Honda C90 Parts Catalog
C90ST C90ST 3 C90ST 4 C90ST 5 C90ST 6 2 13GT03E2 © Honda Motor Co., Ltd. 2005 [C90ST3] FOREWORD INDEX 1 ENGINE GR
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C90ST C90ST 3 C90ST 4 C90ST 5 C90ST 6
2 13GT03E2
© Honda Motor Co., Ltd. 2005
[C90ST3]
FOREWORD INDEX
1
ENGINE GROUP
2
FRAME GROUP
3
PART NUMBER INDEX
4
PART NAME INDEX
5
CONTENTS
Instruction for use of parts catalogue
Page
• This parts catalogue has been created as of June 10, 2005. • Since this date, the sales practice for repair parts may have been changed or the parts may have been eliminated (listed for those not for sale). • The modified information is reflected on the latest Electronic Parts Catalogue (EPC). Also, refer to the parts catalogue news for any change. • See the parts catalogue news for any revision that is made after June 10, 2005. • Always specify the part number when ordering a part. • Check the model, type, serial numbers, color, maker, and the size as needed before ordering a part. • Note that the illustrations (part drawings) can differ from the actual parts in shape. They are given just to help you to refer to the parts.
• Instruction for use of parts catalogue .................................... 1 • How to refer to the part information ....................................... 2 • Part catalogue structure ........................................................ 3 • When the parts were revised................................................. 4 • Abbreviations used in the parts catalogue............................. 4 • Part block and serial number check ...................................... 5 • Color label attachment position check................................... 5 • Models, parts catalogue codes and applicable serial • • • • • • • • •
numbers................................................................................ 6 Color label ............................................................................. 7 Color chart ............................................................................. 8 Fuel hose, general purpose hoses and vinyl hose .............. 13 FLAT RATE SERVICE TIME............................................... 17 Illustrated index ................................................................... 22 ENGINE GROUP................................................................ 28 FRAME GROUP................................................................. 50 PART NO. INDEX................................................................ 86 PART NAME INDEX............................................................ 89
1
1
2 3 4 5
• When modifications or additions to this parts catalogue are made, a revised edition will be issued at an appropriate time, with successively progressing revision numbers on the cover. We recommend obtaining such revisions in order to keep your parts catalogue up-to-date at all times. To check whether a parts catalogue revision has been issued, please contact your Honda distributor.
Initial version issue date
May 10, 2002 Honda Motor Co., Ltd. 1 2005.06.10
E
Reference with “Illustrated index”
How to refer to the part information
1 Reference with “Part number index”
Reference with “Part name index”
2 2005.06.10
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Block title
Part catalogue structure
Block number
Service item/Flat rate time
1
Reference number • Title number marked with the parenthesis or parentheses indicates that it continues from the previous page.
Part number
Honda color code
Description As semblies • Sections framed with broken lines in the exploded view drawings are available as complete assemblies. (Their individual parts can also be obtained.)
Color description Note • Notes are shown with the parentheses in the part name column.
Required quantity • Reqd. QTY shown in the parenthesis or parentheses indicates the optional part. • Reqd. QTY marked with “N” indicates the optional part that should be selected as needed. • Reqd. QTY indicates the number of the part used in the block.
Serial number Parts catalogue code • When the parts catalogue code column is blank, it indicates that the part is applicable to all codes. • Parts enclosed within a dotted line different block.
are covered in a
• A hollow arrow indicates the block No. for the parts enclosed within a dotted line . • A solid arrow indicates the block No. the part in question is connected to.
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When the parts were revised
Abbreviations used in the parts catalogue
1 Be sure to check the serial number!! RIGHT is abbreviated as “R.”
“L.” stands for LEFT
* “L.” or “R.” in the description of a part stands for the LEFT hand side or the RIGHT hand side. Determine the left or right as if you were in the motorcycle seat. • The following abbreviations are used in this parts catalogue.
The number has been When shown at the left side, When shown at the right side, used from the initial model it is applicable to the models it is applicable to the models without revision. o f N o . 1 0 0 8 0 0 1 a n d t h e up to No.1008000. subsequent numbers. • The parts listed with "###" at the end of the parts name have limited supply period (parts not for sale).
A ........... Ampere ABS ....... Anti-lock brake system A.C. ....... Alternating current A.M. ...... Attaching mark ASSY. .... Assembly C.D.I. ..... Capacitive discharge ignition COMP. ... Complete D.C. ....... Direct current EX. ........ Exhaust FR. ........ Front G ........... Gram HEX. ..... Hexagonal IN. ......... Inlet KPH ...... Kilometers per hour
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L. ............Left L (100L) .Link (100 Links) L.E.D. .....Light emitted diode MM .........Millimeter MPH .......Miles per hour R. ...........Right RR. .........Rear STD. .......Standard T (22T) ...Tooth (22 Teeth) TCS ........Traction control system T.M. ........Transcript mark V ............Volt W ...........Watt WL .........With labelling WOL .......Without labelling
Part block and serial number check
Part block
Required serial number
Color label attachment position check
Engine parts
Carburetor parts
Frame parts
E-1~
E-16
F-1~
Engine serial number
Carburetor serial number
Frame serial number
1 Colored parts
Color label
Check point
5 2005.06.10
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Models, parts catalogue codes and applicable serial numbers
1
Models, parts catalogue codes and applicable serial Nos. given in this parts catalogue can be identified as follows. Parts with parts catalogue codes are exclusive for models destined for countries designated. If no area codes are listed, parts are for common use. Model
Area code
Type
Applicable engine serial No.
Applicable frame serial No.
C90ST3
MX
Mexico
C90E-2100001~2199999
JH2HA028*3K400001~3K499999
C90ST4
MX
Mexico
C90E-2100001~2199999
JH2HA028*4K500001~4K599999
C90ST5
MX
Mexico
C90E-2100001~2199999
JH2HA028*5K600001~5K699999
C90ST6
MX
Mexico
C90E-2300001~
3H1HA028*6D000001~
* Of carburetor/throttle body identification numbers, only the portions underlined in the example below are used for registration. PB48F
KC
6 2005.06.10
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Applicable carburetor identification No.
PB48F A
Color label
1
• When ordering parts, check the model name, main color, and code by observing the “COLOR LABEL” on the vehicle. • When ordering a colored part, use the color chart in the instruction for use of parts catalogue.
VFR800FIW R-157 R157
7 2005.06.10
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Color chart
1
• When ordering a colored part, refer to the chart below and use a part number consisting of the relevant basic part number to which has been added a part color code.
C90ST(C90ST3) MODEL
No.
C90ST3
COLOR
Monza red
Spinach green
Neptune blue
CODE
R-110
G-46
PB-109
Basic part No.
R110
G46
PB109
Name of colored parts
Applicable model Initial applicable model
Final applicable model
Applicable block No.
Ref.No.
1
BODY COMP., FRAME
50100-GT0-890
ZC
ZA
ZB
F-26
3
2
CAP, FR. COVER
64365-040-000
ZC
ZC
ZC
F-28
5
3
CAP, FR. FORK SIDE
51341-001-000
ZE
ZE
ZE
F-5
4
4
CASE, DRIVE CHAIN UNDER HALF
40520-GT0-000
ZK
ZK
ZK
F-20
2
5
CASE, DRIVE CHAIN UPPER HALF
40510-GT0-000
ZK
ZK
ZK
F-20
1
6
COVER SET, L. SIDE
83610-GBJ-N20
ZK
ZP
ZQ
F-14
3
7
COVER SET, R. SIDE
83510-GBJ-N20
ZK
ZP
ZQ
F-14
1
8
COVER, FORK CENTER
61150-086-020
ZV
C2
ZY
F-5
13
9
COVER, FR.
64301-GBJ-N10
ZD
ZD
ZD
F-28
1
10
COVER, FR. TOP
64310-GB4-000
ZF
ZF
ZF
F-5
15
11
COVER, HANDLE UNDER
53120-GB4-030
ZM
YV
ZR
F-4
3
12
CUSHION ASSY., RR.
52400-GBJ-681
ZD
ZA
ZC
F-21
1
13
FENDER, FR.
61100-086-000
ZN
A6
ZQ
F-6
1
14
FORK SET, FR.
51110-GBJ-305
ZE
ZC
ZD
F-5
3
15
HANDLE COMP., STEERING
53100-GK4-791
YM
YR
YN
F-4
2
16
LABEL, COLOR
87565-GT0-M00
ZA
ZB
ZC
F-29
6
17
MARK, DRIVE CAUTION
87560-181-760
ZE
ZE
ZE
F-29
5
18
MARK, L. FRAME BODY
87122-GT0-M00
ZA
ZB
ZC
F-30
4
19
MARK, R. FRAME BODY
87121-GT0-M00
ZA
ZB
ZC
F-30
3
20
MARK, SIDE COVER
87101-GBJ-N20
ZA
ZA
ZA
F-30
1
21
SEAT ASSY., SINGLE
77000-GBJ-N10
ZB
ZB
ZB
F-13
2
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C90ST(C90ST3) MODEL
No.
22
C90ST3
COLOR
Monza red
Spinach green
Neptune blue
CODE
R-110
G-46
PB-109
Name of colored parts
STAND COMP., MAIN
Basic part No.
R110
G46
PB109
50500-GT0-680
ZA
ZA
ZA
Applicable model Initial applicable model
Final applicable model
1 Applicable block No.
Ref.No.
F-19
1
23
STAY, MUFFLER UPPER
18315-171-000
ZA
ZA
ZA
F-16
3
24
SWINGARM ASSY.
52000-GB6-761
ZF
ZG
ZH
F-20
12
25
TANK COMP., FUEL
17510-GB4-721
ZC
YP
ZD
F-12
1
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C90ST(C90ST4) MODEL
1 No.
C90ST4
COLOR
Monza red
Spinach green
Neptune blue
CODE
R-110
G-46
PB-109
Name of colored parts
Basic part No.
R110
G46
PB109
Applicable model Initial applicable model
Final applicable model
Applicable block No.
Ref.No.
1
BODY COMP., FRAME
50100-GT0-890
ZC
ZA
ZB
F-26
3
2
CAP, FR. COVER
64365-040-000
ZC
ZC
ZC
F-28
5
3
CAP, FR. FORK SIDE
51341-001-000
ZE
ZE
ZE
F-5
4
4
CASE, DRIVE CHAIN UNDER HALF
40520-GT0-000
ZK
ZK
ZK
F-20
2
5
CASE, DRIVE CHAIN UPPER HALF
40510-GT0-000
ZK
ZK
ZK
F-20
1
6
COVER SET, L. SIDE
83610-GBJ-N20
ZK
ZP
ZQ
F-14
3
7
COVER SET, R. SIDE
83510-GBJ-N20
ZK
ZP
ZQ
F-14
1
8
COVER, FORK CENTER
61150-086-020
ZV
C2
ZY
F-5
13
9
COVER, FR.
64301-GBJ-N10
ZD
ZD
ZD
F-28
1
10
COVER, FR. TOP
64310-GB4-000
ZF
ZF
ZF
F-5
15
11
COVER, HANDLE UNDER
53120-GB4-030
ZM
YV
ZR
F-4
3
12
CUSHION ASSY., RR.
52400-GBJ-681
ZD
ZA
ZC
F-21
1
13
FENDER, FR.
61100-086-000
ZN
A6
ZQ
F-6
1
14
FORK SET, FR.
51110-GBJ-305
ZE
ZC
ZD
F-5
3
15
HANDLE COMP., STEERING
53100-GK4-792
YM
YR
YN
F-4
2
16
LABEL, COLOR
87565-GT0-M10
ZA
ZB
ZC
F-29
6
17
MARK, DRIVE CAUTION
87560-181-760
ZE
ZE
ZE
F-29
5
18
MARK, L. FRAME BODY
87122-GT0-M00
ZA
ZB
ZC
F-30
4
19
MARK, R. FRAME BODY
87121-GT0-M00
ZA
ZB
ZC
F-30
3
20
MARK, SIDE COVER
87101-GBJ-N20
ZA
ZA
ZA
F-30
1
21
SEAT ASSY., SINGLE
77000-GBJ-N10
ZB
ZB
ZB
F-13
2
22
STAND COMP., MAIN
50500-GT0-680
ZA
ZA
ZA
F-19
1
23
STAY, MUFFLER UPPER
18315-171-000
ZA
ZA
ZA
F-16
3
24
SWINGARM ASSY.
52000-GB6-761
ZF
ZG
ZH
F-20
12
25
TANK COMP., FUEL
17510-GB4-721
ZC
YP
ZD
F-12
1
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C90ST(C90ST5) MODEL
No.
C90ST5
COLOR
Monza red
Spinach green
Neptune blue
CODE
R-110
G-46
PB-109
Name of colored parts
Basic part No.
R110
G46
PB109
Applicable model Initial applicable model
Final applicable model
1 Applicable block No.
Ref.No.
1
BODY COMP., FRAME
50100-GT0-890
ZC
ZA
ZB
F-26
3
2
CAP, FR. COVER
64365-040-000
ZC
ZC
ZC
F-28
5
3
CAP, FR. FORK SIDE
51341-001-000
ZE
ZE
ZE
F-5
4
4
CASE, DRIVE CHAIN UNDER HALF
40520-GT0-000
ZK
ZK
ZK
F-20
2
5
CASE, DRIVE CHAIN UPPER HALF
40510-GT0-000
ZK
ZK
ZK
F-20
1
6
COVER SET, L. SIDE
83610-GBJ-N20
ZK
ZP
ZQ
F-14
3
7
COVER SET, R. SIDE
83510-GBJ-N20
ZK
ZP
ZQ
F-14
1
8
COVER, FORK CENTER
61150-086-020
ZV
C2
ZY
F-5
13
9
COVER, FR.
64301-GBJ-N10
ZD
ZD
ZD
F-28
1
10
COVER, FR. TOP
64310-GB4-000
ZF
ZF
ZF
F-5
15
11
COVER, HANDLE UNDER
53120-GB4-030
ZM
YV
ZR
F-4
3
12
CUSHION ASSY., RR.
52400-GBJ-681
ZD
ZA
ZC
F-21
1
13
FENDER, FR.
61100-086-000
ZN
A6
ZQ
F-6
1
14
FORK SET, FR.
51110-GBJ-305
ZE
ZC
ZD
F-5
3
15
HANDLE COMP., STEERING
53100-GK4-792
YM
YR
YN
F-4
2
16
LABEL, COLOR
87565-GFN-710
ZA
ZB
ZC
F-29
6
17
MARK, DRIVE CAUTION
87560-181-760
ZE
ZE
ZE
F-29
5
18
MARK, L. FRAME BODY
87122-GT0-M00
ZA
ZB
ZC
F-30
4
19
MARK, R. FRAME BODY
87121-GT0-M00
ZA
ZB
ZC
F-30
3
20
MARK, SIDE COVER
87101-GBJ-N20
ZA
ZA
ZA
F-30
1
21
SEAT ASSY., SINGLE
77000-GBJ-N10
ZB
ZB
ZB
F-13
2
22
STAND COMP., MAIN
50500-GT0-680
ZA
ZA
ZA
F-19
1
23
STAY, MUFFLER UPPER
18315-171-000
ZA
ZA
ZA
F-16
3
24
SWINGARM ASSY.
52000-GB6-761
ZF
ZG
ZH
F-20
12
25
TANK COMP., FUEL
17510-GB4-721
ZC
YP
ZD
F-12
1
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C90ST(C90ST6) MODEL
1 No.
C90ST6
COLOR
Monza red
Black
Icarai blue
CODE
R-110
NH-1
PB-310
Name of colored parts
Basic part No.
R110
NH1
PB310
Applicable model Initial applicable model
Final applicable model
Applicable block No.
Ref.No.
1
BODY COMP., FRAME
50100-GFN-720
ZC
ZA
ZB
F-26
3
2
CAP, FR. COVER
64365-040-000
ZC
ZC
ZC
F-28
5
3
CAP, FR. FORK SIDE
51341-001-000
ZE
ZE
ZE
F-5
4
4
CASE, DRIVE CHAIN UNDER HALF
40520-GT0-000
ZK
ZK
ZK
F-20
2
5
CASE, DRIVE CHAIN UPPER HALF
40510-GT0-000
ZK
ZK
ZK
F-20
1
6
COVER SET, L. SIDE
83610-GFN-720
ZC
ZA
ZB
F-14
3
7
COVER SET, R. SIDE
83510-GFN-720
ZC
ZA
ZB
F-14
1
8
COVER, FORK CENTER
61150-GFN-720
ZC
ZA
ZB
F-5
13
9
COVER, FR.
64301-GBJ-N10
ZD
ZD
ZD
F-28
1
10
COVER, FR. TOP
64310-GB4-000
ZF
ZF
ZF
F-5
15
11
COVER, HANDLE UNDER
53120-GFN-720
ZC
ZA
ZB
F-4
3
12
CUSHION ASSY., RR.
52400-GBJ-681
ZP
ZP
ZP
F-21
1
13
FENDER, FR.
61100-GFN-720
ZC
ZA
ZB
F-6
1
14
FORK SET, FR.
51110-GBJ-305
ZE
YD
YL
F-5
3
15
HANDLE COMP., STEERING
53100-GK4-792
YM
YU
YV
F-4
2
16
LABEL, COLOR
87565-GFN-720
ZA
ZB
ZC
F-29
6
17
MARK, DRIVE CAUTION
87560-181-760
ZF
ZF
ZF
F-29
8
18
MARK, L. FRAME BODY
87122-GFN-720
ZA
ZA
ZA
F-30
4
19
MARK, R. FRAME BODY
87121-GFN-720
ZA
ZA
ZA
F-30
3
20
MARK, SIDE COVER
87101-GBJ-N20
ZA
ZA
ZA
F-30
1
21
SEAT ASSY., SINGLE
77000-GBJ-N10
ZB
ZB
ZB
F-13
2
22
STAND COMP., MAIN
50500-GT0-680
ZA
ZA
ZA
F-19
1
23
STAY, MUFFLER UPPER
18315-171-000
ZA
ZA
ZA
F-16
3
24
SWINGARM ASSY.
52000-GB6-761
ZF
YG
YM
F-20
12
25
TANK COMP., FUEL
17510-GB4-721
ZC
YN
YT
F-12
1
12 2005.06.10
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Fuel hose, general purpose hoses and vinyl hose
1
• The standard part fuel hose, general purpose hose and vinyl hose may be substituted by the coiled bulk part. • When ordering the standard part fuel hose, general purpose hose and vinyl hose use the bulk part number written in the parts catalogue in brackets ( ) underneath the part name, or use the catalogue below. (The bulk part standard length is 1 m, however, those displayed in the catalogue < > are available in 3 m and 8 m lengths.) • When exchanging the hose, cut and use at the specified length as mentioned in the part name. (For the method of cutting the bulk part, and method of filling out orders etc., please refer to the service manual and the instructions issued with the bulk part.) • The list below is a catalogue of the standard part numbers and bulk part numbers. Note that those numbers are applicable to the listed replacement parts only.
Fuel hoses/Tubes
Fuel hoses/Tubes Bulk part
Standard part No.
Bulk part No.
Inner diameter (mm)
95001-30xxx-2x 95001-30xxx-3x 95001-30xxx-4x
95001-30001-20M 95001-30001-30M 95001-30001-40M 95001-35001-50M
95001-35001-60M
95001-35001-60M
95001-35001-50M
95001-35001-60M
95001-45001-50M
95001-45001-60M
95001-45001-60M
95001-45001-50M
95001-45001-60M
95001-55001-50M
3.0 3.0 3.0
95001-35xxx-2x 95001-35xxx-3x 95001-35xxx-4x 95001-35xxx-5x 95001-35xxx-6x 95001-45xxx-2x 95001-45xxx-3x 95001-45xxx-4x 95001-45xxx-5x 95001-45xxx-6x 95001-55xxx-2x
3.5 3.5 3.5 3.5 3.5 4.5 4.5 4.5 4.5 4.5 5.5
Bulk part
Length (m)
1 1 1 1 3 1 3 1 3 1 3 1 3 1 3 1 3 8 1 3 8 1 3 1 3 8 1 3 8
Standard part No.
95001-55xxx-3x 95001-55xxx-4x 95001-55xxx-5x 95001-55xxx-6x 95001-75xxx-2x 95001-75xxx-3x 95001-75xxx-4x 95001-75xxx-5x 95001-75xxx-6x 95001-80xxx-2x 95001-80xxx-3x 95001-80xxx-4x 95001-80xxx-5x 95001-80xxx-6x
Bulk part No.
95001-55001-60M
95001-55001-60M
95001-55001-50M
95001-55001-60M
95001-75001-50M
95001-75001-60M
95001-75001-60M
95001-75001-50M
95001-75001-60M
95001-80001-50M 95001-80001-60M 95001-80001-60M 95001-80001-50M 95001-80001-60M
Inner diameter (mm)
5.5 5.5 5.5 5.5 7.5 7.5 7.5 7.5 7.5 8.0 8.0 8.0 8.0 8.0
Length (m)
1 3 8 1 3 8 1 3 8 1 3 8 1 3 1 3 8 1 3 8 1 3 1 3 8 1 1 1 1 1
13 2005.06.10
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Vinyl tube
Vinyl tube Bulk part
1
Standard part No.
Bulk part No.
Inner Outer dia- meter dia-meter (mm) (mm)
Vinyl tube Bulk part
Length (m)
Standard part No.
Bulk part No.
Inner Outer dia- meter dia-meter (mm) (mm)
Bulk part Length (m)
95003-01001-60M 95003-01xxx-3x
2.9
6.8
1 3
95003-14001-10M 95003-14xxx-1x
6.0
9.0
1 3
95003-01001-60M 95003-01xxx-60
2.9
6.8
1 3
95003-14001-10M 95003-14xxx-20
6.0
9.0
1 3
95003-03001-60M 95003-03xxx-3x
3.0
6.0
1 3
95003-14001-60M 95003-14xxx-3x
6.0
9.0
1 3
95003-03001-60M 95003-03xxx-60
3.0
6.0
1 3
95003-17001-10M 95003-17xxx-1x
7.0
9.0
1 3
95003-05001-60M 95003-05xxx-3x
3.5
6.5
1 3 8
95003-19001-10M 95003-19xxx-1x
7.0
11.0
1 3 8
95003-05001-60M 95003-05xxx-60
3.5
6.5
1 3 8
95003-19001-10M 95003-19xxx-20
7.0
11.0
1 3 8
95003-07001-10M 95003-07xxx-1x
4.0
7.0
1 3 8
95003-19001-60M 95003-19xxx-3x
7.0
11.0
1 3 8
95003-07001-10M 95003-07xxx-20
4.0
7.0
1 3 8
95003-19001-60M 95003-19xxx-60
7.0
11.0
1 3 8
7.0
1 3 8
95003-21001-10M 95003-21xxx-1x
9.0
1 3
9.0
1 3
95003-07001-60M 95003-07xxx-3x
4.0
95003-07001-60M 95003-07xxx-60
4.0
7.0
1 3 8
95003-07001-70M 95003-07xxx-7x
4.0
7.0
13.0
1 3 8
95003-36001-10M 95003-36xxx-20
11.0
13.0
1 3 8
95003-37001-60M 95003-37xxx-3x 95003-37003-60M>
11.0
15.0
1 3
95003-37001-60M 95003-37xxx-60
11.0
15.0
1 3
95003-38001-10M 95003-38xxx-1x
12.0
13.0
1 3
95003-38001-10M 95003-38xxx-20
12.0
13.0
1 3
95003-39001-10M 95003-39xxx-1x
12.0
14.0
1 3
95003-39001-10M 95003-39xxx-20
12.0
14.0
1 3
95003-40001-10M 95003-40xxx-20
12.0
16.0
1 3
95003-40001-60M 95003-40xxx-3x
12.0
16.0
1 3
95003-40001-60M 95003-40xxx-60
12.0
16.0
1 3
95003-43001-10M 95003-43xxx-1x
13.0
15.0
1 3 8
95003-43001-10M 95003-43xxx-20
13.0
15.0
1 3 8
95003-45001-10M 95003-45xxx-1x
14.0
18.0
1 3 8
12.0
8.0
12.0
1 3
95003-23001-60M 95003-23xxx-3x
8.0
12.0
1 3 8
95003-23001-60M 95003-23xxx-60
8.0
12.0
1 3 8
95003-25001-10M 95003-25xxx-1x
9.0
11.0
1 3
95003-45001-10M 95003-45xxx-20
14.0
18.0
1 3 8
95003-25001-10M 95003-25xxx-20
9.0
11.0
1 3
95003-50001-10M 95003-50xxx-1x
16.0
19.0
1 3
95003-25001-60M 95003-25xxx-3x
9.0
11.0
1 3
95003-50001-10M 95003-50xxx-20
16.0
19.0
1 3
95003-25001-70M 95003-25xxx-7x
9.0
11.0
1 3
95003-50001-60M 95003-50xxx-3x
16.0
19.0
1 3
95003-27001-10M 95003-27xxx-1x
9.0
13.0
1 3
95003-55001-10M 95003-55xxx-1x
17.5
20.5
1 3
95003-27001-10M 95003-27xxx-20
9.0
13.0
1 3
95003-55001-10M 95003-55xxx-20
17.5
20.5
1 3
95003-27001-60M 95003-27xxx-3x
9.0
13.0
1 3
95003-60001-10M 95003-60xxx-1x
22.0
27.0
1 3
95003-27001-60M 95003-27xxx-60
9.0
13.0
1 3
95003-60001-10M 95003-60xxx-20
22.0
27.0
1 3
95003-60001-60M 95003-60xxx-3x
22.0
27.0
1 3
95003-60001-60M 95003-60xxx-60
22.0
27.0
1 3
4.5
8.0
1 3
95003-09001-60M 95003-09xxx-60
4.5
8.0
1 3
95003-10001-10M 95003-10xxx-1x
5.0
8.0
1 3
8.0
1 3
8.0
1 3
8.0
1 3
5.0
11.0
8.0
95003-09001-60M 95003-09xxx-3x
5.0
95003-36001-10M 95003-36xxx-1x
95003-23001-10M 95003-23xxx-20
6.5
95003-10001-60M 95003-10xxx-60
Length (m)
1 3 8
4.5
5.0
8.0
Inner Outer dia- meter dia-meter (mm) (mm)
1 3
1 3 8
95003-10001-60M 95003-10xxx-3x
8.0
Bulk part No.
95003-23001-10M 95003-23xxx-1x
95003-08001-10M 95003-08xxx-1x
95003-10001-10M 95003-10xxx-20
95003-21001-10M 95003-21xxx-20
Standard part No.
95003-11001-60M 95003-11xxx-3x
5.0
9.0
1 3 8
95003-11001-60M 95003-11xxx-60
5.0
9.0
1 3 8
95003-12001-10M 95003-12xxx-1x
5.0
7.0
1 3 8
95003-12001-10M 95003-12xxx-20
5.0
7.0
1 3 8
95003-33001-10M 95003-33xxx-1x
10.0
14.0
1 3
95003-33001-10M 95003-33xxx-20
10.0
14.0
1 3
14 2005.06.10
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General purpose hoses
General purpose hoses Bulk part
Standard part No.
Bulk part No.
Inner diameter (mm)
95005-11xxx-3x 95005-11xxx-5x
95005-11001-30M 95005-11001-50M 95005-12001-10M
95005-12001-20M 95005-12001-30M 95005-12001-50M 95005-14001-10M 95005-14001-20M
95005-14001-30M 95005-14001-50M 95005-17001-10M 95005-17001-20M 95005-17001-30M 95005-17001-50M 95005-30001-30M 95005-30001-50M 95005-35001-10M
95005-35001-20M 95005-35001-30M 95005-35001-10M
95005-35001-50M 95005-45001-10M
95005-45001-20M 95005-45001-30M
11.0 11.0
95005-12xxx-1x 95005-12xxx-2x 95005-12xxx-3x 95005-12xxx-5x 95005-14xxx-1x 95005-14xxx-2x 95005-14xxx-3x 95005-14xxx-5x 95005-17xxx-1x 95005-17xxx-2x 95005-17xxx-3x 95005-17xxx-5x 95005-30xxx-3x 95005-30xxx-5x 95005-35xxx-1x 95005-35xxx-2x 95005-35xxx-3x 95005-35xxx-4x 95005-35xxx-5x 95005-45xxx-1x 95005-45xxx-2x 95005-45xxx-3x
12.0 12.0 12.0 12.0 14.0 14.0 14.0 14.0 17.0 17.0 17.0 17.0 3.0 3.0 3.5 3.5 3.5 3.5 3.5 4.5 4.5 4.5
Bulk part
Length (m)
1 1 1 3 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 3 8 1 1 1 3 8 1 1 3 8 1 1
Standard part No.
95005-45xxx-4x 95005-45xxx-5x 95005-50xxx-3x 95005-50xxx-5x 95005-55xxx-1x 95005-55xxx-2x 95005-55xxx-4x 95005-65xxx-1x 95005-65xxx-2x 95005-70xxx-3x 95005-70xxx-5x 95005-75xxx-1x 95005-75xxx-2x 95005-80xxx-1x 95005-80xxx-2x 95005-80xxx-3x 95005-80xxx-5x 95005-91xxx-3x 95005-91xxx-5x 95005-92xxx-3x 95005-92xxx-5x
Bulk part No.
95005-45001-10M
95005-45001-50M 95005-50001-30M
95005-50001-50M 95005-55001-10M
95005-55001-20M
95005-55001-10M
95005-65001-10M
95005-65001-20M 95005-70001-30M
95005-70001-50M 95005-75001-10M
95005-75001-20M 95005-80001-10M
95005-80001-20M 95005-80001-30M 95005-80001-50M 95005-91001-30M 95005-91001-50M 95005-92001-30M 95005-92001-50M
Inner diameter (mm)
4.5 4.5 5.0 5.0 5.3 5.3 5.3 6.5 6.5 7.0 7.0 7.3 7.3 8.0 8.0 8.0 8.0 12.0 12.0 12.0 12.0
1
Length (m)
1 3 8 1 1 3 1 1 3 8 1 3 1 3 8 1 3 1 1 3 1 1 3 1 1 3 1 1 1 1 1 1 1
NOTE: X is displayed to represent the omitted numerals and letters of the roman alphabet.
CAUTION: It is DANGEROUS to confuse the fuel hose with the general purpose hose or vinyl hose. Never use a general purpose hose or vinyl hose in place of a fuel hose or vice versa. Always use the correct bulk part in the parts catalogue, according to the service manual or the instructions issued with the bulk part.
15 2005.06.10
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• Bulk part number of fuel hose, general purpose hose and vinyl hose. (Example)
1
95001-75001-50M Bulk part number: Refers to the bulk part. Marking code (hose type): (fuel hose and general purpose hose) Change code (for added hose): (Vinyl hose) • Indicates number mark or change sequence, however, the code for the bulk part must be strictly 0 (zero). Types of code: • Fuel hose 2: Red outside braid (3 mm inside dia. only) 5: Black inside braid 3: Red (3 mm inside dia. only) 4: Ash gray with red stripe (3 mm inside dia. only) 6: Black
• Vinyl hose 1: Clear 2: Black 3: Light red 6: Light red 7: Pale black
• General hose 1: Ash gray 2: Ash gray 3: Black 5: Black
Lengths: 001: 1 m (standard) 003: 3 m 008: 8 m I.D code: (fuel hose and general purpose hose) 30: 3.0 mm 11: 11 mm 35: 3.5 mm 91: 12 mm (outside dia. 15) mm 45: 4.5 mm 92: 12 mm (outside dia. 16) mm 50: 5.0 mm 12: 12 mm (outside dia. 17) mm 55: 5.3 mm, 5.5 mm 14: 14 mm 65: 6.5 mm 17: 17 mm 70: 7.0 mm 75: 7.3 mm, 7.5 mm 80: 8.0 mm ID./OD. code: (vinyl hose) 01: ID. 2.9, OD. 6.8 mm 03: ID. 3.0, OD. 6.0 mm 05: ID. 3.5, OD. 6.5 mm 07: ID. 4.0, OD. 7.0 mm 08: ID. 4.5, OD. 6.5 mm 09: ID. 4.5, OD. 8.0 mm 12: ID. 5.0, OD. 7.0 mm 10: ID. 5.0, OD. 8.0 mm 11: ID. 5.0, OD. 9.0 mm
14: ID. 6.0, 17: ID. 7.0, 19: ID. 7.0, 21: ID. 8.0, 23: ID. 8.0, 25: ID. 9.0, 27: ID. 9.0, 33: ID. 10.0, 36: ID. 11.0,
OD. 9.0 mm OD. 9.0 mm OD. 11.0 mm OD. 9.0 mm OD. 12.0 mm OD. 11.0 mm OD. 13.0 mm OD. 14.0 mm OD. 13.0 mm
Hose type: 1: Fuel hose 3: Vinyl hose 5: General hose
16 2005.06.10
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37: ID. 11.0, 38: ID. 12.0, 39: ID. 12.0, 40: ID. 12.0, 43: ID. 13.0, 45: ID. 14.0, 50: ID. 16.0, 55: ID. 17.5, 60: ID. 22.0,
OD. 15.0 mm OD. 13.0 mm OD. 14.0 mm OD. 16.0 mm OD. 15.0 mm OD. 18.0 mm OD. 19.0 mm OD. 20.5 mm OD. 27.0 mm
Editorial style
FLAT RATE SERVICE TIME Flat rate service time (FRT) means the standard time required to service a MC, which is listed in this manual to help the dealers control the actual working process and calculate the service charge by using it as a guide.
The service items shown in the text are listed with the exchange work time for the repair sales parts as the subject. Other representative service items not using repair parts (removal/ installation, adjustment, inspection/measuring, and other work) are listed collectively in the list in the preface, classified according to the work.
FRT setting system
FRT setting standard
Net service time Removal, Disassembly/reassembly, Installation Inspection, Measurement, Adjustment, Confirmation Diagnosis/troubleshooting (Electric system)
1
• Decimal system (in unit of 0.1) is adopted to set FRT as it is convenient to calculate the wage. Example: (0.1) 6 minutes, (0.2) 12 minutes [Labor cost per hour] x [FRT] = [Wage] • FRT is set with a hand tool. • Service items and FRT can be subject to change depending on development of tools and service equipment and improvement in service procedure.
Completion inspection Float time Preparation (Process check, Confirmation arrangement for necessary tools) Related work (Transfer of vehicles) * Float time is set by multiplying the net service time by a given coefficient.
17 2005.06.10
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1
Work procedure
Service item whose FRT is not presented
• As the work procedure is set with the work time according to the method in the separate Service Manual, refer to this Manual as required.
• Accessories and service parts that are not listed to use in this manual.
• Work methods permitting servicing in the shortest time still permitting assurance of safe work and product warranty are used for the setting of service items not listed in the Service Manual. • Work basically is to be performed by one person, and when two or more people are required, setting is done as the total time for the number of people. • The set value for the technological level of the workers uses a person with three years of experience in the repair of Honda vehicles as the standard. • Special tools and service equipment used to set FRT are those specified or recommended in Service Manual.
• Locations with little aging deterioration or breakage during normal use. • Service work that can be finished by one touch. • Service work that is seldom done (i.e. extremely small causes of trouble and service frequency). * When FRT is not presented, please calculate wages based on appropriate actual work time Operation not included of FRT • Oil and coolant water draining, Waiting time for warming up operation and etc.. • Additional operation that involves removal/installation of standard exterior equipment. • Indirect time spent for service by visiting the customer, trade-in, and delivery of a MC. • Indirect time required for ordering and delivery of parts. • Cost for grease, adhesive agent, etc. used for service work.
18 2005.06.10
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Explanation of FRT by using an example (The example may differ from the actual presented items) Ref. No.
L.O.N.
(Relative ref. Number) Description
F.R.T.
Indicating a reference No. whose operation and time are the same as FRT4.5 for the camshaft.
4.5
(The application range is limited to the service items without an LON setting within a same block.)
(1, 3, 4, 7) 2
111118
CAMSHAFT • • • • • • • • • • • • • •
• Includes: Valve clearance adjustment 111118A
Indicating work contents that are included in the service item.
Replace rocker arm add • • • • • • • • • • • • • • • • • • • • • • • • • 1.0
Reference No. of the illustration of part that shows location of the replacement work. FRT is an abbreviation of Flat Rate Time indicating the standard service time required for the replacement.
1
How to refer to the service item by using the sample (camshaft replacement) Open to the page of the block where the camshaft's spare part illustration is shown.
Look for the camshaft illustration, and refer to the service item and FRT that agree with the reference No.
LON is an abbreviation of Labor Operation Number, and it is a classification of the service items by the work unit code. The same operation code is used regardless of the models. Standard operation is indicated with 6 digits code, and additional operation is indicated with 7 digits code. Indicating the camshaft replacement and FRT4.5. Indicating FRT1.0 that will be added when additional operation (replace rocker arm) is done in association with camshaft replacement.
19 2005.06.10
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Indication mark for the listing of service items that continues to the following page
1
Ref.
L.O.N.
No. 2
111118
(Relative ref. Number)
1
•
•
Code
•
•
•
1
Engine
2
Transmission
3
Fuel & Exhaust
4
Frame & Body
5
Steering/Suspension
6
Electrical
7
Wheels/Brakes
8
Controls/instrument
9
-
0
-
Indication of the block with no setting of FRT L.O.N.
(Relative ref. Number)
F.R.T.
Description
NO INFORMATION • • • • • • • • • • • • • • • • • • • • LON code system
1
11
1
18
A
a
b
c
d
e
A
c
•
Mark indicated at the last line.
No.
18
a) Category codes and classification
CAMSHAFT • • • • • • • • • • • • • • • 4.5
+
Ref.
1
a
F.R.T.
Description
11
Category
c) Operation codes and classification Code
Operation category
1
Replace, Removal/Installation, Change
a) Category code..................... Engine
2
Overhaul
b) Location/function code ........ Engine upper
3
Adjust, Balance
c) Operation code.................... Replace
4
(Paint-related work: Top-coat)
d) Operation sequence number (Unit code can be shown with alphabet) ......................... camshaft (No regular rule of code)
5
Test, Inspect/diagnose, Measurment, Check
6
(Overhaul-related work: Rebore)
7
(Overhaul-related work: Reseal)
8
(Resurface)
9
(Paint-related work: Refinish)
0
Repair, Cleaning, Air bleeding
e) Additional code ................... replace rocker arm (No regular rule of code) 20 2005.06.10
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Major service items without using spare parts (1) Removal/Installation, (2) Adjustment, Measurement, (4) Overhaul, (5) Other work
(3)
Inspection/
1
E: Engine, F: Frame * OPERATIONS OTHER THAN REPLACING PARTS (1) Removal and installation Set for the configuration with the parts removed from the vehicle. LON 1101E5 E
1111K0 3111D6 1101E6
DESCRIPTION TILTING ENGINE ASSEMBLYREMOVAL/INSTALLATION INCLUDES: All necessary adjustment CYLINDER HEAD ASSEMBLYREMOVAL/INSTALLATION CARBURETOR ASSEMBLYREMOVAL/INSTALLATION CRANKCASE SEPARATION INCLUDES: Engine removal and installation
FRT 1.3 E 0.9 0.3 2.9
(2) Adjustment LON
E
F
DESCRIPTION
(3) Inspection, Measurement
FRT
3113A0
CARBURETOR IDLE-ADJUSTMENT
0.1
2123A0
CLUTCH-ADJUSTMENT INCLUDES: Clutch lever adjustment
0.1
6143A1
SPARK PLUG-ADJUSTMENT/CLEANING
0.1
1113A0
VALVE CLEARANCE-ADJUSTMENT NOTE: For 1 vehicle
0.2
6163A0
HEADLIGHT-AIMING
0.1
2133A0
DRIVE CHAIN-ADJUSTMENT
0.1
7113A0
0.1
7113A1
FRONT BRAKE-ADJUSTMENT EXCLUDES: Front brake shoe adjustment REAR BRAKE-ADJUSTMENT EXCLUDES: Rear brake shoe adjustment
3113A3
THROTTLE OPERATION-ADJUSTMENT
0.1
0.1
F
LON
DESCRIPTION
FRT
1115A0
COMPRESSION PRESSURE-MEASUREMENT
0.1
3115A0
CARBURETOR FLOAT LEVELMEASUREMENT
0.5
6145A0
IGNITION TIMING-INSPECTION
0.2
1135A0
ENGINE OIL-INSPECTION EXCLUDES: Oil change
0.1
7115A0
BRAKE OPERATION-TEST
0.1
6105A0
BATTERY-CHECKING OF ELECTROLYTE LEVEL & GRAVITY
0.2
(4) Overhaul Work condition: The required Measurements, inspections, adjustments, and cleaning/washing of each part are performed, including the main body removal/installation work and the replacement of defective parts. LON E
311200
DESCRIPTION CARBURETOR-OVERHAUL INCLUDES: All necessary adjustment
FRT 0.6
(5) Other work LON
DESCRIPTION
FRT
E
1130A1
OIL FILTER SCREEN-CLEANING
0.6
F
3120A0
CLEANER ELEMENT-CLEANING
0.1
21 2005.06.10
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ENGINE GROUP E-1
E-2 CYLINDER HEAD COVER
E-3 CYLINDER HEAD
CAMSHAFT/VALVE
2 E-4
E-5 CAM CHAIN/TENSIONER
E-7
E-6 CYLINDER
RIGHT CRANKCASE COVER
E-8 CLUTCH
E-9 OIL PUMP
LEFT CRANKCASE COVER
22 2005.06.10
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ENGINE GROUP E-10
E-11 GENERATOR
E-12 CRANKCASE
CRANKSHAFT/PISTON
2 E-13
E-14 TRANSMISSION
E-16
E-15 GEARSHIFT DRUM
KICK STARTER SPINDLE
EOP-1 CARBURETOR
EOP-2 GASKET KIT A
GASKET KIT B
23 2005.06.10
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FRAME GROUP F-1
F-2 HEADLIGHT
F-4
F-3 METER
HANDLE LEVER/SWITCH/CABLE
F-5 STEERING HANDLE
F-6 FRONT FORK
FRONT FENDER
3
F-7
F-8 FRONT CUSHION
F-9 FRONT BRAKE PANEL
24 2005.06.10
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FRONT WHEEL
FRAME GROUP F-10
F-11 REAR BRAKE PANEL
F-13
F-12 REAR WHEEL
FUEL TANK
F-14 SEAT
F-15 SIDE COVER
AIR CLEANER
3
F-16
F-17 EXHAUST MUFFLER
F-18 PEDAL
STEP
25 2005.06.10
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FRAME GROUP F-19
F-20 STAND
F-22
F-21 SWINGARM/CHAIN CASE
F-23 WINKER
REAR CUSHION
F-24 TAILLIGHT
BATTERY
3
F-25
F-26 WIRE HARNESS
F-27 FRAME BODY
TOOLS
26 2005.06.10
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FRAME GROUP F-28
F-29 FRONT COVER
F-30 CAUTION LABEL
MARK/EMBLEM
3
27 2005.06.10
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E-1
CYLINDER HEAD COVER Ref. (Relative ref. Number) L.O.N. No. Description
1 2 3 8 20
(5) 1111C4 COVER, CYLINDER HEAD ••••••••• (6) 1111D1 COVER, CYLINDER HEAD SIDE :RIGHT •••••••••••••••••••••• (7) 1111D0 COVER, CYLINDER HEAD SIDE :LEFT ••••••••••••••••••••••• (9) 111107 MANIFOLD, INTAKE ••••••••••••• 614130 PLUG, SPARK ••••••••••••••••••
2
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
12301-086-000 12331-GB0-910 12341-GB6-910 12361-035-000 12391-GW8-680
6 12394-GW8-680
COVER, CYLINDER HEAD •••••••• COVER, R. CYLINDER HEAD SIDE COVER, L. CYLINDER HEAD SIDE CAP, TAPPET ADJUSTING HOLE •• GASKET, CYLINDER HEAD COVER •
Serial No.
3
C90ST 4 5
1 1 1 2 1
1 1 1 2 1
1 1 1 2 1
1 1 1 2 1
Parts catalogue code
6
1
1
1
1
8 17111-GT0-000 9 17119-HF7-000 10 90201-415-000
GASKET, R. CYLINDER HEAD SIDE COVER GASKET, L. CYLINDER HEAD SIDE COVER PIPE, IN. ••••••••••••••••••• GASKET, IN. PIPE •••••••••••• NUT, CAP, 6MM •••••••••••••••
1 1 1 3
1 1 1 3
1 1 1 3
1 1 1 3
11 12 13 14 15
90442-035-000 90443-035-000 90461-357-000 91301-GK4-871 91302-001-020
WASHER, SEALING, 6MM •••••••• WASHER A, SEALING, 6MM •••••• WASHER, SEALING, 6.5X12 ••••• O-RING, 27X2.0(ARAI) •••••••• O-RING, 30.8MM ••••••••••••••
3 1 1 1 2
3 1 1 1 2
3 1 1 1 2
3 1 1 1 2
16 17 18 19 20
94050-06000 95701-06110-00 96001-06020-00 96001-06025-00 98056-56713 98056-56723 98056-55713 98056-55723 98056-57713 98056-57723
NUT, FLANGE, 6MM •••••••••••• BOLT, FLANGE, 6X110 ••••••••• BOLT, FLANGE, 6X20 •••••••••• BOLT, FLANGE, 6X25 •••••••••• PLUG, SPARK (C6HSA)(NGK) •••• PLUG, SPARK (U20FS-U)(DENSO) PLUG, SPARK (C5HSA)(NGK) •••• PLUG, SPARK (U16FS-U)(DENSO) PLUG, SPARK (C7HSA)(NGK) •••• PLUG, SPARK (U22FS-U)(DENSO)
1 1 2 4 1 1 (1) (1) (1) (1)
1 1 2 4 1 1 (1) (1) (1) (1)
1 1 2 4 1 1 (1) (1) (1) (1)
1 1 2 4 1 1 (1) (1) (1) (1)
7 12395-GW8-680
28
Description
2005.06.10
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F.R.T.
0.3 0.3 0.2 0.3 0.1
E-2
CYLINDER HEAD Ref. (Relative ref. Number) L.O.N. No. Description
1 111106 HEAD, CYLINDER ••••••••••••••• .INCLUDES: Valve clearance adjustment and reface 2 (7) 1111L9 GUIDE, INTAKE VALVE(ONE) ••••• .INCLUDES: Reaming .INCLUDES: Valve clearance adjustment and reface 1111M9 GUIDE, VALVE :FOR 1 VEHICLE •• .INCLUDES: Reaming .INCLUDES: Valve clearance adjustment and reface 3 (7) 1111M0 GUIDE, EXHAUST VALVE(ONE) •••• .INCLUDES: Reaming .INCLUDES: Valve clearance adjustment and reface 4 111115 GASKET, CYLINDER HEAD ••••••••
F.R.T.
1.8
2.0
2.3
2.0
2
1.1
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
12200-GT0-751 12237-GB4-305 12245-GB4-305 12251-GB5-811 90033-GT0-750
6 90082-035-010 7 91305-028-158
Description
Serial No.
3
C90ST 4 5
HEAD COMP., CYLINDER •••••••• GUIDE, IN. VALVE (O.S.) ••••• GUIDE, EX. VALVE (O.S.) ••••• GASKET, CYLINDER HEAD ••••••• BOLT, STUD, 6X32 ••••••••••••
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
BOLT, 6MM ••••••••••••••••••• O-RING, 9X1.6(ARAI) •••••••••
1 2
1 2
1 2
1 2
Parts catalogue code
6
29 2005.06.10
E
E-3
CAMSHAFT/VALVE Ref. (Relative ref. Number) L.O.N. No. Description
2 111118 CAMSHAFT ••••••••••••••••••••• .INCLUDES: Valve clearance adjustment 3 1111K8 ARM, INTAKE VALVE ROCKER(ONE) .NOTE: Same time for two units .INCLUDES: Valve clearance adjustment 1111K9 ARM, EXHAUST VALVE ROCKER(ONE) .NOTE: Same time for two units .INCLUDES: Valve clearance adjustment 1111L8 ARM, VALVE ROCKER :FOR 1 VEHICLE •••••••••••••• .INCLUDES: Valve clearance adjustment 5 1111N0 VALVE, INTAKE(ONE) ••••••••••• .INCLUDES: Refacing .EXCLUDES: Valve guide replacement 1111P0 VALVE :FOR 1 VEHICLE ••••••••• .INCLUDES: Refacing .EXCLUDES: Valve guide replacement 6 1111N1 VALVE, EXHAUST(ONE) •••••••••• + .INCLUDES: Refacing
2
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
12209-GB4-681 14100-GB5-D10 14431-035-020 14451-035-000 14711-GN5-913
Description
Serial No.
3
C90ST 4 5
SEAL, VALVE STEM (NOK) •••••• CAMSHAFT COMP. •••••••••••••• ARM, VALVE ROCKER ••••••••••• SHAFT, VALVE ROCKER ARM ••••• VALVE, IN. ••••••••••••••••••
2 1 2 2 1
2 1 2 2 1
2 1 2 2 1
2 1 2 2 1
1
1
1
1
2
2
2
2
9 14771-GB4-680 10 14775-MA6-000
VALVE, EX. •••••••••••••••••• SPRING, VALVE OUTER (CHUO HATSUJO) SPRING, VALVE INNER (CHUO HATSUJO) RETAINER, VALVE SPRING •••••• SEAT, VALVE SPRING OUTER ••••
2 2 2
2 2 2
2 2 2
2 2 2
11 12 13 14
COTTER, VALVE ••••••••••••••• SCREW, TAPPET ADJUSTING ••••• NUT, TAPPET ADJUSTING ••••••• DOWEL PIN, 8X12 •••••••••••••
4 2 2 1
4 2 2 1
4 2 2 1
4 2 2 1
6 14721-GF6-010 7 14751-GF6-013 8 14761-GF6-013
14781-MA6-000 90012-333-000 90206-001-000 90702-GB6-910
Parts catalogue code
6
30 2005.06.10
E
F.R.T.
1.0 1.3
1.3
1.3 1.6
1.8
1.6
E-3
CAMSHAFT/VALVE Ref. (Relative ref. Number) L.O.N. No. Description
.EXCLUDES: Valve guide replacement 7 (1,8,9,10) 1111P2 SPRING, INTAKE VALVE(ONE) •••• 1111P3 SPRING, EXHAUST VALVE(ONE) ••• 1111Q2 SPRING, VALVE :FOR 1 VEHICLE •
F.R.T.
+ 6
1.4 1.4 1.5
2
31 2005.06.10
E
E-4
CAM CHAIN/TENSIONER Ref. (Relative ref. Number) L.O.N. No. Description
1 2 3 4 7
1111Q4 110140 111151 111148
1111Q3 9 1111G4 11 1111J0 12 1111V3
SPROCKET, CAM •••••••••••••••• CHAIN, CAM ••••••••••••••••••• ARM, CAM CHAIN TENSIONER ••••• ROLLER(S), CAM CHAIN TENSIONER (6,8) ROD, CAM CHAIN TENSIONER PUSH ROLLER, CAM CHAIN GUIDE •••••• SPROCKET, CAM CHAIN GUIDE •••• BOLT, CAM CHAIN GUIDE ROLLER •
2
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
14321-GBG-900 14401-178-003 14500-035-020 14502-086-000 14531-035-000
6 14541-GB4-681 7 14550-GB0-911 8 14566-086-030 9 14610-086-010 10 14615-035-010 11 14670-035-030 12 14675-178-000 13 90081-035-000 14 90083-GB6-911 15 90441-035-000
Description
Serial No.
3
C90ST 4 5
SPROCKET, CAM (28T) ••••••••• CHAIN, CAM (84L) •••••••••••• ARM COMP., CAM CHAIN TENSIONER ROLLER, CAM CHAIN TENSIONER • PIVOT, CAM CHAIN TENSIONER ••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
SPRING, CAM CHAIN TENSIONER • ROD COMP., CAM CHAIN TENSIONER PUSH HEAD, CAM CHAIN TENSIONER PUSH ROD ROLLER COMP., CAM CHAIN GUIDE PIN, CAM CHAIN GUIDE ROLLER •
1
1
1
1
1
1
1
1
1 1 1
1 1 1
1 1 1
1 1 1
1
1
1
1
1 1 2 1
1 1 2 1
1 1 2 1
1 1 2 1
1 1 1
1 1 1
1 1 1
1 1 1
SPROCKET, CAM CHAIN GUIDE (25T) SPINDLE, CAM CHAIN GUIDE SPROCKET BOLT, SEALING, 14MM ••••••••• BOLT, KNOCK, 5MM •••••••••••• WASHER, SEALING, 14MM •••••••
16 90461-357-000 WASHER, SEALING, 6.5X12 ••••• 17 90481-035-000 WASHER, 8MM ••••••••••••••••• 18 95701-06018-00 BOLT, FLANGE, 6X18 ••••••••••
Parts catalogue code
6
32 2005.06.10
E
F.R.T.
0.6 1.6 0.4 0.4 0.3 1.2 1.3 1.3
E-5
CYLINDER Ref. (Relative ref. Number) L.O.N. No. Description
1 1111A5 CYLINDER ••••••••••••••••••••• 2 111102 GASKET, CYLINDER •••••••••••••
F.R.T.
1.4 1.3
2
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
12101-GB1-900 12191-GW8-681 90082-035-010 90603-GB0-911 90702-GB6-910
6 91301-GB0-911 7 91303-035-000 8 94301-08140
Description
Serial No.
3
C90ST 4 5
CYLINDER •••••••••••••••••••• GASKET, CYLINDER •••••••••••• BOLT, 6MM ••••••••••••••••••• COLLAR, 14.8MM •••••••••••••• DOWEL PIN, 8X12 •••••••••••••
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
O-RING, 14.5MM •••••••••••••• PACKING, RUBBER, 16MM ••••••• DOWEL PIN, 8X14 •••••••••••••
1 1 2
1 1 2
1 1 2
1 1 2
Parts catalogue code
6
33 2005.06.10
E
E-6
RIGHT CRANKCASE COVER Ref. (Relative ref. Number) L.O.N. No. Description
1 110159 COVER, CRANKCASE :RIGHT •••••• 2 110158 GASKET, CRANKCASE COVER :RIGHT 4 2121A7 LEVER, CLUTCH •••••••••••••••• 5 (6,9,10,11) 2121A9 PLATE, CLUTCH CAM •••••••••••• 7 2121C5 PLATE, CLUTCH CAM LIFTER ••••• 8 2121E3 SCREW, CLUTCH ADJUSTING •••••• 15 112105 OIL SEAL, KICK STARTER SPINDLE
2
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
11330-GW8-690 11394-GW8-680 15651-179-701 22811-040-020 22820-918-020
6 7 8 9 10
Description
Serial No.
3
C90ST 4 5
COVER COMP., R. CRANKCASE ••• GASKET, R. CRANKCASE COVER •• GAUGE, OIL LEVEL •••••••••••• LEVER, CLUTCH ••••••••••••••• PLATE COMP., CLUTCH CAM •••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
22825-046-000 22830-041-000 22846-GB4-770 22860-046-000 25551-918-007
SPRING, CAM PLATE SIDE •••••• PLATE COMP., CLUTCH LIFTER •• BOLT, CLUTCH ADJUSTING •••••• RETAINER, CLUTCH BALL ••••••• THROUGH, OIL ••••••••••••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
11 12 13 14 15
25555-065-000 32921-039-000 90485-040-000 90702-GB6-910 91202-302-010
SPRING, OIL THROUGH ••••••••• CLIP, DYNAMO CORD ••••••••••• WASHER, 8MM ••••••••••••••••• DOWEL PIN, 8X12 ••••••••••••• OIL SEAL, 13.8X24X5 •••••••••
1 1 1 2 1
1 1 1 2 1
1 1 1 2 1
1 1 1 2 1
16 17 18 19 20
91303-001-000 91307-035-000 94030-08000 96001-06040-00 96001-06065-00
O-RING, 8MM ••••••••••••••••• O-RING, 18X3 •••••••••••••••• NUT, HEX., 8MM •••••••••••••• BOLT, FLANGE, 6X40 •••••••••• BOLT, FLANGE, 6X65 ••••••••••
1 1 1 5 2
1 1 1 5 2
1 1 1 5 2
1 1 1 5 2
21 96001-06080-00 BOLT, FLANGE, 6X80 ••••••••••
1
1
1
1
Parts catalogue code
6
34 2005.06.10
E
F.R.T.
0.8 0.6 0.6 0.6 0.7 0.7 0.7
E-7
CLUTCH Ref. (Relative ref. Number) L.O.N. No. Description
1 2121A0 OUTER, CLUTCH •••••••••••••••• 2 (3,29) 2121B7 COVER, CLUTCH OUTER •••••••••• 4 (20) 212112 CENTER, CLUTCH ••••••••••••••• 6 (7,8,9,12,17) 2121A1 DISC, CLUTCH FRICTION •••••••• .NOTE: Same time for two units or more 10 (14,15,16) 2121A2 PLATE, DRIVE ••••••••••••••••• 11 212107 SPRING, CLUTCH ••••••••••••••• .NOTE: Same time for two units or more 13 2121B8 SPRING, CLUTCH DAMPER •••••••• .NOTE: Same time for two units or more 19 211100 GEAR, PRIMARY DRIVEN ••••••••• 21 (5,18) 211105 GEAR, PRIMARY DRIVE ••••••••••
F.R.T.
1.0 0.7 0.9 0.9
1.0 1.0 0.7
2
0.8 0.8
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
22101-178-000 22111-178-010 22119-GW8-680 22121-178-000 22131-035-030
6 7 8 9 10
Description
Serial No.
3
C90ST 4 5
OUTER, CLUTCH ••••••••••••••• COVER, CLUTCH OUTER ••••••••• GASKET, CLUTCH OUTER COVER •• CENTER, CLUTCH (17T) •••••••• GUIDE, CLUTCH CENTER ••••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
22201-GW8-681 22310-GB0-910 22321-041-000 22331-GW8-681 22351-178-020
DISK A, CLUTCH FRICTION ••••• PLATE A, CLUTCH ••••••••••••• PLATE B, CLUTCH ••••••••••••• DISK B, CLUTCH FRICTION ••••• PLATE, DRIVE ••••••••••••••••
2 1 1 1 1
2 1 1 1 1
2 1 1 1 1
2 1 1 1 1
11 12 13 14 15
22401-178-010 22411-178-000 22421-040-000 22531-178-000 22535-033-000
SPRING, CLUTCH •••••••••••••• SPRING, CLUTCH FREE ••••••••• SPRING, CLUTCH DAMPER ••••••• WEIGHT, CLUTCH •••••••••••••• RING, CLUTCH WEIGHT CENTER ••
16 17 18 19 20
22536-033-000 22901-001-000 22911-GB4-680 23110-086-030 23112-178-020
RING, CLUTCH WEIGHT STOPPER • SET RING, 101.5MM ••••••••••• COLLAR, 17MM •••••••••••••••• GEAR, PRIMARY DRIVEN (69T) •• OUTER, DRIVE GEAR •••••••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
21 22 23 24 25
23120-086-020 90231-087-010 90431-086-000 90432-086-000 90483-178-000
GEAR, PRIMARY DRIVE (17T) ••• NUT, LOCK, 14MM ••••••••••••• WASHER, LOCK, 14MM •••••••••• WASHER B, LOCK •••••••••••••• WASHER, STOPPER, 14MM •••••••
1 1 1 1 4
1 1 1 1 4
1 1 1 1 4
1 1 1 1 4
Parts catalogue code
6
4 4 4 4 4 4 4 4 4 4 4 4 28 28 28 28 1 1 1 1
2005.06.10
35 E
E-7
CLUTCH
2
Reqd. QTY
Ref. No.
Part No.
26 27 28 29
90601-001-000 93500-05010-0A 93600-05010-0A 96100-60000-00
Description
CIRCLIP, EXTERNAL, 17MM ••••• SCREW, PAN, 5X10 •••••••••••• SCREW, FLAT, 5X10 ••••••••••• BEARING, RADIAL BALL, 6000 ••
3
C90ST 4 5
1 4 4 1
1 4 4 1
1 4 4 1
Serial No.
Parts catalogue code
6
1 4 4 1
36 2005.06.10
E
E-8
OIL PUMP Ref. (Relative ref. Number) L.O.N. No. Description
1
(2) 113105 PUMP ASSY., OIL •••••••••••••• 6 1131B5 SCREEN, OIL FILTER •••••••••••
F.R.T.
0.9 0.6
2
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
15100-GB5-811 15119-178-000 15331-436-000 15332-436-000 15384-178-000
6 7 8 9
15421-035-010 93500-05010-0A 93500-06016-0A 93500-06022-0A
Description
Serial No.
3
C90ST 4 5
PUMP ASSY., OIL ••••••••••••• GASKET, OIL PUMP BODY ••••••• ROTOR, OIL PUMP INNER ••••••• ROTOR, OIL PUMP OUTER ••••••• PIVOT, OIL PUMP •••••••••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
SCREEN, OIL SCREW, PAN, SCREW, PAN, SCREW, PAN,
1 3 2 1
1 3 2 1
1 3 2 1
1 3 2 1
FILTER •••••••••• 5X10 •••••••••••• 6X16 •••••••••••• 6X22 ••••••••••••
Parts catalogue code
6
37 2005.06.10
E
E-9
LEFT CRANKCASE COVER Ref. (Relative ref. Number) L.O.N. No. Description
1 1101A6 COVER, CRANKCASE :LEFT •••••••
2
Ref. No.
Reqd. QTY Part No.
Description
1 11341-GB5-730 COVER, L. CRANKCASE ••••••••• 2 96001-06028-00 BOLT, FLANGE, 6X28 •••••••••• 3 96001-06035-00 BOLT, FLANGE, 6X35 ••••••••••
3
C90ST 4 5
1 1 2
1 1 2
1 1 2
Serial No.
Parts catalogue code
6
1 1 2
38 2005.06.10
E
F.R.T.
0.1
E-10
GENERATOR Ref. (Relative ref. Number) L.O.N. No. Description
1 2 3 8 9
613105 6131A3 6131A4 6131B6 6131B5
ROTOR OR FLYWHEEL •••••••••••• STATOR ••••••••••••••••••••••• BASE, STATOR ••••••••••••••••• OIL SEAL, STATOR BASE •••••••• O-RING, STATOR BASE ••••••••••
F.R.T.
0.3 0.6 0.4 0.4 0.3
2
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
31110-GT0-008 31120-GT0-018 31131-GS9-020 32961-GS9-010 32962-GS9-000
Description
Serial No.
3
C90ST 4 5
FLYWHEEL COMP. (MITSUBA) •••• STATOR COMP. (MITSUBA) •••••• BASE, STATOR •••••••••••••••• CLAMPER, A.C. GENERATOR CORD CLAMPER, PULSER CORD ••••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
6 32981-GB4-770 7 90410-HC4-000 8 91202-GE0-003 91202-GE0-015 9 91301-035-003 10 91317-171-003
GROMMET, NEUTRAL SWITCH CORD WASHER, 10MM •••••••••••••••• OIL SEAL, 18.9X30X5(NOK) •••• OIL SEAL, 18.9X30X5(ARAI) ••• O-RING, 107X2(ARAI) ••••••••• O-RING, 6X1.7(ARAI) •••••••••
1 1 1 1 1 2
1 1 1 1 1 2
1 1 1 1 1 2
1 1 1 1 1 2
11 12 13 14 15
BOLT, HEX., 5X6 ••••••••••••• BOLT, HEX., 5X10 •••••••••••• SCREW, FLAT, 6X16 ••••••••••• NUT, FLANGE, 10MM ••••••••••• BOLT, FLANGE, 6X22 ••••••••••
1 2 2 1 2
1 2 2 1 2
1 2 2 1 2
1 2 2 1 2
93301-05006-0H 93301-05010-0H 93600-06016-0A 94050-10000 96001-06022-00
Parts catalogue code
6
39 2005.06.10
E
E-11
CRANKCASE Ref. (Relative ref. Number) L.O.N. No. Description
1 110120 CRANKCASE :RIGHT ••••••••••••• .INCLUDES: Engine removal and installation 1101A2 CRANKCASE :BOTH •••••••••••••• .INCLUDES: Engine removal and installation 2 110110 GASKET, CRANKCASE •••••••••••• .INCLUDES: Engine removal and installation 3 110115 CRANKCASE :LEFT •••••••••••••• .INCLUDES: Engine removal and installation
2
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
11100-GB6-911 11191-GW8-680 11200-GB6-910 15761-087-611 16236-045-010
6 7 8 9 10 11 12 13 14 15
Description
Serial No.
3
C90ST 4 5
CRANKCASE COMP., R. ••••••••• GASKET, CRANKCASE ••••••••••• CRANKCASE COMP., L. ••••••••• TUBE, BREATHER, 5X320 ••••••• CLAMP, OVER FLOW PIPE •••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
16236-171-000 90031-198-000 90032-198-000 90407-259-000 90703-HC4-000
CLAMPER, TUBE ••••••••••••••• BOLT, CYLINDER STUD, 6X194.5 BOLT, CYLINDER STUD, 6X202 •• PACKING, DRAIN COCK, 12.5X20 DOWEL PIN, 10X14 ••••••••••••
1 2 2 1 2
1 2 2 1 2
1 2 2 1 2
1 2 2 1 2
92800-12000 95002-50000 96001-06050-00 96001-06060-00 96001-06065-00
BOLT, CLIP, BOLT, BOLT, BOLT,
1 1 1 2 4
1 1 1 2 4
1 1 1 2 4
1 1 1 2 4
DRAIN PLUG, 12MM •••••• TUBE (C9) ••••••••••••• FLANGE, 6X50 •••••••••• FLANGE, 6X60 •••••••••• FLANGE, 6X65 ••••••••••
Parts catalogue code
6
40 2005.06.10
E
F.R.T.
4.0 4.8 3.6 4.4
E-12
CRANKSHAFT/PISTON Ref. (Relative ref. Number) L.O.N. No. Description
1 1101B5 CRANKSHAFT ••••••••••••••••••• .INCLUDES: Engine removal and installation 3 (2,4,5) 111103 RING, PISTON AND/OR PISTON (ONE) ••••••••••••••••••••••• 12 1101B6 BEARING, CRANKSHAFT :LEFT •••• .INCLUDES: Engine removal and installation 1101B7 BEARING, CRANKSHAFT :RIGHT ••• .INCLUDES: Engine removal and installation 1101G0 BEARING, CRANKSHAFT :BOTH •••• .INCLUDES: Engine removal and installation
Ref. No.
4.0
1.5 4.2 4.2 4.4
2
Reqd. QTY Part No.
Description 3
1 13000-GT0-000 2 13011-GB5-305 13012-GB5-305 13013-GB5-305 13014-GB5-305 13015-GB5-305 3 13101-GT0-680 13102-GT0-306 13103-GT0-306 13104-GT0-306 13105-GT0-306 4 13111-087-000 5 13115-001-000 6 7 8 9 10
F.R.T.
13201-GF6-300 13310-GT0-300 13321-GT0-300 13381-GF6-300 14311-KEV-900
11 90741-003-010 12 91001-GF6-004 13 91101-GF6-003 91102-GF6-003 91103-GF6-003
C90ST 4 5
Serial No.
Parts catalogue code
6
CRANKSHAFT COMP. •••••••••••• RING SET, PISTON (STD.)(RIKEN) RING SET, PISTON (0.25)(RIKEN) RING SET, PISTON (0.50)(RIKEN) RING SET, PISTON (0.75)(RIKEN) RING SET, PISTON (1.00)(RIKEN) PISTON (STD.) ••••••••••••••• PISTON (0.25) ••••••••••••••• PISTON (0.50) ••••••••••••••• PISTON (0.75) ••••••••••••••• PISTON (1.00) ••••••••••••••• PIN, PISTON ••••••••••••••••• CLIP, PISTON PIN ••••••••••••
1 1 (1) (1) (1) (1) 1 (1) (1) (1) (1) 1 2
1 1 (1) (1) (1) (1) 1 (1) (1) (1) (1) 1 2
1 1 (1) (1) (1) (1) 1 (1) (1) (1) (1) 1 2
1 1 (1) (1) (1) (1) 1 (1) (1) (1) (1) 1 2
ROD, CONNECTING ••••••••••••• CRANKSHAFT COMP., R. •••••••• CRANKSHAFT, L. •••••••••••••• PIN, CRANK •••••••••••••••••• SPROCKET, TIMING (14T) ••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
KEY, WOODRUFF, 4MM •••••••••• BEARING, RADIAL BALL, 6304 •• BEARING, CONNECTING ROD (RED) BEARING, CONNECTING ROD (BLUE) BEARING, CONNECTING ROD (WHITE)
1 2 1 1
1 2 1 1
1 2 1 1
1 2 1 1
1
1
1
1
41 2005.06.10
E
E-13
TRANSMISSION Ref. (Relative ref. Number) L.O.N. No. Description
1
2
9 21
2 22 +
(5,7) 210141 MAINSHAFT, TRANSMISSION •••••• .INCLUDES: Engine removal and installation 210141A .Replace countershaft add •••• (3,6,8) 210142 COUNTERSHAFT, TRANSMISSION ••• .INCLUDES: Engine removal and installation 210142A .Replace mainshaft add ••••••• 213135 SPROCKET, DRIVE •••••••••••••• 2101C2 BEARING, MAINSHAFT :LEFT ••••• .INCLUDES: Engine removal and installation 2101C6 BEARING, MAINSHAFT :BOTH ••••• .INCLUDES: Engine removal and installation 2101D4 BEARING, MAINSHAFT AND COUNTERSHAFT :ALL ••••••••••• .INCLUDES: Engine removal and installation 2101C8 BEARING, COUNTERSHAFT :RIGHT • .INCLUDES: Engine removal and installation 2101C9 BEARING, COUNTERSHAFT :BOTH ••
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
23211-GB6-910 23221-GT0-750 23421-GB6-911 23422-GB6-910 23431-GB1-900
6 23441-GB6-910
Description
Serial No.
3
C90ST 4 5
MAINSHAFT, TRANSMISSION (12T) COUNTERSHAFT, TRANSMISSION •• GEAR, COUNTERSHAFT LOW (34T) BUSH, 20X10 ••••••••••••••••• GEAR, MAINSHAFT SECOND (17T)
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
Parts catalogue code
6
7 8 9 10
23471-GB1-901 23481-GT0-751 23801-179-700 23802-040-000
GEAR, COUNTERSHAFT SECOND (28T) GEAR, MAINSHAFT THIRD (22T) • GEAR, COUNTERSHAFT THIRD (23T) SPROCKET, DRIVE (15T) ••••••• PLATE, DRIVE SPROCKET FIXING
11 12 13 14 15
23911-GT0-750 24305-GT0-000 24306-GB4-770 90084-041-000 90452-GB6-910
COLLAR, GEAR •••••••••••••••• SPRING, CHANGE FRICTION ••••• PLATE, GEARSHIFT DRUM LOCK •• BOLT, DRIVE SPROCKET FIXING • WASHER, 17X1.5 ••••••••••••••
1 1 1 2 1
1 1 1 2 1
1 1 1 2 1
1 1 1 2 1
16 17 18 19 20
90455-107-000 90461-035-000 90601-001-000 90605-200-000 91203-GB5-761
WASHER A, SPLINE, 20MM •••••• WASHER, SPLINE, 17MM •••••••• CIRCLIP, EXTERNAL, 17MM ••••• SET RING, 20MM •••••••••••••• OIL SEAL, 17X29X5(NOK) ••••••
1 1 2 1 1
1 1 2 1 1
1 1 2 1 1
1 1 2 1 1
21 96100-60010-00 BEARING, RADIAL BALL, 6001 •• 22 96100-62010-00 BEARING, RADIAL BALL, 6201 •• 23 96100-62030-00 BEARING, RADIAL BALL, 6203 ••
1 1 2
1 1 2
1 1 2
1 1 2
42 2005.06.10
E
F.R.T.
3.8 0.2 3.8 0.2 0.2 3.8 4.0
4.2 3.8 4.0
E-13
TRANSMISSION Ref. (Relative ref. Number) L.O.N. No. Description
.INCLUDES: Engine removal and installation 23 2101C5 BEARING, MAINSHAFT :RIGHT •••• .INCLUDES: Engine removal and installation 2101C7 BEARING, COUNTERSHAFT :LEFT •• .INCLUDES: Engine removal and installation
F.R.T.
+22
3.8 3.8
2
43 2005.06.10
E
E-14
GEARSHIFT DRUM Ref. (Relative ref. Number) L.O.N. No. Description
1
5 6 8 10 11
2
15 21
44
(2) 210112 FORK, GEARSHIFT •••••••••••••• .INCLUDES: Engine removal and installation .NOTE: Same time for two units 2101A9 DRUM, GEARSHIFT •••••••••••••• .INCLUDES: Engine removal and installation (7,25) 2101D6 PLATE, GEARSHIFT DRUM STOPPER (9) 210125 STOPPER OR SPRING, SHIFT DRUM 210122 SPINDLE, GEARSHIFT ••••••••••• (12,13) 210127 ARM, GEARSHIFT ••••••••••••••• 6151B8 SWITCH, NEUTRAL •••••••••••••• 1101F9 OIL SEAL, GEARSHIFT SPINDLE ••
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
24211-087-010 24221-041-010 24261-121-742 24263-028-000 24301-GB2-714
6 7 8 9 10
Description
Serial No.
3
C90ST 4 5
FORK, L. GEARSHIFT •••••••••• FORK, R. GEARSHIFT •••••••••• PIN, GEARSHIFT FORK GUIDE ••• CLIP, GEARSHIFT FORK GUIDE PIN DRUM, GEARSHIFT •••••••••••••
1 1 2 2 1
1 1 2 2 1
1 1 2 2 1
1 1 2 2 1
24411-GB6-910 24421-200-000 24430-GB4-772 24435-GF6-003 24610-098-730
PLATE, GEARSHIFT DRUM STOPPER PIN, GEARSHIFT DRUM ••••••••• ARM COMP., SHIFT DRUM STOPPER SPRING, SHIFT DRUM STOPPER •• SPINDLE COMP., GEARSHIFT ••••
1 4 1 1 1
1 4 1 1 1
1 4 1 1 1
1 4 1 1 1
11 12 13 14 15
24630-GB2-711 24641-041-000 24651-041-000 24652-035-000 35750-001-020
ARM, GEARSHIFT •••••••••••••• SPRING, GEARSHIFT ARM ••••••• SPRING, GEARSHIFT RETURN •••• PIN, SHIFT RETURN SPRING •••• CONTACT ASSY., NEUTRAL SWITCH
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
16 17 18 19 20
35753-035-010 35755-001-020 90071-171-010 90417-041-000 90801-035-000
ROTOR, NEUTRAL SWITCH ••••••• PLATE, CONTACT FIXING ••••••• BOLT, KNOCK, 6MM •••••••••••• WASHER, GEARSHIFT DRUM SIDE • PLUG, RUBBER, 19MM ••••••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
21 22 23 24 25
91208-KB4-671 91312-107-000 92101-06016-0A 96001-06012-00 96220-30085
OIL SEAL, 11.6X24X10(ARAI) •• O-RING, 7X1.7 ••••••••••••••• BOLT, HEX., 6X16 •••••••••••• BOLT, FLANGE, 6X12 •••••••••• ROLLER, 3X8.5 •••••••••••••••
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
Parts catalogue code
6
2005.06.10
E
F.R.T.
3.8
3.8
0.9 0.9 0.9 0.9 0.2 0.9
E-15
KICK STARTER SPINDLE Ref. (Relative ref. Number) L.O.N. No. Description
1
(2,5) 1121A0 PINION, KICK STARTER ••••••••• .INCLUDES: Engine removal and installation 3 1121A2 SPINDLE, KICK STARTER •••••••• .INCLUDES: Engine removal and installation 6 112103 SPRING, KICK STARTER RETURN ••
F.R.T.
3.7 3.7 0.9
2
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
28211-178-000 28221-178-000 28251-086-701 28262-041-731 28271-121-690
PINION, KICK STARTER (22T) •• RATCHET, STARTER DRIVE •••••• SPINDLE, KICK STARTER ••••••• RETAINER, KICK SPRING ••••••• SPRING, STARTER PINION FRICTION
6 28281-035-003
SPRING, KICK STARTER (NIPPON HATSUJO) SPRING, KICK STARTER (CHUO HATSUJO) WASHER, 17MM •••••••••••••••• WASHER, THRUST, 20MM •••••••• SET RING, 20MM •••••••••••••• CIRCLIP, EXTERNAL, 16MM •••••
28281-035-018 7 8 9 10
90452-115-000 90454-107-000 90605-200-000 94510-16000
Description
Serial No.
3
C90ST 4 5
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1
1
1
1
1
1
1
1
1 1 1 2 1
1 1 1 2 1
1 1 1 2 1
1 1 1 2 1
Parts catalogue code
6
45 2005.06.10
E
E-16
CARBURETOR Ref. (Relative ref. Number) L.O.N. No. Description
2 3111A3 NEEDLE, JET •••••••••••••••••• 3 (15) 311120 FLOAT OR FLOAT VALVE ••••••••• 4 3111A5 TOP SET, CARBURETOR •••••••••• 5 3111A6 CHAMBER, FLOAT ••••••••••••••• 7 3111A8 VALVE, THROTTLE •••••••••••••• 11 3111B5 CARBURETOR ASSEMBLY •••••••••• 16 3111A4 HOLDER, NEEDLE JET ••••••••••• 18 310115 SCREEN, FUEL STRAINER •••••••• 27 (28) 3111D4 JET, MAIN ••••••••••••••••••••
2
46
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
16010-GN5-921 16012-GT0-680 16013-883-005 16014-GB6-610 16015-GT0-013
6 7 8 9 10
Description
Serial No.
3
C90ST 4 5
GASKET SET •••••••••••••••••• NEEDLE SET, JET ••••••••••••• FLOAT SET ••••••••••••••••••• TOP SET ••••••••••••••••••••• CHAMBER SET, FLOAT ••••••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
16016-GB4-003 16022-GB6-761 16028-GC8-004 16040-GB0-911 16041-GB5-D30
SCREW SET A ••••••••••••••••• VALVE SET, THROTTLE ••••••••• SCREW SET B ••••••••••••••••• GASKET SET B •••••••••••••••• NUT SET, SQUARE •••••••••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
11 12 13 14 15
16100-GT0-690 16118-GB4-003 16119-GK4-851 16148-141-881 16155-GZ5-000
CARBURETOR ASSY. (PB48F A) •• CAP, CABLE SEALING •••••••••• PLATE, STAY ••••••••••••••••• CAP, CHOKE DUST ••••••••••••• VALVE COMP., FLOAT ••••••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
16 17 18 19 20
16165-GB5-960 16175-GB0-911 16176-GB0-911 16199-GBJ-000 16199-GB4-003
HOLDER, NEEDLE JET •••••••••• CUP, FUEL STRAINER •••••••••• SCREEN, FUEL STRAINER ••••••• TUBE, AIR VENT •••••••••••••• TUBE, OVERFLOW ••••••••••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
21 22 23 24 25
93892-03012-18 93892-04008-18 93892-04018-18 93892-05010-18 95002-02079
SCREW-WASHER, 3X12 •••••••••• SCREW-WASHER, 4X8 ••••••••••• SCREW-WASHER, 4X18 •••••••••• SCREW-WASHER, 5X10 •••••••••• CLIP, TUBE (B7) •••••••••••••
2 1 2 1 1
2 1 2 1 1
2 1 2 1 1
2 1 2 1 1
Parts catalogue code
6
2005.06.10
E
F.R.T.
0.7 0.6 0.2 0.5 0.3 0.5 0.6 0.2 0.6
E-16
CARBURETOR
2
Ref. No.
Reqd. QTY Part No.
Description
26 95002-02659 CLIP, TUBE (B6.5) ••••••••••• 27 99102-GHB-0820 JET, MAIN, #82 •••••••••••••• 28 99103-943-0400 JET, SLOW, #40 ••••••••••••••
3
C90ST 4 5
1 1 1
1 1 1
1 1 1
Serial No.
Parts catalogue code
6
1 1 1
47 2005.06.10
E
EOP-1
GASKET KIT A Ref. (Relative ref. Number) L.O.N. No. Description
NO INFORMATION •••••••••••••••
2
Ref. No.
Reqd. QTY Part No.
1 06111-GB5-820 12191-GW8-681 12209-GB4-681 12251-GB5-811 12391-GW8-680 12394-GW8-680 12395-GW8-680 17119-HF7-000 18291-HB2-900 91301-GB0-911 91301-GK4-871 91302-001-020 91303-035-000
Description
GASKET KIT A •••••••••••••••• (COMPONENT PARTS) GASKET, CYLINDER •••••••••••• SEAL, VALVE STEM (NOK) •••••• GASKET, CYLINDER HEAD ••••••• GASKET, CYLINDER HEAD COVER • GASKET, R. CYLINDER HEAD SIDE COVER GASKET, L. CYLINDER HEAD SIDE COVER GASKET, IN. PIPE •••••••••••• GASKET, EX. PIPE •••••••••••• O-RING, 14.5MM •••••••••••••• O-RING, 27X2.0(ARAI) •••••••• O-RING, 30.8MM •••••••••••••• PACKING, RUBBER, 16MM •••••••
Serial No.
3
C90ST 4 5
1 1 2 1 1
-
-
-
1
-
-
-
1 1 1 1 1 2 1
-
-
-
Parts catalogue code
6
48 2005.06.10
E
F.R.T.
EOP-2
GASKET KIT B Ref. (Relative ref. Number) L.O.N. No. Description
F.R.T.
NO INFORMATION •••••••••••••••
2
Ref. No.
Reqd. QTY Part No.
1 06112-GB5-811 11191-GW8-680 11394-GW8-680 15119-178-000 22119-GW8-680 90407-259-000 90801-035-000 91301-035-003 91303-001-000 91307-035-000 91312-107-000 91317-171-003
Description
GASKET KIT B •••••••••••••••• (COMPONENT PARTS) GASKET, CRANKCASE ••••••••••• GASKET, R. CRANKCASE COVER •• GASKET, OIL PUMP BODY ••••••• GASKET, CLUTCH OUTER COVER •• PACKING, DRAIN COCK, 12.5X20 PLUG, RUBBER, 19MM •••••••••• O-RING, 107X2(ARAI) ••••••••• O-RING, 8MM ••••••••••••••••• O-RING, 18X3 •••••••••••••••• O-RING, 7X1.7 ••••••••••••••• O-RING, 6X1.7(ARAI) •••••••••
3
C90ST 4 5
1 1 1 1 1 1 1 1 1 1 1 1
-
-
Serial No.
Parts catalogue code
6
-
49 2005.06.10
E
F-1
HEADLIGHT Ref. (Relative ref. Number) L.O.N. No. Description
1 616115 HEADLIGHT ASSEMBLY ••••••••••• 4 (2) 6161A7 HEADLIGHT UNIT ••••••••••••••• 5 6161B1 SOCKET, HEADLIGHT •••••••••••• 6 616118 BULB, HEADLIGHT •••••••••••••• 7 616180 SOCKET, POSITION LIGHT ••••••• 8 616182 BULB, POSITION LIGHT •••••••••
3
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
33100-GT0-692 33101-GBJ-013 33117-GBJ-013 33120-GBJ-681 33130-GBJ-013
6 34901-GT4-003
Description
HEADLIGHT ASSY. (12V 30/30W) RIM COMP., HEADLIGHT •••••••• NUT ••••••••••••••••••••••••• HEADLIGHT UNIT •••••••••••••• SOCKET ASSY., HEADLIGHT •••••
Serial No.
3
C90ST 4 5
1 1 2 1 1
1 1 2 1 1
1 1 2 1 1
1 1 2 1 1
1 1
1 1
1 1
1 1
9 90101-GJ6-000 10 90101-087-720
BULB, HEADLIGHT (12V 30/30W) (STANLEY) SOCKET COMP., POSITION LAMP • BULB, WEDGE BASE (T10) (12V 3.4W) BOLT, ADJUSTING ••••••••••••• SCREW, HEADLIGHT SETTING ••••
1 1 2
1 1 2
1 1 2
1 1 2
11 90307-GJ6-003
WASHER, LOCK, 6MM •••••••••••
1
1
1
1
7 34904-GAC-003 8 34908-GA7-701
Parts catalogue code
6
50 2005.06.10
E
F.R.T.
0.1 0.2 0.1 0.1 0.1 0.1
F-2
METER Ref. (Relative ref. Number) L.O.N. No. Description
3 4 6 7
8121A1 6161G4 811160 8111B2
METER ASSY., COMBINATION ••••• SOCKET ASSY., METER BULB ••••• CABLE, SPEEDOMETER ••••••••••• CABLE, SPEEDOMETER INNER •••••
F.R.T.
0.3 0.2 0.2 0.1
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
34908-GB4-700 34908-MB9-871 37200-GT0-751 37223-GB5-731 37244-086-000
Description
Serial No.
3
C90ST 4 5
BULB (12V 2W) ••••••••••••••• BULB, WEDGE BASE (12V 1.7W) • SPEEDOMETER ASSY. ••••••••••• SOCKET COMP. •••••••••••••••• SPRING, SPEEDOMETER SETTING •
1 2 1 1 1
1 2 1 1 1
1 2 1 1 1
1 2 1 1 1
6 44830-GBJ-000 CABLE COMP., SPEEDOMETER •••• 7 44831-GBJ-000 CABLE, INNER •••••••••••••••• 8 93700-05018-0A SCREW, OVAL, 5X18 •••••••••••
1 1 1
1 1 1
1 1 1
1 1 1
3
Parts catalogue code
6
51 2005.06.10
E
F-3
HANDLE LEVER/SWITCH/CABLE Ref. (Relative ref. Number) L.O.N. No. Description
1 2 3 5 6 7 8 9 10
811100 811120 810140 6151C1 615118 6151B2 811125 810150 8101C0 8101C1 11 8101C7
3
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
17910-GB5-762 17950-GB4-770 17961-GB5-671 17962-GB4-003 35150-GBJ-680
Description
Serial No.
Parts catalogue code
3
C90ST 4 5
CABLE COMP., THROTTLE ••••••• CABLE COMP., CHOKE •••••••••• LEVER, CHOKE •••••••••••••••• STOPPER, CABLE •••••••••••••• SWITCH ASSY., LIGHTING ••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
35200-GK4-790 35340-GBJ-000 45450-GBJ-000 53160-179-700 53160-179-701 10 53165-172-000
SWITCH ASSY., WINKER •••••••• SWITCH ASSY., FR. STOP •••••• CABLE COMP., FR. BRAKE •••••• GRIP COMP., THROTTLE •••••••• •••••••••••••••••••••••••••• GRIP, HANDLE ••••••••••••••••
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
11 12 13 14 15
53175-GR2-010 53176-179-702 88113-GBJ-000 88210-GBJ-004 90115-170-700
LEVER, COVER, COVER, MIRROR SCREW,
R. STEERING HANDLE ••• R. HANDLE LEVER •••••• LOCK NUT ••••••••••••• COMP. (HONDA LOCK) ••• HANDLE LEVER PIVOT •••
1 1 2 2 1
1 1 2 2 1
1 1 2 2 1
1 1 2 2 1
16 17 18 19 20
90116-147-000 90314-GBJ-000 90441-147-000 90442-147-000 93500-05028-0A
SCREW, PAN, 5MM ••••••••••••• NUT, HEX., 8MM(HONDA LOCK) •• WASHER, PLAIN ••••••••••••••• WASHER, WAVE •••••••••••••••• SCREW, PAN, 5X28 ••••••••••••
1 2 1 1 2
1 2 1 1 2
1 2 1 1 2
1 2 1 1 2
21 93500-05040-0A SCREW, PAN, 5X40 •••••••••••• 22 93892-05010-08 SCREW-WASHER, 5X10 •••••••••• 23 94001-05000-0S NUT, HEX., 5MM ••••••••••••••
2 1 1 -
2 1 1 -
2 1 1
2 1 - -------- 5K601256
6 7 8 9
52
CABLE, THROTTLE •••••••••••••• CABLE, CHOKE ••••••••••••••••• LEVER, CHOKE :HANDLE SIDE •••• SWITCH, LIGHTING ••••••••••••• SWITCH, WINKER ••••••••••••••• SWITCH, FRONT STOP ••••••••••• CABLE, FRONT BRAKE ••••••••••• GRIP, THROTTLE ••••••••••••••• GRIP, HANDLE :LEFT ••••••••••• GRIP, HANDLE :RIGHT •••••••••• LEVER, HANDLE :RIGHT •••••••••
6
2005.06.10
E
F.R.T.
0.3 0.3 0.1 0.5 0.6 0.3 0.3 0.2 0.1 0.2 0.1
F-3
Ref. No.
HANDLE LEVER/SWITCH/CABLE
Reqd. QTY Part No.
23) 90302-435-761
Description
NUT, HEX., 5MM ••••••••••••••
3
C90ST 4 5
-
-
1 -
Serial No.
3
Parts catalogue code
6
- 5K601257 1
53 2005.06.10
E
F-4
STEERING HANDLE Ref. (Relative ref. Number) L.O.N. No. Description
1 2 3 4
Ref. No.
3
54
BRIDGE, FORK TOP ••••••••••••• PIPE, STEERING HANDLE •••••••• COVER, HANDLE :LOWER ••••••••• PLATE, FORK TOP BRIDGE •••••••
Reqd. QTY Part No.
Description
1 51102-086-720 BRIDGE, FORK TOP •••••••••••• 2 53100-GK4-791YM HANDLE COMP., STEERING *R110*..............MONZA RED 53100-GK4-791YN *PB109*..........NEPTUNE BLUE 53100-GK4-791YR *G46*...........SPINACH GREEN 53100-GK4-792YM *R110*..............MONZA RED 53100-GK4-792YN *PB109*..........NEPTUNE BLUE 53100-GK4-792YR *G46*...........SPINACH GREEN 53100-GK4-792YU *NH1*...................BLACK 53100-GK4-792YV *PB310*...........ICARAI BLUE 3 53120-GB4-030YV COVER, HANDLE UNDER *G46*...........SPINACH GREEN 53120-GB4-030ZM *R110*..............MONZA RED 53120-GB4-030ZR *PB109*..........NEPTUNE BLUE 53120-GFN-720ZA *NH1*...................BLACK 53120-GFN-720ZB *PB310*...........ICARAI BLUE 53120-GFN-720ZC *R110*..............MONZA RED 4 53231-GB4-010 PLATE, FORK TOP BRIDGE •••••• 5 53232-086-720 SHEET A, TOP BRIDGE RUBBER •• 6 7 8 9 10
510110 810100 4131X2 5101D1
Serial No.
3
C90ST 4 5
1
1
1
1
1 1 1 -
1 1 1 -
1 1 1 -
1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
Parts catalogue code
6
53233-172-000 53234-171-000 53235-086-020 53236-171-000 53237-GB4-680
RUBBER B, TOP BRIDGE SHEET •• COLLAR, STEERING STEM ••••••• WASHER, TOP BRIDGE •••••••••• COLLAR, TOP BRIDGE •••••••••• WASHER ••••••••••••••••••••••
1 1 1 2 1
1 1 1 2 1
1 1 1 2 1
1 1 1 2 1
11 90304-GB4-680 12 90518-086-000 13 90552-001-000
NUT C, STEERING STEM •••••••• WASHER, HANDLE SETTING •••••• WASHER, TOOTHED •••••••••••••
1 2 2
1 2 2
1 2 2
1 2 2 2005.06.10
E
F.R.T.
0.8 1.2 0.9 0.9
F-4
Ref. No.
STEERING HANDLE
Reqd. QTY Part No.
Description
Serial No.
3
C90ST 4 5
14 93401-08016-00 BOLT-WASHER, 8X16 ••••••••••• 15 94070-08080 NUT-WASHER, 8MM •••••••••••••
2 2
2 2
2 2
2 2
16 95801-08032-00 BOLT, FLANGE, 8X32 •••••••••• 17 96001-06014-00 BOLT, FLANGE, 6X14 ••••••••••
2 1
2 1
2 1
2 1
3
Parts catalogue code
6
55 2005.06.10
E
F-5
FRONT FORK Ref. (Relative ref. Number) L.O.N. No. Description
2 5101A0 RACE, STEERING BALL :UPPER ••• .NOTE: Same time for two units 5101A1 RACE, STEERING BALL :LOWER ••• .NOTE: Same time for two units 5101C9 RACE, STEERING BALL :BOTH •••• 3 511100 FORK ASSY., FRONT •••••••••••• 6 5101A9 RACE, STEERING TOP CONE •••••• 7 5101B0 RACE, STEERING BOTTOM CONE ••• 10 5101B2 THREAD, STEERING HEAD TOP •••• 12 615147 LOCK, STEERING ••••••••••••••• 13 4131C7 COVER, FRONT FORK •••••••••••• 14 411105 STAY, FRONT COVER •••••••••••• 15 4111L3 COWL, FRONT CENTER •••••••••••
Ref. No.
3
Reqd. QTY Part No.
3
C90ST 4 5
Serial No.
2 2
2 2
2 2
2 2
1 1 1 -
1 1 1 -
1 1 1 -
1 1 1
2
2
2
2
2
2
2
2
6 7 8 9
RACE, STEERING TOP CONE ••••• RACE, STEERING BOTTOM CONE •• DUST SEAL, STEERING HEAD •••• WASHER, STEERING HEAD DUST SEAL THREAD COMP., STEERING HEAD TOP
1 1 1
1 1 1
1 1 1
1 1 1
1
1
1
1
1
1
1
1
11 53236-086-000 COLLAR, TOP BRIDGE •••••••••• 12 53600-086-007 LOCK, STEERING HANDLE ••••••• 13 61150-086-020C2 COVER, FORK CENTER *G46*...........SPINACH GREEN 61150-086-020ZV *R110*..............MONZA RED 61150-086-020ZY *PB109*..........NEPTUNE BLUE 61150-GFN-720ZA *NH1*...................BLACK 61150-GFN-720ZB *PB310*...........ICARAI BLUE
1 1
1 1
1 1
1 1
1 1 1 -
1 1 1 -
1 1 1 -
1 1
53211-030-000 53212-030-010 53214-001-010 53215-001-000
Parts catalogue code
6
1 50049-046-000 PLUG, HEAD PIPE ••••••••••••• 2 50301-041-010 RACE, STEERING TOP BALL ••••• 3 51110-GBJ-305ZC FORK SET, FR. *G46*...........SPINACH GREEN 51110-GBJ-305ZD *PB109*..........NEPTUNE BLUE 51110-GBJ-305ZE *R110*..............MONZA RED 51110-GBJ-305YD *NH1*...................BLACK 51110-GBJ-305YL *PB310*...........ICARAI BLUE 4 51341-001-000ZE CAP, FR. FORK SIDE *NH1*...................BLACK 5 53210-GS9-003 BALL ASSY., STEERING STEEL (KATO HATSUJO)
10 53220-041-010
56
Description
2005.06.10
E
F.R.T.
1.2 1.2 1.2 1.6 0.9 1.4 0.9 0.3 0.1 0.2 0.1
F-5
Ref. No.
FRONT FORK
Reqd. QTY Part No.
Description
Serial No.
3
C90ST 4 5
1
1
1
1 1
1
1
1
1
GROMMET, TOP COVER •••••••••• SCREW, HEADLIGHT SETTING •••• SCREW, U-LOCK FLAT, 6X12 •••• NUT, SPEED, 4MM ••••••••••••• BOLT, CAP, 8X25 •••••••••••••
1 1 2 2 1
1 1 2 2 1
1 1 2 2 1
1 1 2 2 1
21 94102-08000 WASHER, PLAIN, 8MM •••••••••• 22 95701-06012-00 BOLT, FLANGE, 6X12 ••••••••••
1 4
1 4
1 4
1 4
13) 61150-GFN-720ZC COVER, FORK CENTER *R110*..............MONZA RED 14 64309-GK4-870 STAY, TOP COVER SETTING ••••• 15 64310-GB4-000ZF COVER, FR. TOP *NH138*..........SHASTA WHITE 16 17 18 19 20
64315-GB4-000 90101-087-720 90164-028-000 90313-172-000 92501-08025-0A
3
Parts catalogue code
6
57 2005.06.10
E
F-6
FRONT FENDER Ref. (Relative ref. Number) L.O.N. No. Description
1 4131B7 FENDER, FRONT ••••••••••••••••
Ref. No.
3
Reqd. QTY Part No.
Description
1 61100-086-000A6 FENDER, FR. *G46*...........SPINACH GREEN 61100-086-000ZN *R110*..............MONZA RED 61100-086-000ZQ *PB109*..........NEPTUNE BLUE 61100-GFN-720ZA *NH1*...................BLACK 61100-GFN-720ZB *PB310*...........ICARAI BLUE 61100-GFN-720ZC *R110*..............MONZA RED 2 80102-GK4-970 COLLAR, FR. FENDER •••••••••• 3 90111-162-000 BOLT, FLANGE, 6MM •••••••••••
3
C90ST 4 5
1 1 1 2 2
1 1 1 2 2
1 1 1 2 2
Serial No.
Parts catalogue code
6
1 1 1 2 2
58 2005.06.10
E
F.R.T.
0.2
F-7
FRONT CUSHION Ref. (Relative ref. Number) L.O.N. No. Description
2
5111K7 5111K7A 5111K8 5111K8A 5111K9
3 5111A5 5111A6 4 5111A4 9 5111G7 5111G8 5111H7
(1) BUSH, FORK PIVOT ARM :LEFT ••• .Replace 1 bush add •••••••••• BUSH, FORK PIVOT ARM :RIGHT •• .Replace 1 bush add •••••••••• BUSH, FORK PIVOT ARM :FOR 1 VEHICLE •••••••••••••• ARM, FORK PIVOT :RIGHT ••••••• ARM, FORK PIVOT :BOTH •••••••• ARM, FORK PIVOT :LEFT •••••••• CUSHION ASSY., FRONT :LEFT ••• CUSHION ASSY., FRONT :RIGHT •• CUSHION ASSY., FRONT :BOTH •••
F.R.T.
0.5 0.1 0.5 0.1 1.0 0.4 0.6 0.4 0.4 0.4 0.6
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
51311-GK4-971 51312-GK4-971 51315-041-000 51325-041-000 51331-GK4-970
Description
Serial No.
3
C90ST 4 5
BUSH, FR. CUSHION UNDER ••••• BUSH, FR. ARM PIVOT ••••••••• ARM COMP., R. FR. SUSPENSION ARM COMP., L. FR. SUSPENSION COLLAR, FR. ARM PIVOT •••••••
2 2 1 1 2
2 2 1 1 2
2 2 1 1 2
2 2 1 1 2
4 2
4 2
4 2
4 2
9 51400-GK4-971 10 51486-086-000
CAP, FR. ARM PIVOT DUST SEAL COLLAR, FR. CUSHION DISTANCE CAP, FR. CUSHION UNDER DUST SEAL CUSHION ASSY., FR. •••••••••• COLLAR, RUBBER BUSH •••••••••
4 2 2
4 2 2
4 2 2
4 2 2
11 12 13 14 15
BUSH, RUBBER •••••••••••••••• BOLT, FLANGE, 10X53 ••••••••• BOLT, FR. CUSHION UNDER ••••• NUT, U, 10MM •••••••••••••••• O-RING, 13.8X2.4(ARAI) ••••••
2 2 2 2 8
2 2 2 2 8
2 2 2 2 8
2 2 2 2 8
16 93403-08032-08 BOLT-WASHER, 8X32 ••••••••••• 17 94002-08000-0S NUT, HEX., 8MM ••••••••••••••
2 2
2 2
2 2
2 2
6 51333-001-000 7 51334-GK4-970 8 51336-001-000
51489-086-000 90112-GK4-000 90149-041-010 90304-GE8-003 91311-PH7-004
3
Parts catalogue code
6
59 2005.06.10
E
F-8
FRONT BRAKE PANEL Ref. (Relative ref. Number) L.O.N. No. Description
1 711115 SHOE(PAD) SET, BRAKE :FRONT •• 4 710151 AXLE, FRONT WHEEL •••••••••••• 5 7101C3 GEAR, SPEEDOMETER •••••••••••• 7 (2) 7111D0 PANEL, FRONT BRAKE ••••••••••• 10 7111C3 ARM, FRONT BRAKE •••••••••••••
Ref. No.
3
Reqd. QTY Part No.
Description
Serial No.
3
C90ST 4 5
SHOE SET, BRAKE (ASK) ••••••• SHOE SET, BRAKE (JB) •••••••• CAM, RR. BRAKE •••••••••••••• SPRING, BRAKE SHOE •••••••••• AXLE, FR. WHEEL ••••••••••••• GEAR COMP., SPEEDOMETER •••••
1 1 1 2 1 1
1 1 1 2 1 1
1 1 1 2 1 1
1 1 1 2 1 1
44808-107-720 45010-GBJ-305 45134-250-000 45145-121-710 45410-GB4-000
WASHER, SPEEDOMETER GEAR •••• PANEL SUB ASSY., FR. BRAKE •• DUST SEAL, BRAKE CAM •••••••• INDICATOR, FR. BRAKE •••••••• ARM, FR. BRAKE ••••••••••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
11 45411-GB4-680 12 91251-GK4-003 91251-GK4-005 13 94050-06000 14 95015-32001 15 95015-42000
SPRING, BRAKE ARM RETURN •••• OIL SEAL, 47X60X7(ARAI) ••••• OIL SEAL, 47X60X7(NOK) •••••• NUT, FLANGE, 6MM •••••••••••• JOINT B, BRAKE ARM •••••••••• NUT B, BRAKE ROD ADJUSTING ••
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1
16 95701-06028-00 BOLT, FLANGE, 6X28 ••••••••••
1
1
1
1
1 06430-GBJ-J10 06450-121-730 2 43141-GC5-000 3 43151-110-000 4 44301-GBJ-000 5 44806-GK4-003 6 7 8 9 10
Parts catalogue code
6
60 2005.06.10
E
F.R.T.
0.3 0.2 0.3 0.4 0.1
F-9
FRONT WHEEL Ref. (Relative ref. Number) L.O.N. No. Description
1 4 6 7 8 11
TUBE, FRONT TIRE ••••••••••••• HUB, FRONT WHEEL ••••••••••••• FRONT WHEEL •••••••••••••••••• RIM, WHEEL :FRONT •••••••••••• FRONT TIRE(ONE) •••••••••••••• (5) 710115 BEARING, FRONT WHEEL(ONE) •••• 710115G .Replace 1 bearing add ••••••• 14 7101F2 HUB ASSY., FRONT WHEEL •••••••
Ref. No.
710140 710103 7101D4 710109 710139
F.R.T.
0.8 2.5 0.8 2.2 0.8 0.4 0.1 2.3
Reqd. QTY Part No.
Description 3
C90ST 4 5
Serial No.
1 42712-GS4-006 42712-041-154 2 42713-001-000 3 44311-041-000 4 44601-GBJ-000 5 44620-171-000
TUBE, TIRE (IRC)(2.50-17) ••• TUBE, TIRE (IRC)(2.25/2.50-17) FLAP, TIRE (IRC) •••••••••••• COLLAR, FR. WHEEL SIDE •••••• HUB COMP., FR. WHEEL •••••••• COLLAR, FR. AXLE DISTANCE •••
1 1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
6 44650-GT0-305 7 44701-102-791
WHEEL SUB ASSY., FR. •••••••• RIM, FR. WHEEL (DAIDO) (1.40X17) RIM, FR. WHEEL (FUTABA) (1.40X17) TIRE, FR. (IRC) (2.50-17 4PR/38L 6F) NUT, U, 10MM •••••••••••••••• OIL SEAL, 21X35X7(ARAI) ••••• OIL SEAL, 21X35X7(NOK) ••••••
1
1
1
1
1
1
1
1
1
1
1
-
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 -
2
2
2
2
44701-102-792 8 44711-GB6-885 9 90304-GE8-003 10 90752-GB4-681 90752-GB4-682
11 96140-63000-10 BEARING, RADIAL BALL, 6300U • 12 97172-21157-F0 SPOKE SET A, 12X158.5 ••••••• (INSIDE) 13 97548-21156-F0 SPOKE SET A, 12X158 ••••••••• (OUTSIDE) 14 44635-GB5-J30 HUB SUB ASSY., FR. ••••••••••
3
Parts catalogue code
6
18 18 18 18 18 18 18 18 - 1 1 1
61 2005.06.10
E
F-10
REAR BRAKE PANEL Ref. (Relative ref. Number) L.O.N. No. Description
1 711140 SHOE(PAD) SET, BRAKE :REAR ••• 3 710160 AXLE, REAR WHEEL ••••••••••••• 5 (6) 7111A9 PANEL, REAR BRAKE •••••••••••• 9 7111C4 ARM, REAR BRAKE ••••••••••••••
Ref. No.
3
Reqd. QTY Part No.
1 06430-GBJ-J10 06450-121-730 2 40543-141-850 3 42301-GBJ-000 4 42313-GBJ-000 5 43100-GBJ-000
Description
Serial No.
3
C90ST 4 5
SHOE SET, BRAKE (ASK) ••••••• SHOE SET, BRAKE (JB) •••••••• ADJUSTER, R. CHAIN •••••••••• AXLE, RR. WHEEL ••••••••••••• COLLAR, RR. BRAKE PANEL SIDE PANEL COMP., RR. BRAKE ••••••
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
Parts catalogue code
6
6 7 8 9 10
43141-400-010 43145-KC1-000 43151-110-000 43410-086-720 43434-286-000
CAM, RR. BRAKE •••••••••••••• INDICATOR, RR. BRAKE •••••••• SPRING, BRAKE SHOE •••••••••• ARM, RR. BRAKE •••••••••••••• RUBBER, STOPPER ARM CUSHION •
1 1 2 1 1
1 1 2 1 1
1 1 2 1 1
1 1 2 1 1
11 12 13 14 15
45134-250-000 90301-473-003 90505-425-000 92811-10000 94001-06000-0S
DUST SEAL, BRAKE CAM •••••••• NUT, U, 6MM ••••••••••••••••• WASHER, 8MM ••••••••••••••••• BOLT A, BRAKE STOPPER ••••••• NUT, HEX., 6MM ••••••••••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
16 17 18 19 20
94001-08000-0S 94101-06000 94111-06000 94201-20150 95701-06035-00
NUT, HEX., 8MM •••••••••••••• WASHER, PLAIN, 6MM •••••••••• WASHER, SPRING, 6MM ••••••••• PIN, SPLIT, 2.0X15 •••••••••• BOLT, FLANGE, 6X35 ••••••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
62 2005.06.10
E
F.R.T.
0.4 0.3 0.5 0.1
F-11
REAR WHEEL Ref. (Relative ref. Number) L.O.N. No. Description
1 3 4 6 8 9 10 12 13 14 24
710157 7101A0 7101A1 7101A4 7101D1 7101F3 710118 710127 710142 7101A7
DAMPER, REAR WHEEL ••••••••••• SPROCKET, FINAL DRIVEN ••••••• SLEEVE, REAR WHEEL ••••••••••• FLANGE, FINAL DRIVEN ••••••••• BEARING, FINAL DRIVEN FLANGE • HUB ASSY., REAR WHEEL •••••••• REAR WHEEL ••••••••••••••••••• RIM, WHEEL :REAR ••••••••••••• REAR TIRE(ONE) ••••••••••••••• TUBE, REAR TIRE •••••••••••••• (7) 710133 BEARING, REAR WHEEL(ONE) ••••• 710133G .Replace 1 bearing add ••••••• 27 7101A5 FLANGE ASSY., FINAL DRIVEN •••
F.R.T.
0.3 0.6 0.4 0.7 0.6 2.4 0.8 2.3 0.8 0.8 0.5 0.1 0.6
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
06410-GBJ-J01 40544-141-850 41201-GT0-750 42303-041-000 42304-040-000
6 42610-GBJ-305 7 42620-121-000 8 42630-GK4-003 42630-GK4-005 9 42635-GB5-J30 10 42650-GT0-315 11 42653-001-004
Description
Serial No.
3
C90ST 4 5
DAMPER SET, WHEEL ••••••••••• ADJUSTER, L. DRIVE CHAIN •••• SPROCKET, FINAL DRIVEN (39T) SLEEVE, RR. WHEEL AXLE •••••• COLLAR, RR. WHEEL AXLE SLEEVE
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
FLANGE COMP., FINAL DRIVEN •• COLLAR, RR. AXLE DISTANCE ••• BEARING, RADIAL BALL, 6203 (NTN) BEARING, RADIAL BALL, 6203 (NACHI) HUB SUB ASSY., RR. •••••••••• WHEEL SUB ASSY., RR. ••••••••
1 1
1
1
1
1
1
1
1
1 1 1
1 1 1
1 1 1
1 1 1
1
1
1
1
1
1
1
1
14 42712-GS4-006 42712-041-154 15 42713-001-000
O-RING, 40.5X3 (NIPPON DUST KEEPER) RIM, RR. WHEEL (DAIDO) (1.40X17) TIRE, RR. (IRC) (2.50-17 6PR/38L) TUBE, TIRE (IRC)(2.50-17) ••• TUBE, TIRE (IRC)(2.25/2.50-17) FLAP, TIRE (IRC) ••••••••••••
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
16 17 18 19
BOLT, STUD, 8X18 •••••••••••• NUT, HEX., 12MM ••••••••••••• NUT, RR. AXLE SLEEVE •••••••• NUT, U, 8MM •••••••••••••••••
4 1 1 4
4 1 1 4
4 1 1 4
4 1 1 4
12 42701-030-003 13 42711-096-025
90125-GBJ-000 90306-GAB-711 90307-001-000 90309-ML3-791
3
Parts catalogue code
6
2005.06.10
63 E
F-11
Ref. No.
3
REAR WHEEL
Reqd. QTY Part No.
Description 3
C90ST 4 5
Serial No.
20 90753-GK4-003 90753-GK4-005
OIL SEAL, 27X40X6(ARAI) ••••• OIL SEAL, 27X40X6(NOK) ••••••
1 -
1 1
1 1
1 -
21 22 23 24 25
NUT, HEX., 6MM •••••••••••••• WASHER, PLAIN, 6MM •••••••••• WASHER, SPRING, 6MM ••••••••• BEARING, RADIAL BALL, 6301U • SPOKE SET B, 10X159.0 ••••••• (INSIDE)
1 1 1 2
1 1 1 2
1 1 1 2
1 1 1 2
94001-06000-0S 94101-06000 94111-06000 96140-63010-10 97282-42158-F0
Parts catalogue code
6
18 18 18 18
26 97548-42157-F0 SPOKE SET B, 10X158.5 ••••••• (OUTSIDE) 18 18 18 18 27 42615-GBJ-J00 FLANGE SUB ASSY., FINAL DRIVEN - 1 1 1
64 2005.06.10
E
F-12
FUEL TANK Ref. (Relative ref. Number) L.O.N. No. Description
1 310100 TANK, FUEL ••••••••••••••••••• 3 (4) 3101B5 TUBE, FUEL ••••••••••••••••••• .NOTE: Same time for two units
Ref. No.
F.R.T.
0.4 0.3
Reqd. QTY Part No.
Description
1 17510-GB4-721YP TANK COMP., FUEL *G46*...........SPINACH GREEN 17510-GB4-721ZC *R110*..............MONZA RED 17510-GB4-721ZD *PB109*..........NEPTUNE BLUE 17510-GB4-721YN *NH1*...................BLACK 17510-GB4-721YT *PB310*...........ICARAI BLUE 2 17620-GE7-023 FUEL FILL CAP COMP. ••••••••• 17620-GR1-931
CAP COMP., FUEL FILLER ••••••
3 17630-GBJ-680 4 17631-GBJ-680 5 17631-096-701
TUBE, FUEL, 5.3X520 ••••••••• TUBE, FUEL RESERVE •••••••••• PACKING, FUEL FILLER CAP ••••
17632-383-831
••••••••••••••••••••••••••••
6 95002-02100 CLIP, TUBE (B10) •••••••••••• 7 95701-06016-00 BOLT, FLANGE, 6X16 ••••••••••
Serial No.
3
C90ST 4 5
1 1 1 1 1 1 1 -
1 1 1 1 1 1 1 1 1 -
1 1 1 1 1 1 1
1 1 1 1 1 1 1
4 2
4 2
4 2
4 2
3
Parts catalogue code
6
-------- 4K501676 4K501677
-------- 4K501676 4K501677
65 2005.06.10
E
F-13
SEAT Ref. (Relative ref. Number) L.O.N. No. Description
2 413150 SEAT ••••••••••••••••••••••••• 5 410165 CARRIER, LUGGAGE •••••••••••••
Ref. No.
3
Reqd. QTY Part No.
Description
Serial No.
3
C90ST 4 5
1 17509-398-960 COLLAR, TANK SETTING •••••••• 2 77000-GBJ-N10ZB SEAT ASSY., SINGLE *TYPE2* (HINGE IS INCLUDED) 3 77211-GBJ-830 RUBBER, SEAT MOUNTING ••••••• 4 77300-GT0-M00 SEAT COMP., PILLION ••••••••• 5 81200-GAC-000 CARRIER, LUGGAGE ••••••••••••
2
2
2
2
1 2 1 1
1 2 1 1
1 2 1 1
1 2 1 1
6 7 8 9
2 2 2 1
2 2 2 1
2 2 2 1
2 2 2 1
90443-107-000 92101-08018-0A 93404-06025-00 95011-61000
NUT, CAP, 8MM ••••••••••••••• BOLT, HEX., 8X18 •••••••••••• BOLT-WASHER, 6X25 ••••••••••• RUBBER A, STAND STOPPER •••••
Parts catalogue code
6
66 2005.06.10
E
F.R.T.
0.1 0.1
F-14
SIDE COVER Ref. (Relative ref. Number) L.O.N. No. Description
1 4111H9 COVER, .NOTE: 4111J0 COVER, 3 4111H8 COVER, .NOTE:
Ref. No.
SIDE Same SIDE SIDE Same
:RIGHT ••••••••••• time for two units :BOTH •••••••••••• :LEFT •••••••••••• time for two units
F.R.T.
0.1 0.1 0.1
Reqd. QTY Part No.
Description
1 83510-GBJ-N20ZK COVER SET, R. SIDE (WL) *R110*..............MONZA RED 83510-GBJ-N20ZP *G46*...........SPINACH GREEN 83510-GBJ-N20ZQ *PB109*..........NEPTUNE BLUE 83510-GFN-720ZA *NH1*...................BLACK 83510-GFN-720ZB *PB310*...........ICARAI BLUE 83510-GFN-720ZC *R110*..............MONZA RED 2 83550-GB4-680 LATCH, TOOL BOX ••••••••••••• 3 83610-GBJ-N20ZK COVER SET, L. SIDE (WL) *R110*..............MONZA RED 83610-GBJ-N20ZP *G46*...........SPINACH GREEN 83610-GBJ-N20ZQ *PB109*..........NEPTUNE BLUE 83610-GFN-720ZA *NH1*...................BLACK 83610-GFN-720ZB *PB310*...........ICARAI BLUE 83610-GFN-720ZC *R110*..............MONZA RED 4 83642-171-000 BAG, OWNERS MANUAL •••••••••• 5 83650-GB4-680 LATCH, BATTERY BOX •••••••••• 6 94001-06000-0S NUT, HEX., 6MM ••••••••••••••
Serial No.
3
C90ST 4 5
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
2
2
2
2
3
Parts catalogue code
6
67 2005.06.10
E
F-15
AIR CLEANER Ref. (Relative ref. Number) L.O.N. No. Description
1 5 6 7
Ref. No.
3
312105 312102 3121A5 3121B6
ELEMENT, AIR CLEANER ••••••••• COVER, AIR CLEANER CASE •••••• CASE, AIR CLEANER •••••••••••• TUBE, AIR CLEANER CONNECTING •
Reqd. QTY Part No.
Description
Serial No.
3
C90ST 4 5
ELEMENT COMP., AIR CLEANER •• SEAL, AIR CLEANER COVER ••••• RUBBER, AIR CLEANER ELEMENT SETTING DUCT, AIR CLEANER ••••••••••• CASE, AIR CLEANER UPPER HALF
1 1
1 1
1 1
1 1
1 1 1
1 1 1
1 1 1
1 1 1
CASE, AIR CLEANER UNDER HALF TUBE, AIR CLEANER CONNECTING BAND B, AIR CLEANER CONNECTING TUBE 9 90114-GJ5-000 BOLT, FLANGE, 6MM ••••••••••• 10 93500-05020-0A SCREW, PAN, 5X20 ••••••••••••
1 1
1 1
1 1
1 1
1 2 1
1 2 1
1 2 1
1 2 1
11 93891-05028-08 SCREW-WASHER, 5X28 ••••••••••
4
4
4
4
1 17211-GB4-010 2 17212-GB4-000 3 17213-GB4-000 4 17219-GB4-010 5 17230-GT0-680 6 17231-GB4-020 7 17253-GB5-000 8 17256-053-010
Parts catalogue code
6
68 2005.06.10
E
F.R.T.
0.2 0.3 0.3 0.3
F-16
EXHAUST MUFFLER Ref. (Relative ref. Number) L.O.N. No. Description
1 2 3 5
Ref. No.
313125 3131B4 3131B7 313120
COVER, EXHAUST PIPE •••••••••• GASKET, EXHAUST PIPE ••••••••• BRACKET, MUFFLER ••••••••••••• MUFFLER ••••••••••••••••••••••
F.R.T.
0.1 0.1 0.2 0.2
Reqd. QTY Part No.
Description 3
C90ST 4 5
Serial No.
3
Parts catalogue code
6
1 18240-174-770 COVER, EX. PIPE ••••••••••••• 2 18291-HB2-900 GASKET, EX. PIPE •••••••••••• 3 18315-171-000ZA STAY, MUFFLER UPPER *NH1*...................BLACK 4 18316-GB4-000 CLIP, TUBE •••••••••••••••••• 5 18350-GT0-680 MUFFLER COMP., EX. ••••••••••
1 1
1 1
1 1
1 1
1 1 1
1 1 1
1 1 1
1 1 1
6 90049-GR1-000 SCREW-WASHER, 5X6 ••••••••••• 7 94001-06000-0S NUT, HEX., 6MM •••••••••••••• 8 94050-08000 NUT, FLANGE, 8MM ••••••••••••
2 2 2
2 2 2
2 2 2
2 2 2
69 2005.06.10
E
F-17
PEDAL Ref. (Relative ref. Number) L.O.N. No. Description
1 2 4 6 7 8
3
4101A1 112107 6151B5 811135 810160 8101A8
PEDAL, GEAR CHANGE ••••••••••• ARM, KICK STARTER •••••••••••• SWITCH, REAR STOP :PEDAL SIDE ROD, REAR BRAKE •••••••••••••• PEDAL, REAR BRAKE •••••••••••• SPRING, BRAKE PEDAL ••••••••••
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
24701-141-650 28300-141-640 28311-342-000 35350-GAC-000 35357-041-000
6 7 8 9 10 11 12 13 14 15
Description
Serial No.
3
C90ST 4 5
PEDAL, GEAR CHANGE •••••••••• ARM ASSY., KICK STARTER ••••• RUBBER, KICK STARTER •••••••• SWITCH ASSY., RR. STOP •••••• SPRING, STOP SWITCH •••••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
43451-041-000 46500-086-720 46514-086-720 92101-06020-0A 92101-06022-0A
ROD, RR. BRAKE •••••••••••••• PEDAL COMP., BRAKE •••••••••• SPRING, BRAKE PEDAL ••••••••• BOLT, HEX., 6X20 •••••••••••• BOLT, HEX., 6X22 ••••••••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
94101-05000 94201-20150 95014-73100 95015-32001 95015-42000
WASHER, PLAIN, 5MM •••••••••• PIN, SPLIT, 2.0X15 •••••••••• SPRING A, BRAKE ROD ••••••••• JOINT B, BRAKE ARM •••••••••• NUT B, BRAKE ROD ADJUSTING ••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
Parts catalogue code
6
70 2005.06.10
E
F.R.T.
0.1 0.1 0.2 0.3 0.5 0.1
F-18
STEP Ref. (Relative ref. Number) L.O.N. No. Description
1 410145 BAR, STEP ••••••••••••••••••••
Ref. No.
F.R.T.
0.3
Reqd. QTY Part No.
Description
1 50610-GB2-000 BAR COMP., STEP ••••••••••••• 2 50660-GB2-000 RUBBER, STEP •••••••••••••••• 3 93402-08020-00 BOLT-WASHER, 8X20 •••••••••••
3
C90ST 4 5
1 2 4
1 2 4
1 2 4
Serial No.
3
Parts catalogue code
6
1 2 4
71 2005.06.10
E
F-19
STAND Ref. (Relative ref. Number) L.O.N. No. Description
1
410175 3 4101C0 5 410180 10 410182
Ref. No.
3
Reqd. QTY Part No.
Description
1 50500-GT0-680ZA STAND COMP., MAIN *NH1*...................BLACK 2 50512-GB4-680 SHAFT, RR. BRAKE PIVOT •••••• 3 50523-041-000 HOOK, MAIN STAND SPRING ••••• 4 50524-GBJ-680 RUBBER, STAND STOPPER ••••••• 5 50530-GT0-680 BAR COMP., SIDE STAND ••••••• 6 7 8 9 10
(2) STAND, MAIN •••••••••••••••••• PLATE, MAIN STAND SPRING ••••• BAR, SIDE STAND •••••••••••••• SPRING, SIDE STAND •••••••••••
90108-223-000 94002-10000-0S 94201-30250 95014-71402 95014-72102
SCREW, SIDE STAND PIVOT ••••• NUT, HEX., 10MM ••••••••••••• PIN, SPLIT, 3.0X25 •••••••••• SPRING D, MAIN STAND •••••••• SPRING A, SIDE STAND ••••••••
Serial No.
3
C90ST 4 5
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
Parts catalogue code
6
72 2005.06.10
E
F.R.T.
0.4 0.2 0.2 0.1
F-20
SWINGARM/CHAIN CASE Ref. (Relative ref. Number) L.O.N. No. Description
1 4101L9 CASE, DRIVE CHAIN :UPPER ••••• .NOTE: Same time for two units 4101P7 CASE, DRIVE CHAIN :BOTH •••••• 2 4101M0 CASE, DRIVE CHAIN :LOWER ••••• .NOTE: Same time for two units 3 213165 CHAIN, DRIVE ••••••••••••••••• 7 7111H2 ARM, REAR BRAKE STOPPER •••••• 11 4101C7 BAR, PILLION STEP :LEFT •••••• 4101C8 BAR, PILLION STEP :RIGHT ••••• 4101P4 BAR, PILLION STEP :BOTH •••••• 12 5121B0 SWINGARM ASSEMBLY ••••••••••••
Ref. No.
0.1 0.1 0.1 0.3 0.2 0.1 0.1 0.2 0.7
Reqd. QTY Part No.
Description
1 40510-GT0-000ZK CASE, DRIVE CHAIN UPPER HALF *NH167MU* IRON NAIL SILVER METALLIC-U 2 40520-GT0-000ZK CASE, DRIVE CHAIN UNDER HALF *NH167MU* IRON NAIL SILVER METALLIC-U 3 40530-151-005 CHAIN, DRIVE (RK EXCEL) (RK420M-RJ)(98L) 40530-179-701 CHAIN, DRIVE (DAIDO) (DID420M-RJ)(98L) 4 40531-098-003 JOINT, DRIVE CHAIN (DAIDO) •• 40531-150-005 JOINT, DRIVE CHAIN (RK EXCEL) 5 40545-001-000 CAP, CHAIN CASE PEEP HOLE ••• 6 7 8 9 10
F.R.T.
40591-041-000 43431-086-720 43434-250-000 50710-377-000 50712-377-000
PACKING, DRIVE CHAIN CASE ••• LINK, RR. BRAKE TORQUE •••••• SPRING, STOPPER ARM ••••••••• RUBBER, PILLION STEP •••••••• WASHER, PILLION STEP ••••••••
11 50715-377-000 BAR, PILLION STEP ••••••••••• 12 52000-GB6-761ZF SWINGARM ASSY. *R110*..............MONZA RED 52000-GB6-761ZG *G46*...........SPINACH GREEN 52000-GB6-761ZH *PB109*..........NEPTUNE BLUE 52000-GB6-761YG *NH1*...................BLACK 52000-GB6-761YM *PB310*...........ICARAI BLUE 13 52161-051-000 CAP, CROSS MEMBER SIDE •••••• 14 90118-383-000 BOLT-WASHER, 6X6 ••••••••••••
Serial No.
3
C90ST 4 5
1
1
1
1
1
1
1
1
1
1
1
1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 2 2
1 1 1 2 2
1 1 1 2 2
1 1 1 2 2
2
2
2
2
1 1 1 2 3
1 1 1 2 3
1 1 1 2 3
1 1 1 2 3
3
Parts catalogue code
6
2005.06.10
73 E
F-20
Ref. No.
3
SWINGARM/CHAIN CASE
Reqd. QTY Part No.
Description 3
C90ST 4 5
Serial No.
Parts catalogue code
6
15 90120-121-970
BOLT, SWINGARM PIVOT ••••••••
1
1
1
1
16 17 18 19 20
90122-141-650 90304-GE8-003 93401-06010-00 94001-08000-0S 94101-06000
COLLAR, MUFFLER SETTING ••••• NUT, U, 10MM •••••••••••••••• BOLT-WASHER, 6X10 ••••••••••• NUT, HEX., 8MM •••••••••••••• WASHER, PLAIN, 6MM ••••••••••
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
1 1 1 1 2
21 22 23 24 25
94101-08000 94101-10000 94201-16150 94201-20150 95015-81000
WASHER, PLAIN, 8MM •••••••••• WASHER, PLAIN, 10MM ••••••••• PIN, SPLIT, 1.6X15 •••••••••• PIN, SPLIT, 2.0X15 •••••••••• PIN A, PILLION STEP •••••••••
1 1 2 1 2
1 1 2 1 2
1 1 2 1 2
1 1 2 1 2
74 2005.06.10
E
F-21
REAR CUSHION Ref. (Relative ref. Number) L.O.N. No. Description
1 5121B6 CUSHION ASSY., REAR :LEFT •••• 5121B7 CUSHION ASSY., REAR :RIGHT ••• 5121B8 CUSHION ASSY., REAR :BOTH ••••
Ref. No.
F.R.T.
0.1 0.1 0.2
Reqd. QTY Part No.
Description
1 52400-GBJ-681ZA CUSHION ASSY., RR. (SHOWA) *G46*...........SPINACH GREEN 52400-GBJ-681ZC *PB109*..........NEPTUNE BLUE 52400-GBJ-681ZD *R110*..............MONZA RED 52400-GBJ-681ZP *NH1*...................BLACK 2 52476-001-020 BUSH, RR. CUSHION RUBBER •••• 3 52486-001-000 COLLAR, RR. CUSHION RUBBER BUSH 4 52488-001-010 COLLAR, RR. CUSHION UPPER RUBBER BUSH 5 52489-399-601 BUSH, UPPER RUBBER •••••••••• 6 90551-033-000 WASHER, SPROCKET SETTING •••• 7 94021-10000-0S NUT, CAP, 10MM •••••••••••••• 8 94101-12000 WASHER, PLAIN, 12MM •••••••••
Serial No.
3
C90ST 4 5
2 2 2 2
2 2 2 2
2 2 2 2
2 2
2
2
2
2
2 2
2 2
2 2
2 2
4 4 4
4 4 4
4 4 4
4 4 4
3
Parts catalogue code
6
75 2005.06.10
E
F-22
WINKER Ref. (Relative ref. Number) L.O.N. No. Description
1 6161C4 WINKER :RIGHT FRONT •••••••••• .NOTE: Same time for two units 6161C5 WINKER :BOTH FRONT ••••••••••• 4 6161C3 WINKER :LEFT FRONT ••••••••••• .NOTE: Same time for two units 6 6161C7 WINKER :RIGHT REAR ••••••••••• .NOTE: Same time for two units 6161C8 WINKER :BOTH REAR •••••••••••• 9 6161C6 WINKER :LEFT REAR •••••••••••• .NOTE: Same time for two units 10 616133 BULB, WINKER :FRONT •••••••••• .NOTE: Same time for two units 616139 BULB, WINKER :REAR ••••••••••• .NOTE: Same time for two units 6161G0 BULB, WINKER :FOR 1 VEHICLE ••
3
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
33400-GBJ-003 33402-GBJ-003 33410-GBJ-000 33450-GBJ-003 33460-GBJ-000
6 7 8 9 10 11 12 13 14
Description
Serial No.
3
C90ST 4 5
WINKER ASSY., R. FR. (12V 10W) LENS COMP., WINKER •••••••••• SOCKET COMP., R. FR. WINKER • WINKER ASSY., L. FR. (12V 10W) SOCKET COMP., L. FR. WINKER •
1 4 1 1 1
1 4 1 1 1
1 4 1 1 1
1 4 1 1 1
33600-GBJ-680 33608-GB5-000 33609-179-700 33650-GBJ-680 34905-GM9-003
WINKER ASSY., R. RR. (12V 10W) RUBBER A, RR. WINKER MOUNTING RUBBER B, RR. WINKER MOUNTING WINKER ASSY., L. RR. (12V 10W) BULB, WINKER (12V 10W) ••••••
1 2 2 1 4
1 2 2 1 4
1 2 2 1 4
1 2 2 1 4
80102-GT0-751 90105-GBJ-003 90111-GBJ-000 90114-GT0-751
PLATE, SCREW, SCREW, SCREW,
2 8 4 4
2 8 4 4
2 8 4 4
2 8 4 4
RR. WINKER SETTING ••• TAPPING, 4X40 •••••••• TAPPING, 4X8 ••••••••• PAN, 5X20 ••••••••••••
Parts catalogue code
6
76 2005.06.10
E
F.R.T.
0.2 0.2 0.2 0.4 0.4 0.4 0.1 0.1 0.2
F-23
TAILLIGHT Ref. (Relative ref. Number) L.O.N. No. Description
1 3 4 8
Ref. No.
6161D5 6161E2 6111B4 6161G1
TAILLIGHT UNIT ••••••••••••••• BASE, TAILLIGHT •••••••••••••• CORD, TAILLIGHT •••••••••••••• BULB, TAILLIGHT ••••••••••••••
F.R.T.
0.2 0.2 0.2 0.1
Reqd. QTY Part No.
1 33701-GB6-701 2 33702-323-631 3 33703-GB6-003 4 33707-GB6-003 5 33709-077-671
Description
TAILLIGHT UNIT (STANLEY) (12V 18/5W) LENS, TAILLIGHT ••••••••••••• SOCKET COMP., TAILLIGHT ••••• CORD COMP., TAILLIGHT (STANLEY) PACKING, TAILLIGHT LENS •••••
6 33718-179-701 7 33719-179-700 8 34906-268-600
Serial No.
3
C90ST 4 5
1 1 1
1 1 1
1 1 1
1 1 1
1 1
1 1
1 1
1 1
3
Parts catalogue code
6
PACKING, TAILLIGHT BASE ••••• GROMMET, TAILLIGHT BASE ••••• BULB, STOP & TAILLIGHT (12V 18/5W)(STANLEY) 9 90113-GB5-000 BOLT, FLANGE, 5X18 •••••••••• 10 93500-04050-0A SCREW, PAN, 4X50 ••••••••••••
1 2
1 2
1 2
1 2
1 2 2
1 2 2
1 2 2
1 2 2
11 94050-06000 NUT, FLANGE, 6MM •••••••••••• 12 95701-06010-00 BOLT, FLANGE, 6X10 ••••••••••
1 1
1 1
1 1
1 1
77 2005.06.10
E
F-24
BATTERY Ref. (Relative ref. Number) L.O.N. No. Description
1 610100 BATTERY •••••••••••••••••••••• 2 410185 BOX, BATTERY •••••••••••••••••
3
Reqd. QTY
Ref. No.
Part No.
1 2 3 4
31500-GN2-679 50380-GK4-631 50383-GK4-630 90111-147-000
Description
BATTERY (YT4L-BS)(YUASA) •••• BOX, BATTERY •••••••••••••••• CUSHION, BATTERY •••••••••••• BOLT, FLANGE, 6MM •••••••••••
3
C90ST 4 5
1 1 1 2
1 1 1 2
1 1 1 2
Serial No.
Parts catalogue code
6
1 1 1 2
78 2005.06.10
E
F.R.T.
0.2 0.2
F-25
WIRE HARNESS Ref. (Relative ref. Number) L.O.N. No. Description
3 4 7 8 10 11 13 14
IGNITION CONTROL MODULE •••••• COIL, IGNITION ••••••••••••••• RECTIFIER, REGULATE •••••••••• HARNESS, WIRE •••••••••••••••• KEY SET •••••••••••••••••••••• SWITCH, IGNITION ••••••••••••• HORN(S) •••••••••••••••••••••• RELAY, WINKER ••••••••••••••••
0.3 0.4 0.3 1.1 0.8 0.4 0.1 0.1
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
17640-GB4-010 30401-GB4-680 30410-GT0-681 30510-GK4-800 30511-GBJ-J71
6 30700-152-163 7 31600-GBL-871 8 32100-GT0-690 9 32101-GBJ-680 10 35010-GBJ-680 11 35100-GBJ-000 12 35121-GZ0-003 35122-GZ0-003 13 38110-GT0-700 14 38301-GE8-008 38301-KK4-024 15 38306-GE8-008 38306-KK4-000 16 17 18 19
6141A1 614105 6131B2 611100 6151A1 615146 616169 6111C3
F.R.T.
90112-GK8-010 94050-05000 94050-06000 95014-61300
Description
CLAMPER, FUEL TUBE •••••••••• CUSHION, C.D.I. UNIT •••••••• C.D.I. UNIT ••••••••••••••••• COIL COMP., IGNITION •••••••• STAY, IGNITION COIL ••••••••• CAP ASSY., NOISE SUPPRESSOR (NICHIRIN) RECTIFIER COMP., REGULATE (SHINDENGEN) HARNESS, WIRE ••••••••••••••• SUB CORD, RR. WINKER •••••••• KEY SET •••••••••••••••••••••
C90ST 4 5
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1
1
1
1
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
SWITCH ASSY., COMBINATION ••• 1 1 1 KEY, BLANK (TYPE 1) ••••••••• (1) (1) (1) KEY, BLANK (TYPE 2) ••••••••• (1) (1) (1) HORN COMP. (IMASEN) ••••••••• 1 1 1 RELAY COMP., WINKER (DENSO) • 1 1 1 RELAY COMP., WINKER (MITSUBA) 1 1 1 SUSPENSION, WINKER RELAY (DENSO) 1 1 1 SUSPENSION, WINKER RELAY (MITSUBA) 1 1 1 BOLT, FLANGE, 5X22 •••••••••• NUT, FLANGE, 5MM •••••••••••• NUT, FLANGE, 6MM •••••••••••• BAND A3, WIRE •••••••••••••••
Serial No.
3
1 1 1 2
1 1 1 2
1 1 1 2
3
Parts catalogue code
6
1 (1) (1) 1 1 1 1 1 1 1 1 2 2005.06.10
79 E
F-25
Ref. No.
3
WIRE HARNESS
Reqd. QTY Part No.
Description
Serial No.
3
C90ST 4 5
20 95701-06012-00 BOLT, FLANGE, 6X12 ••••••••••
2
2
2
2
21 95701-06016-00 BOLT, FLANGE, 6X16 •••••••••• 22 98200-10700 FUSE (7A) •••••••••••••••••••
1 2
1 2
1 2
1 2
Parts catalogue code
6
80 2005.06.10
E
F-26
FRAME BODY Ref. (Relative ref. Number) L.O.N. No. Description
3 410100 BODY, FRAME •••••••••••••••••• .INCLUDES: Engine removal and installation 5 410197 LOCK, HELMET •••••••••••••••••
Ref. No.
4.8 0.3
Reqd. QTY Part No.
Description
Serial No.
3
C90ST 4 5
1 2
1 2
1 2
1 2
1 1 1 1
1 1 1 1
1 1 1 1
1 1 1 1
1
1
1
1
BOLT A, RR. ENGINE SUPPORT •• BOLT, RR. ENGINE UNDER •••••• NUT, HEX., 8MM •••••••••••••• NUT, FLANGE, 6MM •••••••••••• WASHER, SPRING, 8MM •••••••••
1 1 2 2 1
1 1 2 2 1
1 1 2 2 1
1 1 2 2 1
11 95701-06010-00 BOLT, FLANGE, 6X10 ••••••••••
1
1
1
1
1 17247-303-000 GROMMET A, AIR CLEANER CASE • 2 32985-300-000 GROMMET, WIRE CORD •••••••••• 3 50100-GT0-890ZA BODY COMP., FRAME (WOL) *G46*...........SPINACH GREEN 50100-GT0-890ZB *PB109*..........NEPTUNE BLUE 50100-GT0-890ZC *R110*..............MONZA RED 50100-GFN-720ZA *NH1*...................BLACK 50100-GFN-720ZB *PB310*...........ICARAI BLUE 50100-GFN-720ZC *R110*..............MONZA RED 4 50385-GB4-000 PLATE COMP., SILENCER ••••••• 5 50710-GB4-007 HOLDER ASSY., HELMET (HONDA LOCK) 6 7 8 9 10
F.R.T.
90112-003-000 90116-001-010 94030-08000 94050-06000 94111-08000
3
Parts catalogue code
6
81 2005.06.10
E
F-27
TOOLS Ref. (Relative ref. Number) L.O.N. No. Description
NO INFORMATION •••••••••••••••
3
Reqd. QTY
Ref. No.
Part No.
1 2 3 4 5
89010-GN5-910 89102-538-000 89103-538-000 89214-041-000 89216-045-010
6 99001-10120 7 99001-14170 8 89210-GBJ-J00 89210-GBJ-J10 9 99005-02000 10 99008-01600
Description
Serial No.
3
C90ST 4 5
TOOL SET •••••••••••••••••••• SHAFT, SCREW DRIVER ••••••••• GRIP •••••••••••••••••••••••• WRENCH, BOX (23MM) •••••••••• WRENCH, SPARK PLUG ••••••••••
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
SPANNER, 10X12 •••••••••••••• SPANNER, 14X17 •••••••••••••• PLIERS, 135(RIKEN) •••••••••• PLIERS, 135(KOWA) ••••••••••• BAR B, HANDLE ••••••••••••••• BAG, TOOL, 160MM ••••••••••••
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
1 1 1 1 1 1
Parts catalogue code
6
82 2005.06.10
E
F.R.T.
F-28
FRONT COVER Ref. (Relative ref. Number) L.O.N. No. Description
1 4111E3 COVER, FRONT •••••••••••••••••
Ref. No.
0.2
Reqd. QTY Part No.
Description
1 64301-GBJ-N10ZD COVER, FR. *NH138*..........SHASTA WHITE 2 64302-GB4-000 PLATE, FR. COVER SETTING •••• 3 64341-GK4-870 HOOK, FR. COVER ••••••••••••• 4 64345-GB4-000 COLLAR, FR. COVER SETTING ••• 5 64365-040-000ZC CAP, FR. COVER *NH138*..........SHASTA WHITE 6 7 8 9 10
F.R.T.
90021-KE9-000 90136-428-870 94021-08020-0S 94101-08000 95701-06070-00
BOLT, SPECIAL, 6MM •••••••••• WASHER, TANK SETTING •••••••• NUT, CAP, 8MM ••••••••••••••• WASHER, PLAIN, 8MM •••••••••• BOLT, FLANGE, 6X70 ••••••••••
Serial No.
3
C90ST 4 5
1 2 1 2
1 2 1 2
1 2 1 2
1 2 1 2
1
1
1
1
2 3 2 2 2
2 3 2 2 2
2 3 2 2 2
2 3 2 2 2
3
Parts catalogue code
6
83 2005.06.10
E
F-29
CAUTION LABEL Ref. (Relative ref. Number) L.O.N. No. Description
NO INFORMATION •••••••••••••••
Ref. No.
3
1 2 3 4 5
Reqd. QTY Part No.
Description 3
C90ST 4 5
Serial No.
Parts catalogue code
6
87125-041-680 87505-GT0-680 87507-065-640 87512-087-641 87560-181-760ZE
PLATE, NAME ••••••••••••••••• LABEL, TIRE ••••••••••••••••• LABEL, DRIVE CHAIN •••••••••• LABEL, SHIFT PATTERN •••••••• MARK, DRIVE CAUTION *TYPEB* •
1 1 1 1 1
1 1 1 1 1
1 1 1 1 1
1 1 -
6 87565-GT0-M00ZA 87565-GT0-M00ZB 87565-GT0-M00ZC 87565-GT0-M10ZA 87565-GT0-M10ZB 87565-GT0-M10ZC 87565-GFN-710ZA 87565-GFN-710ZB 87565-GFN-710ZC 87565-GFN-720ZA 87565-GFN-720ZB 87565-GFN-720ZC 7 87512-087-641 8 87560-181-760ZF
LABEL, COLOR *TYPE1*(R110) •• LABEL, COLOR *TYPE2*(G46) ••• LABEL, COLOR *TYPE3*(PB109) • LABEL, COLOR *TYPE1*(R110) •• LABEL, COLOR *TYPE2*(G46) ••• LABEL, COLOR *TYPE3*(PB109) • LABEL, COLOR *TYPE1*(R110) •• LABEL, COLOR *TYPE2*(G46) ••• LABEL, COLOR *TYPE3*(PB109) • LABEL, COLOR *TYPE1*(R110) •• LABEL, COLOR *TYPE2*(NH1) ••• LABEL, COLOR *TYPE3*(PB310) • LABEL, SHIFT PATTERN •••••••• MARK, DRIVE CAUTION *TYPEW* •
1 1 1 -
1 1 1 -
1 1 1 -
1 1 1 1 1
84 2005.06.10
E
F.R.T.
F-30
MARK/EMBLEM Ref. (Relative ref. Number) L.O.N. No. Description
F.R.T.
NO INFORMATION •••••••••••••••
Ref. No.
Reqd. QTY Part No.
Description
1 87101-GBJ-N20ZA MARK, SIDE COVER *TYPE1* •••• 2 87105-GBJ-N10 EMBLEM, FR. TOP COVER ••••••• 3 87121-GT0-M00ZA MARK, R. FRAME BODY *TYPE1* • 87121-GT0-M00ZB MARK, R. FRAME BODY *TYPE2* • 87121-GT0-M00ZC MARK, R. FRAME BODY *TYPE3* • 87121-GFN-720ZA MARK, R. FRAME BODY *TYPE1* • 4 87122-GT0-M00ZA MARK, L. FRAME BODY *TYPE1* • 87122-GT0-M00ZB MARK, L. FRAME BODY *TYPE2* • 87122-GT0-M00ZC MARK, L. FRAME BODY *TYPE3* • 87122-GFN-720ZA MARK, L. FRAME BODY *TYPE1* • 5 87126-GB1-890 EMBLEM, POINT COVER •••••••••
3
C90ST 4 5
2 1 1 1 1 1 1 1 1
2 1 1 1 1 1 1 1 1
2 1 1 1 1 1 1 1 1
Serial No.
3
Parts catalogue code
6
2 1 1 1 1
85 2005.06.10
E
PART NO. INDEX Part Number
Page Ref.
06000 06111-GB5-820 06112-GB5-811 06410-GBJ-J01 06430-GBJ-J10 06450-121-730
48 49 63 60 62 60 62
11000 11100-GB6-911 11191-GW8-680 11200-GB6-910 11330-GW8-690 11341-GB5-730 11394-GW8-680
40 40 49 40 34 38 34 49
12000 12101-GB1-900 12191-GW8-681 12200-GT0-751 12209-GB4-681 12237-GB4-305 12245-GB4-305 12251-GB5-811 12301-086-000 12331-GB0-910 12341-GB6-910 12361-035-000 12391-GW8-680 12394-GW8-680
4
12395-GW8-680
33 33 48 29 30 48 29 29 29 48 28 28 28 28 28 48 28 48 28 48
13000
86
13000-GT0-000 13011-GB5-305 13012-GB5-305 13013-GB5-305 13014-GB5-305 13015-GB5-305 13101-GT0-680 13102-GT0-306 13103-GT0-306 13104-GT0-306 13105-GT0-306 13111-087-000 13115-001-000
41 41 41 41 41 41 41 41 41 41 41 41 41
Part Number
Page Ref.
13201-GF6-300 13310-GT0-300 1 13321-GT0-300 1 13381-GF6-300 1 1 14000 1 1 14100-GB5-D10 1 14311-KEV-900 14321-GBG-900 14401-178-003 14431-035-020 1 14451-035-000 2 14500-035-020 1 14502-086-000 3 14531-035-000 1 14541-GB4-681 1 14550-GB0-911 2 14566-086-030 1 14610-086-010 14615-035-010 14670-035-030 14675-178-000 1 14711-GN5-913 2 14721-GF6-010 1 14751-GF6-013 1 14761-GF6-013 1 14771-GB4-680 1 14775-MA6-000 2 14781-MA6-000 3 4 15000 1 1 15100-GB5-811 2 15119-178-000 3 4 15331-436-000 5 15332-436-000 1 15384-178-000 6 15421-035-010 1 15651-179-701 7 15761-087-611 1 16000
41 41 41 41
16010-GN5-921 16012-GT0-680 16013-883-005 16014-GB6-610 16015-GT0-013 16016-GB4-003 16022-GB6-761 16028-GC8-004 16040-GB0-911 16041-GB5-D30 16100-GT0-690 16118-GB4-003 16119-GK4-851 16148-141-881
46 46 46 46 46 46 46 46 46 46 46 46 46 46
1 2 2 2 2 2 3 3 3 3 3 4 5
30 41 32 32 30 30 32 32 32 32 32 32 32 32 32 32 30 30 30 30 30 30 30
37 37 49 37 37 37 37 34 40
Part Number
Page Ref.
6 7 8 9
16155-GZ5-000 16165-GB5-960 16175-GB0-911 16176-GB0-911 16199-GB4-003 16199-GBJ-000 16236-045-010 2 16236-171-000 10 1 17000 2 3 17111-GT0-000 4 17119-HF7-000 3 4 17211-GB4-010 5 17212-GB4-000 6 17213-GB4-000 7 17219-GB4-010 8 17230-GT0-680 9 17231-GB4-020 10 17247-303-000 11 17253-GB5-000 12 17256-053-010 5 17509-398-960 6 17510-GB4-721YN 7 17510-GB4-721YP 8 17510-GB4-721YT 9 17510-GB4-721ZC 10 17510-GB4-721ZD 11 17620-GE7-023 17620-GR1-931 17630-GBJ-680 17631-096-701 1 17631-GBJ-680 2 17632-383-831 1 17640-GB4-010 3 17910-GB5-762 4 17950-GB4-770 5 17961-GB5-671 6 17962-GB4-003 3 18000 4
1 2 3 4 5 6 7 8 9 10 11 12 13 14
18240-174-770 18291-HB2-900 18315-171-000ZA 18316-GB4-000 18350-GT0-680
22121-178-000 22131-035-030 22201-GW8-681
22310-GB0-910 22321-041-000 22331-GW8-681 22351-178-020 22401-178-010 22411-178-000 22421-040-000 22531-178-000 22535-033-000 22536-033-000 22811-040-020 22820-918-020 22825-046-000 22830-041-000 22846-GB4-770 22860-046-000 22901-001-000 22911-GB4-680
46 46 46 46 46 46 40 40
15 16 17 18 20 19 5 6
28 28 48 68 68 68 68 68 68 81 68 68 66 65 65 65 65 65 65 65 65 65 65 65 79 52 52 52 52
8 9 1 1 2 3 4 5 6 1 7 8 1 1 1 1 1 1 2 2 3 5 4 5 1 1 2 3 4
69 48 69 69 69 69
1 1 2 3 4 5
35 35 35 49 35 35 35
1 2 3 1 4 25000 5 6 25551-918-007
22000 22101-178-000 22111-178-010 22119-GW8-680
Part Number
Page Ref.
35 35 35 35 35 35 35 35 35 35 34 34 34 34 34 34 35 35
7 8 9 10 11 12 13 14 15 16 4 5 6 7 8 9 17 18
35 35 35 42 42 42 42 42 42 42 42 42 42 42
19 20 21 1 2 3 4 5 6 7 8 9 10 11
23000 23110-086-030 23112-178-020 23120-086-020 23211-GB6-910 23221-GT0-750 23421-GB6-911 23422-GB6-910 23431-GB1-900 23441-GB6-910 23471-GB1-901 23481-GT0-751 23801-179-700 23802-040-000 23911-GT0-750 24000 24211-087-010 24221-041-010 24261-121-742 24263-028-000 24301-GB2-714 24305-GT0-000 24306-GB4-770 24411-GB6-910 24421-200-000 24430-GB4-772 24435-GF6-003 24610-098-730 24630-GB2-711 24641-041-000 24651-041-000 24652-035-000 24701-141-650
2005.06.10
E
44 44 44 44 44 42 42 44 44 44 44 44 44 44 44 44 70
34
Part Number
25555-065-000 28000 28211-178-000 28221-178-000 28251-086-701 28262-041-731 28271-121-690 28281-035-003 28281-035-018 28300-141-640 28311-342-000 30000 30401-GB4-680 30410-GT0-681 30510-GK4-800 30511-GBJ-J71 30700-152-163
Page Ref.
34 11 33707-GB6-003 33709-077-671 33718-179-701 33719-179-700 45 1 34000 45 2 45 3 45 4 34901-GT4-003 45 5 34904-GAC-003 45 6 34905-GM9-003 45 6 34906-268-600 70 2 34908-GA7-701 70 3 34908-GB4-700 34908-MB9-871 79 79 79 79 79
2 3 4 5 6
39 39 39 78 79
1 2 3 1 7
31000 31110-GT0-008 31120-GT0-018 31131-GS9-020 31500-GN2-679 31600-GBL-871 32000
32100-GT0-690 32101-GBJ-680 32921-039-000 32961-GS9-010 32962-GS9-000 32981-GB4-770 1 32985-300-000 2 3 33000 4 5 33100-GT0-692 12 33101-GBJ-013 13 33117-GBJ-013 6 33120-GBJ-681 7 33130-GBJ-013 8 33400-GBJ-003 9 33402-GBJ-003 10 33410-GBJ-000 11 33450-GBJ-003 12 33460-GBJ-000 13 33600-GBJ-680 14 33608-GB5-000 1 33609-179-700 33650-GBJ-680 33701-GB6-701 33702-323-631 10 33703-GB6-003
Part Number
Page Ref.
77 77 77 77
4 5 6 7
50 6 50 7 76 10 77 8 50 8 51 1 51 2
35000 35010-GBJ-680 35100-GBJ-000 35121-GZ0-003 35122-GZ0-003 35150-GBJ-680 35200-GK4-790 35340-GBJ-000 35350-GAC-000 35357-041-000 35750-001-020 35753-035-010 35755-001-020
79 79 79 79 52 52 52 70 70 44 44 44
10 11 12 12 5 6 7 4 5 15 16 17
51 51 51
3 4 5
79 79 79 79 79
13 14 14 15 15
73 73 73 73 73 73 62 63 73 73
1 2 3 3 4 4 2 2 5 6
37000 79 8 37200-GT0-751 79 9 37223-GB5-731 34 12 37244-086-000 39 4 38000 39 5 39 6 81 2 38110-GT0-700 38301-GE8-008 38301-KK4-024 38306-GE8-008 50 1 38306-KK4-000 50 2 40000 50 3 50 4 50 5 40510-GT0-000ZK 76 1 40520-GT0-000ZK 76 2 40530-151-005 76 3 40530-179-701 76 4 40531-098-003 76 5 40531-150-005 76 6 40543-141-850 76 7 40544-141-850 76 8 40545-001-000 76 9 40591-041-000 77 1 77 2 77 3
PART NO. INDEX Part Number
Page Ref.
41000 41201-GT0-750
45000 63
42000 42301-GBJ-000 42303-041-000 42304-040-000 42313-GBJ-000 42610-GBJ-305 42615-GBJ-J00 42620-121-000 42630-GK4-003 42630-GK4-005 42635-GB5-J30 42650-GT0-315 42653-001-004 42701-030-003 42711-096-025 42712-041-154 42712-GS4-006 42713-001-000
62 63 63 62 63 64 63 63 63 63 63 63 63 63 61 63 61 63 61 63
3 45010-GBJ-305 45134-250-000 3 4 5 4 6 27 7 8 8 9 10 11 12 13 1 14 1 14 2 15
43000 43100-GBJ-000 43141-400-010 43141-GC5-000 43145-KC1-000 43151-110-000 43410-086-720 43431-086-720 43434-250-000 43434-286-000 43451-041-000 44000 44301-GBJ-000 44311-041-000 44601-GBJ-000 44620-171-000 44635-GB5-J30 44650-GT0-305 44701-102-791 44701-102-792 44711-GB6-885 44806-GK4-003 44808-107-720 44830-GBJ-000 44831-GBJ-000
Part Number
62 5 62 6 60 2 62 7 60 3 62 8 62 9 73 7 73 8 62 10 70 6
45145-121-710 45410-GB4-000 45411-GB4-680 45450-GBJ-000 46000 46500-086-720 46514-086-720 50000 50049-046-000 50100-GFN-720ZA 50100-GFN-720ZB 50100-GFN-720ZC 50100-GT0-890ZA 50100-GT0-890ZB 50100-GT0-890ZC 50301-041-010 50380-GK4-631 50383-GK4-630 50385-GB4-000 50500-GT0-680ZA 50512-GB4-680 50523-041-000 50524-GBJ-680 50530-GT0-680 50610-GB2-000 50660-GB2-000 50710-377-000 50710-GB4-007 50712-377-000 50715-377-000 51000
51102-086-720 60 4 51110-GBJ-305YD 61 3 51110-GBJ-305YL 61 4 51110-GBJ-305ZC 61 5 51110-GBJ-305ZD 61 14 51110-GBJ-305ZE 61 6 51311-GK4-971 61 7 51312-GK4-971 61 7 51315-041-000 61 8 51325-041-000 60 5 51331-GK4-970 60 6 51333-001-000 51 6 51334-GK4-970 51 7 51336-001-000 51341-001-000ZE 51400-GK4-971 51486-086-000
Page Ref.
Part Number
Page Ref.
51489-086-000 60 7 52000 60 8 62 11 52000-GB6-761YG 60 9 52000-GB6-761YM 60 10 52000-GB6-761ZF 60 11 52000-GB6-761ZG 52 8 52000-GB6-761ZH 52161-051-000 52400-GBJ-681ZA 52400-GBJ-681ZC 70 7 52400-GBJ-681ZD 70 8 52400-GBJ-681ZP 52476-001-020 52486-001-000 52488-001-010 56 1 52489-399-601 81 3 81 3 53000 81 3 81 3 53100-GK4-791YM 81 3 53100-GK4-791YN 81 3 53100-GK4-791YR 56 2 53100-GK4-792YM 78 2 53100-GK4-792YN 78 3 53100-GK4-792YR 81 4 53100-GK4-792YU 72 1 53100-GK4-792YV 72 2 53120-GB4-030YV 72 3 53120-GB4-030ZM 72 4 53120-GB4-030ZR 72 5 53120-GFN-720ZA 71 1 53120-GFN-720ZB 71 2 53120-GFN-720ZC 73 9 53160-179-700 81 5 53160-179-701 73 10 53165-172-000 73 11 53175-GR2-010 53176-179-702 53210-GS9-003 53211-030-000 54 1 53212-030-010 56 3 53214-001-010 56 3 53215-001-000 56 3 53220-041-010 56 3 53231-GB4-010 56 3 53232-086-720 59 1 53233-172-000 59 2 53234-171-000 59 3 53235-086-020 59 4 53236-086-000 59 5 53236-171-000 59 6 53237-GB4-680 59 7 53600-086-007 59 8 61000 56 4 59 9 59 10 61100-086-000A6
Part Number
59 11 61100-086-000ZN 61100-086-000ZQ 61100-GFN-720ZA 61100-GFN-720ZB 73 12 61100-GFN-720ZC 73 12 61150-086-020C2 73 12 61150-086-020ZV 73 12 61150-086-020ZY 73 12 61150-GFN-720ZA 73 13 61150-GFN-720ZB 75 1 61150-GFN-720ZC 75 1 64000 75 1 75 1 75 2 64301-GBJ-N10ZD 75 3 64302-GB4-000 75 4 64309-GK4-870 75 5 64310-GB4-000ZF 64315-GB4-000 64341-GK4-870 64345-GB4-000 54 2 64365-040-000ZC 54 2 77000 54 2 54 2 54 2 77000-GBJ-N10ZB 54 2 77211-GBJ-830 54 2 77300-GT0-M00 54 2 80000 54 3 54 3 54 3 80102-GK4-970 54 3 80102-GT0-751 54 3 54 3 81000 52 9 52 9 81200-GAC-000 52 10 52 11 83000 52 12 56 5 83510-GBJ-N20ZK 56 6 83510-GBJ-N20ZP 56 7 83510-GBJ-N20ZQ 56 8 83510-GFN-720ZA 56 9 83510-GFN-720ZB 56 10 83510-GFN-720ZC 54 4 83550-GB4-680 54 5 83610-GBJ-N20ZK 54 6 83610-GBJ-N20ZP 54 7 83610-GBJ-N20ZQ 54 8 83610-GFN-720ZA 56 11 83610-GFN-720ZB 54 9 83610-GFN-720ZC 54 10 83642-171-000 56 12 83650-GB4-680
Page Ref.
58 58 58 58 58 56 56 56 56 56 57
1 87101-GBJ-N20ZA
2005.06.10
E
87105-GBJ-N10 87121-GFN-720ZA 87121-GT0-M00ZA 87121-GT0-M00ZB 87121-GT0-M00ZC 87122-GFN-720ZA 87122-GT0-M00ZA 87122-GT0-M00ZB 87122-GT0-M00ZC 87125-041-680 87126-GB1-890 87505-GT0-680 87507-065-640 87512-087-641
83 1 83 2 87560-181-760ZE 57 14 87560-181-760ZF 57 15 87565-GFN-710ZA 57 16 87565-GFN-710ZB 83 3 87565-GFN-710ZC 83 4 87565-GFN-720ZA 83 5 87565-GFN-720ZB 87565-GFN-720ZC 87565-GT0-M00ZA 87565-GT0-M00ZB 66 2 87565-GT0-M00ZC 66 3 87565-GT0-M10ZA 66 4 87565-GT0-M10ZB 87565-GT0-M10ZC 88000 58 2 76 11 88113-GBJ-000 88210-GBJ-004 89000
66
5
67 67 67 67 67 67 67 67 67 67 67 67 67 67 67
1 1 1 1 1 1 2 3 3 3 3 3 3 4 5
85
90083-GB6-911 1 90084-041-000
87000 58
1 1 1 1 1 13 13 13 13 13 13
Part Number
89010-GN5-910 89102-538-000 89103-538-000 89210-GBJ-J00 89210-GBJ-J10 89214-041-000 89216-045-010 90000 90012-333-000 90021-KE9-000 90031-198-000 90032-198-000 90033-GT0-750 90049-GR1-000 90071-171-010 90081-035-000 90082-035-010
Page Ref.
85 85 85 85 85 85 85 85 85 84 85 84 84 84 84 84 84 84 84 84 84 84 84 84 84 84 84 84
2 3 3 3 3 4 4 4 4 1 5 2 3 4 7 5 8 6 6 6 6 6 6 6 6 6 6 6 6
Part Number
90101-087-720 90101-GJ6-000 90105-GBJ-003 90108-223-000 90111-147-000 90111-162-000 90111-GBJ-000 90112-003-000 90112-GK4-000 90112-GK8-010 90113-GB5-000 90114-GJ5-000 90114-GT0-751 90115-170-700 90116-001-010 90116-147-000 90118-383-000 90120-121-970 90122-141-650 90125-GBJ-000 90136-428-870 90149-041-010 90164-028-000 90201-415-000 90206-001-000 90231-087-010 90301-473-003 90302-435-761 90304-GB4-680 90304-GE8-003
52 13 52 14 90306-GAB-711 90307-001-000 90307-GJ6-003 90309-ML3-791 82 1 90313-172-000 82 2 90314-GBJ-000 82 3 90407-259-000 82 8 82 8 90410-HC4-000 82 4 90417-041-000 82 5 90431-086-000 90432-086-000 90441-035-000 90441-147-000 30 12 90442-035-000 83 6 90442-147-000 40 7 90443-035-000 40 8 90443-107-000 29 5 90452-115-000 69 6 90452-GB6-910 44 18 90454-107-000 32 13 90455-107-000 29 6 90461-035-000 33 3 90461-357-000 32 14 42 14 90481-035-000
Page Ref.
50 57 50 76 72 78 58 76 81 59 79 77 68 76 52 81 52 73 74 74 63 83 59 57 28 30 35 62 53 54 59 61 74 63 63 50 63 57 52 40 49 39 44 35 35 32 52 28 52 28 66 45 42 45 42 42 28 32 32
10 17 9 12 6 4 3 13 6 12 16 9 9 14 15 7 16 14 15 16 16 7 13 18 10 13 22 12 23 11 14 9 17 17 18 11 19 19 17 9 1 7 19 23 24 15 18 11 19 12 6 7 15 8 16 17 13 16 17
4
87
PART NO. INDEX Part Number
90483-178-000 90485-040-000 90505-425-000 90518-086-000 90551-033-000 90552-001-000 90601-001-000 90603-GB0-911 90605-200-000 90702-GB6-910 90703-HC4-000 90741-003-010 90752-GB4-681 90752-GB4-682 90753-GK4-003 90753-GK4-005 90801-035-000
Page Ref.
35 34 62 54 75 54 36 42 33 42 45 30 33 34 40 41 61 61 64 64 44 49
25 13 13 12 6 13 26 18 4 19 9 14 5 14 10 11 10 10 20 20 20 1
41 41 41 41 34 39 39 42 44 60 60 39 49 33 48 28 48 28 48 34 49 33 48 29 34 49 59 44 49 39 49
12 13 13 13 15 8 8 20 21 12 12 9 1 6 1 14 1 15 1 16 1 7 1 7 17 1 15 22 1 10 1
91000 91001-GF6-004 91101-GF6-003 91102-GF6-003 91103-GF6-003 91202-302-010 91202-GE0-003 91202-GE0-015 91203-GB5-761 91208-KB4-671 91251-GK4-003 91251-GK4-005 91301-035-003 91301-GB0-911
4
91301-GK4-871 91302-001-020 91303-001-000 91303-035-000 91305-028-158 91307-035-000 91311-PH7-004 91312-107-000 91317-171-003
88
Part Number
92000 92101-06016-0A 92101-06020-0A 92101-06022-0A 92101-08018-0A 92501-08025-0A 92800-12000 92811-10000 93000 93301-05006-0H 93301-05010-0H 93401-06010-00 93401-08016-00 93402-08020-00 93403-08032-08 93404-06025-00 93500-04050-0A 93500-05010-0A 93500-05020-0A 93500-05028-0A 93500-05040-0A 93500-06016-0A 93500-06022-0A 93600-05010-0A 93600-06016-0A 93700-05018-0A 93891-05028-08 93892-03012-18 93892-04008-18 93892-04018-18 93892-05010-08 93892-05010-18
Page Ref.
94050-10000 94070-08080 44 23 94101-05000 70 9 94101-06000 70 10 66 7 57 20 94101-08000 40 11 62 14 94101-10000 94101-12000 94102-08000 94111-06000 39 11 39 12 94111-08000 74 18 94201-16150 55 14 94201-20150 71 3 59 16 66 8 94201-30250 77 10 94301-08140 36 27 94510-16000 37 7 95000 68 10 52 20 52 21 95002-02079 37 8 95002-02100 37 9 95002-02659 36 28 95002-50000 39 13 95011-61000 51 8 95014-61300 68 11 95014-71402 46 21 95014-72102 46 22 95014-73100 46 23 95015-32001 52 22 46 24 95015-42000
94000 94001-05000-0S 94001-06000-0S
94001-08000-0S 94002-08000-0S 94002-10000-0S 94021-08020-0S 94021-10000-0S 94030-08000 94050-05000 94050-06000
94050-08000
Part Number
52 62 64 67 69 62 74 59 72 83 75 34 81 79 28 60 77 79 81 69
23 15 21 6 7 16 19 17 7 8 7 18 8 17 16 13 11 18 9 8
95015-81000 95701-06010-00 95701-06012-00 95701-06016-00 95701-06018-00 95701-06028-00 95701-06035-00 95701-06070-00 95701-06110-00 95801-08032-00
Page Ref.
39 55 70 62 64 74 74 83 74 75 57 62 64 81 74 62 70 74 72 33 45
14 15 11 17 22 20 21 9 22 8 21 18 23 10 23 19 12 24 8 8 10
Part Number
96001-06035-00 96001-06040-00 96001-06050-00 96001-06060-00 96001-06065-00 96001-06080-00 96100-60000-00 96100-60010-00 96100-62010-00 96100-62030-00 96140-63000-10 96140-63010-10 96220-30085
38 34 40 40 34 40 34 36 42 42 42 61 64 44
3 19 13 14 20 15 21 29 21 22 23 11 24 25
61 64 61 64
12 25 13 26
28 28 28 28 28 28 80
20 20 20 20 20 20 22
97000 97172-21157-F0 97282-42158-F0 97548-21156-F0 97548-42157-F0 98000
46 65 47 40 66 79 72 72 70 60 70 60 70 74 77 81 57 80 65 80 32 60 62 83 28 55
25 6 26 12 9 19 9 10 13 14 14 15 15 25 12 11 22 20 7 21 18 16 20 10 17 16
44 55 28 39 28 38
24 17 18 15 19 2
98056-55713 98056-55723 98056-56713 98056-56723 98056-57713 98056-57723 98200-10700 99000 99001-10120 99001-14170 99005-02000 99008-01600 99102-GHB-0820 99103-943-0400
96000 96001-06012-00 96001-06014-00 96001-06020-00 96001-06022-00 96001-06025-00 96001-06028-00
Page Ref.
2005.06.10
E
82 6 82 7 82 9 82 10 47 27 47 28
Part Number
Page Ref.
Part Number
Page Ref.
PART NAME INDEX Part name
Page
Ref.
[A ] ADJUSTER, L. DRIVE CHAIN ••••• ADJUSTER, R. CHAIN ••••••••••• ARM ASSY., KICK STARTER •••••• ARM COMP., CAM CHAIN TENSIONER ARM COMP., L. FR. SUSPENSION • ARM COMP., R. FR. SUSPENSION • ARM COMP., SHIFT DRUM STOPPER ARM, FR. BRAKE ••••••••••••••• ARM, GEARSHIFT ••••••••••••••• ARM, RR. BRAKE ••••••••••••••• ARM, VALVE ROCKER •••••••••••• AXLE, FR. WHEEL •••••••••••••• AXLE, RR. WHEEL ••••••••••••••
63 62 70 32 59 59 44 60 44 62 30 60 62
2 2 2 3 4 3 8 10 11 9 3 4 3
67 82 56 79
4 10 5 19
68 82 72 71 73 39 78 41 36 42 42 42 63 61 64 41 81 74 66 73 55 71 59 62 81 29 33 50 57 34 40 40 40 42 59 77
8 9 5 1 11 3 1 13 29 21 22 23 8 11 24 12 3 18 8 14 14 3 16 14 6 6 3 9 20 8 7 8 11 14 12 9
[B ] BAG, BAG, BALL BAND BAND
OWNERS MANUAL ••••••••••• TOOL, 160MM ••••••••••••• ASSY., STEERING STEEL ••• A3, WIRE •••••••••••••••• B, AIR CLEANER CONNECTING TUBE BAR B, HANDLE •••••••••••••••• BAR COMP., SIDE STAND •••••••• BAR COMP., STEP •••••••••••••• BAR, PILLION STEP •••••••••••• BASE, STATOR ••••••••••••••••• BATTERY •••••••••••••••••••••• BEARING, CONNECTING ROD •••••• BEARING, RADIAL BALL, 6000 ••• BEARING, RADIAL BALL, 6001 ••• BEARING, RADIAL BALL, 6201 ••• BEARING, RADIAL BALL, 6203 ••• BEARING, RADIAL BALL, 6300U •• BEARING, RADIAL BALL, 6301U •• BEARING, RADIAL BALL, 6304 ••• BODY COMP., FRAME •••••••••••• BOLT-WASHER, 6X10 •••••••••••• BOLT-WASHER, 6X25 •••••••••••• BOLT-WASHER, 6X6 ••••••••••••• BOLT-WASHER, 8X16 •••••••••••• BOLT-WASHER, 8X20 •••••••••••• BOLT-WASHER, 8X32 •••••••••••• BOLT A, BRAKE STOPPER •••••••• BOLT A, RR. ENGINE SUPPORT ••• BOLT, 6MM •••••••••••••••••••• BOLT, BOLT, BOLT, BOLT, BOLT, BOLT, BOLT, BOLT, BOLT,
ADJUSTING •••••••••••••• CAP, 8X25 •••••••••••••• CLUTCH ADJUSTING ••••••• CYLINDER STUD, 6X194.5 • CYLINDER STUD, 6X202 ••• DRAIN PLUG, 12MM ••••••• DRIVE SPROCKET FIXING •• FLANGE, 10X53 •••••••••• FLANGE, 5X18 •••••••••••
Part name
BOLT, FLANGE, 5X22•••••••••••• BOLT, FLANGE, 6MM••••••••••••• BOLT, FLANGE, 6X10•••••••••••• BOLT, FLANGE, 6X110 ••••••••••• BOLT, FLANGE, 6X12•••••••••••• BOLT, FLANGE, 6X14•••••••••••• BOLT, FLANGE, 6X16•••••••••••• BOLT, BOLT, BOLT, BOLT, BOLT,
FLANGE, FLANGE, FLANGE, FLANGE, FLANGE,
6X18•••••••••••• 6X20•••••••••••• 6X22•••••••••••• 6X25•••••••••••• 6X28••••••••••••
BOLT, FLANGE, 6X35•••••••••••• BOLT, BOLT, BOLT, BOLT,
FLANGE, FLANGE, FLANGE, FLANGE,
6X40•••••••••••• 6X50•••••••••••• 6X60•••••••••••• 6X65••••••••••••
BOLT, FLANGE, 6X70•••••••••••• BOLT, FLANGE, 6X80•••••••••••• BOLT, FLANGE, 8X32•••••••••••• BOLT, FR. CUSHION UNDER••••••• BOLT, HEX., 5X10•••••••••••••• BOLT, HEX., 5X6••••••••••••••• BOLT, HEX., 6X16•••••••••••••• BOLT, HEX., 6X20•••••••••••••• BOLT, HEX., 6X22•••••••••••••• BOLT, HEX., 8X18•••••••••••••• BOLT, KNOCK, 5MM•••••••••••••• BOLT, KNOCK, 6MM•••••••••••••• BOLT, RR. ENGINE UNDER•••••••• BOLT, SEALING, 14MM ••••••••••• BOLT, SPECIAL, 6MM•••••••••••• BOLT, STUD, 6X32•••••••••••••• BOLT, STUD, 8X18•••••••••••••• BOLT, SWINGARM PIVOT •••••••••• BOX, BATTERY•••••••••••••••••• BRIDGE, FORK TOP•••••••••••••• BULB•••••••••••••••••••••••••• BULB, HEADLIGHT••••••••••••••• BULB, STOP & TAILLIGHT•••••••• BULB, WEDGE BASE•••••••••••••• BULB, BUSH, BUSH, BUSH, BUSH, BUSH, BUSH,
WINKER•••••••••••••••••• 20X10••••••••••••••••••• FR. ARM PIVOT ••••••••••• FR. CUSHION UNDER••••••• RR. CUSHION RUBBER•••••• RUBBER•••••••••••••••••• UPPER RUBBER•••••••••••• 2005.06.10
E
Page
Ref.
Part name
79 58 68 78 77 81 28 44 57 80 55 65 80 32 28 39 28 38 60 38 62 34 40 40 34 40 83 34 55 59 39 39 44 70 70 66 32 44 81 32 83 29 63 74 78 54 51 50 77 50 51 76 42 59 59 75 59 75
16 3 9 4 12 11 17 24 22 20 17 7 21 18 18 15 19 2 16 3 20 19 13 14 20 15 10 21 16 13 12 11 23 9 10 7 14 18 7 13 6 5 16 15 2 1 1 6 8 8 2 10 4 2 1 2 11 5
[C ] CABLE COMP., CHOKE•••••••••••• CABLE COMP., FR. BRAKE•••••••• CABLE COMP., SPEEDOMETER•••••• CABLE COMP., THROTTLE••••••••• CABLE, INNER•••••••••••••••••• CAMSHAFT COMP.•••••••••••••••• CAM, RR. BRAKE•••••••••••••••• CAP ASSY., NOISE SUPPRESSOR••• CAP COMP., FUEL FILLER•••••••• CAP, CABLE SEALING•••••••••••• CAP, CHAIN CASE PEEP HOLE••••• CAP, CHOKE DUST••••••••••••••• CAP, CROSS MEMBER SIDE•••••••• CAP, FR. ARM PIVOT DUST SEAL•• CAP, FR. COVER•••••••••••••••• CAP, FR. CUSHION UNDER DUST SEAL CAP, FR. FORK SIDE•••••••••••• CAP, TAPPET ADJUSTING HOLE•••• CARBURETOR ASSY.•••••••••••••• CARRIER, LUGGAGE•••••••••••••• CASE, AIR CLEANER UNDER HALF•• CASE, AIR CLEANER UPPER HALF•• CASE, DRIVE CHAIN UNDER HALF•• CASE, DRIVE CHAIN UPPER HALF•• CENTER, CLUTCH•••••••••••••••• CHAIN, CAM•••••••••••••••••••• CHAIN, DRIVE•••••••••••••••••• CHAMBER SET, FLOAT•••••••••••• CIRCLIP, EXTERNAL, 16MM••••••• CIRCLIP, EXTERNAL, 17MM••••••• CLAMPER, A.C. GENERATOR CORD•• CLAMPER, FUEL TUBE•••••••••••• CLAMPER, PULSER CORD•••••••••• CLAMPER, TUBE••••••••••••••••• CLAMP, OVER FLOW PIPE••••••••• CLIP, DYNAMO CORD••••••••••••• CLIP, GEARSHIFT FORK GUIDE PIN CLIP, PISTON PIN•••••••••••••• CLIP, TUBE••••••••••••••••••••
COIL COMP., IGNITION•••••••••• COLLAR, 14.8MM•••••••••••••••• COLLAR, 17MM•••••••••••••••••• COLLAR, FR. ARM PIVOT••••••••• COLLAR, FR. AXLE DISTANCE••••• COLLAR, FR. COVER SETTING••••• COLLAR, FR. CUSHION DISTANCE•• COLLAR, FR. FENDER•••••••••••• COLLAR, FR. WHEEL SIDE•••••••• COLLAR, GEAR•••••••••••••••••• COLLAR, MUFFLER SETTING•••••••
Page
Ref.
52 52 51 52 51 30 60 62 79 65 46 73 46 73 59 83
2 8 6 1 7 2 2 6 6 2 12 5 14 13 6 5
59 56 28 46 66 68 68 73 73 35 32 73 46 45 36 42 39 79 39 40 40 34 44 41 40 46 47 65 69 79 33 35 59 61 83 59 58 61 42 74
8 4 4 11 5 6 5 2 1 4 2 3 5 10 26 18 4 1 5 6 5 12 4 5 12 25 26 6 4 4 4 18 5 5 4 7 2 3 11 16
5 89
PART NAME INDEX Part name
COLLAR, RR. AXLE DISTANCE •••• COLLAR, RR. BRAKE PANEL SIDE • COLLAR, RR. CUSHION RUBBER BUSH COLLAR, RR. CUSHION UPPER RUBBER BUSH COLLAR, RR. WHEEL AXLE SLEEVE COLLAR, RUBBER BUSH •••••••••• COLLAR, STEERING STEM •••••••• COLLAR, TANK SETTING ••••••••• COLLAR, TOP BRIDGE ••••••••••• CONTACT ASSY., NEUTRAL SWITCH CORD COMP., TAILLIGHT •••••••• COTTER, VALVE •••••••••••••••• COUNTERSHAFT, TRANSMISSION ••• COVER COMP., R. CRANKCASE •••• COVER SET, L. SIDE ••••••••••• COVER SET, R. SIDE ••••••••••• COVER, CLUTCH OUTER •••••••••• COVER, CYLINDER HEAD ••••••••• COVER, EX. PIPE •••••••••••••• COVER, FORK CENTER ••••••••••• COVER, FR. ••••••••••••••••••• COVER, FR. TOP ••••••••••••••• COVER, HANDLE UNDER •••••••••• COVER, LOCK NUT •••••••••••••• COVER, L. CRANKCASE •••••••••• COVER, L. CYLINDER HEAD SIDE • COVER, R. CYLINDER HEAD SIDE • COVER, R. HANDLE LEVER ••••••• CRANKCASE COMP., L. •••••••••• CRANKCASE COMP., R. •••••••••• CRANKSHAFT COMP. ••••••••••••• CRANKSHAFT COMP., R. ••••••••• CRANKSHAFT, L. ••••••••••••••• CUP, FUEL STRAINER ••••••••••• CUSHION ASSY., FR. ••••••••••• CUSHION ASSY., RR. ••••••••••• CUSHION, BATTERY ••••••••••••• CUSHION, C.D.I. UNIT ••••••••• CYLINDER ••••••••••••••••••••• C.D.I. UNIT ••••••••••••••••••
Page
Ref.
63 62
7 4
75
3
75 63 59 54 66 54 56 44 77 30 42 34 67 67 35 28 69 56 57 83 57 54 52 38 28 28 52 40 40 41 41 41 46 59 75 78 79 33 79
4 5 10 7 1 9 11 15 4 11 2 1 3 1 2 1 1 13 13 1 15 3 13 1 3 2 12 3 1 1 7 8 17 9 1 3 2 1 3
63 35 35 40 30 33 34 33 44 68 60 62
1 6 9 10 14 5 14 8 5 4 8 11
[D ] DAMPER SET, WHEEL •••••••••••• DISK A, CLUTCH FRICTION •••••• DISK B, CLUTCH FRICTION •••••• DOWEL PIN, 10X14 ••••••••••••• DOWEL PIN, 8X12 ••••••••••••••
5
DOWEL PIN, 8X14 •••••••••••••• DRUM, GEARSHIFT •••••••••••••• DUCT, AIR CLEANER •••••••••••• DUST SEAL, BRAKE CAM •••••••••
90
Part name
DUST SEAL, STEERING HEAD••••••
Page
Ref.
56
8
68 85 85
1 2 5
58 63 64 61 63 46 39 56 44 44 65 80
1 6 27 2 15 3 1 3 1 2 2 22
[E ] ELEMENT COMP., AIR CLEANER •••• EMBLEM, FR. TOP COVER••••••••• EMBLEM, POINT COVER ••••••••••• [F ] FENDER, FR.••••••••••••••••••• FLANGE COMP., FINAL DRIVEN •••• FLANGE SUB ASSY., FINAL DRIVEN FLAP, TIRE•••••••••••••••••••• FLOAT SET ••••••••••••••••••••• FLYWHEEL COMP. •••••••••••••••• FORK SET, FR.••••••••••••••••• FORK, L. GEARSHIFT•••••••••••• FORK, R. GEARSHIFT•••••••••••• FUEL FILL CAP COMP. ••••••••••• FUSE•••••••••••••••••••••••••• [G ] GASKET KIT A•••••••••••••••••• GASKET KIT B•••••••••••••••••• GASKET SET•••••••••••••••••••• GASKET SET B•••••••••••••••••• GASKET, CLUTCH OUTER COVER •••• GASKET, CRANKCASE••••••••••••• GASKET, CYLINDER•••••••••••••• GASKET, CYLINDER HEAD••••••••• GASKET, CYLINDER HEAD COVER••• GASKET, EX. PIPE•••••••••••••• GASKET, IN. PIPE•••••••••••••• GASKET, L. CYLINDER HEAD SIDE COVER GASKET, OIL PUMP BODY••••••••• GASKET, R. CRANKCASE COVER •••• GASKET, R. CYLINDER HEAD SIDE COVER GAUGE, OIL LEVEL•••••••••••••• GEAR COMP., SPEEDOMETER••••••• GEAR, COUNTERSHAFT LOW•••••••• GEAR, COUNTERSHAFT SECOND ••••• GEAR, COUNTERSHAFT THIRD•••••• GEAR, MAINSHAFT SECOND•••••••• 2005.06.10
E
48 49 46 46 35 49 40 49 33 48 29 48 28 48 48 69 28 48
1 1 1 9 3 1 2 1 2 1 4 1 5 1 1 2 9 1
28 48 37 49 34 49
7 1 2 1 2 1
28 48 34 60 42 42 42 42
6 1 3 5 3 6 8 5
Part name
Page
Ref.
42 35 35 82 52 52 81 39 77 57 81 35 29 29
7 21 19 3 9 10 1 6 7 16 2 5 3 2
54 79 50 50 29
2 8 1 4 1
32 81 46 83 72 79 61 61 63
8 5 16 3 3 13 4 14 9
60 62
9 7
47 47 60 70 73
27 28 14 14 4
79 79 41
10 12 11
LABEL, COLOR•••••••••••••••••• LABEL, DRIVE CHAIN•••••••••••• LABEL, SHIFT PATTERN••••••••••
84 84 84
LABEL, TIRE•••••••••••••••••••
84
6 3 4 7 2
GEAR, MAINSHAFT THIRD••••••••• GEAR, PRIMARY DRIVE••••••••••• GEAR, PRIMARY DRIVEN•••••••••• GRIP•••••••••••••••••••••••••• GRIP COMP., THROTTLE•••••••••• GRIP, HANDLE•••••••••••••••••• GROMMET A, AIR CLEANER CASE••• GROMMET, NEUTRAL SWITCH CORD•• GROMMET, TAILLIGHT BASE••••••• GROMMET, TOP COVER•••••••••••• GROMMET, WIRE CORD•••••••••••• GUIDE, CLUTCH CENTER•••••••••• GUIDE, EX. VALVE•••••••••••••• GUIDE, IN. VALVE•••••••••••••• [H ] HANDLE COMP., STEERING•••••••• HARNESS, WIRE••••••••••••••••• HEADLIGHT ASSY.••••••••••••••• HEADLIGHT UNIT•••••••••••••••• HEAD COMP., CYLINDER•••••••••• HEAD, CAM CHAIN TENSIONER PUSH ROD HOLDER ASSY., HELMET•••••••••• HOLDER, NEEDLE JET•••••••••••• HOOK, FR. COVER••••••••••••••• HOOK, MAIN STAND SPRING••••••• HORN COMP.•••••••••••••••••••• HUB COMP., FR. WHEEL•••••••••• HUB SUB ASSY., FR.•••••••••••• HUB SUB ASSY., RR.•••••••••••• [I ] INDICATOR, FR. BRAKE•••••••••• INDICATOR, RR. BRAKE•••••••••• [J ] JET, MAIN,•••••••••••••••••••• JET, SLOW,•••••••••••••••••••• JOINT B, BRAKE ARM•••••••••••• JOINT, DRIVE CHAIN•••••••••••• [K ] KEY SET••••••••••••••••••••••• KEY, BLANK•••••••••••••••••••• KEY, WOODRUFF, 4MM•••••••••••• [L ]
PART NAME INDEX Part name
Page
Ref.
Part name
67 67 76 77 52 34 52 73 56
5 2 2 2 3 4 11 7 12
NUT, TAPPET ADJUSTING••••••••• NUT, U, 10MM••••••••••••••••••
MAINSHAFT, TRANSMISSION •••••• MARK, DRIVE CAUTION ••••••••••
42 84
MARK, L. FRAME BODY •••••••••• MARK, R. FRAME BODY •••••••••• MARK, SIDE COVER ••••••••••••• MIRROR COMP. ••••••••••••••••• MUFFLER COMP., EX. •••••••••••
85 85 85 52 69
1 5 8 4 3 1 14 5
LATCH, BATTERY BOX ••••••••••• LATCH, TOOL BOX •••••••••••••• LENS COMP., WINKER ••••••••••• LENS, TAILLIGHT •••••••••••••• LEVER, CHOKE ••••••••••••••••• LEVER, CLUTCH •••••••••••••••• LEVER, R. STEERING HANDLE •••• LINK, RR. BRAKE TORQUE ••••••• LOCK, STEERING HANDLE •••••••• [M ]
[N ] NEEDLE SET, JET •••••••••••••• NUT •••••••••••••••••••••••••• NUT-WASHER, 8MM •••••••••••••• NUT B, BRAKE ROD ADJUSTING ••• NUT C, STEERING STEM ••••••••• NUT SET, SQUARE •••••••••••••• NUT, CAP, 10MM ••••••••••••••• NUT, CAP, 6MM •••••••••••••••• NUT, CAP, 8MM •••••••••••••••• NUT, FLANGE, 10MM •••••••••••• NUT, FLANGE, 5MM ••••••••••••• NUT, FLANGE, 6MM •••••••••••••
NUT, NUT, NUT, NUT,
FLANGE, 8MM ••••••••••••• HEX., 10MM •••••••••••••• HEX., 12MM •••••••••••••• HEX., 5MM •••••••••••••••
NUT, HEX., 6MM •••••••••••••••
NUT, HEX., 8MM •••••••••••••••
NUT, LOCK, 14MM •••••••••••••• NUT, RR. AXLE SLEEVE ••••••••• NUT, SPEED, 4MM ••••••••••••••
NUT, U, 6MM••••••••••••••••••• NUT, U, 8MM•••••••••••••••••••
2 3 15 15 15 11 10 7 10 6 8 14 17 16 13 11 18 9 8 7 17 23 23 15 21 6 7 18 17 17 16 19 8 22 18 19
Ref.
Part name
30 59 61 74 62 63
13 14 9 17 12 19
PIN, SHIFT RETURN SPRING•••••• PIN, SPLIT, 1.6X15•••••••••••• PIN, SPLIT, 2.0X15••••••••••••
44 34 42 39 61 64 60 39 49 59 33 48 34 49 28 48 28 48 63 39 49 44 49 34 49 29 35 35
21 15 20 8 10 20 12 9 1 15 6 1 17 1 14 1 15 1 11 10 1 22 1 16 1 7 1 20
40 49 73 65 33 48 77 77 62 60 70 70 45 74 32 41 44 44 41
9 1 6 5 7 1 6 5 5 7 7 1 1 25 10 9 7 3 4
[O ] OIL SEAL, 11.6X24X10 •••••••••• OIL SEAL, 13.8X24X5 ••••••••••• OIL SEAL, 17X29X5••••••••••••• OIL SEAL, 18.9X30X5 ••••••••••• OIL SEAL, 21X35X7••••••••••••• OIL SEAL, 27X40X6••••••••••••• OIL SEAL, 47X60X7••••••••••••• O-RING, 107X2••••••••••••••••• O-RING, 13.8X2.4•••••••••••••• O-RING, 14.5MM •••••••••••••••• O-RING, 18X3••••••••••••••••••
46 50 55 60 70 54 46 75 28 66 83 39 79 28 60 77 79 81 69 72 63 52 53 62 64 67 69 34 52 59 62 74 81 35 63 57
Page
O-RING, 27X2.0 •••••••••••••••• O-RING, 30.8MM •••••••••••••••• O-RING, 40.5X3 •••••••••••••••• O-RING, 6X1.7••••••••••••••••• O-RING, 7X1.7••••••••••••••••• O-RING, 8MM••••••••••••••••••• O-RING, 9X1.6••••••••••••••••• OUTER, CLUTCH••••••••••••••••• OUTER, DRIVE GEAR••••••••••••• [P ] PACKING, DRAIN COCK, 12.5X20•• PACKING, DRIVE CHAIN CASE ••••• PACKING, FUEL FILLER CAP•••••• PACKING, RUBBER, 16MM••••••••• PACKING, TAILLIGHT BASE••••••• PACKING, TAILLIGHT LENS••••••• PANEL COMP., RR. BRAKE•••••••• PANEL SUB ASSY., FR. BRAKE •••• PEDAL COMP., BRAKE•••••••••••• PEDAL, GEAR CHANGE•••••••••••• PINION, KICK STARTER •••••••••• PIN A, PILLION STEP ••••••••••• PIN, CAM CHAIN GUIDE ROLLER••• PIN, CRANK•••••••••••••••••••• PIN, GEARSHIFT DRUM ••••••••••• PIN, GEARSHIFT FORK GUIDE ••••• PIN, PISTON••••••••••••••••••• 2005.06.10
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PIN, SPLIT, 3.0X25•••••••••••• PIPE, IN.••••••••••••••••••••• PISTON•••••••••••••••••••••••• PIVOT, CAM CHAIN TENSIONER•••• PIVOT, OIL PUMP••••••••••••••• PLATE A, CLUTCH••••••••••••••• PLATE B, CLUTCH••••••••••••••• PLATE COMP., CLUTCH CAM••••••• PLATE COMP., CLUTCH LIFTER•••• PLATE COMP., SILENCER••••••••• PLATE, CONTACT FIXING••••••••• PLATE, DRIVE•••••••••••••••••• PLATE, DRIVE SPROCKET FIXING•• PLATE, FORK TOP BRIDGE•••••••• PLATE, FR. COVER SETTING•••••• PLATE, GEARSHIFT DRUM LOCK•••• PLATE, GEARSHIFT DRUM STOPPER• PLATE, NAME••••••••••••••••••• PLATE, RR. WINKER SETTING••••• PLATE, STAY••••••••••••••••••• PLIERS, 135••••••••••••••••••• PLUG, HEAD PIPE••••••••••••••• PLUG, RUBBER, 19MM•••••••••••• PLUG, SPARK••••••••••••••••••• PUMP ASSY., OIL•••••••••••••••
Page
Ref.
44 74 62 70 74 72 28 41 32 37 35 35 34 34 81 44 35 42 54 83 42 44 84 76 46 82 56 44 49 28 37
14 23 19 12 24 8 8 3 5 5 7 8 5 7 4 17 10 10 4 2 13 6 1 11 13 8 1 20 1 20 1
56 56 56 45 79 79 34 45 30 50 61 63 41 35 35
7 2 6 2 7 14 9 4 9 2 7 12 2 15 16
32 41 70 32 44 32 44 37 37
7 6 6 9 25 4 16 3 4
[R ] RACE, STEERING BOTTOM CONE•••• RACE, STEERING TOP BALL••••••• RACE, STEERING TOP CONE••••••• RATCHET, STARTER DRIVE•••••••• RECTIFIER COMP., REGULATE••••• RELAY COMP., WINKER••••••••••• RETAINER, CLUTCH BALL••••••••• RETAINER, KICK SPRING••••••••• RETAINER, VALVE SPRING•••••••• RIM COMP., HEADLIGHT•••••••••• RIM, FR. WHEEL•••••••••••••••• RIM, RR. WHEEL•••••••••••••••• RING SET, PISTON•••••••••••••• RING, CLUTCH WEIGHT CENTER•••• RING, CLUTCH WEIGHT STOPPER••• ROD COMP., CAM CHAIN TENSIONER PUSH ROD, CONNECTING••••••••••••••• ROD, RR. BRAKE•••••••••••••••• ROLLER COMP., CAM CHAIN GUIDE• ROLLER, 3X8.5••••••••••••••••• ROLLER, CAM CHAIN TENSIONER••• ROTOR, NEUTRAL SWITCH••••••••• ROTOR, OIL PUMP INNER••••••••• ROTOR, OIL PUMP OUTER•••••••••
5 91
PART NAME INDEX Part name
RUBBER A, RR. WINKER MOUNTING RUBBER A, STAND STOPPER •••••• RUBBER B, RR. WINKER MOUNTING RUBBER B, TOP BRIDGE SHEET ••• RUBBER, AIR CLEANER ELEMENT SETTING RUBBER, KICK STARTER ••••••••• RUBBER, PILLION STEP ••••••••• RUBBER, SEAT MOUNTING •••••••• RUBBER, STAND STOPPER •••••••• RUBBER, STEP ••••••••••••••••• RUBBER, STOPPER ARM CUSHION ••
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Ref.
76 66 76 54
7 9 8 6
68 70 73 66 72 71 62
3 3 9 3 4 2 10
46 37 46 46 46 46 52 68 69 46 46 36 39 52 50 57 51 77 52 36 37 68 76 52 52 37 37 72 30 76 76 57 68 30 48 66 66 30 35 42 45 72 82 30
18 6 21 23 22 24 22 11 6 6 8 28 13 15 10 17 8 10 16 27 7 10 14 20 21 8 9 6 12 12 13 18 2 1 1 2 4 10 17 19 9 2 2 4
[S ] SCREEN, FUEL STRAINER •••••••• SCREEN, OIL FILTER ••••••••••• SCREW-WASHER, 3X12 ••••••••••• SCREW-WASHER, 4X18 ••••••••••• SCREW-WASHER, 4X8 •••••••••••• SCREW-WASHER, 5X10 ••••••••••• SCREW-WASHER, 5X28 ••••••••••• SCREW-WASHER, 5X6 •••••••••••• SCREW SET A •••••••••••••••••• SCREW SET B •••••••••••••••••• SCREW, FLAT, 5X10 •••••••••••• SCREW, FLAT, 6X16 •••••••••••• SCREW, HANDLE LEVER PIVOT •••• SCREW, HEADLIGHT SETTING ••••• SCREW, SCREW, SCREW, SCREW,
OVAL, 5X18 •••••••••••• PAN, 4X50 ••••••••••••• PAN, 5MM •••••••••••••• PAN, 5X10 •••••••••••••
SCREW, PAN, 5X20 ••••••••••••• SCREW, PAN, 5X28 ••••••••••••• SCREW, PAN, 5X40 ••••••••••••• SCREW, PAN, 6X16 ••••••••••••• SCREW, PAN, 6X22 ••••••••••••• SCREW, SIDE STAND PIVOT •••••• SCREW, TAPPET ADJUSTING •••••• SCREW, TAPPING, 4X40 ••••••••• SCREW, TAPPING, 4X8 •••••••••• SCREW, U-LOCK FLAT, 6X12 ••••• SEAL, AIR CLEANER COVER •••••• SEAL, VALVE STEM ••••••••••••• SEAT ASSY., SINGLE ••••••••••• SEAT COMP., PILLION •••••••••• SEAT, VALVE SPRING OUTER ••••• SET RING, 101.5MM •••••••••••• SET RING, 20MM •••••••••••••••
5 92
SHAFT, RR. BRAKE PIVOT ••••••• SHAFT, SCREW DRIVER •••••••••• SHAFT, VALVE ROCKER ARM ••••••
Part name
SHEET A, TOP BRIDGE RUBBER •••• SHOE SET, BRAKE••••••••••••••• SLEEVE, RR. WHEEL AXLE•••••••• SOCKET ASSY., HEADLIGHT••••••• SOCKET COMP.•••••••••••••••••• SOCKET COMP., L. FR. WINKER••• SOCKET COMP., POSITION LAMP••• SOCKET COMP., R. FR. WINKER••• SOCKET COMP., TAILLIGHT••••••• SPANNER, 10X12 •••••••••••••••• SPANNER, 14X17 •••••••••••••••• SPEEDOMETER ASSY.••••••••••••• SPINDLE COMP., GEARSHIFT•••••• SPINDLE, CAM CHAIN GUIDE SPROCKET SPINDLE, KICK STARTER••••••••• SPOKE SET A, 12X158 ••••••••••• SPOKE SET A, 12X158.5••••••••• SPOKE SET B, 10X158.5••••••••• SPOKE SET B, 10X159.0••••••••• SPRING A, BRAKE ROD ••••••••••• SPRING A, SIDE STAND •••••••••• SPRING D, MAIN STAND •••••••••• SPRING, BRAKE ARM RETURN•••••• SPRING, BRAKE PEDAL ••••••••••• SPRING, BRAKE SHOE•••••••••••• SPRING, SPRING, SPRING, SPRING, SPRING, SPRING, SPRING, SPRING, SPRING, SPRING, SPRING, SPRING, SPRING,
CAM CHAIN TENSIONER••• CAM PLATE SIDE•••••••• CHANGE FRICTION••••••• CLUTCH •••••••••••••••• CLUTCH DAMPER••••••••• CLUTCH FREE ••••••••••• GEARSHIFT ARM••••••••• GEARSHIFT RETURN•••••• KICK STARTER •••••••••• OIL THROUGH ••••••••••• SHIFT DRUM STOPPER •••• SPEEDOMETER SETTING••• STARTER PINION FRICTION SPRING, STOPPER ARM ••••••••••• SPRING, STOP SWITCH ••••••••••• SPRING, VALVE INNER ••••••••••• SPRING, VALVE OUTER ••••••••••• SPROCKET, CAM••••••••••••••••• SPROCKET, CAM CHAIN GUIDE ••••• SPROCKET, DRIVE••••••••••••••• SPROCKET, FINAL DRIVEN•••••••• SPROCKET, TIMING•••••••••••••• STAND COMP., MAIN••••••••••••• STATOR COMP.•••••••••••••••••• STAY, IGNITION COIL ••••••••••• STAY, MUFFLER UPPER ••••••••••• STAY, TOP COVER SETTING••••••• STOPPER, CABLE •••••••••••••••• SUB CORD, RR. WINKER •••••••••• SUSPENSION, WINKER RELAY•••••• 2005.06.10
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Page
Ref.
Part name
54 60 62 63 50 51 76 50 76 77 82 82 51 44
5 1 1 4 5 4 5 7 3 3 6 7 3 10
SWINGARM ASSY.•••••••••••••••• SWITCH ASSY., COMBINATION••••• SWITCH ASSY., FR. STOP•••••••• SWITCH ASSY., LIGHTING•••••••• SWITCH ASSY., RR. STOP•••••••• SWITCH ASSY., WINKER••••••••••
32 45 61 61 64 64 70 72 72 60 70 60 62 32 34 42 35 35 35 44 44 45 34 44 51
12 3 13 12 26 25 13 10 9 11 8 3 8 6 6 12 11 13 12 12 13 6 11 9 5
45 73 70 30 30 32 32 42 63 41 72 39 79 69 57 52 79 79
5 8 5 8 7 1 11 9 3 10 1 2 5 3 14 4 9 15
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Ref.
73 79 52 52 70 52
12 11 7 5 4 6
77 65
1 1
56 34 61 63 82 46 68 46 40 65 65 46 61 63
10 10 8 13 1 4 7 19 4 4 3 20 1 14
46 46 30 30
15 7 6 5
54 28 42 35 39 45 42 32 34 62 44 54 35 50 73 52 74 75 70 62 64 74
10 12 16 24 7 7 15 17 13 13 19 12 23 11 10 18 22 8 11 17 22 20
[T ] TAILLIGHT UNIT•••••••••••••••• TANK COMP., FUEL•••••••••••••• THREAD COMP., STEERING HEAD TOP THROUGH, OIL•••••••••••••••••• TIRE, FR.••••••••••••••••••••• TIRE, RR.••••••••••••••••••••• TOOL SET•••••••••••••••••••••• TOP SET••••••••••••••••••••••• TUBE, AIR CLEANER CONNECTING•• TUBE, AIR VENT•••••••••••••••• TUBE, BREATHER, 5X320••••••••• TUBE, FUEL RESERVE•••••••••••• TUBE, FUEL, 5.3X520••••••••••• TUBE, OVERFLOW•••••••••••••••• TUBE, TIRE•••••••••••••••••••• [V ] VALVE COMP., FLOAT•••••••••••• VALVE SET, THROTTLE••••••••••• VALVE, EX.•••••••••••••••••••• VALVE, IN.•••••••••••••••••••• [W ] WASHER•••••••••••••••••••••••• WASHER A, SEALING, 6MM•••••••• WASHER A, SPLINE, 20MM•••••••• WASHER B, LOCK•••••••••••••••• WASHER, 10MM•••••••••••••••••• WASHER, 17MM•••••••••••••••••• WASHER, 17X1.5•••••••••••••••• WASHER, 8MM••••••••••••••••••• WASHER, WASHER, WASHER, WASHER, WASHER, WASHER, WASHER, WASHER, WASHER, WASHER,
GEARSHIFT DRUM SIDE••• HANDLE SETTING•••••••• LOCK, 14MM•••••••••••• LOCK, 6MM••••••••••••• PILLION STEP•••••••••• PLAIN••••••••••••••••• PLAIN, 10MM••••••••••• PLAIN, 12MM••••••••••• PLAIN, 5MM•••••••••••• PLAIN, 6MM••••••••••••
PART NAME INDEX Part name
WASHER, PLAIN, 8MM ••••••••••• WASHER, SEALING, 14MM •••••••• WASHER, SEALING, 6MM ••••••••• WASHER, SEALING, 6.5X12 •••••• WASHER, SPEEDOMETER GEAR ••••• WASHER, SPLINE, 17MM ••••••••• WASHER, SPRING, 6MM •••••••••• WASHER, SPRING, 8MM •••••••••• WASHER, SPROCKET SETTING ••••• WASHER, STEERING HEAD DUST SEAL WASHER, STOPPER, 14MM •••••••• WASHER, TANK SETTING ••••••••• WASHER, THRUST, 20MM ••••••••• WASHER, TOOTHED •••••••••••••• WASHER, TOP BRIDGE ••••••••••• WASHER, WAVE ••••••••••••••••• WEIGHT, CLUTCH ••••••••••••••• WHEEL SUB ASSY., FR. ••••••••• WHEEL SUB ASSY., RR. ••••••••• WINKER ASSY., L. FR. ••••••••• WINKER ASSY., L. RR. ••••••••• WINKER ASSY., R. FR. ••••••••• WINKER ASSY., R. RR. ••••••••• WRENCH, BOX •••••••••••••••••• WRENCH, SPARK PLUG •••••••••••
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57 74 83 32 28 28 32 60 42 62 64 81 75
21 21 9 15 11 13 16 6 17 18 23 10 6
56 35 83 45 54 54 52 35 61 63 76 76 76 76 82 82
9 25 7 8 13 8 19 14 6 10 4 9 1 6 4 5
Part name
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Part name
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5 93 2005.06.10
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1
FOREWORD INDEX
2
ENGINE GROUP
3
FRAME GROUP
4
PART NUMBER INDEX
5
PART NAME INDEX
E. A .2005.06
Published by Honda Motor Co., Ltd. Printed in Japan