XP500A (2PWC) EUROPE,SOUTH AFRICA 1P2PW-300EV

Transcription

1 XP500A () EUROPE,SOUTH AFRICA 1P2PW-300EV ( )

2 XP500A PARTS CATALOGUE 2014 by Yamaha Motor Co., Ltd. 1st edition, October 2014 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. Engine Serial No. Frame Serial No. 8. Applicable Colour Code (The (*) mark shows Model colour.) Abbreviation Colour Name Colour Code DNMS(*) DARK GRAY METALLIC S 1478 MBL2 MAT BLACK MNM3 MAT GRAY METALLIC

5 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 (4) Colouring Information Model Code Colouring Type Code Colour Code Colour Name Abbreviation A 1478 DARK GRAY METALLIC S DNMS (5) Model Code Production Code Number of Model Listed in This Parts Catalogue Model Code Production Code No. 010 Country (destination) AUSTRIA CZECHO FRANCE GERMANY HUNGARY ITALY SLOVAK SPAIN SWITZERLAND CYPRUS FINLAND GREECE IRELAND 050 POLAND SLOVENIA SOUTH AFRICA TURKEY 060 UNITED KINGDOM Model Code Production Code No. Country (destination)

6 CONTENTS ENGINE CYLINDER... 1 CRANKSHAFT & PISTON... 3 VALVE... 5 CAMSHAFT & CHAIN... 7 WATER PUMP... 8 RADIATOR & HOSE... 9 OIL PUMP INTAKE INTAKE EXHAUST CRANKCASE CRANKCASE COVER CRANKCASE COVER STARTER CLUTCH CLUTCH TRANSMISSION CHASSIS FRAME FENDER SIDE COVER SIDE COVER REAR ARM & SUSPENSION STEERING FRONT FORK FUEL TANK SEAT SEAT FRONT WHEEL FRONT BRAKE CALIPER REAR WHEEL REAR BRAKE CALIPER STEERING HANDLE & CABLE FRONT MASTER CYLINDER STAND & FOOTREST STAND & FOOTREST LEG SHIELD WINDSHIELD GENERATOR FLASHER LIGHT METER HEADLIGHT TAILLIGHT HANDLE SWITCH & LEVER ELECTRICAL ELECTRICAL ELECTRICAL INDEX NUMERICAL INDEX... 73

7 FIG. 1 CYLINDER PART 1 59C CYLINDER HEAD ASSY 1 2 5NL GUIDE, VALVE BOLT, FLANGE PIN, DOWEL BOLT, FLANGE GASKET BOLT, STUD BOLT, STUD PIN, DOWEL P4 WASHER, PLATE NUT NUT, CROWN BOLT, HEXAGON SOCKET HEAD BOLT, HEXAGON SOCKET HEAD PLUG, SPARK (NGK CR7E) C GASKET, CYLINDER HEAD C COVER, CYLINDER HEAD GJ GASKET C PIPE, BREATHER CLIP CLIP C GASKET, HEAD COVER PIN, DOWEL BOLT C CYLINDER C GASKET, CYLINDER PIN, DOWEL 2 1

8 FIG. 1 CYLINDER PART 28 4H PLUG O-RING PS THERMOSENSOR ASSY GASKET 1 2

9 FIG. 2 CRANKSHAFT & PISTON PART 1 59C CRANKSHAFT ASSY C CONNECTING ROD ASSY 2 3 5VU BOLT, CONNECTING ROD NUT 2 5 5GJ PLANE BEARING, CONNECTING ROD 4 UR BLUE 5GJ PLANE BEARING, CONNECTING ROD 4 UR BLACK 5GJ PLANE BEARING, CONNECTING ROD 4 UR BROWN 5GJ PLANE BEARING, CONNECTING ROD 4 UR GREEN 6 59C CONNECTING ROD ASSY 1 7 4X BOLT, CONNECTING ROD NUT 2 9 5GJ PLANE BEARING, CONNECTING ROD 2 UR BLUE 5GJ PLANE BEARING, CONNECTING ROD 2 UR BLACK 5GJ PLANE BEARING, CONNECTING ROD 2 UR BROWN 5GJ PLANE BEARING, CONNECTING ROD 2 UR GREEN 10 5GJ PLANE BEARING, CRANKSHAFT 1 1 UR BLUE 5GJ PLANE BEARING, CRANKSHAFT 1 1 UR BLACK 5GJ PLANE BEARING, CRANKSHAFT 1 1 UR BROWN 5GJ PLANE BEARING, CRANKSHAFT 1 1 UR GREEN 5GJ PLANE BEARING, CRANKSHAFT 1 1 UR YELLOW 5GJ A0 PLANE BEARING, CRANKSHAFT 1 1 UR WHITE 11 5GJ PLANE BEARING, CRANKSHAFT 2 1 UR BLUE 5GJ PLANE BEARING, CRANKSHAFT 2 1 UR BLACK 5GJ PLANE BEARING, CRANKSHAFT 2 1 UR BROWN 5GJ PLANE BEARING, CRANKSHAFT 2 1 UR GREEN 5GJ PLANE BEARING, CRANKSHAFT 2 1 UR YELLOW 5GJ A0 PLANE BEARING, CRANKSHAFT 2 1 UR WHITE 3

10 FIG. 2 CRANKSHAFT & PISTON PART 12 59C PISTON (STD) P PISTON RING SET (STD) SL PIN, PISTON CIRCLIP C A0 PISTON 2 (STD) GJ SHAFT CIRCLIP C SLEEVE, CYLINDER BOLT,HEX. SOCKET BUTTON PIN, DOWEL NUT COLLAR KEY, WOODRUFF BEARING OIL SEAL OIL SEAL 1 4

11 FIG. 3 VALVE PART 1 59C VALVE, INTAKE C VALVE, EXHAUST 4 3 8GC SEAT, VALVE SPRING C SPRING, VALVE INNER 8 5 3TJ RETAINER, VALVE SPRING 8 6 1HX LOCK, VALVE SPRING RETAINER TV SEAL, VALVE STEM 8 8 1HX PAD, ADJUSTING 2 (1.20) 8 UR 1HX PAD, ADJUSTING 2 (1.25) 8 UR 1HX PAD, ADJUSTING 2 (1.30) 8 UR 1HX PAD, ADJUSTING 2 (1.35) 8 UR 1HX PAD, ADJUSTING 2 (1.40) 8 UR 1HX A0 PAD, ADJUSTING 2 (1.45) 8 UR 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 5

12 FIG. 3 VALVE PART 8 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 5EB LIFTER, VALVE 8 UR YELLOW 5EB LIFTER, VALVE (O/S) 8 AP GREEN 6

13 FIG. 4 CAMSHAFT & CHAIN PART 1 59C CAMSHAFT ASSY C CAMSHAFT ASSY CHAIN 1 4 2PW TENSIONER ASSY, CAM CHAIN B GASKET, TENSIONER CASE BOLT C DAMPER, CHAIN GJ DAMPER, CHAIN BOLT, HEXAGON SOCKET HEAD 2 7

14 FIG. 5 WATER PUMP PART 1 59C WATER PUMP ASSY 1 2 5VU HOUSING, WATER PUMP BEARING OIL SEAL 1 5 5VK SEAL, MECHANICAL S IMPELLER SHAFT ASSY 1 7 5GJ COVER, HOUSING 1 8 1WG O-RING BOLT CIRCLIP O-RING M83 BOLT, WITH WASHER C STOPPER B PIPE C PIPE O-RING BOLT, HEXAGON WASHER, PLATE 2 8

15 FIG. 6 RADIATOR & HOSE PART 1 59C PIPE HOSE CLAMP ASSY CLIP 1 4 4JH THERMOSTAT ASSY 1 5 4B COVER, THERMOSTAT BOLT, FLANGE C PIPE BOLT, FLANGE 1 9 2PW RADIATOR COMP VU COCK, DRAIN PW BLOWER ASSY S BOLT, BLOWER HOLDING SL NUT C DAMPER, C DAMPER GROMMET L7 COLLAR C PIPE PW PIPE PW PIPE SL CAP, RADIATOR GJ SUPT, FILLER NECK RIVET C 1243A 01 HOSE PW 1243E 00 HOSE CLIP CLIP 1 9

16 FIG. 6 RADIATOR & HOSE PART A6 CLIP CLIP CLIP C HOSE PW HOSE CLAMP CLAMP 1 10

17 FIG. 7 OIL PUMP PART 1 59C OIL PUMP ASSY BOLT, BUTTON HEAD 3 3 5GJ PIPE, DELIVERY O-RING BOLT, HEXAGON SOCKET HEAD 1 6 5GJ GASKET CHAIN (DID25 58L) 1 8 5GJ OIL PIPE COMP O-RING GJ STRAINER HOUSING ASSY O-RING BOLT, HEXAGON SOCKET HEAD F STRAINER, OIL LD SEAT, CHECK BALL BALL F9 SPRING, COMPRESSION GJ OIL COOLER ASSY JW O-RING BOLT, UNION DM ELEMENT ASSY, OIL CLEANER G RELIEF VALVE ASSY O-RING 1 11

18 FIG. 8 INTAKE PART 1 59C INTAKE MANIFOLD ASSY C JOINT, INTAKE HOSE CLAMP ASSY C PIPE M CAP 1 6 8FP RUBBER, INJECTOR GASKET B BOLT C INJECTOR PS O-RING C GASKET, MANIFOLD BOLT, HEXAGON SOCKET HEAD HOSE HOSE CLAMP ASSY B CASE, AIR CLEANER PW CAP, CLEANER CASE C SEAL SCREW, TAPPING C 1441A 01 COVER, CLEANER CASE B SEAL C FUNNEL C DUCT C 1443A 00 DUCT B ELEMENT, AIR CLEANER PLUG HOSE CLAMP ASSY C HOSE

19 FIG. 8 INTAKE PART CLIP A2 CLIP C 1243F 00 HOSE, A2 CLIP C 1244G 00 HOSE, A2 CLIP 2 13

20 FIG. 9 INTAKE 2 PART 1 59C THROTTLE BODY ASSY 1 2 8GL THROTTLE SENSOR ASSY 1 3 8CC SCREW 2 4 5VX ADJUST SCREW SET 1 5 5JW AIR SCREW SET 2 6 4BH SPRING, AIR ADJUSTING 1 7 1S PLUNGER 1 14

21 FIG. 10 EXHAUST PART 1 59C MUFFLER C 1471M 00.BRACKET, BOLT WASHER, PLAIN 2 5 4B5 1465R 00 PLATE, PROTECTOR VU 1465T 00 PLATE, PROTECTOR VU 1465U 00 PLATE, PROTECTOR C CAP C STAY, PROTECTOR GROMMET BOLT,HEX. SOCKET BUTTON GROMMET COLLAR G3 WASHER, PLATE SCREW, BIND Y DAMPER, FOOTREST COLLAR B PROTECTOR, MUFFLER W DAMPER, LOCATING C 8592A 00 SENSOR, OXYGEN B PROTECTOR, MUFFLER C PROTECTOR, MUFFLER NUT, FLANGE C 1465V 01 PLATE, PROTECTOR C PROTECTOR, MUFFLER BR GASKET, EXHAUST PIPE NUT 4 15

22 FIG. 10 EXHAUST PART WASHER, PLATE BOLT, FLANGE NUT, CROWN 1 16

23 FIG. 11 CRANKCASE PART 1 59C CRANKCASE ASSY PIN, DOWEL BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE B BOLT GASKET O-RING 1 9 4H PLUG O-RING BOLT, FLANGE GASKET 1 17

24 FIG. 12 CRANKCASE COVER 1 PART 1 59C COVER, CRANKCASE H GAUGE, LEVEL C COVER GJ COVER, CAP SCREW 3 6 5GJ GASKET PIN, DOWEL BOLT, FLANGE Y PLUG O-RING GJ GASKET, CRANKCASE COVER PIN, DOWEL BOLT, FLANGE GJ PLUG, OIL O-RING C COVER, GENERATOR GJ GROMMET PW BOLT C DAMPER C DAMPER GJ PROTECTOR, COVER C DAMPER PW BOLT

25 FIG. 13 CRANKCASE COVER 2 PART 1 59C ELEMENT BOLT, FLANGE C DUCT, AIR HOSE CLAMP ASSY HOSE CLAMP ASSY 1 6 5GJ SEAL, AIR DUCT B PLATE C COVER, CRANKCASE GJ PLATE BOLT, BUTTON HEAD C COVER, CRANKCASE C GASKET, CRANKCASE COVER PIN BOLT, FLANGE BOLT, FLANGE C BOLT NUT, CROWN BOLT, FLANGE C GUIDE, CABLE B COVER GJ 1542A 00 DAMPER PW BOLT C COVER C DAMPER C ELEMENT U SEAL C DAMPER

26 FIG. 13 CRANKCASE COVER 2 PART 28 59C 1542B 10 DAMPER PW BOLT GJ PROTECTOR, COVER C DAMPER PW BOLT

27 FIG. 14 STARTER PART 1 22U GEAR, IDLER 1 (12T/50T) Y SHAFT WS STARTER ONE-WAY ASSY 1 4 5GJ GEAR, IDLER WASHER, PLATE BOLT, HEXAGON SOCKET HEAD 3 7 4B MOTOR ASSY 1 8 4B BRUSH HOLDER ASSY 1 9 4B BOLT B GASKET FK O-RING TB O-RING XV 8182A 00.NUT C CORD, STARTER MOTOR XV 8182A 00 NUT BOLT, FLANGE 2 21

28 FIG. 15 CLUTCH PART 1 5VU PRIMARY DRIVE GEAR ASSY BEARING A9 WASHER, PLATE (2.05T) COLLAR C BOSS, CLUTCH NUT C HOUSING, CLUTCH 1 8 5GJ ROLLER WEIGHT ASSY GJ PLATE, THRUST WEIGHT GJ SPRING, CLUTCH C PLATE, FRICTION C PLATE, CLUTCH C PLATE, CLUTCH C SPRING GJ PRESSURE PLATE ASSY GJ SPRING, CLUTCH GJ PLATE, SPRING STOPPER 1 UR (HOLE 0) 5GJ PLATE, SPRING STOPPER 1 UR (HOLE 1) 5GJ PLATE, SPRING STOPPER 1 UR (HOLE 2) 5GJ PLATE, SPRING STOPPER 1 UR (HOLE 3) 18 5GJ CLIP WASHER, PLATE NUT 1 22

29 FIG. 16 CLUTCH 2 PART BEARING C W PRIMARY SLIDING SHEAVE ASSY OIL SEAL 2 4 5RU WEIGHT C CAM C SLIDER C V-BELT C SHEAVE, PRIMARY FIXED C SPACER O-RING BEARING XM PLATE, BEARING COVER SCREW, COUNTERSUNK NUT C SECONDARY FIXED SHEAVE COMP C SECONDARY SLIDING SHEAVE OIL SEAL O-RING CW PIN, GUIDE A0 SPRING, COMPRESSION GJ SPRING SEAT COMP WV SEAT,SPRING NUT NUT VU SHAFT, SECONDARY COLLAR O-RING 1 23

30 FIG. 16 CLUTCH 2 PART OIL SEAL BEARING GJ PLATE, BEARING COVER BOLT, HEXAGON SOCKET HEAD CIRCLIP OIL SEAL BEARING 1 24

31 FIG. 17 TRANSMISSION PART 1 59C AXLE, MAIN C GEAR, PRIMARY DRIVEN (52T) C GEAR,1ST PINION (22T) BEARING C AXLE, DRIVE C GEAR, 1ST WHEEL (36T) CIRCLIP A8 BEARING OIL SEAL 1 25

32 FIG. 18 FRAME PART 1 2PW FRAME COMP VX PLUG, BLIND 1 3 4B5 2113B 00 DAMPER 1 4 5RU CLAMP BOLT, FLANGE NUT, SELF-LOCKING GROMMET BOLT, HEXAGON SOCKET HEAD WASHER, PLATE C REAR FRAME COMP C DAMPER, LOCATING RIVET BOLT, FLANGE BP MOLD, FUEL TANK BOLT, FLANGE NUT, SELF-LOCKING C COLLAR B STAY, MUFFLER NUT, U FLANGE PW 2142K 00 BRACKET, RADIATOR GROMMET BOLT, FLANGE BOLT, FLANGE PW STAY CLAMP GROMMET BOLT, FLANGE 2 26

33 FIG. 18 FRAME PART 28 4B5 2117F 00 COVER B5 2117M 00 COVER RIVET C BRACKET, AIR CLEANER GROMMET SPACER BOLT, FLANGE C 2141A 01 BRACKET BOLT, FLANGE C 2141E 01 BRACKET CLAMP CLAMP BOLT, FLANGE PW 2144H 00 BRACKET, FOOTREST BOLT, FLANGE CLAMP PW 2145H 00 BRACKET, FOOTREST BOLT, FLANGE C BRACKET, TANK FITTING BOLT, WITH WASHER C 2117A 00 STAY CLAMP NUT, FLANGE PW STAY PW STAY, LEG SHIELD BOLT,HEX. SOCKET BUTTON NUT 4 27

34 FIG. 18 FRAME PART 55 2PW 8212B 00 BOX, BATTERY CLAMP CLAMP BOLT, WITH WASHER BOLT, WITH WASHER BOLT, FLANGE COLLAR COLLAR COLLAR COLLAR NUT, SPRING BAND, BATTERY C 8212C 00 BOX, BATTERY RIVET C 2117J 00 STAY, RELAY NUT, SPRING RIVET C 8252R 00 DAMPER CLAMP 1 28

35 FIG. 19 FENDER PART 1 2PW P3 FENDER, FRONT 1 FOR DNMS SCREW BOLT,HEX. SOCKET BUTTON 2 4 2PW STAY, FENDER A6 NUT, SPRING A6 NUT, SPRING 1 7 2PW STAY, FENDER A6 NUT, SPRING A6 NUT, SPRING PW FENDER, FRONT BOLT, WITH WASHER PW BRACKET SCREW, BINDING COLLAR COLLAR BOLT,HEX. SOCKET BUTTON BOLT, FLANGE NUT, FLANGE VU EMBLEM 2 29

36 FIG. 20 SIDE COVER PART 1 2PW 2171E 00 COVER, SIDE C DAMPER 2 3 4B5 2174X 00 DAMPER NUT, SPRING SCREW, TAPPING C P8 COVER, SIDE 1 1 FOR DNMS DAMPER, PLATE DAMPER, PLATE NUT, SPRING GROMMET C 2163E 20 COVER, REAR FENDER SCREW, TAPPING M02 NUT, SPRING SCREW, TAPPING C P8 COVER, SIDE 2 1 FOR DNMS DAMPER, PLATE DAMPER, PLATE NUT, SPRING GROMMET SCREW, TAPPING CLAMP C 2163F 20 COVER, REAR FENDER SCREW, TAPPING M02 NUT, SPRING C 2171A 00 P5 COVER, TOP 1 FOR DNMS RIVET B5 2175N 00 COVER, FLANGE 1 30

37 FIG. 20 SIDE COVER PART M02 NUT, SPRING C COVER, REAR FENDER RIVET GJ 2173B 20 EMBLEM 3D GJ 2173B 20 EMBLEM 3D PW 2173D 00 EMBLEM 3D B5 2473F 00 COVER, SEAT COMP C 2473T 00 LID B5 2477F 10 LEVER, SEAT GJ HOOK, SEAT HC SPRING PIN, DOWEL PW COVER SCREW, TAPPING GJ PIN B REINFORCEMENT SCREW, BIND A7 NUT, SPRING C COVER, SIDE C COVER, SIDE SCREW, TAPPING A0 NUT, SPRING NUT, SPRING DAMPER, PLATE SCREW, TAPPING BOLT, FLANGE 1 31

38 FIG. 21 SIDE COVER 2 PART 1 59C P4 COVER, SIDE 3 1 MNM3 FOR DNMS 2 4B DAMPER BOLT, BUTTON HEAD C P4 COVER, SIDE 4 1 MNM3 FOR DNMS BOLT, BUTTON HEAD BOLT, HEXAGON SOCKET HEAD BOLT, HEXAGON SOCKET HEAD C 2171L 00 P8 MOLE, SIDE COVER 1 1 FOR DNMS SCREW, TAPPING BOLT,HEX. SOCKET BUTTON RIVET C 2178L 00 GUIDE M02 NUT, SPRING C 2171M 00 P8 MOLE, SIDE COVER 2 1 FOR DNMS SCREW, TAPPING BOLT,HEX. SOCKET BUTTON RIVET C 2178M 00 GUIDE M02 NUT, SPRING C GUARD, MUD C LICENCE LIGHT UNIT ASSY HC BULB (12V-5W) SCREW, TAPPING SCREW, BIND GROMMET COLLAR WASHER 2 32

39 FIG. 21 SIDE COVER 2 PART NUT, U Y REAR REFLECTOR ASSY NUT, U FLANGE PW REAR STAY COMP SCREW, TAPPING BOLT,HEX. SOCKET BUTTON Y1 COLLAR C 2161G 00 BRACKET NUT, SELF-LOCKING C TANK, RECOVERY BOLT, FLANGE COLLAR AA CAP AA GASKET PW PIPE HOSE A2 CLIP A1 CLIP 1 33

40 FIG. 22 REAR ARM & SUSPENSION PART 1 15B HOLDER O-RING BOLT BEARING 1 5 2PW 2210M 00 REAR ARM ASSY GJ RETAINER, BEARING OIL SEAL OIL SEAL BOLT NUT, FLANGE PW 2210N 00 REAR ARM ASSY C BUMP, STOP NUT, CAP BOLT NUT, FLANGE PW HOLDER BEARING OIL SEAL PW PULLEY, BELT C 2219X 00 COVER C 2214F 00 DAMPER BOLT, HEXAGON SOCKET HEAD CIRCLIP C COLLAR, GUIDE B SHAFT, PIVOT WASHER, PLATE J NUT 1 34

41 FIG. 22 REAR ARM & SUSPENSION PART BEARING OIL SEAL COLLAR PIN, DOWEL BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE C STAY, PLATE BOLT, FLANGE C 2587A 00 HOLDER, BRAKE HOSE BOLT, FLANGE VY PULLER, CHAIN VY PULLER, CHAIN C CASE, CHAIN C STAY, CHAIH CASE C 2174X 00 DAMPER COLLAR COLLAR M02 NUT, SPRING A0 CLIP C CASE, CHAIN C STAY C 2174Y 00 DAMPER COLLAR COLLAR M02 NUT, SPRING RIVET 2 35

42 FIG. 22 REAR ARM & SUSPENSION PART BOLT,HEX. SOCKET BUTTON RIVET C COVER C STAY, CHAIN CASE C 2834E 00 DAMPER C 2834F 00 DAMPER C DAMPER COLLAR M02 NUT, SPRING COLLAR BOLT, FLANGE RIVET C W BELT C SHOCK ABSORBER ASSY, REAR AA LABEL, WARNING BOLT B WASHER COLLAR BEARING BOLT, FLANGE COLLAR COLLAR WASHER, PLATE NUT, SELF-LOCKING 1 36

43 FIG. 23 STEERING PART 1 4B BRACKET, HORN 1 2 4B COVER, STEERING BOLT, WITH WASHER M9 COLLAR GROMMET BEARING 1 7 4XV WASHER, SPECIAL NUT WASHER, PLATE XV COVER, BALL RACE WASHER, PLATE NUT PW W CROWN, HANDLE C HOLDER, HANDLE LOWER PW 2334H 00 BRACKET WASHER, PLATE NUT, U BOLT BOLT, FLANGE CLAMP PW HOLDER, HANDLE UPPER BOLT, FLANGE 4 37

44 FIG. 24 FRONT FORK PART 1 2PW UNDER BRACKET COMP PW FRONT FORK ASSY (L.H) 1 3 2PW INNER TUBE COMP EB SEAL, DUST H RING, SNAP 1 6 4EB OIL SEAL Y WASHER, OIL SEAL 1 8 1RC METAL, SLIDE FM METAL, SLIDE PW TUBE, OUTER (L.H) PW CYLINDER COMP., FRONT FORK L0.GASKET 1 (KYB) BOLT, HEXAGON SOCKET HEAD LC NUT PW SPRING, FRONT FORK VY SPACER PW BOLT, CAP P O-RING BOLT, HEXAGON SOCKET HEAD PW FRONT FORK ASSY (R.H) PW INNER TUBE COMP EB SEAL, DUST H RING, SNAP EB OIL SEAL Y WASHER, OIL SEAL RC METAL, SLIDE FM METAL, SLIDE 1 38

45 FIG. 24 FRONT FORK PART 28 2PW TUBE, OUTER (L.H) PW CYLINDER COMP., FRONT FORK L0.GASKET 1 (KYB) BOLT, HEXAGON SOCKET HEAD LC NUT PW SPRING, FRONT FORK VY SPACER PW BOLT, CAP P O-RING BOLT, HEXAGON SOCKET HEAD BOLT BEARING FV SEAL, STEERING C CAP, BOLT 1 39

46 FIG. 25 FUEL TANK PART 1 59C FUEL TANK COMP K CAP ASSY NUT, FLANGE WASHER, PLATE SCREW, WITH WASHER 2 6 4B DAMPER, LOCATING BP MOLD, FUEL TANK C FUEL PUMP COMP PW DAMPER, LOCATING DAMPER, PLATE DAMPER, PLATE CLAMP PW BRACKET, FUEL PUMP CA 2414G 01 SEAL BOLT, WITH WASHER VU CLAMP B5 2414A 00 COVER, FILLER JP BOSS, CONNECTOR PW PIPE, OVERFLOW CLAMP B PIPE B PROTECTOR, FUEL TANK A2 CLIP RB ROLL OVER VALVE ASSY B CLAMP SCREW, TAPPING PW PIPE

47 FIG. 25 FUEL TANK PART 28 2PW PIPE, FUEL

48 FIG. 26 SEAT PART 1 2PW DOUBLE SEAT ASSY C COVER, SEAT 1 3 2PW BRACKET, SEAT 1 4 2PW BRACKET, SEAT 1 5 2PW DAMPER, SEAT NUT, SELF U-FLANGE G8.WASHER, PLATE 1 8 4B PLATE BOLT, FLANGE C SEAT BACK ASSY PW HINGE, SEAT PW PIN, SEAT FITTING CIRCLIP B5 2474E 00 ARM NUT, SELF-LOCKING NUT, SELF-LOCKING PW BRACKET, SEAT BOLT, BUTTON HEAD B HINGE, SEAT B HINGE, SEAT BOLT, FLANGE C 2475U 00 BRACKET, TAIL COVER BOLT, FLANGE P DAMPER B5 2478G 02 STOPPER CLIP 2 42

49 FIG. 27 SEAT 2 PART 1 59C 2473R 01 BOX B DAMPER, SEAT 4 3 4HC LIGHT, ACCESSORY 1 4 4HC BULB (12V-2W) 1 5 5GJ 2839M 00 SEAL, BOX C 2173M 00 SEAL NUT, SPRING C DAMPER CLAMP C DAMPER BOLT, FLANGE COLLAR B5 2482H 00 CAP BOLT, FLANGE C DAMPER, SEAT B5 2474A 01 PE ASSIST, GRIP 1 FOR DNMS COLLAR BOLT, FLANGE B5 2476U 00 PROTECTOR B5 2474W 01 PD ASSIST,GRIP 2 1 FOR DNMS COLLAR BOLT, FLANGE B5 2476U 00 PROTECTOR PW SEAT LOCK ASSY BOLT, HEXAGON SOCKET HEAD PW 2478D 00.SEAT LOCK CABLE ASSY BOLT, FLANGE 4 43

50 FIG. 27 SEAT 2 PART COLLAR C 2475K 00 BRACKET PW 2163A 00 COVER, REAR FENDER RIVET B HANGER, HELMET VU LABEL, TIRE PW TOOL KIT TJ BAND, BATTERY PW E0 MANUAL,OWNER'S 1 UR ENGLISH 2PW F0 MANUAL,OWNER'S 1 UR FRENCH 2PW G0 MANUAL,OWNER'S 1 UR GERMAN 2PW H0 MANUAL,OWNER'S 1 UR ITALIAN 2PW S0 MANUAL,OWNER'S 1 UR SPANISH 44

51 FIG. 28 FRONT WHEEL PART 1 2PW X CAST WHEEL, FRONT 1 MBL2/RG FOR DNMS 2 5EA SPACER, BEARING BEARING OIL SEAL 2 5 2DR 2517G 00 ROTOR, SENSOR SCREW TIRE(120/70R15M/C56H GPR-100F) VALVE, RIM (PVR59A) 1 TAIHEIYO 9 5MT BALANCER, WHEEL (10G) 1 UN 5MT BALANCER, WHEEL (20G) 1 UN 5MT BALANCER, WHEEL (30G) 1 UN 10 2C AXLE, WHEEL PW CAP COLLAR COLLAR BOLT, FLANGE 1 45

52 FIG. 29 FRONT BRAKE CALIPER PART 1 59C 2581T 00 DISK BRAKE ASSY G4 BOLT PW 2580T 20 CALIPER ASSY (LEFT) 1 4 4SV PISTON ASSY, CALIPER 1 5 3GM CALIPER SEAL KIT 1 6 4SV PISTON ASSY, CALIPER 1 7 3MA CALIPER SEAL KIT 1 8 4B BRAKE PAD KIT S SUPPORT, PAD SV PIN, PAD GM CLIP J SCREW, BLEED CAP PW 2580U 30 CALIPER ASSY (RIGHT) SV PISTON ASSY, CALIPER GM CALIPER SEAL KIT SV PISTON ASSY, CALIPER MA CALIPER SEAL KIT B BRAKE PAD KIT S SUPPORT, PAD SV PIN, PAD GM CLIP VS SCREW, BLEED CAP VS RUBBER, BUSHING BOLT, FLANGE 4 46

53 FIG. 30 REAR WHEEL PART 1 2PW X CAST WHEEL, REAR 1 MBL2/RG FOR DNMS B5 BEARING BEARING C SPACER, BEARING OIL SEAL 2 6 2PW 2517G 00 ROTOR, SENSOR SCREW TIRE(160/60R15M/C 67H GPR-100) VALVE, RIM (TR412) 1 TAIHEIYO 10 5MT BALANCER, WHEEL (10G) 1 UN 5MT BALANCER, WHEEL (20G) 1 UN 5MT BALANCER, WHEEL (30G) 1 UN 11 2PW SPROCKET, DRIVEN (70T) BOLT, FLANGE PW 2537A 00 HOUSING, SENSOR REAR C 2530S 00 COLLAR ASSY PW COLLAR, WHEEL PW AXLE, WHEEL NUT, SELF-LOCKING WASHER, PLATE 1 47

54 FIG. 31 REAR BRAKE CALIPER PART 1 59C 2582W 00 DISK, REAR BRAKE SCREW C 2580W 00 CALIPER ASSY, REAR C PISTON ASSY, CALIPER C CALIPER SEAL KIT C PIN, SLIDE 2 7 4TT BOOT C BRAKE PAD KIT JW SUPPORT, PAD GM SCREW, BLEED D CAP GM RUBBER, BUSHING PW 259A0 00 CALIPER ASSY C PISTON ASSY, CALIPER C BRAKE PAD KIT C 259A3 00.ARM C 259A4 00.NUT, ADJUSTING C PIN, SLIDE C SLEEVE, CALIPER UY BOOT, CALIPER UY BOLT UY WASHER, SPRING UY BOOT PW BRACKET, SUPPORT C CAP C SPRING, RETURN PIN 1 48

55 FIG. 31 REAR BRAKE CALIPER PART NUT BOLT, FLANGE 2 49

56 FIG. 32 STEERING HANDLE & CABLE PART 1 59C HANDLE COMP YR GRIP (LEFT) 1 3 4YR GRIP ASSY 1 4 5GJ END, GRIP 2 5 2PW THROTTLE CABLE ASSY BOLT, BUTTON HEAD SCREW, PAN HEAD C COVER, HANDLEBAR LOWER SCREW, WITH WASHER SCREW, ROUND TAPPING C COVER, HANDLE UPPER C P1 COVER, HANDLE UPPER 2 1 MBL2 FOR DNMS NUT, SPRING SCREW, TAPPING SCREW, TAPPING C 2835X 00 WIRE NUT, CROWN B GUIDE, CABLE BOLT, FLANGE CLAMP 1 50

57 FIG. 33 FRONT MASTER CYLINDER PART 1 4B5 W MASTER CYLINDER SUB ASSY 1 2 4B5 W CYLINDER KIT, MASTER 1 3 4B CAP, RESERVOIR 1 4 4B BUSH,DIAPHRAGM 1 5 4B DIAPHRAGM, RESERVOIR 1 6 5VS 2589H 00.SCREW 2 7 5VS 2589F 00 BOLT, LEVER NUT, U 1 9 4B LEVER VS BOLT VS BRACKET, MASTER CYLINDER Y STOP SWITCH ASSY SCREW, PAN HEAD WITH WASHER PW HOSE, BRAKE PW HOSE, BRAKE BOLT, FLANGE NUT, FLANGE CLAMP BOLT, UNION BOLT, UNION GASKET PW HOLDER, BRAKE HOSE PW HOLDER, BRAKE HOSE PW 2584D 00 HOSE, BRAKE PW HOLDER, BRAKE HOSE PW HOLDER, BRAKE HOSE B5 W MASTER CYLINDER SUB ASSY 1 51

58 FIG. 33 FRONT MASTER CYLINDER PART 28 4B5 W CYLINDER KIT, MASTER B CAP, RESERVOIR B BUSH,DIAPHRAGM B DIAPHRAGM, RESERVOIR VS 2589H 00.SCREW VS 2589F 00 BOLT, LEVER NUT, U B LEVER VS BOLT VS BRACKET, MASTER CYLINDER Y FRONT STOP SWITCH ASSY SCREW, PAN HEAD WITH WASHER PW 2584B 00 HOSE, BRAKE PW 2584C 00 HOSE, BRAKE BOLT, FLANGE CLAMP BOLT, UNION BOLT, UNION GASKET CLAMP CLAMP CLAMP CLAMP PW PLATE, LOCK BOLT, FLANGE PW PLATE, LOCK BOLT, FLANGE 1 52

59 FIG. 33 FRONT MASTER CYLINDER PART CLAMP CLAMP CLAMP 1 53

60 FIG. 34 STAND & FOOTREST PART 1 2PW STAND, MAIN SPRING, TENSION SPRING, TENSION BOLT NUT, SELF-LOCKING 2 6 2PW BRACKET, MAIN STAND C STOPPER, MAIN STAND BOLT, FLANGE NUT, SELF-LOCKING B BRACKET, MAIN STAND BOLT, FLANGE NUT, SELF-LOCKING PW BRACKET, SIDE STAND PW STAND, SIDE SPRING, TENSION X STOPPER, MAIN STAND BOLT, BUTTON HEAD COLLAR WASHER NUT, U PW REAR FOOTREST ASSY VR FOOTREST, REAR PIN, COTTER PIN, CLEVIS SPRING, COMPRESSION BALL H8.COLLAR 1 54

61 FIG. 34 STAND & FOOTREST PART 28 4B WASHER, SPECIAL C HOLDER, BRAKE HOSE BOLT, FLANGE BOLT, FLANGE PW REAR FOOTREST ASSY VR FOOTREST, REAR PIN, COTTER PIN, CLEVIS SPRING, COMPRESSION BALL H8.COLLAR B WASHER, SPECIAL BOLT, FLANGE 2 55

62 FIG. 35 STAND & FOOTREST 2 PART 1 59C BOARD, FOOTREST SCREW, TAPPING SCREW, TAPPING SCREW, TAPPING NUT, SPRING A6 NUT, SPRING 1 7 2PW SPACER GROMMET BOLT, WITH WASHER A6 NUT, SPRING NUT, SPRING C DAMPER, LOCATING RIVET B DAMPER C DAMPER DAMPER, PLATE C BOARD, FOOTREST PW SPACER SCREW, TAPPING SCREW, TAPPING NUT, SPRING A6 NUT, SPRING GROMMET BOLT, WITH WASHER BOLT, WITH WASHER A6 NUT, SPRING RIVET 1 56

63 FIG. 35 STAND & FOOTREST 2 PART 28 5UX DAMPER B DAMPER B DAMPER C DAMPER PW MAT PW MAT C MAT C MAT PW COVER, FOOTREST PW COVER, FOOTREST C COVER SCREW, TAPPING 1 57

64 FIG. 36 LEG SHIELD PART 1 59C LEG SHIELD PW BRACKET SCREW, TRUSS HEAD TAPPING NUT, SPRING SCREW, TAPPING BOLT, WITH WASHER C P0 LEG SHIELD 2 1 MNM3 FOR DNMS SCREW, TAPPING C LID NUT, SPRING PW 2830P 00 PANEL ASSY PW 2839V 00 LID TAPPING SCREW RIVET P LABEL, WARNING SCREW, TAPPING C 2839K 00 LID C 2836N 00 PANEL, INNER C 2836Y 00 KNOB, PW 2838L 00 BOX C PIN, LOCK C 2848Y 00 COVER, LOCK C SPRING SCREW, TAPPING PLUG PLUG DAMPER, PLATE 1 58

65 FIG. 36 LEG SHIELD PART 28 59C 2838C 00 SPRING NUT, SPRING C DAMPER, SEAT JX DAMPER, LOCATING BOLT, WITH WASHER C LOCK SET C 2117K 00 STAY, LOCK C 2176V 00 SPRING, LOCK SCREW, TAPPING RIVET C 2836K 00 PANEL, INNER SCREW, TAPPING DAMPER, PLATE RIVET BOLT,HEX. SOCKET BUTTON NUT, SPRING C 2839R 00 P1 PANEL, ACCESSORY 1 MNM3 FOR DNMS 45 2PW P3 BODY, COWLING 1 FOR DNMS GROMMET X COLLAR BOLT, FLANGE A6 NUT, SPRING NUT, SPRING PW P3 BODY, COWLING 2 1 FOR DNMS GROMMET X COLLAR BOLT, FLANGE 1 59

66 FIG. 36 LEG SHIELD PART A6 NUT, SPRING NUT, SPRING RC 2413B 00 EMBLEM RC 2413B 00 EMBLEM C PLATE SCREW, TAPPING C PLATE SCREW, TAPPING PW W ROTOR SET PW 2839T 00.GASKET, LOCK PW 2117K 00 STAY, LOCK VY 2176V 00 SPRING, LOCK

67 FIG. 37 WINDSHIELD PART 1 59C COVER SCREW, TAPPING C 2835U 00 PANEL A0 CLIP SCREW, TAPPING C 2835V 00 PANEL A0 CLIP SCREW, TAPPING C 2836L 00 PANEL, INNER SCREW, TAPPING RIVET NUT, SPRING GROMMET PW 2837U 00 SCREEN SCREW, BINDING RIVET C 2842A 00 COVER C 2843C 00 COVER C CAP PW P3 COVER, FRONT 1 FOR DNMS 21 2PW 2286F 00 P1 COVER, FRONT 2 1 MNM3 FOR DNMS SCREW, TAPPING M02 NUT, SPRING RIVET PW MOLE SCREW, TAPPING PW P3 COVER, UNDER 1 MNM3 FOR DNMS 61

68 FIG. 37 WINDSHIELD PART RIVET A0 CLIP PW REAR VIEW MIRROR ASSY (LEFT) C 2628N 00 BASE, MIRROR (LEFT) BOLT, FLANGE PW REAR VIEW MIRROR ASSY (RIGHT) C 2628R 00 BASE, MIRROR (RIGHT) BOLT, FLANGE C DUCT, AIR RIVET RIVET BOLT, FLANGE U0 COLLAR RIVET DAMPER, PLATE DAMPER, PLATE DAMPER, PLATE C FENDER, INNER RIVET RIVET RIVET NUT, SPRING 2 62

69 FIG. 38 GENERATOR PART 1 59C STATOR ASSY 1 2 2PW ROTOR ASSY SCREW SCREW 2 63

70 FIG. 39 FLASHER LIGHT PART 1 59C FRONT FLASHER LIGHT ASSY C BULB, FLASHER (12V PY21W) C CORD C FRONT FLASHER LIGHT ASSY C BULB, FLASHER (12V PY21W) C CORD B MOLD, SEAT RIVET BOLT, WITH WASHER DAMPER, PLATE SCREW, TAPPING C REAR FLASHER LIGHT ASSY C BULB, FLASHER (12V PY21W) C CORD C REAR FLASHER LIGHT ASSY C BULB, FLASHER (12V PY21W) C CORD BOLT SCREW, TAPPING NUT, SPRING 2 64

71 FIG. 40 METER PART 1 2PW METER ASSY (KM/H) 1 UR EXCEPT FOR GBR 2PW METER ASSY (MPH) 1 UR FOR GBR 2 59C LENS, SPEEDOMETER 1 3 2PW 8353L 70.REFLECTOR 1 4 4AS SCREW, TAPPING SCREW, TAPPING 4 65

72 FIG. 41 HEADLIGHT PART 1 2PW HEADLIGHT ASSY NUT, SPRING B MOLD, SEAT BOLT, FLANGE COLLAR 1 6 5PS DAMPER GROMMET BOLT, WITH WASHER 4 9 2PW CORD, HEADLIGHT J4 HOSE (L20) 1 66

73 FIG. 42 TAILLIGHT PART 1 4C TAILLIGHT UNIT ASSY RIVET C DAMPER, TAIL

74 FIG. 43 HANDLE SWITCH & LEVER PART 1 2PW SWITCH, HANDLE RB HOLDER, ADJUSTING 1 3 5RB PLUG, BLIND 1 4 5VU LEVER LOCK ASSY BOLT SCREW, PAN HEAD 1 7 2PW SWITCH, HANDLE SCREW, PAN HEAD 2 68

75 FIG. 44 ELECTRICAL 1 PART 1 2PW 8591A 00 ENGINE CONTROL UNIT ASSY NUT, SELF-LOCKING P BATTERY ASSY (GS YUASA YTZ12S) 1 4 2PW 2116M 01 BRACKET PW 2114V 00 BRACKET PW 2132H 00 PLATE, COVER RIVET C STARTER RELAY ASSY (RC19-101A) 1 9 5EA FUSE (40A-BL) SL COVER, LEAD WIRE C WIRE, MINUS LEAD C WIRE, SUB LEAD BOLT, FLANGE VX RECTIFIER & REGULATOR ASSY BOLT, FLANGE PW WIRE HARNESS ASSY WA DIODE ASSY WP DIODE ASSY JJ FUSE (15A-BL) JJ FUSE (5A-BL) JJ FUSE (7.5A-BL) JJ FUSE (10A-BL) CLAMP C SWITCH, SIDE STAND BOLT, BUTTON HEAD NUT, SELF-LOCKING PW STEERING LOCK ASSY 1 69

76 FIG. 44 ELECTRICAL 1 PART SCREW C SWITCH ASSY SCREW, BIND PS SENSOR, LEAN ANGLE BOLT WASHER, PLATE ST RELAY ASSY (1ST-00) JJ HOLDER, RELAY JJ RELAY ASSY (G8HN-1C4T-DJ-Y51) PW REMOTE CONTROL UNIT ASSY PW TRANSMITTER WITH BLANK KEY PW W862A 00 REMOTE CONTROL UNIT SET 1 AP 40 2PW 8259E 00 SWITCH ASSY Y CLAMP CLAMP TP RELAY ASSY (1TP-00) EA HOLDER, RELAY PW BAND CLAMP 1 70

77 FIG. 45 ELECTRICAL 2 PART 1 59C PLUG CAP ASSY C IGNITION COIL ASSY NUT, FLANGE BOLT, FLANGE 1 5 1WS SENSOR, PRESSURE BOLT 1 7 2PW HORN NUT, FLANGE 1 9 3GM FLASHER RELAY ASSY YU SENSOR, AIR TEMPERATURE BOLT D BUZZER 1 71

78 FIG. 46 ELECTRICAL 3 PART 1 2PW HYDRAULIC UNIT ASSY 1 2 2PW 2175T 00 BRACKET CG DAMPER 3 4 5CG 2535E 00 BOLT 3 5 3P CAP, DAMPER BOLT, BUTTON HEAD NUT, FLANGE 3 8 1PW CONNECTOR 1 9 2PW WHEEL SENSOR ASSY, FRONT BOLT, FLANGE PW WHEEL SENSOR ASSY, REAR BOLT, FLANGE CLAMP C 8431U 00 HOLDER BOLT, FLANGE 1 72

79 NUMERICAL INDEX PART PART PART PART PART PART 59C NL C C C C GJ C C C C GJ GJ GJ GJ GJ GJ A GJ GJ GJ GJ GJ GJ A GJ P C SL C A C VU X GJ GJ GJ GJ C C C TJ HX TV C GC EB EB HX HX HX HX HX HX A 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 C C PW B C GJ PW JH B C VU GJ C VK WG C 1243A PW 1243E C 1243F C 1244G S PW SL PW PW VU B C C C C RU Y PW C GJ SL S LD GJ C GJ GJ F DM GJ JW GJ G S C FP RB B C C C C C C C PW JW BH PS M CC B PW C 1441A C C 1443A B U C B C VX BR C B5 1465R VU 1465T VU 1465U C 1465V C B C 1471M B C C C C GJ Y H B C C C C H GJ XM GJ C C C C C GJ C C GJ 1542A C 1542B C GJ GJ C C GJ B PW GJ B GJ U GJ Y WS C C VU C C C C GJ C C GJ GJ GJ GJ GJ GJ GJ C GJ GJ C C C C B GJ C C RU C WV C PW C C CW C VU GJ PW C B5 2113B C PW 2114V PW 2116M C 2117A B5 2117F C 2117J PW 2117K C 2117K B5 2117M C VX PW 2132H C B C 2141A C 2141E PW 2142K B PW 2144H PW 2145H PW P PW PW C PW C P VU PW C 2161G C PW 2163A C 2163E C 2163F PW