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Yamaha YZF-R1(4C81) Parts Catalog

Yamaha motorcycle parts catalogue.
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YZF-R1
(4C81)
EUROPE, SOUTH AFRICA
1F4C8-300E1
(
)
2F4C8-300E1
A
2

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Table of Contents

   Summary of Contents for Yamaha YZF-R1(4C81)

  • Page 1 YZF-R1 (4C81) EUROPE, SOUTH AFRICA 1F4C8-300E1 2F4C8-300E1...
  • Page 2 YZF-R1 PARTS CATALOGUE ©2006 by Yamaha Motor Co., Ltd. 1st edition, October 2006 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan.
  • Page 3 This Parts Catalogue is related to the parts for the model(s) on the cover page. When you are ordering replacement parts, please refer to this Parts Catalogue and quote both part numbers and part names correctly. 1. Modifications or additions which have been made after the issue of the Parts Catalogue will be announced in the Parts News.
  • Page 4 7. Applicable Serial No. Engine Serial No. Frame Serial No. 8. Applicable Colour Code (The (*) mark shows Model colour.) Abbreviation Colour Name BWC1(*) BLUISH WHITE COCKTAIL 1 DBNM8 DARK BLUISH GRAY METALLIC 8 DPBMC(*) DEEP PURPLISH BLUE METALLIC C LOW GLOSS BLACK MBL2 MAT BLACK 2...
  • Page 5 (1) A label called “Model Label” is affixed in the location as indicated in (3) below. When using this parts catalogue, please be sure to cross–reference the “model code – production code No.” in the catalogue with the “model code – production code No.” indi- cated on the Model Label affixed onto the product concerned.
  • Page 6: Table Of Contents

    ENGINE CYLINDER HEAD ... B2 CYLINDER ... B4 CRANKSHAFT & PISTON ... B5 VALVE ... B6 CAMSHAFT & CHAIN ... B8 WATER PUMP ... B9 RADIATOR & HOSE ... B11 OIL PUMP ... B13 OIL CLEANER ... B14 INTAKE ... B15 INTAKE 2 ...
  • Page 7: Cylinder Head

    FIG. 1 CYLINDER HEAD REF. PART NO. DESCRIPTION 1 4C8–11101–00 CYLINDER HEAD ASSY 2 4C8–11133–10 .GUIDE, VALVE 1 3 4C8–11134–10 .GUIDE, VALVE 2 4 90340–18002 .PLUG, STRAIGHT SCREW 5 91808–16023 .PIN, DOWEL 6 91808–16023 .PIN, DOWEL 7 91808–16023 .PIN, DOWEL 8 90105–06027 .BOLT, FLANGE 9 95024–06012...
  • Page 8 FIG. 1 CYLINDER HEAD REF. PART NO. DESCRIPTION REMARKS 28 99530–10114 PIN, DOWEL...
  • Page 9: Cylinder 1

    FIG. 2 CYLINDER REF. PART NO. DESCRIPTION 1 5VY–11311–10 CYLINDER 1 2 5VY–11351–00 GASKET, CYLINDER 3 99530–10114 PIN, DOWEL REMARKS...
  • Page 10: Crankshaft & Piston

    FIG. 3 CRANKSHAFT & PISTON REF. PART NO. DESCRIPTION 1 4C8–11411–00 CRANKSHAFT 2 4C8–11650–00 CONNECTING ROD ASSY 3 5VY–11654–01 .BOLT, CONNECTING ROD 4 4C8–11656–00 PLANE BEARING, CONNECTING ROD 4C8–11656–10 PLANE BEARING, CONNECTING ROD 4C8–11656–20 PLANE BEARING, CONNECTING ROD 4C8–11656–30 PLANE BEARING, CONNECTING ROD 5 5VY–11549–00 SPROCKET, CAM CHAIN 6 5VY–11416–A0...
  • Page 11: Valve

    FIG. 4 VALVE REF. PART NO. DESCRIPTION 1 4C8–12111–00 VALVE, INTAKE 2 4C8–12121–00 VALVE, EXHAUST 3 4C8–12116–00 SEAT, VALVE SPRING 4 4C8–12113–00 SPRING, VALVE INNER 5 4C8–12114–00 SPRING, VALVE OUTER 6 4C8–12117–00 RETAINER, VALVE SPRING 7 4C8–12127–00 RETAINER, VALVE SPRING 8 1AA–12118–00 COTTER, VALVE 9 1WG–12118–00...
  • Page 12 FIG. 4 VALVE REF. PART NO. DESCRIPTION 12 3LD–12169–T0 PAD, ADJUSTING (2.40) 13 4C8–12153–20 LIFTER, VALVE 4C8–12153–30 LIFTER, VALVE 4C8–12153–09 LIFTER, VALVE (O/S) REMARKS UR BLUE UR RED AP GREEN...
  • Page 13: Camshaft & Chain

    FIG. 5 CAMSHAFT & CHAIN REF. PART NO. DESCRIPTION 1 4C8–12170–00 CAMSHAFT ASSY 1 2 4C8–12180–00 CAMSHAFT ASSY 2 3 4C8–12176–00 SPROCKET, CAM CHAIN 4 90105–07006 BOLT, FLANGE 5 94591–60124 CHAIN 6 4C8–12210–00 TENSIONER ASSY, CAM CHAIN 7 2D1–12213–00 GASKET, TENSIONER CASE 8 90110–06106 BOLT, HEXAGON SOCKET HEAD 9 4C8–12251–00...
  • Page 14: Water Pump

    FIG. 6 WATER PUMP REF. PART NO. DESCRIPTION 1 5VY–12469–00 JOINT 1 2 5VY–12576–00 HOSE 1 3 90450–38040 HOSE CLAMP ASSY 4 93210–47675 O-RING 5 95024–06025 BOLT, FLANGE 6 5VY–12637–00 STAY 1 7 4C8–12420–00 WATER PUMP ASSY 8 93306–00106 .BEARING 9 93102–12372 .OIL SEAL 10 4C8–12438–00...
  • Page 15 FIG. 6 WATER PUMP REF. PART NO. DESCRIPTION 28 5VY–12481–10 PIPE 1 29 93210–235A1 O-RING 30 93210–27370 O-RING 31 5VY–12588–00 HOSE 5 32 90467–200A0 CLIP 33 90450–32001 HOSE CLAMP ASSY 34 90110–06161 BOLT, HEXAGON SOCKET HEAD 35 4C8–12484–00 PIPE 4 36 90430–06014 .GASKET 37 90153–06002...
  • Page 16: Radiator & Hose

    FIG. 7 RADIATOR & HOSE REF. PART NO. DESCRIPTION 1 4C8–12485–00 PIPE 5 2 4C8–1243A–00 HOSE 1 3 90467–11090 CLIP 4 93210–235A1 O-RING 5 90110–06168 BOLT, HEXAGON SOCKET HEAD 6 90450–35001 HOSE CLAMP ASSY 7 5VY–12410–10 THERMOSTAT ASSY 8 5LP–12411–00 .THERMOSTAT 9 93210–49046 .O-RING...
  • Page 17 FIG. 7 RADIATOR & HOSE REF. PART NO. DESCRIPTION 28 90450–35001 HOSE CLAMP ASSY 29 4C8–12659–00 DAMPER, AIR SHROUD 2 30 4C8–12668–00 DAMPER, AIR SHROUD 3 31 5SL–12462–00 CAP, RADIATOR 32 90387–0700G COLLAR 33 91317–06030 BOLT 34 90201–06071 WASHER, PLATE 35 90201–06074 WASHER, PLATE 36 95827–06030...
  • Page 18: Oil Pump

    FIG. 8 OIL PUMP REF. PART NO. DESCRIPTION 1 94580–25078 CHAIN (DID25 78LE) 2 4C8–13410–00 STRAINER HOUSING ASSY 3 93210–22298 O-RING 4 90480–13010 GROMMET 5 5VY–13117–10 COLLAR, DISTANCE 6 90110–06173 BOLT, HEXAGON SOCKET HEAD 7 5VY–13416–00 PIPE, OIL 1 8 93210–14003 O-RING 9 90110–06161 BOLT, HEXAGON SOCKET HEAD...
  • Page 19: Oil Cleaner

    FIG. 9 OIL CLEANER REF. PART NO. DESCRIPTION 1 90401–20145 BOLT, UNION 2 5GH–13440–20 ELEMENT ASSY, OIL CLEANER 3 5VY–13490–00 RELIEF VALVE ASSY 4 93210–15566 O-RING 5 4C8–13417–00 COVER, STRAINER 6 90340–14132 .PLUG, STRAIGHT SCREW 7 214–11198–01 .GASKET 8 99530–08012 PIN, DOWEL 9 4C8–13414–00 GASKET, STRAINER COVER...
  • Page 20: Intake

    FIG. 10 INTAKE REF. PART NO. DESCRIPTION 1 4C8–13595–00 JOINT 2 90450–62002 HOSE CLAMP ASSY 3 4C8–13596–00 JOINT, CARBURETOR 2 4 90450–62002 HOSE CLAMP ASSY 5 4C8–13598–00 JOINT, CARBURETOR 4 6 90450–62002 HOSE CLAMP ASSY 7 2C0–13881–00 COVER 1 8 4C8–14411–00 CASE, AIR CLEANER 1 9 4C8–14462–00 SEAL...
  • Page 21 FIG. 10 INTAKE REF. PART NO. DESCRIPTION REMARKS 28 91312–06016 BOLT...
  • Page 22 FIG. 11 INTAKE 2 REF. PART NO. DESCRIPTION 1 4C8–13750–00 THROTTLE BODY ASSY 2 8A7–14139–00 .CLIP, PIPE 3 895–14169–00 .CAP 4 4C8–13761–00 .INJECTOR ASSY 5 5PS–14147–00 ..O-RING 6 8FP–13556–00 .GASKET, MANIFOLD 7 4C8–82386–00 .EXTENSION, WIRE HARNESS 8 4KM–14137–00 .CLIP 9 5JW–14987–00 .HOSE 10 2C0–14105–00 .PILOT SCREW SET...
  • Page 23: Air Induction System

    FIG. 12 AIR INDUCTION SYSTEM REF. PART NO. DESCRIPTION 1 4C8–14840–00 AIR CUT VALVE ASSY 2 4C8–14881–00 HOSE, BEND 1 3 4C8–14882–00 HOSE, BEND 2 4 90467–18172 CLIP 5 4C8–14883–00 HOSE, BEND 3 6 90467–18172 CLIP 7 90467–180A0 CLIP 8 90467–17128 CLIP 9 90464–28003 CLAMP...
  • Page 24: Exhaust

    FIG. 13 EXHAUST REF. PART NO. DESCRIPTION 1 4C8–14610–00 EXHAUST PIPE ASSY 1 2 4C8–14602–00 .EXHAUST PIPE COMP. 3 4C8–14615–00 .JOINT, EXHAUST 1 4 5VY–14816–00 .PLUG, BLIND 5 5VY–14638–00 .COLLAR 6 5VY–14623–00 .GASKET, EXHAUST PIPE 7 5VY–14821–00 .ARM, SHAFT (VALVE) 8 5VY–14811–00 .HOUSING 9 5VY–14865–10...
  • Page 25 FIG. 13 EXHAUST REF. PART NO. DESCRIPTION 28 90201–06079 .WASHER, PLATE 29 90387–06188 .COLLAR 30 4FM–24181–00 .DAMPER, LOCATING 1 31 4C8–8592A–00 .SENSOR 32 4C8–21880–00 .STAY ASSY. ,1 33 90111–08021 .BOLT,HEX. SOCKET BUTTON 34 90480–12021 .GROMMET 35 4C8–14710–00 MUFFLER ASSY 1 36 5VY–14714–00 .GASKET, MUFFLER 37 90105–08063...
  • Page 26 FIG. 13 EXHAUST REF. PART NO. DESCRIPTION 55 90387–08020 COLLAR 56 95814–08045 BOLT, FLANGE 57 90201–08034 WASHER, PLATE 58 95604–08200 NUT, U FLANGE 59 4C8–1133E–00 CABLE, PULLEY 1 60 4C8–1133F–00 CABLE, PULLEY 2 61 4C8–14718–00–P0 PROTECTOR, MUFFLER 1 62 90387–062L2 COLLAR 63 90111–06038 BOLT,HEX.
  • Page 27: Crankcase

    FIG. 14 CRANKCASE REF. PART NO. DESCRIPTION 1 4C8–15100–00 CRANKCASE ASSY 2 5EB–15155–00 .NOZZLE 3 3 93210–04092 .O-RING 4 99530–10014 .PIN, DOWEL 5 5VY–13418–10 PIPE, OIL 2 6 93210–14003 O-RING 7 90110–06161 BOLT, HEXAGON SOCKET HEAD 8 90116–10032 BOLT, STUD 9 90116–10023 BOLT, STUD 10 90119–09003...
  • Page 28: Crankcase Cover 1

    FIG. 15 CRANKCASE COVER 1 REF. PART NO. DESCRIPTION 1 5VY–15411–00 COVER, CRANKCASE 1 2 93306–20124 BEARING 3 93605–10108 PIN, DOWEL 4 5VY–15164–00 HOUSING, BEARING 2 5 5VY–15542–00 COLLAR 2 6 90149–06064 SCREW 7 90201–06431 WASHER, PLATE 8 5PX–15189–00 PLUG 9 93210–22382 O-RING 10 2D1–15451–10...
  • Page 29 FIG. 15 CRANKCASE COVER 1 REF. PART NO. DESCRIPTION 28 90340–32004 PLUG, STRAIGHT SCREW 29 93210–32172 O-RING 30 90430–08143 GASKET 31 92014–08016 BOLT, BUTTON HEAD 32 4C8–15456–00 GASKET, OIL PUMP COVER 1 33 90109–06014 BOLT 34 5VY–11165–00 PLATE, BREATHER 35 90110–06182 BOLT, HEXAGON SOCKET HEAD 36 4C8–15441–00 HOLDER, CLUTCH CABLE...
  • Page 30 FIG. 15 CRANKCASE COVER 1 REF. PART NO. DESCRIPTION REMARKS 55 91380–06014 BOLT...
  • Page 31: Starter

    FIG. 16 STARTER REF. PART NO. DESCRIPTION 1 2D1–11537–00 GEAR, DRIVEN 2 5VY–16155–00 ABSORBER 1 3 90201–20016 WASHER, PLATE 4 5VY–11478–00 COLLAR 5 5VY–15570–00 STARTER CLUTCH ASSY 6 5VY–15586–00 PLATE, STARTER CLUTCH ASSY 7 5VY–15515–00 GEAR 3 8 5VY–11445–00 SPACER 9 90201–20017 WASHER, PLATE 10 93210–18397...
  • Page 32: Clutch

    FIG. 17 CLUTCH REF. PART NO. DESCRIPTION 1 2D1–16382–00 AXLE, PUSH LEVER 2 92907–08600 WASHER, PLATE 3 99001–07600 CIRCLIP 4 93317–11096 BEARING 5 93102–15212 OIL SEAL 6 93315–21570 BEARING 7 4C8–16150–00 PRIMARY DRIVEN GEAR COMP. 8 4C8–16154–00 PLATE, THRUST 1 9 90208–25002 WASHER, CONICAL SPRING 10 4C8–16360–00...
  • Page 33 FIG. 17 CLUTCH REF. PART NO. DESCRIPTION 25 4B1–16325–00 PLATE, CLUTCH 2 26 4C8–16377–00 NUT, LOCK 27 93310–232R9 BEARING 28 4XV–16356–01 ROD, PUSH 1 29 4C8–16340–00 PUSH LEVER ASSY 30 90508–16041 SPRING, TORSION 31 90201–10029 WASHER, PLATE 32 99009–10400 CIRCLIP 33 5VY–16164–00 PLATE, THRUST 2 34 5VY–16181–00...
  • Page 34: Transmission

    FIG. 18 TRANSMISSION REF. PART NO. DESCRIPTION 1 4C8–17411–00 AXLE, MAIN (15T) 2 90387–28003 COLLAR 3 4C8–17151–00 GEAR, 5TH PINION (22T) 4 90209–25011 WASHER 5 93440–28184 CIRCLIP 6 2D1–17131–00 GEAR, 3RD PINION (21/23T) 7 90387–25007 COLLAR 8 4C8–17161–00 GEAR, 6TH PINION (26T) 9 2D1–17121–10 GEAR, 2ND PINION (16T) 10 5VY–15163–00...
  • Page 35 FIG. 18 TRANSMISSION REF. PART NO. DESCRIPTION 28 90214–28002 WASHER, CLAW 29 5VY–17231–00 GEAR, 3RD WHEEL (37T) 30 4C8–17251–00 GEAR, 5TH WHEEL (30T) 31 90387–25008 COLLAR 32 5VY–17211–00 GEAR,1ST WHEEL (38T) 33 93102–40330 OIL SEAL 34 93440–62032 CIRCLIP 35 4C8–17460–00 SPROCKET,DRIVE (17T) 36 90201–22015 WASHER, PLATE...
  • Page 36: Shift Cam & Fork

    FIG. 19 SHIFT CAM & FORK REF. PART NO. DESCRIPTION 1 5VY–18540–00 SHIFT CAM ASSY 2 136–18542–00 .POINT, NEUTRAL 3 93306–00106 BEARING 4 5VY–18511–01 FORK, SHIFT 1 5 2D1–18512–00 FORK, SHIFT 2 6 5VY–18513–01 FORK, SHIFT 3 7 5VY–18531–00 BAR, SHIFT FORK GUIDE 1 8 5VY–18535–00 BAR, SHIFT FORK GUIDE 2 9 90501–064L1...
  • Page 37: Shift Shaft

    FIG. 20 SHIFT SHAFT REF. PART NO. DESCRIPTION 1 5VY–18144–00 HANGER, SPRING 2 132–16346–00 HOOK, SPRING 3 5VY–18140–00 STOPPER LEVER ASSY 4 90387–0804S COLLAR 5 5VY–18127–10 STOPPER, SCREW 6 93317–11295 BEARING 7 93102–12106 OIL SEAL (SD 12-22-5 HS) 8 99002–10600 CIRCLIP 9 90201–12575 WASHER, PLATE...
  • Page 38: Frame

    FIG. 21 FRAME REF. PART NO. DESCRIPTION 1 4C8–2116J–00 BRACKET 7 2 90480–14005 GROMMET 3 90387–063E6 COLLAR 4 95022–06020 BOLT, FLANGE 5 90201–06M31 WASHER, PLATE 6 95024–06012 BOLT, FLANGE 7 4C8–21110–00 FRAME COMP. 8 4C8–21190–00 REAR FRAME COMP. 9 5VY–21268–00 SEAL 10 5VY–21269–00 SEAL...
  • Page 39 FIG. 21 FRAME REF. PART NO. DESCRIPTION 28 90338–14007 PLUG 29 90338–17004 PLUG 30 90338–23004 PLUG 31 90338–08008 PLUG 32 5VY–21131–00 BRACKET 33 95822–06016 BOLT, FLANGE 34 4C8–2117M–00 COVER 2 35 4C8–2174X–00 DAMPER 36 4C8–21746–00 DAMPER 37 4C8–2139X–00 DAMPER 38 90464–10008 CLAMP 39 2C0–8258J–00 HOUSING, CONNECTEUR 1...
  • Page 40 FIG. 21 FRAME REF. PART NO. DESCRIPTION 55 4C8–2113D–00 .SHEET, 3 56 90109–06043 BOLT 57 90111–05002 BOLT,HEX. SOCKET BUTTON 58 90269–06012 RIVET 59 4C8–24121–00 SEAT, KNEE GRIP 1 60 4C8–24122–00 SEAT, KNEE GRIP 2 61 5SL–84753–00 DAMPER REMARKS...
  • Page 41 FIG. 22 FENDER REF. PART NO. DESCRIPTION 1 5PW–21511–00–P1 FENDER, FRONT 5PW–21511–00–P6 FENDER, FRONT 5PW–21511–00–PB FENDER, FRONT 2 90480–12072 GROMMET 3 90387–065J6 COLLAR 4 90111–06043 BOLT,HEX. SOCKET BUTTON 5 90111–06030 BOLT,HEX. SOCKET BUTTON 6 95707–06500 NUT, FLANGE 7 4C8–8212B–00 BOX, BATTERY 1 8 133–82131–00 BAND, BATTERY 9 4C8–21649–00...
  • Page 42: Fender

    FIG. 22 FENDER REF. PART NO. DESCRIPTION 24 5VY–21669–00 SEAL 25 90465–04020 CLAMP 26 4C8–21639–00 DAMPER 2 27 4C8–21735–00 SEAL 2 28 5VY–21732–00 SEAL 1 29 5PW–21732–00 SEAL 1 30 90269–06081 RIVET 31 90269–06081 RIVET 32 90269–07077 RIVET 33 90465–04020 CLAMP 34 90464–13073 CLAMP...
  • Page 43 FIG. 22 FENDER REF. PART NO. DESCRIPTION 51 4C8–27498–00 .SEAT 1 52 4C8–27499–00 .SEAT 2 53 92017–05012 BOLT, BUTTON HEAD 54 90111–05011 BOLT,HEX. SOCKET BUTTON 55 4C8–28100–00 TOOL KIT REMARKS...
  • Page 44: Side Cover

    FIG. 23 SIDE COVER REF. PART NO. DESCRIPTION 1 4C8–21710–00–P0 SIDE COVER ASSY 1 4C8–21710–00–P1 SIDE COVER ASSY 1 4C8–Y2171–00–P2 COVER, SIDE 1 2 5PW–2174X–00 .DAMPER 3 90338–06018 .PLUG 4 4C8–21747–00 .DAMPER 5 4C8–2172P–00 .SEAT 6 4C8–2173P–00 .SEAT 7 90338–08236 .PLUG 8 4KN–2836B–00 .TUNING FORK MARK...
  • Page 45: Rear Arm

    FIG. 24 REAR ARM REF. PART NO. DESCRIPTION 1 4C8–22110–00 REAR ARM COMP. 2 90101–08013 BOLT 3 95302–08600 4 90201–08057 WASHER, PLATE 5 4C8–22184–00 BUSH 6 93317–52865 BEARING 7 93317–428U8 BEARING 8 5VY–22128–00 COVER, THRUST 1 9 4C8–22128–00 COVER, THRUST 1 10 90201–22019 WASHER, PLATE 11 4C8–22151–00...
  • Page 46 FIG. 24 REAR ARM REF. PART NO. DESCRIPTION 28 90105–10017 BOLT, FLANGE 29 95602–10200 NUT, U FLANGE 30 90387–1012A COLLAR 31 90387–1013U COLLAR 32 90105–10021 BOLT, FLANGE 33 95602–10200 NUT, U FLANGE 34 90387–1012A COLLAR 35 90105–10017 BOLT, FLANGE 36 95602–10200 NUT, U FLANGE 37 2C0–21566–00 TAPE, 1...
  • Page 47: Rear Suspension

    FIG. 25 REAR SUSPENSION REF. PART NO. DESCRIPTION 1 4C8–22210–00 SHOCK ABSORBER ASSY, REAR 2 93315–31758 .BEARING 3 93109–17071 .OIL SEAL 4 90105–10018 BOLT, FLANGE 5 95602–10200 NUT, U FLANGE 6 4C8–22219–00 BRACKET, UPPER 7 4C8–22127–00 SHIM 8 95602–14200 NUT, SELF-LOCKING REMARKS...
  • Page 48: Steering

    FIG. 26 STEERING REF. PART NO. DESCRIPTION 1 93399–99932 BEARING 2 3FV–23462–00 SEAL, STEERING 3 4XV–23415–01 COVER, BALL RACE 1 4 90179–30691 5 4XV–23418–00 WASHER, SPECIAL 6 90202–30235 WASHER, PLATE 7 90170–28419 8 90201–281U8 WASHER, PLATE 9 4C8–23435–00 CROWN, HANDLE 10 91314–08030 BOLT 11 4XV–2341B–00...
  • Page 49: Front Fork

    FIG. 27 FRONT FORK REF. PART NO. DESCRIPTION 1 4C8–23102–00 FRONT FORK ASSY (L.H) 4C8–23102–10 FRONT FORK ASSY (L.H) 2 4C8–23136–00 .TUBE, OUTER 4C8–23136–10 .TUBE, OUTER 3 5PW–23146–00 ..WASHER, OIL SEAL 4 4PU–23145–01 ..OIL SEAL 5 4V4–23153–L0 ..RING, SNAP 6 4PU–23144–00 ..SEAL, DUST 7 4C8–23110–00 .INNER TUBE COMP.1...
  • Page 50 FIG. 27 FRONT FORK REF. PART NO. DESCRIPTION 24 4PU–23144–00 ..SEAL, DUST 25 4C8–23120–00 .INNER TUBE COMP.2 26 4C8–23170–00 .CYLINDER COMP., FRONT FORK 27 509–23158–L0 .GASKET 28 5UX–23181–00 .BOLT, HEXAGON SOCKET HEAD 29 4C8–23141–00 .SPRING, FRONT FORK 30 5VY–12277–00 .WASHER 31 5VY–23118–00 .SPACER 32 3SP–23357–L0...
  • Page 51: Fuel Tank

    FIG. 28 FUEL TANK REF. PART NO. DESCRIPTION 1 4C8–YK241–00–P0 FUEL TANK COMP. 4C8–YK241–00–P1 FUEL TANK COMP. 4C8–Y2410–00–01 FUEL TANK COMP. 2 4C8–24245–00 .GRAPHIC, FUEL TANK 2 3 91312–06016 BOLT 4 5VY–24183–00 DAMPER, LOCATING 3 5 5VY–24191–00 BRACKET, FUEL TANK 1 6 5VY–24181–00 DAMPER, LOCATING 1 7 90480–10542...
  • Page 52 FIG. 28 FUEL TANK REF. PART NO. DESCRIPTION 26 90461–08003 CLAMP 27 90154–05012 SCREW, BINDING 28 5JW–24486–00 O-RING 29 90110–05014 BOLT, HEXAGON SOCKET HEAD 30 5VY–24312–00 PIPE 2 31 4C8–24316–00 PIPE 6 32 90467–09006 CLIP 33 4C8–2171A–00–P0 COVER, TOP 4C8–2171A–00–P5 COVER, TOP 4C8–2171A–00–P2 COVER, TOP...
  • Page 53 FIG. 28 FUEL TANK REF. PART NO. DESCRIPTION 51 4C8–2414H–00 DAMPER, PLATE 1 52 4C8–2414P–00 DAMPER, PLATE 5 53 5PW–2411J–01 DAMPER, SIDE COVER 54 90159–05015 SCREW, WITH WASHER 55 4C8–2414K–00 DAMPER, PLATE 3 56 5VY–2414R–00 DAMPER, PLATE 6 57 5SL–2413B–00 EMBLEM 58 4C8–21568–00 LABEL, WARNING...
  • Page 54: Seat

    FIG. 29 SEAT REF. PART NO. DESCRIPTION 1 4C8–24710–00 SINGLE SEAT ASSY 4C8–24710–10 SINGLE SEAT ASSY 2 4C8–24711–00 .COVER, SINGLE SEAT 4C8–24711–10 .COVER, SINGLE SEAT 3 90110–06258 BOLT, HEXAGON SOCKET HEAD 4 4C8–24750–00 TANDEM SEAT ASSY 4C8–24750–10 TANDEM SEAT ASSY 5 4C8–24751–00 .COVER, TANDEM SEAT 4C8–24751–10...
  • Page 55: Front Wheel

    FIG. 30 FRONT WHEEL REF. PART NO. DESCRIPTION 1 5VY–25168–00–98 CAST WHEEL, FRONT 5VY–25168–00–0X CAST WHEEL, FRONT 2 4XV–25117–00 SPACER, BEARING 3 93306–07208 BEARING 4 93106–28043 OIL SEAL TIRE(120/70 ZR17 M/C 58W) TIRE(120/70 ZR17M/C 58W PILOT) 6 93900–00030 VALVE, RIM (TR412) 7 5MT–25398–00 BALANCER, WHEEL (10G) 5MT–25398–10...
  • Page 56: Front Brake Caliper

    FIG. 31 FRONT BRAKE CALIPER REF. PART NO. DESCRIPTION 1 4C8–2581T–00 DISK BRAKE ASSY 2 90149–06043 SCREW 3 4C8–2580T–00 CALIPER ASSY (LEFT) 4 4C8–W0057–00 .PISTON ASSY, CALIPER 5 4C8–W0047–00 ..CALIPER SEAL KIT 6 4C8–W0045–00 .BRAKE PAD KIT 7 4SV–25924–00 .PIN, PAD 8 4C8–25919–00 .SUPPORT, PAD 9 4C8–25919–10...
  • Page 57: Rear Wheel

    FIG. 32 REAR WHEEL REF. PART NO. DESCRIPTION 1 5VY–25338–00–98 CAST WHEEL, REAR 5VY–25338–00–0X CAST WHEEL, REAR 2 93306–20531 BEARING 3 93106–40013 OIL SEAL 4 93317–43580 BEARING 5 93420–61M07 CIRCLIP 6 5PW–25317–00 SPACER, BEARING 7 4XV–25383–00 COLLAR, WHEEL 8 2C0–25364–00 DAMPER TIRE (190/50 ZR17 M/C 73W) TIRE(190/50 ZR17M/C 73W PILOT)
  • Page 58 FIG. 32 REAR WHEEL REF. PART NO. DESCRIPTION 24 90110–05030 .BOLT, HEXAGON SOCKET HEAD 25 5VY–25389–00 PULLER, CHAIN 2 26 4C8–25381–00 AXLE, WHEEL 27 90185–24007 NUT, SELF-LOCKING 28 90201–25020 WASHER, PLATE 29 94582–10118 CHAIN (DID50VA8-118LL) 30 94682–05031 .JOINT, CHAIN (DID 50VA8-ZJ) REMARKS...
  • Page 59: Rear Brake Caliper

    FIG. 33 REAR BRAKE CALIPER REF. PART NO. DESCRIPTION 1 5SL–2582W–00 DISK, REAR BRAKE 2 2 90149–08009 SCREW 3 5VY–2580W–11 CALIPER ASSY, REAR 2 4 5VY–W0057–00 .PISTON ASSY, CALIPER 5 5SL–W0047–00 ..CALIPER SEAL KIT 6 5SL–25917–00 .BOOT, CALIPER 7 5SL–25838–00 .SLEEVE, CALIPER 8 5SL–25919–00 .SUPPORT, PAD...
  • Page 60: Steering Handle & Cable

    FIG. 34 STEERING HANDLE & CABLE REF. PART NO. DESCRIPTION 1 5VY–26121–00 HANDLEBAR (LEFT) 2 5VY–26122–00 HANDLEBAR (RIGHT) 3 4XV–23434–00 HOLDER, DAMPER 4 5PW–26246–00 END, GRIP 5 91317–06025 BOLT 6 91312–06025 BOLT 7 91312–08030 BOLT 8 2H9–23469–00 CAP, BOLT 9 2C0–26241–00 GRIP 10 4C8–26240–00 GRIP ASSY...
  • Page 61: Front Master Cylinder

    FIG. 35 FRONT MASTER CYLINDER REF. PART NO. DESCRIPTION 1 5SL–W2587–00 MASTER CYLINDER SUB ASSY 2 5VY–W0041–00 .CYLINDER KIT, MASTER 3 5VY–W0048–00 .BLEED SCREW KIT 4 5VY–25975–00 ..SEAL 1 5 5VY–2589F–01 BOLT, LEVER 6 5VS–2586F–00 NUT, COVER 7 5SL–83922–10 LEVER 2 8 4HM–83980–00 FRONT STOP SWITCH ASSY 9 5VS–2585H–00...
  • Page 62: Stand & Footrest

    FIG. 36 STAND & FOOTREST REF. PART NO. DESCRIPTION 1 5VY–27311–01 STAND, SIDE 2 5JJ–27321–00 BRACKET, SIDE STAND 3 4NX–27351–00 GUIDE, SIDE STAND 4 5PW–27352–00 HOOK, SIDE STAND 5 90506–18008 SPRING, TENSION 6 90445–19002 HOSE (L60) 7 90201–081R9 WASHER, PLATE 8 90101–08662 BOLT 9 95607–10200...
  • Page 63 FIG. 36 STAND & FOOTREST REF. PART NO. DESCRIPTION 28 91401–25015 PIN, COTTER 29 90109–083E0 BOLT 30 90201–08103 WASHER, PLATE 31 4C8–2144G–00 STAY, STOP SWITCH 32 90480–12607 GROMMET 33 90387–06023 COLLAR 34 90159–06150 SCREW, WITH WASHER 35 4C8–27446–00 PLATE 2 36 90111–06064 BOLT,HEX.
  • Page 64 FIG. 36 STAND & FOOTREST REF. PART NO. DESCRIPTION 55 4C8–27490–00 PROTECTOR ASSY 56 90387–0603J .COLLAR 57 90183–05024 .NUT, SPRING 58 90183–05076 .NUT, SPRING 59 4C8–2749A–00 .SEAT 3 60 4C8–2749B–00 .SEAT 4 61 4C8–2749D–00 .SEAT 6 62 4C8–21486–00 .DAMPER 2 63 4C8–21488–00 .DAMPER 64 92012–06012...
  • Page 65: Rear Master Cylinder

    FIG. 37 REAR MASTER CYLINDER REF. PART NO. DESCRIPTION 1 4C8–27211–00 PEDAL, BRAKE 2 4C8–27434–00 BOLT 3 90506–20193 SPRING, TENSION 4 90446–15386 HOSE 5 4C8–27813–00 PIN, PEDAL CRANK 6 4C8–2583V–00 RR. MASTER CYLINDER ASSY. 7 5VX–W0042–60 .CYLINDER KIT, MASTER 8 3LN–2585G–00 ..CIRCLIP 9 2D1–2582A–00 .JOINT...
  • Page 66 FIG. 37 REAR MASTER CYLINDER REF. PART NO. DESCRIPTION REMARKS 28 90119–05019 BOLT, WITH WASHER...
  • Page 67: Cowling 1

    FIG. 38 COWLING 1 REF. PART NO. DESCRIPTION 1 4C8–Y2881–00 WINDSHIELD 2 4C8–28428–00 .SEAL 1 3 4C8–28429–00 .SEAL 2 4 4C8–2844E–00 .SEAL 3 5 4C8–2846F–00 .SEAL 4 6 4C8–2847F–00 .SEAL 5 7 4C8–2848F–00 .SEAL 6 8 4C8–2832P–00 .GRAPHIC 18 9 4C8–2835G–00–P0 BODY, FRONT UPPER 1 4C8–2835G–00–P1 BODY, FRONT UPPER 1...
  • Page 68 FIG. 38 COWLING 1 REF. PART NO. DESCRIPTION 26 90160–05006 SCREW, ROUND TAPPING 27 90160–05007 SCREW, ROUND TAPPING 28 4C8–2838N–00–P0 DUCT 1 4C8–2838N–00–P1 DUCT 1 4C8–2838N–00–P2 DUCT 1 29 4C8–2834E–00 DAMPER 3 30 1FK–2171H–00 GUIDE 31 5VY–2834V–00 PROTECTOR 1 32 4C8–28371–00 DAMPER 33 4C8–2838R–00–P0 DUCT 2...
  • Page 69 FIG. 38 COWLING 1 REF. PART NO. DESCRIPTION 49 4C8–2837W–00 GRILL, AIR OUTLET 2 50 5PW–2177L–00 PLATE, SPRING 51 90269–06001 RIVET 52 4C8–26280–00 REAR VIEW MIRROR ASSY (LEFT) 53 4C8–26290–00 REAR VIEW MIRROR ASSY (RIGHT) 54 4C8–26298–00 PLATE, MIRROR FITTING 1 55 90387–064T3 COLLAR 56 90176–06055...
  • Page 70 FIG. 39 COWLING 2 REF. PART NO. DESCRIPTION 1 4C8–Y283U–00–P0 PANEL ASSEMBLY 1 4C8–Y283U–10–P1 PANEL ASSEMBLY 1 4C8–Y283U–20–P2 PANEL ASSEMBLY 1 2 5PW–2177L–00 .PLATE, SPRING 3 4C8–28219–00 .COVER 1 4 90183–05M02 .NUT, SPRING 5 4C8–28425–00 .DAMPER 3 6 4C8–28435–00 .DAMPER 4 7 4C8–28217–00 .DAMPER 1 8 4C8–2117V–00–P0...
  • Page 71 .SEAT 3 31 4C8–2837J–00 .DAMPER 5 32 5TA–21749–00 .COLLAR 33 4C8–28415–00 .DAMPER 1 34 4C8–28416–00 .DAMPER 2 35 4C8–2153E–00 .EMBLEM, YAMAHA 4C8–2153E–10 .EMBLEM, YAMAHA 4C8–2153E–20 .EMBLEM, YAMAHA 36 4C8–Y2809–00–P0 COVER ASSY 2, UNDER 4C8–Y2809–10–P1 COVER ASSY 2, UNDER 4C8–Y2809–20–P2 COVER ASSY 2, UNDER...
  • Page 72 38 90480–12596 .GROMMET 39 90387–065J6 .COLLAR 40 4C8–2848M–00 .SEAT 4 41 4C8–2848P–00 .SEAT 6 42 5TA–21749–00 .COLLAR 43 4C8–2153E–00 .EMBLEM, YAMAHA 4C8–2153E–10 .EMBLEM, YAMAHA 4C8–2153E–20 .EMBLEM, YAMAHA 44 5PW–28386–00 HEAD 45 2TK–21757–00 WASHER, SPECIAL 1 46 4C8–2836A–00 BRACKET 1 47 4C8–2836E–00 BRACKET 2 48 90109–06056...
  • Page 73 FIG. 39 COWLING 2 REF. PART NO. DESCRIPTION 62 5PW–2177L–00 PLATE, SPRING 63 90119–06052 BOLT, WITH WASHER 64 90464–13077 CLAMP REMARKS...
  • Page 74: Generator

    FIG. 40 GENERATOR REF. PART NO. DESCRIPTION 1 5VY–81450–00 ROTOR ASSY 2 2D1–81410–01 STATOR ASSY 3 90149–06067 SCREW 4 4C8–15191–00 PLATE 5 90105–06078 BOLT, FLANGE REMARKS...
  • Page 75: Starting Motor

    FIG. 41 STARTING MOTOR REF. PART NO. DESCRIPTION 1 4C8–81890–00 MOTOR ASSY 2 4C8–81801–00 .BRUSH SET 3 93210–25711 .O-RING 4 4C8–81846–00 .SCREW 5 95302–06700 .NUT 6 90201–05021 .WASHER, PLATE 7 4C8–81861–00 .GASKET 8 4C8–8183G–00 CORD COMP. 9 95302–06700 10 95022–06040 BOLT, FLANGE REMARKS...
  • Page 76: Flasher Light

    FIG. 42 FLASHER LIGHT REF. PART NO. DESCRIPTION 1 2C0–83310–00 FRONT FLASHER LIGHT ASSY 1 2 2C0–83311–00 .BULB, FLASHER (12V-10W) 3 2C0–8333A–00 .LENS COMP 4 97702–40010 .SCREW, TAPPING 5 2C0–83320–00 FRONT FLASHER LIGHT ASSY 2 6 2C0–83311–00 .BULB, FLASHER (12V-10W) 7 2C0–8334A–00 .LENS COMP 8 97702–40010...
  • Page 77: Meter

    FIG. 43 METER REF. PART NO. DESCRIPTION 1 4C8–83500–00 SPEEDOMETER ASSY (KM/H) 4C8–83500–10 SPEEDOMETER ASSY (MPH) 2 4C8–8353E–00 .CASE, METER UPPER 3 5VY–83572–01 .CASE, SPEEDOMETER LOWER 4 5PW–8352S–00 .SCREW, PANEL FTTING 5 90160–05006 SCREW, ROUND TAPPING REMARKS FOR GBR...
  • Page 78: Headlight

    FIG. 44 HEADLIGHT REF. PART NO. DESCRIPTION 1 4C8–84303–00 HEADLIGHT UNIT ASSY 4C8–84303–20 HEADLIGHT UNIT ASSY 2 4SV–84314–00 BULB (12V-55W) 3 4SV–84347–00 BULB (12V-5W) 4 5SL–84397–00 COVER, SOCKET 5 5GJ–84397–00 COVER, SOCKET 6 4C8–84196–00 COVER, SOCKET 7 4C8–84312–00 CORD ASSY 8 90269–06008 RIVET 9 4SV–84350–00...
  • Page 79: Taillight

    FIG. 45 TAILLIGHT REF. PART NO. DESCRIPTION 1 4C8–84710–00 TAILLIGHT UNIT ASSY 2 90269–06081 RIVET 3 5PW–84717–00 CORD, TAILLIGHT 4 4C8–21629–00 GUARD, MUD 5 5VX–84745–01 LICENCE LIGHT UNIT ASSY 6 4HC–84744–00 .BULB (12V-5W) 7 97706–04012 .SCREW, TAPPING 8 95602–05100 NUT, U 9 90159–05011 SCREW, WITH WASHER 10 3Y6–85130–02...
  • Page 80: Handle Switch & Lever

    FIG. 46 HANDLE SWITCH & LEVER REF. PART NO. DESCRIPTION 1 4XV–82910–15 LEVER HOLDER ASSY (LEFT) 2 4XV–83912–11 .LEVER 1 3 2C0–83945–00 .BOLT, LEVER 4 95607–06200 .NUT, SELF U-FLANGE 5 95027–06020 .BOLT, FLANGE 6 5LV–83951–00 .BOLT, CABLE ADJUSTING 7 4XV–82917–01 .SWITCH 8 98707–03016 .SCREW, FLAT HEAD...
  • Page 81: Electrical 1

    FIG. 47 ELECTRICAL 1 REF. PART NO. DESCRIPTION 1 90201–12790 WASHER, PLATE 2 8CC–85790–01 THERMOSENSOR ASSY 3 2D1–81673–00 ROTOR 4 90282–03001 KEY, STRAIGHT 5 90201–10039 WASHER, PLATE 6 90105–10290 BOLT, FLANGE 7 5VY–85820–10 SERVO MOTOR ASSY 8 4C8–85829–00 COVER, SERVO MOTOR 9 97702–50514 SCREW, TAPPING 10 4C8–1479P–00...
  • Page 82 FIG. 47 ELECTRICAL 1 REF. PART NO. DESCRIPTION 28 4C8–15589–00 PLATE, CLUTCH COVER 29 90110–06161 BOLT, HEXAGON SOCKET HEAD 30 90465–08054 CLAMP 31 5VY–85896–00 SENSOR, CAM POSITION 32 90110–06175 BOLT, HEXAGON SOCKET HEAD REMARKS...
  • Page 83 FIG. 48 ELECTRICAL 2 REF. PART NO. DESCRIPTION 1 1D0–81940–02 STARTER RELAY ASSY 2 36Y–82151–00 .FUSE (15A-BL) 3 5PS–82576–01 LEAN ANGLE SENSOR 4 91312–04025 BOLT 5 90201–047A2 WASHER, PLATE 6 90183–04039 NUT, SPRING 7 5VK–81950–30 RELAY ASSY 8 4C8–83350–00 FLASHER RELAY ASSY 9 90109–080G5 BOLT 10 4TH–83371–00...
  • Page 84 FIG. 48 ELECTRICAL 2 REF. PART NO. DESCRIPTION 28 5VY–82100–00 BATTERY ASSY (YUASA YTZ10S) 29 4C8–82590–00 WIRE HARNESS ASSY 30 5JJ–82151–70 .FUSE (25A-BL) 31 5JJ–82151–10 .FUSE (15A-BL) 32 5JJ–82151–00 .FUSE (7.5A-BL) 33 5JW–82151–10 .FUSE (50A) 34 5EA–81950–20 RELAY ASSY 35 5EA–81952–00 .HOLDER, RELAY 36 1D7–81960–00 RECTIFIER &...
  • Page 85: Numerical Index

    GRID GRID PART NO. PART NO. 4C8–11101–00 B – 3LD–12168–R1 B – 5VY–1111G–00 B – 3LD–12168–U1 B – 4C8–11133–10 B – 3LD–12168–W1 B – 4C8–11134–10 B – 3LD–12168–Y1 B – 5VY–11165–00 C – 10 3LD–12169–11 B – 4C8–11181–00 B – 3LD–12169–31 B –...
  • Page 86 GRID GRID PART NO. PART NO. 4C8–2110M–10 D – 4C8–2163A–00 D – 4C8–2110N–00 D – 4C8–2163E–00 D – 4C8–2110P–00 D – 4C8–21649–00 D – 4C8–21110–00 D – 4C8–2164F–00 D – 4C8–2111D–00 D – 4C8–2164K–00 D – 4C8–2112B–00 D – 4C8–2164L–00 D –...
  • Page 87 GRID GRID PART NO. PART NO. 5VY–27442–01 E – 15 4C8–2838N–00–P1 F – 4C8–27443–00 E – 15 4C8–2838N–00–P2 F – 4C8–27445–00 E – 15 4C8–2838R–00–P0 F – 4C8–27446–00 F – 4C8–2838R–00–P1 F – 5JJ–27461–00 E – 15 4C8–2838R–00–P2 F – 4C8–27463–00 G –...
  • Page 88 GRID GRID PART NO. PART NO. 90111–06064 F – 90183–05074 E – 90111–08021 C – 90183–05076 D – 90111–08038 F – D – 11 90111–08058 C – D – 12 90116–10023 C – F – 90116–10032 C – F – 90116–10485 E –...
  • Page 89 GRID GRID PART NO. PART NO. 92012–06012 F – 93306–20124 C – 92012–06014 B – 12 93306–20230 C – 12 92012–06016 D – 12 93306–20531 E – 10 92014–06012 C – 93306–205A2 D – 92014–06014 C – 93306–20652 C – 15 92014–08016 C –...

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