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Yamaha TDM900P manual

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Table of contents for the manual

  • Page 1

    TDM900 (5PS1) EUROPE TDM900P (5PS2) OCEANIA 1A5PS − 300E2[...]

  • Page 2

    A 3 TDM900/TDM900P P ART S CA T ALOGUE E 2002 by Y amaha Motor Co., Ltd. 1st Edition, Apr . 2002 All rights reserved. Any reprinting or unauthorized use without the written permission of Y amaha Motor Co., Ltd. is expressly prohibited. Printed in Japan[...]

  • Page 3

    A 4[...]

  • Page 4

    FOREWORD A 5 This Parts Catalogue is related to the par ts for the model(s) in the below frame. When yo u are ordering replacement part s, please refe r to this P arts Catalogue and quote both part numbers and part names correctly . TDM900(5PS1),TDM900P(5PS2) 1. Modifications or additions which have been made after issue of the Parts Catalogue will[...]

  • Page 5

    MODEL LABEL A 6 (1) A label called “Model Label” is affixed in the location as indicated in (3) below . When using this parts catalogue, please be sure to cross − refer the “model code − production code No.” in the catalogue to the “model code − production code No. “indicated on the Model Label af fixed onto the product concemed. [...]

  • Page 6

    CONTENTS ENGINE CYLINDER HEAD B2 ................................... CYLINDER B4 ......................................... CRANKSHAFT . PIST ON B5 .............................. VA LV E B 6 ............................................. CAMSHAFT . CHAIN B8 ................................. W A TER PUMP B9 ...................................... RADIA[...]

  • Page 7

    B 2 FIG. 1 CYLINDER HEAD 1 5PS − 1 1 101 − 0 0 CYLI NDER H EAD ASSY 1 1 2 3LD − 1 1 133 − 10 .GUIDE, INT AKE V ALVE 6 6 3 3LD − 1 1 134 − 10 .GUIDE, EXHAUST V AL VE 4 4 4 93440 − 10109 .CIRC LIP 10 10 5 91808 − 16023 .PI N, DO WEL 8 8 6 90340 − 18101 .PLUG , STRA IGHT SC REW 2 2 7 90105 − 06153 .BOL T , FLANGE 16 16 8 95617 − [...]

  • Page 8

    B 3 FIG. 1 CYLINDER HEAD 27 90109 − 06044 BOL T 1 1 28 90109 − 06045 BOL T 1 1 29 4KG − 1111 G − 00 RUBBER, MOUNT 1 8 8 P ART NO. DESCRIPTION REMARKS REF . NO. 5PS1 5PS2[...]

  • Page 9

    B 4 FIG. 2 CYLINDER 1 5PS − 1 131 1 − 00 CYLINDER 1 1 1 2 5PS − 1 1351 − 0 0 GASKET , CYLIN DER 1 1 3 99530 − 14016 PIN, DO WEL 2 2 4 90153 − 06029 SCREW , HEXAGON 1 1 5 90430 − 06014 G ASKET 1 1 P ART NO. DESCRIPTION REMARKS REF . NO. 5PS1 5PS2[...]

  • Page 10

    B 5 FIG. 3 CRANKSHAFT . PI STON 1 5PS − 1 1400 − 0 0 CRA NKSH AFT ASSY 1 1 2 3LD − 11416 − 00 PLANE BEARING, CRANKSHAFT 1 6 6 UR BLUE 3LD − 11416 − 10 PLANE BEARING, CRANKSHAFT 1 6 6 UR BLACK 3LD − 11416 − 20 PLANE BEARING, CRANKSHAFT 1 6 6 UR BROWN 3LD − 11416 − 30 PLANE BEARING, CRANKSHAFT 1 6 6 UR GREEN 3LD − 11416 − 40 P[...]

  • Page 11

    B 6 FIG. 4 V AL VE 1 3LD − 121 1 1 − 01 V AL VE, I NT AKE (3LD.) 2 2 2 3LD − 121 12 − 0 1 V ALVE, I NT AKE 2 (3LD:) 4 4 3 5PS − 12121 − 00 V AL VE , EXHAUST 4 4 41 W G − 121 16 − 00 SEAT , V AL VE SPRING 10 10 5 3LD − 121 13 − 00 SPRING, V AL VE INNER 10 10 BLUE 6 3LD − 121 17 − 00 RET AINER, VAL VE SPRING 10 10 7 3LD − 12[...]

  • Page 12

    B 7 FIG. 4 V AL VE 10 3LD − 12169 − 70 P AD, ADJUSTING (2.05) 10 10 UR 3LD − 12169 − 90 P AD, ADJUSTING (2.10) 10 10 UR 3LD − 12169 − E0 P AD, ADJUSTING (2.15) 10 10 UR 3LD − 12169 − G0 PAD, ADJUSTING (2.20) 10 10 UR 3LD − 12169 − J0 P AD, ADJUSTING (2.25) 10 10 UR 3LD − 12169 − L0 P AD, ADJUSTING (2.30) 10 10 UR 3LD − 121[...]

  • Page 13

    B 8 FIG. 5 CAMSHAFT . CHAIN 1 5PS − 12171 − 00 CAMSHAFT 1 1 1 2 5PS − 12180 − 00 CAMSHA FT ASSY 2 1 1 3 3LD − 12176 − 00 SPROCKET , CAM CHAIN 2 2 4 90105 − 07342 BOLT , FLANGE 4 4 5 94591 − 40138 CHAIN (82RH2015 − 138L) 1 1 6 5PS − 12210 − 00 TENSIO NER ASSY , CAM C HAIN 1 1 7 5JW − 12213 − 0 0 GASKET , TENSIONE R CASE 1 1[...]

  • Page 14

    B 9 FIG. 6 W A TER PUM P 1 5PS − 12420 − 00 WA TER PU MP ASSY 1 1 2 3LD − 12439 − 00 .O − RING 1 1 3 91314 − 06020 .BOLT 2 2 4 99009 − 12400 .CIRC LIP 1 1 5 95024 − 06012 .BOLT , FLANGE 1 1 6 90430 − 06014 .G ASKET 1 1 7 93210 − 33133 O − RING 1 1 8 3VD − 12459 − 00 GEAR, IMPELLER SHAFT 1 1 9 90201 − 127E1 W ASHER, PLA T[...]

  • Page 15

    B 10 FIG. 7 RADIA TOR. HOSE 1 5PS − 12461 − 00 RADIA TO R ASSY 1 1 2 5PS − 12405 − 00 BLOWER ASSY 1 1 3 901 19 − 06044 BOL T , W ITH WASHER 4 4 4 1AA − 12535 − 00 PLA TE 4 4 5 4FL − 12462 − 00 CAP , RADIA T OR 1 1 6 1KT − 12437 − 00 STOPPER 1 1 7 97007 − 05012 BOL T 1 1 8 92907 − 05600 WASHER, PLATE 1 1 9 90467 − 10038 C[...]

  • Page 16

    B 11 FIG. 7 RADIA TOR. HOSE 28 1AE − 12410 − 00 THERMOST A T ASSY 1 1 29 5PS − 12417 − 00 HOUSING, THERMOST A T 1 1 30 4NX − 12413 − 00 COVER, THERMOSTA T 1 1 31 93210 − 49046 O − RING 1 1 32 95027 − 06020 BOL T , FLANGE 2 2 33 95027 − 06025 BOL T , FLANGE 1 1 34 5PS − 1244E − 00 BRACKET 1 1 1 35 95027 − 06010 BOL T , FLAN[...]

  • Page 17

    B 12 FIG. 8 OIL PUMP 1 3LD − 13300 − 00 OIL PUM P ASSY 1 1 2 99530 − 08012 PIN, DO WEL 1 1 3 5PS − 13329 − 00 GASKET , PUMP COVER 1 1 4 98507 − 06045 SCREW , PAN HEAD 3 3 5 90430 − 14131 G ASKET 1 1 6 90387 − 120W5 COLLAR 1 1 74 N X − 13303 − 00 OIL PUM P ASSY , 2 1 1 8 3LD − 13371 − 00 .PLA TE 1 1 9 3LD − 13339 − 00 GAS[...]

  • Page 18

    B 13 FIG. 8 OIL PUMP 28 5PS − 13417 − 00 COVER, STRAINER 1 1 29 3LD − 131 13 − 00 SEAT , CHECK BALL 1 1 30 93505 − 08030 BALL 1 1 31 90501 − 104F9 SPRING, COMPRESSION 1 1 32 90387 − 106W6 COLLAR 1 1 33 93210 − 12790 O − RING 1 1 34 1 1H − 13490 − 00 RELIE F V AL VE ASSY 1 1 35 93210 − 10096 O − RING 1 1 36 3LD − 13151 ?[...]

  • Page 19

    B 14 FIG. 8 OIL PUMP 55 90109 − 06056 BOL T 1 1 56 5PS − 13317 − 00 PLA TE, BAFFLE 1 1 57 901 10 − 06018 BOL T , HEXAGON SOCKET HEAD 2 2 58 5PS − 21761 − 00 GAUGE, LEVEL 1 1 59 93210 − 21 190 O − RING 1 1 60 5PS − 21750 − 00 OIL T ANK ASSY 1 1 61 95827 − 06014 BOL T , FLANGE 3 3 62 90445 − 1 1026 HOSE 1 1 63 90467 − 10008 [...]

  • Page 20

    B 15 FIG. 9 INT AKE 1 5PS − 13586 − 00 JOINT , CARBURET OR 1 2 2 2 91317 − 06020 BOL T 4 4 3 90450 − 63001 HOSE CL AMP ASSY 2 2 4 5PS − 14414 − 00 ST A Y 2 1 1 5 95027 − 06010 BOLT , FLANGE 1 1 6 5PS − 1441 1 − 00 CASE, AIR CLEANER 1 1 1 7 5PS − 14421 − 00 CASE, AIR CLEANER 2 1 1 8 5PS − 14451 − 00 ELEMENT , AIR CLEANER 1 [...]

  • Page 21

    C 2 FIG. 9 INT AKE 28 5Y9 − 12491 − 00 CLAMP 1 1 1 29 90450 − 52602 HOSE CL AMP ASSY 2 2 30 90445 − 08012 HOSE 1 1 31 5PS − 14568 − 00 JOINT 1 1 32 901 19 − 06214 BOL T , W ITH WASHER 1 1 33 5PS − 1443E − 00 PIPE, DRAIN 1 1 34 4X7 − 2149Y − 00 FIL TE R ASSY 1 1 35 90445 − 1 16H6 H OSE (L570) 1 1 36 90467 − 1 1 106 CLIP 3 3[...]

  • Page 22

    C 3 FIG. 10 INT AKE 2 1 5PS − 13750 − 00 THROTTLE BODY ASSY 1 1 2 5Y9 − 12491 − 00 .CLAMP 1 2 2 3 5JW − 14589 − 00 .SPRING 1 1 45 D M − 14936 − 00 .SEAT , SPRING 1 1 5 98507 − 05030 .SCRE W , P AN HEAD 2 2 6 98507 − 05014 .SCRE W , P AN HEAD 2 2 78 C C − 14216 − 10 .SCREW 2 2 8 5PS − 85885 − 00 .THROTTLE POSITION SENSOR [...]

  • Page 23

    C 4 FIG. 10 INT AKE 2 28 5JW − 2431 1 − 00 .PIP E, FUEL 1 1 1 29 5FL − 14348 − 10 .PIPE 1 1 1 30 5FL − 14348 − 00 .PIPE 1 1 1 31 5PS − 14103 − 00 .THROTTLE SCREW SET 1 1 32 5JW − 14104 − 00 .AIR SCREW SET 1 1 P ART NO. DESCRIPTION REMARKS REF . NO. 5PS1 5PS2[...]

  • Page 24

    C 5 FIG. 1 1 EXHAUST 1 5PS − 14610 − 00 EXHAUS T PIPE ASSY 1 1 1 2 36Y − 27414 − 00 .DAMPER, FOOTREST 1 1 3 5PS − 14628 − 00 PROTECT OR, EXHAUST P IPE 1 1 4 91380 − 06010 BOL T 2 2 5 3VD − 14613 − 00 GASKET , EXHAUS T PIPE 2 2 6 90179 − 08410 NUT 4 4 7 90109 − 08044 BOL T 1 1 8 90201 − 08753 WASHER, PLATE 1 1 9 5PS − 14710[...]

  • Page 25

    C 6 FIG. 1 2 CRANKCASE 1 5PS − 15100 − 00 CRANKC ASE ASSY 1 1 2 4XV − 15138 − 00 .NOZZLE 1 1 1 34 G 0 − 15138 − 00 .NOZZLE 1 1 1 4 99530 − 101 14 .PIN, DOWEL 1 1 5 99530 − 14016 PIN, DO WEL 2 2 6 3LD − 11361 − 00 BOLT , CYLINDER HOLDI NG 1 6 6 7 90105 − 10560 BOLT , FLANGE 6 6 8 90201 − 1 1597 W ASHER, PLA TE 6 6 9 95814 −[...]

  • Page 26

    C 7 FIG. 1 2 CRANKCASE 28 3LD − 151 18 − 0 0 HOLDER 2 2 29 99530 − 08016 PIN, DO WEL 4 4 30 95817 − 06045 BOL T , FLANGE 2 2 31 95817 − 06070 BOL T , FLANGE 2 2 32 5PS − 15416 − 00 COVER, OIL PUMP 1 1 33 5PS − 15456 − 00 GASKET , OIL PUMP COVER 1 1 1 34 91314 − 06020 BOL T 7 7 35 99530 − 08012 PIN, DO WEL 2 2 P ART NO. DESCRIP[...]

  • Page 27

    C 8 FIG. 1 3 CRANKCASE COVER 1 1 5PS − 1541 1 − 00 COVER, CRANKCASE 1 1 1 2 93317 − 21288 BEARING 1 1 3 93109 − 12075 OIL SEAL 2 2 4 5PS − 15451 − 00 GASKET , CRANKCAS E COVER 1 1 1 5 99530 − 08012 PIN, DO WEL 2 2 6 5PS − 17653 − 00 SLIDER 1 1 7 90109 − 065A8 BOL T 2 2 8 91314 − 06025 BOL T 9 9 9 5PS − 1541E − 00 ST A Y , [...]

  • Page 28

    C 9 FIG. 1 3 CRANKCASE COVER 1 28 90149 − 05009 SCREW 4 4 29 5PS − 15462 − 00 GASKET , CRANKCAS E COVER 3 1 1 30 91314 − 06025 BOL T 7 7 31 91314 − 06030 BOL T 2 2 32 99530 − 08012 PIN, DO WEL 2 2 33 5PS − 15441 − 00 HOLDER, CLUTCH CABLE 1 1 34 5PS − 15425 − 00 COVER, GENERA TOR 2 1 1 35 5PS − 15463 − 00 GASKET , CARBURET OR[...]

  • Page 29

    C 10 FIG. 1 4 ST ARTER CLUTCH 1 5PS − 15515 − 00 GEAR 3 1 1 2 3LD − 15517 − 00 GEAR, IDLER 2 1 1 3 26H − 15521 − 00 SHAFT 1 1 1 4 3LD − 15512 − 00 GEAR, IDLER 1 1 1 5 3LD − 15590 − 02 ST ARTER ONE − W A Y ASSY 1 1 6 90149 − 06026 SCREW 3 3 7 90201 − 30008 WASHER, PLATE 1 1 P ART NO. DESCRIPTION REMARKS REF . NO. 5PS1 5PS2[...]

  • Page 30

    C 11 FIG. 1 5 CLUTCH 1 4TX − 16150 − 02 PRIMARY DRIVEN GEAR COMP . 1 1 2 5PS − 16356 − 00 ROD, PUSH 1 1 1 3 93306 − 00304 BEARING (B6003C4) 1 1 44 H 7 − 16154 − 00 PLA TE, THRUST 1 1 1 5 4TX − 16371 − 0 0 BO SS , CLUTCH 1 1 64 H 7 − 16321 − 02 PLA TE, FRICTION 2 2 7 4TX − 16321 − 00 PLATE, FRICTION 7 7 8 5EB − 16351 − [...]

  • Page 31

    C 12 FIG. 1 5 CLUTCH 25 90201 − 101 19 W ASHER, PLA TE 1 1 26 99009 − 10400 CIRCL IP 1 1 27 3VD − 16164 − 00 PLATE, THRUST 2 1 1 28 3VD − 16154 − 00 PLATE, THRUST 1 1 1 29 4NX − 16181 − 00 SPACER 1 1 1 30 93310 − 365B8 BEARING 1 1 P ART NO. DESCRIPTION REMARKS REF . NO. 5PS1 5PS2[...]

  • Page 32

    C 13 FIG. 16 TRANSMISSION 1 5PS − 17401 − 00 MAIN AXLE ASSY 1 1 2 93306 − 30534 BEARING 1 1 3 5PS − 15163 − 00 HOUSING, BEARING 1 1 1 4 90387 − 25004 COLLAR 1 1 5 5PS − 17151 − 00 GEA R, 5TH PI NION (25T) 1 1 6 90209 − 21332 WASHER 2 2 7 93440 − 25084 CIRCL IP 2 2 8 5PS − 17131 − 00 GEAR, 3RD/4TH PINION (22T/25T) 1 1 9 90387[...]

  • Page 33

    C 14 FIG. 16 TRANSMISSION 28 5PS − 17251 − 00 GEA R, 5TH WH EEL (26T) 1 1 29 90201 − 25M72 W ASHER, PLATE 1 1 30 90387 − 251 1A COL LAR 1 1 31 5PS − 1721 1 − 00 GE AR, 1S T WHEE L (33T) 1 1 32 93102 − 40008 OIL SEAL 1 1 33 5PS − 17460 − 00 SPR OCKET , DRIVE (13T) 1 1 34 90215 − 30233 WASHER, LOCK 1 1 35 90179 − 22003 NUT 1 1 3[...]

  • Page 34

    C 15 FIG. 17 SHIFT CAM. F ORK 1 5PS − 18540 − 00 SHIFT CAM ASSY 1 1 2 90149 − 05321 .SCRE W 1 1 34 U N − 18542 − 00 .POINT , NEUTRAL 1 1 4 90501 − 06022 .SPRING, COMPRESSION 1 1 54 U N − 18566 − 00 .PLA TE, SIDE 2 1 1 6 901 10 − 06060 BOL T , HEXAGON SOCKET HEAD 1 1 7 5PS − 1851 1 − 00 FORK, SHIFT 1 1 1 8 5PS − 18512 − 00 [...]

  • Page 35

    D 2 FIG. 18 SHIFT SHAFT 1 5PS − 18101 − 00 SHIFT SH AFT ASSY 1 1 2 90508 − 32682 .SPRI NG, TORSIO N 1 1 3 90201 − 191J4 .WASHER, PLA TE 1 1 4 99009 − 19400 .CIRC LIP 1 1 5 90201 − 12575 WASHER, PLATE 1 1 6 99001 − 10600 CIRCL IP 1 1 7 5PS − 18130 − 00 SHIFT SH AFT ASSY 1 1 82 H 9 − 18154 − 00 .COVER, DUST 1 1 9 95827 − 06020[...]

  • Page 36

    D 3 FIG. 19 FR AME 1 5PS − 21 1 10 − 00 FRAME COMP . 1 5PS − 21 1 10 − 10 FRAME COMP . 1 2 5PS − 21 190 − 00 REAR FRAME COMP . 1 1 3 90149 − 10002 SCREW 4 4 4 901 1 1 − 12001 BOL T 1 1 5 90387 − 14003 COLLAR 1 1 6 90105 − 08047 BOLT , FLANGE 2 2 7 901 1 1 − 12001 BOL T 1 1 8 90387 − 14003 COLLAR 1 1 9 90105 − 08047 BOLT , [...]

  • Page 37

    D 4 FIG. 2 0 FENDER 1 5PS − 2151 1 − 00 − P0 FENDER, FRONT 1 1 UR VDBMA 5PS − 2151 1 − 00 − P1 FENDER, FRONT 1 1 UR S3 5PS − 2151 1 − 00 − P2 FENDER, FRONT 1 1 UR RYC1 2 901 10 − 06200 BOL T , HEXAGON SOCKET HEAD 2 2 3 92014 − 06020 BOL T , BUTTON HEA D 2 2 4 90179 − 06009 NUT 2 2 5 90464 − 18002 CLAMP 1 1 6 90387 − 065T[...]

  • Page 38

    D 5 FIG. 2 0 FENDER 24 5PS − 2471K − 00 − P1 COVER, T AIL 1 1 1 UR S3 FOR R YC1 25 5PS − 2472K − 00 − 4B COVER, T AIL 2 1 1 UR BL2 FOR VDBMA 5PS − 2472K − 00 − P0 COVER, T AIL 2 1 1 UR BS4 FOR S3 5PS − 2472K − 00 − P1 COVER, T AIL 2 1 1 UR S3 FOR R YC1 26 5PS − 21651 − 00 − 4B COVER, REAR FENDER 1 1 UR BL2 FOR VDBMA 5P[...]

  • Page 39

    D 6 FIG. 2 0 FENDER 47 5PS − 21654 − 10 WIRE 1 1 48 90109 − 06046 BOL T 2 2 49 90206 − 08051 WASHER, WA VE 2 2 50 90201 − 06043 WASHER, PLATE 2 2 51 5PS − 2132F − 00 HOOK 1 1 52 5PS − 2139E − 00 HOOK 2 1 1 P ART NO. DESCRIPTION REMARKS REF . NO. 5PS1 5PS2[...]

  • Page 40

    D 7 FIG. 2 1 SIDE COVER 1 5PS − 21871 − 00 T ANK, RECOVER Y 1 1 2 901 19 − 061 17 BOL T , WITH W ASHER 1 1 3 5EB − 21875 − 00 CAP 1 1 4 26H − 21828 − 00 ELBOW 1 1 5 90467 − 1 1019 CLIP 1 1 6 5PS − 21816 − 00 PIPE 1 1 1 7 90480 − 20566 GROMMET 1 1 8 90464 − 15157 CLAMP 1 1 9 90445 − 083J5 HOSE (L600) 1 1 10 90467 − 08075 [...]

  • Page 41

    D 8 FIG. 22 REAR ARM 1 5PS − 221 10 − 00 REAR ARM COMP . 1 1 2 5PS − 22184 − 00 BUSH 1 1 3 93315 − 42523 BEARING 1 1 4 93315 − 42536 BEARING 1 1 5 5EB − 22127 − 00 SHIM 1 1 6 5EB − 22123 − 00 BUSH 1 1 1 7 3FV − 22128 − 00 COVER, THRUST 1 1 1 8 93109 − 33049 OIL SEAL 1 1 9 5PS − 22141 − 00 SHAFT , PIVOT 1 1 10 90185 −[...]

  • Page 42

    D 9 FIG. 22 REAR ARM 28 90101 − 10659 BOL T 1 1 29 95617 − 10100 NUT , U 1 1 30 90201 − 101J1 WASHER, PLA TE 1 1 31 90387 − 127W0 COLLAR 1 1 32 5PS − 22151 − 00 SEAL, GUARD 1 1 33 901 19 − 06096 BOL T , W ITH WASHER 2 2 34 90387 − 06372 COLLAR 2 2 35 5PS − 25875 − 00 HOLDER, BRAKE HOSE 1 1 1 36 4NK − 25876 − 00 HOLDER, BRAKE[...]

  • Page 43

    D 10 FIG. 23 REAR SUSPENSION 1 5PS − 22210 − 00 SHOCK ABSORBER ASSY , REAR 1 1 24 G Y − 22216 − 20 .BUSH, REAR SHOCK ABSORBER 1 1 3 90105 − 10402 BOLT , FLANGE 1 1 4 95617 − 10100 NUT , U 1 1 5 5PS − 22219 − 00 BRACKET , UPPER 1 1 6 95607 − 14200 NUT , SELF − LOCKING 1 1 7 90201 − 101J1 WASHER, PLA TE 1 1 P ART NO. DESCRIPTION[...]

  • Page 44

    D 11 FIG. 24 STEERING 1 93399 − 99932 BEARING 2 2 2 3FV − 23462 − 00 SEAL, STEERING 1 1 3 4XV − 23415 − 01 COVER, BALL RACE 1 1 1 4 90179 − 30691 NUT 2 2 5 4XV − 23418 − 00 W ASHER, SPECIAL 1 1 6 90202 − 30235 WASHER, PLATE 1 1 7 90176 − 28083 NUT , CROWN 1 1 8 90201 − 281U8 W A SHER , PLATE 1 1 9 5PS − 23435 − 00 CROWN, H[...]

  • Page 45

    D 12 FIG. 25 FRON T FORK 1 5PS − 23102 − 00 FRONT FORK ASSY (L.H) 1 1 2 5PS − 23126 − 00 .TUBE, OUTER (LEFT) 1 1 3 5PS − 231 10 − 00 .INNER TUBE COMP .1 1 1 43 G M − 23171 − 00 ..PIS TON, FRONT FORK 1 1 5 5PS − 23170 − 00 .CYLINDER COMP ., FRONT FORK 1 1 63 G M − 23125 − 00 .MET AL, SLIDE 1 1 1 7 4V4 − 23146 − L0 .WASHER[...]

  • Page 46

    D 13 FIG. 25 FRON T FORK 28 4PU − 23144 − 00 .SEAL, DUST 1 1 29 5PS − 23173 − 00 .SPINDLE, T APER 1 1 30 509 − 23158 − L0 .GASKET 1 1 31 278 − 23181 − 50 .BOL T , HEXAGON SOCKET HEAD 1 1 32 5PS − 23141 − 00 .SPRING, FRONT FORK 1 1 33 3LR − 23149 − 00 .W ASHER, SPRING UPPER 1 1 34 5EA − 231 18 − 10 .S P ACER 1 1 35 3FV ?[...]

  • Page 47

    D 14 FIG. 26 FUEL T ANK 1 5PS − 13971 − 00 PIP E, FUEL 1 1 1 2 90464 − 16007 CLAMP 1 1 3 90464 − 16005 CLAMP 1 1 4 5PS − 13972 − 00 PIP E, FUEL 2 1 1 5 90467 − 12003 CLIP 2 2 6 5PS − Y2410 − 10 − 01 FUEL T ANK COMP . 1 1 UR VDBMA 5PS − Y2410 − 10 − 04 FUEL T ANK COMP . 1 1 UR S3 5PS − Y2410 − 10 − 02 FUEL T ANK COMP [...]

  • Page 48

    D 15 FIG. 26 FUEL T ANK 25 901 10 − 051 12 BOL T , HEXAGON SOCKET HEAD 3 3 26 91317 − 05010 BOL T 1 1 27 5PS − 24318 − 00 PIP E, OVERFLOW 1 1 28 90467 − 09006 CLIP 1 1 29 5PS − 24318 − 00 PIP E, OVERFLOW 1 1 30 90467 − 09006 CLIP 1 1 31 5PS − 2414H − 00 DAMPER, PLATE 1 1 1 32 5PS − 28217 − 00 DAMPER 1 2 2 33 5PS − 2139X ?[...]

  • Page 49

    E 2 FIG. 27 SEA T 1 5PS − 24730 − 00 DOUBLE S EA T ASSY 1 1 2 5PS − 2470F − 00 . SEAT COVER COMP . 1 1 34 H M − 24728 − 00 .BRACKET , SEAT 1 1 4 90179 − 06635 .NUT 1 1 5 22W − 24741 − 00 .PAD, SEA T 2 2 6 90338 − 06018 .PLUG 2 2 7 5PS − 24741 − 00 .P AD, SEAT 4 4 85 L V − 24737 − 00 .DAMPER, SEAT 1 1 9 4BP − 24780 − [...]

  • Page 50

    E 3 FIG. 2 8 FRONT WHEEL 1 5PS − 25168 − 00 − 33 CAST WHEEL, FRONT 1 1 YB 2 4XV − 251 17 − 00 SPACER, BEARING 1 1 3 93306 − 00420 BEARING (B6004) 2 2 4 93106 − 28043 OIL SEAL 2 2 5 941 12 − 18019 TIRE (120/70ZR18 M/C(59W) D 220FST) 1 1 UR DUNLOP * TIRE (120/70ZR18 M/C(59W) MEZ4J) 1 1 UR LM METZELER 6 93900 − 00030 V AL VE, R IM 1 [...]

  • Page 51

    E 4 FIG. 29 FRONT BRAKE CALIPER 1 5PX − 2581T − 00 DISC B RAKE ASSY 2 2 2 90109 − 064G6 B OL T 1 2 12 35 D M − 2580T − 00 CALIPER ASSY ( LEFT) 1 1 4 4SV − W0057 − 00 .PISTO N ASSY , CALIPER 1 1 53 M A − W0047 − 10 ..CALIPER SEAL KIT 1 1 6 4SV − W0057 − 10 .PISTO N ASSY , CALIPER 1 1 73 G M − W0047 − 10 ..CALIPER SEAL KIT 1[...]

  • Page 52

    E 5 FIG. 3 0 REAR WHEEL 1 5PS − 25338 − 00 − 33 CAST WHEEL, REAR 1 1 YB 2 93306 − 07806 BEARING 2 2 3 93106 − 35042 OIL SEAL 1 1 4 5PS − 25317 − 00 SP ACER, BEARING 1 1 5 5EA − 25364 − 00 DAMPER 6 6 6 941 16 − 17008 TIRE (160/60ZR17 M/C(69W) D220ST) 1 1 U R DUNLOP * TIRE (160/60ZR17 M/C(69W) MEZ4J) 1 1 UR LM METZELER 7 93900 −[...]

  • Page 53

    E 6 FIG. 3 0 REAR WHEEL 25 5EB − 25377 − 00 COLLAR, WHEEL 1 1 P ART NO. DESCRIPTION REMARKS REF . NO. 5PS1 5PS2[...]

  • Page 54

    E 7 FIG. 31 REAR BRAKE CALIPER 1 4JH − 2582W − 00 DISC, REAR BRAKE 2 1 1 2 90109 − 083G4 B OL T 6 6 3 5PS − 2580W − 00 CALI PER ASSY , REAR 2 1 1 4 5JW − W0057 − 0 0 .PISTON ASSY , CALIP ER 1 1 5 5JW − W0047 − 00 ..CALIPER SEAL KIT 1 1 6 5JW − 25914 − 10 . PIN, SLIDE 2 2 7 4TT − 25937 − 00 .BOOT 2 2 2 8 5PS − W0046 − 0[...]

  • Page 55

    E 8 FIG. 32 STEERING HANDLE. CABLE 1 5PS − 261 1 1 − 00 HANDLEBAR 1 1 2 5JW − 26241 − 00 GRIP 1 1 3 5PS − 26240 − 00 GRIP ASSY 1 1 4 51J − 26246 − 01 END, GRIP 2 2 5 5PS − 26302 − 00 THROTTLE CABLE ASSY 1 1 6 4KG − 26281 − 00 CAP , GRIP UPPER 1 1 7 3XW − 26282 − 01 CAP , GRIP LOWER 1 1 8 91317 − 05035 BOL T 2 2 9 5PS ?[...]

  • Page 56

    E 9 FIG. 33 FRONT M ASTER CYLINDER 15 D M − W2587 − 00 MASTER CYLINDER SUB ASSY 1 1 25 D M − W0041 − 50 .CYLINDER KIT , MASTER 1 1 34 H M − W2585 − 01 .RESERVOIR CAP SET 1 1 44 H M − 25854 − 00 .DIAPHRAGM, RESERVOIR 1 1 5 98706 − 04012 .SCRE W , FLA T HEAD 2 2 6 5EB − 83922 − 01 LEVER 2 1 1 7 3FV − 2589F − 00 BOL T , LEVER[...]

  • Page 57

    E 10 FIG. 34 ST AND. FO OTRE ST 1 5PS − 2731 1 − 00 ST AND, SIDE 1 1 2 128 − 271 14 − 00 STOPPER, MAIN ST AND 1 1 3 5PS − 27321 − 00 BRACKET , SIDE STAND 1 1 4 5PS − 27352 − 00 HOOK, SIDE ST AND 1 1 5 90506 − 20008 SPRIN G, TEN SION 1 1 6 90445 − 197J2 HOSE (L60) 1 1 7 90201 − 081R9 W A SHER , PLATE 1 1 8 90101 − 08662 BOL T[...]

  • Page 58

    E 11 FIG. 34 ST AND. FO OTRE ST 28 5PS − 27442 − 00 BRACKET 2 1 1 29 5PS − 27443 − 00 BRACKET 3 1 1 30 901 10 − 08220 BOL T , HEXAGON SOCKET HEAD 4 4 31 90383 − 14001 BUSH, FORMED 1 1 32 5L V − 27431 − 01 FOOTREST , REAR 1 1 1 33 5L V − 27441 − 01 FOOTREST , REAR 2 1 1 34 90501 − 15001 SPRING, COMPRESSION 2 2 35 93501 − 0401[...]

  • Page 59

    E 12 FIG. 35 REAR MASTER CYLINDER 1 5PS − 2721 1 − 00 PEDAL, BRAKE 1 1 2 90201 − 14215 WASHER, PLATE 1 1 3 5PS − 27212 − 00 SHAFT , BRAKE PEDAL 1 1 4 92014 − 06025 BOL T , BUTTON HEA D 1 1 5 92990 − 06600 WASHER, PLATE 1 1 6 90506 − 20223 SPRIN G, TEN SION 1 1 7 4BH − 2583V − 00 RR. MASTER CYLINDER ASSY . 1 1 8 4BH − W0042 −[...]

  • Page 60

    E 13 FIG. 35 REAR MASTER CYLINDER 28 5PS − 25874 − 00 HOSE, BRAKE 1 1 29 90401 − 10172 BOL T , UNIO N 2 2 30 90201 − 101 18 W ASHER, PLA TE 4 4 P ART NO. DESCRIPTION REMARKS REF . NO. 5PS1 5PS2[...]

  • Page 61

    E 14 FIG. 36 COW LING 1 1 5PS − 2835G − 00 − 4B BODY , FRONT UPPER 1 1 1 UR BL2 FOR VDBMA 5PS − 2835G − 00 − P0 BODY , FRONT UPPER 1 1 1 UR BS4 FOR S3 5PS − 2835G − 00 − P1 BODY , FRONT UPPER 1 1 1 UR S3 FOR R YC1 2 4TX − 21717 − 00 DAMPER 6 6 3 5PS − 2178A − 00 LABEL 1 1 4 90183 − 05061 NUT , SPRIN G 2 2 5 90183 − 050[...]

  • Page 62

    E 15 FIG. 36 COW LING 1 26 90464 − 15195 CLAMP 3 3 27 95707 − 08500 NUT , FLANGE 1 1 28 5PS − 28396 − 00 PLA TE 1 1 1 29 5PS − 28397 − 00 PLA TE 2 1 1 30 5PS − 28331 − 00 BOL T , LEG SHIELD 1 1 31 90465 − 10098 CLAMP 1 1 32 95817 − 08025 BOL T , FLANGE 4 4 33 5PS − 2835U − 00 − P0 P ANEL 1 1 1 UR VDBMA 5PS − 2835U − 00[...]

  • Page 63

    F 2 FIG. 36 COW LING 1 49 4TX − 21717 − 00 DAMPER 1 1 50 97707 − 50016 SCREW , T APPING 2 2 51 5PS − 28321 − 00 ST A Y 1 1 1 52 95807 − 06020 BOL T , FLANGE 1 1 53 5PS − 28357 − 00 ST A Y 2 1 1 54 95807 − 06020 BOL T , FLANGE 2 2 55 90269 − 07077 RIVET 2 2 56 5PS − 2836A − 00 BRACKET 1 1 1 57 95807 − 06012 BOL T , FLANGE 1[...]

  • Page 64

    F 3 FIG. 3 7 GENERA TOR 1 5PS − 81410 − 00 ST A TOR ASSY 1 1 2 5PS − 81450 − 00 ROT OR ASSY 1 1 3 901 10 − 06042 BOL T , HEXAGON SOCKET HEAD 3 3 4 901 10 − 0501 1 BOL T , HEXAGON SOCKET HEAD 2 2 5 90465 − 08380 CLAMP 1 1 P ART NO. DESCRIPTION REMARKS REF . NO. 5PS1 5PS2[...]

  • Page 65

    F 4 FIG. 38 ST ARTING MOTOR 1 3LD − 81890 − 00 MOT OR ASSY 1 1 2 3AJ − 81801 − 00 .BRUSH SET 1 1 3 3AJ − 81809 − 00 .WASHER KIT 1 1 4 3AJ − 81830 − 00 .FRONT BRACKET ASSY 1 1 5 3AJ − 81826 − 00 .BOLT 2 2 61 1 H − 81844 − 00 .GASKET 2 2 7 1FK − 81847 − 00 .O − RING 1 1 81 H X − 81815 − 00 CORD, STAR TER MOTOR 1 1 94[...]

  • Page 66

    F 5 FIG. 39 FLAS HER LI GHT 1 5PS − 83310 − 00 FRONT FLASHER LIGHT ASSY 1 1 1 2 1KH − 8331 1 − 00 .BULB (12V − 10W) 1 1 3 5PW − 8333A − 00 .LENS COMP 1 1 4 97706 − 04012 .SCREW, T APPING 1 1 5 5PS − 83320 − 00 FRONT FLASHER LIGHT ASSY 2 1 1 6 1KH − 8331 1 − 00 .BULB (12V − 10W) 1 1 7 5PW − 8334A − 00 .LENS COMP 1 1 8 9[...]

  • Page 67

    F 6 FIG. 40 ME TER 1 5PS − 83570 − 00 SPEEDOMETER ASSY 1 1 UR 5PS − 83570 − 10 SPEEDOMETER ASSY 1 UR FOR GBR 2 4YR − 83517 − 00 .BULB (12V − 1.4W T5) 2 2 HI − BEAM,CHECK ENGINE 3 4YR − 83517 − 10 .BULB (12V − 2W T5) 2 2 ILLUMI 4 5PS − 83517 − 00 .BULB (12V − 1.2W T5) 3 3 TURN,NEUTRAL 5 5PS − 8353E − 00 CASE, METER UP[...]

  • Page 68

    F 7 FIG. 41 HEADLIGHT 1 5PS − 84310 − 00 HEADLI GHT UN IT ASSY 1 UR 5PS − 84310 − 10 HEADLI GHT UNI T ASSY 1 1 UR FOR GBR , ZA F , OCE 2 * .BULB (12V − 55W − H7) 2 2 LM HALOGEN 3 4TV − 84397 − 00 .COVER, SOCKET 2 2 4 5PS − 83513 − 00 DAMPER 4 4 5 97707 − 50016 SCREW , T APPING 4 4 6 90164 − 05014 SCREW , T APPING 4 4 7 5PS ?[...]

  • Page 69

    F 8 FIG. 42 T AILLIGHT 1 5PS − 84710 − 00 T AIL LIGH T UNIT ASSY 1 1 2 1A2 − 84714 − 41 .BULB (12V − 21/5W) 1 1 3 5PS − 84721 − 00 .LENS, T AILLIGHT 1 1 4 47X − 84723 − 00 .GASKET , T AIL LENS 1 1 5 5PS − 84735 − 00 .CORD ASSY 1 1 6 90480 − 14323 GROMMET 2 2 7 90201 − 06071 WASHER, PLATE 2 2 8 90387 − 066Y6 COL LAR 2 2 9[...]

  • Page 70

    F 9 FIG. 4 3 HANDLE SWITC H. LEVER 1 5PS − 83969 − 00 SWITCH, HANDLE 5 1 5PS − 83972 − 00 SWITCH, HANDLE 4 1 2 98507 − 05030 .SCRE W , P AN HEAD 1 1 3 98507 − 05040 .SCRE W , P AN HEAD 1 1 4 5PS − 83963 − 00 SWITCH, HANDLE 3 (RIGHT) 1 5R T − 83975 − 00 SWITCH, HANDLE 2 1 5 98507 − 05045 .SCRE W , P AN HEAD 2 98507 − 05022 .S[...]

  • Page 71

    F 10 FIG. 44 ELECTRICAL 1 1 5PS − 8591A − 00 ENG INE CONTROL U NIT ASSY 1 1 2 97024 − 06016 BOL T 2 2 3 92904 − 06600 WASHER 2 2 42 U J − 82310 − 01 IGN ITIO N COIL ASSY 2 2 5 91317 − 05016 BOL T 4 4 6 5JW − 82370 − 0 0 PLUG C AP ASSY 2 2 7 4TX − 82100 − 02 BATTER Y ASSY (G T12B − 4) 1 1 8 5PS − 821 15 − 00 WIRE, PLUS LE[...]

  • Page 72

    F 11 FIG. 44 ELECTRICAL 1 27 90202 − 05187 WASHER, PLATE 2 2 28 5PS − 82501 − 00 MAIN SWITCH STEERING LOCK 1 5PS − 82501 − 10 MAIN SWITCH STEERING LOCK 1 29 90109 − 080G5 BOL T 2 2 30 90465 − 10098 CLAMP 1 1 31 90464 − 25003 CLAMP 1 1 32 5PS − 82576 − 01 EMERGE NCY ST OP SWIT CH ASSY 1 1 33 91317 − 04025 BOL T 2 2 34 90183 −[...]

  • Page 73

    F 12 FIG. 45 ELECTRICAL 2 15 R T − 82566 − 60 SWITCH, SIDE ST AND 1 1 2 98507 − 05020 SCREW , PAN HEAD 2 2 3 95607 − 05200 NUT , U FLANGE 2 2 4 5PS − 82540 − 00 NEUTRA L SWIT CH ASSY 1 1 5 93210 − 29196 O − RING 1 1 6 90149 − 06018 SCREW 2 2 7 90462 − 08017 CLAMP 1 1 8 5PS − 85790 − 00 THERMO SENS OR ASSY 1 1 9 90430 − 122[...]

  • Page 74

    F 13 FIG. 45 ELECTRICAL 2 28 3XV − 83350 − 21 FLASHER RELA Y ASSY 1 1 29 35J − 83371 − 32 HORN 1 1 30 92017 − 06010 BOL T , BUTTON HEA D 1 1 31 5PS − 2317E − 00 ST A Y 1 1 32 95027 − 06010 BOL T , FLANGE 2 2 33 5PS − 23378 − 00 BRACKET , HORN 1 1 34 95827 − 06010 BOL T , FLANGE 1 1 P ART NO. DESCRIPTION REMARKS REF . NO. 5PS1 [...]

  • Page 75

    NUMERICAL INDEX P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . M 1 5DM − W004 1− 50 E − 9 4BH − W0042 − 50 E −1 2 4SV − W0045 − 00 E − 4 5PS − W0046 − 00 E − 7 3GM − W0047 −1 0E − 4 3MA − W0047 −1 0E − 4 5JW − W0047 − 00 E − 7 1 [...]

  • Page 76

    NUMERICAL INDEX P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . M 2 5PS − 2 1 32F − 00 D − 6 4XV − 2 1 376 − 00 D − 5 5PS − 2 1 39E − 00 D − 6 5PS − 2 1 39X − 00 D −1 5 5PS − 2 1 44G − 00 F −1 0 5PS − 2 1 489 − 00 D − 3 4X7 − 2 1 49Y [...]

  • Page 77

    NUMERICAL INDEX P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . M 3 5PS − 82540 − 00 F −1 2 5RT − 82566 − 60 F −1 2 5PS − 82576 − 0 1 F −1 1 5PS − 82590 − 00 F −1 0 5PS − 82590 −1 0F −1 0 1 UA − 8259 1− 00 E − 9 F −1 2 3YX − 829 11?[...]

  • Page 78

    NUMERICAL INDEX P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . M 4 90450 − 25037 B −1 3 90450 − 320 1 5B −1 0 90450 − 38040 B −1 0 90450 − 52602 C − 2 90450 − 6300 1 B −1 5 90462 − 05005 B −1 5 90462 − 080 1 7F −1 2 90464 − 07M56 F −1 0 90[...]

  • Page 79

    NUMERICAL INDEX P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . P ART NO . GRID NO . M 5 99530 − 080 1 6C − 7 99530 −1 0 11 4C − 6 C − 8 C − 9 99530 −1 40 1 6B − 4 C − 6[...]