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Yamaha YZ250 manual

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Table of contents for the manual

  • Page 1

    A 2 YZ250M (5HC1) CANADA,U.S.A.,SOUTH AFRICA YZ250 (5HC2) EUROPE YZ250 (5HC3) JAP AN YZ250M (5HC4) OCEANIA 205HC–100E1[...]

  • Page 2

    A 3[...]

  • Page 3

    FOREWORD A 4 This Parts Catalogue is related to the parts for the model(s) in the below frame. When you are ordering replacement parts, please refer to t his Parts Catalogue and quote both part numbers and part names correctly . YZ250M(5HC1/5HC4),YZ250(5HC2/5HC3) 1. Modifications or additions which have been made after issue of the Parts Catalogue [...]

  • Page 4

    MODEL LABEL A 5 (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 affixed onto the product concemed. (2)[...]

  • Page 5

    B 2 FIG. 1 CYLINDER HEAD 1 5CU– 1111 1–00 HEAD, CYLINDER 1 1 1 1 1 2 94702–00326 PLUG, SP ARK (NGK BR8EG) 1 1 1 1 3 901 16–08394 BOL T , STUD 6 6 6 6 4 93604–08071 PIN, DOWEL 2 2 2 2 5 90176–08026 NUT , CROWN 6 6 6 6 6 90201–08087 W ASHER, PLA TE 6 6 6 6 7 5CU–1 131 1–00 CYLINDER 1 1 1 1 1 8 5CU–1 131D–00 V AL VE ASSY 1 1 1 1 [...]

  • Page 6

    B 3 FIG. 1 CYLINDER HEAD 28 98907–05012 SCREW , BIND 2 2 2 2 29 93104–08040 OIL SEAL 1 1 1 1 30 4SS–1 1832–00 LEVER, LINK 1 1 1 1 31 90508–155B8 SPRING, TORSION 2 2 2 2 32 5CU–1 132E–00 PULLEY 1 1 1 1 1 33 5CU–1 132F–00 PULLEY 2 1 1 1 1 34 90201–081G0 W ASHER, PLA TE 2 2 2 2 35 90501–046L6 SPRING, COMPRESSION 2 2 2 2 36 5CU–[...]

  • Page 7

    B 4 FIG. 2 GOVERNOR 1 4JY–1 1915–01 PLA TE, THRUST 1 1 1 1 1 2 98907–05012 SCREW , BIND 1 1 1 1 3 90105–05002 BOL T , W ASHER BASED 1 1 1 1 4 90201–057H5 WASHER, PLA TE 1 1 1 1 5 90387–085E1 COLLAR 1 1 1 1 6 93104–08040 OIL SEAL 1 1 1 1 7 5CU–1 1990–00 PUSH ROD ASSY 1 1 1 1 8 3JE–1 1922–01 FORK, GOVERNOR 1 1 1 1 9 91317–0400[...]

  • Page 8

    B 5 FIG. 3 CRANKSHAFT . PISTON 1 5CU–1 1631–00–A0 PISTON (STD) 1 1 1 1 UR 5CU–1 1631–00–B0 PISTON (STD) 1 1 1 1 UR 5CU–1 1631–00–C0 PISTON (STD) 1 1 1 1 UR 5CU–1 1631–00–D0 PISTON (STD) 1 1 1 1 UR 2 5CU–1 1603–00 PISTON RING SET (STD) 1 1 1 1 3 5CU–1 1633–10 PIN, PISTON 1 1 1 1 4 93450–19052 CIRCLIP 2 2 2 2 5 93310[...]

  • Page 9

    B 6 FIG. 4 W A TER PUMP 1 5CU–12459–00 GEAR, IMPELLER SHAFT 1 1 1 1 2 5DJ–12451–00 IMPELLER, WA TER PUMP 1 1 1 1 3 90201–08512 W ASHER, PLA TE 1 1 1 1 4 93109–1 1073 OIL SEAL 1 1 1 1 5 93102–12106 OIL SEAL (SD 12–22–5 HS) 1 1 1 1 6 93306–00105 BEARING (B6001) 1 1 1 1 7 90201–08784 W ASHER, PLA TE 1 1 1 1 8 99001–06600 CIRCLI[...]

  • Page 10

    B 7 FIG. 5 RADIA TOR. HOSE 1 4SR–1240A–10 RADIA TOR ASSY 1 1 1 1 2 91A20–05065 TUBE, FLEXIBLE VINYL 1 1 1 1 3 90467–09006 CLIP 1 1 1 1 4 4SR–12461–10 RADIA TOR ASSY 1 1 1 1 5 5HD–12462–00 CAP , RADIA TOR 1 1 1 1 6 5CU–12481–00 PIPE 1 1 1 1 1 7 4SS–12482–00 PIPE 2 2 2 2 2 8 5CU–12484–00 PIPE 4 1 1 1 1 9 90450–28014 HOSE[...]

  • Page 11

    B 8 FIG. 6 INT AKE 1 4XL–13610–00 REED V AL VE ASSY 1 1 1 1 2 4XL–13613–00 .REED, V AL VE 2 2 2 2 3 4XL–13616–00 .STOPPER, REED V AL VE 2 2 2 2 4 98507–03008 .SCREW , P AN HEAD 4 4 4 4 5 92907–03100 .WASHER 4 4 4 4 6 4XL–13625–00 .SP ACER, REED V AL VE 1 1 1 1 7 5HC–13565–00 JOINT , CARBURETOR 1 1 1 1 8 91317–06020 BOL T 5[...]

  • Page 12

    B 9 FIG. 7 CARBURETOR 1 5HC–14101–00 CARBURETOR ASSY 1 1 1 1 5HC–14101–10 CARBURETOR ASSY 1 1 2 4JT–14171–00 .PLUNGER, ST ARTER 1 1 1 1 3 4SR–14985–00 .FLOA T 1 1 1 1 4 4JT–14984–00 .GASKET , FLOA T CHAMBER 1 1 1 1 5 4MX–141 15–00 .PLUG, SCREW 1 1 1 1 6 4MX–14561–00 .O–RING 1 1 1 1 7 4MX–14392–00 .V AL VE, NEEDLE 1[...]

  • Page 13

    B 10 FIG. 7 CARBURETOR 10 4SR–14916–CJ .NEEDLE (N3CJ) 1 1 1 1 AP 4SR–14916–EG .NEEDLE (N3EG) 1 1 1 1 AP 4SR–14916–EH .NEEDLE (N3EH) 1 1 1 1 AP 4SR–14916–EW .NEEDLE (N3EW) 1 1 1 1 AP 4SR–14916–EJ .NEEDLE (N3EJ) 1 1 1 1 AP 1 1 4MX–14919–00 .CLIP 1 1 1 1 12 5HC–14340–A7 .V AL VE ASSY 1 1 1 1 13 5HC–14261–00 .HOLDER 1 1 [...]

  • Page 14

    B 11 FIG. 7 CARBURETOR 23 4MX–14943–95 .JET , MAIN (#188) 1 1 1 1 AP 4MX–14943–45 .JET , MAIN (#190) 1 1 1 1 AP 24 4MX–14194–00 .RING 1 1 1 1 25 98502–04012 .SCREW , P AN HEAD 2 2 2 2 26 4XL–1410E–00 .HOSE 1 1 1 1 27 4JT–1494F–09 .JET (#85) 1 1 1 1 STD 4JT–1494F–07 .JET (#50) 1 1 1 1 AP 4JT–1494F–1 1 .JET (#60) 1 1 1 1[...]

  • Page 15

    B 12 FIG. 8 EXHAUST 1 5CU–14610–00 EXHAUST PIPE ASSY 1 1 1 1 1 2 93210–53638 O–RING 2 2 2 2 3 90507–20052 SPRING, TENSION 2 2 2 2 4 5CU–14771–00 ST A Y , MUFFLER 1 1 1 1 1 5 90480–16561 GROMMET 1 1 1 1 6 90387–063G3 COLLAR 1 1 1 1 7 90201–06071 W ASHER, PLA TE 1 1 1 1 8 483–14781–02 ST A Y , MUFFLER 2 1 1 1 1 9 95027–06012[...]

  • Page 16

    B 13 FIG. 9 CRANKCASE 1 5CU–151 1 1–01 CRANKCASE 1 1 1 1 1 2 5CU–15121–01 CRANKCASE 2 1 1 1 1 3 91317–06050 BOL T 7 7 7 7 4 91317–06060 BOL T 1 1 1 1 5 91317–06070 BOL T 3 3 3 3 6 4JT–15381–01 PLA TE, BEARING COVER 2 2 2 2 7 90149–06326 SCREW 2 2 2 2 8 353–131 15–01 CONNECTOR, SUCTION PIPE 1 1 1 1 9 90445–08605 HOSE 1 1 1 [...]

  • Page 17

    B 14 FIG. 10 CRANKCASE COVER 1 1 5CU–1541 1–00 COVER, CRANKCASE 1 1 1 1 1 2 5CU–15451–00 GASKET , CRANKCASE COVER 1 1 1 1 1 3 98507–06030 SCREW , P AN HEAD 5 5 5 5 4 92907–06600 W ASHER, PLA TE 5 5 5 5 5 5CU–15421–00 COVER, CRANKCASE 2 1 1 1 1 6 5HC–17466–00 GUIDE, CHAIN 1 1 1 1 7 98507–06035 SCREW , P AN HEAD 2 2 2 2 8 92907?[...]

  • Page 18

    B 15 FIG. 1 1 ST ARTER 1 5CU–15601–01 KICK SHAFT ASSY 1 1 1 1 2 90201–20685 .WASHER, PLA TE (0.5T) 1 1 1 1 3 93410–20038 .CIRCLIP 1 1 1 1 4 90501–16107 .SPRING, COMPRESSION 1 1 1 1 5 90201–167P7 .WASHER, PLA TE 1 1 1 1 6 99009–16400 .CIRCLIP 1 1 1 1 7 5CU–15664–00 .GUIDE, SPRING 1 1 1 1 8 90508–305B0 .SPRING, TORSION 1 1 1 1 9 9[...]

  • Page 19

    C 2 FIG. 12 CLUTCH 1 5DJ–161 1 1–00 GEAR, PRIMARY DRIVE 1 1 1 1 2 90387–2513A COLLAR 1 1 1 1 3 5CU–1 1956–00 GEAR, GOVERNOR DRIVE 1 1 1 1 4 90201–105P3 W ASHER, PLA TE 1 1 1 1 5 90105–10445 BOL T , W ASHER BASED 1 1 1 1 6 5DJ–16150–00 PRIMARY DRIVEN GEAR COMP . 1 1 1 1 7 4EW–16371–01 BOSS, CLUTCH 1 1 1 1 8 5HC–16351–00 PLA[...]

  • Page 20

    C 3 FIG. 12 CLUTCH 28 90430–05242 GASKET 1 1 1 1 P ART NO. DESCRIPTION REMARKS REF . NO. 5HC1 5HC2 5HC3 5HC4[...]

  • Page 21

    C 4 FIG. 13 TRANSMISSION 1 5BE–1741 1–00 AXLE, MAIN 1 1 1 1 2 93306–20540 BEARING 1 1 1 1 3 5BE–17151–00 GEAR, 5TH PINION 1 1 1 1 4 90201–253K0 W ASHER, PLA TE (T=1.0) 1 1 1 1 5 93440–25084 CIRCLIP 3 3 3 3 6 5CU–17131–00 GEAR, 3RD PINION 1 1 1 1 7 5BE–17141–10 GEAR, 4TH PINION 1 1 1 1 8 90387–21 13G COLLAR 1 1 1 1 9 5BE–17[...]

  • Page 22

    C 5 FIG. 13 TRANSMISSION 28 9383E–14210 SPROCKET , DRIVE (14T) 1 1 1 1 STD 9383E–13144 SPROCKET ,DRIVE 13T(2141746130) 1 1 1 1 AP 29 90215–21256 W ASHER, LOCK 1 1 1 1 30 90179–20255 NUT 1 1 1 1 P ART NO. DESCRIPTION REMARKS REF . NO. 5HC1 5HC2 5HC3 5HC4[...]

  • Page 23

    C 6 FIG. 14 SHIFT CAM. FORK 1 5CU–18541–00 CAM, SHIFT 1 1 1 1 2 93306–90504 BEARING 1 1 1 1 3 5DH–18562–00 PLA TE, STOPPER 2 2 2 2 2 4 90105–06553 BOL T , W ASHER BASED 2 2 2 2 5 4EW–18185–00 SEGMENT 1 1 1 1 6 93306–90501 BEARING 1 1 1 1 7 5CU–18140–01 STOPPER LEVER ASSY 1 1 1 1 8 90507–14064 SPRING, TENSION 1 1 1 1 9 90201?[...]

  • Page 24

    C 7 FIG. 15 SHIFT SHAFT 1 5CU–18101–00 SHIFT SHAFT ASSY 1 1 1 1 2 5CU–18122–00 LEVER, SHIFT 2 1 1 1 1 3 90387–124F4 COLLAR 1 1 1 1 4 90201–12575 W ASHER, PLA TE 1 1 1 1 5 90508–291A8 SPRING, TORSION 1 1 1 1 6 5CU–181 10–00 SHIFT PEDAL ASSY 1 1 1 1 7 95027–06020 BOL T , FLANGE 1 1 1 1 8 93102–12224 OIL SEAL 1 1 1 1 9 3XJ–1817[...]

  • Page 25

    C 8 FIG. 16 FRAME 1 5HC–21 1 10–00–P0 FRAME COMP . 1 1 1 1 DPBMC 2 5HC–21 190–00–P0 REAR FRAME COMP . 1 1 1 1 DPBMC 3 901 10–08096 BOL T , HEXAGON SOCKET HEAD 2 2 2 2 4 90105–08099 BOL T , W ASHER BASED 1 1 1 1 5 95817–101 10 BOL T , FLANGE 1 1 1 1 6 95607–10200 NUT , SELF–LOCKING 1 1 1 1 7 5CU–21425–00 BRACKET , REAR UPPE[...]

  • Page 26

    C 9 FIG. 17 FENDER 1 5HD–2151 1–00 FENDER, FRONT 1 1 1 1 2 3JD–21748–00 COLLAR 4 4 4 4 3 901 19–06096 BOL T , WITH WASHER 4 4 4 4 4 99241–00080 EMBLEM, Y AMAHA 1 1 1 1 5 5BE–2161 1–10 FENDER, REAR 1 1 1 1 6 901 19–06192 BOL T , WITH WASHER 1 1 1 1 7 95027–06030 BOL T , FLANGE 1 1 1 1 8 90201–06071 W ASHER, PLA TE 1 1 1 1 9 901[...]

  • Page 27

    C 10 FIG. 18 SIDE COVER 1 4SS–2171 1–00 COVER, SIDE 1 1 1 1 1 2 95827–06016 BOL T , FLANGE 1 1 1 1 3 90387–06009 COLLAR 1 1 1 1 4 95827–06016 BOL T , FLANGE 1 1 1 1 5 4SS–21721–00 COVER, SIDE 2 1 1 1 1 6 95827–06016 BOL T , FLANGE 1 1 1 1 7 90387–06009 COLLAR 1 1 1 1 8 95827–06016 BOL T , FLANGE 1 1 1 1 9 5ET–21730–10 SIDE C[...]

  • Page 28

    C 11 FIG. 19 REAR ARM 1 5CU–221 10–00 REAR ARM COMP . 1 1 1 1 2 90151–04048 SCREW , COUNTERSUNK 4 4 4 4 3 5ET–22355–00 P A TCH 2 2 2 2 4 93317–22262 BEARING 4 4 4 4 5 90338–16148 PLUG 2 2 2 2 6 93106–22019 OIL SEAL (DC 22–28–8) 2 2 2 2 7 93342–22217 BEARING 2 2 2 2 8 93109–28043 OIL SEAL 2 2 2 2 9 90387–1714R COLLAR 2 2 2 [...]

  • Page 29

    C 12 FIG. 19 REAR ARM 28 90109–147F2 BOL T 1 1 1 1 29 90109–142F4 BOL T 2 2 2 2 30 90201–164H4 WASHER, PLA TE 2 2 2 2 31 90201–14740 W ASHER, PLA TE 3 3 3 3 32 90185–141 12 NUT , SELF–LOCKING 3 3 3 3 33 5DH–2217F–01 ROD, CONNECTING 1 1 1 1 1 34 93315–32056 BEARING 2 2 2 2 35 93109–20076 OIL SEAL 2 2 2 2 36 5HD–2135F–00 COVER[...]

  • Page 30

    C 13 FIG. 20 REAR SUSPENSION 1 5HC–22210–00 SHOCK ABSORBER ASSY , REAR 1 FOR USA 5HC–22210–10 SHOCK ABSORBER ASSY , REAR 1 5HC–22210–20 SHOCK ABSORBER ASSY , REAR 1 5HC–22210–30 SHOCK ABSORBER ASSY , REAR 1 FOR CAN 5HC–22210–40 SHOCK ABSORBER ASSY , REAR 1 1 FOR ZAF 2 5HC–22201–00 .DAMPER SUB ASSY 1 FOR USA 5HC–22201–10 [...]

  • Page 31

    C 14 FIG. 20 REAR SUSPENSION 19 90105–105A2 BOL T , WASHER BASED 1 1 1 1 20 90201–1 12U6 WASHER, PLA TE 1 1 1 1 P ART NO. DESCRIPTION REMARKS REF . NO. 5HC1 5HC2 5HC3 5HC4[...]

  • Page 32

    C 15 FIG. 21 STEERING 1 93332–00081 BEARING 1 1 1 1 2 93332–00068 BEARING 1 1 1 1 3 4EW–23416–00 COVER, BALL RACE 2 1 1 1 1 4 90179–28650 NUT 1 1 1 1 5 5HC–23435–00 CROWN, HANDLE 1 1 1 5HC–23435–10 CROWN, HANDLE 1 6 90170–24373 NUT 1 1 1 1 7 90201–247L2 W ASHER, PLA TE 1 1 1 1 8 3SP–23441–00 HOLDER, HANDLE UPPER 2 2 2 2 9 [...]

  • Page 33

    D 2 FIG. 22 FRONT FORK 1 5HC–23102–00 FRONT FORK ASSY (L.H) 1 1 5HC–23102–10 FRONT FORK ASSY (L.H) 1 5HC–23102–20 FRONT FORK ASSY (L.H) 1 2 5HD–23136–L0 .TUBE, OUTER (RIGHT) 1 1 1 1 3 5DH–23120–L0 .INNER TUBE COMP .2 1 1 1 1 4 5ET–23171–L0 .PISTON, FRONT FORK 1 1 1 1 5 5ET–23125–L0 .MET AL, SLIDE 1 1 1 1 1 6 4SS–23146?[...]

  • Page 34

    D 3 FIG. 22 FRONT FORK 21 5HC–23103–20 FRONT FORK ASSY (R.H) 1 22 5HD–23136–L0 .TUBE, OUTER (RIGHT) 1 1 1 1 23 5BF–231 10–L0 .INNER TUBE COMP .1 1 1 1 1 24 5ET–23171–L0 .PISTON, FRONT FORK 1 1 1 1 25 5ET–23125–L0 .MET AL, SLIDE 1 1 1 1 1 26 4SS–23146–L0 .WASHER, OIL SEAL 1 1 1 1 27 5ET–23145–L0 .OIL SEAL 1 1 1 1 28 4SS?[...]

  • Page 35

    D 4 FIG. 22 FRONT FORK 45 4SS–23346–L0 BOL T 1 2 2 2 2 46 5DH–2314J–00 PROTECTER COMP ., 2 1 1 1 1 47 5DH–2314H–00 PROTECTER COMP ., 1 1 1 1 1 48 3SP–23356–L0 BOL T 2 6 6 6 6 49 5HC–2331E–00 GUIDE, CABLE 1 1 1 1 50 4DA–23389–00 GUIDE, CABLE 1 1 1 1 51 901 19–05071 BOL T , WITH WASHER 1 1 1 1 P ART NO. DESCRIPTION REMARKS R[...]

  • Page 36

    D 5 FIG. 23 FUEL T ANK 1 5CU–241 10–00 FUEL T ANK COMP . 1 1 1 1 2 1UY–24610–00 CAP ASSY 1 1 1 1 3 90445–09220 HOSE 1 1 1 1 4 3XJ–24380–00 PIPE JOINT ASSY 1 1 1 1 5 90445–09104 HOSE 1 1 1 1 6 24X–24144–00 HOLDER, DAMPER 2 2 2 2 7 90480–18549 GROMMET 2 2 2 2 8 95027–06016 BOL T , FLANGE 4 4 4 4 9 901 19–06214 BOL T , WITH W[...]

  • Page 37

    D 6 FIG. 24 SEA T 1 5DH–24770–00 SEMI–DOUBLE SEA T ASSY 1 1 1 1 2 5DH–24731–00 .COVER, SEA T 1 1 1 1 3 4SS–24728–00 .BRACKET , SEA T 2 2 2 2 4 97007–06012 .BOL T 4 4 4 4 5 92907–06100 .WASHER, SPRING 4 4 4 4 P ART NO. DESCRIPTION REMARKS REF . NO. 5HC1 5HC2 5HC3 5HC4[...]

  • Page 38

    D 7 FIG. 25 FRONT WHEEL 1 4SS–251 1 1–00 HUB, FRONT 1 1 1 1 2 93306–90403 BEARING 2 2 2 2 3 5DH–251 17–00 SP ACER, BEARING 1 1 1 1 4 93102–26468 OIL SEAL 2 2 2 2 5 94416–21613 RIM (1.60–21) 1 1 1 1 6 4DA–25104–00 SPOKE SET , FRONT 1 1 1 1 7 94108–21 12Y TIRE (80/100–21 51M D755F) 1 1 UR DUNLOP FOR CANADA 94108–2101 1 TIRE [...]

  • Page 39

    D 8 FIG. 26 FRONT BRAKE CALIPER 1 4XM–2582T–00 DISC, BRAKE 1 1 1 1 2 90149–06327 SCREW 6 6 6 6 3 5DH–2580T–00 CALIPER ASSY (LEFT) 1 1 1 5DH–2580T–10 CALIPER ASSY (LEFT) 1 4 4EW–W0057–00 .PISTON ASSY , CALIPER 1 1 1 1 5 3JD–W0047–00 ..CALIPER SEAL KIT 1 1 1 1 6 5DH–25919–00 .SUPPORT , P AD 1 1 1 1 7 1UY–W0048–50 .BLEED [...]

  • Page 40

    D 9 FIG. 27 REAR WHEEL 1 5ET–2531 1–00 HUB, REAR 1 1 1 1 2 5ET–25317–00 SP ACER, BEARING 1 1 1 1 3 93306–27205 BEARING 1 1 1 1 4 93306–07202 BEARING 1 1 1 1 5 93106–30044 OIL SEAL 1 1 1 1 6 93106–30045 OIL SEAL 1 1 1 1 7 99009–45500 CIRCLIP 1 1 1 1 8 94421–19602 RIM (2.15–19) 1 1 1 1 9 5HD–25304–00 SPOKE SET , REAR 1 1 1 1[...]

  • Page 41

    D 10 FIG. 27 REAR WHEEL 19 90480–08608 GROMMET 1 1 1 1 20 5ET–25383–00 COLLAR, WHEEL 2 2 2 2 21 5ET–25388–00 PULLER, CHAIN 1 1 1 1 1 22 5ET–25389–00 PULLER, CHAIN 2 1 1 1 1 23 90101–08777 BOL T 2 2 2 2 24 90179–08299 NUT 2 2 2 2 25 5ET–25381–00 AXLE, WHEEL 1 1 1 1 26 90185–20168 NUT , SELF–LOCKING 1 1 1 1 27 90201–203U1 [...]

  • Page 42

    D 11 FIG. 28 REAR BRAKE CALIPER 1 5DH–2582W–00 DISC, REAR BRAKE 2 1 1 1 1 2 90109–065G4 BOL T 6 6 6 6 3 5ET–2580W–00 CALIPER ASSY , REAR 2 1 1 1 1 4 5ET–W0057–50 .PIST ON ASSY , CALIPER 1 1 1 1 5 5ET–W0047–50 ..CALIPER SEAL KIT 1 1 1 1 6 5DH–25919–50 .SUPPORT , P AD 1 1 1 1 7 1UY–W0048–50 .BLEED SCREW KIT 1 1 1 1 8 5ET–W[...]

  • Page 43

    D 12 FIG. 29 STEERING HANDLE. CABLE 1 4XM–261 1 1–00 HANDLEBAR 1 1 1 1 2 4GY–26241–00 GRIP (LEFT) 1 1 1 1 3 4XM–26240–00 GRIP ASSY 1 1 1 1 4 4GY–26242–00 .GRIP (RIGHT) 1 1 1 1 5 4SS–26281–00 CAP , GRIP UPPER 1 1 1 1 6 4SS–26282–10 CAP , GRIP LOWER 1 1 1 1 7 4SS–2628H–00 CAP , WIRE 1 1 1 1 8 95027–06025 BOL T , FLANGE 2[...]

  • Page 44

    D 13 FIG. 30 FRONT MASTER CYLINDER 1 5ET–25872–00 HOSE, BRAKE 1 1 1 1 1 2 90201–101 18 W ASHER, PLA TE 4 4 4 4 3 90401–10168 BOL T , UNION 2 2 2 2 4 4SS–W2587–01 MASTER CYLINDER SUB ASSY 1 1 1 1 5 4SS–W0041–00 .CYLINDER KIT , MASTER 1 1 1 1 6 98706–04012 .SCREW , FLA T HEAD 2 2 2 2 7 4SS–25852–00 .CAP , RESERVOIR 1 1 1 1 8 4SS[...]

  • Page 45

    D 14 FIG. 31 ST AND. FOOTREST 1 4XM–27200–00 PEDAL, BRAKE 1 1 1 1 2 4SS–27217–00 BOL T 1 1 1 1 3 93210–1 1073 O–RING 2 2 2 2 4 91401–20012 PIN, COTTER 1 1 1 1 5 90506–16500 SPRING, TENSION 1 1 1 1 6 90240–08120 PIN, CLEVIS 1 1 1 1 7 90201–08089 W ASHER, PLA TE 1 1 1 1 8 90468–16191 CLIP 1 1 1 1 9 5ET–2741 1–00 FOOTREST 1 1[...]

  • Page 46

    D 15 FIG. 32 REAR MASTER CYLINDER 1 3SP–2583V–00 RR. MASTER CYLINDER ASSY . 1 1 1 1 2 4SS–W0042–50 .CYLINDER KIT , MASTER 1 1 1 1 3 93210–15620 .O–RING 1 1 1 1 4 2VN–25866–00 .CIRCLIP 1 1 1 1 5 2VN–2582A–50 .JOINT 1 1 1 1 6 3SP–27222–00 .JOINT 1 1 1 1 7 4SS–27218–00 .NUT 2 2 2 2 8 4EW–25894–00 T ANK, RESERVOIR 1 1 1 [...]

  • Page 47

    E 2 FIG. 33 GENERA TO R 1 5CU–85560–00 BASE ASSY 1 1 1 1 2 5CU–85550–10 ROTOR ASSY 1 1 1 1 3 90149–0601 1 SCREW 3 3 3 3 4 90179–10394 NUT 1 1 1 1 5 90201–10591 W ASHER, PLA TE 1 1 1 1 P ART NO. DESCRIPTION REMARKS REF . NO. 5HC1 5HC2 5HC3 5HC4[...]

  • Page 48

    E 3 FIG. 34 HANDLE SWITCH. LEVER 1 5HD–8291 1–00 HOLDER, LEVER 1 1 1 1 1 2 38V–82913–00 HOLDER, LEVER LOWER 1 1 1 1 1 3 5HD–83912–00 LEVER 1 1 1 1 1 4 90109–06027 BOL T 1 1 1 1 5 95607–06100 NUT , U 1 1 1 1 6 97007–05016 BOL T 2 2 2 2 7 5HD–26337–00 BOL T , ADJUSTING 1 1 1 1 8 5HD–83951–00 BOL T , CABLE ADJUSTING 1 1 1 1 9[...]

  • Page 49

    E 4 FIG. 35 ELECTRICAL 1 1 5HC–85540–00 C.D.I. UNIT ASSY 1 1 1 1 2 5CU–85546–00 BAND 1 1 1 1 3 5BE–82310–00 IGNITION COIL ASSY 1 1 1 1 4 95027–06016 BOL T , FLANGE 2 2 2 2 5 4PE–82370–10 PLUG CAP ASSY 1 1 1 1 6 90464–15195 CLAMP 1 1 1 1 7 90464–50255 CLAMP 2 2 2 2 8 90464–13073 CLAMP 1 1 1 1 9 90464–50255 CLAMP 1 1 1 1 10 [...]

  • Page 50

    E 5 FIG. 36 AL TERNA TE (CHASSIS) 1 5ET–22212–20 SPRING (K=APPROX.4.6) 1 1 1 1 AP 5ET–22212–00 SPRING (K=APPROX.4.8) 1 1 1 1 AP 5ET–22212–10 SPRING (K=APPROX.5.0) 1 1 1 1 AP 5ET–22212–30 SPRING (K=APPROX.5.2) 1 1 1 1 AP 5ET–22212–40 SPRING (K=APPROX.5.4) 1 1 1 1 AP 5DH–22212–70 SPRING (K=4.4) 1 1 1 1 AP 5DH–22212–10 SPRI[...]

  • Page 51

    E 6 FIG. 37 OPTIONAL P ARTS 1 1 5CU–1 1630–00 PISTON ASSY (STD) 1 1 1 1 2 5CU–1 1631–00–A0 .PISTON (STD) 1 1 1 1 5CU–1 1631–00–B0 .PISTON (STD) 1 1 1 1 5CU–1 1631–00–C0 .PISTON (STD) 1 1 1 1 5CU–1 1631–00–D0 .PISTON (STD) 1 1 1 1 3 5CU–1 1603–00 .PISTON RING SET (STD) 1 1 1 1 4 5CU–1 1633–00 .PIN, PISTON 1 1 1 1 [...]

  • Page 52

    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 4SS–W0041–00 D – 13 4SS–W0042–50 D – 15 5DH–W0045–00 D – 8 5DH–W0045–10 D – 8 5ET–W0046–00 D – 11 3JD–W0047–00 D – 8 5ET–W0047–50 D – 11 1UY–W0048–50 D – 11 D– 8[...]

  • Page 53

    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 3V6–22358–00 D – 5 4EW–22474–00 C – 13 3JE–22475–00 C – 13 5DH–22898–50 D – 11 5HC–23102–00 D – 2 5HC–23102–10 D – 2 5HC–23102–20 D – 2 5HC–23103–00 D – 2 5HC–23[...]

  • Page 54

    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 90201–164H4 C – 11 C–1 2 90201–167P7 B – 15 90201–20276 B – 15 90201–203U1 D – 10 90201–20685 B – 15 90201–247L2 C – 15 90201–253K0 C – 4 90201–286K9 C – 15 90202–05193 D – [...]

  • Page 55

    CONTENTS ENGINE CYLINDER HEAD B2 ................................... GOVERNOR B4 ........................................ CRANKSHAFT . PISTON B5 ............................. W A TER PUMP B6 ...................................... RADIA TOR. HOSE B7 .................................. INT AKE B8 ............................................ CARBURETOR[...]