Parts Catalog Honda Blade 110 — Isi Lengkap 81 Halaman
Halaman 1
TST 08 PC 004
##
## PT Astra Honda Motor
BLADE
Halaman 2
##
## D A F T A R I S I
1
##
## PETUNJUK PEMAKAIAN
2
##
## KELOMPOK MESIN
⚠
##
## KELOMPOK RANGKA
4
##
## INDEKS PART NUMBER
5
##
## INDEKS
Halaman 3
**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
Halaman 4
**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
Halaman 5
**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
Halaman 6
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
Halaman 7
##
## 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**
Halaman 8
##
## 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
Halaman 9
# ENGINE GROUP
| | | |
| :--- | :--- | :--- |
| **E-19 CARBURETOR** <br><br> *[Diagram of Carburetor Assembly]* <br> - **FR.** ↙ <br> - **F-13** <br> - **KWB9E1900** | | |
| | | |
| | | |
<br>
<div style="display: flex; justify-content: space-between; align-items: center;">
<span>PC BLADE</span>
<span>**7**</span>
</div>
---
*(Note: Section tab **2** is located on the right margin of the page)*
Halaman 10
##
## 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
Halaman 11
##
## 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**
Halaman 12
##
## 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
Halaman 13
##
## 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**
⚠
Halaman 14
##
## 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**
Halaman 15
##
## 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
Halaman 16
##
## 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**
Halaman 17
##
## 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
Halaman 18
##
## 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**
Halaman 19
##
## 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
Halaman 20
##
## 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**
Halaman 21
##
## 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
Halaman 22
##
## 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**
Halaman 23
##
## 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
Halaman 24
##
## 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**
Halaman 25
##
## 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
Halaman 26
##
## 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**
Halaman 27
##
## 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
Halaman 28
##
## 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**
Halaman 29
##
## 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
Halaman 30
##
## 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**
Halaman 31
##
## 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
Halaman 32
##
## 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**
Halaman 33
##
## 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
Halaman 34
##
## 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**
Halaman 35
##
## 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
Halaman 36
##
## 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**
Halaman 37
##
## 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**
⚠
Halaman 38
##
## 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**
Halaman 39
##
## 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**
⚠
Halaman 40
##
## 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**
Halaman 41
##
## 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**
⚠
Halaman 42
##
## 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**
Halaman 43
##
## 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**
⚠
Halaman 44
##
## 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**
Halaman 45
##
## 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**
⚠
Halaman 46
##
## 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**
Halaman 47
##
## 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**
⚠
Halaman 48
##
## 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**
Halaman 49
##
## 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**
⚠
Halaman 50
##
## 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**
Halaman 51
##
## 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**
⚠
Halaman 52
##
## 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**
Halaman 53
##
## 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**
⚠
Halaman 54
##
## 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**
Halaman 55
##
## 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**
⚠
Halaman 56
##
## 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**
Halaman 57
##
## 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**
⚠
Halaman 58
##
## 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**
Halaman 59
##
## 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**
⚠
Halaman 60
##
## 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**
Halaman 61
##
## 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**
⚠
Halaman 62
##
## 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**
Halaman 63
##
## 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**
⚠
Halaman 64
##
## 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**
Halaman 65
##
## 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**
⚠
Halaman 66
##
## 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**
Halaman 67
##
## 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**
⚠
Halaman 68
##
## 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**
Halaman 69
##
## 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**
⚠
Halaman 70
##
## 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**
Halaman 71
**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
Halaman 72
**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
Halaman 73
**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
Halaman 74
**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
Halaman 75
**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
Halaman 76
**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
Halaman 77
**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
Halaman 78
**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
Halaman 79
**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
Halaman 80
**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
Halaman 81
##
## PT Astra Honda Motor
##
## TECHNICAL SERVICE DIVISION
1 8 KWB 9 I 1
Printed by GOP-2008
