YFZ450V (5TGC) U.S.A. YFZ450V (5TGE) CANADA YFZ450V (5TGF) EUROPE YFZ450V (5TGC) OCEANIA YFZ450 (5TGC) JAPAN

Transcription

1 YFZ450V (5TGC) U.S.A. YFZ450V (5TGE) ADA YFZ450V (5TGF) OPE YFZ450V (5TGC) ANIA YFZ450 (5TGC) JAPAN 1E5TG-100E1 ( 2E5TG-100E1 )

2 YFZ450V/YFZ450 PARTS CATALOGUE 2005 by Yamaha Motor Co., Ltd. 1st edition, June 2005 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 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 BWS1(*) BLUISH WHITE SOLID DPBSE(*) DEEP PURPLISH BLUE SOLID E Quantity Column Information Column No. Name Of Q ty Column Destination 1 U.S.A. 2 ADA 3 OPE 4 ANIA 5 JAPAN 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. 010 U.S.A. Country (destination) 5TGC 020 AUSTRALIA NEW ZEALAND 030 JAPAN 5TGE 010 ADA 5TGF 010 OPE Model Code Production Code No. Country (destination) (4) Colouring Information Model Code 5TGC 5TGE 5TGF Colouring Type Code Colour Code Colour Name Abbreviation A 0583 DEEP PURPLISH BLUE SOLID E DPBSE B 0892 BLUISH WHITE SOLID 1 BWS1 A 0583 DEEP PURPLISH BLUE SOLID E DPBSE B 0892 BLUISH WHITE SOLID 1 BWS1 A 0583 DEEP PURPLISH BLUE SOLID E DPBSE B 0892 BLUISH WHITE SOLID 1 BWS1 A7

7 CONTENTS ENGINE CYLINDER... B2 CRANKSHAFT & PISTON... B4 VALVE... B5 CAMSHAFT & CHAIN... B7 WATER PUMP... B8 RADIATOR & HOSE... B9 OIL PUMP... B10 INTAKE... B12 CARBURETOR... B14 EXHAUST... C3 CRANKCASE... C4 CRANKCASE COVER 1... C5 STARTER... C7 CLUTCH... C8 TRANSMISSION... C10 SHIFT CAM & FORK... C12 CHASSIS FRAME... C13 FRONT FENDER... C15 REAR FENDER... D2 OIL TANK... D4 REAR ARM... D6 REAR SUSPENSION... D9 STEERING... D10 FRONT SUSPENSION & WHEEL... D11 FUEL TANK... D14 SEAT... D15 FRONT WHEEL... E2 FRONT BRAKE CALIPER... E3 REAR WHEEL... E5 REAR BRAKE CALIPER... E6 STEERING HANDLE & CABLE... E7 FRONT MASTER CYLINDER... E8 STAND & FOOTREST... E9 REAR MASTER CYLINDER... E10 GUARD... E12 GENERATOR... E13 STARTING MOTOR... E14 HEADLIGHT... E15 TAILLIGHT... F2 TAILLIGHT 2... F3 HANDLE SWITCH & LEVER... F4 ELECTRICAL 1... F5 ELECTRICAL 2... F8 EMBLEM & LABEL 1... F9 EMBLEM & LABEL 2... F10 EMBLEM & LABEL 3... F12 EMBLEM & LABEL 4... F13 EMBLEM & LABEL 5... F14 INDEX NUMERICAL INDEX... M1

8 FIG. 1 CYLINDER PART DESCRIPTION 1 5TG CYLINDER HEAD ASSY TA GUIDE, VALVE TA GUIDE, VALVE CIRCLIP BOLT, FLANGE PLUG, STRAIGHT SCREW PIN, DOWEL PIN, DOWEL BOLT, FLANGE GASKET BOLT, STUD BOLT, STUD PLUG, SPARK (NGK R CR8E) PLUG, SPARK (NGK R CR8E) TA GASKET, CYLINDER HEAD A7 BOLT, FLANGE A3 BOLT, FLANGE WASHER, PLATE TG COVER, CYLINDER HEAD PIPE, BREATHER TG PIPE, BREATHER TA GASKET, HEAD COVER F0 BOLT KG 1111G 00 RUBBER, MOUNT TG PIPE, BREATHER CLIP HOSE (L300) B2

9 FIG. 1 CYLINDER PART DESCRIPTION CLIP SPRING, COMPRESSION TA GASKET, CYLINDER NUT PIN, DOWEL BOLT, FLANGE TG HOLDER BOLT, FLANGE TA CYLINDER B3

10 FIG. 2 CRANKSHAFT & PISTON PART DESCRIPTION 1 5TG CRANKSHAFT ASSY TG CRANK TG CRANK TG PIN, CRANK BEARING TG ROD, CONNECTING BEARING TA GEAR, DRIVE TA SHAFT BE WEIGHT TA GEAR, BALANCE WEIGHT SCREW BEARING BEARING NUT WASHER, LOCK KEY, WOODRUFF TG PISTON (STD) TG PISTON RING SET (STD) CIRCLIP TG PIN, PISTON CIRCLIP B4

11 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

12 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

13 FIG. 4 CAMSHAFT & CHAIN PART DESCRIPTION 1 5TA CAMSHAFT ASSY TG CAMSHAFT ASSY CIRCLIP BE GUIDE, STOPPER CHAIN (98XRH M) TA TENSIONER ASSY, CAM CHAIN FM GASKET, TENSIONER CASE BOLT, FLANGE TA DAMPER, CHAIN TA DAMPER, CHAIN TG BOLT, STOPPER B7

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

15 FIG. 6 RADIATOR & HOSE PART DESCRIPTION 1 5TG HOSE CLIP TG PIPE O-RING BOLT, FLANGE TG HOSE TG PIPE TG RADIATOR ASSY TG BLOWER ASSY SL CAP, RADIATOR GROMMET WASHER A7 COLLAR B COLLAR BOLT, FLANGE BOLT, FLANGE TG COVER, RADIATOR RIVET B9

16 FIG. 7 OIL PUMP PART DESCRIPTION 1 5TA OIL PUMP ASSY TA ROTOR ASSY PIN, DOWEL CIRCLIP O-RING PIN, DOWEL PIN, DOWEL BOLT, HEXAGON SOCKET HEAD BOLT TA GEAR, OIL PUMP IDLE BE SHAFT, IDLE GEAR CIRCLIP CIRCLIP WASHER, PLATE TA HOUSING, STRAINER BE STRAINER, OIL BOLT, FLANGE TA ELEMENT ASSY, OIL CLEANER BE COVER, OIL ELEMENT O-RING O-RING BOLT, HEXAGON SOCKET HEAD BOLT BOLT TJ PIPE, DELIVERY BOLT, UNION GASKET B10

17 FIG. 7 OIL PUMP PART DESCRIPTION BOLT, UNION GASKET TG PIPE, DELIVERY O-RING O-RING O-RING BOLT, FLANGE TG PIPE, OIL O-RING PIN, DOWEL BOLT, FLANGE TG PIPE, OIL HOSE CLAMP ASSY O-RING PIN, DOWEL BOLT, FLANGE B11

18 FIG. 8 INTAKE PART DESCRIPTION 1 5XD JOINT, CARBURETOR HOSE CLAMP ASSY HOSE CLAMP ASSY HOSE CLAMP ASSY TG CASE, AIR CLEANER TG JOINT, AIR CLEANER GH HOOK TG ELEMENT, AIR CLEANER TG GUIDE TG FUNNEL TG CAP, CLEANER CASE FU SEAL HOSE CLAMP ASSY TG 1442F 00 PROTECTOR RIVET, BLIND H7 WASHER, PLATE TG HOLDER, GUIDE ES SEAL V SEAL CLIP WASHER BOLT, WING TG DAMPER A GROMMET COLLAR BOLT, FLANGE TG 2177C 00 PLATE, EPA OFFROAD ATV 1 1 B12

19 FIG. 8 INTAKE PART DESCRIPTION 28 5TG BREATHER ASSY BOLT, FLANGE COLLAR WASHER, PLATE TG 1531A 00 HOSE, BREATHER A0 SPRING, COMPRESSION CLIP TG 1532A 00 HOSE, BREATHER TG PIPE B13

20 FIG. 9 CARBURETOR PART DESCRIPTION 1 5TG CARBURETOR ASSY 1 1 5TG CARBURETOR ASSY JG GASKET BOLT SCREW SCREW, PAN HEAD WASHER, PLATE JG WASHER JG SCREW, ADJUST JG VALVE, VACUUM CONTROL TJ ROLLER JG VALVE, NEEDLE FN SEAL TJ CLIP JG SCREW, ADJUST JG SPRING JG COLLAR JG NOZZLE, MAIN MX JET, SLOW (#48) TJ 1494F 23.JET (#90) TA JET, MAIN (#80) SR FLOAT PIN, FLOAT ARM MX VALVE, NEEDLE CLIP JG GASKET, FLOAT CHAMBER TJ PLUG, DRAIN B14

21 FIG. 9 CARBURETOR PART DESCRIPTION 27 3TJ COVER JG DIAPHRAGM ASSY TJ GASKET TJ SPRING, DIAPHRAGM H O-RING TA PLUNGER, STARTER TA SPRING, PLUNGER TA SEAL NX O-RING NX SCREW MX O-RING MX PLUG, SCREW TJ CLIP BE PLATE JG PLATE JG SCREW JG SPRING, ADJUST SCREW JG SCREW PA PLATE TG 8259A 00.SWITCH, CARBURETOR TG THROTTLE SENSOR ASSY TG V1.NEEDLE TJ SCREW, PILOT TJ COIL, SPRING TJ O-RING TJ WASHER TG PLUNGER, STARTER B15

22 FIG. 9 CARBURETOR PART DESCRIPTION 54 5TG CAP TG SCREW TG SPRING TG PIPE TG HOSE TG COVER TG COVER TG GASKET TG O-RING TG PLATE TG SPRING, PLUNGER TG HOLDER TG JET, MAIN (#158) TJ CAP TA COVER TA GASKET TA SEAL TA HOSE TJ CLIP TA BOLT W PIPE A TUBE, FLEXIBLE VINYL TG PIPE, FUEL CLIP CLAMP CLIP C2

23 FIG. 10 EXHAUST PART DESCRIPTION 1 5TG PIPE, EXHAUST TG PROTECTOR, EXHAUST PIPE WASHER, PLATE SCREW, BIND WASHER, PLAIN VD GASKET, EXHAUST PIPE NUT, FLANGE TG MUFFLER BOLT, FLANGE WASHER, PLATE TG PIPE, OUTLET BOLT, FLANGE FA GASKET, MUFFLER TG PROTECTOR, MUFFLER WASHER, PLATE SCREW, BINDING WASHER TG CAP, SILENCER BOLT, HEXAGON SOCKET HEAD BE BAND, SILENCER BOLT, FLANGE WASHER, PLATE C3

24 FIG. 11 CRANKCASE PART DESCRIPTION 1 5TG CRANKCASE ASSY PIN, DOWEL BOLT BOLT BOLT TG HOLDER, CLUTCH CABLE BOLT TA COVER, CRANKCASE SCREW, PAN HEAD TA GUIDE, CHAIN BOLT, FLANGE GASKET JT PLATE, BEARING COVER BE PLATE, BEARING COVER SCREW SCREW L PLATE, COVER DH PLATE, STOPPER BOLT, FLANGE O-RING PIN, DOWEL N2 COLLAR PIN, DOWEL CLAMP C4

25 FIG. 12 CRANKCASE COVER 1 PART DESCRIPTION 1 5TG COVER, CRANKCASE CLAMP BOLT PLUG, STRAIGHT SCREW O-RING PLUG, STRAIGHT SCREW O-RING Y PLUG, OIL O-RING TG GASKET, CRANKCASE COVER PIN, DOWEL BOLT BOLT BOLT TG 1549B 10 COVER ASSY O-RING BOLT, FLANGE TG COVER, CRANKCASE OIL SEAL WASHER, PLATE (T=1.0) CIRCLIP TG COVER, GENERATOR BOLT, FLANGE BOLT, FLANGE SEAT, CHECK BALL BALL E0 SPRING, COMPRESSION C5

26 FIG. 12 CRANKCASE COVER 1 PART DESCRIPTION PIN, DOWEL TG GASKET HOSE (L310) CLIP PLUG TG GASKET, CRANKCASE COVER PIN, DOWEL BOLT, FLANGE CLAMP BOLT, FLANGE CLAMP CLAMP TG CLAMP C6

27 FIG. 13 STARTER PART DESCRIPTION 1 5TG DAMPER ASSY TG GEAR, IDLER L6 BEARING H SHAFT TG GEAR TG STARTER ONE-WAY ASSY BOLT, HEXAGON SOCKET HEAD C7

28 FIG. 14 CLUTCH PART DESCRIPTION 1 5TG GEAR, PRIMARY DRIVE WASHER, LOCK NUT TG PRIMARY DRIVEN GEAR COMP TA BOSS, CLUTCH TG PLATE, PRESSURE X PLATE, CLUTCH TG PLATE, FRICTION A8 SPRING, COMPRESSION SCREW, WITH WASHER JN PLATE, THRUST TG PLATE, FRICTION JG SPRING, CLUTCH BOSS JG PLATE, SEAT WASHER, LOCK NUT TG ROD, PUSH BEARING L6 WASHER, PLATE CIRCLIP BALL TG ROD, PUSH TG AXLE, PUSH LEVER TG LEVER, PUSH WASHER, PLATE CIRCLIP BEARING C8

29 FIG. 14 CLUTCH PART DESCRIPTION OIL SEAL TA PLATE, SEAT SPRING, TORSION BOLT, FLANGE C9

30 FIG. 15 TRANSMISSION PART DESCRIPTION H5 COLLAR CIRCLIP TG AXLE, MAIN TG GEAR, 5TH PINION (20T) WASHER CIRCLIP TG GEAR, 3RD PINION (16T) TG GEAR, 4TH PINION (18T) TG GEAR, 2ND PINION (14T) BEARING BEARING TG DRIVE AXLE ASSY TG GEAR, 2ND WHEEL (27T) WASHER CIRCLIP TG GEAR, 4TH WHEEL (23T) WASHER WASHER U COLLAR TG GEAR, 3RD WHEEL (25T) TG GEAR,5TH WHEEL (21T) BF GEAR, 1ST WHEEL (29T) BEARING BEARING OIL SEAL F COLLAR O-RING C10

31 FIG. 15 TRANSMISSION PART DESCRIPTION 28 5NG SPROCKET, DRIVE (14T) WASHER, LOCK NUT GR PLATE, COVER BOLT, FLANGE C11

32 FIG. 16 SHIFT CAM & FORK PART DESCRIPTION 1 5TG CAM, SHIFT BEARING EW SEGMENT XK STOPPER LEVER ASSY SPRING, TORSION F8 BOLT TG FORK, SHIFT TG FORK, SHIFT TG FORK, SHIFT TG SHIFT SHAFT ASSY SPRING, TORSION MW LEVER, SHIFT XJ PAWL, SHIFTER G5 SPRING, COMPRESSION XJ PIN, PAWL BE GUIDE, SHIFT WASHER, PLATE PIN, DOWEL OIL SEAL XJ PIN, SHIFT XJ ROLLER, SHIFT LEVER BOLT TG SHIFT PEDAL ASSY YT COVER, SHIFT PEDAL BOLT C12

33 FIG. 17 FRAME PART DESCRIPTION 1 5TG FRONT FRAME COMP TG REAR FRAME COMP. (SILVER) BOLT, BUTTON HEAD NUT, SELF-LOCKING CLAMP CLAMP RIVET, BLIND TG STAY, ENGINE BOLT, FLANGE WASHER, PLATE TG STAY, ENGINE TG STAY, ENGINE BOLT, FLANGE BOLT, FLANGE WASHER, PLATE TG STAY, ENGINE TG STAY, ENGINE BOLT, FLANGE BOLT, FLANGE NUT, SELF-LOCKING BOLT, FLANGE NUT, SELF-LOCKING TG PROTECTOR, ENGINE R DAMPER G1 BOLT TG TENSIONER BEARING C13

34 FIG. 17 FRAME PART DESCRIPTION WASHER, PLATE N4 COLLAR BOLT, FLANGE BOLT, FLANGE NUT, SELF-LOCKING BEARING OIL SEAL OIL SEAL GT HOLDER, BEARING PLUG TG DAMPER TG DAMPER TG TOOL KIT NV 2811A 01 GAUGE, AIR C14

35 FIG. 18 FRONT FENDER PART DESCRIPTION 1 5TG W FRONT FENDER COMP. 1 UR FOR DPBSE 5TG W FRONT FENDER COMP. 1 UR FOR BWS1 5TG W215C 00 FRONT FENDER COMP.2 1 UR FOR DPBSE 5TG W215C 10 FRONT FENDER COMP.2 1 UR FOR BWS1 5TG W215B 00 FRONT FENDER COMP. 2 1 UR FOR DPBSE 5TG W215B 10 FRONT FENDER COMP. 2 1 UR FOR BWS1 5TG W215D 00 FRONT FENDER COMP UR FOR DPBSE 5TG W215D 10 FRONT FENDER COMP. 2 1 UR FOR BWS BOLT, FLANGE GROMMET L2 COLLAR BOLT, HEXAGON SOCKET HEAD NUT, SPRING NUT, SELF U-FLANGE BOLT,HEX. SOCKET BUTTON CLAMP TG STAY, FENDER TG COVER, SIDE UR FOR DPBSE 5TG COVER, SIDE UR FOR BWS1 12 5TG COVER, SIDE UR FOR DPBSE 5TG COVER, SIDE UR FOR BWS F1 BOLT RIVET TG 2171A 00 COVER, TOP UR FOR DPBSE 5TG 2171A 10 COVER, TOP UR FOR BWS1 16 5TG DAMPER C15

36 FIG. 19 REAR FENDER PART DESCRIPTION 1 5TG W REAR FENDER COMP UR FOR DPBSE 5TG W REAR FENDER COMP. 1 1 UR FOR BWS1 5TG W216C 02 REAR FENDER COMP.2 1 UR FOR DPBSE 5TG W216C 12 REAR FENDER COMP.2 1 UR FOR BWS1 5TG W216B 02 REAR FENDER COMP.2 1 UR FOR DPBSE 5TG W216B 11 REAR FENDER COMP.2 1 UR FOR BWS BOLT, FLANGE COLLAR BOLT, FLANGE A0 WASHER, PLATE TG STAY, REAR BOLT, FLANGE TG STAY, REAR BOLT, BUTTON HEAD BOLT,HEX. SOCKET BUTTON NUT, SELF U-FLANGE TG 2163A 00 COVER, REAR FENDER TG 2163E 10 COVER, REAR FENDER TG 2163F 10 COVER, REAR FENDER TG DAMPER TG FLAP TG 2164F 10 STAY S3 2164H 00 STAY SCREW, BINDING BOLT, BUTTON HEAD SPACER NUT, SELF U-FLANGE D2

37 FIG. 19 REAR FENDER PART DESCRIPTION WASHER, PLATE COLLAR TG FLAP TG 2164G 10 STAY S3 2164J 00 STAY SCREW, BINDING BOLT, BUTTON HEAD SPACER NUT, SELF U-FLANGE WASHER, PLATE COLLAR BOLT COLLAR WASHER, PLATE NUT, SELF U-FLANGE BOLT, FLANGE NUT, SELF-LOCKING BOLT, FLANGE BOLT, BUTTON HEAD P8 WASHER, PLATE D3

38 FIG. 20 OIL TANK PART DESCRIPTION 1 5TG TANK, RECOVERY TG CAP H ELBOW CLIP F7 HOSE (L1150) CLIP HOSE (L600) BOLT, FLANGE TG WASHER, SPECIAL CLAMP M31 CLAMP CLAMP CLAMP CLIP TG OIL TANK ASSY LP GAUGE, LEVEL O-RING GROMMET Y6 COLLAR TG HOSE, OIL PIN, DOWEL O-RING BOLT, FLANGE TG HOSE, OIL O-RING BOLT BOLT, FLANGE D4

39 FIG. 20 OIL TANK PART DESCRIPTION A6 WASHER, PLATE BOLT, FLANGE GROMMET D5

40 FIG. 21 REAR ARM PART DESCRIPTION 1 5TG REAR ARM COMP TG HUB, REAR BEARING OIL SEAL TG SPACER, BEARING S O-RING BEARING BOLT WASHER, PLATE TG SEAL, DUST TG BRACKET, CALIPER O-RING O-RING CIRCLIP BOLT, HEXAGON SOCKET HEAD COLLAR BEARING BUSH, SOLID W0 COLLAR OIL SEAL (DC ) YF WASHER X COVER, THRUST PLUG LP SHAFT, PIVOT F6 WASHER, PLATE NUT, SELF-LOCKING TG 2217A 10 ARM, RELAY D6

41 FIG. 21 REAR ARM PART DESCRIPTION BEARING OIL SEAL M3 COLLAR BEARING OIL SEAL COLLAR BEARING OIL SEAL COLLAR TG COVER, THRUST BOLT, FLANGE NUT, SELF-LOCKING BOLT, FLANGE NUT, SELF-LOCKING TG 2217F 10 ROD, CONNECTING BEARING OIL SEAL COLLAR BOLT, FLANGE NUT, SELF-LOCKING TG SEAL, GUARD F1 BOLT TG GUARD SUB ASSY BOLT, FLANGE COLLAR WASHER, PLATE TG HOLDER, BRAKE HOSE D7

42 FIG. 21 REAR ARM PART DESCRIPTION 55 5TG HOLDER, BRAKE HOSE BOLT, FLANGE D8

43 FIG. 22 REAR SUSPENSION PART DESCRIPTION 1 5TG P0 SHOCK ABSORBER ASSY, REAR 1 5TG R0 SHOCK ABSORBER ASSY, REAR 1 5TG S0 SHOCK ABSORBER ASSY, REAR 1 1 5TG T0 SHOCK ABSORBER ASSY, REAR 1 2 4AA LABEL, WARNING BOLT WASHER, PLATE NUT, SELF-LOCKING BOLT, WITH HOLE WASHER, PLATE PIN, COTTER D9

44 FIG. 23 STEERING PART DESCRIPTION 1 5TG COLUMN, STEERING TG ARM, PITMAN S ROD, TIE S JOINT, UNIVERSAL S JOINT, UNIVERSAL NUT NUT (RH. THREAD) NUT, CASTLE WASHER PIN, COTTER K HOLDER, HANDLE BOLT, FLANGE UY PLANE BEARING, STEERING OIL SEAL UY BRACKET, STEERING LOWER BOLT UY WASHER, LOCK R0 COLLAR WASHER, PLATE NUT, SELF-LOCKING CLIP NUT, CASTLE WASHER PIN, COTTER D10

45 FIG. 24 FRONT SUSPENSION & WHEEL PART DESCRIPTION 1 5TG FRONT LOWER ARM SUB-ASSY (L.H) UR FOR DPBSE 5TG FRONT LOWER ARM SUB-ASSY (L.H) UR FOR BWS1 2 5LP BALL JOINT CIRCLIP BUSH, SOLID R3.COLLAR YT COVER, THRUST NIPPLE, GREASE TG FRONT LOWER ARM SUB-ASSY (R.H) UR FOR DPBSE 5TG FRONT LOWER ARM SUB-ASSY (R.H) UR FOR BWS1 9 5LP BALL JOINT CIRCLIP BUSH, SOLID R3.COLLAR YT COVER, THRUST NIPPLE, GREASE TG FRONT UPPER ARM SUB ASSY LH UR FOR DPBSE 5TG FRONT UPPER ARM SUB ASSY LH UR FOR BWS1 16 5TG FRONT UPPER ARM COMP. (LEFT) UR FOR DPBSE 5TG FRONT UPPER ARM COMP. (LEFT) UR FOR BWS BUSH, SOLID Y6.COLLAR YT COVER, THRUST NIPPLE, GREASE S STEERING KNUCKLE ASSY (LEFT) WASHER NUT, CASTLE D11

46 FIG. 24 FRONT SUSPENSION & WHEEL PART DESCRIPTION PIN, COTTER TG FRONT UPPER ARM SUB ASSY RH UR FOR DPBSE 5TG FRONT UPPER ARM SUB ASSY RH UR FOR BWS1 26 5TG FRONT UPPER ARM COMP. (RIGHT) UR FOR DPBSE 5TG FRONT UPPER ARM COMP. (RIGHT) UR FOR BWS BUSH, SOLID Y6.COLLAR YT COVER, THRUST NIPPLE, GREASE S STEERING KNUCKLE ASSY (RIGHT) WASHER NUT, CASTLE PIN, COTTER BOLT, FLANGE BOLT, FLANGE WASHER, PLATE WASHER, PLATE NUT, SELF-LOCKING NUT, SELF-LOCKING NUT, CASTLE WASHER PIN, COTTER TG P0 SHOCK ABSORBER ASSY 2 5TG R0 SHOCK ABSORBER ASSY 2 5TG S0 SHOCK ABSORBER ASSY 2 2 5TG T0 SHOCK ABSORBER ASSY AA LABEL, WARNING 1 D12

47 FIG. 24 FRONT SUSPENSION & WHEEL PART DESCRIPTION BOLT, FLANGE NUT, SELF-LOCKING WASHER, PLATE TG HOLDER, BRAKE HOSE TG HOLDER, BRAKE HOSE F4 BOLT D13

48 FIG. 25 FUEL TANK PART DESCRIPTION 1 5TG FUEL TANK COMP KM CAP ASSY TG FUEL COCK ASSY AJ SEAL, COCK SCREW, PAN HEAD X O-RING AC VALVE PACKING SCREW, OVAL HEAD HM LEVER, COCK TG DAMPER, LOCATING SCREW EW 2412F 00 BRACKET, SEAT SCREW, FLAT HEAD GROMMET J1 COLLAR R DAMPER M12 T133A 00 SEAT, DAMPER A F 2139X 00 DAMPER BOLT, FLANGE WASHER, PLATE BOLT, BUTTON HEAD GROMMET J1 COLLAR J4 HOSE (L340) TG 2414H 00 DAMPER, PLATE R DAMPER RIVET D14

49 FIG. 26 SEAT PART DESCRIPTION 1 5TG SINGLE SEAT ASSY TG 2470F 40.SEAT COVER COMP STOPPER, MAIN STAND DAMPER, SEAT W PAD, SEAT TG SPACER D15

50 FIG. 27 FRONT WHEEL PART DESCRIPTION 1 5LP WHEEL COMP TIRE (AT21X7R10 KT341 T/L N) DUNLOP VALVE, RIM (TR412) TAIHEIYO 4 5LP WHEEL COMP TIRE (AT21X7R10 KT341 T/L N) DUNLOP VALVE, RIM (TR412) TAIHEIYO 7 1S HUB, FRONT BOLT, SERRATION LP SPACER, BEARING BEARING BEARING OIL SEAL OIL SEAL NUT, FLANGE WASHER S COVER, PLATE E2

51 FIG. 28 FRONT BRAKE CALIPER PART DESCRIPTION 1 3GD 2582T 10 DISC, BRAKE (LEFT) BOLT TG 2580T 10 CALIPER ASSY (LEFT) TG W PISTON ASSY, CALIPER LC W CALIPER SEAL KIT UY BOOT JD BOOT, CALIPER JD SUPPORT, PAD UY W BLEED SCREW KIT UY BOLT UY WASHER, SPRING JD BOLT JD NUT TG W BRAKE PAD KIT TG PIN, PAD S SHIM, CALIPER TG 2580U 10 CALIPER ASSY (RIGHT) TG W PISTON ASSY, CALIPER LC W CALIPER SEAL KIT UY BOOT JD BOOT, CALIPER JD SUPPORT, PAD UY W BLEED SCREW KIT UY BOLT UY WASHER, SPRING JD BOLT JD NUT E3

52 FIG. 28 FRONT BRAKE CALIPER PART DESCRIPTION 28 5TG W BRAKE PAD KIT TG PIN, PAD S SHIM, CALIPER BOLT, FLANGE COLLAR WASHER, PLATE R1 COLLAR WASHER, PLATE NUT, CASTLE PIN, COTTER TG 2514A 00 RING, WHEEL 1 (LEFT) SCREW, BINDING E4

53 FIG. 29 REAR WHEEL PART DESCRIPTION 1 5LP REAR WHEEL COMP TIRE (AT20X10R9 KT355 TL) DUNLOP VALVE, RIM (TR413) TAIHEIYO 4 1S COLLAR, WHEEL BOLT, SERRATION NUT, FLANGE WASHER M0 WASHER, PLATE NUT, CASTLE PIN, COTTER S COLLAR, SPROCKET AXLE TG SPROCKET, DRIVEN (38T) BOLT NUT, SELF-LOCKING TG AXLE, WHEEL S CIRCLIP CHAIN (DID520MXV) E5

54 FIG. 30 REAR BRAKE CALIPER PART DESCRIPTION 1 1S BRACKET, DISC S3 2582W 00 DISK, REAR BRAKE BOLT NUT WASHER, CONICAL SPRING BOLT, SET O-RING TG 2580W 20 CALIPER ASSY, REAR TG W PISTON ASSY, CALIPER TG W CALIPER SEAL KIT TG RUBBER, BUSHING UG BOLT, FITTING TG SHAFT L UY BOOT UY NUT TG ADJUSTBOLT LD SPRING, PAD TG W BRAKE PAD KIT DH PIN, PAD UY BOOT SP PIN, SLIDE JD BOOT, CALIPER SP BOLT UY W BLEED SCREW KIT TG SPRING, RETURN A9 BOLT, FLANGE E6

55 FIG. 31 STEERING HANDLE & CABLE PART DESCRIPTION 1 5TG CABLE, THROTTLE TG HANDLEBAR LP GRIP TG THROTTLE LEVER ASSY V HOLDER, LEVER LOWER SCREW, PAN HEAD WASHER, SPRING TG COLLAR TG COVER, HANDLE LEVER TG CABLE, CLUTCH HD BOOT, CABLE TG CABLE, BRAKE TG PROTECTOR, HANDLEBAR GT 2836B 10 TUNING FORK MARK BAND, SWITCH CORD E7

56 FIG. 32 FRONT MASTER CYLINDER PART DESCRIPTION 1 5TG 2583T 10 MASTER CYLINDER ASSY LP W CYLINDER KIT, MASTER L DIAPHRAGM, RESERVOIR LP CAP, RESERVOIR NK 2589H 00.SCREW TG LEVER MV 2589F 00.BOLT, LEVER NUT, U LP BRACKET, MASTER CYLINDER MV BOLT, FITTING LP FRONT STOP SWITCH ASSY TG HOSE, BRAKE TG HOSE, BRAKE TG PIPE, BRAKE BOLT, FLANGE GU CIRCLIP BOLT, UNION WASHER, PLATE E8

57 FIG. 33 STAND & FOOTREST PART DESCRIPTION 1 5TG FOOTREST BOLT, FLANGE TG FOOTREST BOLT, FLANGE TG PEDAL, BRAKE TG PIN, PEDAL CRANK NUT, SELF-LOCKING SPRING, TENSION E9

58 FIG. 34 REAR MASTER CYLINDER PART DESCRIPTION 1 5TG 2580E 20 REAR MASTER CYLINDER ASSY TG W CYLINDER KIT, MASTER SS NUT YK JOINT KW PIN, BRAKE ROD PIN, CLEVIS WASHER, PLATE PIN, COTTER TG HOSE, RESERVOIR CLIP TG TANK, RESERVOIR XP CAP, RESERVOIR VN DIAPHRAGM, RESERVOIR VN BUSH,DIAPHRAGM TG HOSE, BRAKE WASHER, PLATE BOLT, UNION BOLT, BUTTON HEAD BOLT, UNION WASHER, PLATE TG 2587A 00 HOLDER, BRAKE HOSE BOLT, FLANGE TG BRACKET, RESERVE TANK BOLT, FLANGE NUT, U FLANGE COLLAR GROMMET E10

59 FIG. 34 REAR MASTER CYLINDER PART DESCRIPTION BOLT, FLANGE E11

60 FIG. 35 GUARD PART DESCRIPTION CLAMP TG 2845N 40 BAR, CARRY FRONT TG 2845N 50 BAR, CARRY FRONT BOLT, FLANGE TG 2845R 40 BAR, CARRY REAR TG 2845R 50 BAR, CARRY REAR BOLT, FLANGE TG WASHER, SPECIAL BOLT, FLANGE COLLAR E12

61 FIG. 36 GENERATOR PART DESCRIPTION 1 5TG STATOR ASSY SCREW BOLT TG ROTOR ASSY NUT WASHER, PLATE E13

62 FIG. 37 STARTING MOTOR PART DESCRIPTION 1 5TG MOTOR ASSY FK O-RING WP GASKET WP BOLT AJ WASHER KIT TG BRUSH SET XV 8182A 00 NUT TG CORD, STARTER MOTOR G CAP BOLT, FLANGE E14

63 FIG. 38 HEADLIGHT PART DESCRIPTION 1 4KB BULB (12V-30/30W) TG HEADLIGHT UNIT ASSY TG RIM, HEADLIGHT COVER TG SOCKET CORD ASSY GROMMET COLLAR BOLT, FLANGE WASHER, PLATE TG STAY, HEADLIGHT BOLT, FLANGE KB BULB (12V-30/30W) TG HEADLIGHT UNIT ASSY TG RIM, HEADLIGHT COVER TG SOCKET CORD ASSY GROMMET COLLAR BOLT, FLANGE WASHER, PLATE TG STAY, HEADLIGHT BOLT, FLANGE E15

64 FIG. 39 TAILLIGHT PART DESCRIPTION 1 5TG TAILLIGHT UNIT ASSY GROMMET SCREW, TAPPING G0 WASHER, PLATE F2

65 FIG. 40 TAILLIGHT 2 PART DESCRIPTION 1 5TG TAILLIGHT UNIT ASSY GROMMET SCREW, TAPPING G0 WASHER, PLATE TG BRACKET, LICENCE 1 5TG 2481M 00 BRACKET, REFLECTOR BOLT, BUTTON HEAD R0 WASHER, PLATE NUT, CROWN TG DAMPER 1 1 F3

66 FIG. 41 HANDLE SWITCH & LEVER PART DESCRIPTION 1 4KB SWITCH, HANDLE TG LEVER HOLDER ASSY (LEFT) TG HOLDER, LEVER TJ LEVER BOLT TA BOLT, ADJUSTING NUT, U HD BOLT, CABLE ADJUSTING UY SWITCH TG HOLDER, LEVER LOWER BOLT TG BRACKET, LEVER TG PLATE, GUIDE TG LEVER, BRAKE TG COLLAR, LEVER BOLT, BUTTON HEAD PLUG BOLT, BUTTON HEAD F4

67 FIG. 42 ELECTRICAL 1 PART DESCRIPTION 1 5TG C.D.I. UNIT ASSY TG BAND TA IGNITION COIL ASSY GB NEUTRAL SWITCH ASSY GASKET EB THERMO SWITCH ASSY LP THERMO SWITCH ASSY TG RECTIFIER & REGULATOR ASSY BOLT, FLANGE UC BATTERY (GS GT7B-4) GY BATTERY (GS GT7B-4) TG BRACKET, BATTERY TG PAD, BATTERY JW STARTER RELAY ASSY Y FUSE (15A-BL) TG WIRE, PLUS LEAD RL RELAY ASSY BOLT, FLANGE CLAMP BOLT, FLANGE TG PAD, BATTERY W SEAT, BATTERY F 2139X 00 DAMPER TG WIRE, LEAD TG WIRE, MINUS LEAD BOLT, FLANGE TG MAIN SWITCH ASSY F5

68 FIG. 42 ELECTRICAL 1 PART DESCRIPTION 27 3HN NUT, MAIN SWITCH HN CAP, KEY TG PILOT LIGHT ASSY RED, GREEN LENS 30 5GH BULB (14V-1.7W) TG WIRE HARNESS ASSY ND CIRCUIT BREAKER ASSY ND THERMO SWITCH ASSY WA DIODE ASSY WP DIODE ASSY CLAMP CLAMP CLAMP CLAMP CLAMP BAND, SWITCH CORD CLAMP CLAMP CLAMP CLAMP CLAMP TB BAND, SWITCH CORD TG STOP SWITCH ASSY TG 2144G 10 STAY, STOP SWITCH SCREW, BIND CLAMP CLAMP TB BAND, SWITCH CORD F6

69 FIG. 42 ELECTRICAL 1 PART DESCRIPTION CLAMP CLAMP CLAMP CLAMP M11 CLAMP TG RESISTOR ASSY BOLT CLAMP CLAMP CLAMP DM RELAY ASSY TB BAND, SWITCH CORD F7

70 FIG. 43 ELECTRICAL 2 PART DESCRIPTION 1 3Y REAR REFLECTOR ASSY WASHER, SPRING NUT EK REFLECTOR, FRONT WASHER WASHER, SPRING REFLECTOR, REAR WASHER WASHER, SPRING 2 F8

71 FIG. 44 EMBLEM & LABEL 1 PART DESCRIPTION 1 5TG GRAPHIC 1 1 UR FOR DPBSE 5TG GRAPHIC 1 1 UR FOR BWS1 2 5TG GRAPHIC SET 1 UR FOR DPBSE 5TG GRAPHIC SET 1 UR FOR BWS1 3 3GD 2153E 00 EMBLEM, YAMAHA 2 UR FOR DPBSE 3GD 2153E 10 EMBLEM, YAMAHA 2 UR FOR BWS1 4 4KN 2836B 10 TUNING FORK MARK 1 5 5FE LABEL, WARNING 1 ENGLISH RIVET, BLIND WASHER, PLATE 6 8 5FE LABEL, CAUTION 2 1 ENGLISH RIVET, BLIND WASHER, PLATE PW 2415E 11 LABEL, CAUTION 1 ENGLISH 12 5TG 2165A 50 GRAPHIC SET,REAR FENDER 1 UR FOR DPBSE 5TG 2165A 60 GRAPHIC SET,REAR FENDER 1 UR FOR BWS1 13 5TG 2163G 30 EMBLEM 1 2 UR FOR DPBSE 5TG 2165B 30 GRAPHIC SET,REAR FENDER 1 UR FOR BWS1 14 4ES 2153E 01 EMBLEM, YAMAHA 1 UR FOR DPBSE 4ES 2153E 10 EMBLEM, YAMAHA 1 UR FOR BWS1 15 5TG LABEL, CAUTION RIVET, BLIND WASHER, PLATE FE 2151H 01 LABEL 5 1 ENGLISH RIVET, BLIND WASHER, PLATE LP 2819R 00 TAG, WARNING 1 F9