Honda Beat Service Manual

B E A T

PARTS CATALOGEDISI 1

TST 08 PC 002 PT Astra Honda Motor

PETUNJUK PEMAKAIAN

KELOMPOK MESIN

KELOMPOK RANGKA

INDEKS PART NUMBER

INDEKS DESCRIPTION

D A F T A R I S I

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5

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1PETUNJUK 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)

I. CARA MEMESAN PARTS

1. Informasi yang diperlukanPemesan 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-perubahanPerubahan-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 Nomor Kode warnadan komponen kode Kode subkontraktor model Kode modifikasi

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

Nomor fungsi Dimensi Pengerjaan permukaan dan tipe secara kimiawi SO

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10. Model dan nomor seri yang berlakuModel-model, kode daerah pemasaran dan nomor seri yang berlaku didalam parts catalog ini dapat diidentifikasi sebagai berikut dibawah ini.

* Dari nomor identifikasi karburator, hanya dipakai bagian yang digaris bawahi didalam contoh dibawah

2. Kode warna

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.

Kode warna pabrik seperti FMB, PFW, ABM dsbnya secara langsung menunjukkan warna part seperti ditunjukkan pada tabel berikut :

WarnaKode Warna

Kode HONDA

BlackPearl Fadeless WhiteAssure Blue MetallicCandy Scarlet RedPowder Pink MetallicCandy Blitz Orange

NH1NH-341PB-201MR-333CRP-178MYR-294C

Kode pabrik

FMBPFWABMCSRPPMCBO

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 hourR ....................... Right L (100L) .......... Link(100 Links)L. ...................... Left A.C ................. Alternating currentSTD .................. Standard D.C ................. Direct current MM ................... Milimeter IN ................... InletG ...................... Gram EX. ................. ExhaustT(22) ................. Tooth (22Teeth) FR .................. FrontA ....................... Ampere RR .................. RearV ....................... Volt Hex ................. HexagonalW ...................... Watt A.M ................. Attaching markWL .................... With labelling T.M ................. Transcript markWOL. ................ Without labelling C.D.I ............... CapacitiveKPH .................. Kilometers per hour Discharge Ignition

4. Dimensi-dimensiSemua ukuran diberikan dalam satuan milimeter (mm) kecuali untuk peluru baja (steel balls), ban luar (tires) dan ban dalam (tire tubes).

Bolt (Screw) 6x12 diameter 6mm, panjang 12mm Pin 8x14 diameter 8mm, panjang 14mm O-Ring 9.5x1.6 diameter 9,5mm, tebal 1,6mm Oil seal 14x24x5 diameter dalam 14 mm, diameter luar 24 mm, tebal 5mm Tube 5x130 diameter dalam 5mm, panjang 130mm

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

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

9. Nama partNama part tidak diterjemahkan kedalam bahasa Indonesia, melainkan tetap mengguna-kan istilah resminya didalam bahasa Inggris, agar seragam dengan istilah internasional yang dipakai di seluruh dunia oleh Honda Motor Co.,Ltd.

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

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.

AVK2CH A KC 7

No. Seri Rangka yang

berlaku mulai

No. Identifikasi Karburator yang

berlaku

No. SeriMesin yang

berlaku mulai

Kodedaerah

pemasaran TipeModel

IndonesiaANC110CCI9 IN JF21E******** MH1JF****K****** AVK2CH A

Part Contoh Pengertian

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

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.

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

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

Jam0.60.70.80.91.0

DAFTAR KONVERSIJam0.10.20.30.40.5

Menit6

12182430

Menit3642485460NOMOR IDENTIFIKASI

KARBURATOR

NOMOR SERI MESIN

NOMOR SERI RANGKA

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F.R.T.

1.5

1.1

0.4

b. Pekerjaan yang terulang

Ambillah F.R.T. untuk part terakhir yang akan diganti.

(contoh) Penggantian piston dan cylinder head gasket.


Cylinder head gasket 1.0

Piston 1.5

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.


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.

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

1.

2.

3.

Service item/Bagian yang diservis

Mesin Kepala silinder Karburator

No.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

12.


0.2

0.1

0.3

0.1

0.1

0.1

0.3

0.1

0.2

0.6

0.6

0.1

Pemeriksaan waktu pengapian

Penyetelan dan pembersihan busi

Penyetelan tappet

Penyetelan stasioner karburator

Pemeriksaan oli mesin (tidak termasukpenggantian oli mesin)

Penyetelan kopling

Pembersihan elemen saringan udara

Pengukuran tekanan kompressi

Pemeriksaan cairan baterai dan berat jenisnya

Pengukuran tinggi pelampung karburator

Pembersihan saringan oli mesin

Penyetelan gas tangan

Rangka

b. Pembongkaran


0.1

0.1

0.1

0.1

0.1

Penyetelan rem depan

Penyetelan rem belakang

Pemeriksaan cara kerja rem

Penyetelan arah lampu depan Rantai roda (termasuk penyetelan tegangan rantaitetapi tidak termasuk penggantian sprocket)

No.

1.

2.

3.

4.

5.

No.

1.


0.7 Karburator

5

2

KELOMPOK MESIN

E-1 E-2 E-3

E-4 E-5 E-6

E-7 E-8 E-9

SHROUD / FAN COVER

CAMSHAFT / VALVE

RIGHT CRANKCASE

CYLINDER HEAD COVER

GENERATOR

CYLINDER HEAD

CAM CHAIN / TENSIONER CYLINDER

OIL PUMP

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2

KELOMPOK MESIN

E-10 E-11 E-12

E-13 E-14 E-15

E-16 E-17

STARTING MOTOR

DRIVEN FACE

CRANKSHAFT / PISTON

LEFT CRANKCASE COVER

TRANSMISSION

CARBURETOR

DRIVE FACE

LEFT CRANKCASE

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KELOMPOK RANGKA

SPEEDOMETERF-1 F-2 F-3

F-4 F-6F-5

F-7 F-8

HEADLIGHT

STEERING STEMFR. BRAKE MASTER CYLINDER

FRONT FENDER

HANDLE LEVER/MIRROR/CABLE

HANDLE PIPE / HANDLE COVER

FRONT COVER F-9 FLOOR PANEL

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KELOMPOK RANGKA

F-10 F-12

F-13

FRONT FORKBODY COVER FRONT BRAKE CALIPERF-11

FRONT WHEEL F-14 REAR WHEEL F-15 SEAT/LUGGAGE BOX

F-16 FUEL TANK F-17 F-17-1AIR CLEANER AIR SUCTION VALVE

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KELOMPOK RANGKAF-20STAND / KICK ARM REAR CUSHIONF-19

F-21 REAR FENDER

EXHAUST MUFFLERF-18

F-22 FRONT WINKER F-23 COMBINATION LIGHT

F-24 BATTERY F-26 FRAME BODYF-25 WIRE HARNESS

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3

KELOMPOK RANGKAF-27 F-29CAUTION LABEL MARK / STRIPETOOLS F-28

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2

Service item F.R.T. No. Part Number Description NotesQTY

TST 08 PC 002 06 . 05 . 2008

Shroud / Fan CoverE - 1

1 COVER, FAN........................................ 0.2 2 SHROUD, ENGINE :UPPER................ 0.7 SHROUD, ENGINE :BOTH................... 1.1 4 (3) SHROUD, ENGINE :LOWER ......... 1.1 SHROUD, ENGINE :BOTH .................. 1.1

1 19610-KVY-900 COVER COMP., FAN 1 2 19621-KVY-900 SHROUD, IN. 1 3 19625-KVY-900 SEAL, SHROUD 1 4 19631-KVY-900 SHROUD, EX. 1 5 19639-GBC-000 RUBBER, MOUNTING 1

6 33715-GB0-900 COLLAR, TAILLIGHT SETTING 1 7 93404-0602000 BOLT-WASHER, 6X20 1 8 93903-25380 SCREW, TAPPING, 5X16 5 9 96001-0602500 BOLT, FLANGE, 6X25 2

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TST 08 PC 002 06 . 05 . 2008

Cylinder Head Cover

E - 2

1 12310-KVY-900 COVER COMP., CYLINDER HEAD 1 2 12391-KVY-900 GASKET, HEAD COVER 1 3 90017-GCC-000 BOLT, HEAD COVER 2 4 90543-MV9-671 RUBBER, MOUNTING 2

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

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TST 08 PC 002 06 . 05 . 2008

Cylinder Head E - 3

1 12200-KVY-900 HEAD COMP., CYLINDER 1 2 12204-KVY-900 GUIDE, VALVE 2 3 12206-KPL-900 CLIP, VALVE GUIDE 2 4 12251-KVY-901 GASKET, CYLINDER HEAD 1 5 16201-KVY-900 GASKET, CARBURETOR INSULATOR 1

6 16222-MV4-300 NUT, SQUARE, 5MM 2 7 17110-KVY-900 PIPE, INLET 1 8 17112-KVY-900 INSULATOR, CARBURETOR 1 9 17256-KVY-900 BAND A, INSULATOR 110 17257-KVB-900 COLLAR 2

11 17258-KVY-900 BAND B, INSULATOR 112 31916-KRM-841 PLUG, SPARK (CPR8EA-9) 1 31928-MFF-D01 PLUG, SPARK (U24EPR9) 113 90001-KVY-900 BOLT, FLANGE, 6X10 114 90201-GCC-000 NUT, HEX., 7MM 415 90401-KVY-900 PLATE, PLUNGER 2

16 90701-KFM-900 DOWEL PIN, SPECIAL, 8X14 217 92900-060120B BOLT, STUD, 6X12 218 92900-060280B BOLT, STUD, 6X28 219 93500-050250H SCREW, PAN, 5X25 220 94050-06000 NUT, FLANGE, 6MM 221 95701-0610000 BOLT, FLANGE, 6X100 2

1 HEAD, CYLINDER.................................. 2.7 2 GUIDE, INTAKE VALVE(ONE)............... 2.4 GUIDE, EXHAUST VALVE(ONE)........... 2.4 GUIDE, VALVE :FOR 1 VEHICLE.......... 2.7 4 GASKET, CYLINDER HEAD.................. 1.5

7 MANIFOLD, INTAKE.............................. 0.6 8 INSULATOR, THROTTLE BODY/ CARBURETOR....................................... 0.612 PLUG, SPARK........................................ 0.2

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TST 08 PC 002 06 . 05 . 2008

Camshaft / ValveE - 4

1 12209-GB4-681 SEAL, VALVE STEM 2 2 14100-KVY-900 CAMSHAFT COMP. 1 3 14125-KVY-900 PLUNGER, CAM SETTING 1 4 14126-KPH-901 SPRING, PLUNGER 1 5 14321-KVY-900 SPROCKET, CAM (34T) 1

6 14430-KVY-900 ARM COMP., IN. VALVE ROCKER 1 7 14440-KVY-900 ARM COMP., EX. VALVE ROCKER 1 8 14451-KVY-900 SHAFT, IN. ROCKER ARM 1 9 14461-KVB-900 SHAFT, EX. ROCKER ARM 110 14711-KVY-900 VALVE, IN. 1

11 14721-KVY-900 VALVE, EX. 112 14751-KVY-900 SPRING, VALVE 213 14771-GB4-680 RETAINER, VALVE SPRING 214 14775-KVY-900 SEAT, VALVE SPRING 215 14781-MA6-000 COTTER, VALVE 4

16 90012-333-000 SCREW, TAPPET ADJUSTING 217 90083-GB6-911 BOLT, KNOCK, 5MM 218 90206-001-000 NUT, TAPPET ADJUSTING 2

2 CAMSHAFT.......................................... 1.7 5 SPROCKET, CAM ............................... 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) .................... 2 12 (1,13,14,15) SPRING AND/OR STEM SEAL, INTAKE VALVE(ONE).......................... 1.8 SPRING AND/OR STEM SEAL, EXHAUST VALVE(ONE)...................... 1.8 SPRING AND/OR STEM SEAL, VALVE :FOR 1 VEHICLE .................... 1.9

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TST 08 PC 002 06 . 05 . 2008

Cam Chain / TensionerE - 5

1 14401-KVB-901 CHAIN, CAM (90L) 1 2 14510-KVB-900 TENSIONER, CAM CHAIN 1 3 14520-KSS-901 LIFTER ASSY., TENSIONER 1 4 14531-KVY-900 PIVOT, CAM CHAIN TENSIONER 1 5 14560-KCW-851 GASKET, TENSIONER LIFTER 1

6 14611-KVB-900 GUIDE, CAM CHAIN 1 7 90005-KY7-000 SCREW, PAN, 6X6 1 8 91301-GR0-004 O-RING, 15.2X1.5 1 9 91306-MG3-001 O-RING, 1.5X9.5 110 95701-0602200 BOLT, FLANGE, 6X22 2

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

6 GUIDE, CAM CHAIN ............................. 1.5

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TST 08 PC 002 06 . 05 . 2008

CylinderE- 6

1 12100-KVY-900 CYLINDER COMP. 1 2 12191-KVY-900 GASKET, CYLINDER 1 3 90701-KFM-900 DOWEL PIN, SPECIAL, 8X14 2

1 CYLINDER............................................ 1.9 2 GASKET, CYLINDER............................ 1.8

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2


TST 08 PC 002 06 . 05 . 2008

Right CrankcaseE - 7

1 11100-KVY-960 CRANKCASE COMP., R. 1 2 11103-KVB-901 BUSH, ENGINE HANGER RUBBER 1 11103-KVB-930 BUSH, ENGINE HANGER RUBBER 1 3 11205-GBC-300 BUSH, MAINSTAND 1 4 11361-KVY-900 COVER, OIL PUMP 1 5 15651-KVY-900 GAUGE, OIL LEVEL 1

6 90031-KVB-900 BOLT A, STUD, 7X193.5 2 7 90131-883-000 BOLT, DRAIN PLUG, 12X15 1 8 90702-KVB-900 PIN, SPECIAL DOWEL, 6.3X10X12 2 9 91201-GCC-771 OIL SEAL, 16X26X7 110 91307-035-000 O-RING, 18X3 1

11 91307-639-000 O-RING, 64X2 112 94109-12001 WASHER, DRAIN PLUG, 12MM 113 95701-0602200 BOLT, FLANGE, 6X22 114 95701-0605500 BOLT, FLANGE, 6X55 315 95701-0608000 BOLT, FLANGE, 6X80 3

16 95701-0608507 BOLT, FLANGE, 6X85 117 95701-0611500 BOLT, FLANGE, 6X115 1

1 CRANKCASE :RIGHT .......................... 3.2 CRANKCASE :BOTH ........................... 4.3

9 OIL SEAL, CRANKSHAFT :RIGHT ...... 3 OIL SEAL, CRANKSHAFT :BOTH........ 4.2

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TST 08 PC 002 06 . 05 . 2008

GeneratorE - 8

1 19510-KVY-900 FAN COMP., COOLING 1 2 31110-KVY-961 FLYWHEEL COMP. 1 3 31120-KVY-961 STATOR COMP. 1 4 32907-KVY-900 CLIP, A.C. GENERATOR CORD 1 5 32976-KVY-900 CLAMPER, WIRE HARNESS 1

6 90002-KGH-901 BOLT, FLANGE, 5X14 2 7 90410-HC4-000 WASHER, 10MM 1 8 94050-10000 NUT, FLANGE, 10MM 1 9 95701-0601600 BOLT, FLANGE, 6X16 310 96001-0601600 BOLT, FLANGE, 6X16 1

11 96001-0602000 BOLT, FLANGE, 6X20 2

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

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2


TST 08 PC 002 06 . 05 . 2008

Oil PumpE - 9

1 15100-KVB-900 PUMP ASSY., OIL 1 2 15133-KVY-900 GEAR, OIL PUMP DRIVEN (39T) 1 3 15135-KVY-900 SHAFT COMP., OIL PUMP 1 4 15331-KVB-900 ROTOR, OIL PUMP INNER 1 5 15332-KVB-900 ROTOR, OIL PUMP OUTER 1

6 90002-GFC-900 BOLT, HEX., 6X30 2 7 90702-KFM-900 DOWEL PIN, 8X12 2 8 93901-34120 SCREW, TAPPING, 4X8 1 9 96220-30168 ROLLER, 3X16.8 1

1 PUMP ASSY., OIL ................................ 0.8 2 (3) GEAR, OIL PUMP DRIVEN ............. 0.6

20


TST 08 PC 002 06 . 05 . 2008

Starting MotorE - 10

1 11205-GW3-931 BUSH, 8X12X6 1 2 28120-KVB-901 PINION ASSY., STARTER 1 3 28150-KVB-900 HOLDER COMP., STARTER PINION 1 4 31204-KG8-004 SPRING, CARBON BRUSH 2 5 31206-GW3-004 PACKING 1

6 31210-KVY-961 MOTOR UNIT, STARTER 1 7 31213-KEE-630 BRACKET COMP., FR. 1 8 32410-KVY-960 SUB CORD, STARTER MOTOR 1 9 91309-KEE-630 O-RING 110 93892-0400608 SCREW-WASHER, 4X6 1

11 93892-0501608 SCREW-WASHER, 5X16 312 96001-0603500 BOLT, FLANGE, 6X35 2

2 PINION, STARTER ............................... 0.3 3 HOLDER, STARTER DRIVE GEAR ..... 0.2

6 MOTOR, STARTING............................. 0.7 7 (4) BRACKET, STARTING MOTOR FRONT ................................................. 0.9 8 SUB HARNESS, STARTER ................. 0.6

21

2


TST 08 PC 002 06 . 05 . 2008

Left Crankcase CoverE - 11

1 11230-KVB-900 COVER, VENT HOLE 1 2 11340-KVY-960 COVER COMP., L. 1 3 11342-KVY-900 PLATE, L. COVER 1 4 11343-KVG-900 TUBE, DRAIN 1 5 11344-GW3-980 RUBBER, STARTER PINION HOLDER 1

6 11395-KVY-900 GASKET, L. COVER 1 7 16236-KVG-900 CLAMPER, DRAIN TUBE 1 8 19416-KEY-900 COLLAR 2 9 19741-KVY-900 DUCT, L. COVER 110 19742-KVY-900 CAP, L. COVER 1

11 19748-KVY-900 SEAL, DUCT 112 19749-KVY-900 SEAL, L. DUCT COVER 113 90652-KVB-900 CIRCLIP, INTERNAL, 32MM 114 90702-KFM-900 DOWEL PIN, 8X12 215 91005-KVB-900 BEARING COMP., RADIAL BALL 1

16 91211-PE9-003 OIL SEAL, 16X26X6 (ARAI) 117 93903-34120 SCREW, TAPPING, 4X8 518 93903-34310 SCREW, TAPPING, 4X12 219 95002-80000 CLIP, TUBE (C12) 120 96001-0601800 BOLT, FLANGE, 6X18 2


2 COVER, CRANKCASE :LEFT .............. 0.5

6 GASKET, CRANKCASE COVER :LEFT 0.210 (9,11,12) DUCT, BELT COVER ............ 0.115 BEARING, DRIVESHAFT :LEFT .......... 0.4 BEARING, DRIVESHAFT :BOTH ......... 1.2

16 OIL SEAL, KICK STARTER SPINDLE.. 0.2

22


TST 08 PC 002 06 . 05 . 2008

Drive FaceE - 12

1 22011-GCC-770 PIECE SET, SLIDE 1 2 22102-KVY-900 FACE, DRIVE (66T) 1 3 22105-KVY-900 BOSS, DRIVE FACE 1 4 22109-KVY-900 RATCHET, STARTER 1 5 22110-KVY-900 FACE COMP., MOVABLE DRIVE 1

6 22113-KVY-900 FIN, DRIVE FACE 1 7 22123-KVY-900 ROLLER SET, WEIGHT 1 8 22131-KVY-900 PLATE, RAMP 1 9 28223-GCC-000 SPRING, KICK DRIVEN GEAR 110 28230-KVB-900 GEAR COMP., KICK STARTER 1

11 28250-KVB-900 SPINDLE COMP., KICK STARTER 112 28253-KVB-901 BUSH, KICK SPINDLE 113 28255-GS6-000 COLLAR, KICK BOSS 114 28281-GCC-000 SPRING, KICK RETURN 115 90412-329-000 WASHER, THRUST, 10MM 1

16 90426-KVB-900 WASHER, SPECIAL, 14MM 117 90439-443-740 WASHER, 16X22 118 94030-14200 NUT, HEX., 14MM 119 94511-16000 CIRCLIP, EXTERNAL, 16MM 1

2 (4,6) FACE, DRIVE............................... 0.4 5 (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

23

2


TST 08 PC 002 06 . 05 . 2008

Driven FaceE - 13

1 22100-KVY-900 OUTER COMP., CLUTCH 1 2 22350-KVY-900 PLATE COMP., DRIVE 1 3 22401-KVY-900 SPRING, CLUTCH 3 4 22535-KVY-900 WEIGHT SET, CLUTCH 1 5 22804-148-000 RUBBER, CLUTCH DAMPER 3

6 23100-KVY-901 BELT, DRIVE 1 7 23205-KVY-900 FACE SET, DRIVEN 1 8 23224-KVY-900 FACE SET, MOVABLE DRIVEN 1 9 23225-KSY-900 PIN, ROLLER GUIDE 310 23226-KVB-900 ROLLER, GUIDE 3

11 23233-GCC-000 SPRING, DRIVEN FACE 112 23237-GCC-C50 COLLAR, SEAL 113 23238-GCC-000 COLLAR, SPRING 114 90202-KN7-670 NUT, SPECIAL, 28MM 115 90441-GY6-940 WASHER, 12.2X29X2.5 1

16 90442-044-000 WASHER, THRUST, 6MM 317 90454-GB2-000 CIRCLIP, 6MM 318 91009-KVY-961 BEARING, RADIAL BALL, 6902U 119 91109-KVY-901 BEARING, NEEDLE, 20X29X18 120 91211-GK8-013 OIL SEAL, 34X39X3 2

21 91351-GR1-000 O-RING, 38.5X2 122 91351-642-000 O-RING, PINION CAP 123 94030-12200 NUT, HEX., 12MM 124 94520-28000 CIRCLIP, INTERNAL, 28MM 1

1 OUTER, CLUTCH ................................ 0.3 4 (2,3) WEIGHT SET, CLUTCH ............. 0.6

6 BELT, DRIVE ........................................ 0.4 7 FACE, DRIVEN .................................... 0.5 8 (9,10,20) FACE, MOVABLE DRIVEN.... 0.5

11 (12,13) SPRING, DRIVEN FACE.......... 0.519 (18) BEARING, DRIVEN FACE.............. 0.6

24


TST 08 PC 002 06 . 05 . 2008

TransmissionE - 14

1 11108-KVB-900 PLATE, MISSION BEARING SETTING 1 2 11204-KGF-900 SLEEVE, RR. BRAKE CAM 1 3 11211-KVB-900 TUBE, BREATHER 1 4 11241-KVB-900 CLAMPER, BREATHER TUBE 1 5 21200-KVB-901 CASE COMP., MISSION 1

6 21395-KVB-900 GASKET, MISSION CASE 1 7 23411-KVY-900 SHAFT, DRIVE (18T) 1 8 23421-KVB-900 SHAFT, COUNTER (12T) 1 9 23422-KVG-900 GEAR, COUNTER (51T) 110 23430-KVB-900 GEAR COMP., FINAL (45T) 1

11 90702-KFM-901 DOWEL PIN, 8X12 212 91001-KE6-832 BEARING, RADIAL BALL, 6204 113 91007-KVB-902 BEARING, RADIAL BALL, 6201 114 91009-KVB-902 BEARING, RADIAL BALL, 60/22 UU 115 91201-434-003 OIL SEAL, 14X20X3 2

16 91255-KVB-901 OIL SEAL, 29X44X7 117 94510-20000 CIRCLIP, EXTERNAL, 20MM 118 95002-50000 CLIP, TUBE (C9) 119 95701-0601400 BOLT, FLANGE, 6X14 220 95701-0603000 BOLT, FLANGE, 6X30 2


5 CASE, TRANSMISSION ...................... 1.1

6 GASKET, TRANSMISSION CASE ....... 0.8 7 SHAFT, DRIVE ..................................... 1.1 8 COUNTERSHAFT, TRANSMISSION.... 0.8 9 GEAR, COUNTER ................................ 0.8 10 SHAFT, FINAL GEAR ........................... 0.8

12 BEARING, DRIVESHAFT :RIGHT ....... 1.1 BEARING, DRIVESHAFT :BOTH.......... 1.2 13 BEARING, COUNTERSHAFT :RIGHT.. 1 BEARING, COUNTERSHAFT :BOTH... 1.114 (16) BEARING, FINAL GEAR SHAFT :RIGHT ................................................. 1 BEARING, FINAL GEAR SHAFT :BOTH.................................................... 1.1

25

2


TST 08 PC 002 06 . 05 . 2008

Left CrankcaseE - 15

1 11103-KVB-901 BUSH, ENGINE HANGER RUBBER 1 11103-KVB-930 BUSH, ENGINE HANGER RUBBER 1 2 11200-KVY-960 CRANKCASE COMP., L. 1 3 11203-KVB-901 BUSH, RR. CUSHION UNDER RUBBER 1 4 11205-GBC-300 BUSH, MAINSTAND 1 5 11205-GW3-981 BUSH, 8X12X6 1

6 12361-035-000 CAP, TAPPET ADJUSTING HOLE 1 7 15421-107-000 SCREEN, OIL FILTER 1 8 15426-KVB-900 SPRING, OIL FILTER SCREEN 1 9 90032-KVB-900 BOLT B, STUD, 7X198.5 210 90474-333-001 WASHER, SEALING, 8MM 2

11 91002-KVY-901 BEARING, RADIAL BALL, 6007 112 91202-KJ9-003 OIL SEAL, 20X32X6 113 91202-KVB-901 OIL SEAL, 20.8X52X6X7.5 114 91302-001-020 O-RING, 30.8MM 115 94520-52150 CIRCLIP, INTERNAL, 52MM 1

16 95701-0801200 BOLT, FLANGE, 8X12 217 96100-6301000 BEARING, RADIAL BALL, 6301 118 96100-6302000 BEARING, RADIAL BALL, 6302 1

2 CRANKCASE :LEFT ............................ 4.1 CRANKCASE :BOTH ........................... 4.3

7 SCREEN, OIL FILTER ......................... 0.2 11 BEARING, CRANKSHAFT :LEFT......... 3.312 OIL SEAL, DRIVESHAFT ..................... 1.113 OIL SEAL, CRANKCASE :LEFT .......... 3.3 OIL SEAL, CRANKCASE :BOTH ......... 3.4

17 BEARING, COUNTERSHAFT :LEFT.... 1 BEARING, COUNTERSHAFT :BOTH... 1.1 18 BEARING, FINAL GEAR SHAFT :LEFT 1 BEARING, FINAL GEAR SHAFT :BOTH 1.1

26


TST 08 PC 002 06 . 05 . 2008

Crankshaft / PistonE - 16

1 13000-KVY-960 CRANKSHAFT COMP. 1 2 13011-KVY-900 RING SET, PISTON (STD) 1 13012-KVY-900 RING SET, PISTON (0,25) (1) 13013-KVY-900 RING SET, PISTON (0,50) (1) 13014-KVY-900 RING SET, PISTON (0,75) (1) 13015-KVY-900 RING SET, PISTON (1,00) (1) 3 13101-KVY-960 PISTON (STD) 1 13102-KVY-960 PISTON (0,25) (1) 13103-KVY-960 PISTON (0,50) (1) 13104-KVY-960 PISTON (0,75) (1) 13105-KVY-960 PISTON (1,00) (1) 4 13111-087-000 PIN, PISTON 1 5 13115-GN5-910 CLIP, PISTON PIN, 13MM 2

6 90741-KVY-900 KEY, WOODRUFF 1

1 CRANKSHAFT....................................... 3.5 3 (2,4,5) RING, PISTON AND/OR PISTON ONE) 2

27

2


TST 08 PC 002 06 . 05 . 2008

CarburetorE - 17

1 16010-KGF-911 GASKET SET 1 2 16012-KVY-961 NEEDLE SET, JET 1 3 16013-KRP-981 FLOAT SET 1 4 16015-KVY-901 CHAMBER SET, FLOAT 1 5 16016-KRP-981 SCREW SET A 1

6 16028-KVB-901 SCREW SET B 1 7 16037-KCW-000 PLATE SET, VALVE 1 8 16046-KVY-902 VALVE SET, STARTER 1 9 16050-KVY-901 SPRING, COMPRESSION COIL 110 16075-GHB-640 O-RING, 1.3X4.3 1

11 16100-KVY-961 CARBURETOR ASSY. 112 16107-GCC-000 TOP 113 16111-KVB-902 PISTON COMP., VACUUM 114 16119-KVB-901 STAY, WIRE 115 16131-ZW9-801 PLATE, SETTING 1

16 16140-GFC-901 BODY COMP., BYSTARTER 117 16155-KJ9-751 VALVE COMP., FLOAT 118 16163-KGF-911 GASKET, FLOAT CHAMBER 119 16165-KVB-901 HOLDER, NEEDLE JET 120 16180-KGH-971 JET, SLOW, #35 1

2 NEEDLE, JET ....................................... 0.8 3 (17) FLOAT OR FLOAT VALVE ............. 0.7 4 CHAMBER, FLOAT .............................. 0.6

8 BYSTARTER, AUTO ............................ 0.4

11 CARBURETOR ASSEMBLY ................ 0.713 PISTON, VACUUM ............................... 0.3

31 (19,20) JET, MAIN ................................ 0.7

28


TST 08 PC 002 06 . 05 . 2008

CarburetorE - 17

21 16190-GEE-003 CAP, HOLDER 122 16199-KVY-901 TUBE, AIR VENT 123 16423-KGH-901 GASKET, BYSTARTER 124 93500-040081H SCREW, PAN, 4X8 225 93500-040120H SCREW, PAN, 4X12 3

26 93500-050121H SCREW, PAN, 5X12 227 93892-0400818 SCREW-WASHER, 4X8 128 93892-0501218 SCREW-WASHER, 5X12 229 95002-02089 CLIP, TUBE (B8) 130 95005-4524050 TUBE, 4.5X240 1

31 99101-KVC-1000 JET, #100 1

3

29


TST 08 PC 002 06 . 05 . 2008

HeadlightF - 1

1 33110-KVY-961 HEADLIGHT UNIT 1 2 33115-KBA-830 NUT, ADJUST 1 3 33130-KVY-961 SOCKET COMP., HEADLIGHT 1 4 34901-KPH-881 BULB, HEADLIGHT (12V 32/32W) 1 5 34908-GA7-701 BULB, WEDGE BASE (T10) 1

6 53209-GAH-000 CLIP, HEADLIGHT 2 7 90101-GJ6-000 BOLT, ADJUSTING 1

1 HEADLIGHT UNIT ............................... 0.3 3 SUB CORD, HEADLIGHT ................... 0.2 4 BULB, HEADLIGHT ............................. 0.2

3

30


TST 08 PC 002 06 . 05 . 2008

SpeedometerF - 2

1 34908-GA7-701 BULB, WEDGE BASE (T10) 1 34909-KVR-600 BULB, WEDGE BASE (T10) 1 2 34908-KVE-900 BULB, WEDGE BASE (T10) 3 34908-MB9-871 BULB, WEDGE BASE (12V 1.7W) 3 3 37200-KVY-960 SPEEDOMETER ASSY. 4 37210-KVY-961 SPEEDOMETER COMP. 1 5 37211-KVY-961 LENS 1

6 37212-KVY-961 CASE ASSY. 1 7 37224-KVY-961 SOCKET COMP. 1 8 37305-KE5-008 SCREW-WASHER, 3X22 3 9 38301-KEV-950 RELAY COMP., WINKER 110 38306-KK4-000 SUSPENSION, WINKER RELAY 1

11 44830-KVY-910 CABLE COMP., SPEEDOMETER 112 90035-166-008 SCREW-WASHER, SPECIAL, 4X10 213 90101-KY6-008 SCREW, TAPPING, 3X14 214 91352-671-003 O-RING, 8.5X1.5 1 91352-671-004 O-RING, 8.5X1.5 115 93903-25310 SCREW, TAPPING, 5X16 3

3 METER ASSY., COMBINATION ........... 0.5 4 METER, COMBINATION ...................... 0.6 5 LENS, METER ..................................... 0.5

6 CASE, METER ..................................... 0.6 7 SOCKET ASSY., METER BULB .......... 0.6 9 RELAY, WINKER .................................. 0.2

11 CABLE, SPEEDOMETER .................... 0.4

3

31


TST 08 PC 002 06 . 05 . 2008

Handle Lever/ Mirror/ Cable

F - 3

1 17910-KVG-900 CABLE COMP., THROTTLE 1 2 30158-GW3-980 E-RING, 3MM 1 3 35150-KPH-880 SWITCH UNIT, LIGHTING 1 4 35160-KPH-881 SWITCH UNIT, STARTING 1 5 35170-KVB-851 SWITCH UNIT, DIMMER 1

6 35180-KPH-881 SWITCH UNIT, HORN 1 7 35200-KVB-851 SWITCH UNIT, WINKER 1 8 35340-KPH-901 SWITCH ASSY., FR. STOP 1 9 43450-KVY-900 CABLE COMP., RR. BRAKE 110 43455-KVB-900 CLAMPER, RR. BRAKE CABLE 1

11 53140-KVB-900 GRIP COMP., THROTTLE 112 53166-KVB-900 GRIP, L. HANDLE 113 53167-KFM-900 HOUSING, UPPER THROTTLE 114 53168-KFM-900 HOUSING, UNDER THROTTLE 115 53178-KVB-900 LEVER, L. STEERING HANDLE 1

16 53181-KVB-900 LEVER COMP., BRAKE LOCK 117 53182-KVB-900 SPRING, RETURN LEVER 118 53183-KVB-900 PIN, PARKING LEVER PIVOT 119 88114-KVB-900 CAP, LOCK NUT 220 88110-KVY-960 MIRROR ASSY, R. BACK 1

1 CABLE, THROTTLE.............................. 1 3 SWITCH, LIGHTING............................. 0.3 4 SWITCH, STARTER ............................. 0.3 5 SWITCH, DIMMER ............................... 0.3

6 SWITCH, HORN ................................... 0.3 7 SWITCH, WINKER ................................ 0.3 8 SWITCH, REAR STOP :LEVER SIDE... 0.3 SWITCH, STOP :BOTH ........................ 0.4 9 CABLE, REAR BRAKE ......................... 1

11 GRIP, THROTTLE ................................. 0.5 12 GRIP, HANDLE :LEFT .......................... 0.1 15 LEVER, HANDLE :LEFT ....................... 0.2 LEVER, HANDLE :BOTH ...................... 0.3

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

3

32


TST 08 PC 002 06 . 05 . 2008

Handle Lever/ Mirror/ Cable

F - 3

21 88120-KVY-960 MIRROR ASSY, L.BACK 1 22 90115-KRS-690 BOLT, HANDLE LEVER PIVOT 123 90302-435-761 NUT, HEX., 5MM 124 90314-KVR-600 NUT, LOCK 225 93500-050250B SCREW, PAN, 5X25 1

3

33


TST 08 PC 002 06 . 05 . 2008

Fr. Brake Master Cylinder

F - 4

1 35340-KGH-901 SWITCH ASSY., FR. STOP 1 2 45126-KVY-911 HOSE COMP., FR. BRAKE 1 3 45156-KVB-850 CLAMPER, BRAKE HOSE 1 4 45157-KVY-910 CLAMPER B, BRAKE HOSE 1 5 45504-410-003 BOOT COMP. 1

6 45510-KVY-911 CYLINDER SUB ASSY., FR. BRAKE 1 7 45512-MA6-006 PROTECTOR 1 8 45513-GW0-911 CAP, MASTER CYLINDER 1 9 45517-GW0-751 HOLDER, MASTER CYLINDER 110 45520-GW0-912 DIAPHRAGM 1

11 45521-GW0-911 PLATE, DIAPHRAGM 112 45530-KVY-911 CYLINDER SET, MASTER 113 53175-KRS-T80 LEVER, R. STEERING HANDLE 114 90114-KGH-900 BOLT, HANDLE LEVER PIVOT 115 90145-KPH-B30 BOLT, OIL, 10X22 2

16 90545-300-000 WASHER, OIL BOLT 417 90651-MA5-671 CIRCLIP 118 93600-040121G SCREW, FLAT, 4X12 219 93893-0401217 SCREW-WASHER, 4X12 120 94050-06000 NUT, FLANGE, 6MM 1


1 SWITCH, FRONT STOP ...................... 0.2 SWITCH, STOP :BOTH ....................... 0.4 2 HOSE, FRONT BRAKE ........................ 0.7

6 CYLINDER, FRONT BRAKE MASTER 0.610 DIAPHRAGM, FRONT BRAKE MASTER CYLINDER ........................... 0.1

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

3

34


TST 08 PC 002 06 . 05 . 2008

Handle Pipe / Handle Cover

F - 5

1 53100-KVY-960 PIPE COMP., STEERING HANDLE 1 2 53205-KVY-910FMB COVER, FR. HANDLE (DISK) *NH1*................... BLACK 1 BLACK 53205-KVY-910PFW *NH-341P*........... PEARL FADELESS WHITE (1) WHITE 53205-KVY-910ABM *B-201M*.............. ASSURE BLUE METALLIC (1) BLUE 53205-KVY-910CSR *R-333C* ............. CANDY SCARLET RED (1) RED 53205-KVY-910PPM *RP-178M* .......... POWDER PINK METALLIC (1) PINK 53205-KVY-910CBO *YR-294C* ........... CANDY BLITZ ORANGE (1) ORANGE 3 53206-KVY-960 COVER, RR. HANDLE 1 4 90106-GN5-900 BOLT, FLANGE, 10X50 1 5 90304-KGH-901 NUT, U, 10MM 1

6 90501-KPH-880 COLLAR A, HANDLE SETTING 1 7 90505-KPH-880 COLLAR B, HANDLE SETTING 1 8 93903-34380 SCREW, TAPPING, 4X12 6 9 93903-35380 SCREW, TAPPING, 5X16 1

1 PIPE, STEERING HANDLE.................. 0.7 2 COVER, HANDLE :FRONT................... 0.2 COVER, HANDLE :BOTH..................... 0.6 3 COVER, HANDLE :REAR..................... 0.6 COVER, HANDLE :BOTH..................... 0.6

3

35


TST 08 PC 002 06 . 05 . 2008

Steering StemF - 6

1 06530-GBG-B20 BALL SET, STEEL, #6X23 1 2 06531-GBG-B20 BALL SET, STEEL, #6X29 1 3 50301-KPH-720 RACE, STEERING TOP BALL 1 4 50302-KPH-720 RACE, STEERING BOTTOM BALL 1 5 50306-GN5-901 NUT, STEERING STEM LOCK 1

6 53211-KPH-720 RACE, STEERING TOP CONE 1 7 53212-KPH-720 RACE, STEERING BOTTOM CONE 1 8 53214-GN5-900 DUST SEAL, STEERING HEAD 1 9 53215-GN5-900 WASHER, STEERING HEAD DUST 110 53216-GN5-830 WASHER, STEERING STEM NUT 1

11 53219-KVY-960 STEM SUB ASSY., STEERING 112 53220-GN5-900 THREAD COMP., STEERING HEAD 113 95801-1004008 BOLT, FLANGE, 10X40 4

1 PIPE, STEERING HANDLE.................. 0.7 3 RACE, STEERING BALL :UPPER ...... 1.1 RACE, STEERING BALL :BOTH ......... 1.1 4 RACE, STEERING BALL :LOWER ...... 1.1 RACE, STEERING BALL :BOTH ......... 1.1

6 RACE, STEERING TOP CONE ........... 0.7 7 (8,9) RACE, STEERING BOTTOM CONE ................................... 1.3

11 STEM OR SHAFT ASSY., STEERING.. 1.112 THREAD, STEERING HEAD TOP ....... 0.7

3

36


TST 08 PC 002 06 . 05 . 2008

Front FenderF - 7

1 61100-KVY-960FMB FENDER, FR. *NH1*................... BLACK 1 BLACK 61100-KVY-960PFW *NH-341P*........... PEARL FADELESS WHITE (1) WHITE 61100-KVY-960ABM *B-201M*.............. ASSURE BLUE METALLIC (1) BLUE 61100-KVY-960CSR *R-333C* ............. CANDY SCARLET RED (1) RED 61100-KVY-960PPM *RP-178M* .......... POWDER PINK METALLIC (1) PINK 61100-KVY-960CBO *YR-294C* ........... CANDY BLITZ ORANGE (1) ORANGE 2 61112-KVG-900 COLLAR, FR. FENDER 4 3 95701-0601600 BOLT, FLANGE, 6X16 4

1 FENDER, FRONT ................................ 0.2

3

37


TST 08 PC 002 06 . 05 . 2008

Front CoverF - 8

1 64301-KVY-960FMB COVER, FR. (WL) *NH1*................... BLACK 1 BLACK 64301-KVY-960PFW *NH-341P*........... PEARL FADELESS WHITE (1) WHITE 64301-KVY-960ABM *B-201M*.............. ASSURE BLUE METALLIC (1) BLUE 64301-KVY-960CSR *R-333C* ............. CANDY SCARLET RED (1) RED 64301-KVY-960PPM *RP-178M* .......... POWDER PINK METALLIC (1) PINK 64301-KVY-960CBO *YR-294C* ........... CANDY BLITZ ORANGE (1) ORANGE

2 64510-KEV-900 CUSHION, FR. TOP COVER 2 3 81110-KVB-930 BRACKET, FR. NUMBER PLATE 1 4 81131-KVY-900 COVER, INNER UPPER 1 5 81132-GAH-000 HOOK, LUGGAGE 1

6 90107-KVB-900 BOLT, SPECIAL, 6MM 1 7 90302-GW3-980 NUT, SPRING, 4MM 4 8 93903-34380 SCREW, TAPPING, 4X12 8 9 95701-0603200 BOLT, FLANGE, 6X32 2

1 COVER, FRONT .................................. 0.4 4 PANEL, INNER :UPPER ...................... 0.3 PANEL, INNER :BOTH ........................ 0.9

3

38


TST 08 PC 002 06 . 05 . 2008

Floor PanelF - 9

1 64310-KVY-900 STEP, FLOOR 1 2 64340-KVY-960 COVER, UNDER 1 3 64520-KVY-900 COVER, FR. LOWER 1 4 81141-KVY-960 COVER, INNER LOWER 1 5 90302-GW3-980 NUT, SPRING, 4MM 4

6 90677-KAN-T00 NUT, CLIP, 5MM 6 7 93894-0501607 SCREW-WASHER, 5X16 6 8 93903-34380 SCREW, TAPPING, 4X12 6 9 93903-34480 SCREW, TAPPING, 4X16 2

1 STEP, FLOOR ..................................... 0.9 2 COVER, UNDER ................................. 0.2 3 COVER, FRONT LOWER ................... 0.3 4 PANEL, INNER :LOWER ..................... 0.9 PANEL, INNER :BOTH ........................ 0.9

3

39


TST 08 PC 002 06 . 05 . 2008

Body CoverF - 10

1 80102-KVY-960 COVER, RR. CUSHION 1 2 80151-KVY-900 COVER, CENTER 1 3 83500-KVY-960FMB COVER , R. BODY (WL) *NH1*................... BLACK 1 BLACK 83500-KVY-960PFW *NH-341P*........... PEARL FADELESS WHITE (1) WHITE 83500-KVY-960ABM *B-201M*.............. ASSURE BLUE METALLIC (1) BLUE 83500-KVY-960CSR *R-333C* ............. CANDY SCARLET RED (1) RED 83500-KVY-960PPM *RP-178M* .......... POWDER PINK METALLIC (1) PINK 83500-KVY-960CBO *YR-294C* ........... CANDY BLITZ ORANGE (1) ORANGE

4 83600-KVY-960FMB COVER, L. BODY (WL) *NH1*................... BLACK 1 BLACK 83600-KVY-960PFW *NH-341P*........... PEARL FADELESS WHITE (1) WHITE 83600-KVY-960ABM *B-201M*.............. ASSURE BLUE METALLIC (1) BLUE 83600-KVY-960CSR *R-333C* ............. CANDY SCARLET RED (1) RED 83600-KVY-960PPM *RP-178M* .......... POWDER PINK METALLIC (1) PINK 83600-KVY-960CBO *YR-294C* ........... CANDY BLITZ ORANGE (1) ORANGE 5 90107-GFC-900 BOLT, SPECIAL, 6MM 1

6 91509-GE2-760 SCREW, PAN, 5X11.5 2 7 93903-24481 SCREW, TAPPING, 4X16 2 8 93903-34380 SCREW, TAPPING, 4X12 7

2 COVER, BODY :CENTER.................... 0.2 3 COVER, BODY :RIGHT........................ 0.4 COVER, BODY :BOTH......................... 0.4 4 (1) COVER, BODY :LEFT .................... 0.4 COVER, BODY :BOTH......................... 0.4

3

40


TST 08 PC 002 06 . 05 . 2008

Front ForkF - 11

1 51400-KVY-871 FORK ASSY., R. FR. 1 2 51401-KVB-901 SPRING, FR. FORK 2 3 51410-KVB-901 PIPE COMP., FR. FORK 2 4 51412-GN5-901 SPRING, REBOUND 2 5 51420-KVY-871 CASE, R. FR. BOTTOM 1

6 51425-GN5-901 DUST SEAL 2 7 51437-KGH-901 RING, PISTON 2 8 51454-KEV-881 SEAT B, SPRING 2 9 51456-KPH-901 RING, STOPPER 210 51466-065-901 RING, OIL SEAL STOPPER 2

11 51470-KVY-901 PIPE, SEAT 212 51490-KGH-901 SEAL SET, FR. FORK 213 51500-KVY-871 FORK ASSY., L. FR. 114 51520-KVY-871 CASE, L. FR. BOTTOM 115 90116-KV3-701 BOLT, SOCKET, 8MM 2

16 90544-283-000 WASHER, SPECIAL, 8MM 217 91356-GM0-003 O-RING 2

1 FORK ASSY., FRONT :RIGHT.............. 0.4 FORK ASSY., FRONT :BOTH............... 0.5

2 SPRING, FRONT FORK :LEFT............. 0.6 SPRING, FRONT FORK :RIGHT........... 0.6 SPRING, FRONT FORK :BOTH........... 0.9

3 PIPE, FRONT FORK :LEFT................... 0.7 PIPE, FRONT FORK :RIGHT................ 0.7 PIPE, FRONT FORK :BOTH................. 1.2

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

12 SEAL SET, FRONT FORK :LEFT.......... 0.8 SEAL SET, FRONT FORK :RIGHT........ 0.8 SEAL SET, FRONT FORK :BOTH........ 1.4

13 FORK ASSY., FRONT :LEFT................. 0.4 FORK ASSY., FRONT :BOTH............... 0.5

14 CASE, BOTTOM :LEFT......................... 0.8 CASE, BOTTOM :BOTH....................... 1.4

3

41


TST 08 PC 002 06 . 05 . 2008

Front Brake CaliperF - 12

1 06451-MA7-405 SEAL SET, PISTON 1 2 06455-KVY-911 PAD SET, FR. 1 3 43352-568-003 SCREW, BLEEDER 1 4 43353-461-771 CAP, BLEEDER 1 5 45108-KVY-911 SPRING, PAD 1

6 45118-MN8-701 PISTON (B) 1 7 45131-GZ0-006 BOLT, PIN 1 8 45132-166-016 BOOT, PIN BUSH 1 9 45133-MA3-006 BOOT B 110 45150-KVY-911 CALIPER SUB ASSY., L. FR. 1

11 45190-KVY-911 BRACKET SUB ASSY., FR. CALIPER 112 45203-MG3-016 PLUG, PIN 113 45215-KVY-911 PIN, HANGER 114 45216-166-006 WASHER, WAVE 115 90131-KPH-880 BOLT, TORX, 8X25 2

2 SHOE(PAD) SET, BRAKE :FRONT...... 0.1

6 (1) PISTON, FRONT BRAKE CALIPER 0.5 10 CALIPER, FRONT BRAKE :LEFT........ 0.4

11 BRACKET, FRONT CALIPER.............. 0.2

3

42


TST 08 PC 002 06 . 05 . 2008

Front WheelF - 13

1 44301-GN5-900 AXLE, FR. WHEEL 1 2 44311-KVB-910 COLLAR, FR. WHEEL SIDE 1 3 44620-KVB-910 COLLAR, FR. DISTANCE 1 4 44601-KVB-912 WHEEL SUB ASSY., FR. *NH303M* 1 5 44711-KVB-930 TIRE, FR. (80/90 - 14M/C 40P) 1

6 27514-300140000 TUBE, TIRE 1 7 44800-KVB-910 BOX ASSY., SPEEDOMETER GEAR 1 8 44806-KVB-911 GEAR, SPEEDOMETER (21T) 1 9 44809-KFM-900 WASHER, SPEEDOMETER GEAR 110 45351-KVY-961 DISK, FR. BRAKE 1

11 90105-KGH-900 BOLT, BRAKE DISK, 8X24 412 90306-KGH-901 NUT, U, 12MM 113 91052-KVB-901 BEARING, RADIAL BALL, 6201(U) 214 91251-KPH-901 DUST SEAL, 21X37X7 115 91258-KM1-004 SEAL, SPEEDOMETER GEAR BOX 1

1 AXLE, FRONT WHEEL......................... 0.2 4 FRONT WHEEL.................................... 0.8 5 FRONT TIRE(ONE)............................... 0.7

6 TUBE, FRONT TIRE(ONE)................... 0.7 7 GEARBOX ASSY., SPEEDOMETER.... 0.2 10 DISC, FRONT BRAKE.......................... 0.3

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

3

43


TST 08 PC 002 06 . 05 . 2008

Rear WheelF - 14

1 43130-KVB-901 SHOE SET, BRAKE 1 2 42601-KVG-912 WHEEL COMP., RR. *NH303M* 1 3 42711-KVB-930 TIRE, RR. 1 4 43141-KVB-900 CAM, RR. BRAKE 1 5 43151-329-000 SPRING, BRAKE SHOE 2

6 43410-KVB-900 ARM, RR. BRAKE 1 7 43472-KVB-900 SPRING, RR. BRAKE ARM 1 8 27514-300140000 TUBE, TIRE 1 9 90112-KVB-900 BOLT, FLANGE, 6X32 110 90305-KVB-901 NUT, U, 16MM 1

11 90501-KBN-900 WASHER, 16MM 112 95015-32001 JOINT B, BRAKE ARM 113 95015-42000 NUT B, BRAKE ROD ADJUSTING 1

1 SHOE(PAD) SET, BRAKE :REAR......... 0.4 2 REAR WHEEL ...................................... 0.8 3 REAR TIRE(ONE) ................................ 0.8 4 CAM, BRAKE :REAR ........................... 0.5

6 ARM, BRAKE :REAR ........................... 0.5 8 TUBE, REAR TIRE(ONE) ..................... 0.8

3

44


TST 08 PC 002 06 . 05 . 2008

Seat / Luggage Box

F - 15

1 50400-KVY-900 RAIL, RR. GRAB 1 2 75581-GN8-920 SPRING, LOCK KEY SETTING 1 3 77200-KVY-960 SEAT COMP., DOUBLE 1 4 77214-KPH-900 RUBBER B, SEAT SETTING 2 5 77215-KVY-900 PIN, SEAT HINGE 1

6 77230-KVY-900 CATCH COMP., SEAT 1 7 77234-GN2-000 SPRING, SEAT LOCK 1 8 77236-KVY-900 WASHER, SEAT LOCK 1 9 77240-KTM-851 LOCK ASSY., SEAT 110 80107-KVY-900 GUARD, HEAT 1

11 81250-KVY-960 BOX, LUGGAGE 112 81251-KVY-900 COVER, LUGGAGE BOX 113 81252-KVY-900 CAP, LUGGAGE BOX 114 81253-KVY-900 CUSHION, C.D.I. UNIT 115 81254-KVY-960 CAP, LUGGAGE SIDE 1

16 81256-KVY-960 COVER ASSY., BATTERY 117 90302-GW3-980 NUT, SPRING, 4MM 318 90501-KVY-900 COLLAR, LUGGAGE SET 219 90683-GAZ-003 CLIP, TRIM 120 93404-0601000 BOLT-WASHER, 6X10 2

1 RAIL, GRAB :REAR ............................. 0.1 3 (5) SEAT :DOUBLE ............................... 0.2

6 CATCH, SEAT :REAR SIDE ................ 0.5 9 KEY, SEAT LOCK ................................ 0.3

11 BOX, LUGGAGE .................................. 0.212 LID, LUGGAGE BOX ........................... 0.1

3

45


TST 08 PC 002 06 . 05 . 2008

Seat / Luggage Box

F - 15

21 93404-0602000 BOLT-WASHER, 6X20 222 95701-0802001 BOLT, FLANGE, 8X20 423 96001-0601201 BOLT, FLANGE, 6X12 224 98200-31000 FUSE, BLADE (10A) 125 98200-31500 FUSE, BLADE (15A) 1

3

46


TST 08 PC 002 06 . 05 . 2008

Fuel TankF - 16

1 16950-KJ9-752 COCK ASSY., FUEL AUTO 1 2 16952-KJ9-752 SCREEN SET, FUEL STRAINER 1 3 16958-397-771 O-RING 1 4 17510-KVY-960 TANK COMP., FUEL 1 5 17525-KVY-900 TRAY, FUEL 1

6 17620-KGH-600 CAP, FUEL FILLER 1 7 17630-KVY-960 TUBE, FUEL 1 8 17631-KEV-900 PACKING, FUEL FILLER CAP 1 9 17635-KVY-900 TUBE, PRESSURE 110 37800-KVY-960 FUEL UNIT 1

11 37801-GA7-700 PACKING, BASE 112 37802-KTL-740 RETAINER, FUEL UNIT 113 95002-02070 CLIP, TUBE (B7) 214 95002-02080 CLIP, TUBE (B8) 215 95701-0601200 BOLT, FLANGE, 6X12 2

1 COCK, FUEL AUTO ............................. 0.5 2 SCREEN, FUEL STRAINER ................ 0.5 4 TANK, FUEL ......................................... 0.6

10 FUEL TANK SENDING UNIT ............... 0.2

3

47


TST 08 PC 002 06 . 05 . 2008

Air CleanerF - 17

1 15771-551-000 CLIP, OIL DRAIN TUBE 2 2 17210-KVY-960 ELEMENT COMP., AIR CLEANER 1 3 17212-KVY-900 SEAL A, AIR CLEANER 2 4 17213-KVY-900 SEAL B, AIR CLEANER 1 5 17218-KVY-900 TUBE, BREATHER 1

6 17225-KVY-960 CASE SUB ASSY., AIR CLEANER 1 7 17235-KVY-900 COVER SUB ASSY., AIR CLEANER 1 8 17236-KVB-900 PLUG, AIR CLEANER DRAIN 1 9 17244-KVY-900 RUBBER, AIR SUCTION VALVE 110 17251-KVY-960 DUCT, AIR CLEANER INTAKE 1

11 17253-KVY-900 TUBE, AIR CLEANER CONNECTING 112 17254-KVY-900 BAND, CONNECTING TUBE (50) 113 17261-KVY-900 TUBE, AIR CLEANER DRAIN 114 17274-KVB-900 TUBE, AIR OPENING 115 17370-419-700 PLUG, BREATHER TUBE 1

16 18805-KVY-900 ELEMENT, AIR CLEANER (ASV) 117 64531-KFM-900 COLLAR, BODY COVER 318 87509-KVB-930 LABEL, AIR CLEANER CASE COVER 119 93903-25510 SCREW, TAPPING, 5X25 620 95002-02130 CLIP, TUBE (B12.5) 2

21 95002-4120008 CLAMP, TUBE (D12) 222 95002-80000 CLIP, TUBE (C12) 123 95701-0602500 BOLT, FLANGE, 6X25 3

2 ELEMENT, AIR CLEANER ................... 0.2

6 CASE, AIR CLEANER ......................... 0.6 7 (10) COVER, AIR CLEANER CASE ..... 0.2

11 TUBE, AIR CLEANER CONNECTING.. 0.6 16 ELEMENT, SUB AIR CLEANER .......... 0.2

3

48


TST 08 PC 002 06 . 05 . 2008

Air Suction ValveF - 17 - 1

1 17240-KVY-900 STAY, AIR SUCTION VALVE 1 2 17622-GB7-900 RUBBER, CUSHION 2 3 18600-KVB-901 VALVE ASSY., AIR SUCTION 1 4 18640-KVY-900 PIPE COMP., AIR FEED 1 5 18645-KVY-900 GASKET, AIR FEED PIPE 1

6 18652-KVY-900 HOSE (AI) 1 7 18655-KVY-900 TUBE, AIR SUCTION VALVE (PB) 1 8 19509-KVB-900 CLAMP, TUBE (D19) 1 9 90501-124-000 WASHER, FR. COVER SETTING 210 90678-MN5-000 CLIP, FUEL HOSE 1

11 93404-0603000 BOLT-WASHER, 6X30 212 94050-06001 NUT, FLANGE, 6MM 213 95002-02070 CLIP, TUBE (B7) 214 95701-0601200 BOLT, FLANGE, 6X12 215 95701-0601800 BOLT, FLANGE, 6X18 3

3 VALVE, SECONDARY AIR CONTROL. 0.5 4 (5) PIPE, SECONDARY AIR................. 0.2

3

49


TST 08 PC 002 06 . 05 . 2008

Exhaust MufflerF - 18

1 18291-KVB-900 GASKET, EX. PIPE 1 2 18293-KSB-900 RUBBER, PROTECTOR PACKING 2 3 18310-KVY-960 MUFFLER COMP., EX. 1 4 18316-KVB-900 COLLAR, MUFFLER PROTECTOR 2 5 18318-KVY-900 PROTECTOR A, MUFFLER 1

6 90202-ZV0-001 NUT, CAP, 6MM 2 7 95701-1004007 BOLT, FLANGE, 10X40 2 8 95801-0601602 BOLT, FLANGE, 6X16 2 9 18300-KVY-960 MUFFLER ASSY, EXHAUST 1

1 GASKET, EXHAUST PIPE ................... 0.2 3 MUFFLER ............................................ 0.2 5 PROTECTOR, MUFFLER .................... 0.1

3

50


TST 08 PC 002 06 . 05 . 2008

Stand / Kick ArmF - 19

1 28300-KVB-900 ARM ASSY., KICK STARTER 1 2 35700-KVY-900 SWITCH ASSY., SIDE STAND 1 3 50500-KVY-870 STAND COMP., MAIN 1 4 50503-KVY-900 SHAFT, MAIN STAND 1 5 50520-KVB-900 SPRING, MAIN STAND 1

6 50530-KVY-870 BAR COMP., SIDE STAND 1 7 61101-KCJ-690 COLLAR, FR. FENDER SETTING 1 8 90101-KVY-900 BOLT, SETTING, 6X16 1 9 90108-MK6-670 BOLT, SIDE STAND PIVOT 110 90147-KVY-900 BOLT, SWITCH SETTING 1

11 90203-KVB-900 NUT, SIDE STAND 112 94101-10800 WASHER, PLAIN, 10MM 113 94201-30201 PIN, SPLIT, 3.0X20 114 95011-61000 RUBBER A, STAND STOPPER 115 95014-72102 SPRING A, SIDE STAND 1

16 95701-0802500 BOLT, FLANGE, 8X25 1

1 ARM, KICK STARTER ......................... 0.1 2 SWITCH, SIDE STAND ....................... 0.7 3 (4) STAND, MAIN .................................. 0.4 5 SPRING, MAIN STAND ....................... 0.2

6 BAR, SIDE STAND .............................. 0.2 15 SPRING, SIDE STAND ........................ 0.1

3

51


TST 08 PC 002 06 . 05 . 2008

Rear CushionF - 20

1 52400-KVB-941 CUSHION ASSY., RR. 1 2 52485-088-901 BUSH, RR. CUSHION RUBBER 1 3 52486-GA7-003 COLLAR, RUBBER BUSH 1 4 95801-0803200 BOLT, FLANGE, 8X32 1 5 95801-1003500 BOLT, FLANGE, 10X35 1

1 CUSHION ASSY., REAR ..................... 0.4

3

52


TST 08 PC 002 06 . 05 . 2008

Rear FenderF - 21

1 80104-KVY-870 GUARD, SPLASH 12 80110-KVY-960 FENDER, RR. 3 90677-KAN-T00 NUT, CLIP, 5MM 24 93404-0601200 BOLT-WASHER, 6X12 3

2 FENDER, REAR .................................. 0.5

3

53


TST 08 PC 002 06 . 05 . 2008

Front WinkerF - 22

1 33402-KVY-961 LENS, R. FR. WINKER 1 2 33403-KVY-961 BASE, R. FR. WINKER 1 3 33404-KVY-961 SEAL, GASKET 2 4 33452-KVY-961 LENS, L. FR. WINKER 1 5 33453-KVY-961 BASE, L. FR. WINKER 1

6 34905-KAN-W01 BULB, WINKER (12V 10W) 2 7 93903-34320 SCREW, TAPPING, 4X12 6 8 33400-KVY-961 WINKER ASSY, R FR 1 9 33450-KVY-961 WINKER ASSY, L FR 1

2 (1,3) BASE, WINKER :RIGHT FRONT 0.2 BASE, WINKER :BOTH FRONT........... 0.3 5 (3,4) BASE, WINKER :LEFT FRONT... 0.2 BASE, WINKER :BOTH FRONT........... 0.3

6 BULB, WINKER :FRONT...................... 0.2 BULB, WINKER :FOR 1 VEHICLE....... 0.3

3

54


TST 08 PC 002 06 . 05 . 2008

Combination LightF - 23

1 33700-KVY-961 LIGHT ASSY., RR. COMBINATION 1 2 33701-KVY-961 LENS COMP., TAILLIGHT 1 3 33702-KVY-961 LENS, R. WINKER 1 4 33704-KVY-961 BASE COMP., TAILLIGHT 1 5 33705-KVY-961 PACKING 1. 1

6 33752-KVY-961 LENS, L. WINKER 1 7 34905-KAN-W01 BULB, WINKER (12V 10W) 2 8 34906-GB6-921 BULB, TAILLIGHT (12V 18/5W) 1 9 90302-GW3-980 NUT, SPRING, 4MM 210 93901-24580 SCREW, TAPPING, 4X20 2

11 93903-34380 SCREW, TAPPING, 4X12 212 95701-0601200 BOLT, FLANGE, 6X12 2

1 TAILLIGHT UNIT .................................. 0.4 4 BASE, TAILLIGHT................................. 0.5

7 (3,6) BULB, WINKER :REAR............... 0.1 BULB, WINKER :FOR 1 VEHICLE....... 0.3 8 (2,5) BULB, TAILLIGHT........................ 0.1

3

55


TST 08 PC 002 06 . 05 . 2008

BatteryF - 24

1 31500-KPH-881 BATTERY 1 1 BATTERY ............................................. 0.2

3

56


TST 08 PC 002 06 . 05 . 2008

Wire HarnessF - 25

1 30410-KVY-961 C.D.I. UNIT 1 2 30500-KVY-901 COIL ASSY., IGNITION 1 3 30700-KVY-960 CAP ASSY., NOISE SUPPRESSOR 1 4 31600-KVB-901 RECTIFIER COMP., REGULATOR 1 5 32100-KVY-960 HARNESS, WIRE 1

6 33714-KL3-620 RUBBER, TAILLIGHT BRACKET 2 7 35010-KVY-960 KEY SET 1 8 35011-KVY-900 SHUTTER SET, KEY 1 9 35100-KVY-961 SWITCH ASSY., COMBINATION & 110 35121-KVY-900 KEY, BLANK (90KEYTOP2REPORDER) 1

11 38110-KTM-851 HORN COMP.(HIGH) 112 38117-KPH-880 COLLAR, HORN SETTING 113 38501-KPH-901 RELAY COMP., STARTER 1 38501-KVB-901 RELAY COMP., STARTER 114 90106-KPH-690 BOLT, SOCKET, 6X10 115 90164-028-000 SCREW, U-LOCK FLAT, 6X12 2

16 95701-0601200 BOLT, FLANGE, 6X12 217 95701-0602000 BOLT, FLANGE, 6X20 318 98200-31000 FUSE, BLADE (10A) 119 98200-31500 FUSE, BLADE (15A) 1

1 IGNITION CONTROL MODULE .......... 0.3 2 COIL, IGNITION.................................... 0.6 4 RECTIFIER, REGULATE...................... 0.5 5 HARNESS, WIRE.................................. 1

7 KEY SET................................................ 1.5 8 KEY, SHUTTER..................................... 1 .EXCLUDES: Key cutting 9 SWITCH, COMBINATION & LOCK ...... 1.1

11 HORN(S) .............................................. 0.2 13 RELAY, STARTER ................................ 0.2

3

57


TST 08 PC 002 06 . 05 . 2008

Frame BodyF - 26

1 50100-KVY-960 BODY COMP., FRAME 1 2 50350-KVY-900 LINK ASSY., ENGINE HANGER 1 3 50352-KVY-900 RUBBER, LINK STOPPER (70) 2 4 64223-KVY-960 STAY, FR. COVER 1 5 90105-KVY-900 BOLT, FLANGE, 10X270 1

6 90106-GCC-000 BOLT, FLANGE, 10X238 1 7 90304-KGH-901 NUT, U, 10MM 2 8 95701-0803200 BOLT, FLANGE, 8X32 2

1 BODY, FRAME...................................... 5.1 2 LINK, ENGINE HANGER ..................... 1 4 STAY, FRONT COVER ......................... 0.3

3

58


TST 08 PC 002 06 . 05 . 2008

ToolsF - 27

1 89102-538-000 DRIVER, SCREW (NO.2 + -) 1 2 89103-538-000 GRIP 1 3 89216-KVY-900 WRENCH, SPARK PLUG 1

3

59


TST 08 PC 002 06 . 05 . 2008

Caution LabelF - 28

1 87505-KVY-960 LABEL, TIRE 1 2 87506-KPH-880 MARK, BATTERY CAUTION 1 3 87560-KVB-930 LABEL, DRIVE CAUTION 1 4 87586-KVB-930 LABEL, FUEL 1

3

60


TST 08 PC 002 06 . 05 . 2008

Mark / StripeF - 29

3

1 871X0-KVY-960ZA STRIPE SET ........ BLACK 1 BLACK 871X0-KVY-960ZB STRIPE SET ........ PEARL FADELESS WHITE (1) WHITE 871X0-KVY-960ZC STRIPE SET ........ ASSURE BLUE METALLIC (1) BLUE 871X0-KVY-960ZD STRIPE SET ........ CANDY SCARLET RED (1) RED 871X0-KVY-960ZE STRIPE SET ........ POWDER PINK METALLIC (1) PINK 871X0-KVY-960ZF STRIPE SET ........ CANDY BLITZ ORANGE (1) ORANGE

I N D E K S PART NUMBER

61

4

Block No.Part Number (00000)06451-MA7-405 F1206455-KVY-911 F1206530-GBG-B20 F606531-GBG-B20 F6

(10000)11100-KVY-960 E711103-KVB-901 E711103-KVB-901 E1511103-KVB-930 E711103-KVB-930 E1511108-KVB-900 E1411200-KVY-960 E1511203-KVB-901 E1511204-KGF-900 E1411205-GBC-300 E711205-GBC-300 E1511205-GW3-931 E1011205-GW3-981 E1511211-KVB-900 E1411230-KVB-900 E1111241-KVB-900 E1411340-KVY-960 E1111342-KVY-900 E1111343-KVG-900 E1111344-GW3-980 E1111361-KVY-900 E711395-KVY-900 E1112100-KVY-900 E612191-KVY-900 E612200-KVY-900 E312204-KVY-900 E312206-KPL-900 E312209-GB4-681 E412251-KVY-901 E312310-KVY-900 E212361-035-000 E1512391-KVY-900 E213000-KVY-960 E1613011-KVY-900 E1613012-KVY-900 E1613013-KVY-900 E1613014-KVY-900 E1613015-KVY-900 E16

13101-KVY-960 E1613102-KVY-960 E1613103-KVY-960 E1613104-KVY-960 E1613105-KVY-960 E1613111-087-000 E1613115-GN5-910 E1614100-KVY-900 E414125-KVY-900 E414126-KPH-901 E414321-KVY-900 E414401-KVB-901 E514430-KVY-900 E414440-KVY-900 E414451-KVY-900 E414461-KVB-900 E414510-KVB-900 E514520-KSS-901 E514531-KVY-900 E514560-KCW-851 E514611-KVB-900 E514711-KVY-900 E414721-KVY-900 E414751-KVY-900 E414771-GB4-680 E414775-KVY-900 E414781-MA6-000 E415100-KVB-900 E915133-KVY-900 E915135-KVY-900 E915331-KVB-900 E915332-KVB-900 E915421-107-000 E1515426-KVB-900 E1515651-KVY-900 E715771-551-000 F1716010-KGF-911 E1716012-KVY-961 E1716013-KRP-981 E1716015-KVY-901 E1716016-KRP-981 E1716028-KVB-901 E1716037-KCW-000 E1716046-KVY-902 E1716050-KVY-901 E17

16075-GHB-640 E1716100-KVY-961 E1716107-GCC-000 E1716111-KVB-902 E1716119-KVB-901 E1716131-ZW9-801 E1716140-GFC-901 E1716155-KJ9-751 E1716163-KGF-911 E1716165-KVB-901 E1716180-KGH-971 E1716190-GEE-003 E1716199-KVY-901 E1716201-KVY-900 E316222-MV4-300 E316236-KVG-900 E1116423-KGH-901 E1716950-KJ9-752 F1616952-KJ9-752 F1616958-397-771 F1617110-KVY-900 E317112-KVY-900 E317210-KVY-960 F1717212-KVY-900 F1717213-KVY-900 F1717218-KVY-900 F1717225-KVY-960 F1717235-KVY-900 F1717236-KVB-900 F1717240-KVY-900 F17-117244-KVY-900 F1717251-KVY-960 F1717253-KVY-900 F1717254-KVY-900 F1717256-KVY-900 E317257-KVB-900 E317258-KVY-900 E317261-KVY-900 F1717274-KVB-900 F1717370-419-700 F1717510-KVY-960 F1617525-KVY-900 F1617620-KGH-600 F1617622-GB7-900 F17-117630-KVY-960 F16

17631-KEV-900 F1617635-KVY-900 F1617910-KVG-900 F318291-KVB-900 F1818293-KSB-900 F1818300-KVY-960 F1818310-KVY-960 F1818316-KVB-900 F1818318-KVY-900 F1818600-KVB-901 F17-118640-KVY-900 F17-118645-KVY-900 F17-118652-KVY-900 F17-118655-KVY-900 F17-118805-KVY-900 F1719416-KEY-900 E1119509-KVB-900 F17-119510-KVY-900 E819610-KVY-900 E119621-KVY-900 E119625-KVY-900 E119631-KVY-900 E119639-GBC-000 E119741-KVY-900 E1119742-KVY-900 E1119748-KVY-900 E1119749-KVY-900 E11

(20000)21200-KVB-901 E1421395-KVB-900 E1422011-GCC-770 E1222100-KVY-900 E1322102-KVY-900 E1222105-KVY-900 E1222109-KVY-900 E1222110-KVY-900 E1222113-KVY-900 E1222123-KVY-900 E1222131-KVY-900 E1222350-KVY-900 E1322401-KVY-900 E1322535-KVY-900 E1322804-148-000 E1323100-KVY-901 E13

23205-KVY-900 E1323224-KVY-900 E1323225-KSY-900 E1323226-KVB-900 E1323233-GCC-000 E1323237-GCC-C50 E1323238-GCC-000 E1323411-KVY-900 E1423421-KVB-900 E1423422-KVG-900 E1423430-KVB-900 E1427514-300140000 F1327514-300140000 F1428120-KVB-901 E1028150-KVB-900 E1028223-GCC-000 E1228230-KVB-900 E1228250-KVB-900 E1228253-KVB-901 E1228255-GS6-000 E1228281-GCC-000 E1228300-KVB-900 F19

(30000)30158-GW3-980 F330410-KVY-961 F2530500-KVY-901 F2530700-KVY-960 F2531110-KVY-961 E831120-KVY-961 E831204-KG8-004 E1031206-GW3-004 E1031210-KVY-961 E1031213-KEE-630 E1031500-KPH-881 F2431600-KVB-901 F2531916-KRM-841 E331928-MFF-D01 E332100-KVY-960 F2532410-KVY-960 E1032907-KVY-900 E832976-KVY-900 E833110-KVY-961 F133115-KBA-830 F133130-KVY-961 F1


62

4

Part Number Block No.33400-KVY-961 F2233402-KVY-961 F2233403-KVY-961 F2233404-KVY-961 F2233450-KVY-961 F2233452-KVY-961 F2233453-KVY-961 F2233700-KVY-961 F2333701-KVY-961 F2333702-KVY-961 F2333704-KVY-961 F2333705-KVY-961 F2333714-KL3-620 F2533715-GB0-900 E133752-KVY-961 F2334901-KPH-881 F134905-KAN-W01 F2234905-KAN-W01 F2334906-GB6-921 F2334908-GA7-701 F134908-GA7-701 F234908-KVE-900 F234908-MB9-871 F234909-KVR-600 F235010-KVY-960 F2535011-KVY-900 F2535100-KVY-961 F2535121-KVY-900 F2535150-KPH-880 F335160-KPH-881 F335170-KVB-851 F335180-KPH-881 F335200-KVB-851 F335340-KGH-901 F435340-KPH-901 F335700-KVY-900 F1937200-KVY-960 F237210-KVY-961 F237211-KVY-961 F237212-KVY-961 F237224-KVY-961 F237305-KE5-008 F237800-KVY-960 F1637801-GA7-700 F16

37802-KTL-740 F1638110-KTM-851 F2538117-KPH-880 F2538301-KEV-950 F238306-KK4-000 F238501-KPH-901 F2538501-KVB-901 F25

(40000)42601-KVG-912 F1442711-KVB-930 F1443130-KVB-901 F1443141-KVB-900 F1443151-329-000 F1443352-568-003 F1243353-461-771 F1243410-KVB-900 F1443450-KVY-900 F343455-KVB-900 F343472-KVB-900 F1444301-GN5-900 F1344311-KVB-910 F1344601-KVG-912 F1344620-KVB-910 F1344711-KVB-930 F1344800-KVB-910 F1344806-KVB-911 F1344809-KFM-900 F1344830-KVY-910 F245108-KVY-911 F1245118-MN8-701 F1245126-KVY-911 F445131-GZ0-006 F1245132-166-016 F1245133-MA3-006 F1245150-KVY-911 F1245156-KVB-850 F445157-KVY-910 F445190-KVY-911 F1245203-MG3-016 F1245215-KVY-911 F1245216-166-006 F1245351-KVY-961 F1345504-410-003 F445510-KVY-911 F4

45512-MA6-006 F445513-GW0-911 F445517-GW0-751 F445520-GW0-912 F445521-GW0-911 F445530-KVY-911 F4

(50000)50100-KVY-960 F2650301-KPH-720 F650302-KPH-720 F650306-GN5-900 F650350-KVY-900 F2650352-KVY-900 F2650400-KVY-900 F1550500-KVY-870 F1950503-KVY-900 F1950520-KVB-900 F1950530-KVY-870 F1951400-KVY-871 F1151401-KVB-901 F1151410-KVB-901 F1151412-GN5-901 F1151420-KVY-871 F1151425-GN5-901 F1151437-KGH-901 F1151454-KEV-881 F1151456-KPH-901 F1151466-065-901 F1151470-KVY-901 F1151490-KGH-901 F1151500-KVY-871 F1151520-KVY-871 F1152400-KVB-941 F2052485-088-901 F2052486-GA7-003 F2053100-KVY-960 F553140-KVB-900 F353166-KVB-900 F353167-KFM-900 F353168-KFM-900 F353175-KRS-T80 F453178-KVB-900 F353181-KVB-900 F353182-KVB-900 F3

53183-KVB-900 F353205-KVY-910ZH F553206-KVY-960ZA F553209-GAH-000 F153211-KPH-720 F653212-KPH-720 F653214-GN5-900 F653215-GN5-900 F653216-GN5-830 F653219-KVY-960 F653220-GN5-900 F6

(60000)61100-KVY-960 F761101-KCJ-690 F1961112-KVG-900 F764223-KVY-960 F2664301-KVY-960 F864310-KVY-900 F964340-KVY-960 F964510-KEV-900 F864520-KVY-900 F964531-KFM-900 F17

(70000)75581-GN8-920 F1577200-KVY-960 F1577214-KPH-900 F1577215-KVY-900 F1577230-KVY-900 F1577234-GN2-000 F1577236-KVY-900 F1577240-KTM-851 F15

(80000)80102-KVY-960 F1080104-KVY-870 F2180107-KVY-900 F1580110-KVY-960 F2180151-KVY-900ZA F1081110-KVB-930 F881131-KVY-900ZA F881132-GAH-000ZW F881141-KVY-960 F981250-KVY-960 F1581251-KVY-900 F15

81252-KVY-900 F1581253-KVY-900 F1581254-KVY-960 F1581256-KVY-960 F1583500-KVY-960 F1083600-KVY-960 F1083642-171-000 F27871X0-KVY-960ZA F29871X0-KVY-960ZB F29871X0-KVY-960ZC F29871X0-KVY-960ZD F29871X0-KVY-960ZE F29871X0-KVY-960ZF F2987505-KVY-960 F2887506-KPH-880 F2887509-KVB-930 F1787560-KVB-930 F2887586-KVB-930 F2888110-KVY-960 F388114-KVB-900 F388120-KVY-960 F389102-538-000 F2789103-538-000 F2789216-KVY-900 F27

(90000)90001-KVY-900 E390002-GFC-900 E990002-KGH-901 E890005-KY7-000 E590012-333-000 E490017-GCC-000 E290031-KVB-900 E790032-KVB-900 E1590035-166-008 F290083-GB6-911 E490101-GJ6-000 F190101-KVY-900 F1990101-KY6-008 F290105-KGH-900 F1390105-KVY-900 F2690106-GCC-000 F2690106-GN5-900 F590106-KPH-690 F2590107-GFC-900 F10


63

4

Block No.Part Number90107-KVB-900 F890108-MK6-670 F1990112-KVB-900 F1490114-KGH-900 F490115-KRS-690 F390116-KV3-701 F1190131-883-000 E790131-KPH-880 F1290145-KPH-B30 F490147-KVY-900 F1990164-028-000 F2590201-GCC-000 E390202-KN7-670 E1390202-ZV0-001 F1890203-KVB-900 F1990206-001-000 E490302-435-761 F390302-GW3-980 F890302-GW3-980 F990302-GW3-980 F1590302-GW3-980 F2390304-KGH-901 F590304-KGH-901 F2690305-KVB-901 F1490306-KGH-901 F1390314-KVR-600 F390401-KVY-900 E390410-HC4-000 E890412-329-000 E1290426-KVB-900 E1290439-443-740 E1290441-GY6-940 E1390442-044-000 E1390454-GB2-000 E1390474-333-001 E1590501-124-000 F17-190501-KBN-900 F1490501-KPH-880 F590501-KVY-900 F1590505-KPH-880 F590543-MV9-671 E290544-283-000 F1190545-300-000 F490651-MA5-671 F4

90652-KVB-900 E1190677-KAN-T00 F990677-KAN-T00 F2190678-MN5-000 F17-190683-GAZ-003 F1590701-KFM-900 E390701-KFM-900 E690702-KFM-900 E990702-KFM-900 E1190702-KFM-901 E1490702-KVB-900 E790741-KVY-900 E1691001-KE6-832 E1491002-KVY-901 E1591005-KVB-900 E1191007-KVB-902 E1491009-KVB-902 E1491009-KVY-961 E1391052-KVB-901 F1391109-KVY-901 E1391201-434-003 E1491201-GCC-771 E791202-KJ9-003 E1591202-KVB-901 E1591211-GK8-013 E1391211-PE9-003 E1191251-KPH-901 F1391255-KVB-901 E1491258-KM1-004 F1391301-GR0-004 E591302-001-020 E1591306-MG3-000 E591307-035-000 E791307-639-000 E791309-KEE-630 E1091351-642-000 E1391351-GR1-000 E1391352-671-003 F291352-671-004 F291356-GM0-003 F1191509-GE2-760 F1092900-060120B E392900-060280B E393404-0601000 F15

93404-0601200 F2193404-0602000 E193404-0602000 F1593404-0603000 F17-193500-040081H E1793500-040120H E1793500-050121H E1793500-050250B F393500-050250H E393600-040121G F493892-0400608 E1093892-0400818 E1793892-0501218 E1793892-0501608 E1093893-0401217 F493894-0501607 F993901-24580 F2393901-34120 E993903-24481 F1093903-25310 F293903-25380 E193903-25510 F1793903-34120 E1193903-34310 E1193903-34320 F2293903-34380 F593903-34380 F893903-34380 F993903-34380 F1093903-34380 F2393903-34480 F993903-35380 F594030-12200 E1394030-14200 E1294050-06000 E394050-06000 F494050-06001 F17-194050-10000 E894101-10800 F1994109-12001 E794201-30201 F1994510-20000 E1494511-16000 E1294520-28000 E13

94520-52150 E1595002-02070 F1695002-02070 F17-195002-02080 F1695002-02089 E1795002-02130 F1795002-4120008 F1795002-50000 E1495002-80000 E1195002-80000 F1795005-4524050 E1795011-61000 F1995014-72102 F1995015-32001 F1495015-42000 F1495701-0601200 F495701-0601200 F1695701-0601200 F17-195701-0601200 F2395701-0601200 F2595701-0601400 E1495701-0601600 E895701-0601600 F795701-0601800 F17-195701-0602000 F2595701-0602200 E595701-0602200 E795701-0602201 F495701-0602500 F1795701-0603000 E1495701-0603200 F895701-0604000 E1495701-0605500 E795701-0608000 E795701-0608507 E795701-0610000 E395701-0611500 E795701-0801200 E1595701-0802001 F1595701-0802500 F1995701-0803200 F2695701-1004007 F1895801-0601602 F1895801-0803200 F20

95801-1003500 F2095801-1004008 F696001-0601201 F1596001-0601600 E896001-0601600 E1496001-0601800 E1196001-0602000 E896001-0602500 E196001-0603500 E1096001-0603500 E1196001-0608500 E1196100-6301000 E1596100-6302000 E1596220-30168 E998200-31000 F1598200-31000 F2598200-31500 F1598200-31500 F2599101-KVC-1000 E17

I N D E K S DESCRIPTION

64

5

Description Block No. Description Block No. Description Block No.

(A)ARM ASSY., KICK STARTER F19ARM COMP., EX. VALVE ROCKER E4ARM COMP., IN. VALVE ROCKER E4ARM, RR. BRAKE F14AXLE, FR. WHEEL F13

(B)BAG, OWNERS MANUAL F27BALL SET, STEEL, #6X23 F6BALL SET, STEEL, #6X29 F6BAND A, INSULATOR E3BAND B, INSULATOR E3BAND, CONNECTING TUBE (50) F17BAR COMP., SIDE STAND F19BASE COMP., TAILLIGHT F23BASE, L. FR. WINKER F22BASE, R. FR. WINKER F22BATTERY F24BEARING COMP., RADIAL BALL E11BEARING, NEEDLE, 20X29X18 E13BEARING, RADIAL BALL, 60/22 UU E14BEARING, RADIAL BALL, 6007 E15BEARING, RADIAL BALL, 6201 E14BEARING, RADIAL BALL, 6201(U) F13BEARING, RADIAL BALL, 6204 E14BEARING, RADIAL BALL, 6301 E15BEARING, RADIAL BALL, 6302 E15BEARING, RADIAL BALL, 6902U E13BELT, DRIVE E13BODY COMP., BYSTARTER E17BODY COMP., FRAME F26BOLT A, STUD, 7X193.5 E7BOLT B, STUD, 7X198.5 E15BOLT, ADJUSTING F1BOLT, BRAKE DISK, 8X24 F13BOLT, DRAIN PLUG, 12X15 E7BOLT, FLANGE, 10X238 F26BOLT, FLANGE, 10X270 F26BOLT, FLANGE, 10X35 F20BOLT, FLANGE, 10X40 F6BOLT, FLANGE, 10X40 F18BOLT, FLANGE, 10X50 F5BOLT, FLANGE, 5X14 E8BOLT, FLANGE, 6X10 E3

BOLT, FLANGE, 6X100 E3BOLT, FLANGE, 6X115 E7BOLT, FLANGE, 6X12 F4BOLT, FLANGE, 6X12 F15BOLT, FLANGE, 6X12 F16BOLT, FLANGE, 6X12 F17-1BOLT, FLANGE, 6X12 F23BOLT, FLANGE, 6X12 F25BOLT, FLANGE, 6X14 E14BOLT, FLANGE, 6X16 E8BOLT, FLANGE, 6X16 E8BOLT, FLANGE, 6X16 E14BOLT, FLANGE, 6X16 F7BOLT, FLANGE, 6X16 F18BOLT, FLANGE, 6X18 E11BOLT, FLANGE, 6X18 F17-1BOLT, FLANGE, 6X20 E8BOLT, FLANGE, 6X20 F25BOLT, FLANGE, 6X22 E5BOLT, FLANGE, 6X22 E7BOLT, FLANGE, 6X22 F4BOLT, FLANGE, 6X25 E1BOLT, FLANGE, 6X25 F17BOLT, FLANGE, 6X30 E14BOLT, FLANGE, 6X32 F8BOLT, FLANGE, 6X32 F14BOLT, FLANGE, 6X35 E10BOLT, FLANGE, 6X35 E11BOLT, FLANGE, 6X40 E14BOLT, FLANGE, 6X55 E7BOLT, FLANGE, 6X80 E7BOLT, FLANGE, 6X85 E7BOLT, FLANGE, 6X85 E11BOLT, FLANGE, 8X12 E15BOLT, FLANGE, 8X20 F15BOLT, FLANGE, 8X25 F19BOLT, FLANGE, 8X32 F20BOLT, FLANGE, 8X32 F26BOLT, HANDLE LEVER PIVOT F3BOLT, HANDLE LEVER PIVOT F4BOLT, HEAD COVER E2BOLT, HEX., 6X30 E9BOLT, KNOCK, 5MM E4BOLT, OIL, 10X22 F4

BOLT, PIN F12BOLT, SETTING, 6X16 F19BOLT, SIDE STAND PIVOT F19BOLT, SOCKET, 6X10 F25BOLT, SOCKET, 8MM F11BOLT, SPECIAL, 6MM F8BOLT, SPECIAL, 6MM F10BOLT, STUD, 6X12 E3BOLT, STUD, 6X28 E3BOLT, SWITCH SETTING F19BOLT, TORX, 8X25 F12BOLT-WASHER, 6X10 F15BOLT-WASHER, 6X12 F21BOLT-WASHER, 6X20 E1BOLT-WASHER, 6X20 F15BOLT-WASHER, 6X30 F17-1BOOT B F12BOOT COMP. F4BOOT, PIN BUSH F12BOSS, DRIVE FACE E12BOX ASSY., SPEEDOMETER GEAR F13BOX, LUGGAGE F15BRACKET COMP., FR. E10BRACKET SUB ASSY., FR. CALIPER F12BRACKET, FR. NUMBER PLATE F8BULB, HEADLIGHT (12V 32/32W) F1BULB, TAILLIGHT (12V 18/5W) F23BULB, WEDGE BASE (12V 1.7W) F2BULB, WEDGE BASE (T10) F1BULB, WEDGE BASE (T10) F2BULB, WEDGE BASE (T10) F2BULB, WEDGE BASE (T10) F2BULB, WINKER (12V 10W) F22BULB, WINKER (12V 10W) F23BUSH, 8X12X6 E10BUSH, 8X12X6 E15BUSH, ENGINE HANGER RUBBER E7BUSH, ENGINE HANGER RUBBER E7BUSH, ENGINE HANGER RUBBER E15BUSH, ENGINE HANGER RUBBER E15BUSH, KICK SPINDLE E12BUSH, MAINSTAND E7BUSH, MAINSTAND E15BUSH, RR. CUSHION RUBBER F20


65


5

BUSH, RR. CUSHION UNDER RUBBER E15

(C)C.D.I. UNIT F25CABLE COMP., RR. BRAKE F3CABLE COMP., SPEEDOMETER F2CABLE COMP., THROTTLE F3CALIPER SUB ASSY., L. FR. F12CAM, RR. BRAKE F14CAMSHAFT COMP. E4CAP ASSY., NOISE SUPPRESSOR F25CAP, BLEEDER F12CAP, FUEL FILLER F16CAP, HOLDER E17CAP, L. COVER E11CAP, LOCK NUT F3CAP, LUGGAGE BOX F15CAP, LUGGAGE SIDE F15CAP, MASTER CYLINDER F4CAP, TAPPET ADJUSTING HOLE E15CARBURETOR ASSY. E17CASE ASSY. F2CASE COMP., MISSION E14CASE SUB ASSY., AIR CLEANER F17CASE, L. FR. BOTTOM F11CASE, R. FR. BOTTOM F11CATCH COMP., SEAT F15CHAIN, CAM (90L) E5CHAMBER SET, FLOAT E17CIRCLIP F4CIRCLIP, 6MM E13CIRCLIP, EXTERNAL, 16MM E12CIRCLIP, EXTERNAL, 20MM E14CIRCLIP, INTERNAL, 28MM E13CIRCLIP, INTERNAL, 32MM E11CIRCLIP, INTERNAL, 52MM E15CLAMP, TUBE (D12) F17CLAMP, TUBE (D19) F17-1CLAMPER B, BRAKE HOSE F4CLAMPER, BRAKE HOSE F4CLAMPER, BREATHER TUBE E14CLAMPER, DRAIN TUBE E11CLAMPER, RR. BRAKE CABLE F3CLAMPER, WIRE HARNESS E8CLIP, A.C. GENERATOR CORD E8

CLIP, FUEL HOSE F17-1CLIP, HEADLIGHT F1CLIP, OIL DRAIN TUBE F17CLIP, PISTON PIN, 13MM E16CLIP, TRIM F15CLIP, TUBE (B12.5) F17CLIP, TUBE (B7) F16CLIP, TUBE (B7) F17-1CLIP, TUBE (B8) E17CLIP, TUBE (B8) F16CLIP, TUBE (C12) E11CLIP, TUBE (C12) F17CLIP, TUBE (C9) E14CLIP, VALVE GUIDE E3COCK ASSY., FUEL AUTO F16COIL ASSY., IGNITION F25COLLAR E3COLLAR E11COLLAR A, HANDLE SETTING F5COLLAR B, HANDLE SETTING F5COLLAR, BODY COVER F17COLLAR, FR. DISTANCE F13COLLAR, FR. FENDER F7COLLAR, FR. FENDER SETTING F19COLLAR, FR. WHEEL SIDE F13COLLAR, HORN SETTING F25COLLAR, KICK BOSS E12COLLAR, LUGGAGE SET F15COLLAR, MUFFLER PROTECTOR F18COLLAR, RUBBER BUSH F20COLLAR, SEAL E13COLLAR, SPRING E13COLLAR, TAILLIGHT SETTING E1COTTER, VALVE E4COVER , R. BODY F10COVER ASSY., BATTERY F15COVER COMP., CYLINDER HEAD E2COVER COMP., FAN E1COVER COMP., L. E11COVER SET, FR. F8COVER SUB ASSY., AIR CLEANER F17COVER, CENTER F10COVER, FR. HANDLE (DISK) F5COVER, FR. LOWER F9COVER, INNER LOWER F9

COVER, INNER UPPER F8COVER, L. BODY F10COVER, LUGGAGE BOX F15COVER, OIL PUMP E7COVER, RR. CUSHION F10COVER, RR. HANDLE F5COVER, UNDER F9COVER, VENT HOLE E11CRANKCASE COMP., L. E15CRANKCASE COMP., R. E7CRANKSHAFT COMP. E16CUSHION ASSY., RR. F20CUSHION, C.D.I. UNIT F15CUSHION, FR. TOP COVER F8CYLINDER COMP. E6CYLINDER SET, MASTER F4CYLINDER SUB ASSY., FR. BRAKE F4

(D)DIAPHRAGM F4DISK, FR. BRAKE F13DOWEL PIN, 8X12 E9DOWEL PIN, 8X12 E11DOWEL PIN, 8X12 E14DOWEL PIN, SPECIAL, 8X14 E3DOWEL PIN, SPECIAL, 8X14 E6DRIVER, SCREW (NO.2 + -) F27DUCT, AIR CLEANER INTAKE F17DUCT, L. COVER E11DUST SEAL F11DUST SEAL, 21X37X7 F13DUST SEAL, STEERING HEAD F6

(E)ELEMENT COMP., AIR CLEANER F17ELEMENT, AIR CLEANER (ASV) F17E-RING, 3MM F3

(F)FACE COMP., MOVABLE DRIVE E12FACE SET, DRIVEN E13FACE SET, MOVABLE DRIVEN E13FACE, DRIVE (66T) E12FAN COMP., COOLING E8FENDER SET, RR. F21FENDER, FR. F7FIN, DRIVE FACE E12


66

5

Description Block No. Description Block No. Description Block No.FLOAT SET E17FLYWHEEL COMP. E8FORK ASSY., L. FR. F11FORK ASSY., R. FR. F11FUEL UNIT F16FUSE, BLADE (10A) F15FUSE, BLADE (10A) F25FUSE, BLADE (15A) F15FUSE, BLADE (15A) F25

(G)GASKET SET E17GASKET, AIR FEED PIPE F17-1GASKET, BYSTARTER E17GASKET, CARBURETOR INSULATOR E3GASKET, CYLINDER E6GASKET, CYLINDER HEAD E3GASKET, EX. PIPE F18GASKET, FLOAT CHAMBER E17GASKET, HEAD COVER E2GASKET, L. COVER E11GASKET, MISSION CASE E14GASKET, TENSIONER LIFTER E5GAUGE, OIL LEVEL E7GEAR COMP., FINAL (45T) E14GEAR COMP., KICK STARTER E12GEAR, COUNTER (51T) E14GEAR, OIL PUMP DRIVEN (39T) E9GEAR, SPEEDOMETER (21T) F13GRIP F27GRIP COMP., THROTTLE F3GRIP, L. HANDLE F3GUARD, HEAT F15GUARD, SPLASH F21GUIDE, CAM CHAIN E5GUIDE, VALVE E3

(H)HARNESS, WIRE F25HEAD COMP., CYLINDER E3HEADLIGHT UNIT F1HOLDER COMP., STARTER PINION E10HOLDER, MASTER CYLINDER F4HOLDER, NEEDLE JET E17HOOK, LUGGAGE F8HORN COMP.(HIGH) F25

HOSE (AI) F17-1HOSE COMP., FR. BRAKE F4HOUSING, UNDER THROTTLE F3HOUSING, UPPER THROTTLE F3

(I)INSULATOR, CARBURETOR E3

(J)JET, #100 E17JET, SLOW, #35 E17JOINT B, BRAKE ARM F14

(K)KEY SET F25KEY, BLANK F25KEY, WOODRUFF E16

(L)LABEL, AIR CLEANER CASE COVER F17LABEL, DRIVE CAUTION F28LABEL, FUEL F28LABEL, TIRE F28LENS F2LENS COMP., TAILLIGHT F23LENS, L. FR. WINKER F22LENS, L. WINKER F23LENS, R. FR. WINKER F22LENS, R. WINKER F23LEVER COMP., BRAKE LOCK F3LEVER, L. STEERING HANDLE F3LEVER, R. STEERING HANDLE F4LIFTER ASSY., TENSIONER E5LIGHT ASSY., RR. COMBINATION F23LINK ASSY., ENGINE HANGER F26LOCK ASSY., SEAT F15

(M)MARK, BATTERY CAUTION F28MIRROR ASSY, L BACK F3MIRROR ASSY, R BACK F3MOTOR UNIT, STARTER E10MUFFLER ASSY, EXHAUST F18MUFFLER COMP., EX. F18

(N)NEEDLE SET, JET E17NUT B, BRAKE ROD ADJUSTING F14NUT, ADJUST F1

NUT, CAP, 6MM F18NUT, CLIP, 5MM F9NUT, CLIP, 5MM F21NUT, FLANGE, 10MM E8NUT, FLANGE, 6MM E3NUT, FLANGE, 6MM F4NUT, FLANGE, 6MM F17-1NUT, HEX., 12MM E13NUT, HEX., 14MM E12NUT, HEX., 5MM F3NUT, HEX., 7MM E3NUT, LOCK F3NUT, SIDE STAND F19NUT, SPECIAL, 28MM E13NUT, SPRING, 4MM F8NUT, SPRING, 4MM F9NUT, SPRING, 4MM F15NUT, SPRING, 4MM F23NUT, SQUARE, 5MM E3NUT, STEERING STEM LOCK F6NUT, TAPPET ADJUSTING E4NUT, U, 10MM F5NUT, U, 10MM F26NUT, U, 12MM F13NUT, U, 16MM F14

(O)OIL SEAL, 14X20X3 E14OIL SEAL, 16X26X6 E11OIL SEAL, 16X26X7 E7OIL SEAL, 20.8X52X6X7.5 E15OIL SEAL, 20X32X6 E15OIL SEAL, 29X44X7 E14OIL SEAL, 34X39X3 E13O-RING E10O-RING F11O-RING F16O-RING, 1.3X4.3 E17O-RING, 1.5X9.5 E5O-RING, 15.2X1.5 E5O-RING, 18X3 E7O-RING, 30.8MM E15O-RING, 38.5X2 E13O-RING, 64X2 E7O-RING, 8.5X1.5 F2


67


5

O-RING, 8.5X1.5 F2O-RING, PINION CAP E13OUTER COMP., CLUTCH E13

(P)PACKING E10PACKING 1. F23PACKING, BASE F16PACKING, FUEL FILLER CAP F16PAD SET, FR. F12PIECE SET, SLIDE E12PIN, HANGER F12PIN, PARKING LEVER PIVOT F3PIN, PISTON E16PIN, ROLLER GUIDE E13PIN, SEAT HINGE F15PIN, SPECIAL DOWEL, 6.3X10X12 E7PIN, SPLIT, 3.0X20 F19PINION ASSY., STARTER E10PIPE COMP., AIR FEED F17-1PIPE COMP., FR. FORK F11PIPE COMP., STEERING HANDLE F5PIPE, INLET E3PIPE, SEAT F11PISTON (0,25) E16PISTON (0,50) E16PISTON (0,75) E16PISTON (1,00) E16PISTON (B) F12PISTON (STD) E16PISTON COMP., VACUUM E17PIVOT, CAM CHAIN TENSIONER E5PLATE COMP., DRIVE E13PLATE SET, VALVE E17PLATE, DIAPHRAGM F4PLATE, L. COVER E11PLATE, MISSION BEARING SETTING E14PLATE, PLUNGER E3PLATE, RAMP E12PLATE, SETTING E17PLUG, AIR CLEANER DRAIN F17PLUG, BREATHER TUBE F17PLUG, PIN F12PLUG, SPARK (CPR8EA-9) E3PLUG, SPARK (U24EPR9) E3

PLUNGER, CAM SETTING E4PROTECTOR F4PROTECTOR A, MUFFLER F18PUMP ASSY., OIL E9

(R)RACE, STEERING BOTTOM BALL F6RACE, STEERING BOTTOM CONE F6RACE, STEERING TOP BALL F6RACE, STEERING TOP CONE F6RAIL, RR. GRAB F15RATCHET, STARTER E12RECTIFIER COMP., REGULATOR F25RELAY COMP., STARTER F25RELAY COMP., STARTER F25RELAY COMP., WINKER F2RETAINER, FUEL UNIT F16RETAINER, VALVE SPRING E4RING SET, PISTON (0,25) E16RING SET, PISTON (0,50) E16RING SET, PISTON (0,75) E16RING SET, PISTON (1,00) E16RING SET, PISTON (STD) E16RING, OIL SEAL STOPPER F11RING, PISTON F11RING, STOPPER F11ROLLER SET, WEIGHT E12ROLLER, 3X16.8 E9ROLLER, GUIDE E13ROTOR, OIL PUMP INNER E9ROTOR, OIL PUMP OUTER E9RUBBER A, STAND STOPPER F19RUBBER B, SEAT SETTING F15RUBBER, AIR SUCTION VALVE F17RUBBER, CLUTCH DAMPER E13RUBBER, CUSHION F17-1RUBBER, LINK STOPPER (70) F26RUBBER, MOUNTING E1RUBBER, MOUNTING E2RUBBER, PROTECTOR PACKING F18RUBBER, STARTER PINION HOLDER E11RUBBER, TAILLIGHT BRACKET F25

(S)SCREEN SET, FUEL STRAINER F16SCREEN, OIL FILTER E15

SCREW SET A E17SCREW SET B E17SCREW, BLEEDER F12SCREW, FLAT, 4X12 F4SCREW, PAN, 4X12 E17SCREW, PAN, 4X8 E17SCREW, PAN, 5X11.5 F10SCREW, PAN, 5X12 E17SCREW, PAN, 5X25 E3SCREW, PAN, 5X25 F3SCREW, PAN, 6X6 E5SCREW, TAPPET ADJUSTING E4SCREW, TAPPING, 3X14 F2SCREW, TAPPING, 4X12 E11SCREW, TAPPING, 4X12 F5SCREW, TAPPING, 4X12 F8SCREW, TAPPING, 4X12 F9SCREW, TAPPING, 4X12 F10SCREW, TAPPING, 4X12 F22SCREW, TAPPING, 4X12 F23SCREW, TAPPING, 4X16 F9SCREW, TAPPING, 4X16 F10SCREW, TAPPING, 4X20 F23SCREW, TAPPING, 4X8 E9SCREW, TAPPING, 4X8 E11SCREW, TAPPING, 5X16 E1SCREW, TAPPING, 5X16 F2SCREW, TAPPING, 5X16 F5SCREW, TAPPING, 5X25 F17SCREW, U-LOCK FLAT, 6X12 F25SCREW-WASHER, 3X22 F2SCREW-WASHER, 4X12 F4SCREW-WASHER, 4X6 E10SCREW-WASHER, 4X8 E17SCREW-WASHER, 5X12 E17SCREW-WASHER, 5X16 E10SCREW-WASHER, 5X16 F9SCREW-WASHER, SPECIAL, 4X10 F2SEAL A, AIR CLEANER F17SEAL B, AIR CLEANER F17SEAL SET, FR. FORK F11SEAL SET, PISTON F12SEAL, DUCT E11SEAL, GASKET F22


68

5

Description Block No. Description Block No. Description Block No.SEAL, L. DUCT COVER E11SEAL, SHROUD E1SEAL, SPEEDOMETER GEAR BOX F13SEAL, VALVE STEM E4SEAT B, SPRING F11SEAT COMP., DOUBLE F15SEAT, VALVE SPRING E4SHAFT COMP., OIL PUMP E9SHAFT, COUNTER (12T) E14SHAFT, DRIVE (18T) E14SHAFT, EX. ROCKER ARM E4SHAFT, IN. ROCKER ARM E4SHAFT, MAIN STAND F19SHOE SET, BRAKE F14SHROUD, EX. E1SHROUD, IN. E1SHUTTER SET, KEY F25SLEEVE, RR. BRAKE CAM E14SOCKET COMP. F2SOCKET COMP., HEADLIGHT F1SPEEDOMETER ASSY. F2SPEEDOMETER COMP. F2SPINDLE COMP., KICK STARTER E12SPRING A, SIDE STAND F19SPRING, BRAKE SHOE F14SPRING, CARBON BRUSH E10SPRING, CLUTCH E13SPRING, COMPRESSION COIL E17SPRING, DRIVEN FACE E13SPRING, FR. FORK F11SPRING, KICK DRIVEN GEAR E12SPRING, KICK RETURN E12SPRING, LOCK KEY SETTING F15SPRING, MAIN STAND F19SPRING, OIL FILTER SCREEN E15SPRING, PAD F12SPRING, PLUNGER E4SPRING, REBOUND F11SPRING, RETURN LEVER F3SPRING, RR. BRAKE ARM F14SPRING, SEAT LOCK F15SPRING, VALVE E4SPROCKET, CAM (34T) E4STAND COMP., MAIN F19

STATOR COMP. E8STAY, AIR SUCTION VALVE F17-1STAY, FR. COVER F26STAY, WIRE E17STEM SUB ASSY., STEERING F6STEP, FLOOR F9STRIPE SET ..... ASSURE BLUE METALLIC F29STRIPE SET ..... BLACK F29STRIPE SET ..... CANDY BLITZ ORANGE F29STRIPE SET ..... CANDY SCARLET RED F29STRIPE SET ..... PEARL FADELESS WHITE F29STRIPE SET ..... POWDER PINK METALLIC F29SUB CORD, STARTER MOTOR E10SUSPENSION, WINKER RELAY F2SWITCH ASSY., COMBINATION & F25SWITCH ASSY., FR. STOP F3SWITCH ASSY., FR. STOP F4SWITCH ASSY., SIDE STAND F19SWITCH UNIT, DIMMER F3SWITCH UNIT, HORN F3SWITCH UNIT, LIGHTING F3SWITCH UNIT, STARTING F3SWITCH UNIT, WINKER F3

(T)TANK COMP., FUEL F16TENSIONER, CAM CHAIN E5THREAD COMP., STEERING HEAD F6TIRE, FR. (80/90 - 14M/C 40P) F13TIRE, RR. (SRI) F14TOP E17TRAY, FUEL F16TUBE, 4.5X240 E17TUBE, AIR CLEANER CONNECTING F17TUBE, AIR CLEANER DRAIN F17TUBE, AIR OPENING F17TUBE, AIR SUCTION VALVE F17-1TUBE, AIR VENT E17TUBE, BREATHER E14TUBE, BREATHER F17TUBE, DRAIN E11TUBE, FUEL F16TUBE, PRESSURE F16TUBE, TIRE F13TUBE, TIRE F14

(V)VALVE ASSY., AIR SUCTION F17-1VALVE COMP., FLOAT E17VALVE SET, STARTER E17VALVE, EX. E4VALVE, IN. E4

(W)WASHER, 10MM E8WASHER, 12.2X29X2.5 E13WASHER, 16MM F14WASHER, 16X22 E12WASHER, DRAIN PLUG, 12MM E7WASHER, FR. COVER SETTING F17-1WASHER, OIL BOLT F4WASHER, PLAIN, 10MM F19WASHER, SEALING, 8MM E15WASHER, SEAT LOCK F15WASHER, SPECIAL, 14MM E12WASHER, SPECIAL, 8MM F11WASHER, SPEEDOMETER GEAR F13WASHER, STEERING HEAD DUST F6WASHER, STEERING STEM NUT F6WASHER, THRUST, 10MM E12WASHER, THRUST, 6MM E13WASHER, WAVE F12WEIGHT SET, CLUTCH E13WHEEL COMP., RR. F14WHEEL SUB ASSY., FR. F13WINKER ASSY, L FR F22WINKER ASSY, R FR F22WRENCH, SPARK PLUG F27

PT Astra Honda MotorTECHNICAL SERVICE DIVISION

1 8 KVYG 9 I 1Printed by CB-2008

Honda Beat Service Manual

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