D5x24 (3-8) 5 4140 180 1105 1 Throttle cable (3-8) 6 4140 440 1900 2 Lead (3-8) 7 4229 430 0201 1 Stop switch (3-8) 8 4140 180 1500 1 Throttle trigger (3-8) 9 4140 182 4500 1 Torsion spring (3-8) 10 4140 791 5400 1 Support (3-8) 11 4140 182 0800 1 Trigger interlock (3-8) 12 4140 182 4505 1 Torsion spring (3-8) 13 9075 478 4155 7 Pan head self-tapping screw IS-D5x24 (3-8) 14 9075 478 4115 1 Pan head self-tapping screw IS-D5x16 (3-8) (1) KM 55, (2) KM 55 C-E, (3) KM 55 R, (4) KM 55 RC-E, (5) KM 55 RC-E DZ, (6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z 16
Drawing J Air filter, Fuel tank 17
Drawing J Air filter, Fuel tank Reference Item number Qty Description 1 4140 124 2800 1 Filter 2 4140 140 2850 1 Filter housing 1, 3, 4, 5, 7 3 4140 141 3700 1 Lever 4 4140 141 3801 1 Choke shutter 5 9417 003 7512 1 Push nut 4.0x9.6x1.8 6 9210 261 0700 2 Hexagon nut M5 7 4140 141 0502 1 Filter cover 8 4140 129 0900 1 Gasket 9 4140 120 0612 1 Carburetor C1Q S97 10 4140 120 0606 1 Carburetor C1Q S71 (25.2004) 11 4140 120 0603 1 Carburetor C1Q-S66 (36.2002) 12 4114 149 1205 1 Gasket 13 4140 121 1605 1 Spacer flange 14 4140 182 7601 1 Tensioner 15 9022 313 0680 1 Spline screw IS-M4x16 16 9075 478 4159 2 Pan head self-tapping screw IS-D5x24 17 9007 319 1135 2 Hexagon head screw M5x65 18 4140 129 0906 1 Gasket (1) KM 55, (2) KM 55 C-E, (3) KM 55 R, (4) KM 55 RC-E, (5) KM 55 RC-E DZ, (6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z 18
Drawing J Air filter, Fuel tank 19
Drawing J Air filter, Fuel tank Reference Item number Qty Description 19 4232 350 0411 1 Fuel tank 20-28 20 1125 084 8900 1 Grommet 21 4140 358 7702 1 Hose 22 0000 350 3506 1 Pickup body 23 0000 351 3201 1 Sleeve 24 4140 353 2402 1 Support 25 9074 478 4135 1 Pan head self-tapping screw IS-P5x20 26 4128 350 0505 1 Filler cap 27, 28 27 0000 350 0900 1 Rope 28 0000 353 0800 1 Filler cap retainer 29 4140 352 8100 3 Insert 30 0000 967 3693 1 Warning pictogram Filler cap (5-8) USA, CDN 4140 007 1050 1 Set of gaskets 8, 12, 18 (1) KM 55, (2) KM 55 C-E, (3) KM 55 R, (4) KM 55 RC-E, (5) KM 55 RC-E DZ, (6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z 18
Drawing K Carburetor C1Q S97 21
Drawing K Carburetor C1Q S97 Reference Item number Qty Description 4140 120 0612 1 Carburetor C1Q S97 1-34 1 4140 120 7101 1 Throttle shaft with lever 2 1123 122 3000 1 Spring 3 4128 121 8900 1 Pin 4 4137 121 8600 1 Washer 5 1120 122 9000 1 E-clip 6 4229 121 3303 1 Throttle shutter 7 1125 122 7403 1 Round head screw 8 1125 122 9001 1 E-clip 9 1129 121 4800 1 Pump diaphragm 10 1123 129 0905 1 Gasket 11 1123 121 0800 1 End cover 12 1120 122 7800 1 Oval head screw 13 4116 121 5100 1 Inlet needle 14 1120 122 3004 1 Spring 15 1125 121 5000 1 Inlet control lever 16 1120 121 9200 1 Spindle 17 1120 122 6600 1 Collar screw 18 4229 129 0901 1 Gasket 19 4229 121 4700 1 Metering diaphragm 20 4228 120 2200 1 Flange 21 4226 122 7100 4 Screw 22 4229 122 6701 1 High speed adjustment screw 23 4140 122 6800 1 Low speed adjustment screw 24 1123 121 7800 1 Strainer 25 4140 121 0800 1 End cover 26 4226 121 2700 1 Cap 27 4140 122 6200 1 Idle speed adjustment screw 28 1125 122 4200 1 Ball 29 4229 121 2701 1 Cap 30 4228 121 5602 1 Fixed jet 0.39 31 4180 121 5800 1 Pump piston 32 1132 122 3600 1 Sealing ring 33 4180 122 3002 1 Spring 34 1120 121 7801 1 Strainer 4140 007 1060 1 Set of carburetor parts 9, 10, 18-20 (1) KM 55, (2) KM 55 C-E, (3) KM 55 R, (4) KM 55 RC-E, (5) KM 55 RC-E DZ, (6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z 22
Drawing L Carburetor C1Q S71 23
Drawing L Carburetor C1Q S71 Reference Item number Qty Description 4140 120 0606 1 Carburetor C1Q S71 (C) (25.2004) 1-34 1 4137 120 7100 1 Throttle shaft with lever (25.2004) 2 1123 122 3000 1 Spring (25.2004) 3 4137 121 8900 1 Pin (25.2004) 4 4137 121 8600 1 Washer (25.2004) 5 1120 122 9000 1 E-clip (25.2004) 6 4140 121 3302 1 Throttle shutter (25.2004) 7 1125 122 7403 1 Round head screw (25.2004) 8 1125 122 9001 1 E-clip (25.2004) 9 1129 121 4800 1 Pump diaphragm (25.2004) 10 1123 129 0905 1 Gasket (25.2004) 11 1123 121 0800 1 End cover (25.2004) 12 1120 122 7800 1 Oval head screw (25.2004) 13 4116 121 5100 1 Inlet needle (25.2004) 14 1120 122 3004 1 Spring (25.2004) 15 1125 121 5000 1 Inlet control lever (25.2004) 16 1120 121 9200 1 Spindle (25.2004) 17 1120 122 6600 1 Collar screw (25.2004) 18 4229 129 0901 1 Gasket (25.2004) 19 4229 121 4700 1 Metering diaphragm (25.2004) 20 4228 120 2200 1 Flange (25.2004) 21 4226 122 7100 4 Screw (25.2004) 22 4229 122 6701 1 High speed adjustment screw (25.2004) 23 4229 122 6800 1 Low speed adjustment screw (25.2004) 24 1123 121 7800 1 Strainer (25.2004) 25 4140 121 0800 1 End cover (25.2004) 26 4226 121 2700 1 Cap (25.2004) 27 4229 122 6200 1 Idle speed adjustment screw (25.2004) 28 1125 122 4200 1 Ball (25.2004) 29 4229 121 2701 1 Cap (25.2004) 30 4228 121 5602 1 Fixed jet 0.39 (25.2004) 31 4229 121 5800 1 Pump piston (25.2004) 32 4140 122 3600 1 Sealing ring (25.2004) 33 4229 122 3001 1 Spring (25.2004) 34 1120 121 7801 1 Strainer (25.2004) 4140 007 1060 1 Set of carburetor parts (25.2004) 9, 10, 18-20 (1) KM 55, (2) KM 55 C-E, (3) KM 55 R, (4) KM 55 RC-E, (5) KM 55 RC-E DZ, (6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z 24
Drawing M Carburetor C1Q S66 (36.2002) 25
Drawing M Carburetor C1Q S66 (36.2002) Reference Item number Qty Description 4140 120 0603 1 Carburetor C1Q-S66 (36.2002) 1-34 1 4137 120 7100 1 Throttle shaft with lever (36.2002) 2 1123 122 3000 1 Spring (36.2002) 3 4137 121 8900 1 Pin (36.2002) 4 4137 121 8600 1 Washer (36.2002) 5 1120 122 9000 1 E-clip (36.2002) 6 4140 121 3302 1 Throttle shutter (36.2002) 7 1125 122 7403 1 Round head screw (36.2002) 8 1125 122 9001 1 E-clip (36.2002) 9 1129 121 4800 1 Pump diaphragm (36.2002) 10 1123 129 0905 1 Gasket (36.2002) 11 1123 121 0800 1 End cover (36.2002) 12 1120 122 7800 1 Oval head screw (36.2002) 13 4116 121 5100 1 Inlet needle (36.2002) 14 1120 122 3004 1 Spring (36.2002) 15 1125 121 5000 1 Inlet control lever (36.2002) 16 1120 121 9200 1 Spindle (36.2002) 17 1120 122 6600 1 Collar screw (36.2002) 18 1129 129 0900 1 Gasket (36.2002) 19 4129 121 4700 1 Metering diaphragm (36.2002) 4140 007 1060 1 Set of carburetor parts (36.2002) 20 20 1 Flange (D) (36.2002) 21 4226 122 7100 4 Screw (36.2002) 22 4229 122 6700 1 High speed adjustment screw (36.2002) 23 4229 122 6800 1 Low speed adjustment screw (36.2002) 24 1123 121 7800 1 Strainer (36.2002) 25 4140 121 0800 1 End cover (36.2002) 26 4226 121 2700 1 Cap (36.2002) 27 4229 122 6200 1 Idle speed adjustment screw (36.2002) 28 1125 122 4200 1 Ball (36.2002) 29 4229 121 2700 1 Cap (36.2002) 30 4229 121 5603 1 Fixed jet 0.37 (36.2002) 31 4229 121 5800 1 Pump piston (36.2002) 32 4140 122 3600 1 Sealing ring (36.2002) 33 4229 122 3001 1 Spring (36.2002) 34 1120 121 7801 1 Strainer (36.2002) (1) KM 55, (2) 1129 KM 007 55 C-E, 1062(3) KM 1 55 Set R, of (4) carburetor KM 55 RC-E, parts (5) (36.2002) KM 55 RC-E DZ, (6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) 9, KM 10, 18, 55 R-Z 19 26
Drawing N Bike handle 27
Drawing N Bike handle Reference Item number Qty Description (1) KM 55, (2) KM 55 C-E, (3) KM 55 R, (4) KM 55 RC-E, (5) KM 55 RC-E DZ, (6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z 28
Drawing O Drive tube assembly, Loop handle 29
Drawing O Drive tube assembly, Loop handle Reference Item number Qty Description 1 4140 710 7128 1 Drive tube assembly Ø 25.4 mm / 1'' 13 2 4140 711 3203 1 Drive shaft 3 4140 740 3501 1 Carrier 4-7 4 4140 160 5201 1 Bushing 5 1118 162 8935 2 Washer 6 4140 716 2200 2 Bow 7 9455 621 0850 1 Circlip 10x1 8 4140 160 0700 1 Coupling sleeve 9-12 9 9022 341 1350 1 Spline screw IS-M6x25 10 4140 790 7501 1 Tommy screw 11 9210 319 0900 2 Hexagon nut M6 12 9291 021 0140 1 Washer 6.4 13 4137 711 2101 1 Plug 14 0000 711 2500 1 Sleeve (3-8) 18 4130 790 1316 1 Loop handle (3-8) 19-22 19 4123 791 7400 2 Clamp (3-8) 20 9022 341 1350 2 Spline screw IS-M6x25 (3-8) 21 9222 068 0900 2 Square nut M6 (3-8) 22 9291 021 0140 2 Washer 6.4 (3-8) 23 4130 791 4400 1 Barrier bar (3-8) 24 0781 120 1110 1 Gear lubricant 225 g (B) (3-8) (1) KM 55, (2) KM 55 C-E, (3) KM 55 R, (4) KM 55 RC-E, (5) KM 55 RC-E DZ, (6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z 30
Drawing P Drive tube extension HT-KM 31
Drawing P Drive tube extension HT-KM Reference Item number Qty Description 2 4140 710 7143 1 Drive tube assembly 1 m (B) (5-8) USA 3, 5-14 3 4140 791 7201 2 Sleeve (B) (3-8) 5 0000 967 3638 1 Instruction label (B) (5-8) USA 6 4230 791 2000 1 Handle hose 185 mm / 7 5/16'' (B) (3-8) 7 4140 710 3200 1 Drive shaft (B) (3-8) 3, 8, 9 8 4140 711 2500 1 Sleeve (B) (3-8) 9 4140 716 2200 1 Bow (B) (3-8) 10 4140 160 0700 1 Coupling sleeve (B) (3-8) 11-14 11 9022 341 1350 1 Spline screw IS-M6x25 (B) (3-8) 12 4140 790 7501 1 Tommy screw (B) (3-8) 13 9210 319 0900 2 Hexagon nut M6 (B) (3-8) 14 9291 021 0140 1 Washer 6.4 (B) (3-8) 15 0781 120 1110 1 Gear lubricant 225 g (B) (3-8) (1) KM 55, (2) KM 55 C-E, (3) KM 55 R, (4) KM 55 RC-E, (5) KM 55 RC-E DZ, (6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z 32
Drawing Q Carbon Drive tube extension HT-KM, HL-KM 33
Drawing Q Carbon Drive tube extension HT-KM, HL-KM Reference Item number Qty Description 4180 710 7107 1 Drive tube assembly 1 m (B) (5-8) USA 2-11, 13 2 4180 710 7108 1 Drive tube assembly Ø 25.4 mm / 1'' (B) (5-8) USA 13 3 4180 711 7300 1 Flexible liner (B) (3-8) 4 4180 710 3200 1 Drive shaft (B) (3-8) 5, 6 5 4140 716 2200 2 Bow (B) (3-8) 6 4180 711 2501 1 Sleeve (B) (3-8) 7 4180 791 7204 1 Sleeve (B) (3-8) 8 4140 160 0700 1 Coupling sleeve (B) (3-8) 9-11 9 9022 341 1350 1 Spline screw IS-M6x25 (B) (3-8) 10 4140 790 7501 1 Tommy screw (B) (3-8) 11 9210 319 0900 2 Hexagon nut M6 (B) (3-8) 13 4180 967 4001 1 Instruction label (B) (5-8) USA 14 0781 120 1109 1 Gear lubricant 80 g (B) (3-8) (1) KM 55, (2) KM 55 C-E, (3) KM 55 R, (4) KM 55 RC-E, (5) KM 55 RC-E DZ, (6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z 34
Drawing R Tools, Extras 35
Drawing R Tools, Extras Reference Item number Qty Description 1 0812 370 1000 1 Screwdriver T27x120x70 2 4130 893 7800 1 Locking pin (B) 3 4128 890 3400 1 Combination wrench (B) 4 0000 890 2300 1 Screwdriver 4 0000 890 2305 1 Screwdriver available in Brazil only 5 0000 891 0801 1 Tool roll (B) 6 0000 884 0307 1 Safety glasses (B) 7 0000 886 1411 1 Safety glasses (B) available in Brazil only 8 4119 710 9001 1 Full harness (B) 9-19 9 4119 710 6306 1 Backplate with strap 10 1 Strap 38x780mm / 1.5x30.7'' (D) 0000 930 2242 1 Webbing 38 mm x 5 m / 1.5x197'' (A, B) 11 1 Strap 25 mm x 1.18 m / 1x46.5'' (D) 0000 930 2241 1 Webbing 25 mm x 10 m / 1'' x 33' (A, B) 12 4119 718 6300 2 Slide 13 4119 718 6305 2 Slide 14 4119 718 6310 1 Slide 15 9408 021 4530 12 Rivet shank 4x8x6 16 9409 021 4420 12 Rivet head 4x8 17 4119 718 7400 1 Guard plate 4119 710 6406 1 Buckle with strap 18 18 4119 710 6400 1 Buckle 19 4119 710 6906 1 Spring safety hook 20 4130 710 9000 1 Harness (B) (1) KM 55, (2) KM 55 C-E, (3) KM 55 R, (4) KM 55 RC-E, (5) KM 55 RC-E DZ, (6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z 36