While every care is taken in publishing this catalogue, thecompany will not be responsible for any error and omission.This...
2
415PART NO. INDEXFRAME GROUP32ENGINE GROUP 3BLOCK INDEX
Function andcomponent No. 1INSTRUCTION FOR USE OF PARTS CATALOGUEThis parts catalogue is compiled of all service parts and...
3. AbbreviationsThe following abbreviations are used in this Parts Catalogue.ASSY. .........Assembly L.E.D.........Light e...
711. Location of stamped serial numberCARBURETTOR IDENTIFICATION NUMBERENGINE SERIAL NUMBERFRAME SERIAL NUMBER
III. How to use the Flat Rate Time (F.R.T.)This F.R.T. (Flat Rate Time) is used to determine the standard labour time allo...
NO. SERVICE ITEM F.R.T.1. Engine 1.72. Cylinder head 1.43. Carburettor 0.44. Crankcase separation *3.54. Operations other ...
211E-1 CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . 17E-1A CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . ...
12F-1 LIGHT ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . 45F-1A FRONT COWL / STAY. . . . . . . . . . . . . ....
BLOCK INDEX - ENGINE GROUP13E-1A 17 E-1A 18 E-2 20E-4 22E-3 21 E-5 23E-7 2524 E-7A 263747216171362118 18512152422919231014...
BLOCK INDEX - ENGINE GROUP14E-7B 27 E-7C 28 E-8 29E-9 32-E-8A 317101 2266798394495310 498112111157681291010231/234/5678910...
15F-1 45 F-1A 46 F-2 48F-3 49BLOCK INDEX - FRAME GROUPF-3A 52 F-4 54F-5 56 F-6 57 F-7 592108861414161621813131717345888891...
16BLOCK INDEX - FRAME GROUPF-8 60 F-9 61 F-10 62F-10A 63 F-10B 65 F-11 66F-12 68 F-13 71 F-14 741451920206121091513 141718...
17BLOCK INDEX - FRAME GROUPF-16 78 F17 74 F-18 80F-18A 82 F-19 83114137812695159 6102311116915420411511131191184151311181-...
17BLOCK INDEX - FRAME GROUPF-24 90 F-24A 92 F-25 93F-26 95 F-27 96ST.MAG.STARTMOTORST. MOTORBATT.+1516823131110ST.MAG.2162...
ENGINE GROUP
12310-KVE-900 COVER, COMP., CYLINDER HEAD ................................................................ 112391-KRM-840 ...
12195-KVE-900 RUBBER, INSERT ................................................................. 3 312200-KVN-970 HEAD COMP....
91304-KRM-840 O-RING, 33.5X3 ..................................................................... 1 194301-10120 DOWEL PI...
12113107196 5917810 1043111210421312209-GB4-685R SEAL, VALVE, STEM ..........................................................
12100-KVE-900 CYLINDER COMP.,................................................................ 1 112191-KWK-900 GASKET, CYL...
4739126512128101114321-KRM-840 SPROCKET, CAM, ( 34 T )..................................................... 1 114401-KCW-8...
11330-AAK-H00 COVER, COMP., R CRANK CASE ........................................ 1 111393-KWK-900 GASKET, RIGHT COVER ......
22100-KTN-900 OUTER COMP., CLUTCH...................................................... 1 122115-KSP-910 GUIDE, CLUTCH OUT...
31100-KSP-B01 AC. GEN. ASSY...................................................................... 1 -31110-KSP-B01 FLY WHE...
28110-KTN-900 GEAR COMP., STARTER DRIVEN........................................ 1 128120-KPH-701 OUTER COMP., STARTING CL...
31200-KSP-901 MOTOR ASSY,. STARTER..................................................... - 131201-KPT-A01 BRUSH, TERMINAL S...
11341-KVN-900 COVER, LEFT CRANK CASE................................................ 1 111360-AAK-H00 COVER COMP., ‘L’ REA...
11100-KVE-900 CRANK CASE COMP., R ....................................................... - 111100-KVE-900 CRANK CASE COMP...
95701-06040-00 BOLT, FLANGE, 6 X 40.......................................................... 7 795701-06045-00 BOLT, FLAN...
14341717216161E - 8AOIL PUMP15100-KRM-840 OIL PUMP ASSY......................................................................
13000-KSP-911 CRANK SHAFT COMP........................................................... 1 113101-KSP-910 PISTON (STD.).....
90741-KFB-000 KEY, WOODRUFF, 4 MM....................................................... 1 190741-KGH-900 KEY, WOODRUFF, 4...
1234567891011121314151617183823210-KVN-900 SHAFT COMP., MAIN TRANS ............................................... 1 12342...
90452-KRM-840 WASHER, SPLINE, 17 X 23 X 1.6 ......................................... 2 290452-GB4-770 WASHER, THURST, 17 ...
13 611198141021074512 1515323427-KSP-910 BUSH, 17 X 20.5 X 8.................................................................
1118174513121961571682311109191424211-KRM-840 FORK, R/L, GEAR SHIFT .........................................................
123456789101112131415161718194216010-KSP-911 GASKET SET......................................................................
202122232425262728294316423-KGH-901 GASKET, BY-ST ..................................................................... 1 ...
123456789101112134533108-KRY-900 SPRING SPL.... ................................................................. 1 133101...
1234567894619052-KV0-000 COLLAR, RADIATOR MOUNTING................................ .. 250451-GB6-920 RUBBER, TAIL LIGHT SE...
10111213141516171819202122234764310-198-D20A PLATE, FRONT NUMBER .......................................... 164312-KVN-9 0...
35505-KVN-971 BULB SOCKET ASSY ............................................................. 1 137100-KVN-971 METER ASSY.,...
16150-KTN-700 COVER, THROTTLE CABLE ................................................ 1 117910-KVN-900 CABLE COMP., THROTTL...
88110-KVN-970ZF MIRROR ASSY., R. BACK (MAPLE BROWN ME ) ............... 1 188110-KVN-970ZG MIRROR ASSY., R. BACK (SPORTS R...
94050-06000 NUT, FLANGE 6 MM .............................................................. 1 194101-04700 WASHER, PLAIN 4...
35340-KCC-841 SW. ASSY., FR. STOP........................................................... 1 145126-KVE-900 HOSE COMP. F...
53175-KSP-900 LEVER R. STRG. HDL.......................................................... 1 190111-KCC-841 BOLT, FLANGE 6...
12345678910111213141516171819205435010-AAK-H01 KEY, SET......................................................................
215596700-08020-00 BOLT, SOCKET 8 MM........................................................... 2 2F- 4HANDLE PIPE / TOP B...
50301-KTR-900 RACE, (STRG. TOP), BALL................................................. 2 253200-KTN-700 STEM, COMP. STRG ....
57F - 6FRONT FENDERFR.*FENDER FRONT.................................. 0.3 61100-KVN-970ZA FENDER, FR. (PANTHER BLACK METAL...
58F - 6FRONT FENDERFR.*FENDER FRONT.................................. 0.3 61300-KVN-970ZG COVER L. FR. FENDER (SPORTS RED)...
12345678910111213141516171819205951400-KVN-971 FORK ASSY., R FRONT...................................................... 1...
123456789101112131460F - 8CALIPER ASSY ‘R’ FR06451-KCC-841 SEAL, SET PISTON..................................................
*TUBE, TYRE (2.75-18). ........................ 0.9* TYRE, FR. (2.75-18-42P).....................* AXLE, FR. WHEEL...........
42313-240-000 COLLAR, RR. BRAKE PANEL SIDE .................................... 1 -43100-KRY-930 PANEL, COMP. RR BRAKE ......
43155-KRY-970 CLAMPER, RR. BRAKE HOSE.............................................. - 243310-KVN-970 HOSE COMP, RR. BRAKE....
93893-04012-17L SCREW WASH, 4X12 ................................................. - 194002-08000-0S NUT, HEX 8MM............
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Hero Hunk
Upcoming SlideShare
Loading in...5
×

Hero Hunk

5,690

Published on

Published in: Automotive, Business, Technology
0 Comments
8 Likes
Statistics
Notes
  • Be the first to comment

No Downloads
Views
Total Views
5,690
On Slideshare
0
From Embeds
0
Number of Embeds
2
Actions
Shares
0
Downloads
371
Comments
0
Likes
8
Embeds 0
No embeds

No notes for slide

Hero Hunk

  1. 1. While every care is taken in publishing this catalogue, thecompany will not be responsible for any error and omission.This catalogue is the property of Hero Motocorp Ltd.Copy right of this catalogue is reserved.
  2. 2. 2
  3. 3. 415PART NO. INDEXFRAME GROUP32ENGINE GROUP 3BLOCK INDEX
  4. 4. Function andcomponent No. 1INSTRUCTION FOR USE OF PARTS CATALOGUEThis parts catalogue is compiled of all service parts and Flat Rate Time (F.R.T.) forHero Motocorp HUNK Motorcycle.I. How to order parts1. Information requiredReplacement parts orders must contain both the part number and thestamped number(s) as described below. This is because any changes andmodifications of parts are registered at Hero Motocorp with the pertinent partsand stamped numbers.Numbers needed(a) Carburettor parts : Part number andStamped carburettor identification number.(b) Engine parts : Part number and Stamped engine number.(c) Frame parts : Part number and Stamped frame number.2. RevisionWhen modifications or additions to this Parts Catalogue are made, a newsletters/revised edition will be issued at an appropriate time, with sucessivelyprogressing revision numbers. We recommend obtaining such revisions in order tokeep your Parts Catalogue up-to-date at all times. To check whether a PartsCatalogue revision has been issued, please contact SPARE PARTSDEPARTMENTS, Hero Motocorp Ldt.II. How to read this Parts Catalogue1. Make-up of the part number(Example) (General Parts)Colour CodeSubcontractor designationModification designationParts classification No.(Example) Bolts, nuts and other standard partsFunction andtype No.Dimension Chemical surface treatmentISOCOLOUR CODE COLOUR DESCRIPTIONCOLOUR REF. MAIN BODY COLOURNH-B08M PANTHER BLACK METALLICNH-A63M EMBONY GREY METALLICNH-411M FORCE SILVER METALLICGY-136P PEARL HARVEST GREENR-195C CANDY BLAZING REDYR-305M MAPLE BROWN METALLICR-321 SPORTS RED2. Colour codesThe colour code at the end of the part number indicates the colour. Code below ZAin alphabetical order (such as ZA, ZB, ZC, etc.) do not indicate the colour directly,but reference must be made to the Hero Motocorp code given in the descriptioncolumn of this Parts Catalogue.5
  5. 5. 3. AbbreviationsThe following abbreviations are used in this Parts Catalogue.ASSY. .........Assembly L.E.D.........Light emitting diodeABS............Anti-lock brake system KPH...........Kilometers per hourCOMP.........Complete TCS...........Traction control systemR.................Right L (100L).....Link (100 Links)L. ...............Left A.C............Alternating currentSTD............Standard D.C............Direct currentMM. ............Millimeter IN ..............InletG. ...............Gram EXH...........ExhaustT (22T). ......Tooth (22Teeth) FR. ...........FrontA.................Ampere RR.............RearV. ................Volt Hex............HexagonalW................Watt A.M............Attaching MarkWL..............With labelling T.M. ...........Transcript MarkWOL...........Without labelling C.D.I..........Capacitive Discharge ignitionINC............Including4. DimensionsAll dimensions are given in millimeters (mm) except in the case of steel balls,tyres and tyre tubes and wheel rims.Parts Example InterpretationBolt (Screw) 6 x 12 6mm diameter, 12mm lengthPin 8 x 14 8mm diameter, 14mm lengthO-Ring 9.5 x 1.6 9.5mm diameter, 1.6mm thicknessOil Seal 14 x 24 x 5 14mm inside diameter, 24mm outsidediameter, 5mm thicknessTube 5 x 130 5mm inside diameter, 130mm length5. Supercedence of partsPart numbers given under the part name in the “Description” column indicate thatthe part number has been superceded by that part number. HERO HONDA maymake such supercedence without notice.6.AssembliesSections framed with broken lines in the exploded view drawings are available ascomplete assemblies. (Their individual parts can also be obtained.)7. Required QuantityThe number given in the “Reqd. No.” column indicates the quantity of parts used inthe section described in that block.Parts with quantities in ( ) represent optional parts.Part whose required number is “N”, is a part whose required number can beselected at need.8. Part modifications and applicable serial numbersIn case where a part has been modified, the serial number of the first vehicle(or frame, engine, carburettor) bearing the modification is listed in the“Serial No.” Column.9. IllustrationIllustration of parts given in parts catalogue diagrams are provided forconvenience identifying parts and may differ from the actual configuration of parts.10. Models, area codes and applicable serial numbersModels, area codes and applicable serial Nos. given in this parts catalogue can beidentified as follows.Example6Applicable Applicable ApplicableAreaModel Type Engine Frame carburettorcodeserial No. serial No. identification No.ID IndiaHUNKXXXXEFYZXYYYYYMBLXXXXEFYZXYYYYY6 AL A 7ECX
  6. 6. 711. Location of stamped serial numberCARBURETTOR IDENTIFICATION NUMBERENGINE SERIAL NUMBERFRAME SERIAL NUMBER
  7. 7. III. How to use the Flat Rate Time (F.R.T.)This F.R.T. (Flat Rate Time) is used to determine the standard labour time allowedfor replacement of parts covered by the warranty during the period the warranty isin effect. The F.R.T. for those parts which are not listed herein should bedetermined from the operation closely related to the replacement of that part.1. The F.R.T. is based on the following service conditions.a. Aliberal allowance is added to the net servicing time.b. Standard times specified are based on the condition that the necessaryservicing tools listed in the service manual (motorcycle) which describesthe HERO HONDA service policies are available close at hand and thework is performed by a mechanic with normal skill.c. Time required for inspection and operational test following the servicing isincluded in the F.R.T.2. Method of computingThe job times are listed in tenth of an hour to simplify computation.(Example) 0.3 = 18 minutes5.6 = 5 hours and 36 minutesCONVERSION CHARTHours Minutes Hours Minutes0.1 6 0.6 360.2 12 0.7 420.3 18 0.8 480.4 24 0.9 540.5 30 1.0 603. Computing the F.R.T.When several jobs are performed at the same time, make the calculation in thefollowing manner.a. Jobs of non duplicated natureThe F.R.T. for the job is obtained by totaling the F.R.T. for each part replaced.(Example) Replacement of head cover gasket and oil filter.SERVICE ITEM F.R.T.Packing, cylinder head cover 0.5Cartridge, oil filter 0.5The F.R.T. For the job is : 0.5+0.5=1.0b. Jobs of duplicated natureTake the F.R.T. For the last part to be replaced.(Example) Replacement of piston and cylinder head gasket.SERVICE ITEM F.R.T.Gasket comp., cylinder head 3.0Piston *5.0The F.R.T. for the job is : 5.0c. Jobs of partially related natureTotal up the F.R.T. For all of the parts replaced and then subtract the F.R.T. forthe duplicated operation (i.e., cylinder head gasket service).(Example) Replacement of valve and cylinder head.SERVICE ITEM F.R.T.Valve *3.0Head assy., cylinder *4.0Gasket comp., cylinder head *2.5The F.R.T. for the job is : (3.0+4.0)-2.5=4.5• The F.R.T. shown with (*) includes engine removal and installation.• The parts, having the same number of man-hour, are identified by a mark•" ", and classified under the title of their representative work.8
  8. 8. NO. SERVICE ITEM F.R.T.1. Engine 1.72. Cylinder head 1.43. Carburettor 0.44. Crankcase separation *3.54. Operations other than replacing partsa. Removal and installationb. Adjustment, measurement and cleaningEngineNO. SERVICE ITEM F.R.T.1. Spark plug–adjustment and cleaning 0.12 Ignition timing–inspection 0.23 Tappet adjustment 0.24 Carburettor idle – adjustment 0.15 Engine oil – inspection (excluding oil change) 0.16 Clutch – adjustment 0.17 Cleaner element – cleaning 0.18 Compression – pressure measurement 0.19 Battery – checking of electrolyte level and gravity 0.210 Carburettor – float level measurement 0.511 Oil filter cleaning 0.612 Valve clearance adjustment 0.4FrameNO. SERVICE ITEM F.R.T.1 Front brake air bleeding 0.22 Rear brake adjustment 0.13 Brake operation test 0.14 Headlight aimings 0.15 Drive chain tension adjustment 0.1c. OverhaulNO. SERVICE ITEM F.R.T.1 Carburettor 0.79
  9. 9. 211E-1 CYLINDER HEAD COVER . . . . . . . . . . . . . . . . . 17E-1A CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . 18-19E-2 CAMSHAFT/VALVE . . . . . . . . . . . . . . . . . . . . . . 20E-3 CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21E-4 CAM CHAIN TENSIONER . . . . . . . . . . . . . . . . . 22E-5 RIGHT CRANKCASE COVER . . . . . . . . . . . . . . 23E-6 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24E-7A A.C. GEN. ASSY.. . . . . . . . . . . . . . . . . . . . . . . . . 25E-7B STARTER MOTOR.. . . . . . . . . . . . . . . . . . . . . . . 26E-7C LEFT CRANKCASE COVER. . . . . . . . . . . . . . . . 27E-8 CRANKCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . 28E-8A OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . 29-30E-9 CRANK SHAFT/PISTON . . . . . . . . . . . . . . . . 32-33E-10 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 34-35E-11 SPINDLE KICK STARTER . . . . . . . . . . . . . . . . . 36E-12 DRUM GEAR SHIFT . . . . . . . . . . . . . . . . . . . . . . 37E-13 CARBURETTOR . . . . . . . . . . . . . . . . . . . . . . 38-39BLOCK INDEX – ENGINE GROUP
  10. 10. 12F-1 LIGHT ASSY . . . . . . . . . . . . . . . . . . . . . . . . . . . 45F-1A FRONT COWL / STAY. . . . . . . . . . . . . . . . . 46-47F-2 SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . . 48F-3 HANDLE LEVER/SWITCH . . . . . . . . . . . . . 49-51F-3A FRONT BARKE M/C . . . . . . . . . . . . . . . . . . 52-53F-4 HANDLE PIPE / TOP BRIDGE . . . . . . . . . . 54-55F-5 STEERING STEEM/ . . . . . . . . . . . . . . . . . . . . . 56F-6 FRONT FENDER. . . . . . . . . . . . . . . . . . . . . 57-58F-7 FRONT FORK. . . . . . . . . . . . . . . . . . . . . . . . . . 59F-8 CALIPPER ASSY . . . . . . . . . . . . . . . . . . . . . . . 60F-9 FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . 37F-10 REAR PANEL BRAKE . . . . . . . . . . . . . . . . . . . . 62F-10A REAR BRAKE MASTER CYLINDER . . . . . . 63-64F-10B CALIPER ASSY REAR . . . . . . . . . . . . . . . . . . . 65F-11 REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . 66-67F-12 SEAT ASSY. / COWLS . . . . . . . . . . . . . . . . 68-70F-13 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . 71-73F-14 SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . 74-75F-15 AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . 76-77F-16 MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78F-17 STEP PILLION. . . . . . . . . . . . . . . . . . . . . . . . . . 79F-18 MAIN STAN/PEDAL BRAKE . . . . . . . . . . . . 80-81F-18A SIDE STAND. . . . . . . . . . . . . . . . . . . . . . . . . . . 82F-19 REAR FORK/CHAIN CASE . . . . . . . . . . . . . 83-84F-20 REAR CUSHTION. . . . . . . . . . . . . . . . . . . . . . . 85F-21 REAR FENDER . . . . . . . . . . . . . . . . . . . . . . 86-87F-22 WINKER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88F-23 TAIL LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89F-24 WIRE HARNESS . . . . . . . . . . . . . . . . . . . . . 90-91F-24A BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92BLOCK INDEX – FRAME GROUPONONRESRESADVEDTMBLEOWANCUFLINIONNDUCTTECHOLOGYONONSRESREF-25 FRAME BODY/ASV/GRIP REAR . . . . . . . . 93-94F-26 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95F-27 STRIPE / MARKS /EMBLEM . . . . . . . . . . . 96-109ONONR SER SEADVNEDTUMBLEFOWACLINDCTIONTCNOLYUEHOGADAND TLLOWVCEUMBE FINDT OCOOYUCI N TEHNLGF-28 GUARD ENGINE. . . . . . . . . . . . . . . . . . . . . . . 110F-29 SAREE GUARD. . . . . . . . . . . . . . . . . . . . . . . . 111F-30 CAUTION LABEL . . . . . . . . . . . . . . . . . . . . . . 112ONONRESRESVEDUBLWADANCTMLEFONOOGYIDUCTIN TECHNOLONONRESRESBADVANCEDTUMLFLOWEINUCTIONTECHNOLOGYDONONRESRESVBADANCED TUMLEFLOWINDUCTION TECHNOLOGY
  11. 11. BLOCK INDEX - ENGINE GROUP13E-1A 17 E-1A 18 E-2 20E-4 22E-3 21 E-5 23E-7 2524 E-7A 263747216171362118 18512152422919231014112320208CABLE ENG.EARTH13161715111453117 79138112106129212113107196 5917810 104311121042138244133473912651212810119126111112 111112121212121212121394857101022175646464653141210159111381 56878328746 1112151415871514910101010101342153101
  12. 12. BLOCK INDEX - ENGINE GROUP14E-7B 27 E-7C 28 E-8 29E-9 32-E-8A 317101 2266798394495310 498112111157681291010231/234/56789101011121213141516161818172217191919 19191919212021212121212119 211434171721616113151161289710515152439781135610111412221520718171630292221251220341314523288 241927110191124692262621813 611198141021074512 151531111181745131219615716823111091914312112271341569101415171811212224242627252511620822F-3281923232329E-10 34-E-12 37E-11 36 E-13 38-
  13. 13. 15F-1 45 F-1A 46 F-2 48F-3 49BLOCK INDEX - FRAME GROUPF-3A 52 F-4 54F-5 56 F-6 57 F-7 59210886141416162181313171734588889111215 1515151515 1515 151516195619162111510101113998121617151281414143 471418181818106510410651012377889999110141523748912165181917132011611152821961062303017201620175121425324NNPPAASSSSIINNGG268122222929 19741318 1823 23271041110586121337912254 171720131721202167 8912141521232312141818192222111633101722221664152813912106127111310 143227272527272529491712310811221222241416151426212019187628135
  14. 14. 16BLOCK INDEX - FRAME GROUPF-8 60 F-9 61 F-10 62F-10A 63 F-10B 65 F-11 66F-12 68 F-13 71 F-14 741451920206121091513 141718168117384721113322519242222182015914 231617171717112110126121138272311373593436333 15256 41816202271325 25252426 2626 28291010141718212626263030313233242431313130303030303030303030303030 3019159195742ONONOFFOFFRESRES361111111111112108108ADVNCEDTUMBLEFLOWAINDUCTIONTECHNOOGYL315177186181612141414141445181411 91013254734213411882263030313118121313122032322313339910101010141617151927272223133724242528282828292929292615101591214131162377843232161617171818182627146788910111213141519212020221352518242714146121313159441081172
  15. 15. 17BLOCK INDEX - FRAME GROUPF-16 78 F17 74 F-18 80F-18A 82 F-19 83114137812695159 6102311116915420411511131191184151311181-2102081915411993121218766995157174181934196158121691610192011131921 2154311822572314 15196 1754521768391312181711 8685341272525251620 16201410232221241513121819192651273 4165884473 4113818914141818176722132267621713216751616419192267222067101131112152021211718161631515191710131256281112182020191917914499181615151615152517171214131110741 96818334181818F-20 85F-21 86 F-22 88 F-23 89
  16. 16. 17BLOCK INDEX - FRAME GROUPF-24 90 F-24A 92 F-25 93F-26 95 F-27 96ST.MAG.STARTMOTORST. MOTORBATT.+1516823131110ST.MAG.21620212743ENG.IGN. COIL282923 1417302752519 18267242291231656642131820209111230101028283168831712452322252949142917191927271515232132323232261627343333262626241417563PP91911CADVANEDTUMBLEFLOWULINDCTIONTECHNOOGY2131410BA78CABC11ABDDC DA12E113323671 24556100/90-18 56P29200 2.00DRIVE CHAINKEEP CHAIN ADJUSTED AND LUBRICATED30 MM (11/4IN.) FREEPLAYSEE OWNER’S MANUALFOR INSTRUCTIONS.FREEPLAY423F-28 110F-29 111 F-30 112
  17. 17. ENGINE GROUP
  18. 18. 12310-KVE-900 COVER, COMP., CYLINDER HEAD ................................................................ 112391-KRM-840 GASKET, HEAD, COVER................................................................................. 112396-KRM-840 GASKET ‘B’, HEAD, COVER ........................................................................... 112397-KSP-910 GASKET, CYLINDER HEAD, COVER ............................................................. 112398-KSP-910 COLLAR, 9MM ................................................................................................. 118640-KTN-900 PIPE COMP., AIR FEED................................................................................... 190003-KFG-000 BOLT, ‘L’ COVER.............................................................................................. 290463-KRM-840 WASHER, SEALING, 6.2 MM .......................................................................... 190543-MV9-670 RUBBER, MOUNT ........................................................................................... 291309-MJ0-003 O-RING, 9.8 X 2.8 ............................................................................................ 194301-08140 DOWEL, PIN, 8 X 14........................................................................................ 195701-06016-00 BOLT, FLANGE, 6 X 16 .................................................................................... 296001-06012-00 BOLT, FLANGE, SH.6X 12 ............................................................................... 112345678910111213E - 1CYLINDER HEAD COVERFR.453117 791381121061292*COVER COMP., CYLINDER HEAD ..... 0.3*GASKET, HEAD COVER........................321Service Item F.R.T. Ref. Part No. Description Reqd. No.HUNKNo. DISC SELF
  19. 19. 12195-KVE-900 RUBBER, INSERT ................................................................. 3 312200-KVN-970 HEAD COMP., CYLINDER..................................................... 1 112204-KRM-305 GUIDE,EXH. VALVE, (O.S.) ................................................... 1 112205-KSP-305 GUIDE, INLET, VALVE (O.S.)................................................. 1 112210-KSP-910 HOLDER COMP., CAM SHAFT ............................................. 1 112212-KRM-840 PLATE, STOPPER ................................................................. 1 112213-KSP-910 CLIP, VALVE GUIDE............................................................... 2 212251-KRM-B41 GASKET, CYLINDER HEAD .................................................. 1 116210-KVN-970 INSULATOR COMP., CARB................................................... 1 116217-KSP-910 BAND, INSULATOR ............................................................... 1 116222-KSP-910 NUT, SQUARE, 5 MM ............................................................ 1 131916-KRM-841 SPARK, PLUG, ...................................................................... 1 190002-KRM-840 BOLT, FLANGE, 5X14............................................................ 2 290006-MEE-000 BOLT, RECESSED, 5X30....................................................... 1 190040-KSP-910 BOLT, STUD, 8X22................................................................. 2 290306-KRM-840 NUT, CYLINDER HEAD ......................................................... 4 490404-KPT-A00 WASHER, PLAIN, 12MM ....................................................... 4 490704-KRM-840 DOWEL, PIN, 6X10................................................................ 2 2123456789101112131415161718E - 1ACYLINDER HEAD37472FR.16171362118 18512152422919231014112320208CABLE ENG.EARTH13* PLUG, SPARK...................................... 0.1* BOLT, STUD, 8 X 22 ............................ 0.3( ADD 0.1 FOR EACH)* INSULATOR COMP., CARBURETOR.. 0.4* HOLDER COMP., CAMSHAFT ............ 0.9* GASKET, CYLINDER HEAD................ 1.4* GUIDE IN VALVE ................................. 2.0(INC. REAMING)(ADD 0.3 FOR EACH)(EXC. VALVE REFACING)(ADD MORE 0.2 IF PERFORMED)* HEAD COMP., CYLINDER................... 2.216171522111Service Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC
  20. 20. 91304-KRM-840 O-RING, 33.5X3 ..................................................................... 1 194301-10120 DOWEL PIN, 10X12 ............................................................... 2 295701-06014-00 BOLT, FLANGE, 6X14............................................................ 1 195701-06016-00 BOLT, FLANGE, 6X16............................................................ 1 195701-06022-00 BOLT, FLANGE, 6X22............................................................ 2 295801-06105-00 BOLT, FLANGE, 6X105.......................................................... 2 219202122232423* PLUG, SPARK...................................... 0.1* BOLT, STUD, 8 X 22 ............................ 0.3( ADD 0.1 FOR EACH)* INSULATOR COMP., CARBURETOR.. 0.4* HOLDER COMP., CAMSHAFT ............ 0.9* GASKET, CYLINDER HEAD................ 1.4* GUIDE IN VALVE ................................. 2.0(INC. REAMING)(ADD 0.3 FOR EACH)(EXC. VALVE REFACING)(ADD MORE 0.2 IF PERFORMED)* HEAD COMP., CYLINDER................... 2.2E - 1ACYLINDER HEADService Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC37472FR.16171362118 18512152422919231014112320208CABLE ENG.EARTH13161715111
  21. 21. 12113107196 5917810 1043111210421312209-GB4-685R SEAL, VALVE, STEM ............................................................ 2 214100-KVE-900 SHAFT COMP., CAM ............................................................. 1 114430-KSP-910 ARM COMP., VALVE ROCKER.............................................. 2 214451-KRM-840 SHAFT, ROCKER ARM.......................................................... 2 214711-KSP-910 VALVE, INLET ........................................................................ 1 114721-KVE-900 VALVE, EXH. .......................................................................... 1 114751-KRM-871 SPG, VALVE, ......................................................................... 2 214771-KVE-900 RETAINER, VALVE, SPRING................................................. 2 214775-KVE-900 SEAT, VALVE, SPRING.......................................................... 2 214781-MA6-000 COTTER, VALVE.................................................................... 4 490012-KK3-830 SCREW, TAPPET ADJUSTING.............................................. 1 190206-250-000 NUT, TAPPET ADJUSTING.................................................... 1 191008-KTN-900 BRG. BALL RADIAL, 12 X 28 X 8 .......................................... 1 112345678910111213* CAMSHAFT COMP., ............................ 0.7* ARM COMP., VALVE ROCKER............ 0.8(SAME TIME FOR TWO UNITS)* BEARING, RADIAL BALL, 6001 .......... 0.9* SPRING, VALVE .................................. 1.6(ADD 0.1 FOR EACH)* VALVE EX ........................................... 1.8(ADD 0.2 FOR EACH)(INC. REFACING)(EXC. VALVE GUIDE REPLACEMENT)24E - 2CAM SHAFT / VALVEFR.8Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF
  22. 22. 12100-KVE-900 CYLINDER COMP.,................................................................ 1 112191-KWK-900 GASKET, CYLINDER ............................................................. 1 112195-KVE-900 RUBBER, INSERT ................................................................. 2 294301-10120 DOWEL, PIN, 10 X12............................................................. 2 21234* GASKET, CYLINDER .......................... 1.6* CYLINDER COMP.,.............................. 1.725E - 3CYLINDER2441FR.33Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF
  23. 23. 4739126512128101114321-KRM-840 SPROCKET, CAM, ( 34 T )..................................................... 1 114401-KCW-851 CHAIN, CAM .......................................................................... 1 114510-KVE-900 TENSIONER, ASSY., CAM CHAIN ........................................ 1 114515-KRM-840 PLATE, TENSIONER SET ..................................................... 1 114520-KVE-900 LIFTER ASSY., TENSIONER ................................................. 1 114560-KSP-910 GASKET, TENSIONER LIFTER............................................. 1 114610-KSP-910 GUIDE, CAM CHAIN.............................................................. 1 190005-KY7-000 SCREW, PAN 6 X 6................................................................ 1 190083-KRM-840 BOLT, KNOCK, 5 MM............................................................. 2 291306-MG3-000 O-RING, 1.5 X 9.5 .................................................................. 1 195701-06016-00 BOLT, FLANGE, 6 X 16.......................................................... 1 196001-06022-00 BOLT, FLANGE, SH.6 X 22.................................................... 2 2123456789101112* LIFTER ASSY., TENSIONER............... 0.2* SPROCKET, CAM, (34 T) .................... 0.5* TENSIONER ASSY., CAM CHAIN ....... 0.9* CHAIN, CAM ........................................ 1.0* GUIDE, CAM CHAIN............................ 1.4E - 4CAM CHAIN TENSIONERFR.926Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF
  24. 24. 11330-AAK-H00 COVER, COMP., R CRANK CASE ........................................ 1 111393-KWK-900 GASKET, RIGHT COVER ...................................................... 1 115650-KVN-970 GAUGE, OIL LEVEL .............................................................. 1 122810-KRM-B00 LEVER COMP., CLUTCH....................................................... 1 122815-428-000 SPRING, CLUTCH LEVER .................................................... 1 122821-KRM-840 RECEIVER, CLUTCH CABLE................................................ 1 190701-KFN-850 PIN, SPRING, 3 X 10 ............................................................. 1 191202-KSP-911 OIL SEAL, 12 X 18 X 4........................................................... 1 191307-KRM-840 O-RING, 18 X 3 ...................................................................... 1 194301-08140 DOWEL PIN, 8 X 14 ............................................................... 2 296001-06030-00 BOLT, FLANGE, SH.6 X 30.................................................... 3 396001-06040-00 BOLT, FLANGE, SH.6 X 40.................................................... 9 927123456789101112* GASKET, R CRANKCASE COVER ..... 0.6* OIL SEAL ,16 X28 X 27* COVER COMP., R CRANKCASE ........ 0.7* LEVER COMP., CLUTCH(INC. RELATIVE PART)E - 5RIGHT CRANK CASE COVER126111112 11111212121212121212139485710102Service Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC
  25. 25. 22100-KTN-900 OUTER COMP., CLUTCH...................................................... 1 122115-KSP-910 GUIDE, CLUTCH OUTER...................................................... 1 122120-KRM-840 CENTER, CLUTCH ................................................................ 1 122201-KPM-850 DISC, CLUTCH FRICTION, 4 X 8 X 45.................................. 3 322201-MR8-000 DISC, CLUTCH FRICTION .................................................... 2 222321-KPS-900 PLATE, CLUTCH.................................................................... 4 422355-KRM-840 PLATE, CLUTCH PRESSURE............................................... 1 122361-KPK-900 PLATE, CLUTCH LIFTER ...................................................... 1 122366-KSP-910 ROD, CLUTCH LIFTER.......................................................... 1 122401-KRM-840 SPRING, CLUTCH ................................................................. 4 490008-KRM-840 BOLT, FLANGE, 6 X 25.......................................................... 4 490202-KRM-840 NUT SPL., FLANGE, 14 MM.................................................. 1 190401-KRM-840 WASHER, PLAIN, 17MM ....................................................... 1 190501-KPT-A00 WASHER, 14.1 X 29 X 2.8 ..................................................... 1 196100-60030-00 BRG., BALL, RADIAL, 6003................................................... 1 1123456789101112131415* ROD, CLUTCH LIFTER ....................... 0.6* SPRING, CLUTCH............................... 0.7(SAME TIME FOR TWO UNITS OR MORE)* CENTER, CLUTCH ............................. 0.8* DISC, CLUTCH FRICTION(INC. RELATIVE PART)(SAME TIME FOR TWO UNITS OR MORE)* OUTER COMP., CLUTCHFR.E - 6CLUTCH21756464646531412101591113828Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF
  26. 26. 31100-KSP-B01 AC. GEN. ASSY...................................................................... 1 -31110-KSP-B01 FLY WHEEL COMP. ............................................................... 1 -31120-KSP-B01 STATOR COMP. .................................................................... 1 132111-KSP-910 CLAMPER, ACG. CORD........................................................ 1 190201-KRM-840 NUT, FLANGE, 14 MM ........................................................... 1 190501-KPT-A00 WASHER, 14.1 X 29 X 2.8 ..................................................... 1 196600-06016-00 SOCKET, BOLT, 6 X 16.......................................................... 3 396600-06025-00 SOCKET, BOLT, 6 X 25.......................................................... 3 329FR.12345678* FLY WHEEL COMP.............................. 0.5* STATOR COMP ...................................1 5687832874E - 7A. C. GEN. ASSY.Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF
  27. 27. 28110-KTN-900 GEAR COMP., STARTER DRIVEN........................................ 1 128120-KPH-701 OUTER COMP., STARTING CLUTCH ................................... 1 128131-KTN-900 GEAR, STARTER DRIVEN .................................................... 1 128132-KN6-930 SHAFT, REDUCTION GEAR.................................................. 1 128133-KRM-850 COLLAR, STARTER REDUCTION ........................................ 1 131100-KSP-B01 AC GEN. ASSY....................................................................... 1 131110-KSP-B01 FLY WHEEL COMP. ............................................................... 1 131120-KSP-B01 STATOR COMP. .................................................................... 1 132111-KSP-910 CLAMPER, ACG. CORD........................................................ 1 190085-KTC-920 BOLT, SOCKET, 6 X 14.......................................................... 6 690201-KRM-840 NUT, FLANGE, 14 MM ........................................................... 1 190501-KPT-A00 WASHER, 14.1 X 29 X 2.8 ..................................................... 1 191022-KTN-900 BRG., NEEDLE, 22 X 29 X 16.8............................................. 1 196600-06016-00 SOCKET, BOLT, 6 X 16.......................................................... 3 396600-06022-00 SOCKET, BOLT, 6 X 22.......................................................... 3 330E - 7AA. C. GEN. ASSY.FR.123456789101112131415* FLY WHEEL COMP.............................. 0.5* STATOR COMP6 1112151415871514910101010101342153Service Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC101
  28. 28. 31200-KSP-901 MOTOR ASSY,. STARTER..................................................... - 131201-KPT-A01 BRUSH, TERMINAL SET....................................................... - 231204-KG8-004 SPRING, BRUSH ................................................................... - 231205-KTC-921 BOLT, SET.............................................................................. - 231206-KPH-881 BRUSH, HOLDER.................................................................. - 131207-MBE-008 RING....................................................................................... - 290071-MB0-000 NUT, WASH, 6 MM................................................................. - 291309-425-003 ‘O’ RING, 24.4X3.1................................................................. - 191320-MB0-000 ‘O’ RING ................................................................................. - 395701-06022-00 BOLT, FLANGE, 6 X 22.......................................................... - 21234567891031E - 7BSTARTER MOTORR.F7101 2266798394495310* MOTOR ASSY., STARTER................... 0.7* BRUSH, TERMINAL SET..................... 0.9Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF
  29. 29. 11341-KVN-900 COVER, LEFT CRANK CASE................................................ 1 111360-AAK-H00 COVER COMP., ‘L’ REAR ...................................................... 1 111365-KSP-910 GUIDE DRIVE CHAIN............................................................ 1 111395-KWK-900 GASKET, ‘L’ COVER .............................................................. 1 190084-MN8-010 CAP, 14 MM............................................................................ 1 190087-KVE-900 CAP, 32 MM............................................................................ 1 191303-KRM-840 O-RING, 13.8 X 2.5 ................................................................ 1 191305-KRM-840 O-RING, 31.7 X 2.4 ................................................................ 1 194301-08140 DOWEL PIN, 8 X 14............................................................... 2 296001-06030-00 BOLT, FLANGE, SH.6 X 30.................................................... 2 296001-06035-00 BOLT, FLANGE, SH.6 X 35.................................................... 7 796001-06045-00 BOLT, FLANGE, SH.6 X 45.................................................... 2 2123456789101112* COVER COMP., L RR ......................... 0.1* GASKET, L COVER ............................. 0.2* COVER, L CRANKCASE ..................... 0.3E - 7CLEFT CRANK CASE COVERFR.3249811211115768129101023Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF
  30. 30. 11100-KVE-900 CRANK CASE COMP., R ....................................................... - 111100-KVE-900 CRANK CASE COMP., R (MGM)........................................... 1 -11108-KTN-900 PLATE, L BRG. SET............................................................... 3 311200-KVE-900 CRANK CASE COMP., L........................................................ - 111200-KVE-900 CRANK CASE COMP., L (MGM)............................................ 1 -11215-KSP-910 PLUG, BRG., PUSH............................................................... 1 111216-KRM-840 SPRING, BRG., PUSH........................................................... 1 111217-KRM-840 PLATE, BRG., PUSH.............................................................. 1 135750-KVN-900 SET, NEUTRAL SW ............................................................... 1 190031-KSP-910 BOLT, STUD, CYLINDER, 8 X 140 ........................................ 4 490131-KRM-840 BOLT, PLUG, DRAIN, 12 MM................................................. 1 190441-KRM-840 PLATE, BRG., HOLD.............................................................. 2 291203-KSP-910 OIL SEAL, 14 X 22 X 5........................................................... 1 191305-KPH-900 O-RING, 19.4 X 2.3 ................................................................ 1 194109-12000 WASHER, PLUG DRAIN........................................................ 1 194301-08140 DOWEL, PIN, 8 X 14.............................................................. 2 295701-06016-00 BOLT, FLANGE, 6 X 16.......................................................... 5 595701-06020-00 BOLT, FLANGE, 6 X 20.......................................................... 2 2123456789101112131415161718* CONTACT ASSY., NEUTRAL SW........ 0.3* BOLT, STUD, CYLINDER, 8 X 140 ...... 1.6(ADD 0.1 FOR EACH)* CRANKCASE COMP., L.......................*4.2* CRANKCASE COMP., R......................*4.533E - 8CRANK CASEFR.1/234/56789101011121213141516161818172217191919 19191919212021212121212119 21Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF
  31. 31. 95701-06040-00 BOLT, FLANGE, 6 X 40.......................................................... 7 795701-06045-00 BOLT, FLANGE, 6 X 45.......................................................... 1 195701-06070-00 BLOT, FLANGE, 6 X70........................................................... 7 796001-06018-00 BOLT, FLANGE, SH.6 X 18.................................................... 1 119202122E - 8CRANK CASE* CONTACT ASSY., NEUTRAL SW........ 0.3* BOLT, STUD, CYLINDER, 8 X 140 ...... 1.6(ADD 0.1 FOR EACH)* CRANKCASE COMP., L.......................*4.2* CRANKCASE COMP., R......................*4.5FR.1/234/56789101011121213141516161818172217191919 19191919212021212121212119 2134Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF
  32. 32. 14341717216161E - 8AOIL PUMP15100-KRM-840 OIL PUMP ASSY..................................................................... 1 115130-KRM-840 GEAR COMP., OIL PUMP...................................................... 1 115331-KRM-840 ROTOR, INNER OIL PUMP ................................................... 1 115332-KRM-840 ROTOR, OUTER OIL PUMP.................................................. 1 115421-KTN-900 SCREEN, OIL FILTER............................................................ 1 115430-KSP-910 ROTOR, OIL FILTER.............................................................. 1 115436-KRM-840 CAP, OIL FILTER, ROTOR..................................................... 1 115441-KCS-650 OIL, THROUGH...................................................................... 1 115446-107-000 SPRING, OIL THROUGH....................................................... 1 115459-KWK-900 GASKET, OIL FILTER CAP .................................................... 1 190231-KM7-700 NUT, LOCK, 14 MM................................................................ 1 190432-KPT-A00 WASHER, 14.2 X 26 X 3 ........................................................ 1 193700-05012-0A SCREW, OVAL, 5 X 12........................................................... 3 393901-34120 SCREW, TAPPING, 4 X 8 ...................................................... 1 194251-08000 PIN, LOCK, 8 MM................................................................... 1 194301-08140 DOWEL, PIN, 8 X 14.............................................................. 2 295701-06035-00 BOLT, FLANGE, 6 X 35.......................................................... 2 21234567891011121314151617* CAP, OIL FILTER ROTOR.................... 0.6* GEAR COMP., OIL PUMP DRIVE........* SCREEN, OIL FILTER .........................* PUMP ASSY., OIL ................................ 0.7* ROTOR, OIL PUMP INNER(SAME TIME FOR TWO UNITS)35FR.131511612897105Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF
  33. 33. 13000-KSP-911 CRANK SHAFT COMP........................................................... 1 113101-KSP-910 PISTON (STD.)....................................................................... 1 113102-KSP-305 PISTON (OS. 0.25)................................................................. (1) (1)13103-KSP-305 PISTON (OS. 0.50)................................................................. (1) (1)13104-KSP-305 PISTON (OS. 0.75)................................................................. (1) (1)13105-KSP-305 PISTON (OS. 1.00)................................................................. (1) (1)13011-KRM-305 RING SET, PISTON (STD.).................................................... 1 113021-KRM-305 RING SET, PISTON (OS. 0.25).............................................. (1) (1)13031-KRM-305 RING SET, PISTON (OS. 0.50).............................................. (1) (1)13041-KRM-305 RING SET, PISTON (OS. 0.75).............................................. (1) (1)13051-KRM-305 RING SET, PISTON (OS. 1.00).............................................. (1) (1)13111-KSP-910 PIN, PISTON .......................................................................... 1 113201-KRM-840 ROD, CONNECTING ............................................................. 1 113380-KRM-840 PIN, COMP., CRANK.............................................................. 1 113412-KSP-910 COLLAR, R CRANK SHAFT .................................................. 1 114311-KRM-840 SPROCKET, TIMING, ( 17 T ) ................................................ 1 123121-KTN-900 GEAR, PRIMARY DRIVE, ( 20 T ).......................................... 1 112345678936E - 9CRANK SHAFT / PISTONFR.SELECTION TABLE OF CONNECTING ROD BIG END BEARINGBCrank PinCODE(Colour)Connectingrod code1 2 3 4 5-0.001+0.001+0.001+0.00391101-KTN-9000(Red)91102-KTN-9000(Blue)aaCADB91101-KTN-9000(Red)91102-KTN-9000(Blue)91101-KTN-9000(Red)91102-KTN-9000(Blue)91103-KTN-9000(White)(Green) (Yellow) (White) (Blue) (Brown)+0.003+0.005+0.005+0.007+0.007+0.0090.000-0.002-0.002-0.0040.000-0.002-0.002-0.0040.000-0.002-0.002-0.004-0.004-0.00615152439781135610111412* PIN, PISTON........................................ 1.7* PISTON ............................................... 1.8* RING SET, PISTON .............................* BEARING, ROLLER 30 X 58 X 17.......*3.7* CRANKSHAFT COMP.,........................Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF
  34. 34. 90741-KFB-000 KEY, WOODRUFF, 4 MM....................................................... 1 190741-KGH-900 KEY, WOODRUFF, 4 MM....................................................... 1 191001-KTN-900 BRG., ROLLER, 30 X 58 X 17................................................ 1 191002-KSP-911 BRG. BALL, RADIAL, 6207 SPL. L ........................................ 1 19110A-KTN-901 BRG., NEEDLE, 28 X 36 X 15.8............................................. 1 191101-KTN-901 BRG., NEEDLE, 28 X 36 X 15.8 (RED).................................. 1 191102-KTN-901 BRG., NEEDLE, 28 X 36 X 15.8 (BLUE)................................ (1) (1)91103-KTN-901 BRG., NEEDLE, 28 X 36 X 15.8 (WHITE).............................. (1) (1)94601-14000 CLIP, PISTON, PIN................................................................. 2 210111213141537E - 9CRANK SHAFT / PISTONFR.* PIN, PISTON........................................ 1.7* PISTON ............................................... 1.8* RING SET, PISTON .............................* BEARING, ROLLER 30 X 58 X 17.......*3.7* CRANKSHAFT COMP.,........................SELECTION TABLE OF CONNECTING ROD BIG END BEARINGECrank PinCODE(Colour)Connectingrod code1 2 3 4 5CFDB91101-KTN-9000(Red)91102-KTN-9000(Blue)91103-KTN-9000(White)91101-KTN-9000(Red)91102-KTN-9000(Blue)91103-KTN-9000(White)0.000-0.002a-0.002-0.004-0.004-0.006-0.002-0.004-0.004-0.0060.000-0.002-0.001+0.001+0.001+0.003(Green) (White) (Blue) (Brown)+0.003+0.005+0.005+0.007+0.007+0.009(Yellow)15152439781135610111412Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF
  35. 35. 1234567891011121314151617183823210-KVN-900 SHAFT COMP., MAIN TRANS ............................................... 1 123421-KVN-900 GEAR, C-1,( 40T)................................................................... 1 123427-KSP-910 BUSH, 17 X 20.5 X 8.............................................................. 1 123431-KVN-900 GEAR, M-2 (19 T)................................................................... 1 123432-KSP-910 BUSH, 20 MM......................................................................... 2 223441-KVN-900 GEAR, C2,(34 T) .................................................................... 1 123451-KVN-900 GEAR, M3,(23T)..................................................................... 1 123461-KVN-900 GEAR, C3,(30T) ..................................................................... 1 123471-KVN-900 GEAR, M4,(22 T).................................................................... 1 123472-KSP-910 BUSH, 17 MM......................................................................... 1 123481-KVN-900 GEAR, C-4,(24 T)................................................................... 1 123491-KVN-900 GEAR, M-5,(32T).................................................................... 1 123492-KSP-910 COLLAR, SPLINE, 17 X 20 X 11............................................ 1 123501-KVN-900 GEAR, C-5(30T)..................................................................... 1 123801-KCT-690 SPROCKET, DRIVE, (14 T).................................................... 1 123811-KR3-600 PLATE, A2 FIXING ................................................................. 1 190084-041-000 BOLT, DRIVE SPROCKET, FIXING ....................................... 2 223220-KTN-900 SHAFT COMP., COUNTER.................................................... 1* SPROCKET, DRIVE............................. 0.2* COUNTER SHAFT COMP. .................*3.7(INC. RELATIVE PART)* SHAFT COMP., MAIN TRANSMISSION(INC. RELATIVE PART)(WHEN SERVICING COMP. UNITF. R T. IS 3.9)E - 10TRANSMISSION221520718171630292221251220341314523288 24192711019112469226262FR.18Service Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC
  36. 36. 90452-KRM-840 WASHER, SPLINE, 17 X 23 X 1.6 ......................................... 2 290452-GB4-770 WASHER, THURST, 17 MM................................................... 2 290453-KRM-840 WASHER, SPLINE, 20 MM .................................................... 1 190454-107-000 WASHER, THURST, 20 MM .................................................. 3 390456-KRM-840 WASHER, THURST, 12 MM................................................... 1 190601-KTC-900 CIRCLIP, 17 MM..................................................................... 2 290605-KTC-900 CIRCLIP, 20 MM..................................................................... 1 191003-KSP-910 BRG., BALL RADIAL, 17 X 42 X 12 ....................................... 1 191004-KTN-900 BRG., BALL RADIAL, 17 X 40 X 12 ....................................... 1 191005-KTN-900 BRG., BALL RADIAL, 12 X 32 X 10 ....................................... 1 191006-KTN-900 BRG., BALL RADIAL, 20 X 47 X 14 ....................................... 1 191216-KSP-910 OIL SEAL, 20 X 34 X 7........................................................... 1 119202122232425262728293039* SPROCKET, DRIVE............................. 0.2* COUNTER SHAFT COMP. .................*3.7(INC. RELATIVE PART)* SHAFT COMP., MAIN TRANSMISSION(INC. RELATIVE PART)(WHEN SERVICING COMP. UNITF. R T. IS 3.9)E - 10TRANSMISSION221520718171630292221251220341314523288 24192711019112469226262FR.18Service Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC
  37. 37. 13 611198141021074512 1515323427-KSP-910 BUSH, 17 X 20.5 X 8.............................................................. 1 128211-KRM-840 PINION, KICK STARTER ....................................................... 1 128215-KRM-840 PLATE, KICK STOPPER........................................................ 1 128221-KTN-900 RATCHET, STARTER............................................................. 1 128223-KRM-840 SPRING, RATCHET............................................................... 1 128231-KRM-840 GEAR, KICK IDLE STARTER ................................................ 1 128251-KTN-900 SPINDLE, KICK STARTER .................................................... 1 128261-KRM-840 SPG., KICK RETURN............................................................. 1 128282-KRM-840 COLLAR, KICK SPG .............................................................. 1 190451-KRM-840 WASHER, THURST, 16 MM................................................... 2 290452-GB4-770 WASHER, THURST, 17 MM................................................... 2 290455-KSP-910 WASHER, SPL., 14 MM ......................................................... 1 190602-KRM-840 CIRCLIP, EXTERNAL, 17 MM................................................ 1 194510-16000 CIRCLIP, EXTERNAL, 16 MM................................................ 1 195701-06016-00 BOLT, FLANGE, 6 X 16.......................................................... 2 2123456789101112131415* SPINDLE, KICK STARTER.................. 0.7(INC. RELATIVE PART)* SPRING, KICK RETURN* GEAR, KICK STARTER IDLE .............. 0.8E - 11SPINDLE KICK STARTERFR.1140Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF
  38. 38. 1118174513121961571682311109191424211-KRM-840 FORK, R/L, GEAR SHIFT ...................................................... 2 224212-KRM-840 FORK, CENTER, GEAR SHIFT ............................................. 1 124241-KRM-840 SHAFT, A GEAR SHIFT FORK............................................... 1 124242-KRM-840 SHAFT, B GEAR SHIFT FORK .............................................. 1 124301-KSP-910 DRUM, GEAR SHIFT ............................................................. 1 124410-KSP-860 PLATE, COMP., SHIFT DRUM STOPPER............................. 1 124430-KRM-B10 STOPR COMP., GEAR SHIFT DRUM.................................... 1 124436-KRM-840 SPRING, DRUM STOPPER................................................... 1 124610-KSP-910 SPINDLE, COMP., GEAR SHIFT ........................................... 1 124651-KSP-910 SPRING, SHIFT RETURN ..................................................... 1 124652-KSP-910 PIN, SHIFT, RETURN SPRING.............................................. 1 135751-KPH-900 CAP, CONTACT CHANGE, SW ............................................. 1 135752-KRM-840 SPRING, CONTACT CHANGE, SW ...................................... 1 190003-KVS-910 BOLT, HEX., 6 X 20................................................................ 1 190022-MG8-000 PIVOT, SHIFT DRUM, STOPR. ARM..................................... 1 190417-041-000 WASHER, SHIFTDRUM SIDE ............................................... 1 190457-KRM-840 WASHER, 14 MM................................................................... 1 194510-14000 CIRCLIP, EXTERNAL, 14 MM................................................ 1 196220-30085 ROLLER, 3 X 8.5.................................................................... 2 212345678910111213141516171819* SPINDLE COMP., GEARSHIFT........... 0.8* PLATE COMP., SHIFT DRUMSTOPPER............................................. 0.9* STOPPER COMP., GEARSHIFT DRUM* DRUM, GEARSHIFT............................*3.6* FORK, GEAR SHIFT(SAME FOR TWO UNITS OR MORE)41E - 12DRUM GEAR SHIFTFR.Service Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC
  39. 39. 123456789101112131415161718194216010-KSP-911 GASKET SET......................................................................... 1 116012-KVE-902 NEEDLE, SET, JET ................................................................ 1 116013-KRC-921 FLOAT SET ............................................................................ 1 116015-KSP-911 CHAMBER SET, FLOAT......................................................... 1 116016-KSP-911 SCREW, SET, ‘A’.................................................................... 1 116028-KPP-901 SCREW, SET, ‘B’.................................................................... 1 116037-KPP-861 PLATE, SET, VALVE............................................................... 1 116046-KVC-901 VALVE, SET, STARTER ......................................................... 1 116050-KVE-901 SPG., COMPRESSION COIL................................................. 1 116075-KRP-981 O-RING................................................................................... 2 216080-KTN-901 SCREW WASH, TORX, 5X16 ................................................ 1 116100-KVE-902 CARBURETTOR, ASSY. ....................................................... 1 116107-KGH-901 TOP ........................................................................................ 1 116111-KVE-901 PISTON COMP., VACUUM..................................................... 1 116119-KSP-911 STAY, WIRE............................................................................ 1 116140-KTE-911 BODY COMP., BY-ST. ............................................................ 1 116155-KFR-701 VALVE COMP., FLOAT........................................................... 1 116163-KRP-981 GASKET, FLOAT CHAMBER ................................................. 1 116179-KVE-901 BINDER.................................................................................. 1 1E - 13CARBURETTORFR.312112271341569101415171811212224242627252511620822F-3281923232329* SENSOR ASSY., THROTLE ................ 0.2* CHAMBER SET, FLOAT ...................... 0.4* PISTON COMP., VACUUM ..................* VALVE SET, STARTER ........................* CARBURETTOR ASSY.,...................... 0.5* FLOAT SET* JET, MAIN,* VALVE COMP., FLOAT* NEEDLE SET, JET.............................. 0.6Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF
  40. 40. 202122232425262728294316423-KGH-901 GASKET, BY-ST ..................................................................... 1 137890-KTN-901 SENSOR ASSY., THROTTLE ................................................ 1 193500-04008-1H SCREW, PAN 4X8.................................................................. 2 293500-04032-0G SCREW, PAN 4X32................................................................ 3 393500-05012-1H SCREW, PAN 5X12................................................................ 2 293892-05012-18 SCREW, WASH 5X12 ............................................................ 2 295002-02089 CLIP, B1 8 TUBE .................................................................... 1 195005-45480-50 TUBE, 4.5X480....................................................................... 1 199101-KVE-1280 JET # 128 ............................................................................... 1 199103-KRM-035 JET, SLOW #35...................................................................... 1 1E - 13CARBURETTORFR.3121122713415691014151718291121222424262327252511620822F-328192323* SENSOR ASSY., THROTLE ................ 0.2* CHAMBER SET, FLOAT ...................... 0.4* PISTON COMP., VACUUM ..................* VALVE SET, STARTER ........................* CARBURETTOR ASSY.,...................... 0.5* FLOAT SET* JET, MAIN,* VALVE COMP., FLOAT* NEEDLE SET, JET.............................. 0.6Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF
  41. 41. 123456789101112134533108-KRY-900 SPRING SPL.... ................................................................. 1 133101-KVN-901 TUBE,................................................................................. 2 23310B-AAK-H01 LIGHT ASSY., HEAD (W/O BULB).................................... 1 133110-AAK-H01 UNIT, HEAD LIGHT............................................................. 1 133112-KSP-911 COVER, RUBBER.............................................................. 1 133128-GBL-000 NUT, SPECIAL................................................................... 1 133150-KVN-901 SOCKET, ASSY., HEAD LIGHT......................................... 1 134901-KSP-910 BULB, HEAD LIGHT (Hs1) 12V-35/35W............................. 1 134908-GA7-700 BULB, WEDGE BASE (12-3.OW)...................................... 1 153209-GAH-000 CLIP, HEADLIGHT............................................................. 2 290101-GJ6-000 BOLT, ADJUST................................................................... 1 190307-GJ6-000 WASHER, LOCK 6MM....................................................... 1 193901-04012-00 SCREW, TAPPING SPL. 4X12.......................................... 1 1F-1HEAD LIGHT(WITH VISOR)FR.* BULB, HEADLIGHT.............................. 0.2* SOCKET ASSY., HEADLIGHT............. 0.2* UNIT, HEADLIGHT .............................. 0.310411105861213379122Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF4
  42. 42. 1234567894619052-KV0-000 COLLAR, RADIATOR MOUNTING................................ .. 250451-GB6-920 RUBBER, TAIL LIGHT SET......................................... ..... 261312-KCT-690 BOOT, HEADLIGHT STAY............................................. ...61330-KVN-900 PANEL, R SIDE.............................................................. .. 161340-KVN-900 PANEL, L SIDE............................................................... .. 164100- - 0 SET, WIND SCREEN................................................ ....... 164206-KVN-9 0 COWL, FR. CENTR ............................................... .............. 2.... 2.... 2 2.... 1.... 1AAK H7 .... 164204-KVN-900ZB COWL R. FR. SIDE (FORCE SILVER METALLIC)............... 1 164204-KVN-900ZD COWL R. FR. SIDE (SPORTS RED)............................... .... 1 164204-KVN-900ZF COWL R. FR. SIDE (CANDY BLAZING RED)................. .... 1 164204-KVN-900ZG COWL R. FR. SIDE (EBONY GREY ).................................. 1 164204-KVN-970ZD COWL R. FR. SIDE (PEARL HARVEST GREEN)............... 1 164204-KVN-970ZF COWL R. FR. SIDE (MAPLE BROWN METALLIC)............. 1 164205-KVN-900ZB COWL L. FR. SIDE (FORCE SILVER METALLIC)............... 1 164205-KVN-900ZD COWL L. FR. SIDE (SPORTS RED)............................... .... 1 164205-KVN-900ZF COWL L. FR. SIDE (CANDY BLAZING RED)................. .... 1 164205-KVN-900ZG COWL L. FR. SIDE (EBONY GREY ).................................. 1 164205-KVN-970ZD COWL L. FR. SIDE (PEARL HARVEST GREEN)............... 1 164205-KVN-970ZF COWL L. FR. SIDE (MAPLE BROWN METALLIC)............. 1 17 E .... 1 1*SET WIND SCREEN............................. 0.2* COWL, FR............................................ 0.4* STAY COMP., FR. COWL .................... 0.5*COWL R FR. SIDE...............................*COWL ‘L FR. SIDE...............................*COWL, FR CENTER.............................F-1AFRONT COWL /STAYFR.54 171720131721202167 89121415212323121418181922221116331017222216Service Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC
  43. 43. 10111213141516171819202122234764310-198-D20A PLATE, FRONT NUMBER .......................................... 164312-KVN-9 0 STAY COMP., FR. COWL...................................................... 1.......... 17 164313-KVN-900 STAY COMP., FR. WINKER.................................................. 1 164315-KVN-900 STAY, FR. NUMBER PLATE.................................................. 1 164316-KVN-900 RUBBER, FR. COWL MOUNTING........................................ 2 277247-KVN-900 RUBBER, STOPPER.............................................................. 1 183551-376-000 GROMMET, SIDE COVER.................................................... 2 290101-GE0-000 SCREW, HINGE PATCH......................................................... 4 490105-KVN-900 BOLT, SPECIAL 6 X 22........................................................... 2 290899-KVN-900 PLUG, CORN.......................................................................... 1 193500-05010-1A SCREW, PAN 5X10................................................................. 2 294101-05000 WASHER, PLAIN 5 MM........................................................... 2 295701-06012-00 BOLT, FLANGE 6X12.............................................................. 4 495701-06020-00 BOLT, FLANGE 6X20.............................................................. 2 2*SET WIND SCREEN............................. 0.2* COWL, FR............................................ 0.4* STAY COMP., FR. COWL .................... 0.5*COWL R FR. SIDE...............................*COWL ‘L FR. SIDE...............................*COWL, FR CENTER.............................Service Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISCF-1AFRONT COWL /STAYFR.54 171720131721202167 89121415212323121418181922221116331017222216
  44. 44. 35505-KVN-971 BULB SOCKET ASSY ............................................................. 1 137100-KVN-971 METER ASSY., COMB ........................................................... 1 137101-KVN-971 SELECT & RESET GROMMET............................................... 1 137213-KVN-971 SELECT KNOB........................................................................ 1 137214-KVN-971 RESET KNOB.......................................................................... 1 137215-KVN-971 SEALING GASKET ................................................................. 1 137216-KVN-971 BULB GROMMET ................................................................... 1 137217-KVN-971 SCREW TAPPING 3X11.......................................................... 7 737300-KVN-970 CASE UPPER ASSY.,.............................................................. 1 137312-KVN-971 GROMMET, IGNITION ............................................................ 1 137400-KVN-971 CASE LOWER ASSY.,............................................................. 1 137500-KVN-971 METER COMP.,....................................................................... 1 180101-443-000 RUBBER, RR. FENDER CUSHION................................... .... 3 390525-030-000 WASHER, PLAIN..................................................................... 3 393901-42480 SCREW TAPPING 3X16 ......................................................... 10 1094001-06090-0S NUT HEX., 6MM...................................................................... 3 31234567891011121314151648F - 2SPEEDOMETER / CABLEFR.* METER ASSY., COMB. ....................... 0.3* SPEEDOMETER COMP.., ................... 0.5* TACHO METER COMP.. . .................... 0.5* CASE, COMP. UPPER.,.......................* CASE, COMP. LOWER.,...................... 0.4* SOCKET COMP., .................................* CABLE ASSY., SPEEDOMETER......... 0.221088614141616218131317Service Item F.R.T.17Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC34588889111215 1515151515 1515 151516
  45. 45. 16150-KTN-700 COVER, THROTTLE CABLE ................................................ 1 117910-KVN-900 CABLE COMP., THROTTLE.................................................. 1 117950-KVE-900 CABLE COMP., CHOKE ........................................................ 1 122870-KVN-900 CABLE COMP., CLUTCH ...................................................... 1 122871-KTN-700 BOOT, CLUTCH CABLE....................................................... 1 132161-404-000 BAND, B1 WIRE .................................................................... 2 235150-KVN-971 SWITCH ASSY., LIGHT START. ............................................ 1 135200-KVN-971 SWITCH ASSY., WINKER ..................................................... 1 135330-413-003 SWITCH COMP. FR. LEVER................................................. 1 145517-166-000 HOLDER MASTER CYLINDER............................................. 1 153140-KFN-850 GRIP, COMP., THROTTLE .................................................... 1 153166-KFN-850 GRIP, LEFT HANDLE ............................................................ 1 153172-KRC-900 BRACKET, HANDLE LEVER................................................. 1 153178-KFN-850 LEVER COMP. L HANDLE................................................... 1 153182-KFN-850 BOOT L. HANDLE COVER ................................................... 1 188110-AAK-H01ZA MIRROR ASSY., R. BACK (PANTHER BLACK ME )............. 1 188110-AAK-H01ZB MIRROR ASSY., R. BACK (EBONY GRAY ME).................... 1 188110-AAK-H01ZC MIRROR ASSY., R. BACK (FORCE SILVER ME) ................. 1 188110-AAK-H01ZD MIRROR ASSY., R. BACK (PEARL HARVEST GREEN) ...... 1 188110-AAK-H01ZE MIRROR ASSY., R. BACK (CANDY BLAZING RED) ............ 1 11234567891011121314151649* CABLE COMP., THROTTLE. ............... 0.3* CABLE COMP., CLUTCH..................... 0.2* SWITCH ASSY., LIGHTING ................. 0.4* SWITCH ASSY., WINKER.................... 0.5* SWITCH ASSY., FR. STOP.................. 0.1* GRIP COMP., THROTTLE ................... 0.1* GRIP L. HANDLE.................................* BRACKET, L HANDLE LEVER ............ 0.2* CABLE COMP., CHOKE ...................... 0.6Service Item F.R.T.F- 3HANDLE LEVER / SWITCH/CABLESFR.Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC11152821961062303017201620175121425324NNPPAASSSSIINNGG268122222929 19741318 1823 2327
  46. 46. 88110-KVN-970ZF MIRROR ASSY., R. BACK (MAPLE BROWN ME ) ............... 1 188110-KVN-970ZG MIRROR ASSY., R. BACK (SPORTS RED) .......................... 1 188114-198-D10 CAP, LOCK NUT..................................................................... 2 288115-KTR-900 BOOT, MIRROR UPPER........................................................ 2 288120-AAK-H01ZA MIRROR ASSY., L. BACK (PANTHER BLACK ME ).............. 1 188120-AAK-H01ZB MIRROR ASSY., L. BACK (EBONY GRAY ME) ..................... 1 188120-AAK-H01ZC MIRROR ASSY., L. BACK (FORCE SILVER ME) .................. 1 188120-AAK-H01ZD MIRROR ASSY., L. BACK (PEARL HARVEST GREEN )....... 1 188120-AAK-H01ZE MIRROR ASSY., L. BACK (CANDY BLAZING RED ) ........... 1 188120-AAK-H01ZF MIRROR ASSY., L. BACK (MAPLE BROWN ME )................. 1 188120-AAK-H01ZF MIRROR ASSY., L. BACK (SPORTS RED )........................... 1 190003-KCC-840 BOLT, ADAPTOR 10MM......................................................... 2 290113-438-000 BOLT, HANDLE LEVER PIVOT.............................................. 1 190140-KAE-000 SCREW, PAN 4X28................................................................ 2 290201-MW3-620 NUT, HEX 10 MM ................................................................... 2 293892-05020-07 SCREW, WASHER 5X20 ....................................................... 1 193892-05025-07 SCREW, WASHER 5X25 ....................................................... 1 193892-05035-07 SCREW, WASHER 5X35 ....................................................... 1 193892-05045-07 SCREW, WASHER 5X45 ....................................................... 1 116171819202122232425262750* CABLE COMP., THROTTLE. ............... 0.3* CABLE COMP., CLUTCH..................... 0.2* SWITCH ASSY., LIGHTING ................. 0.4* SWITCH ASSY., WINKER.................... 0.5* SWITCH ASSY., FR. STOP.................. 0.1* GRIP COMP., THROTTLE ................... 0.1* GRIP L. HANDLE.................................* BRACKET, L HANDLE LEVER ............ 0.2* CABLE COMP., CHOKE ...................... 0.6Service Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISCF- 3HANDLE LEVER / SWITCH/CABLESFR.11152821961062303017201620175121425324NNPPAASSSSIINNGG268122222929 19741318 1823 2327
  47. 47. 94050-06000 NUT, FLANGE 6 MM .............................................................. 1 194101-04700 WASHER, PLAIN 4MM........................................................... 2 296001-06022-07 BOLT, FLANGE SH. 6X22 ...................................................... 2 228293051* CABLE COMP., THROTTLE. ............... 0.3* CABLE COMP., CLUTCH..................... 0.2* SWITCH ASSY., LIGHTING ................. 0.4* SWITCH ASSY., WINKER.................... 0.5* SWITCH ASSY., FR. STOP.................. 0.1* GRIP COMP., THROTTLE ................... 0.1* GRIP L. HANDLE.................................* BRACKET, L HANDLE LEVER ............ 0.2* CABLE COMP., CHOKE ...................... 0.6Service Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISCF- 3HANDLE LEVER / SWITCH/CABLESFR.11152821961062303017201620175121425324NNPPAASSSSIINNGG268122222929 19741318 1823 2327
  48. 48. 35340-KCC-841 SW. ASSY., FR. STOP........................................................... 1 145126-KVE-900 HOSE COMP. FRONT BRAKE.............................................. 1 145155-KTN-710 CLAMPER A, FR. BRAKE HOSE.......................................... 1 145156-KVE-900 CLAMP B FRONT BRK. HOSE............................................. 1 145503-KCC-841 PISTON ................................................................................ 1 145504-KCC-841 BOOT COMP. ........................................................................ 1 145506-KCC-841 SPRING................................................................................. 1 145510-KVN-901 M/C SUB ASSY, FR BRK ...................................................... 1 145513-KCC-841 CAP MASTER CYL. .............................................................. 1 145515-KVN-901 GAUGE COMP., LEVEL ........................................................ 1 145516-KCC-841 O-RING.................................................................................. 1 145517-KCC-841 HOLDER, MASTER CYL....................................................... 1 145518-KCC-841 SEPARETOR COMP., ........................................................... 1 145519-KCC-841 SCREW, FLAT....................................................................... 2 245520-KCC-841 DIAPHRAGM......................................................................... 1 145521-KCC-841 PLATE, DIAPHRAGM............................................................ 1 145522-KCC-841 CLIP, GAUGE ........................................................................ 1 145525-KCC-841 PUSH ROD............................................................................ 1 145526-KCC-841 SPRING, PUSH ROD............................................................ 1 145530-KCC-841 CYLINDER SET MASTER .................................................... 1 1123456789101112131415161718192052FR.F- 3AFRONT BRAK MASTER CYL.3227272527272529491712310811221222241416151426212019187628135* DIAPHRAGM. ...................................... 0.1* LEVER, R STEERING HANDLE..........* SWITCH ASSY. FR. STOP. .................. 0.1* M/C, SUB ASSY, FR. BRK ................... 0.4* HOSE COMP. FR. BRK........................Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF
  49. 49. 53175-KSP-900 LEVER R. STRG. HDL.......................................................... 1 190111-KCC-841 BOLT, FLANGE 6X25 ............................................................ 2 290112-KCC-841 SCREW, PAN, 4X8................................................................ 1 190114-KCC-841 BOLT HANDLE, LEVER ........................................................ 1 190145-MS9-610 OIL, BOLT 10X22 .................................................................. 2 290303-KCC-841 NUT ....................................................................................... 1 190545-300-000 WASHER, OIL BOLT ............................................................. 4 490651-KCC-841 CIRCLIP ................................................................................ 1 196001-06012-07 BOLT, FLANGE SH. 6X12..................................................... 1 121222324252627282953FR.F- 3AFRONT BRAK MASTER CYL.3227272527272529491712310811221222241416151426212019187628135* DIAPHRAGM. ...................................... 0.1* LEVER, R STEERING HANDLE..........* SWITCH ASSY. FR. STOP. .................. 0.1* M/C, SUB ASSY, FR. BRK ................... 0.4* HOSE COMP. FR. BRK........................Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF
  50. 50. 12345678910111213141516171819205435010-AAK-H01 KEY, SET............................................................................... 1 135100-AAK-H00 SWITCH ASSY., COMB & LOCK .......................................... 1 135113-KZJ-H00 EMBLEM ICON ..................................................................... 135114-KZJ-H00 EMBLEM WORD MARK ....................................................... 135121-KZJ-H00 KEY, BLANK NO.1 ................................................................ 1 135122-KZJ-H00 KEY, BLANK NO.2 ................................................................ (1) (1)53100-KVE-930Z PIPE, STEERING HANDLE .................................................. 1 153105-KRC-900 END, STEERING HANDLE.................................................. 2 25313A-AAK-H70 HOLDER, HANDLE UPPER SUB. ASSY.,............................ 1 153132-124-000 HOLDER, HANDLE PIPE UNDER........................................ 2 253133-198-900 RUBBER, HANDLE CUSHION UPPER................................ 2 253134-028-000 RUBBER, HANDLE CUSHION UNDER .............................. 2 253135-198-900 WASHER, HANDLE CUSHION ............................................ 2 253136-198-900 PLATE, HANDLE CUSHION................................................. 2 253230-KTN-700 BRIDGE, COMP., FORK TOP............................................... 1 190102-KVN-900 BOLT SPL., FLANGE SOCKET 6X22................................... 4 490304-GA6-000 NYLOCK NUT 10 MM ........................................................... 2 290304-KSP-900 NUT, STEERING STEM........................................................ 1 190503-KTR-900 WASHER, STEERING STEM ............................................... 1 191455-MG8-000 CAP, SOCKET BOLT 6MM.................................................... 4 4F- 4HANDLE PIPE / TOP BRIDGE* HOLDER, HANDLE UNDER................ 0.2(ADD 0.1 FOR EACH.) .........................* PIPE STRG. HANDLE ......................... 0.5* BRIDGE COMP., FORK TOP............... 0.7* SWITCH ASSY., COMBINATION & LOCK* KEY SET .............................................. 1.12178211821317121213151111101418191714101616163691620202020FR.Service Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC54
  51. 51. 215596700-08020-00 BOLT, SOCKET 8 MM........................................................... 2 2F- 4HANDLE PIPE / TOP BRIDGE* HOLDER, HANDLE UNDER................ 0.2(ADD 0.1 FOR EACH.) .........................* PIPE STRG. HANDLE ......................... 0.5* BRIDGE COMP., FORK TOP............... 0.7* SWITCH ASSY., COMBINATION & LOCK* KEY SET .............................................. 1.1FR.Service Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC217821182131712121315111110141819171410161616369162020202054
  52. 52. 50301-KTR-900 RACE, (STRG. TOP), BALL................................................. 2 253200-KTN-700 STEM, COMP. STRG ........................................................... 1 153211-268-010 RACE, (STRG. TOP) CONE ................................................ 1 153212-200-000 RACE, (STRG. BOTTOM) CONE ........................................ 1 153214-200-000 DUST, SEAL, STRG. HEAD................................................. 1 153215-KTR-900 BALL, ASSY., STRG............................................................. 2 253216-KVE-900 PLATE, WIRE HARNESS GUIDE ........................................ 1 153221-KSP-900 THREAD, STRG. TOP ......................................................... 1 153222-KRM-860 MUD, GUARD STRG. (HEAD TOP)..................................... 1 195701-08035-07 BOLT, FLANGE 8X35........................................................... 2 296001-06012-07 BOLT, FLANGE SH. 6X12.................................................... 1 196211-08000 BALL, STEEL 8 MM ............................................................. 16 1696700-06012-07 BOLT, SOCKET 6X12........................................................... 1 196700-06020-07 BOLT, SOCKET 6X20........................................................... 1 1123456789101112131456F - 5STRG. STEM*RACE, STEERING BALL...................... 1.0(SAME TIME FOR TWO UNITS)..........*STEM COMP., STEERING ................... 1.1*RACE, STEERING TOP CONE............ 0.6*THREAD, STRG. TOP .........................64152813912106127111310 14Service Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELFFR.
  53. 53. 57F - 6FRONT FENDERFR.*FENDER FRONT.................................. 0.3 61100-KVN-970ZA FENDER, FR. (PANTHER BLACK METALLIC).............. ..... 1 161100-KVN-970ZB FENDER, FR. (EBONY GRAY METALLIC).......................... 1 161100-KVN-970ZC FENDER, FR. (FORCE SILVER METALLIC)....................... 1 161100-KVN-970ZD FENDER, FR. (PEARL HARVEST GREEN).................. ...... 1 161100-KVN-970ZE FENDER, FR. (CANDY BLAZING RED).............................. 1 161100-KVN-970ZF FENDER, FR. (MAPLE BROWN METALLIC)................ ...... 1 161100-KVN-970ZG FENDER, FR. (SPORTS RED)....................................... .....61200-KVN-970ZA COVER, R. FR. FENDER (PANTHER BLACK METALLIC).. 1 161200-KVN-970ZB COVER, R. FR. FENDER (EBONY GRAY METALLIC)........ 1 161200-KVN-970ZC COVER, R. FR. FENDER (FORCE SILVER METALLIC)..... 1 161200-KVN-970ZD COVER, R. FR. FENDER (PEARL HARVEST GREEN)...... 1 161200-KVN-970ZE COVER, R. FR. FENDER (CANDY BLAZING RED)............ 1 161200-KVN-970ZF COVER, R. FR. FENDER (MAPLE BROWN METALLIC).... 1 161200-KVN-970ZG COVER, R. FR. FENDER (SPORTS RED).......................... 1 161300-KVN-970ZA COVER, L. FR. FENDER (PANTHER BLACK METALLIC).. 1 161300-KVN-970ZB COVER, L. FR. FENDER (EBONY GRAY METALLIC)........ 1 161300-KVN-970ZC COVER, L. FR. FENDER (FORCE SILVER METALLIC)..... 1 161300-KVN-970ZD COVER, L. FR. FENDER (PEARL HARVEST GREEN)....... 1 161300-KVN-970ZE COVER, L. FR. FENDER (CANDY BLAZING RED)............. 1 161300-KVN-970ZF COVER, L. FR. FENDER (MAPLE BROWN METALLIC)..... 1 1123Service Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC106510410651012377889999
  54. 54. 58F - 6FRONT FENDERFR.*FENDER FRONT.................................. 0.3 61300-KVN-970ZG COVER L. FR. FENDER (SPORTS RED).............................. 1 161102-KVN-900 STAY, FR. FENDER............................................................... 1 161103-KRY-900 COLLAR A FR. FENDER..................................................... 4 461105-KTC-900 RUBBER, FR. FENDER MOUNTING.................................... 4 490106-KRY-970 SCREW FAIRING 5X11.5).................................................... 2 290320-GC3-000 NUT SPRING M5.................................................................. 2 29390334320 SCREW TAPPING 4X12....................................................... 4 496001-06032-00 BOLT, FLANGE SH. 6X32.............................. ...................... 4 4345678910Service Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC106510410651012377889999
  55. 55. 12345678910111213141516171819205951400-KVN-971 FORK ASSY., R FRONT...................................................... 1 151401-KSP-901 SPRING FR. FORK............................................................... 1 151410-KVN-901 PIPE COMP., FR. FORK....................................................... 1 151412-KSP-901 SPRING, REBOUND ............................................................ 1 151412-KFN-851 RING, BACK UP ................................................................... 1 151420-KVN-971 CASE ,COMP., R FR. BOTTOM ......................................... 1 151432-KFN-851 PIECE, OIL LOCK................................................................. 1 151437-KVN-901 RING, PISTON...................................................................... 1 151440-KVN-901 PIPE, SEAT........................................................................... 1 151500-KVN-971 FORK ASSY., L. FRONT....................................................... 1 151520-KVN-971 CASE, COMP., L. FR. BOTTOM .......................................... 1 190116-KAG-900 BOLT, SOCKET 8 MM........................................................... 1 190123-KSP-901 BOLT, A FR. FORK.............................................................. 1 190123-KRM-860 BOLT, FRONT FORK ............................................................ 2 290521-292-000 WASHER, PLAIN 10.3 MM ................................................... 2 290544-KFN-851 WASHER, SPECIAL 8 MM ................................................... 1 190601-KFN-851 RING, OIL SEAL STOP......................................................... 1 191254-GAA-003R SEAL, DUST ......................................................................... 1 191255-GAA-003R SEAL, OIL 31X43X10.3 ........................................................ 1 191356-KAG-900 O-RING ................................................................................. 1 1F - 7FRONT FORKFR.*FORK ASSY., L. FR. ............................. 0.4(ADD 0.1 FOR EACH) ..........................*FORK ASSY., R. . .................................* SPRING, FR. FORK............................. 0.6(ADD 0.3 FOR EACH) ..........................* PIPE COMP., FR. FORK...................... 0.7(ADD 0.4 FOR EACH) ..........................* CASE COMP., L. FR. BOTTOM........... 0.8* (ADD 0.5 FOR EACH)..........................* CASE COMP., R. FR. BOTTOM ..........* SEAL SET, FR. FORK..........................(ADD 0.5 FOR EACH) ..........................1101415237489121651819171320116Service Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC
  56. 56. 123456789101112131460F - 8CALIPER ASSY ‘R’ FR06451-KCC-841 SEAL, SET PISTON.............................................................. 2 206455-KCC-841 PAD SET FR.......................................................................... 1 143216-MAK-003 CLIP ...................................................................................... 1 145107-KCC-841 PISTON 26 ............................................................................ 2 245108-KCC-841 SPRING PAD......................................................................... 1 145132-KCC-841 BUSH, BOOT PIN ................................................................. 1 145133-KCC-841 BOOT B................................................................................. 1 145200-KCC-841 CALIPER ,ASSY., R FR. ...................................................... 1 145220-KCC-841 PIN COMP., HANGER........................................................... 1 145250-KCC-841 CALIPER, SUB ASSY., R FR............................................... 1 145290-KCC-841 BRKT., SUB ASSY., FR. ........................................................ 1 145352-KCC-841 SCREW, BLEEDER .............................................................. 1 145353-KCC-841 CAP, BLEEDER..................................................................... 1 190155-KY4-900 BOLT, FLANGE 8X25............................................................ 2 2* PAD SET, FRONT. ............................... 0.2* PISTON, 26.......................................... 0.5(ADD. 0.1 FOR EACH)(INC. RELATIVE PART)* CALIPER ASSY., R. FR........................ 0.414146121313159441081172R.FService Item F.R.T. Ref. Part No. Description Reqd. No./Model HUNKNo. DISCKICK SELF
  57. 57. *TUBE, TYRE (2.75-18). ........................ 0.9* TYRE, FR. (2.75-18-42P).....................* AXLE, FR. WHEEL............................... 0.3* COLLAR, FRONT DISTANCE.............. 0.4* GEAR BOX ASSY., SPDMT................. 0.3* DISC. FR. BRAKE................................* BEARING, RADIAL BALL(ADD. 0.1 FOR EACH)42704-MER-D00 WEIGHT, BALANCE 10......................................................... - 142705-MER-D00 WEIGHT, BALANCE 20 ........................................................ - 142706-MER-D00 WEIGHT, BALANE 30 ........................................................... - 142753-KWF-901 RIM, VALVE .......................................................................... - 144301-KSP-900 AXLE, FR. WHEEL ............................................................... - 144311-KRC-900 COLLAR, FR. WHEEL SIDE................................................. - 144601-AAK-H71 WHEEL, FRONT .................................................................. - 144620-400-000 COLLAR, FRONT DISTANCE............................................... - 144680-KSP-B00 RETAINER GEAR BOX......................................................... - 144711-KRY-971 TYRE, FR. ............................................................................ - 144800-KVN-971 SENSOR ASSY., SPEED...................................................... - 144818-KSP-B00 CLAMPER B SPEEDOMETER CORD ................................. - 145164-KVN-970 CLAMPER, SP SENSOR...................................................... - 145251-KSP-861 DISC, FR. BRAKE................................................................. - 153216-KVN-970 STAY CLAMPER ................................................................... - 190105-KL8-741 BOLT, FR. DISK 8X24........................................................... - 690306-KF0-000 NUT, FLANGE 12MM............................................................ - 191251-KPH-901 DUST SEAL, 21X37X7.......................................................... - 191258-KWC-901 DUST SEAL, 40X50X5.......................................................... - 196150-63010-10 BEARING, BALL RADIAL 6301 (UU).................................... - 261123456789101112131415161718F - 9FRONT WHEELFR3151771861816121414141414451814Service Item F.R.T.11 91013Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC2
  58. 58. 42313-240-000 COLLAR, RR. BRAKE PANEL SIDE .................................... 1 -43100-KRY-930 PANEL, COMP. RR BRAKE ................................................. 1 -43125-KTN-701 SHOE ,COMP., BRK. ........................................................... 2 -43145-149-000 INDICATOR, RR. BRAKE..................................................... 1 -43410-KRY-930 ARM, REAR BRAKE............................................................. 1 -43434-ME1-670 RUBBER, STOPPER ARM................................................... 1 -45133-KCC-900 SPRING, FR. BRAKE SHOE................................................ 2 -45134-250-000 BRAKE, CAM DUST SEAL................................................... 1 -45141-KTC-900 CAM FR. BRAKE.................................................................. 1 -90301-473-000 NUT, U 6MM ......................................................................... 1 -90505-425-000 WASHER 8 MM .................................................................... 1 -92811-10000 BOLT A BRAKE STOPPER................................................. 1 -94001-08000-0S NUT, HEX. 8MM ................................................................... 1 -94201-20150 PIN, SPLIT 2X15 MM ........................................................... 1 -95701-06035-00 BOLT, FLANGE 6X35 ........................................................... 1 -12345678910111213141562F - 10REAR BRAKE PANEL*PANEL COMP., RR. BRAKE................. 0.5* SHOE COMP., BRAKE......................... 0.4(ONE OR ALL)* ARM, RR. BRAKE ................................ 0.1(INC. RELATIVE PART)15101591214131162377843FRService Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC
  59. 59. 43155-KRY-970 CLAMPER, RR. BRAKE HOSE.............................................. - 243310-KVN-970 HOSE COMP, RR. BRAKE..................................................... - 143503-MEE-006 CONNECTOR......................................................................... - 143504-MB2-006 BOOT COMP., ........................................................................ - 143510-KRY-971 SUB ASSY., REAR M/C.......................................................... - 143511-KW7-881 OIL CUP COMP...................................................................... - 143512-KVN-971 HOSE COMP., REAR M/C...................................................... - 143514-KS6-701 CLAMP, M/C OIL HOSE ......................................................... - 243520-MJ6-315 PISTON SET. M/C .................................................................. - 143530-MV9-006 PUSH ROD COMP., ............................................................... - 145513-GW0-911 CAP MASTER CYLINDER ..................................................... - 145520-GW0-911 DIAPHRAGM.......................................................................... - 145521-GW0-911 PLATE, DIAPHRAGM............................................................. - 146182-MEL-D21 CIRCLIP ................................................................................. - 146504-KV6-702 JOINT BRK., ROD.................................................................. - 190103-MCS-G00 BOLT, FLANGE SH. 6X12 ...................................................... - 290145-MS9-610 OIL BOLT, 10X22.................................................................... - 290545-300-000 WASHER, OIL BOLT .............................................................. - 491212-422-006 O-RING 14- 8X2.4 .................................................................. - 193600-04045-1G SCREW FLAT 4X45 ............................................................... - 2RF.F - 10A* REAR BRAKE MASTER CYL................... 0.1* DIAPHRAGM. ......................................* HOSE COMP., REAR BRAKE. ................. 0.4* CYL. SUB ASSY., REAR BRAKE MASTER.* CYLINDER SET, MASTER ................... .631234567891011121314151617181920REAR BRAKE MASTER CYL.2321616171718181826271467889101112131415192120202213525182427Service Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC
  60. 60. 93893-04012-17L SCREW WASH, 4X12 ................................................. - 194002-08000-0S NUT, HEX 8MM............................................................ - 194201-20150 PIN. SPLIT, 2.0X15...................................................... - 194305-20102 PIN, SPRING 2X10...................................................... - 195015-54000 PIN D, JOINT............................................................... - 195701-06012-08 BOLT, FLANGE-6X12 .................................................. - 195701-06022-08 BOLT, FLANGE 6X22 .................................................. - 2RF.F - 10A6421222324252627REAR BRAKE MASTER CYL.2321616171718181826271467889101112131415192120202213525182427* REAR BRAKE MASTER CYL................... 0.1* DIAPHRAGM. ......................................* HOSE COMP., REAR BRAKE. ................. 0.4* CYL. SUB ASSY., REAR BRAKE MASTER.* CYLINDER SET, MASTER ................... .Service Item F.R.T. Ref. Part No. Description Reqd. No./ Model HUNKNo. SELFDRUM DISC
  1. A particular slide catching your eye?

    Clipping is a handy way to collect important slides you want to go back to later.

×