VMX12S (5GKL) U49 VMX12S (5GKN) CANADA VMX12 (5GKP) SOUTH AFRICA

Transcription

1 VMX12S () U49 VMX12S () CANADA VMX12 () SOUTH AFRICA 1C5GK-100E1 ( 2C5GK-100E1 ) A2

2 VMX12S/VMX12 PARTS CATALOGUE 2003 by Yamaha Motor Co., Ltd. 1st edition, May 2003 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 VMX12S/VMX12 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 CLP CLEAR(WITH BUFF) 0038 CM CHROME PLATED 0093 HPB BLACK (FOR ELECTRODEPOSIT) 00R4 LGB LOW GLOSS BLACK 0098 MBL2(*) MAT BLACK SL SILVER 0035 YB YAMAHA BLACK 0033 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 CANADA 010 SOUTH AFRICA 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 0582 MAT BLACK 2 MBL2 A 0582 MAT BLACK 2 MBL2 A 0582 MAT BLACK 2 MBL2 A7

7 CONTENTS ENGINE CYLINDER HEAD... B2 CRANKSHAFT & PISTON... B4 VALVE... B6 CAMSHAFT & CHAIN... B8 WATER PUMP... B9 RADIATOR & HOSE... B11 OIL PUMP... B14 OIL CLEANER... B15 INTAKE... C3 CARBURETOR... C5 CARBURETOR 2... C8 EXHAUST... C11 CRANKCASE... C13 CRANKCASE COVER 1... C15 STARTER CLUTCH... D3 CLUTCH... D4 TRANSMISSION... D6 MIDDLE DRIVE GEAR... D8 SHIFT CAM & FORK... D10 SHIFT SHAFT... D11 CHASSIS FRAME... D12 FENDER... D13 SIDE COVER... D15 REAR ARM... E5 DRIVE SHAFT... E6 REAR SUSPENSION... E8 STEERING... E9 FRONT FORK... E11 FUEL TANK... E13 SEAT... E15 FRONT WHEEL... F2 FRONT BRAKE CALIPER... F3 REAR WHEEL... F4 REAR BRAKE... F5 STEERING HANDLE & CABLE... F6 FRONT MASTER CYLINDER... F7 FRONT MASTER CYLINDER 2... F8 STAND & FOOTREST... F9 REAR MASTER CYLINDER... F11 GENERATOR... F12 PICK UP COIL & GOVERNOR... F13 STARTING MOTOR... F14 FLASHER LIGHT... F15 METER... G3 HEADLIGHT... G5 TAILLIGHT... G6 HANDLE SWITCH & LEVER... G7 ELECTRICAL 1... G8 ELECTRICAL 2... G10 INDEX NUMERICAL INDEX... M1

8 FIG. 1 CYLINDER HEAD PART DESCRIPTION 1 1FK CYLINDER HEAD ASSY PIN, DOWEL BOLT, FLANGE PLUG, STRAIGHT SCREW X GUIDE, VALVE BOLT, STUD FK W CYLINDER HEAD ASSY PIN, DOWEL BOLT, FLANGE PLUG, STRAIGHT SCREW X GUIDE, VALVE BOLT, STUD H JOINT O-RING O-RING O-RING PIN, SPRING PLUG, SPARK (NGK DPR8EA-9) UR PLUG, SPARK (ND X24EPR-U9) UR 19 26H GASKET, CYLINDER HEAD PIN, DOWEL NUT G9 WASHER, PLATE FK COVER, CYLINDER HEAD BOLT, WITH WASHER WASHER GH 1111G 00 RUBBER, MOUNT B2

9 FIG. 1 CYLINDER HEAD PART DESCRIPTION PLUG H GASKET, HEAD COVER B3

10 FIG. 2 CRANKSHAFT & PISTON PART DESCRIPTION 1 1FK CRANKSHAFT ASSY FK PLANE BEARING, CRANKSHAFT UR BLUE 1FK PLANE BEARING, CRANKSHAFT UR BLACK 1FK PLANE BEARING, CRANKSHAFT UR BROWN 1FK PLANE BEARING, CRANKSHAFT UR GREEN 1FK PLANE BEARING, CRANKSHAFT UR YELLOW 1FK PLANE BEARING, CRANKSHAFT UR PINK 1FK PLANE BEARING, CRANKSHAFT UR RED 3 1FK A0 PISTON (STD) FK PISTON (0.25MM O/S) AP 1FK PISTON (0.50MM O/S) AP 4 1FK PISTON RING SET (STD) FK PISTON RING SET (0.25MM O/S) AP 1FK PISTON RING SET (0.50MM O/S) AP 5 3JP PIN, PISTON CIRCLIP FK CONNECTING ROD ASSY H BOLT, CONNECTING ROD NUT FK PLANE BEARING, CONNECTING ROD UR BLUE 1FK PLANE BEARING, CONNECTING ROD UR BLACK 1FK PLANE BEARING, CONNECTING ROD UR BROWN 1FK PLANE BEARING, CONNECTING ROD UR GREEN 1FK PLANE BEARING, CONNECTING ROD UR YELLOW 1FK PLANE BEARING, CONNECTING ROD UR PINK KEY, WOODRUFF BOLT, FLANGE B4

11 FIG. 2 CRANKSHAFT & PISTON PART DESCRIPTION H0 WASHER, PLATE FK BALANCER ASSY H PLANE BEARING, BALANCE WEIGHT UR BLUE 26H PLANE BEARING, BALANCE WEIGHT UR BLACK 26H PLANE BEARING, BALANCE WEIGHT UR BROWN 26H PLANE BEARING, BALANCE WEIGHT UR GREEN 26H PLANE BEARING, BALANCE WEIGHT UR YELLOW 26H PLANE BEARING, BALANCE WEIGHT UR PINK 26H PLANE BEARING, BALANCE WEIGHT UR RED B5

12 FIG. 3 VALVE PART DESCRIPTION 1 1FK VALVE, INTAKE FK VALVE, EXHAUST H SEAT, VALVE SPRING Y SPRING, VALVE INNER Y SPRING, VALVE OUTER Y SEAL, VALVE STEM X RETAINER, VALVE SPRING X COTTER, VALVE H LIFTER, VALVE H LIFTER, VALVE(O/S) AP 10 26H PAD, ADJUSTING (2.00) UR 26H PAD, ADJUSTING (2.05) UR 26H PAD, ADJUSTING (2.10) UR 26H PAD, ADJUSTING (2.15) UR 26H PAD, ADJUSTING (2.20) UR 26H A0 PAD, ADJUSTING (2.25) UR 26H F0 PAD, ADJUSTING (2.30) UR 26H H0 PAD, ADJUSTING (2.35) UR 26H K0 PAD, ADJUSTING (2.40) UR 26H M0 PAD, ADJUSTING (2.45) UR 26H R0 PAD, ADJUSTING (2.50) UR 26H U0 PAD, ADJUSTING (2.55) UR 26H W0 PAD, ADJUSTING (2.60) UR 26H Y0 PAD, ADJUSTING (2.65) UR 26H PAD, ADJUSTING (2.70) UR 26H PAD, ADJUSTING (2.75) UR 26H PAD, ADJUSTING (2.80) UR B6

13 FIG. 3 VALVE PART DESCRIPTION 10 26H PAD, ADJUSTING (2.85) UR 26H PAD, ADJUSTING (2.90) UR 26H E0 PAD, ADJUSTING (2.95) UR 26H G0 PAD, ADJUSTING (3.00) UR 26H J0 PAD, ADJUSTING (3.05) UR 26H L0 PAD, ADJUSTING (3.10) UR 26H N0 PAD, ADJUSTING (3.15) UR 26H T0 PAD, ADJUSTING (3.20) UR B7

14 FIG. 4 CAMSHAFT & CHAIN PART DESCRIPTION 1 1FK CAMSHAFT FK CAMSHAFT H SPROCKET, CAM CHAIN H SPROCKET, CAM CHAIN BOLT, FLANGE CHAIN (D.I.D 219FTS118LL) SV PIN, JOINT H GUIDE, STOPPER H DAMPER, CHAIN H DAMPER, CHAIN H PLATE, GUIDE STOPPER BOLT, FLANGE H TENSIONER ASSY, CAM CHAIN JP GASKET, TENSIONER CASE BOLT B8

15 FIG. 5 WATER PUMP PART DESCRIPTION 1 1FK WATER PUMP ASSY FK IMPELLER SHAFT ASSY PIN, DOWEL H GEAR, IMPELLER SHAFT (31T) CIRCLIP BEARING (B6000) OIL SEAL H SEAL, MECHANICAL O-RING FK COVER, HOUSING BOLT, HEXAGON SOCKET HEAD PLUG, STRAIGHT SCREW GASKET H DAMPER CLIP H DAMPER, ENGINE MOUNT FK COVER, CHAIN CASE JP GASKET, WATER PUMP BOLT, HEXAGON SOCKET HEAD PIN, DOWEL BOLT, HEXAGON SOCKET HEAD FK JOINT O-RING FK HOUSING, THERMOSTAT BOLT PLUG H THERMOSTAT ASSY B9

16 FIG. 5 WATER PUMP PART DESCRIPTION 28 11H SEAL, THERMOSTAT H COVER, THERMOSTAT O-RING BOLT, HEXAGON SOCKET HEAD B10

17 FIG. 6 RADIATOR & HOSE PART DESCRIPTION 1 1FK HOSE CLAMP, HOSE PLUG FK AIR SHROUD ASSY H MOTOR ASSY H FAN SCREW, PAN HEAD WASHER, PLATE NUT H WASHER WASHER H BOLT, BLOWER HOLDING AA PLATE GROMMET GROMMET COLLAR GROMMET COLLAR BOLT WASHER, PLATE FK COVER, RADIATOR SCREW, PAN HEAD WASHER, PLATE FK 1240J 00 RADIATOR COVER ASS'Y FK PLATE FK 1240K 00 RADIATOR COVER ASSY FK PLATE B11

18 FIG. 6 RADIATOR & HOSE PART DESCRIPTION SCREW, WITH WASHER FK DRAIN COCK ASSY O-RING FK PIPE, BYPASS A4 SPRING, COMPRESSION CLAMP, HOSE HOSE (L470) CLIP FK HOSE FK HOSE CLIP FK HOSE A5 SPRING, COMPRESSION CLAMP, HOSE FK JOINT SCREW, PAN HEAD WASHER, PLATE FK SUPT, FILLER NECK W CAP, RADIATOR O-RING SCREW, PAN HEAD WASHER, PLATE FK 1246A 10 COVER FK 1246E 10 COVER H GASKET, HOUSING COVER BOLT, HEXAGON SOCKET HEAD H GASKET, HOUSING COVER B12

19 FIG. 6 RADIATOR & HOSE PART DESCRIPTION 55 1FK PIPE, BREATHER CLIP FK BOLT FK HOSE CLIP H HOSE CLAMP, HOSE FK 1246K 00 COVER FK RADIATOR ASSY B13

20 FIG. 7 OIL PUMP PART DESCRIPTION 1 1FK OIL PUMP ASSY H GEAR, PUMP DRIVEN (28T) CIRCLIP FK PIPE, DELIVERY O-RING FK GROMMET PIN, DOWEL BOLT H GEAR, PUMP IDLE 1 (16T) H SHAFT, IDLE GEAR H GEAR, PUMP IDLE 2 (15T) CIRCLIP B14

21 FIG. 8 OIL CLEANER PART DESCRIPTION 1 5GH ELEMENT ASSY, OIL CLEANER BOLT, UNION H COVER, STRAINER H Y DELIVERY PIPE ASS'Y O-RING O-RING O-RING H GROMMET H GROMMET BOLT, FLANGE H PIPE, DELIVERY O-RING JP GASKET, STRAINER COVER PLUG, STRAIGHT SCREW GASKET BOLT H PLATE, BAFFLE LOWER BOLT, FLANGE H PIPE, DELIVERY BOLT, UNION GASKET BOLT, UNION WASHER, PLATE PIN, DOWEL H PIPE, DELIVERY O-RING H PIPE, OIL B15

22 FIG. 8 OIL CLEANER PART DESCRIPTION 28 26H GASKET BOLT, UNION GASKET CLAMP CLAMP FK STAY BOLT, FLANGE C2

23 FIG. 9 INTAKE PART DESCRIPTION 1 1FK JOINT, CARBURETOR FK JOINT, CARBURETOR FK JOINT, CARBURETOR FK JOINT G PLUG, BLIND CLIP O-RING BOLT BOLT AE BAND CLAMP, HOSE UT VALVE ASSY FK 1130E 00 CABLE PULLEY ASSY FK 1133E 00.CABLE, PULLEY SPRING, COMPRESSION BOLT, BUTTON HEAD FK 1133F 00.CABLE, PULLEY FK VALVE COVER ASS'Y FK DAMPER SCREW, BINDING CLAMP SCREW, PAN HEAD WASHER, PLATE GROMMET COLLAR HOSE (L150) CLIP C3

24 FIG. 9 INTAKE PART DESCRIPTION 28 41R NOZZLE A9 HOSE (L90) CLIP SCREW, WITH WASHER FK FUEL PUMP COMP E7 HOSE (L220) CLIP FK CASE, AIR CLEANER FK COVER AE SEAL SCREW, TAPPING FK JOINT O-RING FK 1445E 00 FILTER FK JOINT, AIR CLEANER CLAMP, HOSE FK ELEMENT, AIR CLEANER FK CAP, CLEANER CASE FK SEAL SCREW, PAN HEAD WASHER, PLATE FK SEAL FK SEAL FK DUCT SCREW, TAPPING FK STAY FK STAY C4

25 FIG. 10 CARBURETOR PART DESCRIPTION 1 1FK CARBURETOR ASSY FK CARBURETOR ASSY FK CARBURETOR ASSY FK CARBURETOR ASSY SCREW, PAN HEAD SCREW, PAN HEAD FK SPRING, DIAPHRAGM FK 1490J 00.NEEDLE SET FK DIAPHRAGM ASSY O-RING G JET, PILOT AIR (#170) H 1490H 00.DIAPHRAGM SET SCREW, PAN HEAD G JET, MAIN (# 90) H 1490K 00.STOP SCREW SET F SCREW JB GASKET WASHER, SPRING SCREW, PAN HEAD GR 1410A 00.STARTER SET H 1490K 00.STOP SCREW SET R PILOT SCREW SET SCREW H WASHER U PLUG, SCREW U O-RING FK FLOAT 1 1 C5

26 FIG. 10 CARBURETOR PART DESCRIPTION 28 22U SCREW WASHER, MAIN JET SCREW, PAN HEAD WASHER, SPRING H 1411A 00.BLOCK JET ASSY U O-RING H NOZZLE, MAIN JB GASKET FK NEEDLE VALVE ASSY J NET, FILTER FK O-RING R CAP O-RING L PLUG, DRAIN G JET, PILOT (#37.5) V CAP H 1414G 00.PIPE, MAIN BREED U CAP G JET, MAIN (#152.5) V O-RING SCREW, PAN HEAD WASHER, SPRING GR PIPE FK PIPE R PIPE U PIPE F CAP 1 1 C6

27 FIG. 10 CARBURETOR PART DESCRIPTION 55 1JH CLIP, PIPE SCREW, PAN HEAD SCREW, PAN HEAD U 1490M 00 STARTER LEVER SET, H THROTTLE SCREW SET FK LEVER, STARTER H SCREW H ROD SET FK 1490L 00 STARTER LEVER SET, H HOSE H HOSE CLIP H CLIP, PIPE FK 2631J 00 CABLE, THROTTLE FK CABLE, THROTTLE H BRACKET C7

28 FIG. 11 CARBURETOR 2 PART DESCRIPTION 1 1FK CARBURETOR ASSY 1 2 1FK CARBURETOR ASSY FK CARBURETOR ASSY FK CARBURETOR ASSY FK CARBURETOR ASSY SCREW, PAN HEAD SCREW, PAN HEAD 7 8 1FK SPRING, DIAPHRAGM 1 9 1FK 1490J 00..NEEDLE SET FK DIAPHRAGM ASSY O-RING G JET, PILOT AIR (#170) H 1490H 00..DIAPHRAGM SET SCREW, PAN HEAD G JET, MAIN (# 90) H 1490K 00..STOP SCREW SET F SCREW JB GASKET WASHER, SPRING SCREW, PAN HEAD GR 1410A 00..STARTER SET H 1490K 00..STOP SCREW SET R PILOT SCREW SET SCREW H WASHER U PLUG, SCREW U O-RING 1 C8

29 FIG. 11 CARBURETOR 2 PART DESCRIPTION 28 1FK FLOAT U SCREW WASHER, MAIN JET SCREW, PAN HEAD WASHER, SPRING H 1411A 00..BLOCK JET ASSY U O-RING H NOZZLE, MAIN JB GASKET FK NEEDLE VALVE ASSY J NET, FILTER FK O-RING R CAP O-RING L PLUG, DRAIN G JET, PILOT (#37.5) V CAP H 1414G 00..PIPE, MAIN BREED U CAP G JET, MAIN (#152.5) V O-RING SCREW, PAN HEAD WASHER, SPRING GR PIPE FK PIPE R PIPE U PIPE 1 C9

30 FIG. 11 CARBURETOR 2 PART DESCRIPTION 55 3F CAP JH CLIP, PIPE SCREW, PAN HEAD SCREW, PAN HEAD U 1490M 00.STARTER LEVER SET, H THROTTLE SCREW SET FK LEVER, STARTER H SCREW H ROD SET FK 1490L 00.STARTER LEVER SET, H HOSE H HOSE CLIP H CLIP, PIPE FK 2631J 00.CABLE, THROTTLE FK CABLE, THROTTLE H BRACKET 1 2 C10

31 FIG. 12 EXHAUST PART DESCRIPTION 1 3GD GASKET, EXHAUST PIPE FK JOINT, EXHAUST FK JOINT, EXHAUST NUT FK GASKET, EXHAUST PIPE FK RING, STOPPER H BAND, MUFFLER BOLT, HEXAGON SOCKET HEAD FK PIPE, EXHAUST FK PIPE, EXHAUST WASHER, PLATE BOLT FK COVER FK 1465R 00 PLATE, PROTECTOR SCREW, PAN HEAD WASHER, PLATE FK COVER, EXHAUST FK 1465T 00 PLATE, PROTECTOR SCREW, PAN HEAD WASHER, PLATE BOLT BOLT BOLT FK COVER, AIR BOLT, WITH WASHER GD GASKET, EXHAUST PIPE FK EXHAUST PIPE ASSY C11

32 FIG. 12 EXHAUST PART DESCRIPTION 28 3XW GASKET, SILENCER BOLT, FLANGE WASHER, PLATE BOLT FK EXHAUST PIPE ASSY WASHER, PLATE BOLT NUT FK STAY, MUFFLER BOLT K DAMPER, MUFFLER FK DAMPER, MUFFLER FK COLLAR E0 WASHER, PLATE BOLT UT MUFFLER ASSY XW GASKET, SILENCER BOLT, FLANGE WASHER, PLATE BOLT, FLANGE C12

33 FIG. 13 CRANKCASE PART DESCRIPTION 1 1FK CRANKCASE ASSY H NOZZLE G NOZZLE PIN, DOWEL AA DAMPER, ENGINE MOUNT A1 BOLT BOLT, STUD BOLT, STUD FK COVER, CAP SCREW, COUNTERSUNK PLUG AA DAMPER, ENGINE MOUNT AA DAMPER, ENGINE MOUNT H PLUG O-RING BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE GASKET BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE G0 BOLT C13

34 FIG. 13 CRANKCASE PART DESCRIPTION BOLT, FLANGE BOLT, FLANGE WASHER, PLATE H PLATE H PLATE, BEARING COVER SCREW H PLATE, BEARING COVER SCREW, COUNTERSUNK CLAMP CLAMP SCREW, PAN HEAD WASHER, PLATE H GAUGE, LEVEL H PLUG, OIL O-RING BOLT, FLANGE WASHER, PLATE H PIPE, BREATHER O-RING FK HOLDER, CLUTCH CABLE C14

35 FIG. 14 CRANKCASE COVER 1 PART DESCRIPTION 1 1FK COVER, CRANKCASE JP GASKET, CRANKCASE COVER PIN, DOWEL BOLT, HEXAGON SOCKET HEAD CLAMP CLAMP SCREW, PAN HEAD PLUG, STRAIGHT SCREW O-RING FK COVER, CAP O-RING SCREW, COUNTERSUNK FK GASKET FK COVER, CRANKCASE FK COVER, CHAIN CASE H DAMPER CLIP H DAMPER, ENGINE MOUNT JP GASKET, CRANKCASE COVER PIN, DOWEL BOLT, HEXAGON SOCKET HEAD GASKET BOLT, HEXAGON SOCKET HEAD FK COVER, CRANKCASE FK COVER, CHAIN CASE H RING, RUBBER H GROMMET C15

36 FIG. 14 CRANKCASE COVER 1 PART DESCRIPTION WASHER SCREW, PAN HEAD JP GASKET, CRANKCASE COVER PIN, DOWEL BOLT, HEXAGON SOCKET HEAD BOLT, HEXAGON SOCKET HEAD D2

37 FIG. 15 STARTER CLUTCH PART DESCRIPTION 1 26H GEAR 2 (42T) H GEAR 3 (13T) H SHAFT H GEAR, IDLER 1 (27T) H SHAFT H GEAR, IDLER 2 (76T) H STARTER CLUTCH OUTER ASSY SPRING, COMPRESSION J CAP, STARTER CLUTCH SPRING PIN, DOWEL BOLT F3 WASHER, PLATE D3

38 FIG. 16 CLUTCH PART DESCRIPTION 1 26H PRIMARY DRIVEN GEAR COMP H PLATE, THRUST FK BOSS, CLUTCH H RING, CLUTCH BOSS H PLATE, SEAT FK SPRING, CLUTCH BOSS H PLATE, FRICTION H PLATE, CLUTCH H PLATE, FRICTION H PLATE, CLUTCH FK PLATE, PRESSURE FK SPRING, CLUTCH FK HOUSING, SPRING FK PLATE, PRESSURE BOLT BEARING (B6003C4) WASHER, LOCK NUT Y ROD, PUSH O-RING NK ROD, PUSH BALL OIL SEAL H GUIDE, PUSH ROD O-RING PIN, DOWEL FK PUSH LEVER COMP D4

39 FIG. 16 CLUTCH PART DESCRIPTION 28 1NL W BLEED SCREW KIT H W PUSH LEVER SEAL KIT BOLT, HEXAGON SOCKET HEAD BOLT, HEXAGON SOCKET HEAD FK 1638A 00 PIPE, CLUTCH WASHER, PLATE GASKET BOLT, UNION FK COLLAR D5

40 FIG. 17 TRANSMISSION PART DESCRIPTION 1 1FK AXLE, MAIN (17T) FK GEAR, 4TH PINION (26T) WASHER CIRCLIP FK GEAR, 2ND/3RD PINION (22/23T) FK GEAR, 5TH PINION (28T) BEARING BEARING CIRCLIP K5 WASHER, PLATE CIRCLIP NK AXLE, DRIVE FK GEAR, 5TH WHEEL (26T) FK GEAR, 2ND WHEEL (39T) WASHER CIRCLIP H GEAR, 3RD WHEEL (31T) WASHER CIRCLIP FK GEAR, 4TH WHEEL (28T) FK GEAR, 1ST WHEEL (43T) BEARING PLUG BEARING K5 WASHER, PLATE (0.5T) UN K6 WASHER, PLATE (0.9T) UN K7 WASHER, PLATE (1.3T) UN D6

41 FIG. 17 TRANSMISSION PART DESCRIPTION CIRCLIP D7

42 FIG. 18 MIDDLE DRIVE GEAR PART DESCRIPTION 1 2WE HOLDER SPRING, COMPRESSION WE CAM, DRIVEN H W MIDDLE GEAR COMP K4 WASHER, PLATE WASHER BEARING (B6209RSH2-C2) NUT X SHIM, PINION (0.15T) UR 4X SHIM, PINION (0.30T) UR 4X SHIM, PINION (0.50T) UR BEARING WASHER, PLATE H SPACER, EXPANSION BEARING H YOKE, JOINT R6 WASHER, PLATE NUT H HOUSING, BEARING OIL SEAL O-RING UF SHIM, PINION (0.10T) UR 3UF SHIM, PINION (0.15T) UR 3UF SHIM, PINION (0.20T) UR 3UF SHIM, PINION (0.30T) UR 3UF SHIM, PINION (0.40T) UR 3UF SHIM, PINION (0.50T) UR D8

43 FIG. 18 MIDDLE DRIVE GEAR PART DESCRIPTION BOLT, FLANGE WASHER, PLATE D9

44 FIG. 19 SHIFT CAM & FORK PART DESCRIPTION 1 26H SHIFT CAM ASSY BEARING SPACER PIN, DOWEL NK PLATE, STOPPER NK SEGMENT PIN, DOWEL SCREW, COUNTERSUNK SPRING, COMPRESSION UN POINT, NEUTRAL UN PLATE, SIDE SCREW PIN, DOWEL H FORK, SHIFT H FORK, SHIFT H FORK, SHIFT H BAR, SHIFT FORK GUIDE D10

45 FIG. 20 SHIFT SHAFT PART DESCRIPTION 1 26H STOPPER, SHIFT BAR SCREW, COUNTERSUNK BOLT WASHER, LOCK H STOPPER LEVER ASSY F8 BOLT HOOK, SPRING SPRING, TENSION OIL SEAL (SD HS) FK SHIFT SHAFT ASSY SPRING, TENSION SPRING, TORSION CIRCLIP E1 WASHER, PLATE FK SHIFT PEDAL ASSY N COVER, SHIFT PEDAL H COVER, DUST FK BRACKET WASHER, PLATE CIRCLIP FK LEVER, SHIFT H COVER, DUST X ROD, SHIFT NUT NUT(COUNTER CLOCKWISE) BOLT D11

46 FIG. 21 FRAME PART DESCRIPTION 1 2EN P0 FRAME COMP MBL2 2 1AA 2143A 00 CAP FK P0 DOWN TUBE COMP MBL2 4 3UF P0 BACK STAY SUB COMP MBL2 5 1FK 2141V 10 CROSS BAR COMPLETE FK STAY, ENGINE BOLT, HEXAGON SOCKET HEAD NUT BOLT, HEXAGON SOCKET HEAD A0 BOLT, FLANGE NUT, CROWN BOLT, FLANGE BOLT, FLANGE BOLT, FLANGE NUT, CROWN WASHER, SPRING BOLT, FLANGE WASHER, PLATE FK 2117F 01 COVER FK 2117M 00 COVER FK 2117N 01 COVER R HELMET HANGER ASSY SCREW FK TOOL KIT D12

47 FIG. 22 FENDER PART DESCRIPTION 1 1FK P0 FENDER, FRONT MBL COLLAR BOLT WASHER, PLATE FK P5 FENDER, REAR MBL EMBLEM, YAMAHA FK REINF. COMP BOLT, FLANGE NUT, FLANGE BOLT, FLANGE NUT, FLANGE DAMPER FK COVER, TAILLIGHT LGB 14 31A PLATE SCREW, PAN HEAD WASHER, PLATE CLAMP CLAMP FK GUARD, MUD SCREW, PAN HEAD WASHER, PLATE WASHER, PLATE FK STAY, REAR BOLT, FLANGE BOLT PLUG FK 2163A 00 COVER, REAR FENDER D13

48 FIG. 22 FENDER PART DESCRIPTION 28 1FK 2163E 00 COVER, REAR FENDER NUT WASHER, PLATE FK DAMPER D14

49 FIG. 23 SIDE COVER PART DESCRIPTION 1 3JP COVER, SIDE UT EMBLEM JP COVER, SIDE UT EMBLEM BOLT, HEXAGON SOCKET HEAD WASHER N DAMPER JP COVER, SIDE JP COVER, SIDE FK DAMPER, LOCATING NUT, SPRING FK DAMPER BOLT, BUTTON HEAD BOLT, BUTTON HEAD FK 2172G 00 PANEL FK 2837N 00 GRILL, AIR INTAKE FK 2172H 00 PANEL FK 2837R 00 GRILL, AIR INTAKE BOLT FK 2172W 00 COVER CLIP FK 2172A 01 PANEL FK 2172F 00 PANEL SCREW, PAN HEAD WASHER, PLATE SCREW, PAN HEAD WASHER, PLATE D15

50 FIG. 23 SIDE COVER PART DESCRIPTION 28 1FK 2171E 00 COVER, SIDE FK 2171T 00 MOLE, SIDE COVER SCREW, TAPPING WASHER NUT, SPRING FK 2171X 00 COVER, SIDE FK 2171U 00 MOLE, SIDE COVER GROMMET FK Y217F 00 P5 COVER, TOP (FUEL TANK) MBL2 37 5GK 2173L 00.GRAPHIC SET FK 2175J 00 LEVER LOCK COMP BOLT, FLANGE FK DAMPER FK MOLE FK 2171H 00 GUIDE FK 2171L 00 MOLE, SIDE COVER FK SEAL FK EMBLEM FK EMBLEM FK DAMPER, LOCATING FK 2172M 00 BRACKET A DAMPER, SEAT BOLT WASHER, PLATE FK LOCK ASSY FK COVER NUT, FLANGE E2

51 FIG. 23 SIDE COVER PART DESCRIPTION 55 1FK 2176U 00 SHAFT, LOCK FK 2175K 00 LEVER, LOCK CIRCLIP FK 2176V 00 SPRING, LOCK FK PLATE, BRIDGE BOLT WASHER, PLATE FK 2172K 01 BRACKET SCREW, PAN HEAD WASHER, PLATE GROMMET A7 COLLAR WASHER, PLATE NUT, FLANGE UF BRACKET, COIL FK 2171M 00 MOLE, SIDE COVER BOLT WASHER, PLATE N DAMPER GROMMET, WIREHERNESS FK 2177G 00 BOX, BATTERY BOLT, WITH WASHER FK TANK, RECOVERY FK PIPE H CAP H GASKET H PIPE E3

52 FIG. 23 SIDE COVER PART DESCRIPTION 82 26H ELBOW CLIP FK PIPE, BREATHER CLIP FK 2177M 00 DAMPER, LOCATING Y CLAMP KB SEAL TU TAPE JP 2179V F0 PLATE, EPA 1(NON CALIFORNIA) 1 E4

53 FIG. 24 REAR ARM PART DESCRIPTION 1 2EN W REAR ARM COMP SL BEARING COLLAR OIL SEAL X SHAFT, PIVOT WASHER, LOCK J SHAFT, PIVOT J NUT H7 2219X 00 COVER BOLT WASHER H BOOT, RUBBER PLUG SPRING, TENSION E5

54 FIG. 25 DRIVE SHAFT PART DESCRIPTION 1 1FK REAR AXLE GEAR CASE ASSY BOLT, STUD BOLT, STUD BOLT, STUD YE COLLAR, GUIDE BEARING BEARING H RACE, INNER 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 (B6305RB1 SPECIAL) H RETAINER, BEARING O-RING OIL SEAL H COUPLING, GEAR R5.WASHER, PLATE NUT FK HOUSING, BEARING J Y0 25.SHIM, RING GEAR (0.25T) UR 1J Y0 30.SHIM, RING GEAR (0.30T) UR 1J Y0 40.SHIM, RING GEAR (0.40T) UR 1J Y0 50.SHIM, RING GEAR (0.50T) UR BEARING U SHIM, THRUST (1.2T) UR 22U SHIM, THRUST (1.4T) UR 22U SHIM, THRUST (1.6T) UR E6

55 FIG. 25 DRIVE SHAFT PART DESCRIPTION 20 22U SHIM, THRUST (1.8T) UR 22U SHIM, THRUST (2.0T) UR O-RING NUT WASHER, WAVE BOLT, FLANGE OIL SEAL PLUG, STRAIGHT SCREW GASKET H BREATHER COMP PLUG, STRAIGHT SCREW FK COVER, HOUSING FK STOPPER, RING GEAR FK SHIM, STOPPER (T=0.15) UR 1FK SHIM, STOPPER (T=0.20) UR OIL SEAL FK SHAFT, DRIVE OIL SEAL A2 WASHER, PLATE CIRCLIP CIRCLIP X CROSS JOINT COMP BEARING SPRING, COMPRESSION CIRCLIP NUT, CROWN WASHER, SPRING E7

56 FIG. 26 REAR SUSPENSION PART DESCRIPTION 1 3JP SHOCK ABSORBER ASSY, REAR X WASHER BOLT, FLANGE A1 WASHER, PLATE NUT, CROWN E8

57 FIG. 27 STEERING PART DESCRIPTION BEARING BEARING J COVER, BALL RACE NUT WASHER, PLATE H WASHER, SPECIAL NUT, CROWN T0 WASHER, PLATE LR 2313A 00 BRACE, FORK BOLT, FLANGE FK CROWN, HANDLE BOLT FK HOLDER, HANDLE UPPER CLP BOLT PLUG FK HOLDER, HANDLE LOWER CLP NUT, SELF-LOCKING FK COVER, CROWN CLP BOLT WASHER, PLATE FK STAY, HEADLIGHT BOLT FK STAY, PLATE BOLT WASHER, PLATE R STEERING LOCK ASSY SPRING, CONICAL E9

58 FIG. 27 STEERING PART DESCRIPTION CAP, HANDLE LOCK RIVET WASHER, CONICAL SPRING FK HOLDER, CABLE E10

59 FIG. 28 FRONT FORK PART DESCRIPTION 1 5GK FRONT FORK ASSY (L.H) GK TUBE, OUTER (LEFT) V L0.RING, SNAP PU OIL SEAL EB METAL, SLIDE PU SEAL, DUST V L0.WASHER, OIL SEAL GK INNER TUBE COMP EA PISTON, FRONT FORK YR SPINDLE, TAPER GK CYLINDER COMP., FRONT FORK GK SPRING, FRONT FORK L0.GASKET BOLT, HEXAGON SOCKET HEAD LR BOLT, CAP V L0..O-RING LR CAP, FRONT FORK BOLT, FLANGE YF SPACER LR WASHER, SPRING UPPER GK FRONT FORK ASSY (R.H) GK TUBE, OUTER (RIGHT) V L0.RING, SNAP PU OIL SEAL EB METAL, SLIDE PU SEAL, DUST V L0.WASHER, OIL SEAL E11

60 FIG. 28 FRONT FORK PART DESCRIPTION 28 5GK INNER TUBE COMP EA PISTON, FRONT FORK YR SPINDLE, TAPER GK CYLINDER COMP., FRONT FORK GK SPRING, FRONT FORK L0.GASKET BOLT, HEXAGON SOCKET HEAD LR BOLT, CAP V L0..O-RING LR CAP, FRONT FORK YF SPACER LR WASHER, SPRING UPPER LR UNDER BRACKET COMP BOLT PU 2331G 00 COVER KM COVER, LOWER E12

61 FIG. 29 FUEL TANK PART DESCRIPTION 1 1FK FUEL TANK COMP YB BOLT, FLANGE WASHER, PLATE FK DAMPER, LOCATING FK DAMPER, LOCATING FK DAMPER, LOCATING FK WASHER, SPECIAL G5 COLLAR G8 WASHER, PLATE BOLT WASHER, PLATE FK DAMPER, LOCATING FK FILTER ASSY FK PIPE FK PIPE CLAMP CLIP FK BRACKET, FILTER K CAP ASSY FK 2414A 00 COVER, FILLER FK SPRING A8 HOSE (L500) FK PIPE, JOINT CLIP H ROLL OVER VALVE ASSY CLAMP SCREW, TAPPING E13

62 FIG. 29 FUEL TANK PART DESCRIPTION 28 1FK PIPE, FUEL CLIP K7 HOSE (L650) CLIP FK 2419A 00 HOLDER BOLT WASHER, PLATE FK SENDER UNIT ASSY, FUEL METER X GASKET, SENDER UNIT SCREW WASHER, PLATE E14

63 FIG. 30 SEAT PART DESCRIPTION 1 5GK SEAT COMP GK 2470F 00.SEAT COVER COMP GK SEAT BACK ASSY GK 2470F 10.SEAT COVER COMP FK 2476F 00.PIN, GUIDE FK WASHER FK HINGE ASS'Y NUT, FLANGE GK TANDEM SEAT ASSY GK 2470F 20.SEAT COVER COMP W PAD, SEAT BOLT, FLANGE SCREW, WITH WASHER BOLT, WITH WASHER FK 2473T 00 LID H BAND, TOOL FK SEAT LEVER ASSY FK SEAT LOCK ASSY BOLT WASHER, PLATE UF DAMPER, SEAT E15

64 FIG. 31 FRONT WHEEL PART DESCRIPTION 1 2HY CAST WHEEL, FRONT SL SPACER FLANGE, SPACER BEARING OIL SEAL CLUTCH, METER RETAINER, CLUTCH OIL SEAL F TIRE (110/90-18 M/C 61V G525) UR BRIDGESTONE D TIRE (110/90-18 M/C 61V F20) UR DUNLOP VALVE, RIM (TR413) L BALANCER, WHEEL (10G) UN 29L BALANCER, WHEEL (20G) UN 29L BALANCER, WHEEL (30G) UN 12 1FK GEAR UNIT ASSY R6 COLLAR FK AXLE, WHEEL F2

65 FIG. 32 FRONT BRAKE CALIPER PART DESCRIPTION 1 3LR 2581T 00 DISC BRAKE ASSY G4 BOLT JP 2580T 00 CALIPER ASSY (LEFT) HE W PISTON ASSY, CALIPER HE W CALIPER SEAL KIT GM W BRAKE PAD KIT GM SUPPORT, PAD HE PIN, PAD GM CLIP J3 W BLEED SCREW KIT KT COVER, DUST JP 2580U 00 CALIPER ASSY (RIGHT) HE W PISTON ASSY, CALIPER HE W CALIPER SEAL KIT GM W BRAKE PAD KIT GM SUPPORT, PAD HE PIN, PAD GM CLIP J3 W BLEED SCREW KIT KT COVER, DUST BOLT, FLANGE F3

66 FIG. 33 REAR WHEEL PART DESCRIPTION 1 1UT CAST WHEEL, REAR SL 2 2H FLANGE, SPACER SPACER BEARING H7 COLLAR BEARING CIRCLIP OIL SEAL H CLUTCH, HUB PIN FK DAMPER J SEAL, HUB DUST CIRCLIP O-RING OIL SEAL G TIRE (150/90-15 M/C 74V G526) UR BRIDGESTONE E TIRE (150/90-15 M/C 74V K525) UR DUNLOP VALVE, RIM (TR413) L BALANCER, WHEEL (10G) UN 29L BALANCER, WHEEL (20G) UN 29L BALANCER, WHEEL (30G) UN 19 4NK AXLE, WHEEL U5 WASHER, PLATE NUT, SELF-LOCKING WASHER F4

67 FIG. 34 REAR BRAKE PART DESCRIPTION 1 3JP 2582U 00 DISC, BRAKE (RIGHT) G4 BOLT FK COVER, PLATE SCREW, PAN HEAD WASHER, PLATE J2 COLLAR FK BRACKET, CALIPER BH 2580W 00 CALIPER ASSY, REAR A W PISTON ASSY, CALIPER A W CALIPER SEAL KIT FK W BRAKE PAD KIT H SUPPORT, PAD HE PIN, PAD HE CLIP J3 W BLEED SCREW KIT Y COVER, DUST FK SHIM, CALIPER FK SHIM, CALIPER BOLT, FLANGE Y BAR, TENSION BOLT, FLANGE NUT, U FLANGE F5

68 FIG. 35 STEERING HANDLE & CABLE PART DESCRIPTION 1 1FK HANDLEBAR JB GRIP JB ROTOR JB GRIP ASSY JB 2628J 00 CAP, GRIP FK CABLE, THROTTLE FK CABLE, THROTTLE H HOLDER SCREW, PAN HEAD H CONNECTOR, CABLE H CAP, CABLE CONNECTOR H CAP H SLIDER, THROTTLE SCREW, TAPPING F6

69 FIG. 36 FRONT MASTER CYLINDER PART DESCRIPTION 1 3HE 2583T 01 MASTER CYLINDER ASSY HE CAP, RESERVOIR Y 2589H 00.SCREW Y DIAPHRAGM, RESERVOIR Y W CYLINDER KIT, MASTER Y BRACKET, MASTER CYLINDER BOLT, HEXAGON SOCKET HEAD WASHER, SPRING L BOOT, MASTER CYLINDER FK HOSE, BRAKE BOLT, UNION WASHER, PLATE H JOINT BOLT LR HOSE, BRAKE LR HOSE, BRAKE BOLT, UNION WASHER, PLATE BOLT, UNION WASHER, PLATE R HOLDER, BRAKE HOSE BOLT, FLANGE R HOLDER, BRAKE HOSE BOLT, FLANGE BOLT, UNION WASHER, PLATE AA REAR VIEW MIRROR ASSY (RIGHT) F7

70 FIG. 37 FRONT MASTER CYLINDER 2 PART DESCRIPTION 1 2KW W MASTER CYLINDER SUB ASSY KW W CYLINDER KIT, MASTER (CLUTCH) H ROD, PUSH GM BUSH AE DIAPHRAGM, RESERVOIR FK CAP, RESERVOIR SCREW, FLAT HEAD FK LEVER FK 2589F 00 BOLT, LEVER NUT, U AE HOLDER BOLT, HEXAGON SOCKET HEAD WASHER, SPRING L BOOT, MASTER CYLINDER FK HOSE, CLUTCH UA BAND BOLT, UNION WASHER, PLATE FK HOLDER SCREW, PAN HEAD WASHER, PLATE AA REAR VIEW MIRROR ASSY (LEFT) F8

71 FIG. 38 STAND & FOOTREST PART DESCRIPTION 1 1UT FRONT FOOTREST ASSY (LEFT) NH COVER, FOOTREST NUT, U BOLT, FLANGE UT FRONT FOOTREST ASSY (RIGHT) NH COVER, FOOTREST NUT, U BOLT, FLANGE UT REAR FOOTREST ASSY NH COVER, REAR FOOTREST SCREW, PAN HEAD NUT, FLANGE FK BRACKET BOLT, FLANGE BOLT, FLANGE A1 BOLT, FLANGE H DAMPER, FOOTREST H 2743E 00 STOPPER UT REAR FOOTREST ASSY NH COVER, REAR FOOTREST SCREW, PAN HEAD NUT, FLANGE FK BRACKET BOLT, FLANGE BOLT, FLANGE H DAMPER, FOOTREST H 2743E 00 STOPPER F9