YZF-R25 (2YD1) MALAYSIA 1P2YD-440E1

Transcription

1 YZF-R25 () MALAYSIA 1P2YD-440E1 ( )

2 YZF-R25 PARTS CATALOGUE 2015 by Yamaha Motor Co., Ltd. 1st edition, January 2015 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. 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. Frame Serial No. Engine Serial No. 9. Applicable Starting Serial No. Frame Serial No. Serial No. Name Of Q ty Column Model Code Engine Serial No. 8. Applicable Colour Code (The (*) mark shows Model colour.) Serial No. Name Of Q ty Column Model Code Abbreviation Colour Name Colour Code DPBM15 DEEP PURPLISH BLUE METALLIC DPBMC(*) DEEP PURPLISH BLUE METALLIC C 0564 LGB LOW GLOSS BLACK 0098 MBL2 MAT BLACK MS1 MAT SILVER SMX(*) BLACK METALLIC X 0903 VRC1(*) VIVID RED COCKTAIL WM6 WHITE METALLIC

5 CONTENTS ENGINE CYLINDER HEAD... 1 CRANKSHAFT & PISTON... 3 VALVE... 5 CAMSHAFT & CHAIN... 6 WATER PUMP... 7 RADIATOR & HOSE... 8 OIL PUMP... 9 INTAKE EXHAUST CRANKCASE CRANKCASE COVER STARTER CLUTCH CLUTCH TRANSMISSION SHIFT CAM & FORK SHIFT SHAFT CHASSIS FRAME FENDER SIDE COVER REAR ARM & 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 WINDSHIELD COWLING GENERATOR STARTING MOTOR FLASHER LIGHT METER HEADLIGHT TAILLIGHT HANDLE SWITCH & LEVER ELECTRICAL ELECTRICAL INDEX NUMERICAL INDEX... 60

6 FIG. 1 CYLINDER HEAD PART 1 1WD E CYLINDER HEAD ASSY 1 2 1WD E GUIDE, VALVE BOLT, FLANGE PLUG, STRAIGHT SCREW BOLT, FLANGE GASKET BOLT, STUD 4 8 1WD E BOLT, CYLINDER HOLDING WASHER, PLATE BOLT, HEXAGON SOCKET HEAD PLUG, SPARK (NGK R CR9E) WD E GASKET, CYLINDER HEAD PIN, DOWEL BOLT WD E111G 00 RUBBER, MOUNT WD E COVER, CYLINDER HEAD WD E GUIDE, STOPPER WD E GASKET, HEAD COVER VY 1482K 00 PLATE WD E REED VALVE ASSY WD E CAP, CASE BOLT BOLT WD E111G 00 RUBBER, MOUNT WD E CYLINDER WD E GASKET, CYLINDER NL PIPE, WATER 1 1

7 FIG. 1 CYLINDER HEAD PART O-RING PIN, DOWEL WD E AIR CUT VALVE ASSY WD E HOSE, BEND CLIP WD E HOSE, BEND CLIP CLIP 1 2

8 FIG. 2 CRANKSHAFT & PISTON PART 1 1WD CRANKSHAFT 1 2 1WD CONNECTING ROD ASSY 2 3 5SL BOLT, CONNECTING ROD NUT 2 5 1WD PLANE BEARING, CONNECTING ROD 4 UR BLUE 1WD PLANE BEARING, CONNECTING ROD 4 UR BLACK 1WD PLANE BEARING, CONNECTING ROD 4 UR BROWN 1WD PLANE BEARING, CONNECTING ROD 4 UR GREEN 6 1WD E GEAR, DRIVE 1 7 1WD E SPROCKET, CAM CHAIN BOLT, FLANGE R1 WASHER, PLATE WD PLANE BEARING, CRANKSHAFT 1 6 UR BLUE 1WD PLANE BEARING, CRANKSHAFT 1 6 UR BLACK 1WD PLANE BEARING, CRANKSHAFT 1 6 UR BROWN 1WD PLANE BEARING, CRANKSHAFT 1 6 UR GREEN 1WD PLANE BEARING, CRANKSHAFT 1 6 UR YELLOW 11 1WD E PISTON (STD) WD E PISTON RING SET (STD) WD E PIN, PISTON CIRCLIP WD E GEAR, BALANCE WEIGHT F8 BOLT, FLANGE KEY, STRAIGHT WD E BOSS, BUFFER WASHER, PLATE SPRING, COMPRESSION 4 3

9 FIG. 2 CRANKSHAFT & PISTON PART PIN, DOWEL WD E WEIGHT WD METAL, BALANCE WEIGHT 4 UR BLUE 1WD METAL, BALANCE WEIGHT 4 UR BLACK 1WD METAL, BALANCE WEIGHT 4 UR BROWN 1WD METAL, BALANCE WEIGHT 4 UR GREEN 1WD METAL, BALANCE WEIGHT 4 UR YELLOW 4

10 FIG. 3 VALVE PART 1 1WD E VALVE, INTAKE 4 2 1WD E VALVE, EXHAUST 4 3 1WD E SEAT, VALVE SPRING WD SPRING, VALVE INNER 8 5 1WD E RETAINER, VALVE SPRING 8 6 3S0 E LOCK, VALVE SPRING RETAINER PA E SEAL, VALVE STEM 8 8 1HX F0 PAD, ADJUSTING 2 (1.50) 8 UR 1HX H1 PAD, ADJUSTING 2 (1.55) 8 UR 1HX K1 PAD, ADJUSTING 2 (1.60) 8 UR 1HX M1 PAD, ADJUSTING 2 (1.65) 8 UR 1HX R1 PAD, ADJUSTING 2 (1.70) 8 UR 1HX U1 PAD, ADJUSTING 2 (1.75) 8 UR 1HX W1 PAD, ADJUSTING 2 (1.80) 8 UR 1HX Y1 PAD, ADJUSTING 2 (1.85) 8 UR 1HX PAD, ADJUSTING 2 (1.90) 8 UR 1HX PAD, ADJUSTING 2 (1.95) 8 UR 1HX PAD, ADJUSTING 2 (2.00) 8 UR 1HX PAD, ADJUSTING 2 (2.05) 8 UR 1HX PAD, ADJUSTING 2 (2.10) 8 UR 1HX E0 PAD, ADJUSTING 2 (2.15) 8 UR 1HX G0 PAD, ADJUSTING 2 (2.20) 8 UR 1HX J0 PAD, ADJUSTING 2 (2.25) 8 UR 1HX L0 PAD, ADJUSTING 2 (2.30) 8 UR 1HX N0 PAD, ADJUSTING 2 (2.35) 8 UR 1HX T0 PAD, ADJUSTING 2 (2.40) 8 UR 9 1WD LIFTER, VALVE 8 5

11 FIG. 4 CAMSHAFT & CHAIN PART 1 1WD E CAMSHAFT ASSY WD E CAMSHAFT ASSY WD E SPROCKET, CAM CHAIN BOLT, FLANGE CHAIN 1 6 1WD TENSIONER ASSY, CAM CHAIN BOLT, FLANGE GASKET 1 9 1WD E GASKET, TENSIONER CASE BOLT WD E DAMPER, CHAIN WD E DAMPER, CHAIN BOLT, HEXAGON SOCKET HEAD WD E COVER, CHAIN BOLT, HEXAGON SOCKET HEAD 2 6

12 FIG. 5 WATER PUMP PART 1 1WD E WATER PUMP ASSY 1 2 1WD E COVER, CRANKCASE BEARING BEARING OIL SEAL 1 6 1WD E IMPELLER SHAFT ASSY 1 7 1WD E GEAR S E SEAL S E WASHER WD E319L 00.PIN, STRAIGHT CIRCLIP WD E PLATE BOLT WD E COVER, HOUSING WD E GASKET, HOUSING COVER GASKET BOLT, FLANGE H GAUGE, LEVEL WD E PLUG, OIL LEVEL O-RING 1 7

13 FIG. 6 RADIATOR & HOSE PART 1 5P THERMOSTAT 1 2 1WD E COVER, THERMOSTAT BOLT, FLANGE 2 4 1WD E HOSE WD E HOSE A1 CLIP HOSE CLAMP ASSY 2 8 1WD E RADIATOR COMP 1 9 1WD E BLOWER ASSY WD E NUT YP E BOLT, BLOWER HOLDING P0 E CONDUCTION ASSY BOLT, FLANGE WASHER, PLATE W3 COLLAR GROMMET 3 8

14 FIG. 7 OIL PUMP PART 1 1WD E OIL PUMP ASSY CIRCLIP 1 3 1WD E GEAR, OIL PUMP IDLE 1 4 1WD E SHAFT, IDLE GEAR CIRCLIP WASHER, PLATE PIN, DOWEL BOLT 4 9 1WD E STRAINER HOUSING ASSY WD E SEAL, OIL STRAINER WD E ELEMENT ASSY, OIL CLEANER BOLT, UNION WD E COVER, STRAINER PLUG, STRAIGHT SCREW YS E GASKET WD E GASKET, STRAINER COVER BOLT, FLANGE CLAMP 1 9

15 FIG. 8 INTAKE PART 1 1WD E JOINT, CARBURETOR O-RING BOLT HOSE CLAMP ASSY 2 5 1WD E THROTTLE BODY ASSY 1 6 1WD E GASKET 2 7 1WD E INJECTOR 2 8 5PS O-RING 1 9 1WS STEPPING MOTOR WS SPRING, PLUNGER SCREW, PAN HEAD WD E BOLT GL WASHER HG COLLAR JW AIR SCREW SET CAP A CLIP, PIPE P E416A 00.O-RING WD E PLATE WD E PIPE WD E CASE, AIR CLEANER WD E FUNNEL, AIR WD E446C 00 FUNNEL WD E DUCT WD E CAP, CLEANER CASE WD E SEAL WD E SEAL 1 10

16 FIG. 8 INTAKE PART SCREW, TAPPING WD E CAP, CLEANER CASE WD E SEAL SCREW, BIND WD E ELEMENT, AIR CLEANER B E443E 00 PIPE, DRAIN A3 CLIP P E BAND BOLT, FLANGE WD E HOSE, AIR CLIP CLIP WD E PIPE, BREATHER CLIP 2 11

17 FIG. 9 EXHAUST PART 1 1WD E EXHAUST PIPE COMP WD E473L 00 BRACKET BOLT, FLANGE 2 4 1WD E MUFFLER ASSY WD E PROTECTOR, SILENCER BOLT,HEX. SOCKET BUTTON NUT, SPRING 1 8 1WD E PROTECTOR, MUFFLER GROMMET L0.COLLAR BOLT,HEX. SOCKET BUTTON WD E SPACER D E GASKET, MUFFLER WD E BAND, MUFFLER BOLT, FLANGE N4.COLLAR WASHER, PLATE NUT, SPRING WD E GASKET, EXHAUST PIPE NUT, FLANGE G7 BOLT, FLANGE WASHER, PLATE WD E PROTECTOR, EXHAUST PIPE GROMMET L0 COLLAR BOLT,HEX. SOCKET BUTTON NUT, SELF-LOCKING 1 12

18 FIG. 10 CRANKCASE PART 1 1WD E CRANKCASE ASSY PLUG O-RING 2 4 1WD E NOZZLE PIN, DOWEL F7 BOLT, FLANGE G0 BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE GASKET WD E NOZZLE F7 O-RING 1 13

19 FIG. 11 CRANKCASE COVER 1 PART 1 1WD E COVER, CRANKCASE BOLT BOLT, BUTTON HEAD GASKET PLUG, STRAIGHT SCREW O-RING 1 7 1WD E GASKET, CRANKCASE COVER PIN, DOWEL BOLT, FLANGE WD E GASKET, CRANKCASE COVER PIN, DOWEL BOLT, FLANGE BOLT, FLANGE WD E HOLDER, CLUTCH CABLE BOLT WD E COVER WD E GASKET, CRANKCASE COVER BOLT, FLANGE CLAMP CLAMP WD E GUIDE, INLET WD E COVER, CHAIN CASE BOLT, FLANGE CLAMP 2 14

20 FIG. 12 STARTER CLUTCH PART 1 1WD E GEAR D E SHAFT WD E GEAR WD E STARTER CLUTCH OUTER ASSY BOLT, HEXAGON SOCKET HEAD 3 15

21 FIG. 13 CLUTCH PART 1 1WD E GEAR, PRIMARY DRIVE 1 2 1WD E PRIMARY DRIVEN GEAR COMP WD E PLATE, THRUST WD E BOSS, CLUTCH 1 5 1WD E PLATE, FRICTION WD E PLATE, CLUTCH WD E PRESSURE PLATE ASSY 1 8 1WD E SPRING, CLUTCH WD E SCREW, SPRING WASHER, LOCK NUT WASHER, PLATE WD E SPACER WD E ROD, PUSH WD E PUSH LEVER ASSY WASHER, PLATE CIRCLIP SPRING, TORSION WD AXLE, PUSH LEVER WASHER, PLATE CLIP 1 16

22 FIG. 14 TRANSMISSION PART 1 1WD E AXLE, MAIN (15T) 1 2 1WD E GEAR, 5TH PINION (27T) WASHER, CLAW CIRCLIP 1 5 1WD E GEAR, 3RD PINION (22T/25T) 1 6 1WD E GEAR, 6TH PINION (25T) 1 7 1WD E GEAR, 2ND PINION (17T) Y9 BEARING CIRCLIP Y3 BEARING OIL SEAL CIRCLIP WD E DRIVE AXLE ASSY WD E GEAR, 2ND WHEEL (32T) WASHER CIRCLIP WD E GEAR, 6TH WHEEL (23T) WD E GEAR, 3RD WHEEL (32T) WD E GEAR, 4TH WHEEL (30T) WASHER, CLAW CIRCLIP WD E GEAR, 5TH WHEEL (28T) WD E GEAR, 1ST WHEEL (40T) COLLAR WASHER, PLATE (T=1.0) Y3 BEARING OIL SEAL 1 17

23 FIG. 14 TRANSMISSION PART 28 1WD CIRCLIP CIRCLIP OIL SEAL WD E SPROCKET, DRIVE (14T) WASHER, PLATE NUT 1 18

24 FIG. 15 SHIFT CAM & FORK PART 1 1WD E SHIFT CAM ASSY 1 2 5TP E POINT, NEUTRAL SPRING, COMPRESSION 1 4 1WD E FORK, SHIFT WD E FORK, SHIFT WD E FORK, SHIFT WD E BAR, SHIFT FORK GUIDE A2 SPRING, COMPRESSION 4 9 1WD E STOPPER, SHIFT BAR WD E PLATE, STOPPER BOLT, HEXAGON SOCKET HEAD 2 19

25 FIG. 16 SHIFT SHAFT PART 1 1WD E SPRING 1 2 1WD E STOPPER, SCREW 1 3 1WD E SPACER 1 4 1WD E SHIFT SHAFT ASSY SPRING, TORSION CIRCLIP E1 WASHER, PLATE 1 8 1WD E STOPPER LEVER ASSY BEARING OIL SEAL WD E SHIFT PEDAL ASSY EG E COVER, SHIFT PEDAL WD E ROD, SHIFT NUT NUT WD E ARM, SHIFT P F SHAFT WASHER, WAVE WASHER, PLATE BOLT 1 20

26 FIG. 17 FRAME PART 1 1WD F FRAME COMP WD F113B 00 DAMPER 6 3 1WD F112C 00 DAMPER WD F117G 00 PROTECTOR 2 5 1WD F PROTECTOR 1 6 1WD F193A 00 PROTECTOR 1 7 5D9 F414G 00 SEAL 2 8 1WD F BUSH WD F191B 00 PLATE BOLT WASHER BOLT, FLANGE BOLT, FLANGE NUT WD F135F 00 COVER PLUG WD F BOX GROMMET COLLAR BOLT, FLANGE NUT, SPRING CLAMP CLAMP WD F122A 00 STAY WD F122B 00 STAY BOLT BOLT 2 21

27 FIG. 17 FRAME PART WASHER, PLATE COLLAR TP E DAMPER, MUFFLER 1 22

28 FIG. 18 FENDER PART 1 1WD XF P1 FENDER, FRONT 1 UR FOR DPBMC 1WD XF P0 FENDER, FRONT 1 UR FOR SMX 1WD XF P2 FENDER, FRONT 1 UR FOR VRC GROMMET C5.COLLAR GROMMET 2 5 1WD F BRACKET 2 6 1WD F153E 00.EMBLEM, YAMAHA 1 UR FOR DPBMC 1WD F153E 10.EMBLEM, YAMAHA 1 UR FOR SMX 1WD F153E 20.EMBLEM, YAMAHA 1 UR FOR VRC L0.COLLAR BOLT,HEX. SOCKET BUTTON BOLT, FLANGE WD F113J 00 BRACKET, REFLECTOR AG REFLECTOR, FRONT NUT, FLANGE WD F FENDER, REAR WD F SEAL F1 BOLT NUT, SPRING WD F16A2 00 SEAL, WD F163E 00 COVER, REAR FENDER RIVET WD F GUARD, MUD WD F BRACKET, FENDER BOLT,HEX. SOCKET BUTTON A7 NUT, SPRING 4 23

29 FIG. 18 FENDER PART SCREW, TRUSS HEAD TAPPING BOLT,HEX. SOCKET BUTTON WD F BRACKET, REAR STAY WD F BRACKET, REAR STAY J9 COLLAR L9 COLLAR NUT, SELF-LOCKING WD F FLAP BOLT WD F163A 00 COVER, REAR FENDER RIVET 4 24

30 FIG. 19 SIDE COVER PART 1 1WD XF P1 COVER, SIDE 1 1 UR FOR DPBMC 1WD XF P0 COVER, SIDE 1 1 UR FOR SMX 1WD XF P2 COVER, SIDE 1 1 UR FOR VRC NUT, SPRING A7.NUT, SPRING GROMMET COLLAR 1 6 1WD F17F1 00.GRAPHIC, 1 1 UR FOR DPBMC 1WD F17F1 10.GRAPHIC, 1 1 UR FOR SMX 1WD F17F1 20.GRAPHIC, 1 1 UR FOR VRC1 7 1WD F17F3 00.GRAPHIC, 3 1 FOR DPBMC 8 31B F SEAL RIVET BOLT, WITH WASHER WD XF P1 COVER, SIDE 2 1 UR FOR DPBMC 1WD XF P0 COVER, SIDE 2 1 UR FOR SMX 1WD XF P2 COVER, SIDE 2 1 UR FOR VRC NUT, SPRING A7.NUT, SPRING GROMMET COLLAR WD F17F2 00.GRAPHIC, 2 1 UR FOR DPBMC 1WD F17F2 10.GRAPHIC, 2 1 UR FOR SMX 1WD F17F2 20.GRAPHIC, 2 1 UR FOR VRC1 17 1WD F17F4 00.GRAPHIC, 4 1 FOR DPBMC 18 31B F SEAL RIVET 1 25

31 FIG. 19 SIDE COVER PART BOLT, WITH WASHER WD F171L 00 MOLE, SIDE COVER SCREW, TRUSS HEAD TAPPING RIVET WD F171M 00 MOLE, SIDE COVER SCREW, TRUSS HEAD TAPPING RIVET WD F171N 00 MOLE, SIDE COVER SCREW, TRUSS HEAD TAPPING WD F TANK, RECOVERY COLLAR WD F CAP C1 F ELBOW WD F PIPE WD F PIPE CLIP WD F172W 00 COVER BOLT,HEX. SOCKET BUTTON WD F P1 COVER, SIDE 3 1 UR FOR DPBMC 1WD F P0 COVER, SIDE 3 1 UR FOR SMX 1WD F P2 COVER, SIDE 3 1 UR FOR VRC SCREW, ROUND TAPPING WD F171E 00 COVER, SIDE BOLT,HEX. SOCKET BUTTON WD F171X 00 COVER, SIDE BOLT,HEX. SOCKET BUTTON PA F836B 00 TUNING FORK MARK 1 26

32 FIG. 20 REAR ARM & SUSPENSION PART 1 1WD F REAR ARM COMP WD SHAFT, PIVOT 1 3 1WD F COVER, THRUST WD F BUSH BEARING NUT, SELF-LOCKING 1 7 1WD F SEAL, GUARD BOLT, FLANGE 1 9 1WD F248B 00 COLLAR, ROD NUT, U WD F CASE, CHAIN COLLAR BOLT,HEX. SOCKET BUTTON WD F SHOCK ABSORBER ASSY, REAR BOLT, FLANGE NUT, U WD F LABEL, TIRE 1 27

33 FIG. 21 STEERING PART Y3 BEARING 1 2 5BP F COVER, BALL RACE NUT WASHER, PLATE 1 5 5BP F WASHER, SPECIAL 1 6 1WD F CROWN, HANDLE BOLT, FLANGE BOLT 2 28

34 FIG. 22 FRONT FORK PART 1 1WD F FRONT FORK ASSY 1 2 1WD F FRONT FORK ASSY (L.H) 1 3 1WD F TUBE, OUTER (L.H) 1 4 1WD F INNER TUBE COMP WD F CYLINDER COMP., FRONT FORK 1 6 1WD F SPRING, FRONT FORK P F METAL, SLIDE P F WASHER, OIL SEAL P F OIL SEAL P F RING, SNAP P F SEAL, DUST WD F SPINDLE, TAPER F3158 L0..GASKET B F BOLT, HEXAGON SOCKET HEAD P F WASHER, SPRING UPPER WD F SPACER P F BOLT, CAP P F O-RING WD F FRONT FORK ASSY (R.H) WD F TUBE, OUTER WD F INNER TUBE COMP WD F CYLINDER COMP., FRONT FORK WD F SPRING, FRONT FORK P F METAL, SLIDE P F WASHER, OIL SEAL P F OIL SEAL P F RING, SNAP 1 29

35 FIG. 22 FRONT FORK PART 28 45P F SEAL, DUST WD F SPINDLE, TAPER F3158 L0..GASKET B F BOLT, HEXAGON SOCKET HEAD P F WASHER, SPRING UPPER WD F SPACER P F BOLT, CAP P F O-RING WD F UNDER BRACKET COMP BEARING FV SEAL, STEERING P F BOLT WS 2331G 00.COVER 2 30

36 FIG. 23 FUEL TANK PART 1 1WD F FUEL TANK COMP WD F MOLD, FUEL TANK DAMPER, PLATE 1 4 5D9 F414G 00 SEAL P F414H 00 DAMPER, PLATE WD F412Y 00 BRACKET, TANK FITTING 1 7 1WD F GROMMET COLLAR WASHER PLAIN BOLT, FLANGE BOLT, FLANGE WD F BRACKET, FUEL TANK GROMMET COLLAR WASHER PLAIN BOLT, FLANGE BOLT, FLANGE WD WF CAP ASSY BOLT, HEXAGON SOCKET HEAD BOLT GROMMET WD F41B1 00 P1 COVER, TANK 1 MS1 FOR DPBMC 1WD F41B1 00 P0 COVER, TANK 1 MBL2 FOR SMX,VRC GROMMET COLLAR BOLT,HEX. SOCKET BUTTON SCREW, TRUSS HEAD TAPPING 4 31

37 FIG. 23 FUEL TANK PART NUT, SPRING WD F414G 00 SEAL WD F P1 COVER, SIDE 1 1 UR FOR DPBMC 1WD F P0 COVER, SIDE 1 1 UR FOR SMX 1WD F P2 COVER, SIDE 1 1 UR FOR VRC GROMMET COLLAR BOLT, WITH WASHER NUT, SPRING SCREW, TRUSS HEAD TAPPING GROMMET WD F P1 COVER, SIDE 2 1 UR FOR DPBMC 1WD F P0 COVER, SIDE 2 1 UR FOR SMX 1WD F P2 COVER, SIDE 2 1 UR FOR VRC GROMMET COLLAR BOLT, WITH WASHER NUT, SPRING SCREW, TRUSS HEAD TAPPING GROMMET WD F414E 00 SEAL WD E FUEL PUMP COMP WD H SENDER UNIT ASSY, FUEL METER WD F BRACKET, FUEL PUMP C1 F O-RING BOLT WD E PIPE, FUEL

38 FIG. 23 FUEL TANK PART 50 1WD F PIPE WD F PIPE CLIP WD F PIPE, JOINT CLAMP WD F PIPE WD F PIPE CLIP XY JOINT WD F413B 00 EMBLEM P LABEL, WARNING 1 33

39 FIG. 24 SEAT PART 1 1WD F SINGLE SEAT ASSY 1 2 1WD F COVER, SINGLE SEAT 1 3 5BP F PAD, SEAT BOLT, FLANGE 2 5 1WD F TANDEM SEAT ASSY 1 6 3C1 F PAD, SEAT 4 7 1WD F SEAT LOCK ASSY 1 8 1WD F PLATE NUT, FLANGE WD F478E 00 CABLE, SEAT LOCK WD WF ROTOR SUB ASSY WITH KEY WD F117K 00 STAY, LOCK SCREW, WITH WASHER SCREW, TAPPING WD F TOOL KIT TL H BAND, BATTERY 1 34

40 FIG. 25 FRONT WHEEL PART 1 1WD F P0 CAST WHEEL, FRONT 1 UR DPBM15 1WD F X CAST WHEEL, FRONT 1 UR LGB/DRSC 2 1WD F510C 00 COLLAR ASSY OIL SEAL X4 BEARING TIRE (110/70-17M/C 54S RX-01F) 1 INOUE VALVE, RIM 1 7 5MT BALANCER, WHEEL (10G) 1 UN 5MT BALANCER, WHEEL (20G) 1 UN 5MT BALANCER, WHEEL (30G) 1 UN 8 1PA F COLLAR, SPROCKET AXLE 2 9 1WD AXLE, WHEEL NUT, SELF-LOCKING 1 35

41 FIG. 26 FRONT BRAKE CALIPER PART 1 1WD F581U 00 DISK BRAKE ASSY (RIGHT) BOLT,HEX. SOCKET BUTTON 5 3 1WD F580U 01 CALIPER ASSY (RIGHT) 1 4 1WD PISTON ASSY, CALIPER 1 5 1WD CALIPER SEAL KIT 1 6 4C9 W BLEED SCREW KIT 1 7 5YP F BOOT YP F BOOT, CALIPER 1 9 5YP F CLIP WD F SUPPORT, PAD YP F PIN, PAD WD BRAKE PAD KIT SCREW 2 36

42 FIG. 27 REAR WHEEL PART 1 1WD F P0 CAST WHEEL, REAR 1 UR DPBM15 1WD F X CAST WHEEL, REAR 1 UR LGB/DRSC COLLAR BEARING OIL SEAL 1 5 1WD F DAMPER 6 6 1WD F P0 CLUTCH, HUB 1 FOR DPBMC 1WD F CLUTCH, HUB 1 LGB FOR SMX,VRC BEARING OIL SEAL 1 9 1WD F COLLAR, WHEEL WD F SPROCKET, DRIVEN (43T) WD F537W 00 BRACKET WD F537X 00 BRKT WD F539F 00 PLATE BOLT, STUD NUT, U FLANGE TIRE (140/70-17M/C 66S RX-01R) 1 INOUE VALVE, RIM MT BALANCER, WHEEL (10G) 1 UN 5MT BALANCER, WHEEL (20G) 1 UN 5MT BALANCER, WHEEL (30G) 1 UN 19 1WD AXLE, WHEEL WD F COLLAR, SPROCKET AXLE WD F COLLAR, WHEEL NUT, SELF-LOCKING WASHER, PLATE 2 37

43 FIG. 27 REAR WHEEL PART 24 1WD F PULLER, CHAIN WD F END WASHER, PLATE NUT D E443G 00 PIPE, DRAIN H3112 CHAIN (DID520VF 112LE) 1 38

44 FIG. 28 REAR BRAKE CALIPER PART 1 1WD F582W 00 DISK, REAR BRAKE BOLT,HEX. SOCKET BUTTON 3 3 1WD F580W 01 CALIPER ASSY, REAR WD PISTON ASSY, CALIPER 1 5 1WD CALIPER SEAL KIT 1 6 5YP F BOOT, CALIPER X BOOT YP W BLEED SCREW KIT 1 9 1WD F SUPPORT, PAD WD F PIN, PAD YP F CLIP WD F BRACKET, SUPPORT WD F CLIP, PAD WD F CLIP, PAD WD BRAKE PAD KIT WD F PIN, SLIDE KN BOLT TL F SLEEVE, CALIPER 1 39

45 FIG. 29 STEERING HANDLE & CABLE PART 1 1WD F HANDLEBAR (LEFT) BOLT BOLT PLUG 1 5 1WD F HANDLEBAR (RIGHT) BOLT BOLT PLUG 1 9 2DP F GRIP WD F GRIP ASSY WD F622H 00 WEIGHT S7 F622F 00 DAMPER, LOCATING S7 F STOPPER WD F END, GRIP BOLT WD F CABLE, CLUTCH WD F GUIDE, CABLE BOLT, BUTTON HEAD WD F THROTTLE CABLE ASSY SCREW, PAN HEAD BOLT WD F GUIDE, CABLE BOLT, BUTTON HEAD 1 40

46 FIG. 30 FRONT MASTER CYLINDER PART 1 1WD F MASTER CYLINDER SUB ASSY 1 2 1WD F CYLINDER KIT, MASTER 1 3 5RB DIAPHRAGM, RESERVOIR 1 4 1WD F CAP, RESERVOIR Y 2589H 00.SCREW 2 6 3RW F BRACKET, MASTER CYLINDER 1 7 3C1 F BUSH,DIAPHRAGM 1 8 1WD H LEVER NUT, U BOLT HP FRONT STOP SWITCH ASSY SCREW, PAN HEAD WITH WASHER BOLT, FLANGE PLUG WD F HOSE, BRAKE BOLT, UNION WASHER, PLATE WD F HOLDER, BRAKE HOSE NUT, FLANGE WD F HOLDER, BRAKE HOSE

47 FIG. 31 STAND & FOOTREST PART 1 1WD F STAND, SIDE 1 2 1WD F BRACKET, SIDE STAND BOLT, FLANGE SPRING, TENSION A7 BOLT, FLANGE COLLAR NUT, U FLANGE G3 HOSE (L70) 1 9 1WD F BRACKET WD F FOOTREST WD F BOLT B9 SPRING, TORSION PIN, CLEVIS PIN, COTTER WD F PLATE BOLT,HEX. SOCKET BUTTON G6 BOLT WD F BRACKET WD F FOOTREST WD F BOLT B9 SPRING, TORSION PIN, CLEVIS PIN, COTTER WD F PEDAL, BRAKE BP SHAFT WASHER, PLATE SPRING, TENSION 1 42

48 FIG. 31 STAND & FOOTREST PART 28 1WD F144G 00 STAY, STOP SWITCH BOLT, FLANGE G6 BOLT WD F PLATE WD F REAR FOOTREST ASSY WD F FOOTREST, REAR SPRING, COMPRESSION BALL WD F WASHER, SPECIAL PIN, CLEVIS PIN, COTTER BOLT, HEXAGON SOCKET HEAD WD F REAR FOOTREST ASSY WD F FOOTREST, REAR SPRING, COMPRESSION BALL WD F WASHER, SPECIAL PIN, CLEVIS PIN, COTTER BOLT, HEXAGON SOCKET HEAD TP E DAMPER, MUFFLER COLLAR 1 43

49 FIG. 32 REAR MASTER CYLINDER PART 1 1WD F580E 00 REAR MASTER CYLINDER ASSY 1 2 1WD F CYLINDER KIT, MASTER 1 3 4SS NUT C F JOINT C F582A 50.JOINT C F CIRCLIP O-RING 1 8 3KW PIN, BRAKE ROD C F TANK, RESERVOIR VN F DIAPHRAGM, RESERVOIR C F BUSH,DIAPHRAGM WD F CAP, RESERVOIR WD F HOSE, RESERVOIR CLIP C F589A 00.COVER, DUST PIN, CLEVIS WASHER, PLATE PIN, COTTER BOLT, BUTTON HEAD BOLT,HEX. SOCKET BUTTON WD F582E 00 HOLDER, RESERVE TANK WD F HOSE, BRAKE BOLT, UNION WASHER, PLATE WD F HOLDER, BRAKE HOSE BOLT, FLANGE 1 44

50 FIG. 33 WINDSHIELD PART 1 1WD F WINDSHIELD NUT 4 3 1WD H COVER, METER 1 4 1WD F835G 00 BODY, FRONT UPPER WD F TRIM SCREW, TAPPING A7 NUT, SPRING 2 8 1WD XF83F 20 P1 BODY COWLING SUB ASSY 1 UR FOR DPBMC 1WD XF83F 10 P0 BODY COWLING SUB ASSY 1 UR FOR SMX 1WD XF83F 10 P2 BODY COWLING SUB ASSY 1 UR FOR VRC1 9 1WD F GRAPHIC 1 1 UR FOR DPBMC 1WD F GRAPHIC 1 1 UR FOR VRC1 10 1WD F GRAPHIC 2 1 UR FOR DPBMC NUT, SPRING D F HOOK SCREW, ROUND HEAD WD F TRIM WD F836N 00 PANEL, INNER WD F836R 00 PANEL, INNER RIVET BOLT,HEX. SOCKET BUTTON WD F MOLD WD F TRIM WD F STAY BOLT, FLANGE WD F REAR VIEW MIRROR ASSY (LEFT) WD F REAR VIEW MIRROR ASSY (RIGHT) 1 45

51 FIG. 33 WINDSHIELD PART 25 1WD F PLATE, RUBBER WD F PLATE, RUBBER WD F PLATE, RUBBER BOLT C2 COLLAR PLUG PA F836B 00 TUNING FORK MARK 1 46

52 FIG. 34 COWLING 1 PART 1 1WD XF83L 20 P1 BODY, FR. UNDER 1 SUB ASSY 1 UR MS1 FOR DPBMC 1WD XF83L 30 P0 BODY, FR. UNDER 1 SUB ASSY 1 UR FOR SMX 1WD XF83L 30 P2 BODY, FR. UNDER 1 SUB ASSY 1 UR WM6 FOR VRC1 2 1WD F EMBLEM 1 UR FOR DPBMC 1WD F EMBLEM 1 UR FOR VRC1 3 1WD F GRAPHIC 3 1 UR FOR DPBMC 1WD F GRAPHIC 3 1 UR FOR SMX 1WD F GRAPHIC 3 1 UR FOR VRC1 4 1WD F GRAPHIC 5 1 UR FOR DPBMC 1WD F GRAPHIC 5 1 UR FOR SMX 1WD F GRAPHIC 5 1 UR FOR VRC A7.NUT, SPRING NUT, SPRING 4 7 1WD XF83M 20 P1 BODY, FR. UNDER 2 SUB ASSY 1 UR MS1 FOR DPBMC 1WD XF83M 30 P0 BODY, FR. UNDER 2 SUB ASSY 1 UR FOR SMX 1WD XF83M 30 P2 BODY, FR. UNDER 2 SUB ASSY 1 UR WM6 FOR VRC1 8 1WD F EMBLEM 1 UR FOR DPBMC 1WD F EMBLEM 1 UR FOR VRC1 9 1WD F GRAPHIC 4 1 UR FOR DPBMC 1WD F GRAPHIC 4 1 UR FOR SMX 1WD F GRAPHIC 4 1 UR FOR VRC1 10 1WD F GRAPHIC 6 1 UR FOR DPBMC 1WD F GRAPHIC 6 1 UR FOR SMX 1WD F GRAPHIC 6 1 UR FOR VRC A7.NUT, SPRING NUT, SPRING RIVET 1 47

53 FIG. 34 COWLING 1 PART GROMMET WD XF11W 10 P0 COVER 7 1 MBL2(DPBMC,SMX) 1WD XF11W 20 P0 COVER 7 1 MBL2(VRC1) 16 1WD F83GA 00.GRAPHIC, 7 1 FOR VRC A7.NUT, SPRING COLLAR GROMMET GROMMET WD XF11X 10 P0 COVER 8 1 MBL2(DPBMC,SMX) 1WD XF11X 20 P0 COVER 8 1 MBL2(VRC1) 22 1WD F83GB 00.GRAPHIC, 8 1 FOR VRC A7.NUT, SPRING COLLAR GROMMET GROMMET BOLT, WITH WASHER SCREW, TRUSS HEAD TAPPING NUT, FLANGE WASHER PLAIN WD F835U 00 P0 PANEL 1 1 MBL2 32 1WD F835V 00 P0 PANEL 2 1 MBL SCREW, TRUSS HEAD TAPPING NUT, SPRING NUT, SPRING WD F P0 COVER, UNDER 1 MBL BOLT,HEX. SOCKET BUTTON WASHER, PLATE 2 48

54 FIG. 34 COWLING 1 PART COLLAR GROMMET BOLT,HEX. SOCKET BUTTON WD F P0 COVER, UNDER 2 1 MBL BOLT,HEX. SOCKET BUTTON WASHER, PLATE COLLAR GROMMET BOLT,HEX. SOCKET BUTTON WD F833E 00 BRACKET BOLT, FLANGE WD F836K 00 PANEL, INNER WD F836L 00 PANEL, INNER SCREW, TRUSS HEAD TAPPING RIVET WD F836M 00 PANEL, INNER SCREW, TRUSS HEAD TAPPING WD F EMBLEM 2 FOR SMX 49

55 FIG. 35 GENERATOR PART 1 1WD H ROTOR ASSY 1 2 1WD H STATOR ASSY BOLT BOLT, FLANGE R1 WASHER, PLATE KEY, WOODRUFF 1 50

56 FIG. 36 STARTING MOTOR PART 1 1WD H STARTING MOTOR ASSY 1 2 1WD H BRUSH SET 1 3 1WD H GASKET 2 4 1WD H SCREW WD H183G 00.CORD COMP FP H182L 00.O-RING BOLT, FLANGE 2 51

57 FIG. 37 FLASHER LIGHT PART 1 1WD H FRONT FLASHER LIGHT ASSY KB BULB, FLASHER (12V-10W) 1 3 3D9 H SCREW, LENS FITTING 1 4 1KB 8333A 00.LENS COMP WD H FRONT FLASHER LIGHT ASSY KB BULB, FLASHER (12V-10W) 1 7 3D9 H SCREW, LENS FITTING 1 8 1KB 8334A 00.LENS COMP D STAY, FLASHER WD H REAR FLASHER LIGHT ASSY KB BULB, FLASHER (12V-10W) D9 H SCREW, LENS FITTING KB 8334A 00.LENS COMP WD H REAR FLASHER LIGHT ASSY KB BULB, FLASHER (12V-10W) D9 H SCREW, LENS FITTING KB 8333A 00.LENS COMP WD H STAY, FLASHER

58 FIG. 38 METER PART 1 1WD H METER ASSY 1 2 1WD H CASE, SPEEDOMETER UPPER 1 3 1WD H CASE, SPEEDOMETER LOWER SCREW, TAPPING 7 5 1WD H BRACKET, METER GROMMET SCREW, TAPPING WASHER, PLATE BOLT, FLANGE 2 53

59 FIG. 39 HEADLIGHT PART 1 1WD H HEADLIGHT ASSY 1 2 1WD H BULB (12V-55W) 2 3 1WD H HEADLIGHT UNIT ASSY 1 4 1WD H COVER, SOCKET 2 5 1WD H SOCKET CORD ASSY WD H BULB (12V-5W) GROMMET WASHER, PLATE SCREW, TRUSS HEAD TAPPING 4 54

60 FIG. 40 TAILLIGHT PART 1 1WD H TAILLIGHT UNIT ASSY BOLT,HEX. SOCKET BUTTON V1 COLLAR GROMMET NUT, SPRING GROMMET 2 7 1WD F SEAL WD H LICENCE LIGHT ASSY 1 9 1WD H BULB (12V-5W) WD H CORD, LICENCE LIGHT WD H SCREW WD H DAMPER SCREW, TAPPING WASHER, PLATE GROMMET COLLAR 2 55

61 FIG. 41 HANDLE SWITCH & LEVER PART 1 1WD H SWITCH, HANDLE WD H SCREW, FITTING 1 3 1WD H395W 00.SCREW, SWITCH FITTING 1 4 1WD H SWITCH, HANDLE P H SCREW, FITTING P H395W 00.SCREW, SWITCH FITTING CLAMP CLAMP 1 9 1WD H LEVER HOLDER ASSY (LEFT) WD H HOLDER, LEVER WD H LEVER A BOLT, LEVER A COLLAR, LEVER H5.O-RING NUT, U BP H SWITCH SCREW, COUNTERSUNK BOLT NUT BOLT, WITH WASHER PLUG 1 56

62 FIG. 42 ELECTRICAL 1 PART 1 1WD H IGNITION COIL ASSY 2 2 1WD H COVER, IGNITION COIL 1 3 1WD H COVER, IGNITION COIL BOLT, FLANGE 2 5 1WD H PLUG CAP ASSY 2 6 2YD H BATTERY ASSY (GS GTZ8V) 1 7 1WD H PAD, BATTERY 1 8 1WD H BAND, BATTERY 1 9 1WD H WIRE HARNESS ASSY WA DIODE ASSY WP DIODE ASSY WD H RELAY ASSY WD H STARTER RELAY ASSY WD H FUSE (30A-BL) BOLT WD H WIRE, PLUS LEAD WD H WIRE, MINUS LEAD CLAMP CLAMP CLAMP CLAMP WD H MAIN SWITCH STEERING LOCK G4 BOLT WD XH MAIN SW. STRG. LOCK SUB ASSY 1 AP 25 1WD F179E 00 BAND 1 57

63 FIG. 43 ELECTRICAL 2 PART 1 1WD H591A 00 ENGINE CONTROL UNIT ASSY 1 2 1WD H BAND 1 3 1WD H NEUTRAL SWITCH ASSY O-RING SCREW, PAN HEAD P H THERMO UNIT GASKET 1 8 1WD H592A 00 SENSOR, OXYGEN 1 9 1WD H SENSOR, SPEED BOLT WS OIL PRESSURE SWITCH ASSY WD H LEAD WIRE ASSY WD H COVER BOLT, FLANGE WD H RECTIFIER & REGULATOR ASSY BOLT, FLANGE WD H STOP SWITCH ASSY WD H SENSOR, LEAN ANGLE SCREW, ROUND TAPPING WASHER, PLATE B NUT, ADJUSTING WD H RELAY, FLASHER WD H HORN BOLT, FLANGE WD H STAY, HORN BOLT, FLANGE C1 H REAR REFLECTOR ASSY 1 58

64 FIG. 43 ELECTRICAL 2 PART NUT, U WASHER, PLATE 1 59

65 NUMERICAL INDEX PART PART PART PART PART PART 1WD WD WD WD WD WD WD WD WD WD WD WD SL WD WD WD WD WD WD HX F HX H HX K HX M HX R HX U HX W HX Y HX HX HX HX HX HX E HX G HX J HX L HX N HX T WD P NL GL JW A PS WS HG XY VY 1482K H WD WD P WD WS 2331G FV WD WD MT MT MT WD WD WD WD WD WD RB Y 2589H KN X SS KW BP WP WA WS KB D KB 8333A KB 8334A A A HP B AG WS WD E WD E111G WD E WD E WD E WD E YS E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E S0 E PA E WD E WD E WD E WD E WD E WD E S E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E S E WD E WD E WD E P0 E WD E YP E WD E WD E319L WD E WD E WD E WD E WD E WD E WD E WD E P E WD E WD E WD E WD E WD E WD E WD E WD E WD E P E416A WD E WD E WD E WD E WD E B E443E D E443G WD E WD E WD E WD E WD E WD E446C WD E WD E WD E WD E D E WD E WD E WD E473L TP E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E D E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E EG E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E WD E TP E WD E WD F WD F112C WD F113B WD F113J WD F WD F117G WD F117K WD F122A WD F122B WD F WD F135F WD F144G WD F153E WD F153E WD F153E WD F WD F WD F WD F WD F WD F163A WD F163E WD F WD F WD F WD F WD F WD F16A WD F171E WD F171L WD F171M

66 NUMERICAL INDEX PART PART PART PART PART PART 1WD F171N WD F171X WD F172W WD F P WD F P WD F P WD F WD F179E WD F17F WD F17F WD F17F WD F17F WD F17F WD F17F WD F17F WD F17F WD F WD F C1 F WD F WD F WD F191B WD F193A WD F WD F WD F WD F WD F WD F WD F WD F WD F248B WD F WD F WD F WD F P F WD F P F WD F WD F WD F P F P F P F P F P F P F F3158 L WD F WD F B F P F WD F P F BP F BP F WD F WD F WD F P WD F P WD F P WD F412Y WD F P WD F P WD F P WD F413B WD F414E WD F414G D9 F414G P F414H WD F WD F WD F41B1 00 P WD F41B1 00 P WD F WD F WD F WD F WD F WD F C1 F WD F WD F WD F C1 F BP F WD F WD F WD F478E WD F WD F510C WD F X WD F P WD F X WD F P WD F WD F WD F P WD F WD F537W WD F537X WD F PA F WD F WD F WD F539F WD F WD F WD F WD F580E WD F580U WD F580W WD F581U C F582A WD F582E WD F582W TL F WD F WD F VN F C1 F C F C F RW F WD F WD F WD F WD F WD F WD F C F WD F C F589A WD F YP F WD F WD F WD F YP F WD F YP F YP F WD F WD F WD F WD F WD F WD F S7 F622F WD F622H WD F DP F WD F S7 F WD F WD F WD F WD F WD F C F P F WD F WD F WD F WD F WD F WD F WD F WD F WD F WD F WD F WD F WD F WD F WD F B F WD F WD F WD F WD F833E WD F WD F835G WD F835U 00 P WD F835V 00 P PA F836B WD F836K WD F836L WD F836M WD F836N WD F836R WD F D F WD F WD F P WD F WD F WD F WD F WD F WD F WD F WD F WD F WD F P WD F WD F WD F WD F WD F WD F WD F83GA WD F83GB WD F WD F WD F WD H WD H WD H WD H WD H WD H FP H182L WD H183G WD H WD H WD H WD H WD H YD H WD H WD H WD H WD H TL H WD H P H WD H WD H WD H WD H WD H WD H WD H WD H WD H WD H WD H WD H BP H WD H WD H WD H WD H D9 H WD H WD H WD H WD H

67 NUMERICAL INDEX PART PART PART PART PART PART 1WD H WD H WD H WD H WD H P H WD H WD H WD H WD H395W P H395W WD H WD H WD H WD H WD H WD H WD H WD H WD H WD H WD H WD H WD H WD H C1 H WD H WD H WD H591A WD H592A C9 W YP W WD WF WD WF WD XF11W 10 P WD XF11W 20 P WD XF11X 10 P WD XF11X 20 P WD XF P WD XF P WD XF P WD XF P WD XF P WD XF P WD XF P WD XF P WD XF P WD XF83F 10 P WD XF83F 10 P WD XF83F 20 P WD XF83L 20 P WD XF83L 30 P WD XF83L 30 P WD XF83M 20 P WD XF83M 30 P WD XF83M 30 P WD XH F F G G A G F G A R E W J V C C L L N L G A A