Honda Blade 110

Manual Honda Blade 110 ini merangkum panduan penggunaan dan perawatan utama kendaraan. Pembahasan utama mencakup Keamanan Berkendara, Petunjuk Pengoperasian, Perawatan Berkala, Mengatasi Masalah, Spesifikasi

Unduh gratis Katalog Suku Cadang Honda Blade 110 2008-2011 dalam format PDF. Panduan lengkap, spesifikasi, dan prosedur perawatan resmi.

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TST 08 PC 004


## 

## PT Astra Honda Motor

BLADE

Page 1

## 

## D A F T A R I S I

1

## 

## PETUNJUK PEMAKAIAN

2

## 

## KELOMPOK MESIN

⚠

## 

## KELOMPOK RANGKA

4

## 

## INDEKS PART NUMBER

5

## 

## INDEKS 

Page 2

**PETUNJUK PEMAKAIAN PARTS CATALOG**

Parts catalog ini digunakan untuk memesan/mencari parts pengganti; di dalamnya terdapat semua parts dan waktu kerja standard (F.R.T.) untuk tipe sepeda motor **HONDA** 
 **BLADE**

**I. CARA MEMESAN PARTS**

**1. Informasi yang diperlukan**

Pemesan parts pengganti sebaiknya mencantumkan Part Number dan Nomor seri seperti diterangkan dibawah. Hal ini diperlukan oleh karena setiap perubahan dan modiﬁkasi 
pada parts telah didaftarkan di HONDA berikut nomor part dan Nomor seri yang bersangkutan.

Nomor-nomor yang dibutuhkan :

(a) Parts mesin 
: 
Part Number dan Nomor seri mesin

(b) Parts rangka 
: 
Part Number dan Nomor seri rangka

(c) Parts karburator 
: 
Part Number dan Nomor identifkasi karburator

**2. Perubahan-perubahan**

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

**II. CARA MEMBACA PARTS CATALOG**

**1. Susunan nomor part**

(contoh) Parts umum (General parts)

Nomor fungsi 
Nomor 
Kode warna
dan 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

1

Page 3

**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.

1

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

**Warna** 
 **Kode Warna**

**Kode pabrik**

**Kode HONDA**

FMB
FMK
FMI
FMH

NH-1
R-201
RP-140M
NH-131M

Black 
Magna Red 
Vortex Purple Metalic 
Starlight Silver Metalic

**3. Singkatan-singkatan**

Dibawah ini adalah daftar singkatan-singkatan yang digunakan di dalam parts 
catalog, sebagai berikut :
ASSY ................ Assembly 
L.E.D .............. Light emitting diode 
COMP .............. Complete. 
MPH ............... Miles per hour
R ....................... Right 
L (100L) .......... Link(100 Links)
L. ...................... Left 
A.C ................. Alternating current
STD .................. Standard 
D.C ................. Direct current 
MM ................... Milimeter 
IN ................... Inlet
G ...................... Gram 
EX. ................. Exhaust
T(22) ................. Tooth (22Teeth) 
FR .................. Front
A ....................... Ampere 
RR .................. Rear
V ....................... Volt 
Hex ................. Hexagonal
W ...................... Watt 
A.M ................. Attaching mark
WL .................... With labelling 
T.M ................. Transcript mark
WOL. ................ Without labelling 
C.D.I ............... Capacitive
KPH .................. Kilometers per hour 
 Discharge Ignition

**4. Dimensi-dimensi**

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

Part
Contoh
Pengertian

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

**5. Parts yang digantikan oleh part lain**

Nomor 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.

**7. Jumlah yang diperlukan**

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

**8. Illustrasi**

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

**9. Nama part** 
Nama 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.

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

**Kode** 
 **daerah** 
 **pemasaran** 
 **Tipe** 
 **Model**

**No. Identiﬁkasi** 
 **Karburator yang**

**No. Seri** 
 **Mesin yang** 
 **berlaku mulai**

**No. Seri** 
 **Rangka yang** 
 **berlaku mulai**

**berlaku**

Indonesia 
ANF110
2IN
JBB*E******* 
MH1JBB****K******
PB7UA A

* 
Dari nomor identiﬁkasi karburator, hanya dipakai bagian yang digaris bawahi di-
dalam contoh dibawah

PB7UA A A KC

Page 4

**11. Lokasi nomor seri pada sepeda motor** 
 **III. 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 :**

**NOMOR SERI**

a. Disamping waktu servis yang sebenarnya ditambahkan lagi waktu ekstra.

**RANGKA**

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**

**NOMOR SERI MESIN**

Waktu pekerjaan ditulis dalam sepersepuluh jam untuk mempermudahkan perhitungan.
(contoh) 0.3 = 18 menit
5.6 = 5 jam dan 36 menit

**NOMOR ** 
 ****

1

**DAFTAR KONVERSI**

**Jam**

**Menit**

**Jam**

**Menit**

0.1
0.2
0.3
0.4
0.5

6
12
18
24
30

0.6
0.7
0.8
0.9
1.0

36
42
48
54
60

**3. Menghitung F.R.T.**

Jika beberapa pekerjaan dilakukan sekaligus, hitunglah sebagai berikut :

a. Pekerjaan yang tidak berhubungan 
F.R.T. untuk pekerjaan diperoleh dengan menjumlahkan F.R.T. untuk setiap
part yang diganti
(contoh) Penggantian cylinder dan clutch spring

**Service item/Bagian yang diservis** 
 **F.R.T.**

Cylinder 
 1.4

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

Page 5

b. Pekerjaan yang terulang

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

(contoh) Penggantian piston dan cylinder head gasket.

1

**Service item/Bagian yang diservis** 
 **F.R.T.**

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.

**Service item/Bagian yang diservis** 
 **F.R.T.**

Gearshift drum 
 * 3.9

Crankshaft 
 * 4.1

Pembongkaran crankcase 
 * 3.7

F.R.T. untuk pekerjaan ini adalah : (3.9 + 4.1) - 3.7 = 4.3

Pekerjaan yang terulang adalah pembongkaran crankcase.

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

**4. Pengerjaan lain disamping penggantian parts**

a. Penurunan dan pemasangan
 **No.**

**Service item/Bagian yang diservis**

**F.R.T.**

1.

1.5

Mesin 
Kepala silinder 
Karburator

2.

1.1

3.

0.4

**No.**

**Service item/Bagian yang diservis** 
 **F.R.T.**

1.

Pemeriksaan waktu pengapian

0.2

2.

Penyetelan dan pembersihan busi

0.1

3.

0.3

Penyetelan tappet

Penyetelan stasioner karburator

4.

0.1

Pemeriksaan oli mesin (tidak termasuk
penggantian oli mesin)

5.

0.1

6.

Penyetelan kopling

0.1

7.

Pembersihan elemen saringan udara

0.3

8.

Pengukuran tekanan kompressi

0.1

9.

Pemeriksaan cairan baterai dan berat jenisnya

0.2

10.

Pengukuran tinggi pelampung karburator

0.6

11.

Pembersihan saringan oli mesin

0.6

12.

Penyetelan gas tangan

0.1

**Rangka**

**Service item/Bagian yang diservis** 
 **F.R.T.**

**No.**

1.

Penyetelan rem depan

0.1

2.

Penyetelan rem belakang

0.1

3.

Pemeriksaan cara kerja rem

0.1

4.

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

0.1

5.

0.1

b. Pembongkaran

**No.**

**Service item/Bagian yang diservis** 
 **F.R.T.**

1.

0.7
Karburator

Page 6

## 

## ENGINE GROUP

**E-1** 
 **E-2** 
 **E-3**

**CYLINDER HEAD COVER**

**CYLINDER HEAD**

**E-4** 
 **E-5** 
 **E-6**

**CAM CHAIN/TENSIONER**

**CYLINDER**

**E-7** 
 **E-8** 
 **E-9**

**ONE WAY CLUTCH**

**CLUTCH**

PC BLADE

**CAMSHAFT/VALVE**

2

**RIGHT CRANKCASE COVER**

**OIL PUMP**

Page 7

## 

## ENGINE GROUP

**E-10** 
 **E-11** 
 **E-12**

**LEFT CRANKCASE COVER**

**GENERATOR**

2

**E-13** 
 **E-14** 
 **E-15**

**STARTING MOTOR**

**CRANKCASE**

**E-16** 
 **E-17** 
 **E-18**

****

**GEARSHIFT DRUM**

**STARTING CLUTCH**

**/PISTON**

**KICK STARTER SPINDLE**

PC BLADE

Page 8

# ENGINE GROUP

| | | |
| :--- | :--- | :--- |
| **E-19 CARBURETOR** *[Diagram of Carburetor Assembly]* - **FR.** ↙ - **F-13** - **KWB9E1900** | | |
| | | |
| | | |

 

<div style="display: flex; justify-content: space-between; align-items: center;">
 PC BLADE
 **7**
</div>

---
*(Note: Section tab **2** is located on the right margin of the page)*

Page 9

## 

## FRAME GROUP

**METER** 
 **F-1** 
 **F-2** 
 **F-3**

**HEADLIGHT**

**F-4** 
 **F-6** 
 **F-5**

**STEERING STEM** 
 **FR. BRAKE MASTER CYLINDER**

**HANDLE PIPE/ HANDLE COVER**

⚠

**F-7** 
 **F-8**

**FRONT FENDER**

**FRONT FORK**

**SWITCH / CABLE**

**F-9** 
 **FRONT BRAKE CALIPER**

PC BLADE

Page 10

## 

## FRAME GROUP

**F-10** 
 **F-11** 
 **F-12**

**REAR BRAKE PANEL**

**FRONT WHEEL**

**F-13**

**F-14** 
 **F-15** 
 **FUEL TANK**

**SEAT / BATTERY**

**F-16-1** 
 **AIR SUCTION VALVE**

**F-16**

**AIR CLEANER**

PC BLADE

**REAR WHEEL**

**BODY COVER**

⚠

**F-17** 
 **EXHAUST MUFFLER**

Page 11

## 

## FRAME GROUP

**F-18** 
 **F-20**

**PEDAL/KICK STARTER ARM**

**F-19**

**F-22** 
 **F-21** 
 **F-23**

**SWINGARM**

**REAR CUSHION**

⚠

**F-24** 
 **FRONT WINKER**

**F-25** 
 **REAR  LIGHT**

**STEP**

**STAND**

**REAR FENDER**

**F-26** 
 **WIRE HARNESS**

PC BLADE

Page 12

## 

## FRAME GROUP

**F-27** 
 **F-29**

**FRAME BODY** 
 **FRONT COVER**

**F-28** 
 **MAIN PIPE COVER**

**F-30**

**F-31** 
 **CAUTION LABEL**

**MARK/ STRIPE**

PC BLADE

**F-32** 
 **TOOLS**

⚠

Page 13

## 

## Cylinder Head Cover


## 

## E - 1

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
COVER, CYLINDER HEAD................. 
0.1
2 
GASKET, CYLINDER HEAD COVER.. 
0.1

1 
 
COVER COMP., CYLINDER HEAD 
1
2 
 
GASKET, HEAD COVER 
1
 ⚠ 
 
BOLT, HEAD COVER 
2
4 
 
RUBBER, MOUNTING 
2
5 
 
DOWEL PIN, SPECIAL, 8X14 
1

**07 . 07 . 2008**

**TST 08 PC 004**

Page 14

## 

## Cylinder Head


## 

## E - 2

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
HEAD, CYLINDER ............................. 1.7
.INCLUDES: Valve adjust and reface .

1 
 
HEAD COMP., CYLINDER 
1
2 
 
GUIDE, VALVE 
2
 ⚠ 
 
CLIP, VALVE GUIDE 
2
4 
 
GASKET, CYLINDER HEAD 
1
5 
 
GASKET,  INSULATOR 
1

2 
GUIDE, INTAKE VALVE(ONE) ........... 1.7
.INCLUDES: Reaming ........................
.INCLUDES: Valve adjust and reface .

6 
 
INSULATOR,  
1
7 
 
PIPE COMP., INLET 
1
8 
 
PLUG, SPARK (CPR6EA-9S) 
1
 
PLUG, SPARK (U20EPR9S) 
(1)
9 
 
BOLT, FLANGE, 5X12 
1
10 
 
BOLT, FLANGE, 6X32 
2

GUIDE, EXHAUST VALVE(ONE) ....... 1.7
.INCLUDES: Reaming 
.INCLUDES: Valve adjust and reface .

GUIDE, VALVE :FOR 1 VEHICLE ...... 2
.INCLUDES: Reaming ........................
.INCLUDES: Valve adjust and reface .

11 
 
NUT, HEX., 7MM 
4
12 
 
PLATE, PLUNGER 
1
13 
 
WASHER, 7.2X16X2.5 
2
14 
 
DOWEL PIN, SPECIAL, 8X14 
2
15 
 
O-RING, 25X2.4 
1

4 
GASKET, CYLINDER HEAD .............. 0.8

6 
INSULATOR, THROTTLE BODY/
 .................................. 0.2
7 
MANIFOLD, INTAKE .......................... 0.3
8 
PLUG, SPARK .................................... 0.1

16 
 
BOLT, STUD, 8X32 
2
17 
 
, 6X12 
1
18 
 
BOLT, FLANGE, 6X22 
2
19 
 
BOLT, FLANGE, 6X100 
2

**07 . 07 . 2008**

**TST 08 PC 004**

2

Page 15

## 

## Camshaft / Valve


## 

## E - 3

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

2 
CAMSHAFT ........................................ 
1
.INCLUDES: Valve adjustment
 ⚠ 
ARM, INTAKE VALVE ROCKER(ONE) 1
.INCLUDES: Valve adjustment

1 
 
SEAL, VALVE STEM 
2
 
CAMSHAFT COMP. 
1
 ⚠ 
 
ARM COMP., IN. VALVE ROCKER 
1
4 
 
ARM COMP., EX. VALVE ROCKER 
1
5 
 
SHAFT, ROCKER ARM 
2

4 
ARM, EXHAUST VALVE ROCKER
(ONE) .................................................. 
1
.INCLUDES: Valve adjustment
ARM, VALVE ROCKER
:FOR 1 VEHICLE ................................ 
1
.INCLUDES: Valve adjustment

6 
 
VALVE, IN. 
1
7 
 
VALVE, EX. 
1
8 
 
SPRING, VALVE 
2
 
SPRING, VALVE 
2
9 
 
RETAINER, VALVE SPRING 
2
10 
 
SEAT, VALVE SPRING 
2

6 
VALVE, INTAKE(ONE) ........................ 
1.3
.INCLUDES: Refacing
7 
VALVE, EXHAUST(ONE) .................... 
1.3
.INCLUDES: Refacing
VALVE :FOR 1 VEHICLE .................... 
1.5
.INCLUDES: Refacing

11 
 
COTTER, VALVE 
4
12 
 
SCREW, TAPPET ADJUSTING 
2
13 
 
NUT, TAPPET ADJUSTING 
2

8 
(1,9,10,11) SPRING AND/OR STEM 
SEAL, INTAKE VALVE(ONE) .............. 
1.1
SPRING AND/OR STEM SEAL,
EXHAUST VALVE(ONE) ..................... 
1.1
SPRING AND/OR STEM SEAL,
VALVE :FOR 1 VEHICLE .................... 
1.2

**07 . 07 . 2008**

**TST 08 PC 004**

Page 16

## 

## E - 4

## 

## Cam Chain /


## 

## Tensioner

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 SPROCKET, CAM ............................... 0.4
2 CHAIN, CAM ....................................... 1.6
3 ARM, CAM CHAIN TENSIONER ........ 0.6
4 ROLLER(S), CAM CHAIN TENSIONER 0.6

1 
 
SPROCKET, CAM (32T) 
1
2 
 
CHAIN, CAM (90L) 
1
 ⚠ 
 
ARM COMP., CAM CHAIN TENSIONER 
1
4 
 
ROLLER, CAM CHAIN TENSIONER 
1
5 
 
COLLAR, CAM CHAIN TENSIONER 
1

7 (6,8) ROD, CAM CHAIN TENSIONER 
PUSH .................................................. 0.3
9 ROLLER, CAM CHAIN GUIDE ........... 0.9

6 
 
SPRING, CAM CHAIN TENSIONER 
1
7 
 
ROD COMP., CAM CHAIN TENSIONER 
1
8 
 
HEAD, CAM CHAIN TENSIONER PUSH 
1
9 
 
ROLLER COMP., CAM CHAIN GUIDE 
1
10 
 
PIN, GUIDE ROLLER 
1

11 SPROCKET, CAM CHAIN GUIDE ...... 2.7
.INCLUDES: Engine removal and
 installation
12 BOLT, CAM CHAIN GUIDE ROLLER .. 2.7
.INCLUDES: Engine removal and
 installation

11 
 
SPROCKET COMP., CAM CHAIN 
1
12 
 
SPINDLE, CAM CHAIN GUIDE 
1
13 
 
BOLT, SEALING, 14MM 
1
14 
 
BOLT, KNOCK, 5MM 
2
15 
 
WASHER, 8.5X26X2.3 
1

16 
 
WASHER, SEALING, 6.5MM 
1
17 
 
WASHER, 8MM 
1
18 
 
WASHER, SEALING, 14MM 
1
19 
 
BOLT, FLANGE, 6X18 
1
20 
 
BOLT, FLANGE, 8X25 
1

**07 . 07 . 2008**

**TST 08 PC 004**

2

Page 17

## 

## Cylinder


## 

## E- 5

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
CYLINDER ........................................... 1.1
2 
GASKET, CYLINDER .......................... 1
1 
 
CYLINDER COMP. 
1
2 
 
GASKET, CYLINDER 
1
 ⚠ 
 
DOWEL PIN, SPECIAL, 8X14 
2

**07 . 07 . 2008**

**TST 08 PC 004**

Page 18

## 

## E - 6

## 

## Right Crankcase


## 

## Cover

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 COVER, CRANKCASE :RIGHT .......... 0.8
2 GASKET, CRANKCASE COVER :
RIGHT .................................................. 0.6
5 LEVER, CLUTCH ................................ 0.7

1 
 
COVER COMP., R. CRANKCASE 
1
2 
 
GASKET, R. CRANKCASE COVER 
1
 ⚠ 
 
CLIP, PISTON PIN, 13MM 
1
4 
 
GAUGE, OIL LEVEL 
1
5 
 
LEVER COMP., CLUTCH 
1

6 (7,10) PLATE, CLUTCH CAM .............. 0.6
8 PLATE, CLUTCH CAM LIFTER ........... 0.7
9 SCREW, CLUTCH ADJUSTING .......... 0.7

6 
 
PLATE, CLUTCH LIFTER CAM 
1
7 
 
SPRING, CAM PLATE SIDE 
1
8 
 
PLATE COMP., CLUTCH LIFTER 
1
9 
 
BOLT, CLUTCH ADJUSTING 
1
10 
 
RETAINER COMP., BALL 
1

12 OIL SEAL, KICK STARTER SPINDLE.. 0.7

11 
 
WASHER, 8MM 
1
12 
 
OIL SEAL, 13.8X24X5 
1
13 
 
O-RING, 8MM 
1
14 
 
O-RING, 18X3 
1
15 
 
NUT, HEX., 8MM 
1

16 
 
DOWEL PIN, 8X14 
2
17 
 
BOLT, FLANGE, 6X40 
10

**07 . 07 . 2008**

**TST 08 PC 004**

2

Page 19

## 

## One Way Clutch


## 

## E - 7

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
(2) COVER, OIL FILTER ..................... 0.6
 ⚠ 
(7,12,27) WEIGHT SET, CLUTCH ...... 0.9
5 
PLATE, CLUTCH DRIVE .................... 0.9

1 
 
COVER, OIL FILTER 
1
2 
 
GASKET, OIL FILTER 
1
 ⚠ 
 
WEIGHT SET, PRIMARY CLUTCH 
1
4 
 
SPRING, ONE WAY RETAINER 
6
5 
 
PLATE COMP., PRIMARY DRIVE 
1

6 
(4,28) INNER, ONE-WAY CLUTCH .... 0.9

11 
OUTER, PRIMARY CLUTCH ............. 0.9
 13 
GEAR, PRIMARY DRIVE ................... 1

6 
 
INNER COMP., ONE-WAY CLUTCH 
1
7 
 
SPRING, PRIMARY CLUTCH 
 ⚠ 
8 
 
WASHER, CLUTCH SIDE 
1
9 
 
SPRING, SIDE FRICTION 
1
10 
 
PLATE, CLUTCH SIDE 
1

11 
 
OUTER ASSY., PRIMARY CLUTCH 
1
12 
 
RUBBER, CLUTCH DAMPER 
 ⚠ 
13 
 
GEAR COMP., PRIMARY DRIVE 
1 
14 
 
SUB GEAR (17T) 
1
15 
 
RETAINER, SPRING 
1

16 
 
SPRING, SUB GEAR 
1
17 
 
PIN 
1
18 
 
COLLAR, 19X28X4 
1
19 
 
BOLT, SPECIAL FLANGE, 5X8 
 ⚠ 
20 
 
NUT, LOCK, 14MM 
1

**07 . 07 . 2008**

**TST 08 PC 004**

Page 20

## 

## One Way Clutch


## 

## E - 7

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

21 
 
WASHER, 30X45X0.8 
1
22 
 
WASHER, LOCK 
1
23 
 
WASHER B, LOCK 
1
24 
 
WASHER, 17X23X1.5 
1

25 
 
CIRCLIP, INTERNAL, 45MM 
1
26 
 
SET RING, 23MM 
1
27 
 
CIRCLIP, 7MM 
 ⚠ 
28 
 
ROLLER, 5X8 
6

**07 . 07 . 2008**

**TST 08 PC 004**

2

Page 21

## 

## Clutch


## 

## E - 8

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
SEPARATOR, OIL ................................ 0.9
2 
OUTER, CLUTCH ................................ 0.9
5 
CENTER, CLUTCH ............................. 1.1

1 
 
PLATE, OIL SEPARATOR 
1
2 
 
OUTER COMP., CLUTCH 
1
 ⚠ 
 
GUIDE, CLUTCH OUTER 
1
4 
 
COLLAR, CLUTCH OUTER 
1
5 
 
CENTER, CLUTCH 
1

6 
(7,8) DISC, CLUTCH FRICTION ......... 1.1
.NOTE: Same time for two units
or more
9 
PLATE, CLUTCH PRESSURE ............ 1.1
 10 
PLATE, CLUTCH LIFTER .................... 0.9

6 
 
DISK, CLUTCH FRICTION 
2
7 
 
DISK B, CLUTCH FRICTION 
1
8 
 
PLATE, CLUTCH 
2
9 
 
PLATE, CLUTCH PRESSURE 
1
10 
 
PLATE, CLUTCH LIFTER 
1

11 
SPRING, CLUTCH .............................. 0.9
 18 
BEARING, CLUTCH LIFTER ............... 0.7

11 
 
SPRING, CLUTCH 
1
12 
 
SEAT, CLUTCH SPRING 
1
13 
 
BOLT, SPECIAL FLANGE, 6X16 
4
14 
 
NUT B, LOCK, 14MM 
1
15 
 
WASHER, THRUST, 17MM 
1

16 
 
WASHER, 14MM 
1
17 
 
BOLT, FLANGE, 6X20 
2
18 
 
BEARING, RADIAL BALL, 6200 
1

**07 . 07 . 2008**

**TST 08 PC 004**

Page 22

## 

## Oil Pump


## 

## E - 9

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
(2) PUMP ASSY., OIL ......................... 0.7
 5 
SCREEN, OIL FILTER ........................ 0.6

1 
 
PUMP ASSY., OIL 
1
2 
 
GASKET, OIL PUMP BODY 
1
 ⚠ 
 
ROTOR, OIL PUMP INNER 
1
4 
 
ROTOR, OIL PUMP OUTER 
1
5 
 
SCREEN, OIL FILTER 
1

6 
 
SCREW, PAN, 5X10 
 ⚠ 
7 
 
BOLT, FLANGE, 6X16 
2
8 
 
BOLT, FLANGE, 6X22 
1

**07 . 07 . 2008**

**TST 08 PC 004**

2

Page 23

## 

## E - 10

## 

## Left Crankcase


## 

## Cover

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
COVER, CRANKCASE :LEFT .............. 0.4
2 
COVER, CRANKCASE :LEFT REAR ... 0.1
 ⚠ 
GASKET, CRANKCASE COVER :
LEFT ..................................................... 0.3

1 
 
COVER, L. CRANKCASE 
1
2 
 
COVER COMP., L. RR. CRANKCASE 
1
 ⚠ 
 
GASKET, L. CRANKCASE COVER 
1
4 
 
CAP, A.C. GENERATOR 
1
5 
 
O-RING, 13.8X2.5 
1

6 
 
DOWEL PIN, 8X14 
2
7 
 
BOLT, FLANGE, 6X25 
2
8 
 
BOLT, FLANGE, 6X35 
8

**07 . 07 . 2008**

**TST 08 PC 004**

Page 24

## 

## Generator


## 

## E - 11

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 ROTOR OR FLYWHEEL ...................... 0.5
2 STATOR ............................................... 0.6

1 
 
FLYWHEEL COMP. 
1
2 
 
STATOR COMP. 
1
 ⚠ 
 
WASHER, 10X24 
1
4 
 
NUT, FLANGE, 10MM 
1
5 
 
BOLT, FLANGE, 6X16 
2

6 
 
BOLT, FLANGE, 6X20 
2

**07 . 07 . 2008**

**TST 08 PC 004**

2

Page 25

## 

## Starting Clutch


## 

## E - 12

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
(6) GEAR, STARTER DRIVEN............. 0.4
2 
CLUTCH, STARTING ONE WAY.......... 0.5
 ⚠ 
(4) GEAR, STARTER REDUCTION..... 0.3

1 
 
GEAR COMP., STARTER DRIVEN 
1
 
GEAR, STARTER DRIVEN (55T) 
1
2 
 
CLUTCH ASSY., ONE WAY 
1
 
CLUTCH ASSY., ONE WAY 
1
 ⚠ 
 
GEAR COMP., STARTER REDUCTION 
1
4 
 
SHAFT, REDUCTION GEAR 
1
5 
 
BOLT, SOCKET, 6X14 
6

6 
 
BEARING, NEEDLE, 19X23X17 
1

**07 . 07 . 2008**

**TST 08 PC 004**

Page 26

## 

## Starting Motor


## 

## E - 13

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

⚠ 
MOTOR, STARTING........................... 
0.4
4 
(1) TERMINAL, BRUSH (STARTER).. 0.6

1 
 
SPRING, CARBON BRUSH 
2
 
PACKING 
1
 ⚠ 
 
MOTOR UNIT, STARTER 
1
4 
 
BRUSH SET 
1
5 
 
SUB CORD, STARTER MOTOR 
1

6 
 
O-RING 
1
7 
 
, 4X6 
1
8 
 
, 5X16 
 ⚠ 
9 
 
BOLT, FLANGE, 6X32 
2

**07 . 07 . 2008**

**TST 08 PC 004**

2

Page 27

## 

## Crankcase


## 

## E - 14

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
 CRANKCASE :RIGHT.......................... 
3.3
 .INCLUDES: Engine removal and 
 installation

1 
 
CRANKCASE COMP., R. 
1
2 
 
CRANKCASE COMP., L. 
1
 ⚠ 
 
PLATE, OIL STOPPER 
1
4 
 
CONTACT ASSY., CHANGE SWITCH 
1 
5 
 
BOLT, STUD, 7X180.5 
4

CRANKCASE :BOTH........................... 
3.6
 .INCLUDES: Engine removal and 
 installation

6 
 
PACKING, DRAIN COCK, 12.5X20 
1
7 
 
DOWEL PIN, 10X14 
2
8 
 
OIL SEAL, 11.6X22X7 
1
9 
 
BOLT, DRAIN PLUG, 12MM 
1
10 
 
BOLT, HEX., 6X14 
1

2 
 CRANKCASE :LEFT ........................... 
2.9
 .INCLUDES: Engine removal and 
 installation

CRANKCASE :BOTH........................... 
3.6
 .INCLUDES: Engine removal and 
 installation

11 
 
BOLT, FLANGE, 6X18 
1
12 
 
BOLT, FLANGE, 6X60 
10
13 
 
BOLT, FLANGE, 6X75 
1

4 
 SWITCH, GEAR CHANGE................... 
0.2

8 
 OIL SEAL, GEARSHIFT SPINDLE....... 1.2

**07 . 07 . 2008**

**TST 08 PC 004**

Page 28

## 

## Crankshaft / Piston


## 

## E - 15

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 ...................................... 3.4
 .INCLUDES: Engine removal and 
 installation 
3 (2,4,5) RING, PISTON AND/OR 
 PISTON (ONE)..................................... 1.2

1 
 
MAINSHAFT (12T) 
1
2 
 
 
1
 ⚠ 
 
BUSH, 15MM 
2
4 
 
GEAR,  LOW (34T) 
1
5 
 
GEAR, MAINSHAFT SECOND (17T) 
1

7 BEARING,  :RIGHT...... 
3.3
 .INCLUDES: Engine removal and 
 installation

6 
 
WASHER, 6X19X2.3 
7 
 
GEAR, MAINSHAFT THIRD (21T) 
1
8 
 
GEAR,  THIRD (26T) 
1
9 
 
GEAR, MAINSHAFT FOURTH (24T) 
1
10 
 
GEAR,  FOURTH 
1

11 
 
SPROCKET, DRIVE (14T) 
1
12 
 
PLATE, FIXING 
1
13 
 
COLLAR, LOCK PLATE 
1
14 
 
SPRING, CHANGE FRICTION 
1
15 
 
PLATE, DRUM LOCK 
1

16 
 
WASHER, 6X19X2.3 
2
17 
 
WASHER, SPECIAL, 12X23 
2
18 
 
WASHER, THRUST, 15MM 
1
19 
 
WASHER, THRUST, 17MM 
1
20 
 
WASHER, THRUST, 20MM 
1

**07 . 07 . 2008**

**TST 08 PC 004**

2

Page 29

## 

## Transmission


## 

## E - 16

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
(5,7,9) MAINSHAFT,  2.8
.INCLUDES: Engine removal and 
installation 
.Replace countershaft add 
0.2

1 
 
MAINSHAFT (12T) 
1
2 
 
 
1
 ⚠ 
 
BUSH, 15MM 
2
4 
 
GEAR,  LOW (34T) 
1
5 
 
GEAR, MAINSHAFT SECOND (17T) 
1

2 
(4,6,8,10) , 
 ................................ 
2.8
.INCLUDES: Engine removal and 
installation 
.Replace mainshaft add 
0.2

6 
 
WASHER, 6X19X2.3 
1 
7 
 
GEAR, MAINSHAFT THIRD (21T) 
1
8 
 
GEAR,  THIRD (26T) 
1
9 
 
GEAR, MAINSHAFT FOURTH (24T) 
1
10 
 
GEAR,  FOURTH 
1

11 
SPROCKET, DRIVE............................ 
0.2

11 
 
SPROCKET, DRIVE (14T) 
1
12 
 
PLATE, FIXING 
1
13 
 
COLLAR, LOCK PLATE 
1
14 
 
SPRING, CHANGE FRICTION 
1
15 
 
PLATE, DRUM LOCK 
1

30 
BEARING, MAINSHAFT :LEFT........... 
2.8
.INCLUDES: Engine removal and 
installation 
 31 
BEARING,  :RIGHT 
3.5
.INCLUDES: Engine removal and 
installation

16 
 
WASHER, 6X19X2.3 
2
17 
 
WASHER, SPECIAL, 12X23 
2
18 
 
WASHER, THRUST, 15MM 
1
19 
 
WASHER, THRUST, 17MM 
1
20 
 
WASHER, THRUST, 20MM 
1

**07 . 07 . 2008**

**TST 08 PC 004**

Page 30

## 

## Transmission


## 

## E - 16

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

32 BEARING, MAINSHAFT :RIGHT......... 3.5
.INCLUDES: Engine removal and 
 installation

21 
 
WASHER, SPLINE, 20MM 
1
22 
 
WASHER, SPLINE, 17MM 
2
23 
 
WASHER, SPLINE, 20MM 
1
24 
 
WASHER, LOCK, 20MM 
1
25 
 
CIRCLIP, EXTERNAL, 17MM 
2

BEARING, MAINSHAFT :BOTH......... 
3.7
.INCLUDES: Engine removal and 
 installation

26 
 
CIRCLIP, 20MM 
1
27 
 
OIL SEAL, 17X29X5 
1
28 
 
BOLT, HEX., 6X10 
2
29 
 
BOLT, FLANGE, 6X12 
2
30 
 
BEARING, RADIAL BALL, 6001 
1

BEARING,  :LEFT.. 
2.8
.INCLUDES: Engine removal and 
 installation

BEARING,  :BOTH 
3.7
.INCLUDES: Engine removal and 
 installation

31 
 
BEARING, RADIAL BALL, 6201 
1
32 
 
BEARING, RADIAL BALL, 6203 
2

BEARING, MAINSHAFT AND 
  :ALL .................... 
3.9
.INCLUDES: Engine removal and 
 installation

**07 . 07 . 2008**

**TST 08 PC 004**

2

Page 31

## 

## Gearshift Drum


## 

## E - 17

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
(2,3) FORK, GEARSHIFT ................. 
2.6
.INCLUDES: Engine removal and 
installation 
.NOTE: Same time for two units 
4 
DRUM, GEARSHIFT .......................... 
2.6
.INCLUDES: Engine removal and 
installation 
5 
PLATE, GEARSHIFT DRUM 
STOPPER .......................................... 
1

1 
 
FORK, GEARSHIFT 
2
 
PIN, GEARSHIFT FORK GUIDE 
2
 ⚠ 
 
CLIP, GEARSHIFT FORK GUIDE PIN 
2
4 
 
DRUM, GEARSHIFT 
1
5 
 
PLATE, GEARSHIFT DRUM STOPPER 
1

6 
 
PIN, GEARSHIFT DRUM 
5
7 
 
ARM COMP., SHIFT DRUM STOPPER 
1
8 
 
SPRING, GEARSHIFT DRUM STOPPER 
1
9 
 
SPINDLE COMP., GEARSHIFT 
1
10 
 
ARM COMP., GEARSHIFT 
1

7 
(8) STOPPER OR SPRING, SHIFT 
DRUM ................................................. 1
9 
SPINDLE, GEARSHIFT ...................... 1.1
 10 
(12) ARM, GEARSHIFT ...................... 1.1

11 
 
SPRING, GEARSHIFT ARM 
1
12 
 
SPRING, GEARSHIFT RETURN 
1
13 
 
PIN, SHIFT RETURN SPRING 
1
14 
 
CAP, CHANGE SWITCH CONTACT 
1
15 
 
SPRING, CHANGE SWITCH CONTACT 
1

16 
 
BOLT, KNOCK, 6MM 
1
17 
 
ROLLER, 3X10 
2

**07 . 07 . 2008**

**TST 08 PC 004**

Page 32

## 

## Kick Starter Spindle


## 

## E - 18

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
(2,6) PINION, KICK STARTER .......... 
2.7
.INCLUDES: Engine removal and 
 installation

1 
 
PINION, KICK STARTER (22T) 
1
2 
 
RATCHET, STARTER DRIVE 
1
 ⚠ 
 
SPINDLE, KICK STARTER 
1
4 
 
RETAINER, KICK SPINDLE 
1
5 
 
COLLAR, KICK SPRING 
1

⚠ 
SPINDLE, KICK STARTER................. 
2.7
.INCLUDES: Engine removal and 
 installation

6 
 
SPRING, FRICTION STARTER GEAR 
1
7 
 
SPRING, KICK RETURN 
1
8 
 
WASHER, SPECIAL, 14MM 
1
9 
 
WASHER, THRUST, 20MM 
1
10 
 
SET RING, 20MM 
2

7 
SPRING, KICK STARTER RETURN... 
2.7
.INCLUDES: Engine removal and 
installation

11 
 
CIRCLIP, EXTERNAL, 16MM 
1

**07 . 07 . 2008**

**TST 08 PC 004**

2

Page 33

## 

## Carburetor


## 

## E - 19

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

2 
NEEDLE, JET ..................................... 
0.7
 ⚠ 
(18) FLOAT OR FLOAT VALVE .......... 
0.6
4 
TOP SET,  .................. 0.2
5 
CHAMBER, FLOAT ............................ 
0.5

1 
 
GASKET SET 
1
2 
 
NEEDLE SET, JET 
1
 ⚠ 
 
FLOAT SET 
1
4 
 
TOP SET 
1
5 
 
CHAMBER SET, FLOAT 
1

7 
VALVE, THROTTLE ........................... 
0.3

6 
 
SCREW SET 
1
7 
 
VALVE SET, THROTTLE 
1
8 
 
SCREW SET 
1
9 
 
PLATE SET, VALVE 
1
10 
 
GASKET SET 
1

12 
VALVE, AIR CUT ................................ 
0.1
 15 
 ASSEMBLY .............. 
0.6

25 
COCK ASSY., FUEL ........................... 
0.2
 32 
(20,33) JET, MAIN .............................. 
0.6

11 
 
NUT SET, SQUARE 
1
12 
 
VALVE SET, AIR CUT 
1
13 
 
O-RING, 2.4X25 
1
14 
 
O-RING, 1.3X4.3 
2
15 
 
 ASSY. (PB7UA A) 
1

16 
 
CAP, CABLE SEALING 
1
17 
 
CAP, CHOKE DUST 
1
18 
 
VALVE COMP., FLOAT 
1
19 
 
GASKET, FLOAT CHAMBER 
1
20 
 
HOLDER, NEEDLE JET 
1

**07 . 07 . 2008**

**TST 08 PC 004**

Page 34

## 

## Carburetor


## 

## E - 19

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

21 
 
CUP, FUEL STRAINER 
1
22 
 
SCREEN, FUEL STRAINER 
1
23 
 
TUBE, AIR VENT 
1
24 
 
TUBE, OVERFLOW 
1
25 
 
BODY SET, COCK 
1

26 
 
LEVER SET, COCK 
1
27 
 
, 3X12 
2
28 
 
, 4X10 
2
29 
 
, 4X14 
2
30 
 
, 5X10 
1

31 
 
CLIP, TUBE (B6.5) 
1
32 
 
JET, MAIN, 

## 92 
1
33 
 
JET, SLOW, 

## 35 
1

**07 . 07 . 2008**

**TST 08 PC 004**

2

Page 35

## 

## F - 1

## 

## Headlight

⚠

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
HEADLIGHT UNIT................................ 
0.3
 ⚠ 
SOCKET, HEADLIGHT......................... 
0.2
4 
BULB, HEADLIGHT.............................. 
0.2
5 
BULB, POSITION LIGHT...................... 
0.1
.NOTE: Same time for two units

1 
 
HEADLIGHT UNIT 
1
2 
 
NUT, ADJUST 
1
 ⚠ 
 
SOCKET COMP., HEADLIGHT 
1
4 
 
BULB, HEADLIGHT 
1
5 
 
BULB, WEDGE BASE (T10) 
2

6 
 
CLIP, HEADLIGHT 
2
7 
 
BOLT, ADJUSTING 
1

**TST 08 PC 004**

**07 . 07 . 2008**

Page 36

## 

## F - 2

## 

## Meter

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
(2) BULB, METER ............................... 
0.5
.NOTE: Same time for two units 
or more 
4 
METER ASSY.,  ......... 
0.5
5 
METER,  .................... 
0.7

1 
 
BULB, WEDGE BASE (T10) 
2
 
BULB, WEDGE BASE (T10) 
8
 ⚠ 
 
CLAMP 
1
4 
 
 ASSY. 
1
5 
 
METER COMP., SPEED & FUEL 
1

6 
LENS, METER .................................... 
0.6
7 
CASE, METER .................................... 
0.7
8 
SOCKET ASSY., METER BULB .......... 
0.6

6 
 
GLASS 
1
7 
 
CASE COMP., UNDER 
1
8 
 
SOCKET COMP. 
1
9 
 
, 3X22 
 ⚠ 
10 
 
RELAY COMP., WINKER 
1

10 
RELAY, WINKER ................................. 
0.6
 12 
CABLE,  ................... 
0.5

11 
 
, WINKER RELAY 
1
12 
 
CABLE COMP.,  
1
13 
 
, SPECIAL, 4X10 
2
14 
 
SCREW, TAPPING, 4X14 
1
15 
 
O-RING, 10X1.5 
1

16 
 
BAND, WIRE HARNESS 
1
17 
 
SCREW, TAPPING, 5X16 
 ⚠

**TST 08 PC 004**

**07 . 07 . 2008**

⚠

Page 37

## 

## F - 3

## 

## Switch / Cable

⚠

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
 
CABLE COMP., THROTTLE 
1
2 
 
CABLE COMP., CHOKE 
1
 ⚠ 
 
LEVER, CHOKE 
1
4 
 
STOPPER, CABLE 
1
5 
 
SWITCH UNIT, LIGHTING 
1

1 
CABLE, THROTTLE ........................... 
0.7
2 
CABLE, CHOKE ................................. 
0.5
5 
SWITCH, LIGHTING ........................... 
0.5

6 
SWITCH, STARTER ........................... 
0.5
7 
SWITCH, DIMMER ............................. 
0.5
8 
SWITCH, HORN ................................. 
0.5
9 
SWITCH, WINKER ............................. 
0.5
 10 GRIP, THROTTLE ............................... 
0.5

6 
 
SWITCH UNIT, STARTING 
1
7 
 
SWITCH UNIT, DIMMER 
1
8 
 
SWITCH UNIT, HORN 
1
9 
 
SWITCH ASSY., WINKER 
1
10 
 
GRIP COMP., THROTTLE 
1

11 GRIP, HANDLE :LEFT ........................ 
0.1
 13 HOUSING, THROTTLE ...................... 
0.5

11 
 
GRIP, L. HANDLE 
1
12 
 
HOUSING, UPPER THROTTLE 
1
13 
 
HOUSING, UNDER THROTTLE 
1
14 
 
MIRROR ASSY., R. BLACK 
1
15 
 
MIRROR ASSY., l. BLACK 
1

16 
 
WASHER, WAVE 
1
17 
 
SCREW, PAN, 5X10 
1
18 
 
SCREW, PAN, 5X12 
1
19 
 
SCREW, PAN, 5X25 
1
20 
 
NUT, HEX., 5MM 
1

 
WASHER, PLAIN, 5MM

**TST 08 PC 004**

**07 . 07 . 2008**

Page 38

## 

## F - 4

## 

## Fr. Brake Master


## 

## Cylinder

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
SWITCH, FRONT STOP...................... 
0.5
 ⚠ 
HOSE, FRONT BRAKE....................... 
0.6
.INCLUDES: Bleed brakes

1 
 
SWITCH ASSY., FR. STOP 
1
2 
 
CAP, MASTER CYLINDER 
1
 ⚠ 
 
HOSE COMP., FR. BRAKE 
1
4 
 
CLAMPER, BRAKE HOSE 
1
5 
 
CLAMPER B, BRAKE HOSE 
1

7 
CYLINDER, FRONT BRAKE MASTER 
0.7
.INCLUDES: Bleed brakes 
 10 
DIAPHRAGM, FRONT BRAKE 
MASTER CYLINDER .......................... 
0.1

6 
 
BOOT COMP. 
1
7 
 
CYLINDER SUB ASSY., FR. BRAKE 
1
8 
 
PROTECTOR 
1
9 
 
HOLDER, MASTER CYLINDER 
1
10 
 
DIAPHRAGM 
1

12 
PISTON SET, FRONT BRAKE 
MASTER ............................................. 
0.7
.INCLUDES: Bleed brakes 
 13 
LEVER, HANDLE :RIGHT .................. 
0.2

11 
 
PLATE, DIAPHRAGM 
1
12 
 
CYLINDER SET, MASTER 
1
13 
 
LEVER, R. STEERING HANDLE 
1
14 
 
BOLT, FLANGE, 6X10 
1
15 
 
BOLT, HANDLE LEVER PIVOT 
1

16 
 
BOLT, OIL, 10X22 
2
17 
 
WASHER, OIL BOLT 
4
18 
 
CIRCLIP 
1
19 
 
SCREW, FLAT, 4X12 
2
20 
 
, 4X12 
1

21 
 
NUT, FLANGE, 6MM 
1
 
BOLT, FLANGE, 6X22 
 
BOLT, FLANGE, 6X12

**TST 08 PC 004**

**07 . 07 . 2008**

⚠

Page 39

## 

## F - 5

## 

## Handle Pipe /


## 

## Handle Cover

⚠

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
PIPE, STEERING HANDLE ................. 1.1
5 
WEIGHT B, HANDLE :LEFT ................ 0.2
WEIGHT B, HANDLE :RIGHT ............. 
0.2
WEIGHT B, HANDLE :BOTH .............. 
0.4

1 
 
PIPE COMP., STEERING HANDLE 
1
2 
 
WEIGHT A, STEERING HANDLE 
2
 ⚠ 
 
RUBBER A, HANDLE WEIGHT 
4
 
RING, HANDLE WEIGHT SNAP 
2
5 
 
WEIGHT B, STEERING HANDLE 
2

6 
COVER, HANDLE :FRONT ................. 0.4
COVER, HANDLE :BOTH .................... 0.6
7 
COVER, HANDLE :REAR .................... 0.6
COVER, HANDLE :BOTH .................... 0.6

6 
 
COVER SET, FR. HANDLE (WL) *TYPE1* 1
7 
 
COVER, RR. HANDLE 
1
8 
 
NUT, CLIP, 4MM 
6
9 
 
BOLT, FLANGE, 10X50 
1
10 
 
SCREW, OVAL, 6X45 
2

11 
 
NUT, U, 10MM 
1
12 
 
COLLAR A, HANDLE SETTING 
1
13 
 
COLLAR B, HANDLE SETTING 
1
14 
 
SCREW, PAN, 5X11.5 
1
15 
 
, 4X16 
6

16 
 
SCREW, TAPPING, 4X12 
2

**TST 08 PC 004**

**07 . 07 . 2008**

Page 40

## 

## F - 6

## 

## Steering Stem

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

4 
RACE, STEERING BALL :UPPER........ 
1.4
RACE, STEERING BALL :BOTH ......... 
1.4
5 
RACE, STEERING BALL :LOWER....... 
1.4
RACE, STEERING BALL :BOTH.......... 
1.4

1 
 
BALL SET, STEEL, 

## 6X23 
1
2 
 
BALL SET, STEEL, 

## 6X29 
1
 ⚠ 
 
GUIDE, FR. BRAKE CABLE 
1
4 
 
RACE, STEERING TOP BALL 
1
5 
 
RACE, STEERING BOTTOM BALL 
1

7 
RACE, STEERING TOP CONE............ 
0.8
8 
(9) RACE, STEERING BOTTOM CONE. 1.5

6 
 
NUT, STEERING STEM LOCK 
1
7 
 
RACE, STEERING TOP CONE 
1
8 
 
RACE, STEERING BOTTOM CONE 
1
9 
 
DUST SEAL, STEERING HEAD 
1
10 
 
WASHER, STEERING STEM NUT 
1

11 STEM OR SHAFT ASSY., STEERING.. 
1.4
 12 THREAD, STEERING HEAD TOP........ 
0.8

11 
 
STEM SUB ASSY., STEERING 
1
12 
 
THREAD COMP., STEERING HEAD 
1
13 
 
BOLT, FLANGE, 10X45 
4
14 
 
BOLT, FLANGE, 6X12 
1

**TST 08 PC 004**

**07 . 07 . 2008**

⚠

Page 41

## 

## F - 7

## 

## Front Fender

⚠

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

2 
(3) FENDER, FRONT .......................... 0.3

1 
 
GROMMET, WIRE 
1
2 
 
FENDER., FR. TECHNO BLUE METALIC 
1
 
FENDER., FR. BLACK 
(1)
 
FENDER., FR. WINNING RED 
(1)
 
FENDER., FR. SPORTY BLUE METALIC 
(1)
 
FENDER., FR. PEARL FLASH YELLOW 
(1)
 
FENDER., FR. PEARL FADELESS WHITE 
(1)
 
FENDER., FR. PEARL TWISTER BLUE 
(1)

⚠ 
 
COLLAR, FR. FENDER 
4
 
BOLT, COWL SETTING 
2

5 
 
BOLT, FLANGE, 6X20 
2

**TST 08 PC 004**

**07 . 07 . 2008**

Page 42

## 

## F - 8

## 

## Front Fork

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
FORK ASSY., FRONT :RIGHT ............. 
0.5
FORK ASSY., FRONT :BOTH .............. 
0.7
2 
SPRING, FRONT FORK :LEFT ............ 
0.7
SPRING, FRONT FORK :RIGHT ......... 
0.7
SPRING, FRONT FORK :BOTH .......... 
1
 ⚠ 
PIPE, FRONT FORK :LEFT ................. 
0.8
PIPE, FRONT FORK :RIGHT .............. 
0.8
PIPE, FRONT FORK :BOTH ................ 
1.3

1 
 
FORK ASSY., R. FR. 
1
2 
 
SPRING, FR. FORK 
2
 ⚠ 
 
PIPE COMP., FR. FORK 
2
4 
 
SPRING, REBOUND 
2
5 
 
RING, BACK UP 
2

6 
 
CASE COMP., R. FR. BOTTOM 
1
7 
 
DUST SEAL 
2
8 
 
RING, PISTON 
2
9 
 
SEAT B, SPRING 
2
10 
 
RING, STOPPER 
2

6 
CASE, BOTTOM :RIGHT ..................... 
0.9
CASE, BOTTOM :BOTH ....................... 
1.5

13 SEAL SET, FRONT FORK :LEFT ......... 
0.9
SEAL SET, FRONT FORK :RIGHT ....... 
0.9
SEAL SET, FRONT FORK :BOTH ........ 
1.5
 14 FORK ASSY., FRONT :LEFT ................ 
0.5
FORK ASSY., FRONT :BOTH .............. 
0.7
 15 CASE, BOTTOM :LEFT ........................ 
0.9
CASE, BOTTOM :BOTH ...................... 
1.5

11 
 
RING, OIL SEAL STOPPER 
2
12 
 
PIPE, SEAT 
2
13 
 
SEAL SET, FR. FORK 
2
14 
 
FORK ASSY., L. FR.. 
1
15 
 
CASE COMP., L. FR. BOTTOM 
1

16 
 
BOLT, SOCKET, 8MM 
2
17 
 
WASHER, SPECIAL, 8MM 
2
18 
 
O-RING 
2

**TST 08 PC 004**

**07 . 07 . 2008**

⚠

Page 43

## 

## F - 9

## 

## Front Brake Caliper

⚠

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

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

1 
 
SEAL SET, PISTON 
1
2 
 
PAD SET, FR. 
1
 ⚠ 
 
SCREW, BLEEDER. 
1
4 
 
CAP, BLEEDER 
1
5 
 
RING, STOPPER 
1

12 (1) PISTON, FRONT BRAKE CALIPER 0.5
.INCLUDES: Bleed brakes 
 13 CALIPER, FRONT BRAKE ................. 
0.4
.INCLUDES: Bleed brakes 
 14 BRACKET, FRONT CALIPER ............. 
0.2

6 
 
BOLT, PIN 
1
7 
 
BOOT, PIN BUSH. 
1
8 
 
BOOT B 
1
9 
 
SPRING, PAD 
1
10 
 
PIN, HANGER 
1

11 
 
WASHER, WAVE 
1
12 
 
PISTON 
1
13 
 
CALIPER SUB ASSY., R. FR. 
1
14 
 
BRACKET SUB ASSY., FR. 
1
15 
 
BOLT, TORX, 8X25 
2

**TST 08 PC 004**

**07 . 07 . 2008**

Page 44

## 

## F - 10

## 

## Front Wheel

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

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

1 
 
AXLE, FR. WHEEL 
1
2 
 
COLLAR, FR. WHEEL SIDE 
1
 ⚠ 
 
COLLAR, FR. AXLE DISTANCE 
1
4 
 
WHEEL SUB ASSY., FR. *NH303M* 
1
5 
 
TIRE, FR. 
1

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

6 
 
TUBE, TIRE (IRC) (70/90-17M/C) 
1
7 
 
BOX ASSY.,  GEAR 
1
8 
 
GEAR,  (19T) 
1
9 
 
WASHER,  GEAR 
1
10 
 
DISK, FR. BRAKE 
1
 
DISK, FR. BRAKE 
1

13 
(3) BEARING, FRONT WHEEL(ONE) 
0.4
.Replace 1 bearing add 
0.1

11 
 
BOLT, BRAKE DISK, 8X24 
4
12 
 
NUT, U, 12MM 
1
13 
 
BEARING, RADIAL BALL, 6201U 
2
 
BEARING, RADIAL BALL, 6201U 
2
14 
 
DUST SEAL, 21X37X7 
1
15 
 
DUST SEAL, 42X54X7 
1

**TST 08 PC 004**

**07 . 07 . 2008**

⚠

Page 45

## 

## F - 11

## 

## Rear Brake Panel

⚠

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
SHOE(PAD) SET, BRAKE :REAR ....... 0.4
4 
(5) PANEL, REAR BRAKE .................. 0.5
6 
ARM, BRAKE :REAR .......................... 0.1

1 
 
SHOE SET, BRAKE 
1
2 
 
ADJUSTER, R. CHAIN 
1
 ⚠ 
 
COLLAR, RR. BRAKE PANEL SIDE 
1
4 
 
PANEL COMP., RR. BRAKE *NH303M* 1
5 
 
CAM, RR. BRAKE 
1

6 
 
ARM, RR. BRAKE 
1
7 
 
RUBBER, STOPPER ARM 
1
8 
 
SPRING, BRAKE SHOE 
2
9 
 
DUST SEAL, BRAKE CAM 
1
10 
 
INDICATOR, FR. BRAKE 
1

11 
 
NUT, U, 6MM 
1
12 
 
NUT, SPECIAL, 6MM 
1
13 
 
NUT, U, 12MM 
1
14 
 
WASHER, 8MM 
1
15 
 
BOLT A, BRAKE STOPPER 
1

16 
 
NUT, HEX., 6MM 
1
17 
 
NUT, HEX., 8MM 
1
18 
 
PIN, SPLIT, 2.0X15 
1
19 
 
BOLT, FLANGE, 6X35 
1

**TST 08 PC 004**

**07 . 07 . 2008**

Page 46

## 

## F - 12

## 

## Rear Wheel

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
 
DAMPER SET, WHEEL 
1
2 
 
ADJUSTER, R. CHAIN 
1
 ⚠ 
 
SPROCKET COMP., FINAL DRIVEN 
1
 
SPROCKET COMP., FINAL DRIVEN 
1
4 
 
AXLE, RR. WHEEL 
1
5 
 
SLEEVE, RR. WHEEL 
1

1 
DAMPER, REAR WHEEL................... 
0.3
 ⚠ 
SPROCKET, FINAL DRIVEN............... 
0.4
4 
AXLE, REAR WHEEL ......................... 
0.3

7 
FLANGE ASSY., FINAL DRIVEN ........ 
0.4
9 
REAR WHEEL ..................................... 
0.8

6 
 
COLLAR, RR. WHEEL SIDE 
1
7 
 
FLANGE SUB ASSY., FINAL DRIVEN 
1
8 
 
COLLAR, RR. AXLE DISTANCE 
1
9 
 
WHEEL SUB ASSY., RR. *NH303M* 
1
10 
 
O-RING, 40.5X3 
1

11 
REAR TIRE(ONE) .............................. 
0.8
 12 
TUBE, REAR TIRE(ONE) ................... 
0.8

16 
(17) BEARING, REAR WHEEL(ONE). 
0.5
.Replace 1 bearing add 
0.1
 18 
BEARING, FINAL DRIVEN FLANGE.. 
0.5

11 
 
TIRE, RR. 
1
12 
 
TUBE, TIRE 
1
13 
 
BOLT, STUD, 8X18 
4
14 
 
NUT, SPECIAL, 6MM 
1
15 
 
NUT, U, 8MM 
4

16 
 
BEARING, RADIAL BALL, 6201U 
1
 
BEARING, RADIAL BALL, 6201U 
1
17 
 
BEARING, RADIAL BALL, 6301U 
1
 
BEARING, RADIAL BALL, 6301U 
1
18 
 
BEARING, RADIAL BALL, 6203U 
1
 
BEARING, RADIAL BALL, 6203U 
 
DUST SEAL, 27X40X4.5 
 
NUT, HEX., 6MM

**TST 08 PC 004**

**07 . 07 . 2008**

⚠

Page 47

## 

## F - 13

## 

## Fuel Tank

⚠

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
STRAINER, FUEL ............................... 
0.5
2 
TANK, FUEL ........................................ 1

1 
 
STRAINER COMP., FUEL 
1
2 
 
TANK COMP., FUEL 
1
 ⚠ 
 
CAP, FUEL FILLER 
1
4 
 
TUBE, FUEL, 5.3X560 
1
5 
 
PACKING, FUEL FILLER CAP 
1

6 
FUEL TANK SENDING UNIT .............. 
0.2

6 
 
FUEL UNIT 
1
7 
 
PACKING, BASE 
1
8 
 
RETAINER, FUEL UNIT 
1
9 
 
TUBE, FUEL, 5.3X45 
1
10 
 
CLIP, TUBE 
4

11 
 
BOLT, FLANGE, 6X12 
4

**TST 08 PC 004**

**07 . 07 . 2008**

Page 48

## 

## F - 14

## 

## Seat / Battery

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
 
BATTERY ASSY. (GTZ5S) 
1
 
BATTERY (YTZ5S) 
1
2 
 
COVER, BATTERY 
1
 ⚠ 
 
RAIL, RR. GRAB 
1
4 
 
SPRING, LOCK KEY SETTING 
1
5 
 
RUBBER, SEAL 
1

1 
BATTERY ............................................ 
0.2
 ⚠ 
RAIL, GRAB :REAR ............................ 
0.1

6 
SEAT :DOUBLE .................................. 
0.1
7 
HINGE, SEAT ...................................... 
0.7
9 
CATCH, SEAT :REAR SIDE ................ 
0.7

6 
 
SEAT COMP., DOUBLE 
1
7 
 
HINGE, SEAT 
1
8 
 
RUBBER B, SEAT SETTING 
4
9 
 
CATCH COMP., SEAT 
1
10 
 
SPRING, SEAT LOCK 
1

12 KEY, SEAT LOCK ................................ 
0.8
 13 BOX, LUGGAGE ................................. 
0.9

11 
 
WASHER, SEAT LOCK 
1
12 
 
LOCK ASSY., SEAT 
1
13 
 
BOX COMP., LUGGAGE 
1
14 
 
RUBBER, LUGGAGE BOX MOUNTING 
 ⚠ 
15 
 
BOLT, SEAT HINGE 
1

16 
 
BOLT, SPECIAL, 6X30 
2
17 
 
COLLAR, 6.2X20 
 ⚠ 
18 
 
CLIP, BATTERY COVER 
1
19 
 
NUT, HEX., 6MM 
2
20 
 
BOLT, FLANGE, 6X12 
2

 
BOLT, FLANGE, 8X14 
 
BOLT, FLANGE, 6X30

**TST 08 PC 004**

**07 . 07 . 2008**

⚠

Page 49

## 

## F - 15

## 

## Body Cover

⚠

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
COVER, SIDE :RIGHT ........................ 
0.6
COVER, SIDE :BOTH ......................... 
0.6
2 
COVER, SIDE :LEFT........................... 
0.6
COVER, SIDE :BOTH.......................... 
0.6
4 
COVER, BODY :RIGHT ...................... 
0.6
COVER, BODY :BOTH ....................... 
0.6
5 
COVER, BODY :LEFT.......................... 
0.6
COVER, BODY :BOTH........................ 
0.6

1 
 
COVER, R. CENTER 
1
2 
 
COVER, L. CENTER 
1
 ⚠ 
 
MAT, RR. BODY COVER 
2
4 
 
COVER COMP., R. RR. BODY 
1
5 
 
COVER COMP., L. RR. BODY 
1

6 
 
COVER SET, R. BODY 
DIGITAL SILVER METALLIC 
1
 
BLACK 
(1)
 
VOSTOK SILVER METALLIC 
(1)
 
ANCHOR GREY METALLIC 
(1)
 
TECHNO BLUE METALLIC 
(1)
 
PEARL FADELESS WHITE 
(1)

6 
COVER, BODY SIDE :RIGHT.............. 
0.6
COVER, BODY SIDE :BOTH............... 
0.7
7 
COVER, BODY SIDE :LEFT................ 
0.6
COVER, BODY SIDE :BOTH............... 
0.7

7 
 
COVER SET, L. BODY 
DIGITAL SILVER METALLIC 
1
 
BLACK 
(1)
 
VOSTOK SILVER METALLIC 
(1)
 
ANCHOR GREY METALLIC 
(1)
 
TECHNO BLUE METALLIC 
(1)
 
PEARL FADELESS WHITE 
(1)

**TST 08 PC 004**

**07 . 07 . 2008**

Page 50

## 

## F - 15

## 

## Body Cover

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

8 
 
GROMMET, AIR CLEANER CASE 
4
9 
 
NUT, CLIP, 5MM 
1
10 
 
SCREW, PAN, 5X11.5 
7

11 
 
SCREW, TAPPING, 5X12 
14

**TST 08 PC 004**

**07 . 07 . 2008**

⚠

Page 51

## 

## F - 16

## 

## Air Cleaner

⚠

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

2 
ELEMENT, AIR CLEANER.................... 0.1
5 
CASE, AIR CLEANER........................... 0.5

1 
 
HOSE, BREATHER 
1
2 
 
ELEMENT COMP., AIR CLEANER 
1
 ⚠ 
 
SEAL, AIR CLEANER COVER 
1
4 
 
SEAL, AIR CLEANER CASE 
1
5 
 
CASE SUB ASSY., AIR CLEANER 
1

8 
COVER, AIR CLEANER CASE............. 0.1
9 
TUBE, AIR CLEANER  
0.5

6 
 
TUBE, VINYL, 11X15X35 
1
7 
 
TUBE, AIR CLEANER DRAIN 
1
8 
 
COVER SUB ASSY., AIR CLEANER 
1
9 
 
TUBE, AIR CLEANER  
1
10 
 
BAND A, AIR CLEANER  
1

11 
 
BOLT, FLANGE, 6MM 
2
12 
 
SCREW, PAN, 5X25 
1
13 
 
SCREW, TAPPING, 5X25 
5
14 
 
CLAMP, TUBE (D13) 
1
15 
 
CLIP, TUBE (C12) 
 ⚠

**TST 08 PC 004**

**07 . 07 . 2008**

Page 52

## 

## F - 16 - 1

## 

## Air Suction Valve

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

2 
FILTER, SECONDARY AIR SUPPLY.. 
0.4
 ⚠ 
VALVE, SECONDARY AIR CONTROL 
0.3

1 
 
CLIP, OIL DRAIN TUBE 
 ⚠ 
2 
 
FILTER COMP., AIR 
1
 ⚠ 
 
VALVE ASSY., AIR SUCTION 
1
4 
 
STAY, AIR SUCTION VALVE 
1
5 
 
CLAMPER, HIGH TENSION CORD 
1

6 
PIPE, SECONDARY AIR.................... 
0.2
 10 (8) TUBE, SECONDARY AIR 
................................ 
0.4

6 
 
PIPE COMP., AIR FEED 
1
7 
 
GASKET, AIR FEED PIPE 
1
8 
 
TUBE A, AIR INTAKE 
1
9 
 
TUBE B, AIR INTAKE 
1
10 
 
TUBE C, AIR SUCTION VALVE 
1

11 
 
CLAMP, TUBE (D19) 
1
12 
 
CLIP, FUEL HOSE 
1
13 
 
CLIP, TUBE (B7) 
2
14 
 
TUBE, 3.5X110 
1
15 
 
BOLT, FLANGE, 6X8 
2

16 
 
BOLT, FLANGE, 6X16 
 ⚠ 
17 
 
BOLT, FLANGE, 6X18 
2

**TST 08 PC 004**

**07 . 07 . 2008**

⚠

Page 53

## 

## F - 17

## 

## Exhaust Mufﬂer

⚠

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
GASKET, EXHAUST PIPE................... 
0.2
2 
MUFFLER............................................ 
0.2

1 
 
GASKET, EX. PIPE 
1
2 
 
MUFFLER COMP., EX. 
1
 ⚠ 
 
COVER, MUFFLER 
1
4 
 
RUBBER, MUFFLER MOUNTING 
1
5 
 
COLLAR, MUFFLER MOUNTING 
1

6 
 
NUT, FLANGE, 8MM 
2
7 
 
NUT, FLANGE, 8MM 
1
8 
 
WASHER, PLAIN, 8MM 
1
9 
 
BOLT, FLANGE, 8X12 
1
10 
 
BOLT, FLANGE, 8X45 
1

11 
 
BOLT, FLANGE, 6X8 
2
12 
 
MUFFLER ASSY, EXHAUST 
1

**TST 08 PC 004**

**07 . 07 . 2008**

Page 54

## 

## F - 18

## 

## Pedal / Kick Arm

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
PEDAL, GEAR CHANGE .................... 
0.1
 2 
ARM, KICK STARTER ........................ 
0.1
 ⚠ 
SWITCH, REAR STOP :PEDAL SIDE. 
0.6
 5 
ROD, REAR BRAKE............................ 
0.5

1 
 
PEDAL, GEAR CHANGE 
1
2 
 
ARM ASSY., KICK STARTER 
1
 ⚠ 
 
SWITCH ASSY., RR. STOP 
1
4 
 
SPRING, STOP SWITCH 
1
5 
 
ROD COMP., RR. BRAKE 
1

6 
PEDAL, REAR BRAKE........................ 
0.5

6 
 
PEDAL COMP., BRAKE 
1
7 
 
SPRING ASSY., RR. BRAKE RETURN 
1
8 
 
CLIP, SWITCH COVER 
1
9 
 
BOLT, HEX., 6X20 
1
10 
 
WASHER, PLAIN, 5MM 
1

11 
 
PIN, SPLIT, 2.0X15 
1
12 
 
SPRING A, BRAKE ROD 
1
13 
 
JOINT B, BRAKE ARM 
1
14 
 
NUT B, BRAKE ROD ADJUSTING 
1
15 
 
BOLT, FLANGE, 6X25 
1

**TST 08 PC 004**

**07 . 07 . 2008**

⚠

Page 55

## 

## F - 19

## 

## Step

⚠

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
BAR, STEP........................................... 
0.4
2 
RUBBER, STEP :LEFT......................... 
0.1
RUBBER, STEP :RIGHT ..................... 
0.1
RUBBER, STEP :BOTH ...................... 
0.1
4 
(3) BAR, PILLION STEP :RIGHT.......... 
0.1
BAR, PILLION STEP :BOTH................ 
0.2
5 
(3) BAR, PILLION STEP :LEFT............ 
0.1
BAR, PILLION STEP :BOTH................ 
0.2

1 
 
BAR COMP., STEP 
1
2 
 
RUBBER, STEP 
2
 ⚠ 
 
RUBBER, PILLION STEP 
2
4 
 
BAR, R. PILLION STEP 
1
5 
 
BAR, L. PILLION STEP 
1

6 
 
PLATE, PILLION STEP SIDE 
2
7 
 
HOLDER, R. PILLION STEP 
1
8 
 
HOLDER, L. PILLION STEP 
1
9 
 
PIN, PILLION STEP 
2
10 
 
BOLT, SOCKET, 8X16 
2

7 
BRACKET, PILLION STEP :RIGHT...... 
0.2
BRACKET, PILLION STEP :BOTH....... 
0.4
8 
BRACKET, PILLION STEP :LEFT........ 
0.2
BRACKET, PILLION STEP :BOTH....... 
0.4

11 
 
BOLT, SOCKET, 8X32 
2
12 
 
WASHER, PLAIN, 6MM 
2
13 
 
PIN, SPLIT, 1.6X15 
2
14 
 
BOLT, FLANGE, 8X18 
4

**TST 08 PC 004**

**07 . 07 . 2008**

Page 56

## 

## F - 20

## 

## Stand

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
(2) STAND, MAIN ................................ 
0.5
5 
BAR, SIDE STAND ............................. 
0.2

1 
 
STAND COMP., MAIN 
1
2 
 
SHAFT, RR. BRAKE PIVOT 
1
 ⚠ 
 
HOOK, MAIN STAND SPRING 
1
4 
 
RUBBER, STAND STOPPER 
1
5 
 
BAR COMP., SIDE STAND 
1

9 
(3) SPRING, MAIN STAND ................. 
0.2
 10 SPRING, SIDE STAND ....................... 
0.1

6 
 
SCREW, SIDE STAND PIVOT 
1
7 
 
NUT, HEX., 10MM 
1
8 
 
PIN, SPLIT, 3.0X30 
1
9 
 
SPRING A, MAIN STAND 
1
10 
 
SPRING A, SIDE STAND 
1

**TST 08 PC 004**

**07 . 07 . 2008**

⚠

Page 57

## 

## F - 21

## 

## Swingarm

⚠

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

2 
CASE, DRIVE CHAIN ......................... 
0.1
 ⚠ 
CHAIN, DRIVE .................................... 
0.2
5 
ARM, REAR BRAKE STOPPER ......... 
0.3

1 
 
BRACKET, MUFFLER 
1
2 
 
CASE, DRIVE CHAIN 
1
 ⚠ 
 
CHAIN, DRIVE () 
1
 
CHAIN, DRIVE () 
1
4 
 
JOINT, DRIVE CHAIN 
1
 
JOINT, DRIVE CHAIN 
1
5 
 
ARM, RR. BRAKE STOPPER 
1

7 
SLIDER, CHAIN .................................. 
0.3
8 
SWINGARM ASSEMBLY .................... 
0.8

6 
 
BOLT, SWINGARM PIVOT 
1
7 
 
SLIDER, CHAIN 
1
8 
 
SWINGARM SET, RR. 
1
9 
 
BOLT, FLANGE, 6MM 
1
10 
 
WASHER, PIVOT BOLT 
1

11 
 
NUT, U, 12MM 
1
12 
 
BOLT A, STOPPER ARM 
1
13 
 
NUT, HEX., 8MM 
1
14 
 
WASHER, PLAIN, 8MM 
1
15 
 
WASHER, PLAIN, 12MM 
1

16 
 
WASHER, SPRING, 10MM 
1
17 
 
PIN, SPLIT, 2.0X15 
1
18 
 
BOLT, FLANGE, 8X12 
1

**TST 08 PC 004**

**07 . 07 . 2008**

Page 58

## 

## F - 22

## 

## Rear Cushion

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
CUSHION ASSY., REAR :LEFT ......... 
0.6
CUSHION ASSY., REAR :RIGHT ....... 
0.6
CUSHION ASSY., REAR :BOTH ........ 
0.7

1 
 
CUSHION ASSY., RR. 
2
 
BUSH, RUBBER 
4
 ⚠ 
 
COLLAR, RUBBER BUSH 
4
 
NUT, HEX., 10MM 
1
5 
 
NUT, CAP, 10MM 
1

6 
 
WASHER, PLAIN, 10MM 
2
7 
 
BOLT, FLANGE, 10X35 
2

**TST 08 PC 004**

**07 . 07 . 2008**

⚠

Page 59

## 

## F - 23

## 

## Rear Fender

⚠

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
FENDER, REAR.................................. 1.1

1 
 
FENDER SET, RR. 
1
2 
 
BOLT, FLANGE, 6MM 
2
 ⚠ 
 
NUT, CLIP, 5MM 
4
 
PLUG, CONE TYPE 
1
5 
 
BOLT, FLANGE, 6X12 
2

**TST 08 PC 004**

**07 . 07 . 2008**

Page 60

## 

## F - 24

## 

## Front Winker

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

2 
(1,3) BASE, WINKER :RIGHT FRONT 
0.3
BASE, WINKER :BOTH FRONT.......... 
0.4
4 
SOCKET, WINKER :RIGHT FRONT..... 
0.2
SOCKET, WINKER :BOTH FRONT..... 
0.2

1 
 
LENS, R. FR. WINKER 
1
2 
 
BASE, R. FR. WINKER 
1
 ⚠ 
 
GASKET 
2
4 
 
SOCKET COMP., R. WINKER 
1
5 
 
LENS, L. FR. WINKER 
1

6 
(3,5) BASE, WINKER :LEFT FRONT... 
0.3
BASE, WINKER :BOTH FRONT.......... 
0.4
7 
SOCKET, WINKER :LEFT FRONT....... 
0.2
SOCKET, WINKER :BOTH FRONT...... 
0.2
8 
BULB, WINKER :FRONT..................... 
0.2
.NOTE: Same time for two units 
BULB, WINKER :FOR 1 VEHICLE...... 
0.3

6 
 
BASE, L. FR. WINKER 
1
7 
 
SOCKET COMP., L. WINKER 
1
8 
 
BULB, WINKER (12V 10W) 
2
9 
 
SCREW, TAPPING, 5X12 
6
10 
 
WINKER ASSY, R FR 
1

11 
 
WINKER ASSY, L FR 
1

**TST 08 PC 004**

**07 . 07 . 2008**

⚠

Page 61

## 

## F - 25

## 

## Rear Combination


## 

## Light

⚠

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
TAILLIGHT UNIT................................... 0.2
 ⚠ 
BASE, TAILLIGHT ............................... 0.3
5 
(2) BULB, WINKER :REAR ................. 
0.1
.NOTE: Same time for two units 
BULB, WINKER :FOR 1 VEHICLE....... 0.3

1 
 
LIGHT ASSY., RR.  
1
2 
 
LENS COMP., TAILLIGHT 
1
 ⚠ 
 
BASE COMP., TAILLIGHT 
1
4 
 
RUBBER A, TAILLIGHT MOUNTING 
2
5 
 
BULB, WINKER (12V 10W) 
2

6 
(2) BULB, TAILLIGHT .......................... 0.1

6 
 
BULB, TAILLIGHT (12V 18/5W) 
1
7 
 
GROMMET, SIDE COVER 
1
8 
 
SCREW, TAPPING, 4X16 
2
9 
 
WASHER, PLAIN, 6MM 
2
10 
 
BOLT, FLANGE, 6X12 
2

**TST 08 PC 004**

**07 . 07 . 2008**

Page 62

## 

## F - 26

## 

## Wire Harness

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

2 
IGNITION CONTROL MODULE........... 0.7
 ⚠ 
COIL, IGNITION .................................. 0.8
5 
RECTIFIER, REGULATE ..................... 0.8

1 
 
CUSHION, C.D.I. UNIT 
1
2 
 
C.D.I. UNIT 
1
 ⚠ 
 
COIL ASSY., IGNITION 
1
4 
 
CAP ASSY., NOISE  
1
5 
 
RECTIFIER COMP., REGULATOR 
1

6 
HARNESS, WIRE ................................ 1.2
7 
SUB HARNESS, BATTERY ................. 0.8

6 
 
HARNESS, WIRE 
1
7 
 
SUB HARNESS, BATTERY 
1
8 
 
BAND B1, WIRE 
1
9 
 
RUBBER, TAILLIGHT BRACKET 
2
10 
 
HORN COMP. (HIGH) 
1

10 
HORN(S) ............................................. 0.4
 12 
RELAY, STARTER ............................... 0.2

11 
 
COLLAR, HORN SETTING 
1
12 
 
RELAY COMP., STARTER 
1
13 
 
, STARTER RELAY 
1
14 
 
CLIP, HARNESS BAND 
 ⚠ 
15 
 
BOLT, FLANGE, 6X14 
1

16 
 
BOLT, FLANGE, 6X20 
 ⚠ 
17 
 
FUSE, BLADE (7.5A) 
2
18 
 
FUSE, BLADE (10A) 
2

**TST 08 PC 004**

**07 . 07 . 2008**

⚠

Page 63

## 

## F - 27

## 

## Frame Body

⚠

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
KEY SET ............................................. 
2.1
2 
SWITCH,  & LOCK..... 
1.5
4 
KEY, SHUTTER ................................... 
1.4
.EXCLUDES: Key cutting

1 
 
KEY SET 
1
2 
 
BOLT, SOCKET, 5X8 
1
 ⚠ 
 
BODY COMP., FRAME 
1
4 
 
STAY, FR. TOP COVER 
1
5 
 
CUSHION, FR. TOP COVER 
2

6 
BODY, FRAME .................................... 
6
.INCLUDES: Engine removal and 
installation 
7 
STAY, FRONT COVER ........................ 
0.3

6 
 
GROMMET, SIDE COVER 
1
7 
 
SCREW, U-LOCK FLAT, 6X12 
2
8 
 
NUT, FLANGE, 10MM 
 ⚠ 
9 
 
BOLT, FLANGE, 8X32 
2
10 
 
BOLT, FLANGE, 10X110 
 ⚠

**TST 08 PC 004**

**07 . 07 . 2008**

Page 64

## 

## F - 28

## 

## Front Cover

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
COVER, FRONT................................... 
0.4

1 
 
COVER SET, FR. TOP BLACK 
1
 
COVER SET, FR. TOP WINNING RED 
(1)
2 
 
BRACKET, FR. NUMBER PLATE 
1
 ⚠ 
 
NUT, CLIP, 5MM 
6
4 
 
SCREW, PAN, 5X11.5 
2
5 
 
BOLT, FLANGE, 6X25 
2

**TST 08 PC 004**

**07 . 07 . 2008**

⚠

Page 65

## 

## F - 29

## 

## Main Pipe Cover

⚠

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
 
COVER SET, R. MAIN PIPE SIDE 
BLACK 
1
 
WINNING RED 
(1)
 
SPORTY BLUE METALLIC 
(1)
 
PEARL FLASH YELLOW 
(1)
 
PEARL FEDELESS WHITE 
(1)
 
PEARL TWISTER BLUE 
(1)
 
CANDY BLITZ ORANGE 
(1)

1 
COVER, MAIN PIPE SIDE :RIGHT...... 0.5
COVER, MAIN PIPE SIDE :BOTH ...... 0.6
2 
COVER, MAIN PIPE SIDE :LEFT ....... 0.5
COVER, MAIN PIPE SIDE :BOTH ...... 0.6
4 
COVER, MAIN PIPE UPPER .............. 0.6
5 
COVER, FRONT SIDE :RIGHT ........... 0.1
COVER, FRONT SIDE :BOTH ............ 0.2

6 
COVER, FRONT SIDE :LEFT ............. 0.1
COVER, FRONT SIDE :BOTH ............ 0.2

2 
 
COVER SET, L. MAIN PIPE SIDE 
BLACK 
1
 
WINNING RED 
(1)
 
SPORTY BLUE METALLIC 
(1)
 
PEARL FLASH YELLOW 
(1)
 
PEARL FEDELESS WHITE 
(1)
 
PEARL TWISTER BLUE 
(1)
 
CANDY BLITZ ORANGE 
(1)

⚠ 
 
STAY, LOWER COVER 
1
4 
 
COVER, MAIN PIPE 
1
5 
 
COVER SET, R. LOWER (WL) 
VOSTOK SILVER METALLIC 
1
 
DIGITAL SILVER METALLIC 
(1)
 
ANCHOR GREY METALLIC 
(1)
 
PEARL FEDELESS WHITE 
(1)
 
TECHNO BLUE METALLIC 
(1)

**TST 08 PC 004**

**07 . 07 . 2008**

Page 66

## 

## F - 29

## 

## Main Pipe Cover

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

6 
 
COVER SET, L. LOWER (WL) 
VOSTOK SILVER METALLIC 
1
 
DIGITAL SILVER METALLIC 
(1)
 
ANCHOR GREY METALLIC 
(1)
 
PEARL FEDELESS WHITE 
(1)
 
TECHNO BLUE METALLIC 
(1)
7 
 
SCREW, 6X12 
 ⚠ 
8 
 
SCREW, COWL SETTING (A) 
2
9 
 
SCREW, SPECIAL, 6X15 
2
10 
 
NUT, CLIP, 5MM 
6

11 
 
SCREW, PAN, 5X11.5 
10
12 
 
SCREW, TAPPING, 5X12 
11
13 
 
WASHER, PLAIN, 10MM 
2
14 
 
BOLT, FLANGE, 6X20 
2

**TST 08 PC 004**

**07 . 07 . 2008**

⚠

Page 67

## 

## F - 30

## 

## Caution Label

⚠

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
 
LABEL, TIRE & DRIVE CHAIN 
1
2 
 
LABEL, ENGINE STARTER *TWHITE* 
1
 ⚠ 
 
MARK, DRIVE CAUTION *TWHITE* 
1

**TST 08 PC 004**

**07 . 07 . 2008**

Page 68

## 

## F - 31

## 

## Mark / Stripe

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
 
STRIPE SET ...... SPEED BLACK 
1
 
STRIPE SET ...... WINNING RED 
(1)
 
STRIPE SET ...... SPORTY BLUE 
(1)
 
STRIPE SET ...... FLASH YELLOW 
(1) 
 
STRIPE SET ...... VICTORY WHITE 
(1) 
 
STRIPE SET ...... CHAMPION BLUE 
(1) 
 
STRIPE SET ...... REPSOL HONDA 
(1)

**TST 08 PC 004**

**07 . 07 . 2008**

⚠

Page 69

## 

## F - 32

## 

## Tools

⚠

**Service item** 
 **F.R.T.** 
 **No.** 
 **Part Number** 
 **Description** 
 **Notes** 
 **QTY**

1 
 
WRENCH, SPARK PLUG 
1
2 
 
DRIVER SCREW (+/-) 
1
 ⚠ 
 
GRIP 
1

**TST 08 PC 004**

**07 . 07 . 2008**

Page 70

**I N D E K S PART NUMBER**

**Block No.** 
 **Part Number**

**(00000)** 
 
F12
 
F11
 
F9
 
F9
 
F6
 
F6

 
E3
 
E3
 
E3
 
E3
 
E3
 
E9
 
E9
 
E9
 
E9
 
E9
 
E7
 
E7
 
E6
 
E8
 
F16
 
F16-1
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E19
 
E2
 
E2
 
F13
 
E19
 
E19

 
E2
 
F16
 
F16
 
F16
 
F16
 
F16
 
F16
 
F16
 
F16
 
F16
 
F16-1
 
F13
 
F13
 
F13
 
F13
 
F3
 
F3
 
F3
 
F3
 
F17
 
F17
 
F21
 
F17
 
F17
 
F17
 
F17
 
F16-1
 
F16-1
 
F16-1
 
F16-1
 
F16-1
 
F16-1
 
F16-1
 
F16-1
 
F16-1

**(10000)** 
 
E14
 
E14
 
E14
 
E6
 
E10
 
E10
 
E6
 
E10
 
E5
 
E5
 
E2
 
E2
 
E2
 
E3
 
E2
 
E1
 
E1
 
E6
 
E3
 
E4
 
E4
 
E3
 
E3
 
E3
 
E4
 
E4
 
E4
 
E4
 
E4
 
E4
 
E4
 
E4
 
E4
 
E4
 
E3
 
E3

**(20000)** 
 
E8
 
E8
 
E8
 
E8
 
E8
 
E8
 
E8
 
E8

 
E8
 
E8
 
E8
 
E7
 
E7
 
E7
 
E7
 
E7
 
E7
 
E7
 
E7
 
E7
 
E7
 
E6
 
E6
 
E6
 
E6
 
E6
 
E6
 
E7
 
E7
 
E7
 
E7
 
E7
 
E7
 
E15
 
E16
 
E15
 
E16
 
E15
 
E16
 
E15
 
E16
 
E15
 
E16
 
E15
 
E16
 
E15
 
E16
 
E15
 
E16
 
E15
 
E16
 
E15
 
E16

 
E15
 
E16
 
E15
 
E16
 
E17
 
E17
 
E17
 
E17
 
E15
 
E16
 
E15
 
E16
 
E17
 
E17
 
E17
 
E17
 
E17
 
E17
 
E17
 
E17
 
E17
 
F18
 
E12
 
E12
 
E12
 
E12
 
E12
 
E12
 
E18
 
E18
 
E18
 
E18
 
E18
 
E18
 
E18
 
F18

4

**(30000)** 
 
F26
 
F26
 
F26
 
F26
 
E11
 
E11
 
E13

Page 71

**I N D E K S PART NUMBER**

**Part Number** 
 **Block No.**

 
E13
 
E13
 
F14
 
F14
 
F26
 
E2
 
E2
 
F26
 
E13
 
F26
 
E13
 
F26
 
F1
 
F1
 
F1
 
F24
 
F24
 
F24
 
F24
 
F24
 
F24
 
F24
 
F24
 
F24
 
F25
 
F25
 
F25
 
F25
 
F26
 
F1
 
F24
 
F25
 
F25
 
F1
 
F2
 
F2
 
F27
 
F27
 
F3
 
F3
 
F3
 
F3
 
F3
 
F4

 
F18
 
F18
 
E17
 
E17
 
E14
 
F2
 
F2
 
F2
 
F2
 
F2
 
F2
 
F2
 
F13
 
F13
 
F13
 
F26
 
F26
 
F2
 
F2
 
F26
 
F26

 
F9
 
F11
 
F21
 
F11
 
F18
 
F4
 
F10
 
F10
 
F10
 
F10
 
F10
 
F10
 
F10
 
F10
 
F10
 
F2
 
F9
 
F4
 
F9
 
F9
 
F11
 
F9
 
F11
 
F11
 
F4
 
F4
 
F9
 
F9
 
F9
 
F9
 
F9
 
F10
 
F10
 
F9
 
F7
 
F6
 
F4
 
F4
 
F4
 
F4
 
F4
 
F4
 
F4
 
F18

**(40000)** 
 
F21
 
F21
 
F21
 
F21
 
F21
 
F11
 
F12
 
F12
 
F12
 
F12
 
F12
 
F12
 
F11
 
F12
 
F12
 
F12
 
F12
 
F12
 
F12
 
F11
 
F11
 
F9

4

 
F18

 
F5
 
F5
 
F5
 
F3
 
F3
 
F3
 
F3
 
F4
 
F5
 
F5
 
F1
 
F6
 
F6
 
F6
 
F6
 
F6
 
F6

**(50000)** 
 
F27
 
F6
 
F6
 
F6
 
F14
 
F14
 
F20
 
F20
 
F20
 
F20
 
F20
 
F19
 
F19
 
F19
 
F19
 
F19
 
F19
 
F19
 
F19
 
F8
 
F8
 
F8
 
F8
 
F8
 
F8
 
F8
 
F8
 
F8
 
F8
 
F8
 
F8
 
F8
 
F8
 
F8
 
F21
 
F21
 
F21
 
F22
 
F22
 
F22
 
F5
 
F5

**(60000)** 
 
F7
 
F29
 
F27
 
F29
 
F28
 
F29
 
F29
 
F15
 
F15
 
F29
 
F29
 
F15
 
F15
 
F15
 
F27
 
F5
 
F15
 
F15

**(70000)** 
 
F14
 
F14
 
F14
 
F14
 
F14
 
F14

Page 72

**I N D E K S PART NUMBER**

**Block No.** 
 **Part Number**

 
F14
 
F14
 
F14

 
F2
 
F21
 
F4
 
F8
 
F16
 
F23
 
F21
 
F12
 
F14
 
F9
 
F19
 
F19
 
F19
 
F4
 
F27
 
F5
 
E2
 
E3
 
E7
 
E8
 
F11
 
F17
 
F11
 
F12
 
F5
 
F10
 
F11
 
F21
 
F12
 
F29
 
E7
 
E2
 
E2
 
E11
 
E8
 
E15
 
E15
 
E16
 
E16
 
E4
 
E14
 
E15
 
E16
 
E15

 
E16
 
E7
 
E7
 
E7
 
F3
 
E18
 
E15
 
E16
 
E15
 
E16
 
E18
 
E7
 
E16
 
E16
 
E16
 
E4
 
E16
 
E4
 
E6
 
E8
 
F5
 
F14
 
F11
 
F5
 
E1
 
F8
 
E4
 
F4
 
E16
 
E16
 
F18
 
E7
 
E7
 
E18
 
F14
 
F4
 
F15
 
F23
 
F28
 
F29
 
F16-1
 
E1
 
E2
 
E5

**(80000)** 
 
F23
 
F28
 
F14
 
F14
 
F7
 
F15
 
F25
 
F27
 
F31
 
F30
 
F30
 
F30
 
F3
 
F3
 
F32
 
F32
 
F32

**(90000)** 
 
E2
 
E2
 
E3
 
E1
 
E14
 
F2
 
E8
 
E17
 
E4
 
E4
 
E7
 
E10
 
E12
 
F1
 
F4
 
F10
 
F14
 
F5
 
F29
 
F7
 
F29
 
F20

 
E14
 
F23
 
E12
 
F10
 
F12
 
F12
 
F12
 
E7
 
E6
 
E16
 
E14
 
F12
 
F10
 
F10
 
F2
 
E6
 
E10
 
E2
 
E6
 
E13
 
F8
 
F5
 
F15
 
F28
 
F29
 
F26
 
F2
 
E16
 
F18
 
E14
 
F11
 
F21
 
E2
 
E14
 
E2
 
E9
 
F3
 
F3
 
F3
 
F16
 
F4
 
F5
 
E19
 
E13

 
E19
 
E19
 
E19
 
E13
 
F4
 
F25
 
F5
 
F15
 
F24
 
F29
 
F2
 
F16
 
F3
 
F11
 
F12
 
F14
 
F11
 
F21
 
F22
 
F20
 
F22
 
E6
 
F4
 
F17
 
E11
 
F27
 
F18
 
F19
 
F21
 
F22
 
F29
 
F21
 
F3
 
F25
 
F17
 
F21
 
F19
 
F11
 
F18
 
F21
 
F20
 
E6
 
E10
 
E18

4

Page 73

**I N D E K S PART NUMBER**

**Part Number** 
 **Block No.** 
 
F13
 
F16-1
 
F13
 
E19
 
F16
 
F16
 
F16-1
 
F20
 
F20
 
F18
 
F18
 
F18
 
F16-1
 
E16
 
F13
 
F14
 
F23
 
F25
 
F26
 
E4
 
E14
 
E8
 
F7
 
F26
 
F4
 
F18
 
F28
 
F11
 
F17
 
F21
 
F14
 
F19
 
E4
 
F27
 
F17
 
F22
 
F6
 
F27
 
F17
 
F4
 
F6
 
E9
 
E11
 
F16-1
 
F16-1

 
E11
 
F29
 
E2
 
E9
 
E10
 
F14
 
E13
 
E10
 
E6
 
E14
 
E14
 
E2
 
E16
 
E8
 
E16
 
E16
 
F10
 
F12
 
F12
 
F12
 
E17
 
F26
 
F26
 
E19
 
E19

4

Page 74

**I N D E K S **

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

**(A)** 
ADJUSTER, R. CHAIN 
F11
ADJUSTER, R. CHAIN 
F12
ARM ASSY., KICK STARTER 
F18
ARM COMP., CAM CHAIN TENSIONER 
E4
ARM COMP., EX. VALVE ROCKER 
E3
ARM COMP., GEARSHIFT 
E17
ARM COMP., IN. VALVE ROCKER 
E3
ARM COMP., SHIFT DRUM STOPPER 
E17
ARM, RR. BRAKE 
F11
ARM, RR. BRAKE STOPPER 
F21
AXLE, FR. WHEEL 
F10
AXLE, RR. WHEEL 
F12
 **(B)** 
BALL SET, STEEL, 

## 6X23 
F6
BALL SET, STEEL, 

## 6X29 
F6
BAND A, AIR CLEANER  
F16
BAND B1, WIRE 
F26
BAND, WIRE HARNESS 
F2
BAR COMP., SIDE STAND 
F20
BAR COMP., STEP 
F19
BAR, L. PILLION STEP 
F19
BAR, R. PILLION STEP 
F19
BASE COMP., TAILLIGHT 
F25
BASE, L. FR. WINKER 
F24
BASE, R. FR. WINKER 
F24
BATTERY (YTZ5S) 
F14
BATTERY ASSY. (GTZ5S) 
F14
BEARING, NEEDLE, 19X23X17 
E12
BEARING, RADIAL BALL, 6001 
E16
BEARING, RADIAL BALL, 6200 
E8
BEARING, RADIAL BALL, 6201 
E16
BEARING, RADIAL BALL, 6201U 
F10
BEARING, RADIAL BALL, 6201U 
F10
BEARING, RADIAL BALL, 6201U 
F12
BEARING, RADIAL BALL, 6201U 
F12
BEARING, RADIAL BALL, 6203 
E16
BEARING, RADIAL BALL, 6203U 
F12
BEARING, RADIAL BALL, 6203U 
F12
BEARING, RADIAL BALL, 6301U 
F12
BEARING, RADIAL BALL, 6301U 
F12
BODY COMP., FRAME 
F27
BODY SET, COCK 
E19
BOLT A, BRAKE STOPPER 
F11

BOLT A, STOPPER ARM 
F21
BOLT, ADJUSTING 
F1
BOLT, BRAKE DISK, 8X24 
F10
BOLT, CLUTCH ADJUSTING 
E6
BOLT, COWL SETTING 
F7
BOLT, DRAIN PLUG, 12MM 
E14
BOLT, FLANGE, 10X110 
F27
BOLT, FLANGE, 10X35 
F22
BOLT, FLANGE, 10X45 
F6
BOLT, FLANGE, 10X50 
F5
BOLT, FLANGE, 5X12 
E2
BOLT, FLANGE, 6MM 
F16
BOLT, FLANGE, 6MM 
F21
BOLT, FLANGE, 6MM 
F23
BOLT, FLANGE, 6X10 
F4
BOLT, FLANGE, 6X100 
E2
BOLT, FLANGE, 6X12 
E16
BOLT, FLANGE, 6X12 
F4
BOLT, FLANGE, 6X12 
F6
BOLT, FLANGE, 6X12 
F13
BOLT, FLANGE, 6X12 
F14
BOLT, FLANGE, 6X12 
F23
BOLT, FLANGE, 6X12 
F25
BOLT, FLANGE, 6X14 
F26
BOLT, FLANGE, 6X16 
E9
BOLT, FLANGE, 6X16 
E11
BOLT, FLANGE, 6X16 
F16-1
BOLT, FLANGE, 6X18 
E4
BOLT, FLANGE, 6X18 
E14
BOLT, FLANGE, 6X18 
F16-1
BOLT, FLANGE, 6X20 
E8
BOLT, FLANGE, 6X20 
E11
BOLT, FLANGE, 6X20 
F7
BOLT, FLANGE, 6X20 
F26
BOLT, FLANGE, 6X20 
F29
BOLT, FLANGE, 6X22 
E2
BOLT, FLANGE, 6X22 
E9
BOLT, FLANGE, 6X22 
F4
BOLT, FLANGE, 6X25 
E10
BOLT, FLANGE, 6X25 
F18
BOLT, FLANGE, 6X25 
F28
BOLT, FLANGE, 6X30 
F14
BOLT, FLANGE, 6X32 
E2
BOLT, FLANGE, 6X32 
E13

BOLT, FLANGE, 6X35 
E10
BOLT, FLANGE, 6X35 
F11
BOLT, FLANGE, 6X40 
E6
BOLT, FLANGE, 6X60 
E14
BOLT, FLANGE, 6X75 
E14
BOLT, FLANGE, 6X8 
F16-1
BOLT, FLANGE, 6X8 
F17
BOLT, FLANGE, 8X12 
F17
BOLT, FLANGE, 8X12 
F21
BOLT, FLANGE, 8X14 
F14
BOLT, FLANGE, 8X18 
F19
BOLT, FLANGE, 8X25 
E4
BOLT, FLANGE, 8X32 
F27
BOLT, FLANGE, 8X45 
F17
BOLT, HANDLE LEVER PIVOT 
F4
BOLT, HEAD COVER 
E1
BOLT, HEX., 6X10 
E16
BOLT, HEX., 6X14 
E14
BOLT, HEX., 6X20 
F18
BOLT, KNOCK, 5MM 
E4
BOLT, KNOCK, 6MM 
E17
BOLT, OIL, 10X22 
F4
BOLT, PIN 
F9
BOLT, SEALING, 14MM 
E4
BOLT, SEAT HINGE 
F14
BOLT, SOCKET, 5X8 
F27
BOLT, SOCKET, 6X14 
E12
BOLT, SOCKET, 8MM 
F8
BOLT, SOCKET, 8X16 
F19
BOLT, SOCKET, 8X32 
F19
BOLT, SPECIAL FLANGE, 5X8 
E7
BOLT, SPECIAL FLANGE, 6X16 
E8
BOLT, SPECIAL, 6X30 
F14
BOLT, STUD, 7X180.5 
E14
BOLT, STUD, 8X18 
F12
BOLT, STUD, 8X32 
E2
BOLT, SWINGARM PIVOT 
F21
BOLT, TORX, 8X25 
F9
, 6X12 
E2
BOOT B 
F9
BOOT COMP. 
F4
BOOT, PIN BUSH. 
F9
BOX ASSY.,  GEAR 
F10
BOX COMP., LUGGAGE 
F14

5

Page 75

**I N D E K S **

**Description** 
 **Block No.** 
 **Description** 
 **Block No.** 
 **Description** 
 **Block No.** 
BRACKET SUB ASSY., FR. 
F9
BRACKET, FR. NUMBER PLATE 
F28
BRACKET, MUFFLER 
F21
BRUSH SET 
E13
BULB, HEADLIGHT 
F1
BULB, TAILLIGHT (12V 18/5W) 
F25
BULB, WEDGE BASE (T10) 
F1
BULB, WEDGE BASE (T10) 
F2
BULB, WEDGE BASE (T10) 
F2
BULB, WINKER (12V 10W) 
F24
BULB, WINKER (12V 10W) 
F25
BUSH, 15MM 
E15
BUSH, 15MM 
E16
BUSH, RUBBER 
F22
 **(C)** 
C.D.I. UNIT 
F26
CABLE COMP., CHOKE 
F3
CABLE COMP.,  
F2
CABLE COMP., THROTTLE 
F3
CALIPER SUB ASSY., R. FR. 
F9
CAM, RR. BRAKE 
F11
CAMSHAFT COMP. 
E3
CAP ASSY., NOISE  
F26
CAP, A.C. GENERATOR 
E10
CAP, BLEEDER 
F9
CAP, CABLE SEALING 
E19
CAP, CHANGE SWITCH CONTACT 
E17
CAP, CHOKE DUST 
E19
CAP, FUEL FILLER 
F13
CAP, MASTER CYLINDER 
F4
 ASSY. (PB7UA A) 
E19
CASE COMP., L. FR. BOTTOM 
F8
CASE COMP., R. FR. BOTTOM 
F8
CASE COMP., UNDER 
F2
CASE SUB ASSY., AIR CLEANER 
F16
CASE, DRIVE CHAIN 
F21
CATCH COMP., SEAT 
F14
CENTER, CLUTCH 
E8
CHAIN, CAM (90L) 
E4
CHAIN, DRIVE () 
F21
CHAIN, DRIVE () 
F21
CHAMBER SET, FLOAT 
E19
CIRCLIP 
F4
CIRCLIP, 20MM 
E16

CIRCLIP, 7MM 
E7
CIRCLIP, EXTERNAL, 16MM 
E18
CIRCLIP, EXTERNAL, 17MM 
E16
CIRCLIP, INTERNAL, 45MM 
E7
CLAMP 
F2
CLAMP, TUBE (D13) 
F16
CLAMP, TUBE (D19) 
F16-1
CLAMPER B, BRAKE HOSE 
F4
CLAMPER, BRAKE HOSE 
F4
CLAMPER, HIGH TENSION CORD 
F16-1
CLIP, BATTERY COVER 
F14
CLIP, FUEL HOSE 
F16-1
CLIP, GEARSHIFT FORK GUIDE PIN 
E17
CLIP, HARNESS BAND 
F26
CLIP, HEADLIGHT 
F1
CLIP, OIL DRAIN TUBE 
F16-1
CLIP, PISTON PIN, 13MM 
E6
CLIP, SWITCH COVER 
F18
CLIP, TUBE 
F13
CLIP, TUBE (B6.5) 
E19
CLIP, TUBE (B7) 
F16-1
CLIP, TUBE (C12) 
F16
CLIP, VALVE GUIDE 
E2
CLUTCH ASSY., ONE WAY 
E12
CLUTCH ASSY., ONE WAY 
E12
COIL ASSY., IGNITION 
F26
COLLAR A, HANDLE SETTING 
F5
COLLAR B, HANDLE SETTING 
F5
COLLAR, 19X28X4 
E7
COLLAR, 6.2X20 
F14
COLLAR, CAM CHAIN TENSIONER 
E4
COLLAR, CLUTCH OUTER 
E8
COLLAR, FR. AXLE DISTANCE 
F10
COLLAR, FR. FENDER 
F7
COLLAR, FR. WHEEL SIDE 
F10
COLLAR, HORN SETTING 
F26
COLLAR, KICK SPRING 
E18
COLLAR, LOCK PLATE 
E15
COLLAR, LOCK PLATE 
E16
COLLAR, MUFFLER MOUNTING 
F17
COLLAR, RR. AXLE DISTANCE 
F12
COLLAR, RR. BRAKE PANEL SIDE 
F11
COLLAR, RR. WHEEL SIDE 
F12
COLLAR, RUBBER BUSH 
F22
CONTACT ASSY., CHANGE SWITCH 
E14

5

COTTER, VALVE 
E3
 
E15
 
E16
COVER COMP., CYLINDER HEAD 
E1
COVER COMP., L. RR. BODY 
F15
COVER COMP., L. RR. CRANKCASE 
E10
COVER COMP., R. CRANKCASE 
E6
COVER COMP., R. RR. BODY 
F15
COVER SET, FR. HANDLE (WL) *TYPE1* 
F5
COVER SET, FR. TOP BLACK 
F28
COVER SET, FR. TOP WINNING RED 
F28
COVER SET, L. BODY 
F15
COVER SET, L. LOWER (WL) 
F29
COVER SET, L. MAIN PIPE SIDE 
F29
COVER SET, R. BODY 
F15
COVER SET, R. LOWER (WL) 
F29
COVER SET, R. MAIN PIPE SIDE 
F29
COVER SUB ASSY., AIR CLEANER 
F16
COVER, BATTERY 
F14
COVER, L. CENTER 
F15
COVER, L. CRANKCASE 
E10
COVER, MAIN PIPE 
F29
COVER, MUFFLER 
F17
COVER, OIL FILTER 
E7
COVER, R. CENTER 
F15
COVER, RR. HANDLE 
F5
CRANKCASE COMP., L. 
E14
CRANKCASE COMP., R. 
E14
CUP, FUEL STRAINER 
E19
CUSHION ASSY., RR. 
F22
CUSHION, C.D.I. UNIT 
F26
CUSHION, FR. TOP COVER 
F27
CYLINDER COMP. 
E5
CYLINDER SET, MASTER 
F4
CYLINDER SUB ASSY., FR. BRAKE 
F4
 **(D)** 
DAMPER SET, WHEEL 
F12
DIAPHRAGM 
F4
DISK B, CLUTCH FRICTION 
E8
DISK, CLUTCH FRICTION 
E8
DISK, FR. BRAKE 
F10
DISK, FR. BRAKE 
F10
DOWEL PIN, 10X14 
E14
DOWEL PIN, 8X14 
E6

Page 76

**I N D E K S **

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

DOWEL PIN, 8X14 
E10
DOWEL PIN, SPECIAL, 8X14 
E1
DOWEL PIN, SPECIAL, 8X14 
E2
DOWEL PIN, SPECIAL, 8X14 
E5
DRIVER SCREW (+/-) 
F32
DRUM, GEARSHIFT 
E17
DUST SEAL 
F8
DUST SEAL, 21X37X7 
F10
DUST SEAL, 27X40X4.5 
F12
DUST SEAL, 42X54X7 
F10
DUST SEAL, BRAKE CAM 
F11
DUST SEAL, STEERING HEAD 
F6
 **(E)** 
ELEMENT COMP., AIR CLEANER 
F16
 **(F)** 
FENDER SET, RR. 
F23
FENDER., FR. BLACK 
F7
FENDER., FR. PEARL FADELESS WHITE 
F7
FENDER., FR. PEARL FLASH YELLOW 
F7
FENDER., FR. PEARL TWISTER BLUE 
F7
FENDER., FR. SPORTY BLUE METALIC F7
FENDER., FR. TECHNO BLUE METALIC 
F7
FENDER., FR. WINNING RED 
F7
FILTER COMP., AIR 
F16-1
FLANGE SUB ASSY., FINAL DRIVEN 
F12
FLOAT SET 
E19
FLYWHEEL COMP. 
E11
FORK ASSY., L. FR.. 
F8
FORK ASSY., R. FR. 
F8
FORK, GEARSHIFT 
E17
FUEL UNIT 
F13
FUSE, BLADE (10A) 
F26
FUSE, BLADE (7.5A) 
F26
 **(G)** 
GASKET 
F24
GASKET SET 
E19
GASKET SET 
E19
GASKET, AIR FEED PIPE 
F16-1
GASKET,  INSULATOR 
E2
GASKET, CYLINDER 
E5
GASKET, CYLINDER HEAD 
E2
GASKET, EX. PIPE 
F17
GASKET, FLOAT CHAMBER 
E19
GASKET, HEAD COVER 
E1

GASKET, L. CRANKCASE COVER 
E10
GASKET, OIL FILTER 
E7
GASKET, OIL PUMP BODY 
E9
GASKET, R. CRANKCASE COVER 
E6
GAUGE, OIL LEVEL 
E6
GEAR COMP., PRIMARY DRIVE 
E7
GEAR COMP., STARTER DRIVEN 
E12
GEAR COMP., STARTER REDUCTION 
E12
GEAR,  FOURTH 
E15
GEAR,  FOURTH 
E16
GEAR,  LOW (34T) 
E15
GEAR,  LOW (34T) 
E16
GEAR,  THIRD (26T) 
E15
GEAR,  THIRD (26T) 
E16
GEAR, MAINSHAFT FOURTH (24T) 
E15
GEAR, MAINSHAFT FOURTH (24T) 
E16
GEAR, MAINSHAFT SECOND (17T) 
E15
GEAR, MAINSHAFT SECOND (17T) 
E16
GEAR, MAINSHAFT THIRD (21T) 
E15
GEAR, MAINSHAFT THIRD (21T) 
E16
GEAR,  (19T) 
F10
GEAR, STARTER DRIVEN (55T) 
E12
GLASS 
F2
GRIP 
F32
GRIP COMP., THROTTLE 
F3
GRIP, L. HANDLE 
F3
GROMMET, AIR CLEANER CASE 
F15
GROMMET, SIDE COVER 
F25
GROMMET, SIDE COVER 
F27
GROMMET, WIRE 
F7
GUIDE, CLUTCH OUTER 
E8
GUIDE, FR. BRAKE CABLE 
F6
GUIDE, VALVE 
E2
 **(H)** 
HARNESS, WIRE 
F26
HEAD COMP., CYLINDER 
E2
HEAD, CAM CHAIN TENSIONER PUSH 
E4
HEADLIGHT UNIT 
F1
HINGE, SEAT 
F14
HOLDER, L. PILLION STEP 
F19
HOLDER, MASTER CYLINDER 
F4
HOLDER, NEEDLE JET 
E19
HOLDER, R. PILLION STEP 
F19
HOOK, MAIN STAND SPRING 
F20
HORN COMP. (HIGH) 
F26

HOSE COMP., FR. BRAKE 
F4
HOSE, BREATHER 
F16
HOUSING, UNDER THROTTLE 
F3
HOUSING, UPPER THROTTLE 
F3
 **(I)** 
INDICATOR, FR. BRAKE 
F11
INNER COMP., ONE-WAY CLUTCH 
E7
INSULATOR,  
E2
 **(J)** 
JET, MAIN, 

## 92 
E19
JET, SLOW, 

## 35 
E19
JOINT B, BRAKE ARM 
F18
JOINT, DRIVE CHAIN 
F21
JOINT, DRIVE CHAIN 
F21
 **(K)** 
KEY SET 
F27
 **(L)** 
LABEL, ENGINE STARTER *TWHITE* 
F30
LABEL, TIRE & DRIVE CHAIN 
F30
LENS COMP., TAILLIGHT 
F25
LENS, L. FR. WINKER 
F24
LENS, R. FR. WINKER 
F24
LEVER COMP., CLUTCH 
E6
LEVER SET, COCK 
E19
LEVER, CHOKE 
F3
LEVER, R. STEERING HANDLE 
F4
LIGHT ASSY., RR.  
F25
LOCK ASSY., SEAT 
F14
 **(M)** 
MAINSHAFT (12T) 
E15
MAINSHAFT (12T) 
E16
MARK, DRIVE CAUTION *TWHITE* F30
MAT, RR. BODY COVER 
F15
METER COMP., SPEED & FUEL 
F2
MIRROR ASSY., l. BLACK 
F3
MIRROR ASSY., R. BLACK 
F3
MOTOR UNIT, STARTER 
E13
MUFFLER ASSY, EXHAUST 
F17
MUFFLER COMP., EX. 
F17
 **(N)** 
NEEDLE SET, JET 
E19
NUT B, BRAKE ROD ADJUSTING 
F18
NUT B, LOCK, 14MM 
E8

5

Page 77

**I N D E K S **

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

O-RING, 2.4X25 
E19
O-RING, 25X2.4 
E2
O-RING, 40.5X3 
F12
O-RING, 8MM 
E6
OUTER ASSY., PRIMARY CLUTCH 
E7
OUTER COMP., CLUTCH 
E8
 **(P)** 
PACKING 
E13
PACKING, BASE 
F13
PACKING, DRAIN COCK, 12.5X20 
E14
PACKING, FUEL FILLER CAP 
F13
PAD SET, FR. 
F9
PANEL COMP., RR. BRAKE *NH303M* F11
PEDAL COMP., BRAKE 
F18
PEDAL, GEAR CHANGE 
F18
PIN 
E7
PIN, GEARSHIFT DRUM 
E17
PIN, GEARSHIFT FORK GUIDE 
E17
PIN, GUIDE ROLLER 
E4
PIN, HANGER 
F9
PIN, PILLION STEP 
F19
PIN, SHIFT RETURN SPRING 
E17
PIN, SPLIT, 1.6X15 
F19
PIN, SPLIT, 2.0X15 
F11
PIN, SPLIT, 2.0X15 
F18
PIN, SPLIT, 2.0X15 
F21
PIN, SPLIT, 3.0X30 
F20
PINION, KICK STARTER (22T) 
E18
PIPE COMP., AIR FEED 
F16-1
PIPE COMP., FR. FORK 
F8
PIPE COMP., INLET 
E2
PIPE COMP., STEERING HANDLE 
F5
PIPE, SEAT 
F8
PISTON 
F9
PLATE COMP., CLUTCH LIFTER 
E6
PLATE COMP., PRIMARY DRIVE 
E7
PLATE SET, VALVE 
E19
PLATE, CLUTCH 
E8
PLATE, CLUTCH LIFTER 
E8
PLATE, CLUTCH LIFTER CAM 
E6
PLATE, CLUTCH PRESSURE 
E8
PLATE, CLUTCH SIDE 
E7
PLATE, DIAPHRAGM 
F4
PLATE, DRUM LOCK 
E15

NUT SET, SQUARE 
E19
NUT, ADJUST 
F1
NUT, CAP, 10MM 
F22
NUT, CLIP, 4MM 
F5
NUT, CLIP, 5MM 
F15
NUT, CLIP, 5MM 
F23
NUT, CLIP, 5MM 
F28
NUT, CLIP, 5MM 
F29
NUT, FLANGE, 10MM 
E11
NUT, FLANGE, 10MM 
F27
NUT, FLANGE, 6MM 
F4
NUT, FLANGE, 8MM 
F17
NUT, FLANGE, 8MM 
F17
NUT, HEX., 10MM 
F20
NUT, HEX., 10MM 
F22
NUT, HEX., 5MM 
F3
NUT, HEX., 6MM 
F11
NUT, HEX., 6MM 
F12
NUT, HEX., 6MM 
F14
NUT, HEX., 7MM 
E2
NUT, HEX., 8MM 
E6
NUT, HEX., 8MM 
F11
NUT, HEX., 8MM 
F21
NUT, LOCK, 14MM 
E7
NUT, SPECIAL, 6MM 
F11
NUT, SPECIAL, 6MM 
F12
NUT, STEERING STEM LOCK 
F6
NUT, TAPPET ADJUSTING 
E3
NUT, U, 10MM 
F5
NUT, U, 12MM 
F10
NUT, U, 12MM 
F11
NUT, U, 12MM 
F21
NUT, U, 6MM 
F11
NUT, U, 8MM 
F12
 **(O)** 
OIL SEAL, 11.6X22X7 
E14
OIL SEAL, 13.8X24X5 
E6
OIL SEAL, 17X29X5 
E16
O-RING 
E13
O-RING 
F8
O-RING, 1.3X4.3 
E19
O-RING, 10X1.5 
F2
O-RING, 13.8X2.5 
E10
O-RING, 18X3 
E6

5

PLATE, DRUM LOCK 
E16
PLATE, FIXING 
E15
PLATE, FIXING 
E16
PLATE, GEARSHIFT DRUM STOPPER 
E17
PLATE, OIL SEPARATOR 
E8
PLATE, OIL STOPPER 
E14
PLATE, PILLION STEP SIDE 
F19
PLATE, PLUNGER 
E2
PLUG, CONE TYPE 
F23
PLUG, SPARK (CPR6EA-9S) 
E2
PLUG, SPARK (U20EPR9S) 
E2
PROTECTOR 
F4
PUMP ASSY., OIL 
E9
 **(R)** 
RACE, STEERING BOTTOM BALL 
F6
RACE, STEERING BOTTOM CONE 
F6
RACE, STEERING TOP BALL 
F6
RACE, STEERING TOP CONE 
F6
RAIL, RR. GRAB 
F14
RATCHET, STARTER DRIVE 
E18
RECTIFIER COMP., REGULATOR 
F26
RELAY COMP., STARTER 
F26
RELAY COMP., WINKER 
F2
RETAINER COMP., BALL 
E6
RETAINER, FUEL UNIT 
F13
RETAINER, KICK SPINDLE 
E18
RETAINER, SPRING 
E7
RETAINER, VALVE SPRING 
E3
RING, BACK UP 
F8
RING, HANDLE WEIGHT SNAP 
F5
RING, OIL SEAL STOPPER 
F8
RING, PISTON 
F8
RING, STOPPER 
F8
RING, STOPPER 
F9
ROD COMP., CAM CHAIN TENSIONER 
E4
ROD COMP., RR. BRAKE 
F18
ROLLER COMP., CAM CHAIN GUIDE 
E4
ROLLER, 3X10 
E17
ROLLER, 5X8 
E7
ROLLER, CAM CHAIN TENSIONER 
E4
ROTOR, OIL PUMP INNER 
E9
ROTOR, OIL PUMP OUTER 
E9
RUBBER A, HANDLE WEIGHT 
F5
RUBBER A, TAILLIGHT MOUNTING 
F25

Page 78

**I N D E K S **

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

RUBBER B, SEAT SETTING 
F14
RUBBER, CLUTCH DAMPER 
E7
RUBBER, LUGGAGE BOX MOUNTING 
F14
RUBBER, MOUNTING 
E1
RUBBER, MUFFLER MOUNTING 
F17
RUBBER, PILLION STEP 
F19
RUBBER, SEAL 
F14
RUBBER, STAND STOPPER 
F20
RUBBER, STEP 
F19
RUBBER, STOPPER ARM 
F11
RUBBER, TAILLIGHT BRACKET 
F26
 **(S)** 
SCREEN, FUEL STRAINER 
E19
SCREEN, OIL FILTER 
E9
SCREW SET 
E19
SCREW SET 
E19
SCREW, 6X12 
F29
SCREW, BLEEDER. 
F9
SCREW, COWL SETTING (A) 
F29
SCREW, FLAT, 4X12 
F4
SCREW, OVAL, 6X45 
F5
SCREW, PAN, 5X10 
E9
SCREW, PAN, 5X10 
F3
SCREW, PAN, 5X11.5 
F5
SCREW, PAN, 5X11.5 
F15
SCREW, PAN, 5X11.5 
F28
SCREW, PAN, 5X11.5 
F29
SCREW, PAN, 5X12 
F3
SCREW, PAN, 5X25 
F3
SCREW, PAN, 5X25 
F16
SCREW, SIDE STAND PIVOT 
F20
SCREW, SPECIAL, 6X15 
F29
SCREW, TAPPET ADJUSTING 
E3
SCREW, TAPPING, 4X12 
F5
SCREW, TAPPING, 4X14 
F2
SCREW, TAPPING, 4X16 
F25
SCREW, TAPPING, 5X12 
F15
SCREW, TAPPING, 5X12 
F24
SCREW, TAPPING, 5X12 
F29
SCREW, TAPPING, 5X16 
F2
SCREW, TAPPING, 5X25 
F16
SCREW, U-LOCK FLAT, 6X12 
F27
, 3X12 
E19
, 3X22 
F2

, 4X10 
E19
, 4X12 
F4
, 4X14 
E19
, 4X16 
F5
, 4X6 
E13
, 5X10 
E19
, 5X16 
E13
, SPECIAL, 4X10 
F2
SEAL SET, FR. FORK 
F8
SEAL SET, PISTON 
F9
SEAL, AIR CLEANER CASE 
F16
SEAL, AIR CLEANER COVER 
F16
SEAL, VALVE STEM 
E3
SEAT B, SPRING 
F8
SEAT COMP., DOUBLE 
F14
SEAT, CLUTCH SPRING 
E8
SEAT, VALVE SPRING 
E3
SET RING, 20MM 
E18
SET RING, 23MM 
E7
SHAFT, REDUCTION GEAR 
E12
SHAFT, ROCKER ARM 
E3
SHAFT, RR. BRAKE PIVOT 
F20
SHOE SET, BRAKE 
F11
SLEEVE, RR. WHEEL 
F12
SLIDER, CHAIN 
F21
SOCKET COMP. 
F2
SOCKET COMP., HEADLIGHT 
F1
SOCKET COMP., L. WINKER 
F24
SOCKET COMP., R. WINKER 
F24
 ASSY. 
F2
SPINDLE COMP., GEARSHIFT 
E17
SPINDLE, CAM CHAIN GUIDE 
E4
SPINDLE, KICK STARTER 
E18
SPRING A, BRAKE ROD 
F18
SPRING A, MAIN STAND 
F20
SPRING A, SIDE STAND 
F20
SPRING ASSY., RR. BRAKE RETURN 
F18
SPRING, BRAKE SHOE 
F11
SPRING, CAM CHAIN TENSIONER 
E4
SPRING, CAM PLATE SIDE 
E6
SPRING, CARBON BRUSH 
E13
SPRING, CHANGE FRICTION 
E15
SPRING, CHANGE FRICTION 
E16
SPRING, CHANGE SWITCH CONTACT 
E17

SPRING, CLUTCH 
E8
SPRING, FR. FORK 
F8
SPRING, FRICTION STARTER GEAR 
E18
SPRING, GEARSHIFT ARM 
E17
SPRING, GEARSHIFT DRUM STOPPER 
E17
SPRING, GEARSHIFT RETURN 
E17
SPRING, KICK RETURN 
E18
SPRING, LOCK KEY SETTING 
F14
SPRING, ONE WAY RETAINER 
E7
SPRING, PAD 
F9
SPRING, PRIMARY CLUTCH 
E7
SPRING, REBOUND 
F8
SPRING, SEAT LOCK 
F14
SPRING, SIDE FRICTION 
E7
SPRING, STOP SWITCH 
F18
SPRING, SUB GEAR 
E7
SPRING, VALVE 
E3
SPRING, VALVE 
E3
SPROCKET COMP., CAM CHAIN 
E4
SPROCKET COMP., FINAL DRIVEN 
F12
SPROCKET COMP., FINAL DRIVEN 
F12
SPROCKET, CAM (32T) 
E4
SPROCKET, DRIVE (14T) 
E15
SPROCKET, DRIVE (14T) 
E16
STAND COMP., MAIN 
F20
STATOR COMP. 
E11
STAY, AIR SUCTION VALVE 
F16-1
STAY, FR. TOP COVER 
F27
STAY, LOWER COVER 
F29
STEM SUB ASSY., STEERING 
F6
STOPPER, CABLE 
F3
STRAINER COMP., FUEL 
F13
STRIPE SET 
F31
SUB CORD, STARTER MOTOR 
E13
SUB GEAR (17T) 
E7
SUB HARNESS, BATTERY 
F26
, STARTER RELAY 
F26
, WINKER RELAY 
F2
SWINGARM SET, RR. 
F21
SWITCH ASSY., FR. STOP 
F4
SWITCH ASSY., RR. STOP 
F18
SWITCH ASSY., WINKER 
F3
SWITCH UNIT, DIMMER 
F3
SWITCH UNIT, HORN 
F3
SWITCH UNIT, LIGHTING 
F3

5

Page 79

**I N D E K S **

**Description** 
 **Block No.** 
 **Description** 
 **Block No.** 
 **Description** 
 **Block No.** 
SWITCH UNIT, STARTING 
F3
 **(T)** 
TANK COMP., FUEL 
F13
THREAD COMP., STEERING HEAD 
F6
TIRE, FR. 
F10
TIRE, RR. 
F12
TOP SET 
E19
TUBE A, AIR INTAKE 
F16-1
TUBE B, AIR INTAKE 
F16-1
TUBE C, AIR SUCTION VALVE 
F16-1
TUBE, 3.5X110 
F16-1
TUBE, AIR CLEANER  
F16
TUBE, AIR CLEANER DRAIN 
F16
TUBE, AIR VENT 
E19
TUBE, FUEL, 5.3X45 
F13
TUBE, FUEL, 5.3X560 
F13
TUBE, OVERFLOW 
E19
TUBE, TIRE 
F12
TUBE, TIRE (IRC) (70/90-17M/C) 
F10
TUBE, VINYL, 11X15X35 
F16
 **(V)** 
VALVE ASSY., AIR SUCTION 
F16-1
VALVE COMP., FLOAT 
E19
VALVE SET, AIR CUT 
E19
VALVE SET, THROTTLE 
E19
VALVE, EX. 
E3
VALVE, IN. 
E3
 **(W)** 
WASHER B, LOCK 
E7
WASHER, 10X24 
E11
WASHER, 14MM 
E8
WASHER, 17X23X1.5 
E7
WASHER, 30X45X0.8 
E7
WASHER, 6X19X2.3 
E15
WASHER, 6X19X2.3 
E15
WASHER, 6X19X2.3 
E16
WASHER, 6X19X2.3 
E16
WASHER, 7.2X16X2.5 
E2
WASHER, 8.5X26X2.3 
E4
WASHER, 8MM 
E4
WASHER, 8MM 
E6
WASHER, 8MM 
F11
WASHER, CLUTCH SIDE 
E7

WASHER, LOCK 
E7
WASHER, LOCK, 20MM 
E16
WASHER, OIL BOLT 
F4
WASHER, PIVOT BOLT 
F21
WASHER, PLAIN, 10MM 
F22
WASHER, PLAIN, 10MM 
F29
WASHER, PLAIN, 12MM 
F21
WASHER, PLAIN, 5MM 
F3
WASHER, PLAIN, 5MM 
F18
WASHER, PLAIN, 6MM 
F19
WASHER, PLAIN, 6MM 
F25
WASHER, PLAIN, 8MM 
F17
WASHER, PLAIN, 8MM 
F21
WASHER, SEALING, 14MM 
E4
WASHER, SEALING, 6.5MM 
E4
WASHER, SEAT LOCK 
F14
WASHER, SPECIAL, 12X23 
E15
WASHER, SPECIAL, 12X23 
E16
WASHER, SPECIAL, 14MM 
E18
WASHER, SPECIAL, 8MM 
F8
WASHER,  GEAR 
F10
WASHER, SPLINE, 17MM 
E16
WASHER, SPLINE, 20MM 
E16
WASHER, SPLINE, 20MM 
E16
WASHER, SPRING, 10MM 
F21
WASHER, STEERING STEM NUT 
F6
WASHER, THRUST, 15MM 
E15
WASHER, THRUST, 15MM 
E16
WASHER, THRUST, 17MM 
E8
WASHER, THRUST, 17MM 
E15
WASHER, THRUST, 17MM 
E16
WASHER, THRUST, 20MM 
E15
WASHER, THRUST, 20MM 
E16
WASHER, THRUST, 20MM 
E18
WASHER, WAVE 
F3
WASHER, WAVE 
F9
WEIGHT A, STEERING HANDLE 
F5
WEIGHT B, STEERING HANDLE 
F5
WEIGHT SET, PRIMARY CLUTCH 
E7
WHEEL SUB ASSY., FR. *NH303M* F10
WHEEL SUB ASSY., RR. *NH303M* F12
WINKER ASSY, L FR 
F24
WINKER ASSY, R FR 
F24
WRENCH, SPARK PLUG 
F32

5

Page 80

## 

## PT Astra Honda Motor


## 

## TECHNICAL SERVICE DIVISION

1 8 KWB 9 I 1
Printed by GOP-2008

Parts Catalog Honda Blade 110 2008-2011

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