XVS65AW (4C59) U49 XVS65AWC (4C5A) CALIFORNIA XVS65AW (4C5B) CANADA

Transcription

1 XVS65AW () U49 XVS65AWC () CALIFORNIA XVS65AW () CANADA 1F4C5-100E1 ( 2F4C5-100E1 ) A2

2 XVS65AW/XVS65AWC PARTS CATALOGUE 2006 by Yamaha Motor Co., Ltd. 1st edition, April 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan. A3

3 XVS65AW/XVS65AWC A4

4 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 DESCRIPTION Q TY 2F FRONT FLASHER LIGHT ASSY BULB (6V 18W) 1 4. Applicable colours of graphics are represented in the as shown below. PART DESCRIPTION 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. A5

5 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 BWC1(*) BLUISH WHITE COCKTAIL DRMK(*) DEEP RED METALLIC K 0918 SL SILVER 0035 SMX(*) BLACK METALLIC X 0903 A6

6 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. Country (destination) 010 U CALIFORNIA 010 CANADA 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 A 0903 BLACK METALLIC X SMX B 0918 DEEP RED METALLIC K DRMK C 0390 BLUISH WHITE COCKTAIL 1 BWC1 A 0903 BLACK METALLIC X SMX B 0918 DEEP RED METALLIC K DRMK C 0390 BLUISH WHITE COCKTAIL 1 BWC1 A 0903 BLACK METALLIC X SMX B 0918 DEEP RED METALLIC K DRMK C 0390 BLUISH WHITE COCKTAIL 1 BWC1 A7

7 CONTENTS ENGINE CYLINDER HEAD... B2 CYLINDER... B4 CRANKSHAFT & PISTON... B5 VALVE... B6 CAMSHAFT & CHAIN... B7 OIL PUMP... B8 INTAKE... B9 CARBURETOR... B11 EXHAUST... B14 CRANKCASE... C2 CRANKCASE COVER 1... C4 STARTER CLUTCH... C6 CLUTCH... C7 TRANSMISSION... C9 MIDDLE DRIVE GEAR... C10 SHIFT CAM & FORK... C11 SHIFT SHAFT... C12 CHASSIS FRAME... C13 FENDER... C15 SIDE COVER... D4 REAR ARM & SUSPENSION... D6 DRIVE SHAFT... D7 STEERING... D9 FRONT FORK... D10 FUEL TANK... D12 SEAT... D15 FRONT WHEEL... E2 FRONT BRAKE CALIPER... E3 REAR WHEEL... E4 STEERING HANDLE & CABLE... E6 FRONT MASTER CYLINDER... E7 STAND & FOOTREST... E8 GENERATOR... E11 FLASHER LIGHT... E12 METER... E14 HEADLIGHT... E15 TAILLIGHT... F2 HANDLE SWITCH & LEVER... F3 ELECTRICAL 1... F4 ELECTRICAL 2... F6 INDEX NUMERICAL INDEX... M1

8 FIG. 1 CYLINDER HEAD PART DESCRIPTION 1 5BN CYLINDER HEAD ASSY H GUIDE, VALVE CIRCLIP XP CYLINDER HEAD ASSY H GUIDE, VALVE CIRCLIP PIN, DOWEL VR GASKET, CYLINDER HEAD NUT WASHER, PLATE NUT, FLANGE TR BRACKET, CYLINDER HEAD COVER TR BRACKET, CYLINDER HEAD COVER TR 1111F 00 PLATE TR 1112F 00 PLATE TR 1135A 00 BRACKET NUT, CROWN WASHER, PLATE BOLT, HEXAGON SOCKET HEAD BOLT, STUD TR COVER, CYLINDER HEAD SIDE TR COVER, CYLINDER HEAD SIDE U PLATE, BREATHER O-RING TR PIPE, BREATHER CLIP O-RING B2

9 FIG. 1 CYLINDER HEAD PART DESCRIPTION BOLT U COVER, CYLINDER HEAD SIDE U COVER, CYLINDER HEAD SIDE O-RING BOLT WASHER, PLATE BOLT WASHER BOLT, UNION GASKET U 1111F 01 PLATE WASHER, LOCK BOLT BOLT PLUG, SPARK (NGK DPR7EA) GROMMET B3

10 FIG. 2 CYLINDER PART DESCRIPTION 1 4VR CYLINDER VR CYLINDER O-RING BOLT BOLT, HEXAGON SOCKET HEAD VR GASKET, CYLINDER VR COVER, CYLINDER HEAD VR COVER, CYLINDER HEAD VR COVER, CYLINDER HEAD VR 1111N 00 COVER GROMMET BOLT, WITH WASHER COLLAR SCREW B4

11 FIG. 3 CRANKSHAFT & PISTON PART DESCRIPTION 1 4VR CRANKSHAFT VR A0 PISTON (STD) VR PISTON (0.50MM O/S) AP 4VR PISTON (1.00MM O/S) AP 3 4VR PISTON RING SET (STD) VR PISTON RING SET (0.50MM O/S) AP 4VR PISTON RING SET (1.00MM O/S) AP 4 3LD PIN, PISTON CIRCLIP VR CONNECTING ROD ASSY U BOLT, CONNECTING ROD NUT LD PLANE BEARING, CONNECTING ROD UR BLUE 3LD PLANE BEARING, CONNECTING ROD UR BLACK 3LD PLANE BEARING, CONNECTING ROD UR BROWN 3LD PLANE BEARING, CONNECTING ROD UR GREEN KEY, WOODRUFF B5

12 FIG. 4 VALVE PART DESCRIPTION 1 4VR VALVE, INTAKE VR VALVE, EXHAUST Y SEAT, VALVE SPRING Y SPRING, VALVE OUTER J SEAL, VALVE STEM Y RETAINER, VALVE SPRING J COTTER, VALVE U ARM, VALVE ROCKER U SHAFT, ROCKER U SCREW, VALVE ADJUSTING NUT B6

13 FIG. 5 CAMSHAFT & CHAIN PART DESCRIPTION 1 4VR CAMSHAFT VR CAMSHAFT U PLATE, BREATHER WASHER, PLATE BOLT PIN, DOWEL BUSH, SOLID CHAIN U SPROCKET, CAM CHAIN H TENSIONER ASSY, CAM CHAIN BT GASKET, TENSIONER CASE BOLT VR GUIDE, STOPPER U GUIDE, STOPPER BOLT WASHER, PLATE B7

14 FIG. 6 OIL PUMP PART DESCRIPTION 1 4VR OIL PUMP ASSY O-RING BOLT VR GEAR, PUMP DRIVEN (39T) CIRCLIP U GEAR, DRIVE (24T) TR STRAINER HOUSING ASSY VR COVER, STRAINER U SEAL, OIL STRAINER O-RING BOLT BOLT B8

15 FIG. 7 INTAKE PART DESCRIPTION 1 4TR JOINT, CARBURETOR TR JOINT, CARBURETOR G PLUG, BLIND CLIP O-RING BOLT TR BAND TR CASE, AIR CLEANER TR COVER SCREW, TAPPING TR DUCT TR ELEMENT, AIR CLEANER TR JOINT, AIR CLEANER TR BAND TR CASE, AIR CLEANER BOLT, BUTTON HEAD TR SEAL TR 1440G 00 JOINT, AIR FILTER HOSE (L100) CLIP PLUG TR STAY VR SILENCER, INTAKE TR JOINT, AIR CLEANER CLAMP, HOSE TR 1440F 00 JOINT, AIR FILTER TR BAND B9

16 FIG. 7 INTAKE PART DESCRIPTION 28 4VR COVER, MANIFOLD SCREW, TAPPING TR BAND TR STAY GROMMET BOLT BOLT WASHER, PLATE TR PROTECTOR, HEAT B10

17 FIG. 8 CARBURETOR PART DESCRIPTION 1 5SC CARBURETOR ASSY 1 1 5SC CARBURETOR ASSY 1 2 5SC CARBURETOR ASSY (#1) REAR 3 5SC CARBURETOR ASSY (#2) FRONT 4 4TR THROTTLE SCREW SET (#2) FRONT 5 4TR PILOT SCREW SET F CAP BN 1490J 00..NEEDLE SET DN 1410A 01..STARTER SET CF NEEDLE VALVE SET HX JET,PILOT AIR(#100) KM JET, PILOT (# 20) DM 1414M 34..NOZZLE, MAIN G2 1414E 36..JET, MAIN (#91.3) F O-RING VR SPRING, DIAPHRAGM FU HEATER ASSY (15W) FU HEATER ASSY (20W) WASHER, PLATE UR (#1) REAR WASHER, PLATE UR (#2) FRONT 19 4DH TERMINAL (#1) REAR 20 1HX O-RING AE O-RING SC HOLDER AE GASKET HX SCREW WASHER, MAIN JET B11

18 FIG. 8 CARBURETOR PART DESCRIPTION 26 4TR DIAPHRAGM ASSY UY SCREW KW SCREW, ROD (#2) FRONT 29 22V DIAPHRAGM ASSY SC SPRING TR PIPE SCREW, PAN HEAD UR (#1) REAR SCREW, PAN HEAD UR (#2) FRONT SCREW, FLAT HEAD UR (#1) REAR SCREW, FLAT HEAD UR (#2) FRONT 34 4VR SCREW (#2) FRONT 35 5LW PLUG, DRAIN TR CLIP (#2) FRONT 37 1FN SCREW PIN, FLOAT HX FLOAT SC 1410H 10..FUEL CUT SOLENOID VALVE UR (#1) REAR 5SC 1410H 00..FUEL CUT SOLENOID VALVE UR (#2) FRONT WASHER HM SEAL TR 1490L 00.STARTER LEVER SET, KW 1490K 00.STOP SCREW SET Y O-RING WG NIPPLE TR HOSE KM SCREW NK THROTTLE POSITION SENSOR ASSY B12

19 FIG. 8 CARBURETOR PART DESCRIPTION 50 5SC WIRE, SUB LEAD H CLIP, PIPE X CLIP GK 1491A 00.CAP 1 1 B13

20 FIG. 9 EXHAUST PART DESCRIPTION 1 4TR GASKET, EXHAUST PIPE TR JOINT, EXHAUST NUT, SELF-LOCKING BR GASKET, EXHAUST PIPE SC EXHAUST PIPE ASSY BOLT WASHER, PLATE NUT, SELF-LOCKING SC MUFFLER COMP BH GASKET, MUFFLER BOLT, FLANGE SC MUFFLER COMP BOLT WASHER, PLATE BH GASKET, MUFFLER BOLT, FLANGE BOLT BOLT, BUTTON HEAD BOLT, BUTTON HEAD BN COVER, AIR BOLT, HEXAGON SOCKET HEAD WASHER, PLATE BN COVER BOLT WASHER BN HOSE, BEND BN AIR CUT VALVE ASSY B14

21 FIG. 9 EXHAUST PART DESCRIPTION PLUG BN HOSE, BEND CLIP BN REED VALVE ASSY SCREW, TAPPING SCREW, TAPPING BN HOSE, BEND BN PIPE BN PIPE CLIP KM GASKET, MUFFLER BN CASE, AIR CLEANER BN CAP, CASE NUT, U WASHER WASHER, PLATE P7 WASHER, PLATE BN HOSE, BEND BN HOSE, VACUUM SENSING BN HOSE, VACUUM SENSING MM PIPE CLIP BN HOSE, BEND BN HOSE, BEND BN PIPE B15

22 FIG. 10 CRANKCASE PART DESCRIPTION 1 4TR CRANKCASE ASSY PIN, DOWEL U PLANE BEARING, CRANKSHAFT UR BLUE 22U PLANE BEARING, CRANKSHAFT UR GREEN BOLT, STUD BOLT, STUD PIN, DOWEL COLLAR O-RING BOLT, STUD BOLT, STUD PIN, DOWEL COLLAR O-RING COLLAR O-RING BOLT BOLT BOLT BOLT BOLT BOLT BOLT H PLATE, BEARING COVER SCREW, COUNTERSUNK SCREW U HOLDER, CLUTCH CABLE C2

23 FIG. 10 CRANKCASE PART DESCRIPTION PLUG, STRAIGHT SCREW GASKET C3

24 FIG. 11 CRANKCASE COVER 1 PART DESCRIPTION 1 4TR COVER, CRANKCASE OIL SEAL VR GASKET, CRANKCASE COVER H GAUGE, LEVEL F PLUG, OIL LEVEL O-RING PLUG, STRAIGHT SCREW O-RING PLUG, STRAIGHT SCREW O-RING PIN, DOWEL BOLT BOLT BOLT BOLT BOLT BT CLAMP TR COVER, GENERATOR TR COVER O-RING BOLT TR COVER, CRANKCASE VR GASKET, CRANKCASE COVER OIL SEAL CIRCLIP PIN, DOWEL BOLT C4

25 FIG. 11 CRANKCASE COVER 1 PART DESCRIPTION BOLT BOLT BOLT CLAMP O-RING PIN, DOWEL VR COVER BOLT, BUTTON HEAD CLAMP BOLT X ELEMENT ASSY, OIL CLEANER TR COVER, OIL ELEMENT O-RING BOLT, HEXAGON SOCKET HEAD BOLT BOLT C5

26 FIG. 12 STARTER CLUTCH PART DESCRIPTION 1 22U GEAR, IDLER 1 (12T/50T) H SHAFT TR STARTER ONE-WAY ASSY VR GEAR, IDLER 2 (66T) WASHER, PLATE JB MOTOR ASSY FK O-RING HE BOLT KS BRUSH HOLDER ASSY XV 8182A 00.NUT H GASKET VR CORD, STARTER MOTOR XV 8182A 00 NUT BOLT WASHER, PLATE C6

27 FIG. 13 CLUTCH PART DESCRIPTION 1 4VR GEAR, PRIMARY DRIVE (38T) KEY, WOODRUFF WASHER, CLAW WASHER, LOCK NUT BN PRIMARY DRIVEN GEAR COMP U PLATE, THRUST VR BOSS, CLUTCH X PLATE, CLUTCH U PLATE, FRICTION X PLATE, CLUTCH U PLATE, PRESSURE SPRING, COMPRESSION SCREW, WITH WASHER W PLATE, PUSH VR ROD, PUSH O-RING WASHER NUT WASHER, LOCK NUT BEARING OIL SEAL U PUSH LEVER ASSY SPRING, TORSION WASHER, PLATE GASKET C7

28 FIG. 13 CLUTCH PART DESCRIPTION SCREW U ROD, PUSH BALL C8

29 FIG. 14 TRANSMISSION PART DESCRIPTION 1 4VR AXLE, MAIN (14T) JB GEAR, 4TH PINION (24T) WASHER CIRCLIP VR GEAR, 3RD PINION (24T) VR GEAR, 5TH PINION (30T) KU GEAR, 2ND PINION (20T) BEARING BEARING U DRIVE AXLE ASSY KU GEAR, 2ND WHEEL (38T) WASHER CIRCLIP VR GEAR, 5TH WHEEL (29T) VR GEAR, 3RD WHEEL (35T) WASHER CIRCLIP TR GEAR, 4TH WHEEL (28T) U GEAR, 1ST WHEEL (38T) BEARING C9

30 FIG. 15 MIDDLE DRIVE GEAR PART DESCRIPTION 1 4VR Y MIDDLE GEAR COMP BEARING H SHIM, THRUST (0.20T) UR 4H SHIM, THRUST (0.30T) UR 4H SHIM, THRUST (0.40T) UR NUT VR SHAFT, MIDDLE DRIVEN VR W HOUSHING COMP O-RING OIL SEAL U YOKE, JOINT WASHER, PLATE NUT, SELF-LOCKING VR CAM, DRIVEN SPRING, COMPRESSION U HOLDER H WASHER, THRUST R COLLAR BEARING JB SHIM, PINION (0.10T) UR 3JB SHIM, PINION (0.15T) UR 3JB SHIM, PINION (0.20T) UR 3JB SHIM, PINION (0.30T) UR 3JB SHIM, PINION (0.40T) UR 3JB SHIM, PINION (0.50T) UR BOLT, FLANGE C10

31 FIG. 16 SHIFT CAM & FORK PART DESCRIPTION 1 4TR SHIFT CAM ASSY BEARING H SEGMENT PIN, DOWEL PIN, DOWEL SCREW, FLAT HEAD SPRING, COMPRESSION UN POINT, NEUTRAL UN PLATE, SIDE SCREW TR FORK, SHIFT TR FORK, SHIFT TR FORK, SHIFT YF BAR, SHIFT FORK GUIDE TR BAR, SHIFT FORK GUIDE C11

32 FIG. 17 SHIFT SHAFT PART DESCRIPTION WASHER, LOCK G STOPPER, SCREW TR STOPPER LEVER ASSY B5 SPRING, TORSION OIL SEAL (SD HS) TR SHIFT LEVER ASSY SPRING, TENSION SPRING, TORSION CIRCLIP WASHER, PLATE WASHER, PLATE CIRCLIP BN SHIFT PEDAL ASSY NK COVER, SHIFT PEDAL N COVER, SHIFT PEDAL H COVER, DUST BOLT TR ARM, SHIFT H COVER, DUST A ROD, SHIFT NUT(COUNTER CLOCKWISE) NUT WASHER, PLATE CIRCLIP WASHER, WAVE C12

33 FIG. 18 FRAME PART DESCRIPTION 1 4VR FRAME COMP VR STAY, ENGINE A4 BOLT, FLANGE A1 BOLT, FLANGE NUT BOLT, FLANGE VR STAY, ENGINE BN STAY, ENGINE BOLT, FLANGE BOLT, FLANGE NUT BOLT, FLANGE BOLT, FLANGE BOLT NUT TR 2171E 00 COVER, SIDE BN DAMPER TR 2171X 00 COVER, SIDE BN DAMPER SV DAMPER BOLT, WITH WASHER TR STAY, MUFFLER BOLT, FLANGE BOLT, FLANGE VR STAY A2 BOLT, FLANGE TR BRACKET, FUEL PUMP C13

34 FIG. 18 FRAME PART DESCRIPTION BOLT, FLANGE GROMMET TR 2144G 01 STAY, STOP SWITCH BOLT, FLANGE VR HOLDER, CABLE FY SEAL GY 2214F 00 DAMPER SP SEAL HA PROTECTOR, FUEL TANK KP SHEET FB 2179W 10 PLATE, EPA (NON CALIFORNIA) 1 5FB 2179R 60 PLATE, EPA 2 (CALIFORNIA) BN PLATE, ROUTING BN LABEL, TIRE BN LABEL, TIRE 1 C14

35 FIG. 19 FENDER PART DESCRIPTION 1 5BN Y2151 0H P4 FRONT FENDER COMP UR SMX 5BN Y2151 0J P6 FRONT FENDER COMP UR DRMK 5BN Y2151 0K P3 FRONT FENDER COMP UR BWC1 2 5SC GRAPHIC SET, FRONT FENDER UR FOR DRMK 5BN S0.GRAPHIC SET, FRONT FENDER UR FOR BWC1 3 5BN E0.EMBLEM UR FOR SMX 5BN N0.EMBLEM UR FOR DRMK 5BN M0.EMBLEM UR FOR BWC BOLT, FLANGE BOLT, FLANGE BN HOLDER, CABLE BN HOLDER, WIRE BN STAY BOLT, FLANGE BN BRACKET, REFLECTOR BN BRACKET, REFLECTOR WASHER, PLATE H REFLECTOR ASSY NUT, FLANGE BN W216R V2 P4 REAR FENDER COMP UR SMX 5BN W216R W2 P6 REAR FENDER COMP UR DRMK 5BN W216R X2 P3 REAR FENDER COMP UR BWC1 16 3SP SEAL NK SEAL SC 2165A 50.GRAPHIC SET,REAR FENDER UR FOR DRMK 5BN 2165A S0.GRAPHIC SET,REAR FENDER UR FOR BWC1 19 1D6 2153E 00.EMBLEM, YAMAHA C15

36 FIG. 19 FENDER PART DESCRIPTION GROMMET BN STAY, FENDER SCREW, PAN HEAD BOLT, BUTTON HEAD BOLT, BUTTON HEAD NUT BN STAY, FENDER SCREW, PAN HEAD BOLT, BUTTON HEAD BOLT, BUTTON HEAD NUT R HELMET HANGER ASSY SCREW TR GUARD, MUD RIVET VN DAMPER, FLASHER NK PLUG, BLIND BN 2317W 40 STAY, BOLT, FLANGE WASHER, PLATE REFLECTOR, REAR BN BRACKET BN BRACKET, LICENSE BOLT, FLANGE FK REAR REFLECTOR ASSY NUT, FLANGE CLAMP D2

37 FIG. 19 FENDER PART DESCRIPTION 47 42U DAMPER D3

38 FIG. 20 SIDE COVER PART DESCRIPTION 1 4TR 2160A 00 BOX COMP BOLT, WITH WASHER TR 2177G 10 BOX, BATTERY SC 2172K 00 BRACKET RIVET, BLIND F 2139X 00 DAMPER Y SEAT, BATTERY HOSE NUT, SPRING BOLT, WITH WASHER NUT, SPRING BOLT, WITH WASHER BN PE COVER, SIDE UR SMX 5BN PL COVER, SIDE UR DRMK 5BN PC COVER, SIDE UR BWC1 14 4TR DAMPER GROMMET K LOCK ASSY NUT GROMMET BN PE COVER, SIDE UR SMX 5BN PL COVER, SIDE UR DRMK 5BN P8 COVER, SIDE UR BWC M PROTECTOR GROMMET GROMMET SCREW D4

39 FIG. 20 SIDE COVER PART DESCRIPTION 24 5BN COVER, SIDE BOLT, HEXAGON SOCKET HEAD GROMMET V COLLAR BOLT WASHER, PLATE VR COVER, SIDE BOLT, HEXAGON SOCKET HEAD TR TOOL KIT BR A0 LABEL, CAUTION JJ A1 LABEL, CAUTION BR B0 LABEL, CAUTION JJ B1 LABEL, CAUTION 1 D5

40 FIG. 21 REAR ARM & SUSPENSION PART DESCRIPTION 1 4VR REAR ARM COMP KM SHAFT, PIVOT BEARING OIL SEAL COLLAR J SHAFT, PIVOT J NUT A9 BOLT, FLANGE U0 WASHER, PLATE TR BOOT, RUBBER VR BUSH BN SHOCK ABSORBER ASSY, REAR 1 1 5BN SHOCK ABSORBER ASSY, REAR OIL SEAL F1 BOLT NUT, SELF-LOCKING F1 BOLT NUT, U G9 WASHER, PLATE X6 COLLAR D6

41 FIG. 22 DRIVE SHAFT PART DESCRIPTION 1 4TR REAR AXLE GEAR CASE ASSY BOLT, STUD BOLT, WITH WASHER U COLLAR, GUIDE OIL SEAL BEARING H BEARING ASSY J Y0 30.SHIM, THRUST (0.30T) UR 1J Y0 40.SHIM, THRUST (0.40T) UR 1J Y0 50.SHIM, THRUST (0.50T) UR BEARING H RETAINER, BEARING O-RING OIL SEAL G9.COLLAR U SEAL U HOUSING, BEARING U SHIM, RING GEAR (0.25T) UR 22U SHIM, RING GEAR (0.30T) UR 22U SHIM, RING GEAR (0.40T) UR BEARING U SHIM, THRUST (1.2T) UR 22U SHIM, THRUST (1.4T) UR 22U SHIM, THRUST (1.6T) UR 22U SHIM, THRUST (1.8T) UR 22U SHIM, THRUST (2.0T) UR O-RING D7

42 FIG. 22 DRIVE SHAFT PART DESCRIPTION BOLT, FLANGE OIL SEAL PLUG, STRAIGHT SCREW GASKET W BREATHER COMP J SEAL, HUB DUST U COUPLING, GEAR BN SHAFT DRIVE ASSY CIRCLIP U SEAL CIRCLIP SPRING, COMPRESSION X CROSS JOINT COMP BEARING CIRCLIP NUT, CROWN WASHER, PLATE D COLLAR TR COVER, HOUSING TR COVER, DUST D8

43 FIG. 23 STEERING PART DESCRIPTION BEARING WASHER, PLATE WASHER, PLATE W COVER, BALL RACE NUT H WASHER, SPECIAL NUT, CROWN T0 WASHER, PLATE VR Y CROWN, HANDLE BOLT DM DAMPER WASHER, PLATE MB HOLDER, HANDLE LOWER MB HOLDER, HANDLE UPPER BOLT PLUG BN STAY, HEADLIGHT BN 2317J 00 DAMPER BOLT, BUTTON HEAD NUT, FLANGE BN HOLDER, BRAKE HOSE BOLT, FLANGE BN GUIDE, CABLE CLAMP NUT, CROWN D9

44 FIG. 24 FRONT FORK PART DESCRIPTION 1 5BN FRONT FORK ASSY (L.H) BN TUBE, OUTER (LEFT) BN GUIDE, BOOT BN INNER TUBE COMP BN PISTON, FRONT FORK BN CYLINDER COMP., FRONT FORK FM METAL, SLIDE Y WASHER, OIL SEAL EB OIL SEAL H CLIP, OIL SEAL EB SEAL, DUST YR SPINDLE, TAPER L0.GASKET BOLT, HEXAGON SOCKET HEAD BN SPRING, FRONT FORK DW WASHER, SPRING UPPER TR SPACER D BOLT, CAP F O-RING BN FRONT FORK ASSY (R.H) BN TUBE, OUTER (RIGHT) BN GUIDE, BOOT BN INNER TUBE COMP BN PISTON, FRONT FORK BN CYLINDER COMP., FRONT FORK FM METAL, SLIDE Y WASHER, OIL SEAL D10

45 FIG. 24 FRONT FORK PART DESCRIPTION 28 4EB OIL SEAL H CLIP, OIL SEAL EB SEAL, DUST YR SPINDLE, TAPER L0.GASKET BOLT, HEXAGON SOCKET HEAD BN SPRING, FRONT FORK DW WASHER, SPRING UPPER TR SPACER D BOLT, CAP F O-RING BOLT KS UNDER BRACKET COMP BOLT BN COVER, LOWER BN COVER, LOWER KS COVER, UPPER KS COVER, UPPER BN GASKET BN BOLT, SPECIAL KS WASHER, FELT KM COVER, LOWER BEARING FV SEAL, STEERING D11

46 FIG. 25 FUEL TANK PART DESCRIPTION 1 5SC Y X4 FUEL TANK COMP. 1 1 UR SMX 5SC Y X5 FUEL TANK COMP. 1 1 UR DRMK 5SC Y X6 FUEL TANK COMP. 1 1 UR BWC1 5SC Y W8 FUEL TANK COMP. 1 UR SMX 5SC Y W9 FUEL TANK COMP. 1 UR DRMK 5SC Y FUEL TANK COMP. 1 UR BWC1 2 5FB K0.GRAPHIC SET UR FOR DRMK 5FB GRAPHIC SET UR FOR BWC1 3 5FB 2416B 00 EMBLEM FB 2417B 00 EMBLEM GK 2118K 00 LABEL, CAUTION GK 2118K 10 LABEL, CAUTION 1 7 4TR DAMPER, LOCATING TR 2413Y 00 BRACKET, TANK FITTING TR DAMPER, LOCATING WASHER BOLT, BUTTON HEAD BOLT, FLANGE H DAMPER, LOCATING BN CAP ASSY 1 1 4NK CAP ASSY V FUEL COCK ASSY AJ SEAL, COCK SCREW, PAN HEAD X O-RING AC VALVE PACKING SCREW D12

47 FIG. 25 FUEL TANK PART DESCRIPTION WASHER, PLATE FK 2171L 00 MOLE, SIDE COVER BP MOLD, FUEL TANK TR PIPE M31 CLAMP CLIP FK FILTER ASSY FK BRACKET, FILTER EB BAND CLIP CLIP TR PIPE, FUEL CLAMP TR 2171A 00 COVER, TOP SCREW NUT TR 2414G 00 SEAL XV DAMPER SC 2414H 00 DAMPER, PLATE SC 2414J 00 DAMPER, PLATE SC 2414K 00 DAMPER, PLATE CLIP BN PIPE PX ROLL OVER VALVE ASSY CLAMP SCREW, BIND BN PIPE 4 1 D13

48 FIG. 25 FUEL TANK PART DESCRIPTION 48 5BN PROTECTOR, PIPE CLIP JU CANISTER ASSY BN 2419F 00 BRACKET, CANISTOR BN PIPE CLAMP CLIP BOLT, FLANGE BN PIPE BN PROTECTOR, PIPE CLAMP CLAMP TR 2413B 00 EMBLEM TR HOSE CLIP CLIP KS FUEL PUMP COMP TR 2637G 00 HOLDER, WIRE TR CABLE, STARTER UA BAND VJ NUT D14

49 FIG. 26 SEAT PART DESCRIPTION 1 5BN SINGLE SEAT ASSY BOLT WASHER, SPRING BN 2475H 00.BRACKET, SEAT LEVER T DAMPER, SEAT BN DAMPER, SEAT BN PAD, SEAT BN WASHER BN DAMPER, SEAT BN DAMPER, SEAT BN DAMPER, SEAT BN 2475Y 00.COLLAR BOLT, FLANGE BN 2475K 00 BRACKET BOLT BN TANDEM SEAT ASSY BN COVER, TANDEM SEAT YS 2475J 00.BRACKET, SEAT LEVER DAMPER, SEAT BOLT WASHER, SPRING YS GROMMET NUT, CROWN YS 2471N 00 COLLAR WASHER, PLATE BN SEAT BAND ASSY D15

50 FIG. 27 FRONT WHEEL PART DESCRIPTION 1 4TR HUB, FRONT OIL SEAL BEARING OIL SEAL M5 COLLAR CLUTCH, METER RETAINER, CLUTCH HT BALANCER, WHEEL (15G) UN RIM (MT M/C) BN SPOKE SET, FRONT E TIRE (130/90-16 M/C 67S D404F) UR DUNLOP N TIRE (130/90-16 M/C 67S G703) UR BRIDGESTONE TUBE (130/90-16 M/C TR4) UR DUNLOP TUBE (130/90-16 M/C TR4) UR BRIDGESTONE BAND,RIM ( ) UR DUNLOP BAND, RIM ( ) UR BRIDGESTONE 14 1FK GEAR UNIT ASSY R6 COLLAR KS AXLE, WHEEL E2

51 FIG. 28 FRONT BRAKE CALIPER PART DESCRIPTION 1 5BN 2582U 00 DISK, BRAKE (RIGHT) G4 BOLT WM 2580U 01 CALIPER ASSY (RIGHT) JB W PISTON ASSY, CALIPER JB W CALIPER SEAL KIT JW PIN, SLIDE TT BOOT WM W BRAKE PAD KIT BP SUPPORT, PAD YX SPRING, ANTI RATTLE L W BLEED SCREW KIT BN SHIM, CALIPER G0 BOLT E3

52 FIG. 29 REAR WHEEL PART DESCRIPTION 1 3JB HUB, REAR SL 2 2GV SPACER, BEARING GV FLANGE, SPACER BEARING BEARING TR CLUTCH, HUB TR DAMPER G WASHER NUT O-RING O-RING TR PLATE, BRAKE SHOE DR W253E 00 BRAKE SHOE KIT SPRING, TENSION H CAMSHAFT LEVER, CAMSHAFT WASHER, PLATE H7 2533A 02 PLATE, INDICATOR BOLT RIM (15M/C X MT3.50) VR SPOKE SET, REAR TIRE (170/80-15 M/C 77S D404) UR DUNLOP P TIRE (170/80-15 M/C 77S G702) UR BRIDGESTONE TUBE (170/80-15 M/C PV78) UR DUNLOP TUBE (170/80-15 M/C PV78) UR BRIDGESTONE BAND,RIM (170/80-15) UR DUNLOP BAND,RIM ( ) UR BRIDGESTONE E4

53 FIG. 29 REAR WHEEL PART DESCRIPTION 25 3HT BALANCER, WHEEL (15G) UN 26 4TR AXLE, WHEEL L7 WASHER, PLATE R1 COLLAR NUT, SELF-LOCKING TR BAR, TENSION G1 BOLT NUT, U FLANGE E5

54 FIG. 30 STEERING HANDLE & CABLE PART DESCRIPTION 1 5BN HANDLEBAR CLAMP NK GRIP(LEFT) NK 2628J 00 CAP, GRIP NK GRIP ASSY NK 2635J 00.CAP BN CABLE, THROTTLE BN CABLE, THROTTLE SCREW, PAN HEAD BN CABLE, CLUTCH E BOOT, CABLE NUT NK REAR VIEW MIRROR ASSY (LEFT) BN REAR VIEW MIRROR ASSY (RIGHT) E6

55 FIG. 31 FRONT MASTER CYLINDER PART DESCRIPTION 1 4TR MASTER CYLINDER SUB ASSY TR CAP, RESERVOIR BH SEAL, PISTON TR 2589H 00.SCREW BH DIAPHRAGM, RESERVOIR KR W CYLINDER KIT, MASTER TR BRACKET, MASTER CYLINDER L BOOT, MASTER CYLINDER BOLT BN HOSE, BRAKE BOLT, UNION GASKET E7

56 FIG. 32 STAND & FOOTREST PART DESCRIPTION 1 5BN PEDAL, BRAKE NK PEDAL, BRAKE B1 SPRING, TORSION PIN, CLEVIS PIN, COTTER NK CAP BOLT, HEXAGON SOCKET HEAD WASHER, WAVE NUT BOLT SPRING, TENSION TR ROD PIN, CLEVIS P7 WASHER, PLATE PIN, COTTER TR BOSS, BRAKE PEDAL BOLT WASHER, SPRING TR SHAFT, BRAKE PEDAL CIRCLIP TR ROD, BRAKE PIN, CLEVIS P7 WASHER, PLATE PIN, COTTER SPRING, COMPRESSION PIN NUT E8

57 FIG. 32 STAND & FOOTREST PART DESCRIPTION 28 4KU STAND, SIDE EL WASHER BOLT, FLANGE G COLLAR NUT, U FLANGE SPRING, TENSION SPRING, TENSION EL LINK, SIDE STAND HOSE (L60) BN BRACKET, SIDE STAND BOLT, FLANGE NUT, U FLANGE BN FRONT FOOTREST ASSY (LEFT) BN FOOTREST BN COVER, FOOTREST NK SHAFT NK SPRING, RETURN CIRCLIP WM MOLE SCREW, COUNTERSUNK A3 BOLT, FLANGE BN FRONT FOOTREST ASSY (RIGHT) BN FOOTREST BN COVER, FOOTREST NK SHAFT NK SPRING, RETURN CIRCLIP E9

58 FIG. 32 STAND & FOOTREST PART DESCRIPTION 55 4WM MOLE SCREW, COUNTERSUNK A3 BOLT, FLANGE TR REAR FOOTREST ASSY COVER, REAR FOOTREST PIN, CLEVIS PIN, COTTER WASHER, PLATE A5 BOLT, FLANGE TR REAR FOOTREST ASSY COVER, REAR FOOTREST PIN, CLEVIS PIN, COTTER WASHER, PLATE A5 BOLT, FLANGE E10

59 FIG. 33 GENERATOR PART DESCRIPTION 1 4VR ROTOR ASSY SC STATOR ASSY BOLT, HEXAGON SOCKET HEAD E9 WASHER, PLATE BOLT, FLANGE SCREW, PAN HEAD WASHER, PLATE SCREW, PAN HEAD WASHER, PLATE E11

60 FIG. 34 FLASHER LIGHT PART DESCRIPTION 1 5YS FRONT FLASHER LIGHT ASSY VN BULB, FLASHER (12V-23/8W) VN LENS, FLASHER D GASKET, FLASHER LENS D LENS, RIM M SCREW, SPECIAL YS FRONT FLASHER LIGHT ASSY VN BULB, FLASHER (12V-23/8W) VN LENS, FLASHER D GASKET, FLASHER LENS D LENS, RIM M SCREW, SPECIAL BOLT, FLANGE NUT, FLANGE BN 2317V 00 STAY BOLT NK COVER, OUTER VN DAMPER, FLASHER NK PLUG, BLIND D REAR FLASHER LIGHT ASSY VN BULB, FLASHER (12V-21W) D LENS, FLASHER D GASKET, FLASHER LENS D LENS, RIM M SCREW, SPECIAL D REAR FLASHER LIGHT ASSY VN BULB, FLASHER (12V-21W) E12

61 FIG. 34 FLASHER LIGHT PART DESCRIPTION 28 1D LENS, FLASHER D GASKET, FLASHER LENS D LENS, RIM M SCREW, SPECIAL BOLT, FLANGE NUT, FLANGE E13

62 FIG. 35 METER PART DESCRIPTION 1 5SC SPEEDOMETER ASSY (MPH) 1 1 5SC SPEEDOMETER ASSY (KM/H) 1 2 5SC SOCKET CORD ASSY GV BULB (12V-1.7W T6.5) YT BULB (12V-1.7W T10) TR TUBE JK KNOB, TRIP METER SCREW, PAN HEAD TR DAMPER TR DAMPER WASHER, PLATE NUT BN SPEEDOMETER CABLE ASSY E14

63 FIG. 36 HEADLIGHT PART DESCRIPTION 1 4NK RING, MOUNTING NK LENS ASSY F BULB (12V-60/55W) (H4)HALOGEN 4 3SX COVER, SOCKET F RING, RETAINING SCREW, PAN HEAD WASHER, SPRING NK RIM, HEADLIGHT SPRING, SET SCREW, RIM ADJUSTING G SPRING, SCREW NUT, ADJUSTING BN BODY ASSY X DAMPER, HEADLIGHT SCREW, FLAT HEAD BOLT, BUTTON HEAD BOLT, BUTTON HEAD A3 WASHER, PLATE K5 WASHER, PLATE J COLLAR COLLAR E15

64 FIG. 37 TAILLIGHT PART DESCRIPTION 1 5BN TAILLIGHT ASSY NK GASKET,TAILLENS NK LENS, TAILLIGHT BN CORD ASSY BULB (12V-21/5W) SCREW, TAPPING SCREW, TAPPING BN GROMMET NK DAMPER COLLAR NUT G8 WASHER, PLATE BN DAMPER BN CORD, TAILLIGHT F2

65 FIG. 38 HANDLE SWITCH & LEVER PART DESCRIPTION 1 5BN LEVER BN HOLDER, LEVER TR COLLAR, LEVER TR BOLT, LEVER BOLT NUT BOLT NUT, U YX SWITCH SCREW, FLAT HEAD BN LEVER BOLT, HEXAGON SOCKET HEAD Y COLLAR, LEVER NUT, U SCREW NUT SPRING, COMPRESSION Y FRONT STOP SWITCH ASSY SCREW, PAN HEAD WASHER VN SWITCH, HANDLE SCREW, PAN HEAD KS SWITCH, HANDLE SCREW, PAN HEAD F3

66 FIG. 39 ELECTRICAL 1 PART DESCRIPTION 1 5KP RECTIFIER & REGULATOR ASSY BOLT, FLANGE BH STARTER RELAY ASSY AE FUSE (30A-BL) BOLT, FLANGE TX BATTERY ASSY (GS GT12B-4) BN COVER, BATTERY N DAMPER VR 2176E 00 PLATE N DAMPER BAND, BATTERY BN WIRE, PLUS LEAD BN WIRE, MINUS LEAD TR MAIN SWITCH STEERING LOCK BH BLANK KEY AP SCREW HN STOP SWITCH ASSY SC WIRE HARNESS ASSY JJ FUSE (5A-BL) JJ FUSE (10A-BL) JJ FUSE (15A-BL) RT B0 SWITCH, SIDE STAND SCREW, PAN HEAD KS RELAY ASSY UY RELAY ASSY FU THERMO SWITCH ASSY U RELAY ASSY F4

67 FIG. 39 ELECTRICAL 1 PART DESCRIPTION 28 1UA BAND CLAMP CLAMP CLAMP CLAMP CLAMP F5

68 FIG. 40 ELECTRICAL 2 PART DESCRIPTION 1 4VR IGNITION COIL ASSY SCREW, PAN HEAD WASHER, PLATE VR IGNITION COIL ASSY SCREW, PAN HEAD WASHER, PLATE CLAMP CLAMP FK PLUG CAP ASSY TR PLUG CAP ASSY L NEUTRAL SWITCH ASSY O-RING SCREW TR WIRE, SUB LEAD SC IGNITOR UNIT ASSY SCREW, TAPPING PLUG UJ FLASHER RELAY ASSY YS HORN A5 BOLT, FLANGE F6

69 NUMERICAL INDEX PART GRID PART GRID PART GRID PART GRID PART GRID PART GRID 4XP B 2 5BN B 2 4TR 1111F 00 B 2 22U 1111F 01 B 3 4VR 1111N 00 B 4 4TR 1112F 00 B 2 4H B 2 4TR B 2 22U B 7 4TR B 2 22U B 2 4TR B 2 4VR B 2 22U B 3 4TR B 2 22U B 3 4TR B 2 4VR B 4 4VR B 4 4VR B C 3 D 8 4VR B 4 4VR B 4 4VR B 4 4TR 1135A 00 B 2 4VR B 5 22U C 2 22U C 2 4VR B 5 4VR B 5 4VR B 5 4VR A0 B 5 3LD B 5 4VR B 5 4VR B 5 4VR B 5 22U B 5 3LD B 5 3LD B 5 3LD B 5 3LD B 5 4VR B 6 3Y B 6 3Y B 6 3Y B 6 1J B 6 1J B 6 4VR B 6 22U B 6 22U B 6 22U B 6 4VR B 7 22U B 7 4VR B 7 11H B 7 3BT B 7 4VR B 7 22U B 7 4TR B 10 4VR B 8 22U B 8 4VR B 8 4TR B 8 22U B 8 4VR B 8 4X C 5 4TR C 5 4TR B 9 5BN B 15 5BN B 15 16G B 9 4TR B 9 4MM B 15 4TR B 9 4VR B 10 4TR B 9 5KS D 14 4TR B 11 4TR B 11 3CF B 11 4DN 1410A 01 B 11 5SC 1410H 00 B 12 5SC 1410H 10 B 12 3F B 11 35H B 13 4KM B 11 1HX B 11 36Y B 12 8F B 11 3G2 1414E 36 B 11 3DM 1414M 34 B B B 12 5LW B 12 1AE B 11 1HX B 11 1AE B 11 4HM B 12 1WG B 12 5SC B 11 5SC B 12 4TR D 14 4TR B 12 4TR 1440F 00 B 9 4TR 1440G 00 B 9 4TR B 9 4TR B 9 4TR B 9 4TR B 9 29N F 4 4VR B 9 4TR B 9 4TR B 9 4TR B 9 4TR B 9 4TR B 10 4TR B 9 4TR B 9 3KW B 12 4TR B 10 1FN B 12 1HX B 11 1UY B 12 5BN B 14 5BN B 14 4BR B 14 4TR B 14 4TR B 14 5SC B 14 5SC B 14 5SC B 14 4BH B 14 4KM B 15 5BN B 15 5BN B 14 5BN B 15 5BN B 15 5BN B 15 5BN B 15 5BN B 15 5BN B 15 5BN B 15 5BN B 14 5BN B 15 5BN B 15 5BN B 15 5SC B 11 5SC B 11 5SC B 11 5SC B 11 5BN 1490J 00 B 11 3KW 1490K 00 B 12 4TR 1490L 00 B 12 5GK 1491A 00 B 13 4VR B 11 4TR B 12 55X B 13 22V B 12 4TR B B 12 1HX B 12 4TR B 12 4TR C 2 2H C 4 3F C 4 11H C 2 4TR C 4 4TR C 4 4TR C 4 4VR C 5 4TR C 4 22U C 2 4VR C 4 4VR C 4 3BT C 4 22U C 6 4VR C 6 5H C 6 4TR C 6 4VR C 7 5BN C 7 22U C 7 22U C 7 4X C 7 4X C 7 22U C 7 4VR C 7 22U C 8 1W C 7 4VR C 7 22U C 7 4KU C 9 4VR C 9 3JB C 9 4VR C 9 22U C 9 4KU C 9 4VR C 9 4TR C 9 4VR C 9 22U C 9 4VR C 9 22U C 10 4VR C 10 3H C 10 3JB C 10 3JB C 10 3JB C 10 3JB C 10 3JB C 10 3JB C 10 4H C 10 4H C 10 4H C 10 1J Y0 30 D 7 1J Y0 40 D 7 1J Y0 50 D 7 4VR C 10 22U C 10 56W D 8 5BN C 12 4TR C 12 22N C 12 4NK C 12 5A C 12 4TR C 12 4G C 12 4TR C 12 2H C 12 4H C 11 4TR C 11 4TR C 11 4TR C 11 3YF C 11 4TR C 11 4TR C 11 4UN C 11 4UN C 11 4VR C 13 4VR C 14 5GK 2118K 00 D 12 5GK 2118K 10 D 12 5KP C 14 4R D 2 4VR C 13 4VR C 13 5BN C 13 22F 2139X 00 D 4 4TR 2144G 01 C 14 4TR C 13 5BN C 15 1D6 2153E 00 C 15 5SC C 15 5BN S0 C 15 3FY C 14 5BN E0 C 15 5BN M0 C 15 5BN N0 C 15 5BN C 15 5BN C 15 4TR 2160A 00 D 4 5BN D 2 5BN D 2 4TR D 2 42U D 3 5SC 2165A 50 C 15 5BN 2165A S0 C 15 5BN C 14 5BN C 14 5BN C 14 55K D 4 5BN PC D 4 5BN PE D 4 5BN PL D 4 3XV D 13 4TR D 4 4TR 2171A 00 D 13 4TR 2171E 00 C 13 1FK 2171L 00 D 13 4TR 2171X 00 C 13 5BN P8 D 4 5BN PE D 4 5BN PL D 4 5SC 2172K 00 D 4 5BN D 5 3SP C 14 C 15 M1