YZ450FX (2S2B) U.S.A.,CANADA YZ450F (2S2C) EUROPE YZ450F (2S2D) JAPAN YZ450FX (2S2E) OCEANIA,SOUTH AFRICA

Transcription

1 YZ450FX () U.S.A.,CANADA YZ450F () EUROPE YZ450F () JAPAN YZ450FX () OCEANIA,SOUTH AFRICA NEWS No. DATE COMMENT PE0-MC Oct.,17,2007 FIG.26:FRONT FORK LIST CORRECTION 1G2S2-100E1 ( 2G2S2-100E1 ) A2

2 YZ450FX/YZ450F PARTS CATALOGUE 2007 by Yamaha Motor Co., Ltd. 1st edition, June 2007 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. A3

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 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. A4

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 DPBSE(*) DEEP PURPLISH BLUE SOLID E 0583 PWS1(*) PURPLISH WHITE SOLID A5

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 (5) Model Code Production Code Number of Model Listed in This Parts Catalogue Model Code Production Code No. Country (destination) 010 U.S.A. 020 CANADA 010 EUROPE 010 JAPAN 010 AUSTRALIA NEW ZEALAND SOUTH AFRICA Model Code Production Code No. Country (destination) (4) Colouring Information Model Code Colouring Type Code Colour Code Colour Name Abbreviation A 0583 DEEP PURPLISH BLUE SOLID E DPBSE B 0206 PURPLISH WHITE SOLID 1 PWS1 A 0583 DEEP PURPLISH BLUE SOLID E DPBSE B 0206 PURPLISH WHITE SOLID 1 PWS1 A 0583 DEEP PURPLISH BLUE SOLID E DPBSE A 0583 DEEP PURPLISH BLUE SOLID E DPBSE B 0206 PURPLISH WHITE SOLID 1 PWS1 A6

6 CONTENTS ENGINE CYLINDER... B2 CRANKSHAFT & PISTON... B4 VALVE... B5 CAMSHAFT & CHAIN... B7 WATER PUMP... B8 RADIATOR & HOSE... B9 OIL PUMP... B11 OIL CLEANER... B12 INTAKE... B13 CARBURETOR... B14 EXHAUST... C4 EXHAUST 2... C5 CRANKCASE... C6 CRANKCASE COVER 1... C8 STARTER... C10 CLUTCH... C11 TRANSMISSION... C12 SHIFT CAM & FORK... C14 SHIFT SHAFT... C15 CHASSIS FRAME... D2 FENDER... D4 SIDE COVER... D6 REAR ARM... D7 REAR SUSPENSION... D9 STEERING... D11 FRONT FORK... D12 FUEL TANK... D15 SEAT... E3 FRONT WHEEL... E4 FRONT BRAKE CALIPER... E5 REAR WHEEL... E6 REAR BRAKE CALIPER... E8 STEERING HANDLE & CABLE... E9 FRONT MASTER CYLINDER... E10 STAND & FOOTREST... E11 REAR MASTER CYLINDER... E12 GENERATOR... E13 HANDLE SWITCH & LEVER... E14 ELECTRICAL 1... E15 ALTERNATE FOR CHASSIS... F2 INDEX NUMERICAL INDEX... M1

7 FIG. 1 CYLINDER PART DESCRIPTION 1 2S CYLINDER HEAD ASSY TA GUIDE, VALVE TA GUIDE, VALVE BOLT, FLANGE PLUG, STRAIGHT SCREW PIN, DOWEL BOLT, FLANGE GASKET BOLT, FLANGE BOLT, STUD NUT, WITH WASHER PLUG, SPARK (NGK R CR8E) STD PLUG, SPARK (NGK R CR8E) 1 STD PLUG, SPARK (NGK R CR9E) AP PLUG, SPARK (NGK R CR9E) 1 AP 13 2S GASKET, CYLINDER HEAD BOLT, FLANGE WASHER, PLATE S COVER, CYLINDER HEAD BE GUIDE, STOPPER UM 1119E 00 BOLT, COVER HEAD PIPE, BREATHER S PIPE, BREATHER A4 CLIP S GASKET, HEAD COVER S CYLINDER S GASKET, CYLINDER B2

8 FIG. 1 CYLINDER PART DESCRIPTION PIN, DOWEL BOLT, FLANGE S HOLDER, CLUTCH CABLE BOLT, FLANGE B3

9 FIG. 2 CRANKSHAFT & PISTON PART DESCRIPTION 1 2S CRANKSHAFT ASSY S CRANK S CRANK TG PIN, CRANK BEARING S ROD, CONNECTING BEARING S GEAR, DRIVE S SHAFT BEARING S GEAR, BALANCE WEIGHT NUT WASHER, LOCK S WEIGHT SCREW S WEIGHT KEY, STRAIGHT NUT WASHER, LOCK KEY, WOODRUFF S PISTON (STD) JG PISTON RING SET (STD) TA PIN, PISTON CIRCLIP B4

10 FIG. 3 VALVE PART DESCRIPTION 1 5TA VALVE, INTAKE TA VALVE, INTAKE TA VALVE, EXHAUST GM SEAT, VALVE SPRING TA SPRING, VALVE INNER TA SPRING, VALVE OUTER BE RETAINER, VALVE SPRING GY RETAINER, VALVE SPRING AA COTTER, VALVE WG COTTER, VALVE M SEAL, VALVE STEM SV SEAL, VALVE STEM LD PAD, ADJUSTING (1.20) UR 3LD PAD, ADJUSTING (1.25) UR 3LD PAD, ADJUSTING (1.30) UR 3LD PAD, ADJUSTING (1.35) UR 3LD PAD, ADJUSTING (1.40) UR 3LD A0 PAD, ADJUSTING (1.45) UR 3LD F0 PAD, ADJUSTING (1.50) UR 3LD H1 PAD, ADJUSTING (1.55) UR 3LD K1 PAD, ADJUSTING (1.60) UR 3LD M1 PAD, ADJUSTING (1.65) UR 3LD R1 PAD, ADJUSTING (1.70) UR 3LD U1 PAD, ADJUSTING (1.75) UR 3LD W1 PAD, ADJUSTING (1.80) UR 3LD Y1 PAD, ADJUSTING (1.85) UR 3LD PAD, ADJUSTING (1.90) UR B5

11 FIG. 3 VALVE PART DESCRIPTION 13 3LD PAD, ADJUSTING (1.95) UR 3LD PAD, ADJUSTING (2.00) UR 3LD PAD, ADJUSTING (2.05) UR 3LD PAD, ADJUSTING (2.10) UR 3LD E0 PAD, ADJUSTING (2.15) UR 3LD G0 PAD, ADJUSTING (2.20) UR 3LD J0 PAD, ADJUSTING (2.25) UR 3LD L0 PAD, ADJUSTING (2.30) UR 3LD N0 PAD, ADJUSTING (2.35) UR 3LD T0 PAD, ADJUSTING (2.40) UR 14 3FV LIFTER, VALVE YELLOW B6

12 FIG. 4 CAMSHAFT & CHAIN PART DESCRIPTION 1 2S CAMSHAFT ASSY S CAMSHAFT ASSY CIRCLIP CHAIN (98XRH M) TA TENSIONER ASSY, CAM CHAIN FM GASKET, TENSIONER CASE BOLT, FLANGE GASKET S DAMPER, CHAIN TA DAMPER, CHAIN BOLT WASHER, PLATE B7

13 FIG. 5 WATER PUMP PART DESCRIPTION 1 5GR SHAFT, IMPELLER DJ IMPELLER, WATER PUMP WASHER, PLATE OIL SEAL OIL SEAL (SD HS) BEARING BE COVER, HOUSING BE O-RING PIN, DOWEL GASKET BOLT, FLANGE BE PIPE, WATER O-RING B8

14 FIG. 6 RADIATOR & HOSE PART DESCRIPTION 1 2S2 1240A 70 RADIATOR ASSY S STAY, RADIATOR BOLT, BUTTON HEAD A6.NUT, SPRING S RADIATOR ASSY S STAY, RADIATOR BOLT, BUTTON HEAD A6.NUT, SPRING W CAP, RADIATOR A TUBE, FLEXIBLE VINYL A2 CLIP S PIPE BOLT O-RING S HOSE C PIPE S HOSE S HOSE S PIPE BOLT, FLANGE O-RING HOSE CLAMP ASSY HOSE CLAMP ASSY HOSE CLAMP ASSY GROMMET COLLAR BOLT, FLANGE B9

15 FIG. 6 RADIATOR & HOSE PART DESCRIPTION WASHER, PLATE B10

16 FIG. 7 OIL PUMP PART DESCRIPTION 1 2S OIL PUMP ASSY TA ROTOR ASSY PIN, DOWEL CIRCLIP PIN, DOWEL BOLT S SHAFT, IDLE GEAR SCREW S GEAR, OIL PUMP IDLE CIRCLIP WASHER, PLATE S HOUSING, STRAINER BE STRAINER, OIL BOLT, FLANGE PIN, DOWEL HOSE HOSE CLAMP ASSY B11

17 FIG. 8 OIL CLEANER PART DESCRIPTION 1 5TA ELEMENT ASSY, OIL CLEANER BE COVER, OIL ELEMENT O-RING O-RING BOLT, HEXAGON SOCKET HEAD BOLT BOLT B12

18 FIG. 9 INTAKE PART DESCRIPTION 1 2S JOINT, CARBURETOR HOSE CLAMP ASSY BOLT TA COVER TA GASKET TA SEAL TA HOSE TJ CLIP BOLT, HEXAGON SOCKET HEAD HOSE CLAMP ASSY S AIR CLEANER CASE ASSY S JOINT, AIR CLEANER NY HOLDER, GUIDE NY BAND NY SPACER XC COVER RIVET, BLIND WASHER, PLATE XM ELEMENT, AIR CLEANER WASHER BOLT, WING BE GUIDE BOLT B13

19 FIG. 10 CARBURETOR PART DESCRIPTION 1 2S B0 CARBURETOR ASSY JG GASKET BOLT SCREW WASHER, PLATE JG WASHER JG SCREW, ADJUST S VALVE, VACUUM CONTROL TJ ROLLER JG VALVE, NEEDLE FN SEAL TA LR.NEEDLE (#NFLR) STD 5TA LN.NEEDLE (#NFLN) AP 5TA LP.NEEDLE (#NFLP) AP 5TA L1.NEEDLE (#NFLQ) AP 5TA LS.NEEDLE (#NFLS) AP 5TA LT.NEEDLE (#NFLT) AP 5TA LU.NEEDLE (#NFLU) AP 5TA PN.NEEDLE (#NFPN) AP 5TA PP.NEEDLE (#NFPP) AP 5TA P1.NEEDLE (#NFPQ) AP 5TA PR.NEEDLE (#NFPR) AP 5TA PS.NEEDLE (#NFPS) AP 5TA PT.NEEDLE (#NFPT) AP 5TA PU.NEEDLE (#NFPU) AP 13 3TJ CLIP JG SCREW, ADJUST B14

20 FIG. 10 CARBURETOR PART DESCRIPTION 15 5JG SPRING JG COLLAR XD NOZZLE, MAIN MX JET, MAIN (#160) STD 4MX JET, MAIN (#148) AP 4MX JET, MAIN (#150) AP 4MX JET, MAIN (#152) AP 4MX JET, MAIN (#155) AP 4MX JET, MAIN (#158) AP 4MX JET, MAIN (#162) AP 4MX JET, MAIN (#165) AP 4MX JET, MAIN (#168) AP 4MX JET, MAIN (#170) AP 4MX JET, MAIN (#172) AP 19 4MX JET, SLOW (#45) STD 4MX JET, SLOW (#38) AP 4MX JET, SLOW (#40) AP 4MX JET, SLOW (#42) AP 4MX JET, SLOW (#48) AP 4MX JET, SLOW (#50) AP 4MX JET, SLOW (#52) AP 20 3TJ 1494F 16.JET (#72) STD 3TJ 1494F 14.JET (#68) AP 3TJ 1494F 15.JET (#70) AP 3TJ 1494F 17.JET (#75) AP 3TJ 1494F 18.JET (#78) AP 21 4JT 1494F 09.JET (#55) STD B15

21 FIG. 10 CARBURETOR PART DESCRIPTION 21 4JT 1494F 05.JET (#45) AP 4JT 1494F 07.JET (#50) AP 4JT 1494F 11.JET (#60) AP 4JT 1494F 13.JET (#65) AP 22 5TA JET, MAIN (#100) NL PILOT SCREW SET SR FLOAT PIN, FLOAT ARM MX VALVE, NEEDLE CLIP JG GASKET, FLOAT CHAMBER TJ PLUG, DRAIN TJ COVER JG DIAPHRAGM ASSY STD 5JG DIAPHRAGM ASSY AP 5JG DIAPHRAGM ASSY AP 32 3TJ GASKET TJ SPRING, DIAPHRAGM H O-RING XC PLUNGER, STARTER TA PLUNGER, STARTER TA SPRING, PLUNGER TA SCREW S CAP, PLUNGER TA GUIDE, CABLE TA SEAL JG ROD, STARTER C2

22 FIG. 10 CARBURETOR PART DESCRIPTION 43 3TJ O-RING XC SCREW, THROTTLE WASHER, PLATE TA SPRING, THROTTLE STOP XC THROTTLE SENSOR ASSY NX O-RING NX SCREW MX O-RING MX PLUG, SCREW TJ CLIP BE PLATE TA HOLDER UL PIPE TA PIPE TJ HOSE JG PLATE JG SCREW JG SPRING, ADJUST SCREW JG SCREW PA PLATE XD SCREW, PAN HEAD C3

23 FIG. 11 EXHAUST PART DESCRIPTION 1 2S PIPE, EXHAUST TA PROTECTOR, EXHAUST PIPE BD WASHER, PROTECTOR SCREW, BIND WASHER, WAVE VD GASKET, EXHAUST PIPE BOLT, HEXAGON SOCKET HEAD S B0 SILENCER ASSY S2 1466G B0.BODY, SILENCER RIVET, BLIND S2 1478H B0.FIBER, S2 1469F B0.FIBER VY GASKET, MUFFLER BE DAMPER, MUFFLER COLLAR S BAND, SILENCER BOLT, FLANGE BOLT, FLANGE WASHER, PLATE 1 1 C4

24 FIG. 12 EXHAUST 2 PART DESCRIPTION 1 2S PIPE, EXHAUST S PROTECTOR, EXHAUST PIPE WASHER, PLATE SCREW, BIND VD GASKET, EXHAUST PIPE BOLT, HEXAGON SOCKET HEAD S C0 SILENCER ASSY S2 1466G C0.BODY, SILENCER RIVET, BLIND S2 1469A 10.FIBER S2 1469E 00.FIBER S2 1469F 00.FIBER S GASKET, MUFFLER BE DAMPER, MUFFLER COLLAR S BAND, SILENCER BOLT, FLANGE BOLT, FLANGE WASHER, PLATE 1 1 C5

25 FIG. 13 CRANKCASE PART DESCRIPTION 1 2S CRANKCASE ASSY S NOZZLE XC PIPE, BREATHER PIN, DOWEL BOLT BOLT BOLT S COVER, CRANKCASE S GUIDE, CHAIN SCREW, PAN HEAD BOLT, FLANGE GASKET JT PLATE, BEARING COVER BE PLATE, BEARING COVER SCREW, COUNTERSUNK SCREW S PLATE, BEARING COVER S PLATE, STOPPER BOLT, FLANGE PIN, DOWEL O-RING COLLAR PIN, DOWEL BOLT BOLT, FLANGE GASKET S2 1536A 00 PLUG, OIL LEVEL C6

26 FIG. 13 CRANKCASE PART DESCRIPTION O-RING CLAMP BOLT, FLANGE GASKET C7

27 FIG. 14 CRANKCASE COVER 1 PART DESCRIPTION 1 2S COVER, CRANKCASE PLUG, STRAIGHT SCREW O-RING PLUG, STRAIGHT SCREW O-RING Y PLUG, OIL O-RING S HOLDER S GASKET, CRANKCASE COVER PIN, DOWEL O-RING BOLT, FLANGE BOLT, FLANGE S COVER, CRANKCASE OIL SEAL WASHER, PLATE (T=1.0) CIRCLIP XC PIPE, BREATHER S GASKET, CRANKCASE COVER PIN, DOWEL BOLT, FLANGE BOLT, FLANGE TA COVER, GENERATOR TA GASKET PIN, DOWEL BOLT, FLANGE BOLT, FLANGE C8

28 FIG. 14 CRANKCASE COVER 1 PART DESCRIPTION BOLT, FLANGE SEAT, CHECK BALL BALL E0 SPRING, COMPRESSION C9

29 FIG. 15 STARTER PART DESCRIPTION 1 2S KICK SHAFT ASSY WASHER, PLATE (T=0.5) CIRCLIP S WHEEL, RATCHET A2.SPRING, COMPRESSION P7.WASHER, PLATE CIRCLIP GR GUIDE, SPRING B0.SPRING, TORSION H4 WASHER, PLATE SG STOPPER WASHER, LOCK BOLT OIL SEAL TA GEAR, KICK IDLE WASHER, PLATE (T=0.5) CIRCLIP S KICK CRANK ASSY XD BOSS, KICK CRANK A5.SPRING, COMPRESSION BALL SCREW, COUNTERSUNK O-RING BOLT, HEXAGON SOCKET HEAD WASHER, PLATE C10

30 FIG. 16 CLUTCH PART DESCRIPTION 1 2S GEAR, PRIMARY DRIVE WASHER, CONICAL SPRING NUT XD PRIMARY DRIVEN GEAR COMP TA BOSS, CLUTCH S PLATE, PRESSURE X PLATE, CLUTCH TA PLATE, FRICTION E4 SPRING, COMPRESSION SCREW, WITH WASHER XD PLATE, THRUST WASHER, LOCK NUT JG ROD, PUSH BEARING L6 WASHER, PLATE CIRCLIP BALL S ROD, PUSH S PUSH LEVER ASSY BEARING OIL SEAL CIRCLIP C11

31 FIG. 17 TRANSMISSION PART DESCRIPTION BEARING S AXLE,MAIN(14T) S GEAR, 5TH PINION(21T) K0 WASHER, PLATE (T=1.0) CIRCLIP S GEAR, 3RD PINION(18T) S GEAR, 4TH PINION (22T) COLLAR S GEAR, 2ND PINION(15T) WASHER BEARING BEARING S DRIVE AXLE ASSY S GEAR, 1ST WHEEL(27T) COLLAR E7 WASHER, PLATE S GEAR, 5TH WHEEL(20T) CIRCLIP WASHER S GEAR, 3RD WHEEL(23T) K0 WASHER, PLATE (T=1.0) CIRCLIP S GEAR, 4TH WHEEL(24T) WASHER S GEAR, 2ND WHEEL(23T) COLLAR A5 BEARING C12

32 FIG. 17 TRANSMISSION PART DESCRIPTION OIL SEAL F COLLAR O-RING E SPROCKET, DRIVE (13T) WASHER, LOCK NUT S PLATE, COVER BOLT, FLANGE C13

33 FIG. 18 SHIFT CAM & FORK PART DESCRIPTION 1 5NL CAM, SHIFT BEARING POINT, NEUTRAL SPRING, COMPRESSION BEARING S STOPPER LEVER ASSY SPRING, TORSION BOLT WASHER, PLATE S FORK, SHIFT S FORK, SHIFT BE FORK, SHIFT C14

34 FIG. 19 SHIFT SHAFT PART DESCRIPTION 1 2S SHIFT SHAFT ASSY MW LEVER, SHIFT F4 COLLAR SPRING, TORSION E1 WASHER, PLATE PIN, DOWEL S SHIFT PEDAL ASSY BOLT, FLANGE OIL SEAL XJ PIN, SHIFT XJ ROLLER, SHIFT LEVER XJ PAWL, SHIFTER G5 SPRING, COMPRESSION XJ PIN, PAWL TJ GUIDE, SHIFT BOLT S SEGMENT C15

35 FIG. 20 FRAME PART DESCRIPTION 1 2S B0 FRONT FRAME COMP C BRACKET, FOOTREST C BRACKET, FOOTREST SCREW XC L0 REAR FRAME COMP S DAMPER, LOCATING S DAMPER, LOCATING S2 2177M 00 DAMPER, LOCATING BOLT, FLANGE BOLT, FLANGE X TENSIONER V BUSH WASHER, PLATE COLLAR BOLT, FLANGE JD TENSIONER BEARING N4 COLLAR BOLT, FLANGE NUT, SELF-LOCKING WASHER, PLATE BOLT, FLANGE NUT WASHER, PLATE BOLT, FLANGE S BRACKET, REAR UPPER S BRACKET, REAR UPPER D2

36 FIG. 20 FRAME PART DESCRIPTION BOLT, FLANGE WASHER, PLATE BOLT, FLANGE NUT WASHER, PLATE C NUT S BRACKET, FRONT LOWER BOLT, FLANGE WASHER XC PLATE, PATCH S PROTECTOR, ENGINE BOLT, WITH WASHER S2 2147E 00 GUARD, ENGINE BOLT, WITH WASHER XC BRACKET, C.D.I. UNIT SCREW, COUNTERSUNK S HOLDER, CLUTCH CABLE XC HOLDER, CABLE BOLT, BUTTON HEAD XC GUIDE, CABLE BOLT, FLANGE ET WRENCH, HEXAGON TA 2814F 00 BOX, SPARK PLUG XC TOOL, SPECIAL D3

37 FIG. 21 FENDER PART DESCRIPTION 1 1C FENDER, FRONT UR FOR DPBSE 2S FENDER, FRONT UR FOR PWS COLLAR BOLT, WITH WASHER ES 2153E 01 EMBLEM, YAMAHA UR FOR DPBSE 4ES 2153E 10 EMBLEM, YAMAHA UR FOR PWS1 5 3FB 2415E 02 LABEL, CAUTION 1 3FB 2415E C1 LABEL, CAUTION 1 JAPANESE 6 3FB 2415E 12 LABEL, CAUTION 1 FOR CAN 7 4SR 2416E 00 LABEL, CAUTION CANADA 1 FOR CAN 8 5XC REAR FENDER COMP UR FOR DPBSE 2S REAR FENDER COMP UR FOR PWS1 9 5XE NUT, REAR FENDER BOLT, FLANGE WASHER, PLATE BOLT, FLANGE WASHER, PLATE COLLAR TA GUARD, FLAP SCREW, TAPPING WF 2153E 10 EMBLEM, YAMAHA UR FOR DPBSE 3WF 2153E 70 EMBLEM, YAMAHA UR FOR PWS1 18 5PA 2118K 00 LABEL, CAUTION 1 5PA 2118K 20 LABEL, CAUTION PA 2118K 10 LABEL, CAUTION 1 FOR CAN 20 3XJ 2151H A1 LABEL 5 1 4LB 2151H 02 LABEL 5 1 JAPANESE D4

38 FIG. 21 FENDER PART DESCRIPTION 21 3XJ 2151H B1 LABEL 5 1 FOR CAN 22 5RU LABEL, WARNING S2 2163G 00 EMBLEM UR FOR DPBSE 2S2 2165A 10 GRAPHIC SET,REAR FENDER UR FOR PWS1 24 3ME 2415E 01 LABEL, CAUTION 1 D5

39 FIG. 22 SIDE COVER PART DESCRIPTION 1 5XC SIDE COVER ASSY BOLT, FLANGE BOLT, WITH WASHER XC SIDE COVER ASSY S2 2174A C0 INSULATOR, SIDE COVER S2 2174T C0 INSULATOR, SIDE COVER BOLT, FLANGE BOLT, WITH WASHER XC SIDE COVER ASSY UR FOR DPBSE 2S SIDE COVER ASSY UR FOR PWS1 10 5XC 2173L 20 GRAPHIC SET UR FOR DPBSE 2S2 2173E 00 GRAPHIC UR FOR PWS BOLT, FLANGE S2 2172A 70 PANEL XC SIDE COVER ASSY UR FOR DPBSE 2S SIDE COVER ASSY UR FOR PWS1 14 5XC 2174L 20 GRAPHIC SET UR FOR DPBSE 2S2 2173F 00 GRAPHIC UR FOR PWS BOLT, FLANGE S2 2172A 80 PANEL D6

40 FIG. 23 REAR ARM PART DESCRIPTION 1 2S REAR ARM COMP SCREW, COUNTERSUNK P PATCH BEARING BEARING OIL SEAL OIL SEAL COLLAR COLLAR S SEAL, GUARD C SCREW, S SUPPORT, CHAIN S COVER, THRUST BOLT, FLANGE NUT BOLT, FLANGE C SHAFT, PIVOT NUT, SELF-LOCKING WASHER, PLATE XC 2217A L0 ARM, RELAY BEARING OIL SEAL COLLAR WASHER WASHER, PLATE XC 2217F L0 ROD, CONNECTING BEARING D7

41 FIG. 23 REAR ARM PART DESCRIPTION OIL SEAL COLLAR XC SHAFT XC L0 SHAFT WASHER, PLATE NUT, SELF-LOCKING C3 2135F 00 COVER C3 2139R 00 COVER RV A0 LABEL, TIRE RV B0 LABEL, TIRE 1 FOR CAN D8

42 FIG. 24 REAR SUSPENSION PART DESCRIPTION 1 2S A0 SHOCK ABSORBER ASSY, REAR 1 UR FOR DPBSE(USA) 2S E0 SHOCK ABSORBER ASSY, REAR 1 UR FOR DPBSE(CAN) 2S F0 SHOCK ABSORBER ASSY, REAR 1 UR FOR PWS1(USA) 2S J0 SHOCK ABSORBER ASSY, REAR 1 UR FOR PWS1(CAN) 2S B0 SHOCK ABSORBER ASSY, REAR 1 UR FOR DPBSE 2S G0 SHOCK ABSORBER ASSY, REAR 1 UR FOR PWS1 2S C0 SHOCK ABSORBER ASSY, REAR 1 2S D0 SHOCK ABSORBER ASSY, REAR 1 UR FOR DPBSE 2S H0 SHOCK ABSORBER ASSY, REAR 1 UR FOR PWS1 2 2S A0.DAMPER SUB ASSY 1 UR FOR DPBSE(USA) 2S E0.DAMPER SUB ASSY 1 UR FOR DPBSE(CAN) 2S F0.DAMPER SUB ASSY 1 UR FOR PWS1(USA) 2S J0.DAMPER SUB ASSY 1 UR FOR PWS1(CAN) 2S B0.DAMPER SUB ASSY 1 UR FOR DPBSE 2S G0.DAMPER SUB ASSY 1 UR FOR PWS1 2S C0.DAMPER SUB ASSY 1 2S D0.DAMPER SUB ASSY 1 UR FOR DPBSE 2S H0.DAMPER SUB ASSY 1 UR FOR PWS1 3 3SP GUIDE, SPRING C L0..SEAT, SPRING UPPER L0..CAP, AIR VALVE JX BUSH, SHOCK ABSORBER LOWER DH CIRCLIP AA LABEL, WARNING 1 UR FOR USA 4AA LABEL, WARNING 1 UR FOR CAN 4AA LABEL, WARNING 1 1 4AA LABEL, WARNING 1 D9

43 FIG. 24 REAR SUSPENSION PART DESCRIPTION 9 5MV GUIDE, SPRING C COLLAR, DISTANCE JE SEAL, DUST EW SEAL, RING UN BEARING MV BUSH C L0.COLLAR, DISTANCE NY SEAL, DUST C SPRING (K=54N/MM) UR FOR DPBSE 1C B0.SPRING (K=54N/MM) UR FOR PWS1 18 1C GUIDE, SPRING C SPRING SEAT XE BOLT NUT, U FLANGE WASHER NY BOLT NUT, SELF-LOCKING D10

44 FIG. 25 STEERING PART DESCRIPTION BEARING EW COVER, BALL RACE NUT K9 WASHER, PLATE (T1.0) S CROWN, HANDLE NUT WASHER, PLATE XC HOLDER, HANDLE UPPER UM E0 HOLDER, HANDLE LOWER WASHER NUT, U FLANGE BOLT, FLANGE C PLATE, NUMBER BOLT, WITH WASHER XE GUIDE, CABLE BOLT, FLANGE COLLAR D11

45 FIG. 26 FRONT FORK PART DESCRIPTION 1 2S A0 FRONT FORK ASSY (L.H) 1 1 2S B0 FRONT FORK ASSY (L.H) S TUBE, OUTER (RIGHT) S INNER TUBE COMP XE L0.PISTON, FRONT FORK XE L0.METAL, SLIDE XC WASHER, OIL SEAL C M0.OIL SEAL XE L0.RING, SNAP XE L0.SEAL, DUST S CYLINDER COMP., FRONT FORK 1 1 2S CYLINDER COMP., FRONT FORK C L0..O-RING S2 2316A 20.VALVE COMP S2 2316A 30.VALVE COMP C L0..O-RING C N0..O-RING C P0..O-RING C R0..O-RING AE O-RING C L0..AIR VALVE COMP C L0.SEAT, SPRING UPPER S L1.SPRING, FRONT FORK(K=4.6N/MM) XC BOLT, CAP HH L0..GASKET GASKET XC 2314F 00.PROTECTER GUIDE COMP., D12

46 FIG. 26 FRONT FORK PART DESCRIPTION 25 2S A0 FRONT FORK ASSY (R.H) 1 1 2S B0 FRONT FORK ASSY (R.H) S TUBE, OUTER (RIGHT) S INNER TUBE COMP XE L0.PISTON, FRONT FORK XE L0.METAL, SLIDE XC WASHER, OIL SEAL C M0.OIL SEAL XE L0.RING, SNAP XE L0.SEAL, DUST S CYLINDER COMP., FRONT FORK 1 1 2S CYLINDER COMP., FRONT FORK C L0..O-RING S2 2316A 20.VALVE COMP S2 2316A 30.VALVE COMP C L0..O-RING C N0..O-RING C P0..O-RING C R0..O-RING AE O-RING C L0..AIR VALVE COMP C L0.SEAT, SPRING UPPER S L1.SPRING, FRONT FORK(K=4.6N/MM) XC BOLT, CAP HH L0..GASKET GASKET XC 2314F 00.PROTECTER GUIDE COMP., D13

47 FIG. 26 FRONT FORK PART DESCRIPTION 49 2S UNDER BRACKET COMP BEARING BOLT, FLANGE XC 2315H 00 PROTECTOR XL 2153A 10 EMBLEM, YAMAHA XC 2315J 00 PROTECTOR XL 2153A 10 EMBLEM, YAMAHA BOLT XC L0 CLAMP XC L0 CLAMP NUT, WITH WASHER D14

48 FIG. 27 FUEL TANK PART DESCRIPTION 1 2S FUEL TANK COMP NY CAP ASSY HOSE (L30) XJ PIPE JOINT ASSY HOSE (L350) XE HOLDER, DAMPER GROMMET BOLT, FLANGE BOLT, FLANGE WASHER, PLATE JD WASHER, SPECIAL XC 2419A 90 HOLDER COLLAR XC GROMMET BOLT, FLANGE BOLT, FLANGE WASHER, PLATE COLLAR EW 2412F 00 BRACKET, SEAT SCREW, FLAT HEAD XC DAMPER, LOCATING JT FUEL COCK ASSY AJ SEAL, COCK SCREW, PAN HEAD X O-RING AC VALVE PACKING S PIPE, FUEL D15

49 FIG. 27 FUEL TANK PART DESCRIPTION A1 CLIP WASHER, PLATE SCREW XC DAMPER, LOCATING XC DAMPER, LOCATING CLAMP E2

50 FIG. 28 SEAT PART DESCRIPTION 1 2S SINGLE SEAT ASSY UR FOR DPBSE 2S SINGLE SEAT ASSY 1 1 UR FOR PWS1 5XC A0 SINGLE SEAT ASSY 1 UR FOR DPBSE 5XC B0 SINGLE SEAT ASSY 1 UR FOR PWS1 2 5XC 2470F 90.SEAT COVER COMP UR FOR DPBSE 2S2 2470F 80.SEAT COVER COMP. 1 1 UR FOR PWS1 5XC 2470F A0.SEAT COVER COMP. 1 UR FOR DPBSE 5XC 2470F B0.SEAT COVER COMP. 1 UR FOR PWS1 E3

51 FIG. 29 FRONT WHEEL PART DESCRIPTION 1 5NY HUB, FRONT BEARING NY SPACER, BEARING OIL SEAL RIM ( ) UR FOR DPBSE RIM ( ) UR FOR PWS1 6 5NY SPOKE SET, FRONT TIRE (80/ M D742FA) 1 1 DUNLOP * TIRE(80/ M M601) 1 LM BRIDGESTONE * TIRE (80/ R MST) 1 LM PIRELLI TUBE (80/ M/C TR4) 1 1 DUNLOP * TUBE (80/100-21) 1 LM PIRELLI * TUBE (80/ M/C TR4) 1 LM BRIDGESTONE BAND, RIM ( ) 1 1 DUNLOP * BAND, RIM (80/100-21) 1 LM PIRELLI * BAND,RIM ( ) 1 LM BRIDGESTONE 10 5SF SPACER, BEAD XC G0 AXLE, WHEEL XC G0 COLLAR, WHEEL XC G0 COLLAR, WHEEL NUT E4

52 FIG. 30 FRONT BRAKE CALIPER PART DESCRIPTION 1 5XC 2581T G0 DISK BRAKE ASSY SCREW, COUNTERSUNK XC 2580T G0 CALIPER ASSY (LEFT) XC W PISTON ASSY, CALIPER KM W CALIPER SEAL KIT DH SUPPORT, PAD UY W BLEED SCREW KIT XC W BRAKE PAD KIT DH PIN, PAD DH PLUG SP BOLT SP PIN, SLIDE JD BOOT, CALIPER UY BOOT XC G0.RETAINER, CALIPER BOLT, FLANGE E5

53 FIG. 31 REAR WHEEL PART DESCRIPTION 1 5ET HUB, REAR ET SPACER, BEARING BEARING BEARING OIL SEAL OIL SEAL CIRCLIP RIM ( ) UR FOR DPBSE RIM ( ) UR FOR PWS1 9 5HD SPOKE SET, REAR TIRE (120/ M D756) 1 1 DUNLOP * TIRE (110/ M NHS) 1 LM PIRELLI * TIRE (110/ M M602) 1 LM BRIDGESTONE TUBE (110/90-19 M/C TR4) 1 1 DUNLOP * TUBE (110/90-19) 1 LM PIRELLI * TUBE (110/90-19 M/C TR4) 1 LM BRIDGESTONE BAND, RIM ( ) 1 1 DUNLOP * BAND, RIM ( ) 1 LM METZELER * BAND, RIM ( ) 1 LM BRIDGESTONE 13 3JE SPACER, BEAD XM DAMPER C SPROCKET, DRIVEN (49T) STD 1C SPROCKET, DRIVEN (47T) AP 1C SPROCKET, DRIVEN (48T) AP 1C SPROCKET, DRIVEN (50T) AP 1C SPROCKET, DRIVEN (51T) AP 1C SPROCKET, DRIVEN (52T) AP E6

54 FIG. 31 REAR WHEEL PART DESCRIPTION BOLT NUT, SELF-LOCKING WASHER, PLATE GROMMET TJ 2530S 80 COLLAR ASSY C PULLER, CHAIN C PULLER, CHAIN BOLT NUT C AXLE, WHEEL NUT, SELF-LOCKING WASHER, PLATE Y CHAIN (DID 520D 114L) JOINT,CHAIN (DID 520DM-RJ) E7

55 FIG. 32 REAR BRAKE CALIPER PART DESCRIPTION 1 2S2 2582W 70 DISK, REAR BRAKE BOLT, FLANGE C3 2580W 51 CALIPER ASSY, REAR C3 2580W 71 CALIPER ASSY, REAR UN W PISTON ASSY, CALIPER UN W CALIPER SEAL KIT DH SUPPORT, PAD UY W BLEED SCREW KIT C3 W BRAKE PAD KIT C3 W0046 B0.BRAKE PAD KIT UN SHIM, CALIPER UN SHIM, CALIPER UN INSULATOR, HEAT CR PIN, PAD DH PLUG DH PIN, SLIDE JD BOOT, CALIPER UN PIN, SLIDE UY BOOT C PROTECTOR, DISK BRAKE BOLT, FLANGE C PROTECTOR BOLT, FLANGE BOLT, FLANGE E8

56 FIG. 33 STEERING HANDLE & CABLE PART DESCRIPTION 1 5XC L0 HANDLEBAR GY GRIP TJ C0 GRIP ASSY GY GRIP (RIGHT) Y RING, LEAF BE CAP, GRIP UPPER BE CAP, GRIP LOWER SCREW, PAN HEAD SF COVER, CAP GRIP S THROTTLE CABLE ASSY S CABLE, CLUTCH N2 COLLAR C BOOT, CABLE XC PROTECTOR, HANDLEBAR XC L0 COVER, HANDLEBAR UPPER UR FOR DPBSE 5XC M0 COVER, HANDLEBAR UPPER UR FOR PWS1 E9

57 FIG. 34 FRONT MASTER CYLINDER PART DESCRIPTION 1 5XC L0 HOSE, BRAKE GASKET BOLT, UNION XC W MASTER CYLINDER SUB ASSY XC W CYLINDER KIT, MASTER XC G0.DIAPHRAGM, RESERVOIR XC G0.CAP, RESERVOIR SCREW, FLAT HEAD CG SEPARATOR ASSY XC G0.FLOAT, RESERVOIR XC L0 LEVER MV 2589F 00 BOLT, LEVER NUT, WITH WASHER MV BRACKET, MASTER CYLINDER MV BOLT, FITTING XC G0 COVER, HANDLE LEVER E10

58 FIG. 35 STAND & FOOTREST PART DESCRIPTION 1 2S PEDAL, BRAKE C BOLT O-RING PIN, COTTER SPRING, TENSION PIN, CLEVIS WASHER, PLATE CLIP XC M0 FOOTREST XC M0 FOOTREST PIN, CLEVIS PIN, COTTER SPRING, TORSION SPRING, TORSION C STAND, SIDE WASHER, PLATE E11

59 FIG. 36 REAR MASTER CYLINDER PART DESCRIPTION 1 1C3 2583V 00 RR. MASTER CYLINDER ASSY UN W CYLINDER KIT, MASTER UN NUT UN JOINT UN CAP, RESERVOIR UN 2585B 00.PLATE, DIAPHRAGM UN DIAPHRAGM, RESERVOIR UN BOLT CG SEPARATOR ASSY BOLT,HEX. SOCKET BUTTON XC L0 HOSE, BRAKE BOLT, UNION GASKET C HOLDER, BRAKE HOSE SCREW, PAN HEAD C HOLDER, BRAKE HOSE E12

60 FIG. 37 GENERATOR PART DESCRIPTION 1 2S BASE ASSY S ROTOR ASSY SCREW NUT E1 WASHER, PLATE E13

61 FIG. 38 HANDLE SWITCH & LEVER PART DESCRIPTION 1 5XE HOLDER, LEVER MV LEVER BOLT LP NUT, LENS FITTING HD BOLT, ADJUSTING HD BOLT, CABLE ADJUSTING HD COVER, HANDLE LEVER XD HOLDER, STARTER LEVER XD HOLDER, LEVER LOWER TA LEVER, STARTER S CABLE, STARTER BOLT BOLT, BUTTON HEAD NUT, U SCREW TA BOOT C SWITCH, HANDLE E14

62 FIG. 39 ELECTRICAL 1 PART DESCRIPTION 1 2S B0 C.D.I. UNIT ASSY 1 1 2S C0 C.D.I. UNIT ASSY C BAND TA IGNITION COIL ASSY S NEUTRAL SWITCH ASSY O-RING SCREW, BINDING CLAMP CLAMP CLAMP Y CLAMP CLAMP CLAMP S WIRE, SUB LEAD E15

63 FIG. 40 ALTERNATE FOR CHASSIS PART DESCRIPTION 1 5UN SPRING (K=42N/MM) AP 1C SPRING (K=44N/MM) AP 1C SPRING (K=46N/MM) AP 1C SPRING (K=48N/MM) AP 1C SPRING (K=50N/MM) AP 1C SPRING (K=52N/MM) AP 1C SPRING (K=54N/MM) AP 1C SPRING (K=55.8N/MM) AP 5UN A0 SPRING (K=APPROX.44N/MM) AP 5UN B0 SPRING (K=APPROX.46N/MM) AP 5UN C0 SPRING (K=APPROX.48N/MM) AP 5UN D0 SPRING (K=APPROX.50N/MM) AP 5UN E0 SPRING (K=APPROX.52N/MM) AP 5UN F0 SPRING (K=APPROX.54N/MM) AP 5UN G0 SPRING (K=APPROX.56N/MM) AP 2 1C A1 SPRING, FRONT FORK(K=3.9N/MM) AP 1C B1 SPRING, FRONT FORK(K=4.0N/MM) AP 1C C1 SPRING, FRONT FORK(K=4.1N/MM) AP 1C D1 SPRING, FRONT FORK(K=4.2N/MM) AP 1C E1 SPRING, FRONT FORK(K=4.3N/MM) AP 1C F1 SPRING, FRONT FORK(K=4.4N/MM) AP 1C G1 SPRING, FRONT FORK(K=4.5N/MM) AP 1C H1 SPRING, FRONT FORK(K=4.6N/MM) AP 1C J1 SPRING, FRONT FORK(K=4.7N/MM) AP F2

64 NUMERICAL INDEX PART GRID PART GRID PART GRID PART GRID PART GRID PART GRID 2S B 2 5TA B 2 5TA B 2 2S B B 2 2S B 2 2S B 2 2S B 2 5UM 1119E 00 B 2 2S B 2 2S B 2 2S B 4 2S B 4 2S B 4 2S B 4 2S B 4 2S B 4 2S B 4 2S B 4 5JG B 4 2S B 4 5TA B 4 2S B 4 5TG B 4 5TA B 5 5TA B 5 5TA B 5 5TA B 5 4GY B 5 5BE B 5 1AA B 5 1WG B 5 33M B 5 4SV B 5 5TA B 5 3GM B 5 3FV B 6 3LD B 5 3LD B 5 3LD B 5 3LD B 5 3LD B 5 3LD A0 B 5 3LD F0 B 5 3LD H1 B 5 3LD K1 B 5 3LD M1 B 5 3LD R1 B 5 3LD U1 B 5 3LD W1 B 5 3LD Y1 B 5 3LD B 5 3LD B 6 3LD B 6 3LD B 6 3LD B 6 3LD E0 B 6 3LD G0 B 6 3LD J0 B 6 3LD L0 B 6 3LD N0 B 6 3LD T0 B 6 2S B 7 2S B 7 5TA B 7 4FM B 7 5BE B 2 2S B 7 5TA B 7 2S2 1240A 70 B 9 5BE B 8 5BE B 8 5DJ B 8 5GR B 8 2S B 9 22W B 9 2S B 9 2S B 9 1C B 9 2S B 9 5Y E 15 5BE B 8 2S B 9 2S B 9 2S B C 9 2S B 11 5TA B 11 2S B 11 2S B 11 5BE B 11 2S B 11 5TA B 12 5BE B 12 2S B 13 2S B0 B 14 5NL C 2 4MX C 3 3TJ B 13 C 3 5BE C 3 5PA C 3 5TA C C 2 3TJ B 14 5XC C 2 3TJ C 2 5UL C 3 5TA C 3 5NX C 3 5TA B 13 5TA B 13 5TA C 3 5JG B 15 3TJ B 14 5JG B 15 5TA B 13 3TJ C 2 5XD C 3 5TA C 2 5JG C 3 5TA C 2 2S C 2 5JG C 2 2S B 14 4MX C 2 2S B 13 5XC B 13 5NY B 13 4XM B 13 2S B 13 5NY B 13 5BE B 13 5NY B 13 5JG B 14 5JG B 14 5JG C 3 3TJ C 2 5JG B C 2 4MX C 3 6H C 2 5NX C 3 3TJ C 3 5JG C 3 5JG C B 14 2S C 5 2S C 4 3VD C 4 C 5 2S C 5 5TA C 4 2S2 1466G B0 C 4 2S2 1466G C0 C 5 2S2 1469A 10 C 5 2S2 1469E 00 C 5 2S2 1469F 00 C 5 2S2 1469F B0 C 4 2S C 5 5VY C 4 5BE C 4 C 5 2S B0 C 4 2S C0 C 5 4BD C 4 2S C 4 C 5 2S2 1478H B0 C 4 5TA L1 B 14 5TA LN B 14 5TA LP B 14 5TA LR B 14 5TA LS B 14 5TA LT B 14 5TA LU B 14 5TA P1 B 14 5TA PN B 14 5TA PP B 14 5TA PR B 14 5TA PS B 14 5TA PT B 14 5TA PU B 14 5XC C 3 3TJ C 2 5TA C 3 5JG C 2 5JG C 2 5JG C 2 5TA C 2 4MX B 15 4MX B 15 4MX B 15 4MX B 15 4MX B 15 4MX B 15 4MX B 15 4MX B 15 4MX B 15 4MX B 15 4MX B 15 5XD B 15 4MX B 15 4MX B 15 4MX B 15 4MX B 15 4MX B 15 4MX B 15 4MX B 15 4JT 1494F 05 C 2 4JT 1494F 07 C 2 4JT 1494F 09 B 15 4JT 1494F 11 C 2 4JT 1494F 13 C 2 3TJ 1494F 14 B 15 3TJ 1494F 15 B 15 3TJ 1494F 16 B 15 3TJ 1494F 17 B 15 3TJ 1494F 18 B 15 5JG B 14 5JG B 14 5JG C 2 4SR C 2 5TA B 13 5TJ C 3 5TA C 2 4FN B 14 5TA C 2 2S C 6 2S C 6 3Y C 8 2S2 1536A 00 C 6 5XC C 6 C 8 2S C 8 4JT C 6 5BE C 6 2S C 6 2S C 8 5TA C 8 2S C 6 2S C 8 2S B 3 2S C 8 5TA C 8 2S C 8 2S C 10 2S C 10 5XD C 10 5TA C 10 5GR C 10 5SG C 10 2S C C 10 2S C 11 5XD C 11 5XD C 11 5TA C 11 4X C 11 2S C 11 5JG C 11 2S C 11 5TA C 11 2S C 11 2S C 12 2S C 12 2S C 12 2S C 12 2S C 12 2S C 12 2S C 12 2S C 12 2S C 12 2S C 12 2S C 12 2S C 6 2S C 13 2S C 15 2S C 15 5MW C 15 2S C 14 5TJ C 15 3XJ C 15 3XJ C 15 3XJ C 15 3XJ C 15 2S C 15 2S C 14 M1