YP250 (5SJ2) EUROPE 1A5SJ-300E2 ( 2A5SJ-300E2 )

Transcription

1 YP250 () EUROPE 1A5SJ-300E2 ( 2A5SJ-300E2 )

2 YP250 PARTS CATALOGUE 2002 by Yamaha Motor Co., Ltd. 1st edition, December 2002 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 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 Yamaha Parts News. It is advisable that you make the necessary corrections to the Parts Catalogue according to the Yamaha 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. A5

5 FOREWORD 7. Applicable Serial No. Engine Serial No. Frame Serial No. 8. Applicable Colour Code Abbreviation Colour Name Colour Code DRMD DULL RED METALLIC D 0779 MAS MARBLE SILVER 000L PPBM3 PALE PURPLISH BLUE METALLIC SL SILVER 0035 VDBMA VERY DARK BLUE METALLIC A 0781 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 (3) Model Label Affixing Location (5) Model Code Production Code Number of Model Listed in This Parts Catalogue Model Code Production Code No. Country (destination) 020 BELGIUM 030 SWITZERLAND 060 UNITED KINGDOM 070 GREECE 080 ITALY 090 NETHERLANDS 100 NORWAY 110 PORTUGAL 120 SWEDEN Model Code Production Code No. Country (destination) (4) Colouring Information Model Code Colouring Type Code Colour Code Colour Name Abbreviation A 000L MARBLE SILVER MAS B 0776 PALE PURPLISH BLUE METALLIC 3 PPBM3 C 0779 DULL RED METALLIC D DRMD D 0781 VERY DARK BLUE METALLIC A VDBMA A7

7 CONTENTS ENGINE CYLINDER... B2 CRANKSHAFT. PISTON... B3 VALVE... B4 CAMSHAFT. CHAIN... B5 WATER PUMP... B6 RADIATOR. HOSE... B7 OIL PUMP... B9 INTAKE... B10 CARBURETOR... B11 EXHAUST... B13 CRANKCASE... B15 CRANKCASE COVER 1... C3 STARTER... C5 CLUTCH... C6 TRANSMISSION... C8 CHASSIS FRAME... C9 FENDER... C10 SIDE COVER... C11 REAR ARM. SUSPENSION... C13 STEERING... C14 FUEL TANK... D2 SEAT... D4 FRONT WHEEL... D6 FRONT BRAKE CALIPER... D7 REAR WHEEL... D8 REAR BRAKE CALIPER... D9 STEERING HANDLE. CABLE... D10 FRONT MASTER CYLINDER... D11 STAND. FOOTREST... D12 LEG SHIELD... D14 GENERATOR... E3 STARTING MOTOR... E4 FLASHER LIGHT... E5 METER... E6 HEADLIGHT... E7 TAILLIGHT... E8 HANDLE SWITCH. LEVER... E9 ELECTRICAL 1... E10 ELECTRICAL 2... E12 INDEX NUMERICAL INDEX... M1

8 FIG. 1 CYLINDER 1 5GM CYLINDER HEAD ASSY 1 2 4G GUIDE, INTAKE VALVE CIRCLIP SCREW, HEXAGON GASKET BOLT, STUD BOLT, STUD 2 8 4HC BREATHER ASSY O-RING BOLT, FLANGE GC COVER, CYLINDER HEAD SIDE GC COVER, CYLINDER HEAD SIDE O-RING BOLT, FLANGE NUT, CROWN WASHER, PLATE HC GASKET, CYLINDER HEAD PIN, DOWEL BOLT, FLANGE PLUG, SPARK (NGK DR8EA) HC CYLINDER HC GASKET, CYLINDER PIN, DOWEL HC PIPE, BREATHER CLIP 2 B2

9 FIG. 2 CRANKSHAFT. PISTON 1 5GM CRANKSHAFT ASSY NUT F6 WASHER, PLATE KEY, WOODRUFF 1 5 4HC PISTON (STD) 1 4HC PISTON (0.50MM O/S) 1 AP 4HC PISTON (1.00MM O/S) 1 AP 6 4HC PISTON RING SET (STD) 1 4HC PISTON RING SET (0.50MM O/S) 1 AP 4HC PISTON RING SET (1.00MM O/S) 1 AP 7 4JH PIN, PISTON CLIP 2 B3

10 FIG. 3 VALVE 1 5GM VALVE, INTAKE 1 2 5H VALVE, EXHAUST 1 3 4G SEAT, VALVE SPRING 2 4 4HC SPRING, VALVE INNER 2 5 4HC SPRING, VALVE OUTER 2 6 5H SEAL, VALVE STEM 2 7 4G RETAINER, VALVE SPRING 2 8 4G COTTER, VALVE X ARM, VALVE ROCKER Y SHAFT, ROCKER H SHAFT, ROCKER O-RING NX SCREW, VALVE ADJUSTING NUT 2 B4

11 FIG. 4 CAMSHAFT. CHAIN 1 4HC CAMSHAFT ASSY BEARING BEARING (B6202Z) 1 KOYO 4 4GA 1111F 00 PLATE BOLT WASHER, LOCK 1 7 4HC SPROCKET, CAM CHAIN PIN, DOWEL BOLT WASHER, PLATE KB PLATE, BREATHER CHAIN HC GUIDE, STOPPER HC GUIDE, STOPPER UJ TENSIONER ASSY, CAM CHAIN RF GASKET, TENSIONER CASE BOLT HC BOLT O-RING 1 B5

12 FIG. 5 WATER PUMP 1 5GM WATER PUMP ASSY 1 2 5GM IMPELLER SHAFT ASSY 1 3 4HC COVER, HOUSING 1 4 4HC GASKET, HOUSING COVER BOLT BEARING (B6000) 1 7 4HC HOUSING, WATER PUMP OIL SEAL H SEAL, MECHANICAL CIRCLIP GASKET BOLT, FLANGE O-RING GM SHAFT PIN, DOWEL WASHER, PLATE HC GEAR, IMPELLER SHAFT CIRCLIP HC JOINT O-RING BOLT HC 2637G 00 HOLDER, WIRE BOLT, FLANGE CLAMP 1 B6

13 FIG. 6 RADIATOR. HOSE 1 4HC THERMOSTAT 1 2 4HC COVER, THERMOSTAT BOLT 2 4 5GM RADIATOR ASSY 1 5 5GM BLOWER ASSY BOLT, FLANGE 3 7 4JH CAP, RADIATOR 1 8 4HC SUPT, FILLER NECK BOLT GM PIPE GM PIPE GM PIPE GM PIPE GM PIPE GM PIPE CLIP HOSE CLAMP ASSY CLIP SPRING, COMPRESSION HOSE CLAMP ASSY HC HOSE HC HOSE CLIP BOLT, FLANGE GM STAY BOLT, FLANGE GROMMET 1 B7

14 FIG. 6 RADIATOR. HOSE GROMMET B COLLAR BOLT, WITH WASHER GM THERMO SWITCH ASSY GH THERMO SWITCH ASSY 1 B8

15 FIG. 7 OIL PUMP 1 4HC OIL PUMP ASSY PIN, DOWEL 2 3 4HC GEAR, PUMP DRIVEN PIN, DOWEL WASHER, PLATE CIRCLIP 1 7 4HC GASKET BOLT, BUTTON HEAD Y STRAINER, OIL SPRING, COMPRESSION HC PLUG, DRAIN O-RING 1 B9

16 FIG. 8 INTAKE 1 4HC JOINT, CARBURETOR O-RING E6 BOLT 2 4 4HC JOINT NUT, FLANGE 2 6 4HC CASE, AIR CLEANER GM CAP, CLEANER CASE GM DUCT 1 9 4HC JOINT, AIR CLEANER HC ELEMENT, AIR CLEANER HC PLATE, ELEMENT HC SEAL SCREW, TAPPING HOSE PLUG CLIP GROMMET GM 1441A 00 COVER, CLEANER CASE W3 COLLAR E6 BOLT HOSE CLAMP ASSY GM HOSE CLIP CLAMP 1 B10

17 FIG. 9 CARBURETOR 1 5GM CARBURETOR ASSY GM PILOT SCREW SET THROTTLE SCREW 4 4 4HC THROTTLE SCREW SET 1 5 4HC 1490A 00.DIAPHRAGM SET SCREW, LEVER FITTING 9 7 4HC NEEDLE VALVE ASSY SCREW, BIND N FLOAT KL PIN, FLOAT SCREW, PAN HEAD HC 1490H 08.DIAPHRAGM SET HC COVER, DIAPHRAGM O-RING KL VALVE, CHECK SEAT KL PLUG, DRAIN KL GASKET, FLOAT CHAMBER KL BOOT HC SCREW HC SCREW H O-RING KL GASKET KL O-RING GM 1410A 10.STARTER SET JP PLATE GM 1490J 00.NEEDLE SET HC VALVE ASSY 1 B11

18 FIG. 9 CARBURETOR 28 4HC SPRING UC NOZZLE, MAIN UC NOZZLE, MAIN M JET, MAIN (#128) V JET, PILOT(#43) M PLUG HC PIPE HC PIPE GM PIPE GM SCREW GM CLAMP GM THROTTLE SENSOR ASSY SCREW, PAN HEAD 1 B12

19 FIG. 10 EXHAUST 1 5RB MUFFLER SJ PROTECTOR, MUFFLER BOLT GROMMET 2 5 4BH GASKET, MUFFLER 1 6 5SJ CAP 1 7 5GM PROTECTOR, MUFFLER GM PROTECTER, MUFFLER RB PROTECTER, SILENCER RB PROTECTOR, MUFFLER BOLT RB WASHER, PROTECTOR GM 1482K 00 PLATE GM PIPE, EXHAUST HC PROTECTOR, EXHAUST PIPE BOLT, BUTTON HEAD WASHER BD WASHER, PROTECTOR MT GASKET, EXHAUST PIPE NUT, SELF-LOCKING BOLT, FLANGE GM GASKET GM PIPE GM HOSE, BEND CLIP CLIP BOLT, FLANGE 2 B13

20 FIG. 10 EXHAUST 28 5GM AIR INDUCTION SYSTEM ASSY GM HOSE, BEND GM HOSE, BEND CLIP GM HOSE, VACUUM SENSING CLIP CLIP GM AIR FILTER WASHER, PLATE BOLT, FLANGE NUT, SELF U-FLANGE CLAMP 1 B14

21 FIG. 11 CRANKCASE 1 5GM CRANKCASE ASSY 1 2 4HC HOLDER BUSH, REAR SHOCK ABSORBER J COLLAR O-RING WASHER, PLATE CIRCLIP J8 HOSE (L330) PIN, DOWEL BOLT, FLANGE BOLT, FLANGE OIL SEAL BOLT, STUD BOLT, FLANGE GASKET T PLUG, OIL O-RING GM COVER, CRANKCASE HC GASKET, CRANKCASE COVER PIN, DOWEL BOLT, FLANGE HC COVER BOLT PLUG, STRAIGHT SCREW GASKET GM BRACKET F5 BOLT 4 B15

22 FIG. 11 CRANKCASE 28 5GM SPACER BEARING O-RING 1 C2

23 FIG. 12 CRANKCASE COVER 1 1 5GM COVER, CRANKCASE GM GASKET, CRANKCASE COVER PIN, DOWEL BOLT 8 5 5GM DUCT, AIR 1 6 4HC SEAL, AIR DUCT 1 7 5GM ELEMENT W SEAL SCREW, TAPPING SCREW, PAN HEAD WASHER, PLATE GM COVER, CRANKCASE GM DAMPER, ENGINE MOUNT GM DAMPER, ENGINE MOUNT GM DAMPER GM DAMPER GM DAMPER, ENGINE MOUNT GM PROTECTOR GM PROTECTOR, COVER KJ BOLT GM COVER, CAP HC GASKET OIL SEAL (S HS) PIN, DOWEL BOLT, FLANGE HC PLUG, OIL O-RING 1 C3

24 FIG. 12 CRANKCASE COVER Y PLUG O-RING 1 C4

25 FIG. 13 STARTER 1 4HC GEAR, IDLER HT SHAFT WASHER, PLATE CIRCLIP 1 5 4HC GEAR, IDLER HC STARTER ONE-WAY ASSY BOLT 3 C5

26 FIG. 14 CLUTCH 1 5GM CLUTCH HOUSING COMP NUT 1 3 5GM PRIMARY SLIDING SHEAVE COMP OIL SEAL 2 5 4CW WEIGHT 8 6 4HC CAM 1 7 4HC SLIDER O-RING 1 9 5CG STOPPER SCREW, PAN HEAD HC SPACER E COLLAR R9 WASHER, PLATE M8 WASHER, PLATE CG V-BELT HC SHEAVE, PRIMARY FIXED NUT GM SECONDARY FIXED SHEAVE COMP HC SECONDARY SLIDING SHEAVE OIL SEAL O-RING CW PIN, GUIDE J6 SPRING, COMPRESSION GM SEAT,SPRING GM CLUTCH CARRIER ASSY KD SPRING, CLUTCH WEIGHT CIRCLIP 3 C6

27 FIG. 14 CLUTCH NUT 1 C7

28 FIG. 15 TRANSMISSION 1 5GM AXLE, MAIN 1 2 5GM GEAR, PRIMARY DRIVEN (15T) WASHER, CONICAL SPRING R4 WASHER, PLATE BEARING 2 6 5GM AXLE, DRIVE 1 7 5GM GEAR, 1ST WHEEL (34T) CIRCLIP K5 WASHER, PLATE WASHER, CONICAL SPRING BEARING BEARING OIL SEAL BEARING (B6302) GM GEAR, PRIMARY DRIVE (15T) BEARING OIL SEAL 1 C8

29 FIG. 16 FRAME 1 5GM FRAME COMP CG ENGINE BRACKET COMP HC STAY, ENGINE BOLT, FLANGE A2 WASHER, PLATE NUT, SELF-LOCKING BOLT, FLANGE NUT, SELF-LOCKING BOLT, FLANGE SJ STAY NUT, FLANGE BOLT, FLANGE GM BRACKET, FRONT LOWER BOLT, FLANGE GM BRACKET, FOOTREST BOLT, FLANGE GM BRACKET, FOOTREST BOLT, FLANGE GM PLATE DAMPER GM DAMPER, FOOTREST GM PLATE UF SEAL, CRANKCASE 1 C9

30 FIG. 17 FENDER 1 4HC L FENDER, FRONT 1 UR MAS 4HC PG FENDER, FRONT 1 UR PPBM3 4HC PH FENDER, FRONT 1 UR DRMD 4HC PE FENDER, FRONT 1 UR VDBMA SCREW, BINDING SCREW, BINDING F3 BOLT 2 5 5CG PLUG, BLIND 1 6 5GM FENDER, INNER BOLT, WITH WASHER BOLT, WITH WASHER SCREW, TAPPING NUT, SPRING 1 C10

31 FIG. 18 SIDE COVER 1 5GM L COVER, SIDE 1 1 UR MAS 5GM P7 COVER, SIDE 1 1 UR PPBM3 5GM P8 COVER, SIDE 1 1 UR DRMD 5GM P5 COVER, SIDE 1 1 UR VDBMA SCREW, TAPPING SCREW, TAPPING WASHER, PLATE 1 5 5GM DAMPER, LOCATING GM HOOK 1 7 5GM L COVER, SIDE 2 1 UR MAS 5GM P7 COVER, SIDE 2 1 UR PPBM3 5GM P8 COVER, SIDE 2 1 UR DRMD 5GM P5 COVER, SIDE 2 1 UR VDBMA SCREW, TAPPING SCREW, TAPPING WASHER, PLATE GM DAMPER, LOCATING GM HOOK GM 2171L 00 0L MOLE, SIDE COVER 1 1 UR MAS 5GM 2171L 00 P7 MOLE, SIDE COVER 1 1 UR PPBM3 5GM 2171L 00 P8 MOLE, SIDE COVER 1 1 UR DRMD 5GM 2171L 00 P5 MOLE, SIDE COVER 1 1 UR VDBMA SCREW, TAPPING SCREW, TAPPING GM HOOK GM 2171M 00 0L MOLE, SIDE COVER 2 1 UR MAS 5GM 2171M 00 P7 MOLE, SIDE COVER 2 1 UR PPBM3 C11

32 FIG. 18 SIDE COVER 17 5GM 2171M 00 P8 MOLE, SIDE COVER 2 1 UR DRMD 5GM 2171M 00 P5 MOLE, SIDE COVER 2 1 UR VDBMA SCREW, TAPPING SCREW, TAPPING GM HOOK GM 2171N 00 0L MOLE, SIDE COVER 3 1 UR MAS 5GM 2171N 00 P7 MOLE, SIDE COVER 3 1 UR PPBM3 5GM 2171N 00 P8 MOLE, SIDE COVER 3 1 UR DRMD 5GM 2171N 00 P5 MOLE, SIDE COVER 3 1 UR VDBMA NUT, SPRING EMBLEM, YAMAHA 1 EXCEPT FOR VDBMA EMBLEM, YAMAHA 1 FOR VDBMA 24 5GM TANK, RECOVERY F1 BOLT GROMMET AA CAP AA GASKET GM PIPE GM PIPE CLIP CLIP GM 2173B 00 EMBLEM GM 2173B 00 EMBLEM GM COVER, SIDE SCREW, TAPPING 4 C12

33 FIG. 19 REAR ARM. SUSPENSION 1 5GM REAR ARM ASSY BUSH, REAR SHOCK ABSORBER BOLT, FLANGE OIL SEAL OIL SEAL COLLAR BEARING E1 COLLAR F2 COLLAR GM HOLDER, BRAKE HOSE BOLT, FLANGE GM SHOCK ABSORBER ASSY, REAR BOLT, FLANGE A2 WASHER, PLATE BOLT, FLANGE 2 C13

34 FIG. 20 STEERING 1 5GM FRONT FORK ASSY 1 2 4HC TUBE, OUTER (RIGHT) 1 3 4HC TUBE, OUTER (LEFT) W L0.RING, SNAP 2 5 2UJ OIL SEAL 2 6 4HC METAL, SLIDE UJ SEAL, DUST 2 8 5GM INNER TUBE COMP GM CYLINDER COMP., FRONT FORK HC SPINDLE, TAPER GM UNDER BRACKET COMP SEAL, STEERING GM SPRING, FRONT FORK J O-RING L0.GASKET RB BOLT, CAP BOLT, HEXAGON SOCKET HEAD BOLT, FLANGE W L0.WASHER, OIL SEAL HC CAP, AIR VALVE G RING, SNAP DM WASHER, SPRING UPPER BEARING F RACE, BALL F 2341E 00 RETAINER, BALL BEARING F RACE, BALL NUT 3 C14

35 FIG. 20 STEERING WASHER, PLATE YF WASHER, SPECIAL VP COVER, BALL RACE SJ HOLDER, HANDLE LOWER SJ HOLDER, BRAKE HOSE BOLT, FLANGE KEY, WOODRUFF NUT H HOLDER, HANDLE UPPER 2 LGB BOLT HC HOLDER, BRAKE HOSE BOLT, FLANGE RB HOLDER, CABLE CLAMP 1 C15

36 FIG. 21 FUEL TANK 1 5GM FUEL TANK COMP KJ CAP ASSY BOLT, FLANGE NUT, FLANGE 2 5 5GM PIPE, FUEL CLIP CLIP 1 8 5GM PIPE CLIP CLIP FK FILTER ASSY AE CLAMP, FUEL PIPE BOLT, FLANGE GM BRACKET, FUEL TANK CLAMP BOLT, FLANGE GM 2414A 00 COVER, FILLER SCREW, TAPPING GM 2414G 00 SEAL GM GUIDE, PIPE GROMMET GROMMET GM DAMPER, SIDE COVER GM DAMPER, SIDE COVER CLAMP GM 2414H 00 DAMPER, PLATE GV FUEL PUMP COMP. 1 D2

37 FIG. 21 FUEL TANK 28 5GM BUSH, FULEL PUMP 1 D3

38 FIG. 22 SEAT 1 5SJ SINGLE SEAT ASSY 1 2 5SJ 2470F 20.SEAT COVER COMP GM A0 TANDEM SEAT ASSY 1 4 5GM 2470F B0.SEAT COVER COMP GM DAMPER, SEAT WASHER, PLATE NUT, CROWN 2 8 5GM 2470E 02 BOTTOM PLATE COMP BOLT, HEXAGON SOCKET HEAD COLLAR NUT, SPRING GM PIN GM BOX ASSY HC LIGHT, ACCESORY HC BULB (12V-2W) GM 2839M 00 SEAL, BOX F DAMPER, LOCATING F1 BOLT SCREW, TAPPING PLUG GM 2467E 00 CAP GM BRACKET, SEAT SPACER NUT, FLANGE GM 2177F 00 COVER GM DAMPER, SEAT GM L HANDLE, SEAT 1 UR MAS D4

39 FIG. 22 SEAT 27 5GM P7 HANDLE, SEAT 1 UR PPBM3 5GM P8 HANDLE, SEAT 1 UR DRMD 5GM P5 HANDLE, SEAT 1 UR VDBMA F7 BOLT CAP, BOLT WASHER, PLATE GM 2478G 01 STOPPER CLIP GM GUARD, MUD NUT, SPRING F1 BOLT A DAMPER GM SEAT LOCK ASSY F1 BOLT GM 2478D 01 SEAT LOCK CABLE ASSY SCREW, PAN HEAD GM TOOL KIT KG 2814E 10 HOOK 1 D5

40 FIG. 23 FRONT WHEEL 1 5RB CAST WHEEL, FRONT 1 SL 2 5RB COLLAR, WHEEL BEARING OIL SEAL N TIRE (110/ L MB67/TL) 1 UR INOUE * TIRE (110/ L TL/TT) 1 UR LM MICHELIN VALVE, RIM (TR413) 1 TAIHEIYO 7 5MT BALANCER, WHEEL (10G) 1 UN 5MT BALANCER, WHEEL (20G) 1 UN 5MT BALANCER, WHEEL (30G) 1 UN 8 4HC AXLE, WHEEL R0 COLLAR NUT, SELF-LOCKING RB SENSOR, SPEED CLAMP CLAMP 1 D6

41 FIG. 24 FRONT BRAKE CALIPER 1 4HC 2582T 00 DISC, BRAKE (LEFT) G4 BOLT 6 3 5SJ 2580U 00 CALIPER ASSY (RIGHT) 1 4 5KS W PISTON ASSY, CALIPER 1 5 4FU W CALIPER SEAL KIT 1 6 5JW PIN, SLIDE 2 7 4TT BOOT HM W BRAKE PAD KIT 1 9 4BP SUPPORT, PAD YX SPRING, ANTI RATTLE L W BLEED SCREW KIT BOLT, FLANGE 2 D7

42 FIG. 25 REAR WHEEL 1 5GM CAST WHEEL, REAR 1 SL P TIRE (130/ L MB67/TL) 1 UR INOUE * TIRE (130/ L TL/TT) 1 UR LM MICHELIN VALVE, RIM (TR413) 1 4 5MT BALANCER, WHEEL (10G) 1 UN 5MT BALANCER, WHEEL (20G) 1 UN 5MT BALANCER, WHEEL (30G) 1 UN J8 WASHER, PLATE NUT, SELF-LOCKING 1 7 5GM PLATE, BRAKE SHOE 1 SL 8 5GM BUSH, CAMSHAFT BEARING OIL SEAL GM SEAL, HUB DUST OIL SEAL PLUG GM SPACER 1 D8

43 FIG. 26 REAR BRAKE CALIPER 1 5GM 2582W 00 DISC, REAR BRAKE G4 BOLT 3 3 5GM 2580W 01 CALIPER ASSY, REAR GM W PISTON ASSY, CALIPER 1 5 4TT W CALIPER SEAL KIT 1 6 5GM PIN, SLIDE 2 7 4TT BOOT GM W BRAKE PAD KIT TT SUPPORT, PAD GM W BLEED SCREW KIT EB SHIM, CALIPER GM SHIM, CALIPER BOLT, FLANGE 3 D9

44 FIG. 27 STEERING HANDLE. CABLE 1 5SJ HANDLE COMP YR GRIP (LEFT) 1 3 4YR GRIP ASSY M END, GRIP 2 5 5SJ CABLE, THROTTLE SJ CABLE, THROTTLE CLAMP CLAMP CLAMP, HOSE CLAMP H HOLDER SCREW, PAN HEAD CG REAR VIEW MIRROR ASSY (LEFT) CG REAR VIEW MIRROR ASSY (RIGHT) SJ COVER, HANDLEBAR UPPER SJ COVER, HANDLEBAR LOWER SCREW, TAPPING SCREW, TAPPING SCREW, WITH WASHER NUT, SPRING LV 2836B 01 TUNING FORK MARK 1 D10

45 FIG. 28 FRONT MASTER CYLINDER 1 5RB 2583T 00 MASTER CYLINDER ASSY 1 2 1JL W CYLINDER KIT, MASTER 1 3 3RW DIAPHRAGM, RESERVOIR 1 4 3RW CAP, RESERVOIR SCREW, FLAT HEAD 2 6 3RW BRACKET, MASTER CYLINDER BOLT 2 8 5SJ HOSE, BRAKE HC HOLDER, BRAKE HOSE BOLT, FLANGE L BOOT, MASTER CYLINDER BOLT, UNION WASHER, PLATE CG 2583T A4 MASTER CYLINDER ASSY CG W CYLINDER KIT, MASTER RW DIAPHRAGM, RESERVOIR GY CAP, RESERVOIR Y 2589H 00.SCREW RW BRACKET, MASTER CYLINDER BOLT SJ 2584A 10 BRAKE HOSE ASSY L BOOT, MASTER CYLINDER GM CLAMP CLAMP BOLT, UNION WASHER, PLATE CG WASHER, LOCK 1 D11

46 FIG. 29 STAND. FOOTREST 1 4HC STAND, MAIN 1 2 4HC STOPPER, MAIN STAND 1 3 4HC SHAFT, MAIN STAND CIRCLIP SPRING, TENSION SPRING, TENSION K SHAFT, MAIN STAND CIRCLIP 1 9 5GM STAND, SIDE VR STOPPER, MAIN STAND SPRING, TENSION SPRING, TENSION BOLT NUT, SELF-LOCKING GM BOARD, FOOTREST BOLT, WITH WASHER NUT, SPRING SCREW, TAPPING GM DAMPER, FOOTREST GM DAMPER, FOOTREST GM SEAL GM COVER GM LOCK ASSY SCREW, TAPPING GM 2849E 00 HINGE SCREW, TAPPING SCREW, TAPPING 2 D12

47 FIG. 29 STAND. FOOTREST 28 5GM MAT GM MAT GM COVER GM MOLD, FOOTREST GM MOLD, FOOTREST SCREW, TAPPING GM CAP GM CAP GM COVER GM COVER 2 1 D13

48 FIG. 30 LEG SHIELD 1 5SJ LEG SHIELD ASSY 1 2 5GM DAMPER GM DAMPER GM DAMPER GROMMET J6 COLLAR J0 WASHER, PLATE 1 8 5GM 2835U 02 PANEL KJ SCREW CLAMP HC HINGE SCREW, TAPPING G5 HOSE (L10) NUT, SPRING BOLT, WITH WASHER SCREW, TAPPING SCREW, TAPPING SCREW, TAPPING GM DAMPER GM 2839K 00 LID SJ 2478A 00 LID ASSY SJ DAMPER RIVET GM 2837G 00 LOCK BH LOCK ASSY GM 2837H 00 LOCK SCREW, TAPPING 1 D14

49 FIG. 30 LEG SHIELD 28 5SJ 2836K 00 PANEL, INNER NUT, SPRING GM 2836T 00 DAMPER, LOCATING SCREW, TAPPING GM L BODY, COWLING 1 UR MAS 5GM P7 BODY, COWLING 1 UR PPBM3 5GM P8 BODY, COWLING 1 UR DRMD 5GM P5 BODY, COWLING 1 UR VDBMA 33 5GM 2836B 01 TUNING FORK MARK NUT, SPRING NUT, SPRING NUT BOLT, WITH WASHER NUT, FLANGE WASHER, PLATE GROMMET N5 COLLAR SCREW, TAPPING GM 2836L 00 PANEL, INNER SCREW, TAPPING GM WINDSCREEN ASSY GM 2838B 00.GRILL ASSY GM TAPE NUT, SPRING GM TRIM GM 2834E 00.DAMPER GM 2834F 00.DAMPER 1 D15

50 FIG. 30 LEG SHIELD SCREW, ROUND HEAD GM L MOLE 1 1 UR MAS 5GM P7 MOLE 1 1 UR PPBM3 5GM P8 MOLE 1 1 UR DRMD 5GM P4 MOLE 1 1 UR VDBMA 54 5GM HOOK GM MOLE SCREW, TAPPING 2 E2

51 FIG. 31 GENERATOR 1 5GM STATOR ASSY 1 2 5GM ROTOR ASSY BOLT BOLT 2 E3

52 FIG. 32 STARTING MOTOR 1 4HC MOTOR ASSY 1 2 3KS BRUSH HOLDER ASSY 1 3 3WP BOLT H GASKET 2 5 1FK O-RING 1 6 5GM CORD, STARTER MOTOR 1 7 4XV 8182A 00 NUT BOLT, FLANGE 2 E4

53 FIG. 33 FLASHER LIGHT 1 5GM FRONT FLASHER LIGHT ASSY GM LENS, FLASHER H BULB, FLASHER (12V-21W) 1 4 5GM GASKET, FLASHER LENS 1 5 5GM FRONT FLASHER LIGHT ASSY GM LENS, FLASHER H BULB, FLASHER (12V-21W) 1 8 5GM GASKET, FLASHER LENS SCREW, TAPPING 4 E5

54 FIG. 34 METER 1 5SJ SPEEDOMETER ASSY 1 UR 5SJ SPEEDOMETER ASSY 1 UR FOR GBR 2 5SJ SPEEDOMETER ASSY 1 UR 5SJ SPEEDOMETER ASSY 1 UR FOR GBR 3 5SJ 8350F 00.FUEL METER MOVEMENT ASSY 1 4 5SJ LENS, SPEEDOMETER 1 5 5SJ COVER, METER PANEL 1 6 5SJ 8353H 00.CASE, UNDER 1 7 4HC CLAMP 1 8 5EA 8352K 00.PLUG, BLIND 1 9 5SJ SOCKET CORD ASSY YT BULB (12V-1.7W T10) R BULB (12V-3.4W T10) SCREW,WITH WASHER SCREW, TAPPING GM SCREW, TAPPING GG 8352K 00.PLUG, BLIND SCREW, TAPPING HC 2837G 00 LOCK 1 2 E6

55 FIG. 35 HEADLIGHT 1 5GM HEADLIGHT UNIT ASSY 1 UR 5GM HEADLIGHT UNIT ASSY 1 UR FOR GBR 2 4SV BULB (12V-55W) 1 (H7)HALOGEN 3 8G BULB (12V-60/55W) 1 (H4)HALOGEN SCREW, TAPPING 5 5 4SV SOCKET CORD ASSY SV BULB (12V-5W) 1 7 4XV SOCKET CORD ASSY GM COVER, SOCKET BOLT, WITH WASHER 4 E7

56 FIG. 36 TAILLIGHT 1 5SJ TAILLIGHT UNIT ASSY 1 2 1A BULB (12V-21/5W) 2 3 5GM BULB (12V-18W) 2 4 4HC BULB (12V-5W) SCREW, TAPPING 2 6 3Y REAR REFLECTOR ASSY NUT, FLANGE 1 8 4HC LENS, LICENCE LIGHT 1 9 4HC GASKET, LENS SJ CORD ASSY NUT, SPRING F1 BOLT 2 E8

57 FIG. 37 HANDLE SWITCH. LEVER 1 5CG LEVER SCREW, HEXAGON NUT SPRING, COMPRESSION BOLT NUT, U 1 7 4FU FRONT STOP SWITCH ASSY 1 8 5SJ SWITCH, HANDLE SCREW, PAN HEAD SJ SWITCH, HANDLE SCREW, PAN HEAD CLAMP CG LEVER SCREW, HEXAGON NUT SPRING, COMPRESSION BOLT NUT, U FU FRONT STOP SWITCH ASSY 1 E9

58 FIG. 38 ELECTRICAL 1 1 4UC BATTERY (GS GT7B-4) 1 2 5GM WIRE, PLUS LEAD 1 3 5GM WIRE, MINUS LEAD 1 4 4DN STARTER RELAY ASSY 1 5 1AE FUSE (30A-BL) BOLT, FLANGE 2 7 4XY RECTIFIER & REGULATOR ASSY SCREW, PAN HEAD WASHER, PLATE SJ WIRE HARNESS ASSY WP DIODE ASSY WA DIODE ASSY JJ FUSE (4A-BL) JJ FUSE (15A-BL) JJ FUSE (7.5A-BL) JJ FUSE (10A-BL) CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP CLAMP RT SWITCH, SIDE STAND SCREW, PAN HEAD SJ MAIN SWITCH STEERING LOCK 1 E10

59 FIG. 38 ELECTRICAL SJ CAP, SWITCH A7 BOLT HC RELAY ASSY U RELAY ASSY GM SWITCH ASSY SCREW, BIND Y CLAMP Y CLAMP CLAMP 1 E11

60 FIG. 39 ELECTRICAL 2 1 5SJ IGNITOR UNIT ASSY BOLT, FLANGE 2 3 4BP PLUG CAP ASSY X THERMO UNIT 1 5 4HC IGNITION COIL ASSY SCREW, PAN HEAD WASHER, PLATE 2 8 3TB HORN 1 9 5GM HORN BOLT, FLANGE GM FLASHER RELAY ASSY GM SENDER UNIT ASSY, FUEL METER JG RETAINER US GASKET, SENDER UNIT BOLT, WITH WASHER GM WIRE, SUB LEAD 1 17 JT THERMISTOR ASSY CLAMP SJ TUBE CLAMP 1 E12

61 NUMERICAL INDEX GRID GRID GRID GRID GRID GRID 5GM B 2 4GA 1111F 00 B 5 4G B 2 4KB B 5 4HC B 2 4HC B 2 4HC B 2 3GC B 2 3GC B 2 4HC B 2 4HC B 2 5GM B 3 4HC B 3 4HC B 3 4HC B 3 4HC B 3 4JH B 3 4HC B 3 4HC B 3 5GM B 4 4HC B 4 4HC B 4 4G B 4 4G B 4 4G B 4 5H B 4 5H B 4 5H B 4 36X B 4 3Y B 4 4HC B 5 2NX B 4 4HC B 5 4HC B 5 2UJ B 5 4RF B 5 4HC B 5 4HC B 5 5GM B 7 4HC B 7 4HC B 7 5GM B 6 4HC B 6 4HC B 6 5GM B 6 4HC B 6 11H B 6 5GM B 7 4HC B 6 5GM B 6 4HC B 6 5GM B 7 4JH B 7 5GM B 7 5GM B 7 5GM B 7 5GM B 7 5GM B 7 5GM B 7 5Y E 11 4HC B 7 4HC B 7 4HC B 7 4HC B 9 4HC B 9 51Y B 9 4HC B 9 5GM B 14 4HC B 10 4HC B 10 2GV D 2 4HC B 11 5GM B 11 5GM 1410A 10 B 11 4KL B B 11 4HC B 12 4HC B 12 5GM B 12 5GM B 12 4JP B 11 4KL B 11 4HC B 12 5GM B 10 5GM B 11 4HC B 11 4UC B 12 4UC B 12 38V B 12 50M B 12 50M B 12 4KL B 11 25N B 11 4KL B 11 4HC B 11 4KL B 11 5H B 11 4KL B 11 4HC B 10 5GM B 10 5GM 1441A 00 B 10 4HC B 11 5GM B 10 4HC B 10 4HC B 10 4HC B 10 17W C 3 4HC B 10 4KL B 11 5GM B 12 4HC B 11 5GM B 13 3MT B 13 4HC B 13 5RB B 13 4BH B 13 5SJ B 13 5GM B 13 5GM B 13 5RB B 13 5RB B 13 4BD B 13 5RB B 13 5SJ B 13 5GM B 14 5GM B 14 5GM B 13 5GM 1482K 00 B 13 5GM B 13 5GM B 13 5GM B 14 5GM B 14 4HC 1490A 00 B 11 4HC 1490H 08 B 11 5GM 1490J 00 B 11 4HC B 11 5GM B 15 36Y C 4 5GM B 15 5GM C 3 5GM C 3 5GM C 3 5GM C 3 5GM C 3 4HC B 9 2T B 15 4HC C 3 4HC B 15 1UF C 9 5GM C 3 5GM C 3 5GM C 3 5GM B 15 5GM C 3 5GM C 3 4HC C 3 4HC B 15 5GM C 3 4HC C 3 3KJ C 3 5GM C 3 4HC B 15 5GM C 3 4HC C 5 4HC C 5 2HT C 5 4HC C 5 5GM C 8 5GM C 8 5GM C 6 5GM C 6 5KD C 6 5GM C 8 5GM C 8 5GM C 8 4HC C 6 5GM C 6 4HC C 6 4CW C 6 5CG C 6 5CG C 6 5GM C 6 5GM C 2 4HC C 6 4HC C 6 5GM C 6 4CW C 6 4HC C 6 5GM C 9 5CG C 10 5GM C 9 5CG C 9 4HC C 9 4HC L C 10 4HC PE C 10 4HC PG C 10 4HC PH C 10 5GM C 10 5GM D 5 5A D 5 5GM L C 11 5GM P5 C 11 5GM P7 C 11 5GM P8 C 11 5GM 2171L 00 0L C 11 5GM 2171L 00 P5 C 11 5GM 2171L 00 P7 C 11 5GM 2171L 00 P8 C 11 5GM 2171M 00 0L C 11 5GM 2171M 00 P5 C 12 5GM 2171M 00 P7 C 11 5GM 2171M 00 P8 C 12 5GM 2171N 00 0L C 12 5GM 2171N 00 P5 C 12 5GM 2171N 00 P7 C 12 5GM 2171N 00 P8 C 12 5GM L C 11 5GM P5 C 11 5GM P7 C 11 5GM P8 C 11 5GM C 12 5GM 2173B 00 C 12 5GM C 11 5GM C 11 5GM 2177F 00 D 4 5GM D 12 4BH D 14 4HC D 14 1AA C 12 5GM C 12 5GM C 12 5GM C 12 1AA C 12 5GM C 13 5GM C B 15 C 13 5GM C 14 5GM C 14 5RB C 14 3J C 14 4HC C 14 4HC C 14 4HC C 14 5GM C 14 2UJ C 14 2UJ C 14 22W L0 C 14 3DM C 14 22W L0 C L0 C 14 5GM C 14 4HC C C 14 3G C 14 4HC C 14 5RB C 15 5GM C 14 22F C 14 22F C 14 3VP C 15 3YF C 15 22F 2341E 00 C 14 4H C 15 5SJ C C D 5 5GM D 2 5GM D 2 5GM D 2 5GM 2414A 00 D 2 5GM 2414G 00 D 2 5GM 2414H 00 D 2 22F D 4 5GM D 2 5GM D 2 5GM D 2 1AE D 2 3KJ D 14 5GM D B 11 1FK D 2 3KJ D 2 5GM D 2 5GM 2467E 00 D 4 5GM D 4 5GM 2470E 02 D 4 5SJ 2470F 20 D 4 M1

62 NUMERICAL INDEX GRID GRID GRID GRID GRID GRID 5GM 2470F B0 D 4 5SJ D 4 5GM D 4 5GM D 4 5GM D 4 5GM A0 D 4 5GM L D 4 5GM P5 D 5 5GM P7 D 5 5GM P8 D 5 5GM D 4 5GM D 5 5SJ 2478A 00 D 14 5GM 2478D 01 D 5 5GM 2478G 01 D 5 5RB D 6 4HC D 6 5GM D 8 5GM D 8 5GM D 8 5GM D 8 5RB D 6 5MT D 6 D 8 5MT D 6 D 8 5MT D 6 D 8 5GM D 8 5SJ 2580U 00 D 7 5GM 2580W 01 D 9 5EB D 9 5GM D 9 4HC 2582T 00 D 7 5GM 2582W 00 D 9 5RB 2583T 00 D 11 5CG 2583T A4 D 11 5CG D 11 5SJ 2584A 10 D 11 3RW D 11 4GY D 11 3RW D 11 4L D 11 3RW D 11 5SJ D 11 5GM C 13 4HC C 15 4HC D 11 5SJ C 15 36Y 2589H 00 D 11 5GM D 9 5JW D 7 4BP D 7 4TT D 9 3YX D 7 4TT D 7 D 9 5SJ D 10 5SJ D 10 5SJ D 10 4YR D 10 4YR D 10 33M D 10 5CG D 10 5CG D 10 5SJ D 10 5SJ D 10 4HC 2637G 00 B 6 5H D 10 4HC D 12 4HC D 12 58K D 12 3VR D 12 4HC D 12 5GM D 12 5GM D 12 5GM C 9 5GM C 9 D 12 5GM C 9 5GM C 9 5GM D 12 5GM C 9 5GM D 13 5GM D 13 5GM D 13 5GM D 12 5GM D 13 5GM D 13 5GM D 13 5GM D 12 5GM D 13 5GM D 13 5GM D 13 5GM D 5 4KG 2814E 10 D 5 5SJ D 14 5GM D 15 5GM L E 2 5GM P4 E 2 5GM P7 E 2 5GM P8 E 2 5GM E 2 5GM 2834E 00 D 15 5GM 2834F 00 D 15 5GM L D 15 5GM P5 D 15 5GM P7 D 15 5GM P8 D 15 5SJ C 9 5GM 2835U 02 D 14 5GM 2836B 01 D 15 5LV 2836B 01 D 10 5SJ 2836K 00 D 15 5GM 2836L 00 D 15 5GM 2836T 00 D 15 5GM D 14 5SJ D 14 5GM D 15 5GM C 11 E 2 4HC 2837G 00 E 6 5GM 2837G 00 D 14 5GM 2837H 00 D 14 5GM D 15 5GM 2838B 00 D 15 5GM 2839K 00 D 14 5GM 2839M 00 D 4 5GM D 14 5GM D 14 5GM D 14 5GM 2849E 00 D 12 5GM E 3 5GM E 3 5GM D 11 5GM E 4 3WP E 4 4XV 8182A 00 E 4 3KS E 4 11H E 4 1FK E 4 5GM E 11 4HC E 4 4DN E 10 4HC E 11 29U E 11 4XY E 10 3WP E 10 4WA E 10 4UC E 10 5GM E 10 5GM E 10 1AE E 10 5JJ E 10 5JJ E 10 5JJ E 10 5JJ E 10 5SJ E 12 4HC E 12 4BP E 12 5SJ E 10 5GM E 12 5SJ E 11 5GH B 8 5GM B 8 5RT E 10 5SJ E 10 5GM E 5 5GM E 8 5GM E 5 5GM E 5 5GM E 5 5GM E 5 32H E 5 3GM E 12 3TB E 12 5GM E 12 5SJ E 6 5SJ E 6 5SJ E 6 5SJ 8350F 00 E 6 5SJ E 6 5SJ E 6 5SJ E 6 1YT E 6 4R E 6 2GG 8352K 00 E 6 5EA 8352K 00 E 6 5SJ E 12 5SJ 8353H 00 E 6 46X E 12 4HC E 6 5SJ E 6 5GM E 6 5RB D 6 5CG E 9 5CG E 9 5SJ E 9 5SJ E 9 4FU E 9 5GM E 7 5GM E 7 4XV E 7 4SV E 7 8G E 7 4HC D 4 4SV E 7 4SV E 7 5GM E 7 4HC E 8 5SJ E 8 1A E 8 5SJ E 8 4HC E 8 4HC E 8 4HC D 4 3Y E 8 JT E 12 5GM E 12 4US E 12 2JG E 12 5GM B 12 1JL W D 11 5CG W D 11 4HM W D 7 5GM W D 9 4FU W D 7 4TT W D 9 51L W D 7 5GM W D 9 5GM W D 9 5KS W D B C C D 7 D C F3 C F1 C F1 D 4 E E A7 E E6 B F5 B G4 D 7 D F7 D D D B B B E C E C 10 D D B D E C E B C C E D C C 11 D 10 D D E B B C C D B D C C D D C 10 M2

63 NUMERICAL INDEX GRID GRID GRID GRID GRID GRID C 12 D 4 D 10 D 12 D 15 E D D C C D D R9 C C D 4 D B B 6 B B J0 D D D B A2 C 9 C C M8 C R4 C F6 B B J8 D K5 C C C C B D C B B D D B W3 B D J6 D N5 D B B J B R0 D C E1 C F2 C E C D B 2 B B B G5 D J8 B B B B D E C 15 D D 2 E D D E E B B E E E D 10 E D 14 E E D B E D D B C B B 10 C B D B D B B B B B B B D C D B D D B B B E B B J6 C D D D D D E B 5 B B B D E B C C B B E B C 3 E B C C D D C B C C C C 13 D B B B B 6 B C C C B B B C B B C B B B C C C C 13 D 6 D C C C C D B B B 6 B B D D N D P D B B B E D E B B B C B B B B 15 C E B B B B E D B 10 D C 9 D B B 7 E C 9 C B B 13 D C C E B C C B C D C C B B E E E D E D 12 D C 11 D 2 D 13 D E C 10 C 11 D 4 D 12 D 14 E B B B B D D E E E C E D B E D B B C B C B C C C B 2 B 15 C B 2 M3