Honda Beat Service Manual

BEAT

PARTS CATALOG EDISI 1

TST 08 PC 002

PT Astra Honda Motor

DAFTAR

ISI

PETUNJUK PEMAKAIAN

1

KELOMPOK MESIN

2

KELOMPOK RANGKA

3

INDEKS PART NUMBER

4

INDEKS DESCRIPTION

5

PETUNJUK PEMAKAIAN PARTS CATALOG Parts catalog ini digunakan untuk memesan/mencari parts pengganti; di dalamnya terdapat semua parts dan waktu kerja standard (F.R.T.) untuk tipe sepeda motor HONDA BEAT (KVYG)

1

I. CARA MEMESAN PARTS 1. Informasi yang diperlukan Pemesan parts pengganti sebaiknya mencantumkan Part Number dan Nomor seri seperti diterangkan dibawah. Hal ini diperlukan oleh karena setiap perubahan dan modifikasi pada parts telah didaftarkan di HONDA berikut nomor part dan Nomor seri yang bersangkutan. Nomor-nomor yang dibutuhkan : (a) Parts mesin

:

Part Number dan Nomor seri mesin

(b) Parts rangka

:

Part Number dan Nomor seri rangka

(c) Parts karburator

:

Part Number dan Nomor identifkasi karburator

2. Perubahan-perubahan Perubahan-perubahan pada parts catalog ini akan dimuat dalam Parts Bulletin yang diterbitkan sebagai pelengkap dari pada parts catalog ini. Bila jumlah perubahan-perubahan cukup banyak, pada suatu waktu dapat diterbitkan edisi baru yang disesuaikan daripada parts catalog ini, dan masing-masing edisi akan diberikan nomor urut pada sampulnya. Kami menganjurkan agar Sdr. selalu menyimpan parts bulletin bersama parts catalog ini, agar informasi parts Sdr. selalu lengkap dan up-to-date.

II. CARA MEMBACA PARTS CATALOG 1. Susunan nomor part (contoh) Parts umum (General parts) Nomor fungsi dan komponen model

Nomor kode

Kode warna Kode subkontraktor Kode modifikasi

(contoh) Baut-baut, mur-mur dan standar parts lain. Nomor fungsi dan tipe

Dimensi

Pengerjaan permukaan secara kimiawi SO

1

2. Kode warna

5. Parts yang digantikan oleh part lain Nomor part yang diletakkan dibawah nama part pada kolom "Description" menunjukkan bahwa nomor part disebelahnya telah diganti dengan nomor part tersebut. Pergantian parts sedemikian (supersedence) dapat dilakukan oleh HONDA tanpa pemberitahuan apapun.

Kode warna pada bagian belakang nomor part menunjukkan warna part tersebut. Kode-kode ZA, ZB, ZC dan seterusnya tidak secara langsung menunjukkan warna part, melainkan warna dapat dilihat dari kode HONDA pada kolom "Part Number" di sebelahnya nomor part yang bersangkutan.

1

Kode warna pabrik seperti FMB, PFW, ABM dsbnya secara langsung menunjukkan warna part seperti ditunjukkan pada tabel berikut : Kode Warna Kode pabrik Kode HONDA NH1 NH-341P B-201M R-333C RP-178M YR-294C

FMB PFW ABM CSR PPM CBO

6. Part yang dipersatukan (Assemblies) Part pada gambar yang dikelilingi dengan garis terputus-putus tersedia sebagai parts yang dipersatukan. Masing-masing komponen daripada susunan parts itu dapat juga diperoleh secara terpisah.

Warna

7. Jumlah yang diperlukan Angka didalam kolom "Q'ty" menunjukkan jumlah part tersebut yang dipakai di dalam bagian yang bersangkutan.

Black Pearl Fadeless White Assure Blue Metallic Candy Scarlet Red Powder Pink Metallic Candy Blitz Orange

8. Illustrasi Gambar-gambar parts yang dimuat di dalam part catalog ini disediakan untuk mempermudah pengenalan part dan mungkin berbeda daripada bentuk part sebenarnya.

3. Singkatan-singkatan Dibawah ini adalah daftar singkatan-singkatan yang digunakan di dalam parts catalog, sebagai berikut : ASSY................ Assembly L.E.D .............. Light emitting diode COMP .............. Complete. MPH ............... Miles per hour R....................... Right L (100L) .......... Link(100 Links) L. ...................... Left A.C ................. Alternating current STD .................. Standard D.C ................. Direct current MM ................... Milimeter IN ................... Inlet G ...................... Gram EX. ................. Exhaust T(22)................. Tooth (22Teeth) FR .................. Front A ....................... Ampere RR .................. Rear V ....................... Volt Hex ................. Hexagonal W ...................... Watt A.M ................. Attaching mark WL .................... With labelling T.M ................. Transcript mark WOL. ................ Without labelling C.D.I ............... Capacitive KPH .................. Kilometers per hour Discharge Ignition 4. Dimensi-dimensi Semua ukuran diberikan dalam satuan milimeter (mm) kecuali untuk peluru baja (steel balls), ban luar (tires) dan ban dalam (tire tubes). Part Bolt (Screw) Pin O-Ring Oil seal Tube

2

Contoh 6x12 8x14 9.5x1.6 14x24x5 5x130

Pengertian diameter 6mm, panjang 12mm diameter 8mm, panjang 14mm diameter 9,5mm, tebal 1,6mm diameter dalam 14 mm, diameter luar 24 mm, tebal 5mm diameter dalam 5mm, panjang 130mm

9. Nama part Nama part tidak diterjemahkan kedalam bahasa Indonesia, melainkan tetap menggunakan istilah resminya didalam bahasa Inggris, agar seragam dengan istilah internasional yang dipakai di seluruh dunia oleh Honda Motor Co.,Ltd. 10. Model dan nomor seri yang berlaku Model-model, kode daerah pemasaran dan nomor seri yang berlaku didalam parts catalog ini dapat diidentifikasi sebagai berikut dibawah ini.

Model

Kode daerah pemasaran

Tipe

No. Seri Mesin yang berlaku mulai

No. Seri Rangka yang berlaku mulai

No. Identifikasi Karburator yang berlaku

ANC110CCI9

IN

Indonesia

JF21E********

MH1JF****K******

AVK2CH A

*

Dari nomor identifikasi karburator, hanya dipakai bagian yang digaris bawahi didalam contoh dibawah AVK2CH A KC 7

III. CARA MEMAKAI FLAT RATE TIME (F.R.T.) 11. Lokasi nomor seri pada sepeda motor

F.R.T. (Flate Rate Time) yang terletak di halaman paling akhir buku ini dipakai untuk menentukan waktu kerja standard yang diperbolehkan untuk penggantian parts.

NOMOR SERI RANGKA

1

F.R.T untuk parts yang tidak tercantum didalam buku ini harus ditentukan dari jenis pekerjaan yang erat hubungannya dengan penggantian parts tersebut. 1. F.R.T. didasarkan atas kondisi servis sebagai berikut : a. Disamping waktu servis yang sebenarnya ditambahkan lagi waktu ekstra. b. Waktu standard yang ditentukan didasarkan atas persyaratan bahwa alat-alat servis yang diperlukan seperti terdaftar didalam buku pedoman reparasi sudah siap tersedia, dan pekerjaan dilakukan oleh seorang mekanik dengan ketrampilan normal. c

Waktu yang dibutuhkan untuk pemeriksaan dan percobaan pemakaian setelah diservis, dimasukkan juga kedalam F.R.T.

2. Metode perhitungan Waktu pekerjaan ditulis dalam sepersepuluh jam untuk mempermudahkan perhitungan. (contoh) 0.3 = 18 menit 5.6 = 5 jam dan 36 menit DAFTAR KONVERSI NOMOR SERI MESIN

NOMOR IDENTIFIKASI KARBURATOR

Jam 0.1 0.2 0.3 0.4 0.5

Menit 6 12 18 24 30

Jam 0.6 0.7 0.8 0.9 1.0

Menit 36 42 48 54 60

3. Menghitung F.R.T. Jika beberapa pekerjaan dilakukan sekaligus, hitunglah sebagai berikut : a. Pekerjaan yang tidak berhubungan F.R.T. untuk pekerjaan diperoleh dengan menjumlahkan F.R.T. untuk setiap part yang diganti (contoh) Penggantian cylinder dan clutch spring Service item/Bagian yang diservis

F.R.T.

Cylinder

1.4

Clutch spring

0.7 F.R.T. untuk pekerjaan ini adalah : 1.4 + 0.7 = 2.1

3

b. Pekerjaan yang terulang No.

Ambillah F.R.T. untuk part terakhir yang akan diganti. (contoh) Penggantian piston dan cylinder head gasket.

1

Service item/Bagian yang diservis

F.R.T.

1.

Pemeriksaan waktu pengapian

0.2

F.R.T.

2.

Penyetelan dan pembersihan busi

0.1

Cylinder head gasket

1.0

3.

Penyetelan tappet

0.3

Piston

1.5

4.

Penyetelan stasioner karburator

0.1

5.

Pemeriksaan oli mesin (tidak termasuk penggantian oli mesin)

0.1

6.

Penyetelan kopling

0.1

7.

Pembersihan elemen saringan udara

0.3

8.

Pengukuran tekanan kompressi

0.1

9.

Pemeriksaan cairan baterai dan berat jenisnya

0.2

10.

Pengukuran tinggi pelampung karburator

0.6

11.

Pembersihan saringan oli mesin

0.6

12.

Penyetelan gas tangan

0.1

Service item/Bagian yang diservis

F.R.T. untuk pekerjaan ini adalah : 1.5 c. Pekerjaan yang sebagian berhubungan Jumlahkan F.R.T. untuk semua parts yang diganti dan kurangi dengan F.R.T untuk pekerjaan yang terulang. (contoh) Penggantian gear shift drum dan crankshaft assembly. Service item/Bagian yang diservis

F.R.T.

Gearshift drum

* 3.9

Crankshaft

* 4.1

Pembongkaran crankcase

* 3.7

F.R.T. untuk pekerjaan ini adalah : (3.9 + 4.1) - 3.7 = 4.3 Pekerjaan yang terulang adalah pembongkaran crankcase. *

F.R.T. dengan tanda (*) termasuk menurunkan dan memasang kembali mesin.

No.

4. Pengerjaan lain disamping penggantian parts a. Penurunan dan pemasangan No.

Service item/Bagian yang diservis

Rangka

F.R.T.

1.

Mesin

1.5

2.

Kepala silinder

1.1

3.

Karburator

0.4

Service item/Bagian yang diservis

F.R.T.

1.

Penyetelan rem depan

0.1

2.

Penyetelan rem belakang

0.1

3.

Pemeriksaan cara kerja rem

0.1

4.

Penyetelan arah lampu depan

0.1

5.

Rantai roda (termasuk penyetelan tegangan rantai tetapi tidak termasuk penggantian sprocket)

0.1

b. Pembongkaran No. 1.

4

Service item/Bagian yang diservis Karburator

F.R.T. 0.7

KELOMPOK MESIN E-1

SHROUD / FAN COVER

E-2

CYLINDER HEAD COVER

E-3

CYLINDER HEAD

2 E-4

CAMSHAFT / VALVE

E-5

E-7

RIGHT CRANKCASE

E-8

CAM CHAIN / TENSIONER

GENERATOR

E-6

CYLINDER

E-9

OIL PUMP

5

KELOMPOK MESIN E-10

STARTING MOTOR

E-11

LEFT CRANKCASE COVER

E-12

DRIVE FACE

E-13

DRIVEN FACE

E-14

TRANSMISSION

E-15

LEFT CRANKCASE

E-16

CRANKSHAFT / PISTON

E-17

CARBURETOR

2

6

KELOMPOK RANGKA F-1

HEADLIGHT

F-4 FR. BRAKE MASTER CYLINDER

F-2

SPEEDOMETER

F-5 HANDLE PIPE / HANDLE COVER

F-3

F-6

HANDLE LEVER/MIRROR/CABLE

STEERING STEM

3

F-7

FRONT FENDER

F-8

FRONT COVER

F-9

FLOOR PANEL

7

KELOMPOK RANGKA F-10

F-13

BODY COVER

FRONT WHEEL

F-11

FRONT FORK

F-12

FRONT BRAKE CALIPER

F-14

REAR WHEEL

F-15

SEAT/LUGGAGE BOX

3

F-16

8

FUEL TANK

F-17

AIR CLEANER

F-17-1

AIR SUCTION VALVE

KELOMPOK RANGKA F-18

EXHAUST MUFFLER

F-19

STAND / KICK ARM

F-20

REAR CUSHION

F-21

REAR FENDER

F-22

FRONT WINKER

F-23

COMBINATION LIGHT

3

F-24

BATTERY

F-25

WIRE HARNESS

F-26

FRAME BODY

9

KELOMPOK RANGKA F-27

3

10

TOOLS

F-28

CAUTION LABEL

F-29

MARK / STRIPE

E-1 Shroud / Fan Cover

2 Service item

F.R.T.

1 COVER, FAN........................................ 2 SHROUD, ENGINE :UPPER................ SHROUD, ENGINE :BOTH................... 4 (3) SHROUD, ENGINE :LOWER ......... SHROUD, ENGINE :BOTH ..................

TST 08 PC 002

0.2 0.7 1.1 1.1 1.1

No.

QTY

Part Number

Description

1 2 3 4 5

19610-KVY-900 19621-KVY-900 19625-KVY-900 19631-KVY-900 19639-GBC-000

COVER COMP., FAN SHROUD, IN. SEAL, SHROUD SHROUD, EX. RUBBER, MOUNTING

1 1 1 1 1

6 7 8 9

33715-GB0-900 93404-0602000 93903-25380 96001-0602500

COLLAR, TAILLIGHT SETTING BOLT-WASHER, 6X20 SCREW, TAPPING, 5X16 BOLT, FLANGE, 6X25

1 1 5 2

06 . 05 . 2008

Notes

11

E-2 Cylinder Head Cover

Service item

F.R.T.

1 COVER, CYLINDER HEAD.................... 0.3 2 GASKET, CYLINDER HEAD COVER..... 0.3

12

TST 08 PC 002

No. 1 2 3 4

Part Number

Description

12310-KVY-900 12391-KVY-900 90017-GCC-000 90543-MV9-671

COVER COMP., CYLINDER HEAD GASKET, HEAD COVER BOLT, HEAD COVER RUBBER, MOUNTING

06 . 05 . 2008

QTY 1 1 2 2

Notes

E-3 Cylinder Head

2 Service item

F.R.T.

1 HEAD, CYLINDER.................................. 2 GUIDE, INTAKE VALVE(ONE)............... GUIDE, EXHAUST VALVE(ONE)........... GUIDE, VALVE :FOR 1 VEHICLE.......... 4 GASKET, CYLINDER HEAD..................

No.

Part Number

Description

QTY

2.7 2.4 2.4 2.7 1.5

1 2 3 4 5

12200-KVY-900 12204-KVY-900 12206-KPL-900 12251-KVY-901 16201-KVY-900

HEAD COMP., CYLINDER GUIDE, VALVE CLIP, VALVE GUIDE GASKET, CYLINDER HEAD GASKET, CARBURETOR INSULATOR

1 2 2 1 1

7 MANIFOLD, INTAKE.............................. 0.6 8 INSULATOR, THROTTLE BODY/ CARBURETOR....................................... 0.6 12 PLUG, SPARK........................................ 0.2

6 7 8 9 10

16222-MV4-300 17110-KVY-900 17112-KVY-900 17256-KVY-900 17257-KVB-900

NUT, SQUARE, 5MM PIPE, INLET INSULATOR, CARBURETOR BAND A, INSULATOR COLLAR

2 1 1 1 2

11 12 13 14 15

17258-KVY-900 31916-KRM-841 31928-MFF-D01 90001-KVY-900 90201-GCC-000 90401-KVY-900

BAND B, INSULATOR PLUG, SPARK (CPR8EA-9) PLUG, SPARK (U24EPR9) BOLT, FLANGE, 6X10 NUT, HEX., 7MM PLATE, PLUNGER

1 1 1 1 4 2

16 17 18 19 20 21

90701-KFM-900 92900-060120B 92900-060280B 93500-050250H 94050-06000 95701-0610000

DOWEL PIN, SPECIAL, 8X14 BOLT, STUD, 6X12 BOLT, STUD, 6X28 SCREW, PAN, 5X25 NUT, FLANGE, 6MM BOLT, FLANGE, 6X100

2 2 2 2 2 2

TST 08 PC 002

06 . 05 . 2008

Notes

13

E-4 Camshaft / Valve

Service item 2 CAMSHAFT.......................................... 5 SPROCKET, CAM ...............................

F.R.T.

No.

1.7 0.6

6 (8) ARM, INTAKE VALVE ROCKER(ONE) 1.7 ARM, VALVE ROCKER :FOR 1 VEHICLE ................................. 1.7 7 (9) ARM, EXHAUST VALVE ROCKER (ONE) .................................................. 1.7 10 VALVE, INTAKE(ONE) ........................ 2 VALVE :FOR 1 VEHICLE .................... 2.2 11 VALVE, EXHAUST(ONE) .................... 12 (1,13,14,15) SPRING AND/OR STEM SEAL, INTAKE VALVE(ONE).......................... SPRING AND/OR STEM SEAL, EXHAUST VALVE(ONE)...................... SPRING AND/OR STEM SEAL, VALVE :FOR 1 VEHICLE ....................

14

TST 08 PC 002

2 1.8 1.8 1.9

QTY

Part Number

Description

1 2 3 4 5

12209-GB4-681 14100-KVY-900 14125-KVY-900 14126-KPH-901 14321-KVY-900

SEAL, VALVE STEM CAMSHAFT COMP. PLUNGER, CAM SETTING SPRING, PLUNGER SPROCKET, CAM (34T)

2 1 1 1 1

6 7 8 9 10

14430-KVY-900 14440-KVY-900 14451-KVY-900 14461-KVB-900 14711-KVY-900

ARM COMP., IN. VALVE ROCKER ARM COMP., EX. VALVE ROCKER SHAFT, IN. ROCKER ARM SHAFT, EX. ROCKER ARM VALVE, IN.

1 1 1 1 1

11 12 13 14 15

14721-KVY-900 14751-KVY-900 14771-GB4-680 14775-KVY-900 14781-MA6-000

VALVE, EX. SPRING, VALVE RETAINER, VALVE SPRING SEAT, VALVE SPRING COTTER, VALVE

1 2 2 2 4

16 17 18

90012-333-000 90083-GB6-911 90206-001-000

SCREW, TAPPET ADJUSTING BOLT, KNOCK, 5MM NUT, TAPPET ADJUSTING

2 2 2

06 . 05 . 2008

Notes

E-5 Cam Chain / Tensioner

2 Service item

F.R.T.

1 CHAIN, CAM ......................................... 3.3 2 TENSIONER, CAM CHAIN ................... 1.1 3 (5) LIFTER, TENSIONER ...................... 0.3 6 GUIDE, CAM CHAIN ............................. 1.5

TST 08 PC 002

No.

QTY

Part Number

Description

1 2 3 4 5

14401-KVB-901 14510-KVB-900 14520-KSS-901 14531-KVY-900 14560-KCW-851

CHAIN, CAM (90L) TENSIONER, CAM CHAIN LIFTER ASSY., TENSIONER PIVOT, CAM CHAIN TENSIONER GASKET, TENSIONER LIFTER

1 1 1 1 1

6 7 8 9 10

14611-KVB-900 90005-KY7-000 91301-GR0-004 91306-MG3-001 95701-0602200

GUIDE, CAM CHAIN SCREW, PAN, 6X6 O-RING, 15.2X1.5 O-RING, 1.5X9.5 BOLT, FLANGE, 6X22

1 1 1 1 2

06 . 05 . 2008

Notes

15

E- 6 Cylinder

Service item 1 CYLINDER............................................ 2 GASKET, CYLINDER............................

16

TST 08 PC 002

F.R.T.

No.

1.9 1.8

1 2 3

Part Number

Description

12100-KVY-900 12191-KVY-900 90701-KFM-900

CYLINDER COMP. GASKET, CYLINDER DOWEL PIN, SPECIAL, 8X14

06 . 05 . 2008

QTY 1 1 2

Notes

E-7 Right Crankcase

2 Service item

F.R.T.

No.

QTY

Part Number

Description CRANKCASE COMP., R. BUSH, ENGINE HANGER RUBBER BUSH, ENGINE HANGER RUBBER BUSH, MAINSTAND COVER, OIL PUMP GAUGE, OIL LEVEL

1 1 1 1 1 1

1 CRANKCASE :RIGHT .......................... CRANKCASE :BOTH ...........................

3.2 4.3

1 2

9 OIL SEAL, CRANKSHAFT :RIGHT ...... OIL SEAL, CRANKSHAFT :BOTH........

3 4.2

3 4 5

11100-KVY-960 11103-KVB-901 11103-KVB-930 11205-GBC-300 11361-KVY-900 15651-KVY-900

6 7 8 9 10

90031-KVB-900 90131-883-000 90702-KVB-900 91201-GCC-771 91307-035-000

BOLT A, STUD, 7X193.5 BOLT, DRAIN PLUG, 12X15 PIN, SPECIAL DOWEL, 6.3X10X12 OIL SEAL, 16X26X7 O-RING, 18X3

2 1 2 1 1

11 12 13 14 15

91307-639-000 94109-12001 95701-0602200 95701-0605500 95701-0608000

O-RING, 64X2 WASHER, DRAIN PLUG, 12MM BOLT, FLANGE, 6X22 BOLT, FLANGE, 6X55 BOLT, FLANGE, 6X80

1 1 1 3 3

16 17

95701-0608507 95701-0611500

BOLT, FLANGE, 6X85 BOLT, FLANGE, 6X115

1 1

TST 08 PC 002

06 . 05 . 2008

Notes

17

E-8 Generator

Service item

F.R.T.

1 FAN, COOLING .................................... 0.3 2 ROTOR OR FLYWHEEL ...................... 0.5 3 STATOR ................................................ 0.8

18

TST 08 PC 002

QTY

No.

Part Number

Description

1 2 3 4 5

19510-KVY-900 31110-KVY-961 31120-KVY-961 32907-KVY-900 32976-KVY-900

FAN COMP., COOLING FLYWHEEL COMP. STATOR COMP. CLIP, A.C. GENERATOR CORD CLAMPER, WIRE HARNESS

1 1 1 1 1

6 7 8 9 10

90002-KGH-901 90410-HC4-000 94050-10000 95701-0601600 96001-0601600

BOLT, FLANGE, 5X14 WASHER, 10MM NUT, FLANGE, 10MM BOLT, FLANGE, 6X16 BOLT, FLANGE, 6X16

2 1 1 3 1

11

96001-0602000

BOLT, FLANGE, 6X20

2

06 . 05 . 2008

Notes

E-9 Oil Pump

2 Service item 1 2

F.R.T.

PUMP ASSY., OIL ................................ 0.8 (3) GEAR, OIL PUMP DRIVEN ............. 0.6

TST 08 PC 002

No.

QTY

Part Number

Description

1 2 3 4 5

15100-KVB-900 15133-KVY-900 15135-KVY-900 15331-KVB-900 15332-KVB-900

PUMP ASSY., OIL GEAR, OIL PUMP DRIVEN (39T) SHAFT COMP., OIL PUMP ROTOR, OIL PUMP INNER ROTOR, OIL PUMP OUTER

1 1 1 1 1

6 7 8 9

90002-GFC-900 90702-KFM-900 93901-34120 96220-30168

BOLT, HEX., 6X30 DOWEL PIN, 8X12 SCREW, TAPPING, 4X8 ROLLER, 3X16.8

2 2 1 1

06 . 05 . 2008

Notes

19

E - 10 Starting Motor

Service item 2 3

PINION, STARTER ............................... HOLDER, STARTER DRIVE GEAR .....

0.3 0.2

6 7

MOTOR, STARTING............................. (4) BRACKET, STARTING MOTOR FRONT ................................................. SUB HARNESS, STARTER .................

0.7

8

20

F.R.T.

TST 08 PC 002

0.9 0.6

No.

QTY

Part Number

Description

1 2 3 4 5

11205-GW3-931 28120-KVB-901 28150-KVB-900 31204-KG8-004 31206-GW3-004

BUSH, 8X12X6 PINION ASSY., STARTER HOLDER COMP., STARTER PINION SPRING, CARBON BRUSH PACKING

1 1 1 2 1

6 7 8 9 10

31210-KVY-961 31213-KEE-630 32410-KVY-960 91309-KEE-630 93892-0400608

MOTOR UNIT, STARTER BRACKET COMP., FR. SUB CORD, STARTER MOTOR O-RING SCREW-WASHER, 4X6

1 1 1 1 1

11 12

93892-0501608 96001-0603500

SCREW-WASHER, 5X16 BOLT, FLANGE, 6X35

3 2

06 . 05 . 2008

Notes

E - 11 Left Crankcase Cover

2 Service item 2

F.R.T.

COVER, CRANKCASE :LEFT ..............

0.5

6 GASKET, CRANKCASE COVER :LEFT 10 (9,11,12) DUCT, BELT COVER ............ 15 BEARING, DRIVESHAFT :LEFT .......... BEARING, DRIVESHAFT :BOTH .........

0.2 0.1 0.4 1.2

16 OIL SEAL, KICK STARTER SPINDLE..

0.2

TST 08 PC 002

No.

QTY

Part Number

Description

1 2 3 4 5

11230-KVB-900 11340-KVY-960 11342-KVY-900 11343-KVG-900 11344-GW3-980

COVER, VENT HOLE COVER COMP., L. PLATE, L. COVER TUBE, DRAIN RUBBER, STARTER PINION HOLDER

1 1 1 1 1

6 7 8 9 10

11395-KVY-900 16236-KVG-900 19416-KEY-900 19741-KVY-900 19742-KVY-900

GASKET, L. COVER CLAMPER, DRAIN TUBE COLLAR DUCT, L. COVER CAP, L. COVER

1 1 2 1 1

11 12 13 14 15

19748-KVY-900 19749-KVY-900 90652-KVB-900 90702-KFM-900 91005-KVB-900

SEAL, DUCT SEAL, L. DUCT COVER CIRCLIP, INTERNAL, 32MM DOWEL PIN, 8X12 BEARING COMP., RADIAL BALL

1 1 1 2 1

16 17 18 19 20

91211-PE9-003 93903-34120 93903-34310 95002-80000 96001-0601800

OIL SEAL, 16X26X6 (ARAI) SCREW, TAPPING, 4X8 SCREW, TAPPING, 4X12 CLIP, TUBE (C12) BOLT, FLANGE, 6X18

1 5 2 1 2

21 22

96001-0603500 96001-0608500

BOLT, FLANGE, 6X35 BOLT, FLANGE, 6X85

13 1

06 . 05 . 2008

Notes

21

E - 12 Drive Face

Service item 2 5

F.R.T.

(4,6) FACE, DRIVE............................... 0.4 (3) FACE, MOVABLE DRIVE ................. 0.4

7 (1,8) ROLLER, WEIGHT ...................... 0.4 10 (9) GEAR, KICK STARTER DRIVEN...... 0.2 11 SPINDLE, KICK STARTER................... 0.4 14 (12) SPRING, KICK STARTER RETURN 0.4

22

TST 08 PC 002

No.

QTY

Part Number

Description

1 2 3 4 5

22011-GCC-770 22102-KVY-900 22105-KVY-900 22109-KVY-900 22110-KVY-900

PIECE SET, SLIDE FACE, DRIVE (66T) BOSS, DRIVE FACE RATCHET, STARTER FACE COMP., MOVABLE DRIVE

1 1 1 1 1

6 7 8 9 10

22113-KVY-900 22123-KVY-900 22131-KVY-900 28223-GCC-000 28230-KVB-900

FIN, DRIVE FACE ROLLER SET, WEIGHT PLATE, RAMP SPRING, KICK DRIVEN GEAR GEAR COMP., KICK STARTER

1 1 1 1 1

11 12 13 14 15

28250-KVB-900 28253-KVB-901 28255-GS6-000 28281-GCC-000 90412-329-000

SPINDLE COMP., KICK STARTER BUSH, KICK SPINDLE COLLAR, KICK BOSS SPRING, KICK RETURN WASHER, THRUST, 10MM

1 1 1 1 1

16 17 18 19

90426-KVB-900 90439-443-740 94030-14200 94511-16000

WASHER, SPECIAL, 14MM WASHER, 16X22 NUT, HEX., 14MM CIRCLIP, EXTERNAL, 16MM

1 1 1 1

06 . 05 . 2008

Notes

E - 13 Driven Face

2 Service item

F.R.T.

No.

1 4

OUTER, CLUTCH ................................ (2,3) WEIGHT SET, CLUTCH .............

0.3 0.6

6 7 8

BELT, DRIVE ........................................ FACE, DRIVEN .................................... (9,10,20) FACE, MOVABLE DRIVEN....

0.4 0.5 0.5

11 (12,13) SPRING, DRIVEN FACE.......... 0.5 19 (18) BEARING, DRIVEN FACE.............. 0.6

TST 08 PC 002

QTY

Part Number

Description

1 2 3 4 5

22100-KVY-900 22350-KVY-900 22401-KVY-900 22535-KVY-900 22804-148-000

OUTER COMP., CLUTCH PLATE COMP., DRIVE SPRING, CLUTCH WEIGHT SET, CLUTCH RUBBER, CLUTCH DAMPER

1 1 3 1 3

6 7 8 9 10

23100-KVY-901 23205-KVY-900 23224-KVY-900 23225-KSY-900 23226-KVB-900

BELT, DRIVE FACE SET, DRIVEN FACE SET, MOVABLE DRIVEN PIN, ROLLER GUIDE ROLLER, GUIDE

1 1 1 3 3

11 12 13 14 15

23233-GCC-000 23237-GCC-C50 23238-GCC-000 90202-KN7-670 90441-GY6-940

SPRING, DRIVEN FACE COLLAR, SEAL COLLAR, SPRING NUT, SPECIAL, 28MM WASHER, 12.2X29X2.5

1 1 1 1 1

16 17 18 19 20

90442-044-000 90454-GB2-000 91009-KVY-961 91109-KVY-901 91211-GK8-013

WASHER, THRUST, 6MM CIRCLIP, 6MM BEARING, RADIAL BALL, 6902U BEARING, NEEDLE, 20X29X18 OIL SEAL, 34X39X3

3 3 1 1 2

21 22 23 24

91351-GR1-000 91351-642-000 94030-12200 94520-28000

O-RING, 38.5X2 O-RING, PINION CAP NUT, HEX., 12MM CIRCLIP, INTERNAL, 28MM

1 1 1 1

06 . 05 . 2008

Notes

23

E - 14 Transmission

Service item

24

F.R.T.

No.

5

CASE, TRANSMISSION ......................

1.1

6 7 8 9 10

GASKET, TRANSMISSION CASE ....... SHAFT, DRIVE ..................................... COUNTERSHAFT, TRANSMISSION.... GEAR, COUNTER ................................ SHAFT, FINAL GEAR ...........................

0.8 1.1 0.8 0.8 0.8

12 BEARING, DRIVESHAFT :RIGHT ....... BEARING, DRIVESHAFT :BOTH.......... 13 BEARING, COUNTERSHAFT :RIGHT.. BEARING, COUNTERSHAFT :BOTH... 14 (16) BEARING, FINAL GEAR SHAFT :RIGHT ................................................. BEARING, FINAL GEAR SHAFT :BOTH....................................................

1.1 1.2 1 1.1

TST 08 PC 002

1 1.1

QTY

Part Number

Description

1 2 3 4 5

11108-KVB-900 11204-KGF-900 11211-KVB-900 11241-KVB-900 21200-KVB-901

PLATE, MISSION BEARING SETTING SLEEVE, RR. BRAKE CAM TUBE, BREATHER CLAMPER, BREATHER TUBE CASE COMP., MISSION

1 1 1 1 1

6 7 8 9 10

21395-KVB-900 23411-KVY-900 23421-KVB-900 23422-KVG-900 23430-KVB-900

GASKET, MISSION CASE SHAFT, DRIVE (18T) SHAFT, COUNTER (12T) GEAR, COUNTER (51T) GEAR COMP., FINAL (45T)

1 1 1 1 1

11 12 13 14 15

90702-KFM-901 91001-KE6-832 91007-KVB-902 91009-KVB-902 91201-434-003

DOWEL PIN, 8X12 BEARING, RADIAL BALL, 6204 BEARING, RADIAL BALL, 6201 BEARING, RADIAL BALL, 60/22 UU OIL SEAL, 14X20X3

2 1 1 1 2

16 17 18 19 20

91255-KVB-901 94510-20000 95002-50000 95701-0601400 95701-0603000

OIL SEAL, 29X44X7 CIRCLIP, EXTERNAL, 20MM CLIP, TUBE (C9) BOLT, FLANGE, 6X14 BOLT, FLANGE, 6X30

1 1 1 2 2

21 22

95701-0604000 96001-0601600

BOLT, FLANGE, 6X40 BOLT, FLANGE, 6X16

6 1

06 . 05 . 2008

Notes

E - 15 Left Crankcase

2 Service item

F.R.T.

2

CRANKCASE :LEFT ............................ CRANKCASE :BOTH ...........................

4.1 4.3

7 11 12 13

SCREEN, OIL FILTER ......................... BEARING, CRANKSHAFT :LEFT......... OIL SEAL, DRIVESHAFT ..................... OIL SEAL, CRANKCASE :LEFT .......... OIL SEAL, CRANKCASE :BOTH .........

0.2 3.3 1.1 3.3 3.4

17 BEARING, COUNTERSHAFT :LEFT.... BEARING, COUNTERSHAFT :BOTH... 18 BEARING, FINAL GEAR SHAFT :LEFT BEARING, FINAL GEAR SHAFT :BOTH

TST 08 PC 002

1 1.1 1 1.1

No.

QTY

Part Number

Description

2 3 4 5

11103-KVB-901 11103-KVB-930 11200-KVY-960 11203-KVB-901 11205-GBC-300 11205-GW3-981

BUSH, ENGINE HANGER RUBBER BUSH, ENGINE HANGER RUBBER CRANKCASE COMP., L. BUSH, RR. CUSHION UNDER RUBBER BUSH, MAINSTAND BUSH, 8X12X6

1 1 1 1 1 1

6 7 8 9 10

12361-035-000 15421-107-000 15426-KVB-900 90032-KVB-900 90474-333-001

CAP, TAPPET ADJUSTING HOLE SCREEN, OIL FILTER SPRING, OIL FILTER SCREEN BOLT B, STUD, 7X198.5 WASHER, SEALING, 8MM

1 1 1 2 2

11 12 13 14 15

91002-KVY-901 91202-KJ9-003 91202-KVB-901 91302-001-020 94520-52150

BEARING, RADIAL BALL, 6007 OIL SEAL, 20X32X6 OIL SEAL, 20.8X52X6X7.5 O-RING, 30.8MM CIRCLIP, INTERNAL, 52MM

1 1 1 1 1

16 17 18

95701-0801200 96100-6301000 96100-6302000

BOLT, FLANGE, 8X12 BEARING, RADIAL BALL, 6301 BEARING, RADIAL BALL, 6302

2 1 1

1

06 . 05 . 2008

Notes

25

E - 16 Crankshaft / Piston

Service item 1 3

F.R.T.

CRANKSHAFT....................................... 3.5 (2,4,5) RING, PISTON AND/OR PISTON ONE) 2

No.

Part Number

Description

1 2

4 5

13000-KVY-960 13011-KVY-900 13012-KVY-900 13013-KVY-900 13014-KVY-900 13015-KVY-900 13101-KVY-960 13102-KVY-960 13103-KVY-960 13104-KVY-960 13105-KVY-960 13111-087-000 13115-GN5-910

CRANKSHAFT COMP. RING SET, PISTON (STD) RING SET, PISTON (0,25) RING SET, PISTON (0,50) RING SET, PISTON (0,75) RING SET, PISTON (1,00) PISTON (STD) PISTON (0,25) PISTON (0,50) PISTON (0,75) PISTON (1,00) PIN, PISTON CLIP, PISTON PIN, 13MM

6

90741-KVY-900

KEY, WOODRUFF

3

26

TST 08 PC 002

06 . 05 . 2008

QTY 1 1 (1) (1) (1) (1) 1 (1) (1) (1) (1) 1 2 1

Notes

E - 17 Carburetor

2 Service item

F.R.T.

2 3 4

NEEDLE, JET ....................................... 0.8 (17) FLOAT OR FLOAT VALVE ............. 0.7 CHAMBER, FLOAT .............................. 0.6

8

BYSTARTER, AUTO ............................

0.4

11 CARBURETOR ASSEMBLY ................ 13 PISTON, VACUUM ...............................

0.7 0.3

31 (19,20) JET, MAIN ................................

0.7

TST 08 PC 002

No.

QTY

Part Number

Description

1 2 3 4 5

16010-KGF-911 16012-KVY-961 16013-KRP-981 16015-KVY-901 16016-KRP-981

GASKET SET NEEDLE SET, JET FLOAT SET CHAMBER SET, FLOAT SCREW SET A

1 1 1 1 1

6 7 8 9 10

16028-KVB-901 16037-KCW-000 16046-KVY-902 16050-KVY-901 16075-GHB-640

SCREW SET B PLATE SET, VALVE VALVE SET, STARTER SPRING, COMPRESSION COIL O-RING, 1.3X4.3

1 1 1 1 1

11 12 13 14 15

16100-KVY-961 16107-GCC-000 16111-KVB-902 16119-KVB-901 16131-ZW9-801

CARBURETOR ASSY. TOP PISTON COMP., VACUUM STAY, WIRE PLATE, SETTING

1 1 1 1 1

16 17 18 19 20

16140-GFC-901 16155-KJ9-751 16163-KGF-911 16165-KVB-901 16180-KGH-971

BODY COMP., BYSTARTER VALVE COMP., FLOAT GASKET, FLOAT CHAMBER HOLDER, NEEDLE JET JET, SLOW, #35

1 1 1 1 1

06 . 05 . 2008

Notes

27

E - 17 Carburetor

Service item

28

TST 08 PC 002

F.R.T.

QTY

No.

Part Number

Description

21 22 23 24 25

16190-GEE-003 16199-KVY-901 16423-KGH-901 93500-040081H 93500-040120H

CAP, HOLDER TUBE, AIR VENT GASKET, BYSTARTER SCREW, PAN, 4X8 SCREW, PAN, 4X12

1 1 1 2 3

26 27 28 29 30

93500-050121H 93892-0400818 93892-0501218 95002-02089 95005-4524050

SCREW, PAN, 5X12 SCREW-WASHER, 4X8 SCREW-WASHER, 5X12 CLIP, TUBE (B8) TUBE, 4.5X240

2 1 2 1 1

31

99101-KVC-1000

JET, #100

1

06 . 05 . 2008

Notes

F-1 Headlight

Service item 1 3 4

F.R.T.

HEADLIGHT UNIT ............................... SUB CORD, HEADLIGHT ................... BULB, HEADLIGHT .............................

TST 08 PC 002

0.3 0.2 0.2

No.

QTY

Part Number

Description

1 2 3 4 5

33110-KVY-961 33115-KBA-830 33130-KVY-961 34901-KPH-881 34908-GA7-701

HEADLIGHT UNIT NUT, ADJUST SOCKET COMP., HEADLIGHT BULB, HEADLIGHT (12V 32/32W) BULB, WEDGE BASE (T10)

1 1 1 1 1

6 7

53209-GAH-000 90101-GJ6-000

CLIP, HEADLIGHT BOLT, ADJUSTING

2 1

06 . 05 . 2008

3

Notes

29

F-2 Speedometer

3

Service item

F.R.T.

No.

Description BULB, WEDGE BASE (T10) BULB, WEDGE BASE (T10) BULB, WEDGE BASE (T10) BULB, WEDGE BASE (12V 1.7W) SPEEDOMETER ASSY. SPEEDOMETER COMP. LENS

1 1 3 3

3 4 5

METER ASSY., COMBINATION ........... METER, COMBINATION ...................... LENS, METER .....................................

0.5 0.6 0.5

1

6 7 9

CASE, METER ..................................... SOCKET ASSY., METER BULB .......... RELAY, WINKER ..................................

0.6 0.6 0.2

3 4 5

34908-GA7-701 34909-KVR-600 34908-KVE-900 34908-MB9-871 37200-KVY-960 37210-KVY-961 37211-KVY-961

11 CABLE, SPEEDOMETER ....................

0.4

6 7 8 9 10

37212-KVY-961 37224-KVY-961 37305-KE5-008 38301-KEV-950 38306-KK4-000

CASE ASSY. SOCKET COMP. SCREW-WASHER, 3X22 RELAY COMP., WINKER SUSPENSION, WINKER RELAY

1 1 3 1 1

11 12 13 14

44830-KVY-910 90035-166-008 90101-KY6-008 91352-671-003 91352-671-004 93903-25310

CABLE COMP., SPEEDOMETER SCREW-WASHER, SPECIAL, 4X10 SCREW, TAPPING, 3X14 O-RING, 8.5X1.5 O-RING, 8.5X1.5 SCREW, TAPPING, 5X16

1 2 2 1 1 3

2

15

30

QTY

Part Number

TST 08 PC 002

06 . 05 . 2008

1 1

Notes

F-3 Handle Lever/ Mirror/ Cable

Service item

F.R.T.

No.

CABLE, THROTTLE.............................. SWITCH, LIGHTING............................. SWITCH, STARTER ............................. SWITCH, DIMMER ...............................

1 0.3 0.3 0.3

6 SWITCH, HORN ................................... 7 SWITCH, WINKER ................................ 8 SWITCH, REAR STOP :LEVER SIDE... SWITCH, STOP :BOTH ........................ 9 CABLE, REAR BRAKE .........................

0.3 0.3 0.3 0.4 1

11 GRIP, THROTTLE ................................. 12 GRIP, HANDLE :LEFT .......................... 15 LEVER, HANDLE :LEFT ....................... LEVER, HANDLE :BOTH ......................

0.5 0.1 0.2 0.3

1 3 4 5

16 LEVER, PARKING LOCK ...................... 0.2

TST 08 PC 002

QTY

Part Number

Description

1 2 3 4 5

17910-KVG-900 30158-GW3-980 35150-KPH-880 35160-KPH-881 35170-KVB-851

CABLE COMP., THROTTLE E-RING, 3MM SWITCH UNIT, LIGHTING SWITCH UNIT, STARTING SWITCH UNIT, DIMMER

1 1 1 1 1

6 7 8 9 10

35180-KPH-881 35200-KVB-851 35340-KPH-901 43450-KVY-900 43455-KVB-900

SWITCH UNIT, HORN SWITCH UNIT, WINKER SWITCH ASSY., FR. STOP CABLE COMP., RR. BRAKE CLAMPER, RR. BRAKE CABLE

1 1 1 1 1

11 12 13 14 15

53140-KVB-900 53166-KVB-900 53167-KFM-900 53168-KFM-900 53178-KVB-900

GRIP COMP., THROTTLE GRIP, L. HANDLE HOUSING, UPPER THROTTLE HOUSING, UNDER THROTTLE LEVER, L. STEERING HANDLE

1 1 1 1 1

16 17 18 19 20

53181-KVB-900 53182-KVB-900 53183-KVB-900 88114-KVB-900 88110-KVY-960

LEVER COMP., BRAKE LOCK SPRING, RETURN LEVER PIN, PARKING LEVER PIVOT CAP, LOCK NUT MIRROR ASSY, R. BACK

1 1 1 2 1

06 . 05 . 2008

3

Notes

31

F-3 Handle Lever/ Mirror/ Cable

3

Service item

32

TST 08 PC 002

F.R.T.

No.

Part Number

Description

21 22 23 24 25

88120-KVY-960 90115-KRS-690 90302-435-761 90314-KVR-600 93500-050250B

MIRROR ASSY, L.BACK BOLT, HANDLE LEVER PIVOT NUT, HEX., 5MM NUT, LOCK SCREW, PAN, 5X25

06 . 05 . 2008

QTY 1 1 1 2 1

Notes

F-4 Fr. Brake Master Cylinder

Service item 1

F.R.T.

SWITCH, FRONT STOP ...................... SWITCH, STOP :BOTH ....................... HOSE, FRONT BRAKE ........................

0.2 0.4 0.7

6 CYLINDER, FRONT BRAKE MASTER 10 DIAPHRAGM, FRONT BRAKE MASTER CYLINDER ...........................

0.6

2

0.1

12 PISTON SET, FRONT BRAKE MASTER 0.6 13 LEVER, HANDLE :RIGHT .................... 0.2 LEVER, HANDLE :BOTH ..................... 0.3

TST 08 PC 002

No.

QTY

Part Number

Description

1 2 3 4 5

35340-KGH-901 45126-KVY-911 45156-KVB-850 45157-KVY-910 45504-410-003

SWITCH ASSY., FR. STOP HOSE COMP., FR. BRAKE CLAMPER, BRAKE HOSE CLAMPER B, BRAKE HOSE BOOT COMP.

1 1 1 1 1

6 7 8 9 10

45510-KVY-911 45512-MA6-006 45513-GW0-911 45517-GW0-751 45520-GW0-912

CYLINDER SUB ASSY., FR. BRAKE PROTECTOR CAP, MASTER CYLINDER HOLDER, MASTER CYLINDER DIAPHRAGM

1 1 1 1 1

11 12 13 14 15

45521-GW0-911 45530-KVY-911 53175-KRS-T80 90114-KGH-900 90145-KPH-B30

PLATE, DIAPHRAGM CYLINDER SET, MASTER LEVER, R. STEERING HANDLE BOLT, HANDLE LEVER PIVOT BOLT, OIL, 10X22

1 1 1 1 2

16 17 18 19 20

90545-300-000 90651-MA5-671 93600-040121G 93893-0401217 94050-06000

WASHER, OIL BOLT CIRCLIP SCREW, FLAT, 4X12 SCREW-WASHER, 4X12 NUT, FLANGE, 6MM

4 1 2 1 1

21 22

95701-0601200 95701-0602201

BOLT, FLANGE, 6X12 BOLT, FLANGE, 6X22

2 2

06 . 05 . 2008

3

Notes

33

F-5 Handle Pipe / Handle Cover

3

Service item 1 2 3

34

F.R.T.

PIPE, STEERING HANDLE.................. COVER, HANDLE :FRONT................... COVER, HANDLE :BOTH..................... COVER, HANDLE :REAR..................... COVER, HANDLE :BOTH.....................

TST 08 PC 002

0.7 0.2 0.6 0.6 0.6

No.

Part Number

Description

1 2

53100-KVY-960 53205-KVY-910FMB

3 4 5

53205-KVY-910PFW 53205-KVY-910ABM 53205-KVY-910CSR 53205-KVY-910PPM 53205-KVY-910CBO 53206-KVY-960 90106-GN5-900 90304-KGH-901

PIPE COMP., STEERING HANDLE COVER, FR. HANDLE (DISK) *NH1*................... BLACK *NH-341P*........... PEARL FADELESS WHITE *B-201M*.............. ASSURE BLUE METALLIC *R-333C* ............. CANDY SCARLET RED *RP-178M* .......... POWDER PINK METALLIC *YR-294C* ........... CANDY BLITZ ORANGE COVER, RR. HANDLE BOLT, FLANGE, 10X50 NUT, U, 10MM

6 7 8 9

90501-KPH-880 90505-KPH-880 93903-34380 93903-35380

COLLAR A, HANDLE SETTING COLLAR B, HANDLE SETTING SCREW, TAPPING, 4X12 SCREW, TAPPING, 5X16

06 . 05 . 2008

QTY

Notes

1 1 (1) (1) (1) (1) (1) 1 1 1 1 1 6 1

BLACK WHITE BLUE RED PINK ORANGE

F-6

Steering Stem

Service item 1 3

F.R.T.

No.

Part Number

Description

QTY

PIPE, STEERING HANDLE.................. RACE, STEERING BALL :UPPER ...... RACE, STEERING BALL :BOTH ......... RACE, STEERING BALL :LOWER ...... RACE, STEERING BALL :BOTH .........

0.7 1.1 1.1 1.1 1.1

1 2 3 4 5

06530-GBG-B20 06531-GBG-B20 50301-KPH-720 50302-KPH-720 50306-GN5-901

BALL SET, STEEL, #6X23 BALL SET, STEEL, #6X29 RACE, STEERING TOP BALL RACE, STEERING BOTTOM BALL NUT, STEERING STEM LOCK

1 1 1 1 1

RACE, STEERING TOP CONE ........... (8,9) RACE, STEERING BOTTOM CONE ...................................

0.7 1.3

11 STEM OR SHAFT ASSY., STEERING.. 12 THREAD, STEERING HEAD TOP .......

1.1 0.7

6 7 8 9 10

53211-KPH-720 53212-KPH-720 53214-GN5-900 53215-GN5-900 53216-GN5-830

RACE, STEERING TOP CONE RACE, STEERING BOTTOM CONE DUST SEAL, STEERING HEAD WASHER, STEERING HEAD DUST WASHER, STEERING STEM NUT

1 1 1 1 1

11 12 13

53219-KVY-960 53220-GN5-900 95801-1004008

STEM SUB ASSY., STEERING THREAD COMP., STEERING HEAD BOLT, FLANGE, 10X40

1 1 4

4 6 7

TST 08 PC 002

06 . 05 . 2008

3

Notes

35

F-7 Front Fender

3

Service item 1

36

FENDER, FRONT ................................

TST 08 PC 002

F.R.T.

No.

0.2

Part Number

Description

1

61100-KVY-960FMB

2 3

61100-KVY-960PFW 61100-KVY-960ABM 61100-KVY-960CSR 61100-KVY-960PPM 61100-KVY-960CBO 61112-KVG-900 95701-0601600

FENDER, FR. *NH1*................... BLACK *NH-341P*........... PEARL FADELESS WHITE *B-201M*.............. ASSURE BLUE METALLIC *R-333C* ............. CANDY SCARLET RED *RP-178M* .......... POWDER PINK METALLIC *YR-294C* ........... CANDY BLITZ ORANGE COLLAR, FR. FENDER BOLT, FLANGE, 6X16

06 . 05 . 2008

QTY

1 (1) (1) (1) (1) (1) 4 4

Notes

BLACK WHITE BLUE RED PINK ORANGE

F-8 Front Cover

Service item 1 4

F.R.T.

COVER, FRONT .................................. PANEL, INNER :UPPER ...................... PANEL, INNER :BOTH ........................

TST 08 PC 002

0.4 0.3 0.9

No.

QTY

Notes

1 (1) (1) (1) (1) (1)

BLACK WHITE BLUE RED PINK ORANGE

Part Number

Description

64301-KVY-960FMB 64301-KVY-960PFW 64301-KVY-960ABM 64301-KVY-960CSR 64301-KVY-960PPM 64301-KVY-960CBO

COVER, FR. (WL) *NH1*................... *NH-341P*........... *B-201M*.............. *R-333C* ............. *RP-178M* .......... *YR-294C* ...........

2 3 4 5

64510-KEV-900 81110-KVB-930 81131-KVY-900 81132-GAH-000

CUSHION, FR. TOP COVER BRACKET, FR. NUMBER PLATE COVER, INNER UPPER HOOK, LUGGAGE

2 1 1 1

6 7 8 9

90107-KVB-900 90302-GW3-980 93903-34380 95701-0603200

BOLT, SPECIAL, 6MM NUT, SPRING, 4MM SCREW, TAPPING, 4X12 BOLT, FLANGE, 6X32

1 4 8 2

1

06 . 05 . 2008

BLACK PEARL FADELESS WHITE ASSURE BLUE METALLIC CANDY SCARLET RED POWDER PINK METALLIC CANDY BLITZ ORANGE

3

37

F-9 Floor Panel

3

Service item 1 2 3 4

38

F.R.T.

STEP, FLOOR ..................................... COVER, UNDER ................................. COVER, FRONT LOWER ................... PANEL, INNER :LOWER ..................... PANEL, INNER :BOTH ........................

TST 08 PC 002

0.9 0.2 0.3 0.9 0.9

No.

QTY

Part Number

Description

1 2 3 4 5

64310-KVY-900 64340-KVY-960 64520-KVY-900 81141-KVY-960 90302-GW3-980

STEP, FLOOR COVER, UNDER COVER, FR. LOWER COVER, INNER LOWER NUT, SPRING, 4MM

1 1 1 1 4

6 7 8 9

90677-KAN-T00 93894-0501607 93903-34380 93903-34480

NUT, CLIP, 5MM SCREW-WASHER, 5X16 SCREW, TAPPING, 4X12 SCREW, TAPPING, 4X16

6 6 6 2

06 . 05 . 2008

Notes

F - 10 Body Cover

Service item 2 3 4

F.R.T.

COVER, BODY :CENTER.................... COVER, BODY :RIGHT........................ COVER, BODY :BOTH......................... (1) COVER, BODY :LEFT .................... COVER, BODY :BOTH.........................

TST 08 PC 002

0.2 0.4 0.4 0.4 0.4

No. 1 2 3

QTY

Part Number

Description

80102-KVY-960 80151-KVY-900 83500-KVY-960FMB

COVER, RR. CUSHION COVER, CENTER COVER , R. BODY (WL) *NH1*................... BLACK *NH-341P*........... PEARL FADELESS WHITE *B-201M*.............. ASSURE BLUE METALLIC *R-333C* ............. CANDY SCARLET RED *RP-178M* .......... POWDER PINK METALLIC *YR-294C* ........... CANDY BLITZ ORANGE

1 (1) (1) (1) (1) (1)

BLACK WHITE BLUE RED PINK ORANGE

1 (1) (1) (1) (1) (1) 1

BLACK WHITE BLUE RED PINK ORANGE

83500-KVY-960PFW 83500-KVY-960ABM 83500-KVY-960CSR 83500-KVY-960PPM 83500-KVY-960CBO 4

83600-KVY-960FMB

5

83600-KVY-960PFW 83600-KVY-960ABM 83600-KVY-960CSR 83600-KVY-960PPM 83600-KVY-960CBO 90107-GFC-900

COVER, L. BODY (WL) *NH1*................... BLACK *NH-341P*........... PEARL FADELESS WHITE *B-201M*.............. ASSURE BLUE METALLIC *R-333C* ............. CANDY SCARLET RED *RP-178M* .......... POWDER PINK METALLIC *YR-294C* ........... CANDY BLITZ ORANGE BOLT, SPECIAL, 6MM

6 7 8

91509-GE2-760 93903-24481 93903-34380

SCREW, PAN, 5X11.5 SCREW, TAPPING, 4X16 SCREW, TAPPING, 4X12

06 . 05 . 2008

3

Notes

1 1

2 2 7

39

F - 11 Front Fork

3

Service item

40

F.R.T.

1

FORK ASSY., FRONT :RIGHT.............. FORK ASSY., FRONT :BOTH...............

0.4 0.5

2

SPRING, FRONT FORK :LEFT............. SPRING, FRONT FORK :RIGHT........... SPRING, FRONT FORK :BOTH...........

0.6 0.6 0.9

3

PIPE, FRONT FORK :LEFT................... PIPE, FRONT FORK :RIGHT................ PIPE, FRONT FORK :BOTH.................

0.7 0.7 1.2

5

CASE, BOTTOM :RIGHT....................... 0.8 CASE, BOTTOM :BOTH........................ 1.4

12 SEAL SET, FRONT FORK :LEFT.......... SEAL SET, FRONT FORK :RIGHT........ SEAL SET, FRONT FORK :BOTH........

0.8 0.8 1.4

13 FORK ASSY., FRONT :LEFT................. FORK ASSY., FRONT :BOTH...............

0.4 0.5

14 CASE, BOTTOM :LEFT......................... CASE, BOTTOM :BOTH.......................

0.8 1.4

TST 08 PC 002

No.

QTY

Part Number

Description

1 2 3 4 5

51400-KVY-871 51401-KVB-901 51410-KVB-901 51412-GN5-901 51420-KVY-871

FORK ASSY., R. FR. SPRING, FR. FORK PIPE COMP., FR. FORK SPRING, REBOUND CASE, R. FR. BOTTOM

1 2 2 2 1

6 7 8 9 10

51425-GN5-901 51437-KGH-901 51454-KEV-881 51456-KPH-901 51466-065-901

DUST SEAL RING, PISTON SEAT B, SPRING RING, STOPPER RING, OIL SEAL STOPPER

2 2 2 2 2

11 12 13 14 15

51470-KVY-901 51490-KGH-901 51500-KVY-871 51520-KVY-871 90116-KV3-701

PIPE, SEAT SEAL SET, FR. FORK FORK ASSY., L. FR. CASE, L. FR. BOTTOM BOLT, SOCKET, 8MM

2 2 1 1 2

16 17

90544-283-000 91356-GM0-003

WASHER, SPECIAL, 8MM O-RING

2 2

06 . 05 . 2008

Notes

F - 12 Front Brake Caliper

Service item 2

F.R.T.

SHOE(PAD) SET, BRAKE :FRONT......

0.1

6 (1) PISTON, FRONT BRAKE CALIPER 10 CALIPER, FRONT BRAKE :LEFT........

0.5 0.4

11 BRACKET, FRONT CALIPER..............

0.2

TST 08 PC 002

No.

QTY

Part Number

Description

1 2 3 4 5

06451-MA7-405 06455-KVY-911 43352-568-003 43353-461-771 45108-KVY-911

SEAL SET, PISTON PAD SET, FR. SCREW, BLEEDER CAP, BLEEDER SPRING, PAD

1 1 1 1 1

6 7 8 9 10

45118-MN8-701 45131-GZ0-006 45132-166-016 45133-MA3-006 45150-KVY-911

PISTON (B) BOLT, PIN BOOT, PIN BUSH BOOT B CALIPER SUB ASSY., L. FR.

1 1 1 1 1

11 12 13 14 15

45190-KVY-911 45203-MG3-016 45215-KVY-911 45216-166-006 90131-KPH-880

BRACKET SUB ASSY., FR. CALIPER PLUG, PIN PIN, HANGER WASHER, WAVE BOLT, TORX, 8X25

1 1 1 1 2

06 . 05 . 2008

3

Notes

41

F - 13 Front Wheel

3

Service item 1 4 5

F.R.T.

AXLE, FRONT WHEEL......................... FRONT WHEEL.................................... FRONT TIRE(ONE)...............................

0.2 0.8 0.7

6 TUBE, FRONT TIRE(ONE)................... 7 GEARBOX ASSY., SPEEDOMETER.... 10 DISC, FRONT BRAKE..........................

0.7 0.2 0.3

13 (3) BEARING, FRONT WHEEL(ONE).... 0.4

42

TST 08 PC 002

No.

QTY

Part Number

Description

1 2 3 4 5

44301-GN5-900 44311-KVB-910 44620-KVB-910 44601-KVB-912 44711-KVB-930

AXLE, FR. WHEEL COLLAR, FR. WHEEL SIDE COLLAR, FR. DISTANCE WHEEL SUB ASSY., FR. *NH303M* TIRE, FR. (80/90 - 14M/C 40P)

1 1 1 1 1

6 7 8 9 10

27514-300140000 44800-KVB-910 44806-KVB-911 44809-KFM-900 45351-KVY-961

TUBE, TIRE BOX ASSY., SPEEDOMETER GEAR GEAR, SPEEDOMETER (21T) WASHER, SPEEDOMETER GEAR DISK, FR. BRAKE

1 1 1 1 1

11 12 13 14 15

90105-KGH-900 90306-KGH-901 91052-KVB-901 91251-KPH-901 91258-KM1-004

BOLT, BRAKE DISK, 8X24 NUT, U, 12MM BEARING, RADIAL BALL, 6201(U) DUST SEAL, 21X37X7 SEAL, SPEEDOMETER GEAR BOX

4 1 2 1 1

06 . 05 . 2008

Notes

F - 14 Rear Wheel

Service item

F.R.T.

1 2 3 4

SHOE(PAD) SET, BRAKE :REAR......... REAR WHEEL ...................................... REAR TIRE(ONE) ................................ CAM, BRAKE :REAR ...........................

0.4 0.8 0.8 0.5

6 8

ARM, BRAKE :REAR ........................... TUBE, REAR TIRE(ONE) .....................

0.5 0.8

TST 08 PC 002

No.

QTY

Part Number

Description

1 2 3 4 5

43130-KVB-901 42601-KVG-912 42711-KVB-930 43141-KVB-900 43151-329-000

SHOE SET, BRAKE WHEEL COMP., RR. *NH303M* TIRE, RR. CAM, RR. BRAKE SPRING, BRAKE SHOE

1 1 1 1 2

6 7 8 9 10

43410-KVB-900 43472-KVB-900 27514-300140000 90112-KVB-900 90305-KVB-901

ARM, RR. BRAKE SPRING, RR. BRAKE ARM TUBE, TIRE BOLT, FLANGE, 6X32 NUT, U, 16MM

1 1 1 1 1

11 12 13

90501-KBN-900 95015-32001 95015-42000

WASHER, 16MM JOINT B, BRAKE ARM NUT B, BRAKE ROD ADJUSTING

1 1 1

06 . 05 . 2008

3

Notes

43

F - 15 Seat / Luggage Box

3

Service item

44

F.R.T.

1 3

RAIL, GRAB :REAR ............................. 0.1 (5) SEAT :DOUBLE ............................... 0.2

6 9

CATCH, SEAT :REAR SIDE ................ KEY, SEAT LOCK ................................

0.5 0.3

11 BOX, LUGGAGE .................................. 12 LID, LUGGAGE BOX ...........................

0.2 0.1

TST 08 PC 002

No.

QTY

Part Number

Description

1 2 3 4 5

50400-KVY-900 75581-GN8-920 77200-KVY-960 77214-KPH-900 77215-KVY-900

RAIL, RR. GRAB SPRING, LOCK KEY SETTING SEAT COMP., DOUBLE RUBBER B, SEAT SETTING PIN, SEAT HINGE

1 1 1 2 1

6 7 8 9 10

77230-KVY-900 77234-GN2-000 77236-KVY-900 77240-KTM-851 80107-KVY-900

CATCH COMP., SEAT SPRING, SEAT LOCK WASHER, SEAT LOCK LOCK ASSY., SEAT GUARD, HEAT

1 1 1 1 1

11 12 13 14 15

81250-KVY-960 81251-KVY-900 81252-KVY-900 81253-KVY-900 81254-KVY-960

BOX, LUGGAGE COVER, LUGGAGE BOX CAP, LUGGAGE BOX CUSHION, C.D.I. UNIT CAP, LUGGAGE SIDE

1 1 1 1 1

16 17 18 19 20

81256-KVY-960 90302-GW3-980 90501-KVY-900 90683-GAZ-003 93404-0601000

COVER ASSY., BATTERY NUT, SPRING, 4MM COLLAR, LUGGAGE SET CLIP, TRIM BOLT-WASHER, 6X10

1 3 2 1 2

06 . 05 . 2008

Notes

F - 15 Seat / Luggage Box

Service item

TST 08 PC 002

F.R.T.

No.

Part Number

Description

21 22 23 24 25

93404-0602000 95701-0802001 96001-0601201 98200-31000 98200-31500

BOLT-WASHER, 6X20 BOLT, FLANGE, 8X20 BOLT, FLANGE, 6X12 FUSE, BLADE (10A) FUSE, BLADE (15A)

06 . 05 . 2008

QTY

3

Notes

2 4 2 1 1

45

F - 16 Fuel Tank

3

Service item 1 2 4

46

F.R.T.

COCK, FUEL AUTO ............................. SCREEN, FUEL STRAINER ................ TANK, FUEL .........................................

0.5 0.5 0.6

10 FUEL TANK SENDING UNIT ...............

0.2

TST 08 PC 002

No.

QTY

Part Number

Description

1 2 3 4 5

16950-KJ9-752 16952-KJ9-752 16958-397-771 17510-KVY-960 17525-KVY-900

COCK ASSY., FUEL AUTO SCREEN SET, FUEL STRAINER O-RING TANK COMP., FUEL TRAY, FUEL

1 1 1 1 1

6 7 8 9 10

17620-KGH-600 17630-KVY-960 17631-KEV-900 17635-KVY-900 37800-KVY-960

CAP, FUEL FILLER TUBE, FUEL PACKING, FUEL FILLER CAP TUBE, PRESSURE FUEL UNIT

1 1 1 1 1

11 12 13 14 15

37801-GA7-700 37802-KTL-740 95002-02070 95002-02080 95701-0601200

PACKING, BASE RETAINER, FUEL UNIT CLIP, TUBE (B7) CLIP, TUBE (B8) BOLT, FLANGE, 6X12

1 1 2 2 2

06 . 05 . 2008

Notes

F - 17 Air Cleaner

Service item

F.R.T.

No.

2

ELEMENT, AIR CLEANER ...................

0.2

6 7

CASE, AIR CLEANER ......................... (10) COVER, AIR CLEANER CASE .....

0.6 0.2

11 TUBE, AIR CLEANER CONNECTING.. 16 ELEMENT, SUB AIR CLEANER ..........

0.6 0.2

TST 08 PC 002

QTY

Part Number

Description

1 2 3 4 5

15771-551-000 17210-KVY-960 17212-KVY-900 17213-KVY-900 17218-KVY-900

CLIP, OIL DRAIN TUBE ELEMENT COMP., AIR CLEANER SEAL A, AIR CLEANER SEAL B, AIR CLEANER TUBE, BREATHER

2 1 2 1 1

6 7 8 9 10

17225-KVY-960 17235-KVY-900 17236-KVB-900 17244-KVY-900 17251-KVY-960

CASE SUB ASSY., AIR CLEANER COVER SUB ASSY., AIR CLEANER PLUG, AIR CLEANER DRAIN RUBBER, AIR SUCTION VALVE DUCT, AIR CLEANER INTAKE

1 1 1 1 1

11 12 13 14 15

17253-KVY-900 17254-KVY-900 17261-KVY-900 17274-KVB-900 17370-419-700

TUBE, AIR CLEANER CONNECTING BAND, CONNECTING TUBE (50) TUBE, AIR CLEANER DRAIN TUBE, AIR OPENING PLUG, BREATHER TUBE

1 1 1 1 1

16 17 18 19 20

18805-KVY-900 64531-KFM-900 87509-KVB-930 93903-25510 95002-02130

ELEMENT, AIR CLEANER (ASV) COLLAR, BODY COVER LABEL, AIR CLEANER CASE COVER SCREW, TAPPING, 5X25 CLIP, TUBE (B12.5)

1 3 1 6 2

21 22 23

95002-4120008 95002-80000 95701-0602500

CLAMP, TUBE (D12) CLIP, TUBE (C12) BOLT, FLANGE, 6X25

2 1 3

06 . 05 . 2008

3

Notes

47

F - 17 - 1 Air Suction Valve

3

Service item 3 4

48

F.R.T.

VALVE, SECONDARY AIR CONTROL. (5) PIPE, SECONDARY AIR.................

TST 08 PC 002

0.5 0.2

No.

QTY

Part Number

Description

1 2 3 4 5

17240-KVY-900 17622-GB7-900 18600-KVB-901 18640-KVY-900 18645-KVY-900

STAY, AIR SUCTION VALVE RUBBER, CUSHION VALVE ASSY., AIR SUCTION PIPE COMP., AIR FEED GASKET, AIR FEED PIPE

1 2 1 1 1

6 7 8 9 10

18652-KVY-900 18655-KVY-900 19509-KVB-900 90501-124-000 90678-MN5-000

HOSE (AI) TUBE, AIR SUCTION VALVE (PB) CLAMP, TUBE (D19) WASHER, FR. COVER SETTING CLIP, FUEL HOSE

1 1 1 2 1

11 12 13 14 15

93404-0603000 94050-06001 95002-02070 95701-0601200 95701-0601800

BOLT-WASHER, 6X30 NUT, FLANGE, 6MM CLIP, TUBE (B7) BOLT, FLANGE, 6X12 BOLT, FLANGE, 6X18

2 2 2 2 3

06 . 05 . 2008

Notes

F - 18 Exhaust Muffler

Service item 1 3 5

F.R.T.

GASKET, EXHAUST PIPE ................... MUFFLER ............................................ PROTECTOR, MUFFLER ....................

TST 08 PC 002

0.2 0.2 0.1

No.

QTY

Part Number

Description

1 2 3 4 5

18291-KVB-900 18293-KSB-900 18310-KVY-960 18316-KVB-900 18318-KVY-900

GASKET, EX. PIPE RUBBER, PROTECTOR PACKING MUFFLER COMP., EX. COLLAR, MUFFLER PROTECTOR PROTECTOR A, MUFFLER

1 2 1 2 1

6 7 8 9

90202-ZV0-001 95701-1004007 95801-0601602 18300-KVY-960

NUT, CAP, 6MM BOLT, FLANGE, 10X40 BOLT, FLANGE, 6X16 MUFFLER ASSY, EXHAUST

2 2 2 1

06 . 05 . 2008

3

Notes

49

F - 19 Stand / Kick Arm

3

Service item 1 2 3 5

F.R.T.

ARM, KICK STARTER ......................... SWITCH, SIDE STAND ....................... (4) STAND, MAIN .................................. SPRING, MAIN STAND .......................

6 BAR, SIDE STAND .............................. 15 SPRING, SIDE STAND ........................

50

TST 08 PC 002

0.1 0.7 0.4 0.2 0.2 0.1

No.

QTY

Part Number

Description

1 2 3 4 5

28300-KVB-900 35700-KVY-900 50500-KVY-870 50503-KVY-900 50520-KVB-900

ARM ASSY., KICK STARTER SWITCH ASSY., SIDE STAND STAND COMP., MAIN SHAFT, MAIN STAND SPRING, MAIN STAND

1 1 1 1 1

6 7 8 9 10

50530-KVY-870 61101-KCJ-690 90101-KVY-900 90108-MK6-670 90147-KVY-900

BAR COMP., SIDE STAND COLLAR, FR. FENDER SETTING BOLT, SETTING, 6X16 BOLT, SIDE STAND PIVOT BOLT, SWITCH SETTING

1 1 1 1 1

11 12 13 14 15

90203-KVB-900 94101-10800 94201-30201 95011-61000 95014-72102

NUT, SIDE STAND WASHER, PLAIN, 10MM PIN, SPLIT, 3.0X20 RUBBER A, STAND STOPPER SPRING A, SIDE STAND

1 1 1 1 1

16

95701-0802500

BOLT, FLANGE, 8X25

1

06 . 05 . 2008

Notes

F - 20 Rear Cushion

Service item 1

F.R.T.

CUSHION ASSY., REAR .....................

TST 08 PC 002

0.4

No. 1 2 3 4 5

Part Number

Description

52400-KVB-941 52485-088-901 52486-GA7-003 95801-0803200 95801-1003500

CUSHION ASSY., RR. BUSH, RR. CUSHION RUBBER COLLAR, RUBBER BUSH BOLT, FLANGE, 8X32 BOLT, FLANGE, 10X35

06 . 05 . 2008

QTY

3

Notes

1 1 1 1 1

51

F - 21 Rear Fender

3

Service item 2

52

FENDER, REAR ..................................

TST 08 PC 002

F.R.T. 0.5

No. 1 2 3 4

Part Number 80104-KVY-870 80110-KVY-960 90677-KAN-T00 93404-0601200

Description GUARD, SPLASH FENDER, RR. NUT, CLIP, 5MM BOLT-WASHER, 6X12

06 . 05 . 2008

QTY 1 2 3

Notes

F - 22 Front Winker

Service item 2 5 6

F.R.T.

(1,3) BASE, WINKER :RIGHT FRONT BASE, WINKER :BOTH FRONT........... (3,4) BASE, WINKER :LEFT FRONT... BASE, WINKER :BOTH FRONT...........

0.2 0.3 0.2 0.3

BULB, WINKER :FRONT...................... BULB, WINKER :FOR 1 VEHICLE.......

0.2 0.3

TST 08 PC 002

No.

QTY

Part Number

Description

1 2 3 4 5

33402-KVY-961 33403-KVY-961 33404-KVY-961 33452-KVY-961 33453-KVY-961

LENS, R. FR. WINKER BASE, R. FR. WINKER SEAL, GASKET LENS, L. FR. WINKER BASE, L. FR. WINKER

1 1 2 1 1

6 7 8 9

34905-KAN-W01 93903-34320 33400-KVY-961 33450-KVY-961

BULB, WINKER (12V 10W) SCREW, TAPPING, 4X12 WINKER ASSY, R FR WINKER ASSY, L FR

2 6 1 1

06 . 05 . 2008

3

Notes

53

F - 23 Combination Light

3

Service item 1 4

TAILLIGHT UNIT .................................. BASE, TAILLIGHT.................................

0.4 0.5

7

(3,6) BULB, WINKER :REAR............... BULB, WINKER :FOR 1 VEHICLE....... (2,5) BULB, TAILLIGHT........................

0.1 0.3 0.1

8

54

F.R.T.

TST 08 PC 002

No.

QTY

Part Number

Description

1 2 3 4 5

33700-KVY-961 33701-KVY-961 33702-KVY-961 33704-KVY-961 33705-KVY-961

LIGHT ASSY., RR. COMBINATION LENS COMP., TAILLIGHT LENS, R. WINKER BASE COMP., TAILLIGHT PACKING 1.

1 1 1 1 1

6 7 8 9 10

33752-KVY-961 34905-KAN-W01 34906-GB6-921 90302-GW3-980 93901-24580

LENS, L. WINKER BULB, WINKER (12V 10W) BULB, TAILLIGHT (12V 18/5W) NUT, SPRING, 4MM SCREW, TAPPING, 4X20

1 2 1 2 2

11 12

93903-34380 95701-0601200

SCREW, TAPPING, 4X12 BOLT, FLANGE, 6X12

2 2

06 . 05 . 2008

Notes

F - 24 Battery

Service item 1

BATTERY .............................................

TST 08 PC 002

F.R.T.

No.

0.2

1

Part Number

Description

31500-KPH-881

BATTERY

06 . 05 . 2008

QTY

3

Notes

1

55

F - 25 Wire Harness

3

Service item 1 2 4 5

IGNITION CONTROL MODULE .......... COIL, IGNITION.................................... RECTIFIER, REGULATE...................... HARNESS, WIRE..................................

0.3 0.6 0.5 1

7 8

KEY SET................................................ KEY, SHUTTER..................................... .EXCLUDES: Key cutting SWITCH, COMBINATION & LOCK ......

1.5 1

11 HORN(S) .............................................. 13 RELAY, STARTER ................................

0.2 0.2

9

56

F.R.T.

TST 08 PC 002

1.1

No.

QTY

Part Number

Description

1 2 3 4 5

30410-KVY-961 30500-KVY-901 30700-KVY-960 31600-KVB-901 32100-KVY-960

C.D.I. UNIT COIL ASSY., IGNITION CAP ASSY., NOISE SUPPRESSOR RECTIFIER COMP., REGULATOR HARNESS, WIRE

1 1 1 1 1

6 7 8 9 10

33714-KL3-620 35010-KVY-960 35011-KVY-900 35100-KVY-961 35121-KVY-900

RUBBER, TAILLIGHT BRACKET KEY SET SHUTTER SET, KEY SWITCH ASSY., COMBINATION & KEY, BLANK (90KEYTOP2REPORDER)

2 1 1 1 1

11 12 13 14 15

38110-KTM-851 38117-KPH-880 38501-KPH-901 38501-KVB-901 90106-KPH-690 90164-028-000

HORN COMP.(HIGH) COLLAR, HORN SETTING RELAY COMP., STARTER RELAY COMP., STARTER BOLT, SOCKET, 6X10 SCREW, U-LOCK FLAT, 6X12

1 1 1 1 1 2

16 17 18 19

95701-0601200 95701-0602000 98200-31000 98200-31500

BOLT, FLANGE, 6X12 BOLT, FLANGE, 6X20 FUSE, BLADE (10A) FUSE, BLADE (15A)

2 3 1 1

06 . 05 . 2008

Notes

F - 26 Frame Body

Service item 1 2 4

BODY, FRAME...................................... LINK, ENGINE HANGER ..................... STAY, FRONT COVER .........................

TST 08 PC 002

F.R.T.

No.

5.1 1 0.3

QTY

Part Number

Description

1 2 3 4 5

50100-KVY-960 50350-KVY-900 50352-KVY-900 64223-KVY-960 90105-KVY-900

BODY COMP., FRAME LINK ASSY., ENGINE HANGER RUBBER, LINK STOPPER (70) STAY, FR. COVER BOLT, FLANGE, 10X270

1 1 2 1 1

6 7 8

90106-GCC-000 90304-KGH-901 95701-0803200

BOLT, FLANGE, 10X238 NUT, U, 10MM BOLT, FLANGE, 8X32

1 2 2

06 . 05 . 2008

3

Notes

57

F - 27 Tools

3

Service item

F.R.T.

No. 1 2 3

58

TST 08 PC 002

Part Number

Description

89102-538-000 89103-538-000 89216-KVY-900

DRIVER, SCREW (NO.2 + -) GRIP WRENCH, SPARK PLUG

06 . 05 . 2008

QTY 1 1 1

Notes

F - 28 Caution Label

Service item

F.R.T.

No. 1 2 3 4

TST 08 PC 002

Part Number

Description

87505-KVY-960 87506-KPH-880 87560-KVB-930 87586-KVB-930

LABEL, TIRE MARK, BATTERY CAUTION LABEL, DRIVE CAUTION LABEL, FUEL

06 . 05 . 2008

QTY

3

Notes

1 1 1 1

59

F - 29 Mark / Stripe

3

3

Service item

F.R.T.

No. 1

60

TST 08 PC 002

Part Number

Description

871X0-KVY-960ZA 871X0-KVY-960ZB 871X0-KVY-960ZC 871X0-KVY-960ZD 871X0-KVY-960ZE 871X0-KVY-960ZF

STRIPE SET ........ STRIPE SET ........ STRIPE SET ........ STRIPE SET ........ STRIPE SET ........ STRIPE SET ........

06 . 05 . 2008

QTY BLACK PEARL FADELESS WHITE ASSURE BLUE METALLIC CANDY SCARLET RED POWDER PINK METALLIC CANDY BLITZ ORANGE

1 (1) (1) (1) (1) (1)

Notes BLACK WHITE BLUE RED PINK ORANGE

I N D E K S PART NUMBER Part Number

(00000)

06451-MA7-405 06455-KVY-911 06530-GBG-B20 06531-GBG-B20

(10000)

11100-KVY-960 11103-KVB-901 11103-KVB-901 11103-KVB-930 11103-KVB-930 11108-KVB-900 11200-KVY-960 11203-KVB-901 11204-KGF-900 11205-GBC-300 11205-GBC-300 11205-GW3-931 11205-GW3-981 11211-KVB-900 11230-KVB-900 11241-KVB-900 11340-KVY-960 11342-KVY-900 11343-KVG-900 11344-GW3-980 11361-KVY-900 11395-KVY-900 12100-KVY-900 12191-KVY-900 12200-KVY-900 12204-KVY-900 12206-KPL-900 12209-GB4-681 12251-KVY-901 12310-KVY-900 12361-035-000 12391-KVY-900 13000-KVY-960 13011-KVY-900 13012-KVY-900 13013-KVY-900 13014-KVY-900 13015-KVY-900

Block No. F12 F12 F6 F6 E7 E7 E15 E7 E15 E14 E15 E15 E14 E7 E15 E10 E15 E14 E11 E14 E11 E11 E11 E11 E7 E11 E6 E6 E3 E3 E3 E4 E3 E2 E15 E2 E16 E16 E16 E16 E16 E16

13101-KVY-960 13102-KVY-960 13103-KVY-960 13104-KVY-960 13105-KVY-960 13111-087-000 13115-GN5-910 14100-KVY-900 14125-KVY-900 14126-KPH-901 14321-KVY-900 14401-KVB-901 14430-KVY-900 14440-KVY-900 14451-KVY-900 14461-KVB-900 14510-KVB-900 14520-KSS-901 14531-KVY-900 14560-KCW-851 14611-KVB-900 14711-KVY-900 14721-KVY-900 14751-KVY-900 14771-GB4-680 14775-KVY-900 14781-MA6-000 15100-KVB-900 15133-KVY-900 15135-KVY-900 15331-KVB-900 15332-KVB-900 15421-107-000 15426-KVB-900 15651-KVY-900 15771-551-000 16010-KGF-911 16012-KVY-961 16013-KRP-981 16015-KVY-901 16016-KRP-981 16028-KVB-901 16037-KCW-000 16046-KVY-902 16050-KVY-901

E16 E16 E16 E16 E16 E16 E16 E4 E4 E4 E4 E5 E4 E4 E4 E4 E5 E5 E5 E5 E5 E4 E4 E4 E4 E4 E4 E9 E9 E9 E9 E9 E15 E15 E7 F17 E17 E17 E17 E17 E17 E17 E17 E17 E17

16075-GHB-640 16100-KVY-961 16107-GCC-000 16111-KVB-902 16119-KVB-901 16131-ZW9-801 16140-GFC-901 16155-KJ9-751 16163-KGF-911 16165-KVB-901 16180-KGH-971 16190-GEE-003 16199-KVY-901 16201-KVY-900 16222-MV4-300 16236-KVG-900 16423-KGH-901 16950-KJ9-752 16952-KJ9-752 16958-397-771 17110-KVY-900 17112-KVY-900 17210-KVY-960 17212-KVY-900 17213-KVY-900 17218-KVY-900 17225-KVY-960 17235-KVY-900 17236-KVB-900 17240-KVY-900 17244-KVY-900 17251-KVY-960 17253-KVY-900 17254-KVY-900 17256-KVY-900 17257-KVB-900 17258-KVY-900 17261-KVY-900 17274-KVB-900 17370-419-700 17510-KVY-960 17525-KVY-900 17620-KGH-600 17622-GB7-900 17630-KVY-960

E17 E17 E17 E17 E17 E17 E17 E17 E17 E17 E17 E17 E17 E3 E3 E11 E17 F16 F16 F16 E3 E3 F17 F17 F17 F17 F17 F17 F17 F17-1 F17 F17 F17 F17 E3 E3 E3 F17 F17 F17 F16 F16 F16 F17-1 F16

17631-KEV-900 17635-KVY-900 17910-KVG-900 18291-KVB-900 18293-KSB-900 18300-KVY-960 18310-KVY-960 18316-KVB-900 18318-KVY-900 18600-KVB-901 18640-KVY-900 18645-KVY-900 18652-KVY-900 18655-KVY-900 18805-KVY-900 19416-KEY-900 19509-KVB-900 19510-KVY-900 19610-KVY-900 19621-KVY-900 19625-KVY-900 19631-KVY-900 19639-GBC-000 19741-KVY-900 19742-KVY-900 19748-KVY-900 19749-KVY-900

(20000)

21200-KVB-901 21395-KVB-900 22011-GCC-770 22100-KVY-900 22102-KVY-900 22105-KVY-900 22109-KVY-900 22110-KVY-900 22113-KVY-900 22123-KVY-900 22131-KVY-900 22350-KVY-900 22401-KVY-900 22535-KVY-900 22804-148-000 23100-KVY-901

F16 F16 F3 F18 F18 F18 F18 F18 F18 F17-1 F17-1 F17-1 F17-1 F17-1 F17 E11 F17-1 E8 E1 E1 E1 E1 E1 E11 E11 E11 E11 E14 E14 E12 E13 E12 E12 E12 E12 E12 E12 E12 E13 E13 E13 E13 E13

23205-KVY-900 23224-KVY-900 23225-KSY-900 23226-KVB-900 23233-GCC-000 23237-GCC-C50 23238-GCC-000 23411-KVY-900 23421-KVB-900 23422-KVG-900 23430-KVB-900 27514-300140000 27514-300140000 28120-KVB-901 28150-KVB-900 28223-GCC-000 28230-KVB-900 28250-KVB-900 28253-KVB-901 28255-GS6-000 28281-GCC-000 28300-KVB-900

(30000)

30158-GW3-980 30410-KVY-961 30500-KVY-901 30700-KVY-960 31110-KVY-961 31120-KVY-961 31204-KG8-004 31206-GW3-004 31210-KVY-961 31213-KEE-630 31500-KPH-881 31600-KVB-901 31916-KRM-841 31928-MFF-D01 32100-KVY-960 32410-KVY-960 32907-KVY-900 32976-KVY-900 33110-KVY-961 33115-KBA-830 33130-KVY-961

E13 E13 E13 E13 E13 E13 E13 E14 E14 E14 E14 F13 F14 E10 E10 E12 E12 E12 E12 E12 E12 F19 F3 F25 F25 F25 E8 E8 E10 E10 E10 E10 F24 F25 E3 E3 F25 E10 E8 E8 F1 F1 F1

4

61

I N D E K S PART NUMBER Part Number

4

62

33400-KVY-961 33402-KVY-961 33403-KVY-961 33404-KVY-961 33450-KVY-961 33452-KVY-961 33453-KVY-961 33700-KVY-961 33701-KVY-961 33702-KVY-961 33704-KVY-961 33705-KVY-961 33714-KL3-620 33715-GB0-900 33752-KVY-961 34901-KPH-881 34905-KAN-W01 34905-KAN-W01 34906-GB6-921 34908-GA7-701 34908-GA7-701 34908-KVE-900 34908-MB9-871 34909-KVR-600 35010-KVY-960 35011-KVY-900 35100-KVY-961 35121-KVY-900 35150-KPH-880 35160-KPH-881 35170-KVB-851 35180-KPH-881 35200-KVB-851 35340-KGH-901 35340-KPH-901 35700-KVY-900 37200-KVY-960 37210-KVY-961 37211-KVY-961 37212-KVY-961 37224-KVY-961 37305-KE5-008 37800-KVY-960 37801-GA7-700

Block No. F22 F22 F22 F22 F22 F22 F22 F23 F23 F23 F23 F23 F25 E1 F23 F1 F22 F23 F23 F1 F2 F2 F2 F2 F25 F25 F25 F25 F3 F3 F3 F3 F3 F4 F3 F19 F2 F2 F2 F2 F2 F2 F16 F16

37802-KTL-740 38110-KTM-851 38117-KPH-880 38301-KEV-950 38306-KK4-000 38501-KPH-901 38501-KVB-901

(40000)

42601-KVG-912 42711-KVB-930 43130-KVB-901 43141-KVB-900 43151-329-000 43352-568-003 43353-461-771 43410-KVB-900 43450-KVY-900 43455-KVB-900 43472-KVB-900 44301-GN5-900 44311-KVB-910 44601-KVG-912 44620-KVB-910 44711-KVB-930 44800-KVB-910 44806-KVB-911 44809-KFM-900 44830-KVY-910 45108-KVY-911 45118-MN8-701 45126-KVY-911 45131-GZ0-006 45132-166-016 45133-MA3-006 45150-KVY-911 45156-KVB-850 45157-KVY-910 45190-KVY-911 45203-MG3-016 45215-KVY-911 45216-166-006 45351-KVY-961 45504-410-003 45510-KVY-911

F16 F25 F25 F2 F2 F25 F25 F14 F14 F14 F14 F14 F12 F12 F14 F3 F3 F14 F13 F13 F13 F13 F13 F13 F13 F13 F2 F12 F12 F4 F12 F12 F12 F12 F4 F4 F12 F12 F12 F12 F13 F4 F4

45512-MA6-006 45513-GW0-911 45517-GW0-751 45520-GW0-912 45521-GW0-911 45530-KVY-911

(50000)

50100-KVY-960 50301-KPH-720 50302-KPH-720 50306-GN5-900 50350-KVY-900 50352-KVY-900 50400-KVY-900 50500-KVY-870 50503-KVY-900 50520-KVB-900 50530-KVY-870 51400-KVY-871 51401-KVB-901 51410-KVB-901 51412-GN5-901 51420-KVY-871 51425-GN5-901 51437-KGH-901 51454-KEV-881 51456-KPH-901 51466-065-901 51470-KVY-901 51490-KGH-901 51500-KVY-871 51520-KVY-871 52400-KVB-941 52485-088-901 52486-GA7-003 53100-KVY-960 53140-KVB-900 53166-KVB-900 53167-KFM-900 53168-KFM-900 53175-KRS-T80 53178-KVB-900 53181-KVB-900 53182-KVB-900

F4 F4 F4 F4 F4 F4 F26 F6 F6 F6 F26 F26 F15 F19 F19 F19 F19 F11 F11 F11 F11 F11 F11 F11 F11 F11 F11 F11 F11 F11 F11 F20 F20 F20 F5 F3 F3 F3 F3 F4 F3 F3 F3

53183-KVB-900 53205-KVY-910ZH 53206-KVY-960ZA 53209-GAH-000 53211-KPH-720 53212-KPH-720 53214-GN5-900 53215-GN5-900 53216-GN5-830 53219-KVY-960 53220-GN5-900

(60000)

61100-KVY-960 61101-KCJ-690 61112-KVG-900 64223-KVY-960 64301-KVY-960 64310-KVY-900 64340-KVY-960 64510-KEV-900 64520-KVY-900 64531-KFM-900

(70000)

75581-GN8-920 77200-KVY-960 77214-KPH-900 77215-KVY-900 77230-KVY-900 77234-GN2-000 77236-KVY-900 77240-KTM-851

(80000)

80102-KVY-960 80104-KVY-870 80107-KVY-900 80110-KVY-960 80151-KVY-900ZA 81110-KVB-930 81131-KVY-900ZA 81132-GAH-000ZW 81141-KVY-960 81250-KVY-960 81251-KVY-900

F3 F5 F5 F1 F6 F6 F6 F6 F6 F6 F6 F7 F19 F7 F26 F8 F9 F9 F8 F9 F17 F15 F15 F15 F15 F15 F15 F15 F15 F10 F21 F15 F21 F10 F8 F8 F8 F9 F15 F15

81252-KVY-900 81253-KVY-900 81254-KVY-960 81256-KVY-960 83500-KVY-960 83600-KVY-960 83642-171-000 871X0-KVY-960ZA 871X0-KVY-960ZB 871X0-KVY-960ZC 871X0-KVY-960ZD 871X0-KVY-960ZE 871X0-KVY-960ZF 87505-KVY-960 87506-KPH-880 87509-KVB-930 87560-KVB-930 87586-KVB-930 88110-KVY-960 88114-KVB-900 88120-KVY-960 89102-538-000 89103-538-000 89216-KVY-900

(90000)

90001-KVY-900 90002-GFC-900 90002-KGH-901 90005-KY7-000 90012-333-000 90017-GCC-000 90031-KVB-900 90032-KVB-900 90035-166-008 90083-GB6-911 90101-GJ6-000 90101-KVY-900 90101-KY6-008 90105-KGH-900 90105-KVY-900 90106-GCC-000 90106-GN5-900 90106-KPH-690 90107-GFC-900

F15 F15 F15 F15 F10 F10 F27 F29 F29 F29 F29 F29 F29 F28 F28 F17 F28 F28 F3 F3 F3 F27 F27 F27 E3 E9 E8 E5 E4 E2 E7 E15 F2 E4 F1 F19 F2 F13 F26 F26 F5 F25 F10

I N D E K S PART NUMBER Part Number 90107-KVB-900 90108-MK6-670 90112-KVB-900 90114-KGH-900 90115-KRS-690 90116-KV3-701 90131-883-000 90131-KPH-880 90145-KPH-B30 90147-KVY-900 90164-028-000 90201-GCC-000 90202-KN7-670 90202-ZV0-001 90203-KVB-900 90206-001-000 90302-435-761 90302-GW3-980 90302-GW3-980 90302-GW3-980 90302-GW3-980 90304-KGH-901 90304-KGH-901 90305-KVB-901 90306-KGH-901 90314-KVR-600 90401-KVY-900 90410-HC4-000 90412-329-000 90426-KVB-900 90439-443-740 90441-GY6-940 90442-044-000 90454-GB2-000 90474-333-001 90501-124-000 90501-KBN-900 90501-KPH-880 90501-KVY-900 90505-KPH-880 90543-MV9-671 90544-283-000 90545-300-000 90651-MA5-671

Block No. F8 F19 F14 F4 F3 F11 E7 F12 F4 F19 F25 E3 E13 F18 F19 E4 F3 F8 F9 F15 F23 F5 F26 F14 F13 F3 E3 E8 E12 E12 E12 E13 E13 E13 E15 F17-1 F14 F5 F15 F5 E2 F11 F4 F4

90652-KVB-900 90677-KAN-T00 90677-KAN-T00 90678-MN5-000 90683-GAZ-003 90701-KFM-900 90701-KFM-900 90702-KFM-900 90702-KFM-900 90702-KFM-901 90702-KVB-900 90741-KVY-900 91001-KE6-832 91002-KVY-901 91005-KVB-900 91007-KVB-902 91009-KVB-902 91009-KVY-961 91052-KVB-901 91109-KVY-901 91201-434-003 91201-GCC-771 91202-KJ9-003 91202-KVB-901 91211-GK8-013 91211-PE9-003 91251-KPH-901 91255-KVB-901 91258-KM1-004 91301-GR0-004 91302-001-020 91306-MG3-000 91307-035-000 91307-639-000 91309-KEE-630 91351-642-000 91351-GR1-000 91352-671-003 91352-671-004 91356-GM0-003 91509-GE2-760 92900-060120B 92900-060280B 93404-0601000

E11 F9 F21 F17-1 F15 E3 E6 E9 E11 E14 E7 E16 E14 E15 E11 E14 E14 E13 F13 E13 E14 E7 E15 E15 E13 E11 F13 E14 F13 E5 E15 E5 E7 E7 E10 E13 E13 F2 F2 F11 F10 E3 E3 F15

93404-0601200 93404-0602000 93404-0602000 93404-0603000 93500-040081H 93500-040120H 93500-050121H 93500-050250B 93500-050250H 93600-040121G 93892-0400608 93892-0400818 93892-0501218 93892-0501608 93893-0401217 93894-0501607 93901-24580 93901-34120 93903-24481 93903-25310 93903-25380 93903-25510 93903-34120 93903-34310 93903-34320 93903-34380 93903-34380 93903-34380 93903-34380 93903-34380 93903-34480 93903-35380 94030-12200 94030-14200 94050-06000 94050-06000 94050-06001 94050-10000 94101-10800 94109-12001 94201-30201 94510-20000 94511-16000 94520-28000

F21 E1 F15 F17-1 E17 E17 E17 F3 E3 F4 E10 E17 E17 E10 F4 F9 F23 E9 F10 F2 E1 F17 E11 E11 F22 F5 F8 F9 F10 F23 F9 F5 E13 E12 E3 F4 F17-1 E8 F19 E7 F19 E14 E12 E13

94520-52150 95002-02070 95002-02070 95002-02080 95002-02089 95002-02130 95002-4120008 95002-50000 95002-80000 95002-80000 95005-4524050 95011-61000 95014-72102 95015-32001 95015-42000 95701-0601200 95701-0601200 95701-0601200 95701-0601200 95701-0601200 95701-0601400 95701-0601600 95701-0601600 95701-0601800 95701-0602000 95701-0602200 95701-0602200 95701-0602201 95701-0602500 95701-0603000 95701-0603200 95701-0604000 95701-0605500 95701-0608000 95701-0608507 95701-0610000 95701-0611500 95701-0801200 95701-0802001 95701-0802500 95701-0803200 95701-1004007 95801-0601602 95801-0803200

E15 F16 F17-1 F16 E17 F17 F17 E14 E11 F17 E17 F19 F19 F14 F14 F4 F16 F17-1 F23 F25 E14 E8 F7 F17-1 F25 E5 E7 F4 F17 E14 F8 E14 E7 E7 E7 E3 E7 E15 F15 F19 F26 F18 F18 F20

95801-1003500 95801-1004008 96001-0601201 96001-0601600 96001-0601600 96001-0601800 96001-0602000 96001-0602500 96001-0603500 96001-0603500 96001-0608500 96100-6301000 96100-6302000 96220-30168 98200-31000 98200-31000 98200-31500 98200-31500 99101-KVC-1000

F20 F6 F15 E8 E14 E11 E8 E1 E10 E11 E11 E15 E15 E9 F15 F25 F15 F25 E17

4

63

I N D E K S DESCRIPTION Description

(A)

ARM ASSY., KICK STARTER ARM COMP., EX. VALVE ROCKER ARM COMP., IN. VALVE ROCKER ARM, RR. BRAKE AXLE, FR. WHEEL

F19 E4 E4 F14 F13

BAG, OWNERS MANUAL BALL SET, STEEL, #6X23 BALL SET, STEEL, #6X29 BAND A, INSULATOR BAND B, INSULATOR BAND, CONNECTING TUBE (50) BAR COMP., SIDE STAND BASE COMP., TAILLIGHT BASE, L. FR. WINKER BASE, R. FR. WINKER BATTERY BEARING COMP., RADIAL BALL BEARING, NEEDLE, 20X29X18 BEARING, RADIAL BALL, 60/22 UU BEARING, RADIAL BALL, 6007 BEARING, RADIAL BALL, 6201 BEARING, RADIAL BALL, 6201(U) BEARING, RADIAL BALL, 6204 BEARING, RADIAL BALL, 6301 BEARING, RADIAL BALL, 6302 BEARING, RADIAL BALL, 6902U BELT, DRIVE BODY COMP., BYSTARTER BODY COMP., FRAME BOLT A, STUD, 7X193.5 BOLT B, STUD, 7X198.5 BOLT, ADJUSTING BOLT, BRAKE DISK, 8X24 BOLT, DRAIN PLUG, 12X15 BOLT, FLANGE, 10X238 BOLT, FLANGE, 10X270 BOLT, FLANGE, 10X35 BOLT, FLANGE, 10X40 BOLT, FLANGE, 10X40 BOLT, FLANGE, 10X50 BOLT, FLANGE, 5X14 BOLT, FLANGE, 6X10

F27 F6 F6 E3 E3 F17 F19 F23 F22 F22 F24 E11 E13 E14 E15 E14 F13 E14 E15 E15 E13 E13 E17 F26 E7 E15 F1 F13 E7 F26 F26 F20 F6 F18 F5 E8 E3

(B)

5 64

Block No.

Description BOLT, FLANGE, 6X100 BOLT, FLANGE, 6X115 BOLT, FLANGE, 6X12 BOLT, FLANGE, 6X12 BOLT, FLANGE, 6X12 BOLT, FLANGE, 6X12 BOLT, FLANGE, 6X12 BOLT, FLANGE, 6X12 BOLT, FLANGE, 6X14 BOLT, FLANGE, 6X16 BOLT, FLANGE, 6X16 BOLT, FLANGE, 6X16 BOLT, FLANGE, 6X16 BOLT, FLANGE, 6X16 BOLT, FLANGE, 6X18 BOLT, FLANGE, 6X18 BOLT, FLANGE, 6X20 BOLT, FLANGE, 6X20 BOLT, FLANGE, 6X22 BOLT, FLANGE, 6X22 BOLT, FLANGE, 6X22 BOLT, FLANGE, 6X25 BOLT, FLANGE, 6X25 BOLT, FLANGE, 6X30 BOLT, FLANGE, 6X32 BOLT, FLANGE, 6X32 BOLT, FLANGE, 6X35 BOLT, FLANGE, 6X35 BOLT, FLANGE, 6X40 BOLT, FLANGE, 6X55 BOLT, FLANGE, 6X80 BOLT, FLANGE, 6X85 BOLT, FLANGE, 6X85 BOLT, FLANGE, 8X12 BOLT, FLANGE, 8X20 BOLT, FLANGE, 8X25 BOLT, FLANGE, 8X32 BOLT, FLANGE, 8X32 BOLT, HANDLE LEVER PIVOT BOLT, HANDLE LEVER PIVOT BOLT, HEAD COVER BOLT, HEX., 6X30 BOLT, KNOCK, 5MM BOLT, OIL, 10X22

Block No. E3 E7 F4 F15 F16 F17-1 F23 F25 E14 E8 E8 E14 F7 F18 E11 F17-1 E8 F25 E5 E7 F4 E1 F17 E14 F8 F14 E10 E11 E14 E7 E7 E7 E11 E15 F15 F19 F20 F26 F3 F4 E2 E9 E4 F4

Description BOLT, PIN BOLT, SETTING, 6X16 BOLT, SIDE STAND PIVOT BOLT, SOCKET, 6X10 BOLT, SOCKET, 8MM BOLT, SPECIAL, 6MM BOLT, SPECIAL, 6MM BOLT, STUD, 6X12 BOLT, STUD, 6X28 BOLT, SWITCH SETTING BOLT, TORX, 8X25 BOLT-WASHER, 6X10 BOLT-WASHER, 6X12 BOLT-WASHER, 6X20 BOLT-WASHER, 6X20 BOLT-WASHER, 6X30 BOOT B BOOT COMP. BOOT, PIN BUSH BOSS, DRIVE FACE BOX ASSY., SPEEDOMETER GEAR BOX, LUGGAGE BRACKET COMP., FR. BRACKET SUB ASSY., FR. CALIPER BRACKET, FR. NUMBER PLATE BULB, HEADLIGHT (12V 32/32W) BULB, TAILLIGHT (12V 18/5W) BULB, WEDGE BASE (12V 1.7W) BULB, WEDGE BASE (T10) BULB, WEDGE BASE (T10) BULB, WEDGE BASE (T10) BULB, WEDGE BASE (T10) BULB, WINKER (12V 10W) BULB, WINKER (12V 10W) BUSH, 8X12X6 BUSH, 8X12X6 BUSH, ENGINE HANGER RUBBER BUSH, ENGINE HANGER RUBBER BUSH, ENGINE HANGER RUBBER BUSH, ENGINE HANGER RUBBER BUSH, KICK SPINDLE BUSH, MAINSTAND BUSH, MAINSTAND BUSH, RR. CUSHION RUBBER

Block No. F12 F19 F19 F25 F11 F8 F10 E3 E3 F19 F12 F15 F21 E1 F15 F17-1 F12 F4 F12 E12 F13 F15 E10 F12 F8 F1 F23 F2 F1 F2 F2 F2 F22 F23 E10 E15 E7 E7 E15 E15 E12 E7 E15 F20

I N D E K S DESCRIPTION Description BUSH, RR. CUSHION UNDER RUBBER

(C)

C.D.I. UNIT CABLE COMP., RR. BRAKE CABLE COMP., SPEEDOMETER CABLE COMP., THROTTLE CALIPER SUB ASSY., L. FR. CAM, RR. BRAKE CAMSHAFT COMP. CAP ASSY., NOISE SUPPRESSOR CAP, BLEEDER CAP, FUEL FILLER CAP, HOLDER CAP, L. COVER CAP, LOCK NUT CAP, LUGGAGE BOX CAP, LUGGAGE SIDE CAP, MASTER CYLINDER CAP, TAPPET ADJUSTING HOLE CARBURETOR ASSY. CASE ASSY. CASE COMP., MISSION CASE SUB ASSY., AIR CLEANER CASE, L. FR. BOTTOM CASE, R. FR. BOTTOM CATCH COMP., SEAT CHAIN, CAM (90L) CHAMBER SET, FLOAT CIRCLIP CIRCLIP, 6MM CIRCLIP, EXTERNAL, 16MM CIRCLIP, EXTERNAL, 20MM CIRCLIP, INTERNAL, 28MM CIRCLIP, INTERNAL, 32MM CIRCLIP, INTERNAL, 52MM CLAMP, TUBE (D12) CLAMP, TUBE (D19) CLAMPER B, BRAKE HOSE CLAMPER, BRAKE HOSE CLAMPER, BREATHER TUBE CLAMPER, DRAIN TUBE CLAMPER, RR. BRAKE CABLE CLAMPER, WIRE HARNESS CLIP, A.C. GENERATOR CORD

Block No. E15 F25 F3 F2 F3 F12 F14 E4 F25 F12 F16 E17 E11 F3 F15 F15 F4 E15 E17 F2 E14 F17 F11 F11 F15 E5 E17 F4 E13 E12 E14 E13 E11 E15 F17 F17-1 F4 F4 E14 E11 F3 E8 E8

Description CLIP, FUEL HOSE CLIP, HEADLIGHT CLIP, OIL DRAIN TUBE CLIP, PISTON PIN, 13MM CLIP, TRIM CLIP, TUBE (B12.5) CLIP, TUBE (B7) CLIP, TUBE (B7) CLIP, TUBE (B8) CLIP, TUBE (B8) CLIP, TUBE (C12) CLIP, TUBE (C12) CLIP, TUBE (C9) CLIP, VALVE GUIDE COCK ASSY., FUEL AUTO COIL ASSY., IGNITION COLLAR COLLAR COLLAR A, HANDLE SETTING COLLAR B, HANDLE SETTING COLLAR, BODY COVER COLLAR, FR. DISTANCE COLLAR, FR. FENDER COLLAR, FR. FENDER SETTING COLLAR, FR. WHEEL SIDE COLLAR, HORN SETTING COLLAR, KICK BOSS COLLAR, LUGGAGE SET COLLAR, MUFFLER PROTECTOR COLLAR, RUBBER BUSH COLLAR, SEAL COLLAR, SPRING COLLAR, TAILLIGHT SETTING COTTER, VALVE COVER , R. BODY COVER ASSY., BATTERY COVER COMP., CYLINDER HEAD COVER COMP., FAN COVER COMP., L. COVER SET, FR. COVER SUB ASSY., AIR CLEANER COVER, CENTER COVER, FR. HANDLE (DISK) COVER, FR. LOWER COVER, INNER LOWER

Block No. F17-1 F1 F17 E16 F15 F17 F16 F17-1 E17 F16 E11 F17 E14 E3 F16 F25 E3 E11 F5 F5 F17 F13 F7 F19 F13 F25 E12 F15 F18 F20 E13 E13 E1 E4 F10 F15 E2 E1 E11 F8 F17 F10 F5 F9 F9

Description COVER, INNER UPPER COVER, L. BODY COVER, LUGGAGE BOX COVER, OIL PUMP COVER, RR. CUSHION COVER, RR. HANDLE COVER, UNDER COVER, VENT HOLE CRANKCASE COMP., L. CRANKCASE COMP., R. CRANKSHAFT COMP. CUSHION ASSY., RR. CUSHION, C.D.I. UNIT CUSHION, FR. TOP COVER CYLINDER COMP. CYLINDER SET, MASTER CYLINDER SUB ASSY., FR. BRAKE

(D)

Block No. F8 F10 F15 E7 F10 F5 F9 E11 E15 E7 E16 F20 F15 F8 E6 F4 F4

DIAPHRAGM DISK, FR. BRAKE DOWEL PIN, 8X12 DOWEL PIN, 8X12 DOWEL PIN, 8X12 DOWEL PIN, SPECIAL, 8X14 DOWEL PIN, SPECIAL, 8X14 DRIVER, SCREW (NO.2 + -) DUCT, AIR CLEANER INTAKE DUCT, L. COVER DUST SEAL DUST SEAL, 21X37X7 DUST SEAL, STEERING HEAD

F4 F13 E9 E11 E14 E3 E6 F27 F17 E11 F11 F13 F6

ELEMENT COMP., AIR CLEANER ELEMENT, AIR CLEANER (ASV) E-RING, 3MM

F17 F17 F3

FACE COMP., MOVABLE DRIVE FACE SET, DRIVEN FACE SET, MOVABLE DRIVEN FACE, DRIVE (66T) FAN COMP., COOLING FENDER SET, RR. FENDER, FR. FIN, DRIVE FACE

E12 E13 E13 E12 E8 F21 F7 E12

(E)

(F)

5 65

I N D E K S DESCRIPTION Description FLOAT SET FLYWHEEL COMP. FORK ASSY., L. FR. FORK ASSY., R. FR. FUEL UNIT FUSE, BLADE (10A) FUSE, BLADE (10A) FUSE, BLADE (15A) FUSE, BLADE (15A)

5

(G)

GASKET SET GASKET, AIR FEED PIPE GASKET, BYSTARTER GASKET, CARBURETOR INSULATOR GASKET, CYLINDER GASKET, CYLINDER HEAD GASKET, EX. PIPE GASKET, FLOAT CHAMBER GASKET, HEAD COVER GASKET, L. COVER GASKET, MISSION CASE GASKET, TENSIONER LIFTER GAUGE, OIL LEVEL GEAR COMP., FINAL (45T) GEAR COMP., KICK STARTER GEAR, COUNTER (51T) GEAR, OIL PUMP DRIVEN (39T) GEAR, SPEEDOMETER (21T) GRIP GRIP COMP., THROTTLE GRIP, L. HANDLE GUARD, HEAT GUARD, SPLASH GUIDE, CAM CHAIN GUIDE, VALVE

E17 F17-1 E17 E3 E6 E3 F18 E17 E2 E11 E14 E5 E7 E14 E12 E14 E9 F13 F27 F3 F3 F15 F21 E5 E3

HARNESS, WIRE HEAD COMP., CYLINDER HEADLIGHT UNIT HOLDER COMP., STARTER PINION HOLDER, MASTER CYLINDER HOLDER, NEEDLE JET HOOK, LUGGAGE HORN COMP.(HIGH)

F25 E3 F1 E10 F4 E17 F8 F25

(H)

66

Block No. E17 E8 F11 F11 F16 F15 F25 F15 F25

Description

Block No.

HOSE (AI) HOSE COMP., FR. BRAKE HOUSING, UNDER THROTTLE HOUSING, UPPER THROTTLE

F17-1 F4 F3 F3

INSULATOR, CARBURETOR

E3

JET, #100 JET, SLOW, #35 JOINT B, BRAKE ARM

E17 E17 F14

(I)

KEY SET KEY, BLANK KEY, WOODRUFF

(J)

(K)

(L)

F25 F25 E16

LABEL, AIR CLEANER CASE COVER LABEL, DRIVE CAUTION LABEL, FUEL LABEL, TIRE LENS LENS COMP., TAILLIGHT LENS, L. FR. WINKER LENS, L. WINKER LENS, R. FR. WINKER LENS, R. WINKER LEVER COMP., BRAKE LOCK LEVER, L. STEERING HANDLE LEVER, R. STEERING HANDLE LIFTER ASSY., TENSIONER LIGHT ASSY., RR. COMBINATION LINK ASSY., ENGINE HANGER LOCK ASSY., SEAT

F17 F28 F28 F28 F2 F23 F22 F23 F22 F23 F3 F3 F4 E5 F23 F26 F15

MARK, BATTERY CAUTION MIRROR ASSY, L BACK MIRROR ASSY, R BACK MOTOR UNIT, STARTER MUFFLER ASSY, EXHAUST MUFFLER COMP., EX.

F28 F3 F3 E10 F18 F18

NEEDLE SET, JET NUT B, BRAKE ROD ADJUSTING NUT, ADJUST

E17 F14 F1

(M)

(N)

Description NUT, CAP, 6MM NUT, CLIP, 5MM NUT, CLIP, 5MM NUT, FLANGE, 10MM NUT, FLANGE, 6MM NUT, FLANGE, 6MM NUT, FLANGE, 6MM NUT, HEX., 12MM NUT, HEX., 14MM NUT, HEX., 5MM NUT, HEX., 7MM NUT, LOCK NUT, SIDE STAND NUT, SPECIAL, 28MM NUT, SPRING, 4MM NUT, SPRING, 4MM NUT, SPRING, 4MM NUT, SPRING, 4MM NUT, SQUARE, 5MM NUT, STEERING STEM LOCK NUT, TAPPET ADJUSTING NUT, U, 10MM NUT, U, 10MM NUT, U, 12MM NUT, U, 16MM

(O)

OIL SEAL, 14X20X3 OIL SEAL, 16X26X6 OIL SEAL, 16X26X7 OIL SEAL, 20.8X52X6X7.5 OIL SEAL, 20X32X6 OIL SEAL, 29X44X7 OIL SEAL, 34X39X3 O-RING O-RING O-RING O-RING, 1.3X4.3 O-RING, 1.5X9.5 O-RING, 15.2X1.5 O-RING, 18X3 O-RING, 30.8MM O-RING, 38.5X2 O-RING, 64X2 O-RING, 8.5X1.5

Block No. F18 F9 F21 E8 E3 F4 F17-1 E13 E12 F3 E3 F3 F19 E13 F8 F9 F15 F23 E3 F6 E4 F5 F26 F13 F14 E14 E11 E7 E15 E15 E14 E13 E10 F11 F16 E17 E5 E5 E7 E15 E13 E7 F2

I N D E K S DESCRIPTION Description O-RING, 8.5X1.5 O-RING, PINION CAP OUTER COMP., CLUTCH

Block No.

(P)

PACKING PACKING 1. PACKING, BASE PACKING, FUEL FILLER CAP PAD SET, FR. PIECE SET, SLIDE PIN, HANGER PIN, PARKING LEVER PIVOT PIN, PISTON PIN, ROLLER GUIDE PIN, SEAT HINGE PIN, SPECIAL DOWEL, 6.3X10X12 PIN, SPLIT, 3.0X20 PINION ASSY., STARTER PIPE COMP., AIR FEED PIPE COMP., FR. FORK PIPE COMP., STEERING HANDLE PIPE, INLET PIPE, SEAT PISTON (0,25) PISTON (0,50) PISTON (0,75) PISTON (1,00) PISTON (B) PISTON (STD) PISTON COMP., VACUUM PIVOT, CAM CHAIN TENSIONER PLATE COMP., DRIVE PLATE SET, VALVE PLATE, DIAPHRAGM PLATE, L. COVER PLATE, MISSION BEARING SETTING PLATE, PLUNGER PLATE, RAMP PLATE, SETTING PLUG, AIR CLEANER DRAIN PLUG, BREATHER TUBE PLUG, PIN PLUG, SPARK (CPR8EA-9) PLUG, SPARK (U24EPR9)

F2 E13 E13 E10 F23 F16 F16 F12 E12 F12 F3 E16 E13 F15 E7 F19 E10 F17-1 F11 F5 E3 F11 E16 E16 E16 E16 F12 E16 E17 E5 E13 E17 F4 E11 E14 E3 E12 E17 F17 F17 F12 E3 E3

Description PLUNGER, CAM SETTING PROTECTOR PROTECTOR A, MUFFLER PUMP ASSY., OIL

(R)

Block No. E4 F4 F18 E9

RACE, STEERING BOTTOM BALL RACE, STEERING BOTTOM CONE RACE, STEERING TOP BALL RACE, STEERING TOP CONE RAIL, RR. GRAB RATCHET, STARTER RECTIFIER COMP., REGULATOR RELAY COMP., STARTER RELAY COMP., STARTER RELAY COMP., WINKER RETAINER, FUEL UNIT RETAINER, VALVE SPRING RING SET, PISTON (0,25) RING SET, PISTON (0,50) RING SET, PISTON (0,75) RING SET, PISTON (1,00) RING SET, PISTON (STD) RING, OIL SEAL STOPPER RING, PISTON RING, STOPPER ROLLER SET, WEIGHT ROLLER, 3X16.8 ROLLER, GUIDE ROTOR, OIL PUMP INNER ROTOR, OIL PUMP OUTER RUBBER A, STAND STOPPER RUBBER B, SEAT SETTING RUBBER, AIR SUCTION VALVE RUBBER, CLUTCH DAMPER RUBBER, CUSHION RUBBER, LINK STOPPER (70) RUBBER, MOUNTING RUBBER, MOUNTING RUBBER, PROTECTOR PACKING RUBBER, STARTER PINION HOLDER RUBBER, TAILLIGHT BRACKET

F6 F6 F6 F6 F15 E12 F25 F25 F25 F2 F16 E4 E16 E16 E16 E16 E16 F11 F11 F11 E12 E9 E13 E9 E9 F19 F15 F17 E13 F17-1 F26 E1 E2 F18 E11 F25

SCREEN SET, FUEL STRAINER SCREEN, OIL FILTER

F16 E15

(S)

Description SCREW SET A SCREW SET B SCREW, BLEEDER SCREW, FLAT, 4X12 SCREW, PAN, 4X12 SCREW, PAN, 4X8 SCREW, PAN, 5X11.5 SCREW, PAN, 5X12 SCREW, PAN, 5X25 SCREW, PAN, 5X25 SCREW, PAN, 6X6 SCREW, TAPPET ADJUSTING SCREW, TAPPING, 3X14 SCREW, TAPPING, 4X12 SCREW, TAPPING, 4X12 SCREW, TAPPING, 4X12 SCREW, TAPPING, 4X12 SCREW, TAPPING, 4X12 SCREW, TAPPING, 4X12 SCREW, TAPPING, 4X12 SCREW, TAPPING, 4X16 SCREW, TAPPING, 4X16 SCREW, TAPPING, 4X20 SCREW, TAPPING, 4X8 SCREW, TAPPING, 4X8 SCREW, TAPPING, 5X16 SCREW, TAPPING, 5X16 SCREW, TAPPING, 5X16 SCREW, TAPPING, 5X25 SCREW, U-LOCK FLAT, 6X12 SCREW-WASHER, 3X22 SCREW-WASHER, 4X12 SCREW-WASHER, 4X6 SCREW-WASHER, 4X8 SCREW-WASHER, 5X12 SCREW-WASHER, 5X16 SCREW-WASHER, 5X16 SCREW-WASHER, SPECIAL, 4X10 SEAL A, AIR CLEANER SEAL B, AIR CLEANER SEAL SET, FR. FORK SEAL SET, PISTON SEAL, DUCT SEAL, GASKET

Block No. E17 E17 F12 F4 E17 E17 F10 E17 E3 F3 E5 E4 F2 E11 F5 F8 F9 F10 F22 F23 F9 F10 F23 E9 E11 E1 F2 F5 F17 F25 F2 F4 E10 E17 E17 E10 F9 F2 F17 F17 F11 F12 E11 F22

5 67

I N D E K S DESCRIPTION Description SEAL, L. DUCT COVER SEAL, SHROUD SEAL, SPEEDOMETER GEAR BOX SEAL, VALVE STEM SEAT B, SPRING SEAT COMP., DOUBLE SEAT, VALVE SPRING SHAFT COMP., OIL PUMP SHAFT, COUNTER (12T) SHAFT, DRIVE (18T) SHAFT, EX. ROCKER ARM SHAFT, IN. ROCKER ARM SHAFT, MAIN STAND SHOE SET, BRAKE SHROUD, EX. SHROUD, IN. SHUTTER SET, KEY SLEEVE, RR. BRAKE CAM SOCKET COMP. SOCKET COMP., HEADLIGHT SPEEDOMETER ASSY. SPEEDOMETER COMP. SPINDLE COMP., KICK STARTER SPRING A, SIDE STAND SPRING, BRAKE SHOE SPRING, CARBON BRUSH SPRING, CLUTCH SPRING, COMPRESSION COIL SPRING, DRIVEN FACE SPRING, FR. FORK SPRING, KICK DRIVEN GEAR SPRING, KICK RETURN SPRING, LOCK KEY SETTING SPRING, MAIN STAND SPRING, OIL FILTER SCREEN SPRING, PAD SPRING, PLUNGER SPRING, REBOUND SPRING, RETURN LEVER SPRING, RR. BRAKE ARM SPRING, SEAT LOCK SPRING, VALVE SPROCKET, CAM (34T) STAND COMP., MAIN

5 68

Block No. E11 E1 F13 E4 F11 F15 E4 E9 E14 E14 E4 E4 F19 F14 E1 E1 F25 E14 F2 F1 F2 F2 E12 F19 F14 E10 E13 E17 E13 F11 E12 E12 F15 F19 E15 F12 E4 F11 F3 F14 F15 E4 E4 F19

Description STATOR COMP. STAY, AIR SUCTION VALVE STAY, FR. COVER STAY, WIRE STEM SUB ASSY., STEERING STEP, FLOOR STRIPE SET ..... ASSURE BLUE METALLIC STRIPE SET ..... BLACK STRIPE SET ..... CANDY BLITZ ORANGE STRIPE SET ..... CANDY SCARLET RED STRIPE SET ..... PEARL FADELESS WHITE STRIPE SET ..... POWDER PINK METALLIC SUB CORD, STARTER MOTOR SUSPENSION, WINKER RELAY SWITCH ASSY., COMBINATION & SWITCH ASSY., FR. STOP SWITCH ASSY., FR. STOP SWITCH ASSY., SIDE STAND SWITCH UNIT, DIMMER SWITCH UNIT, HORN SWITCH UNIT, LIGHTING SWITCH UNIT, STARTING SWITCH UNIT, WINKER

(T)

TANK COMP., FUEL TENSIONER, CAM CHAIN THREAD COMP., STEERING HEAD TIRE, FR. (80/90 - 14M/C 40P) TIRE, RR. (SRI) TOP TRAY, FUEL TUBE, 4.5X240 TUBE, AIR CLEANER CONNECTING TUBE, AIR CLEANER DRAIN TUBE, AIR OPENING TUBE, AIR SUCTION VALVE TUBE, AIR VENT TUBE, BREATHER TUBE, BREATHER TUBE, DRAIN TUBE, FUEL TUBE, PRESSURE TUBE, TIRE TUBE, TIRE

Block No. E8 F17-1 F26 E17 F6 F9 F29 F29 F29 F29 F29 F29 E10 F2 F25 F3 F4 F19 F3 F3 F3 F3 F3 F16 E5 F6 F13 F14 E17 F16 E17 F17 F17 F17 F17-1 E17 E14 F17 E11 F16 F16 F13 F14

Description

(V)

Block No.

VALVE ASSY., AIR SUCTION VALVE COMP., FLOAT VALVE SET, STARTER VALVE, EX. VALVE, IN.

F17-1 E17 E17 E4 E4

WASHER, 10MM WASHER, 12.2X29X2.5 WASHER, 16MM WASHER, 16X22 WASHER, DRAIN PLUG, 12MM WASHER, FR. COVER SETTING WASHER, OIL BOLT WASHER, PLAIN, 10MM WASHER, SEALING, 8MM WASHER, SEAT LOCK WASHER, SPECIAL, 14MM WASHER, SPECIAL, 8MM WASHER, SPEEDOMETER GEAR WASHER, STEERING HEAD DUST WASHER, STEERING STEM NUT WASHER, THRUST, 10MM WASHER, THRUST, 6MM WASHER, WAVE WEIGHT SET, CLUTCH WHEEL COMP., RR. WHEEL SUB ASSY., FR. WINKER ASSY, L FR WINKER ASSY, R FR WRENCH, SPARK PLUG

E8 E13 F14 E12 E7 F17-1 F4 F19 E15 F15 E12 F11 F13 F6 F6 E12 E13 F12 E13 F14 F13 F22 F22 F27

(W)

PT Astra Honda Motor TECHNICAL SERVICE DIVISION

1 8 KVYG 9 I 1 Printed by CB-2008