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Yamaha YZF-R1 Parts Catalog

Manual is about: 2001

Summary of YZF-R1

  • Page 1

    1f4c8-300e1 2f4c8-300e1 ( ) a 2 yzf-r1 (4c81) europe, south africa.

  • Page 2

    A 3 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

    A 4 foreword 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 ...

  • Page 4

    A 5 foreword 7. Applicable serial no. Engine serial no. Frame serial no. 8. Applicable colour code (the (*) mark shows model colour.) abbreviation colour name colour code bwc1(*) bluish white cocktail 1 0390 dbnm8 dark bluish gray metallic 8 0919 dpbmc(*) deep purplish blue metallic c 0564 lgb low g...

  • Page 5

    A 6 model label (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...

  • Page 6

    Contents engine cylinder head ................................................................. B2 cylinder ............................................................................ B4 crankshaft & piston .................................................... B5 valve .................................

  • Page 7

    B 2 fig. 1 cylinder head ref. No. Part no. Description 4c 81 remarks 1 4c8–11101–00 cylinder head assy 1 2 4c8–11133–10 .Guide, valve 1 8 3 4c8–11134–10 .Guide, valve 2 8 4 90340–18002 .Plug, straight screw 3 5 91808–16023 .Pin, dowel 2 6 91808–16023 .Pin, dowel 2 7 91808–16023 .Pin, dowel 2 8 90105...

  • Page 8

    B 3 fig. 1 cylinder head ref. No. Part no. Description 4c 81 remarks 28 99530–10114 pin, dowel 2.

  • Page 9

    B 4 fig. 2 cylinder ref. No. Part no. Description 4c 81 remarks 1 5vy–11311–10 cylinder 1 1 2 5vy–11351–00 gasket, cylinder 1 3 99530–10114 pin, dowel 2.

  • Page 10

    B 5 fig. 3 crankshaft & piston ref. No. Part no. Description 4c 81 remarks 1 4c8–11411–00 crankshaft 1 2 4c8–11650–00 connecting rod assy 4 3 5vy–11654–01 .Bolt, connecting rod 2 4 4c8–11656–00 plane bearing, connecting rod 8 ur red-blue 4c8–11656–10 plane bearing, connecting rod 8 ur red-black 4c8–...

  • Page 11

    B 6 fig. 4 valve ref. No. Part no. Description 4c 81 remarks 1 4c8–12111–00 valve, intake 8 2 4c8–12121–00 valve, exhaust 8 3 4c8–12116–00 seat, valve spring 16 4 4c8–12113–00 spring, valve inner 8 5 4c8–12114–00 spring, valve outer 8 6 4c8–12117–00 retainer, valve spring 8 7 4c8–12127–00 retainer, ...

  • Page 12

    B 7 fig. 4 valve ref. No. Part no. Description 4c 81 remarks 12 3ld–12169–t0 pad, adjusting (2.40) 16 ur 13 4c8–12153–20 lifter, valve 16 ur blue 4c8–12153–30 lifter, valve 16 ur red 4c8–12153–09 lifter, valve (o/s) 16 ap green.

  • Page 13

    B 8 fig. 5 camshaft & chain ref. No. Part no. Description 4c 81 remarks 1 4c8–12170–00 camshaft assy 1 1 2 4c8–12180–00 camshaft assy 2 1 3 4c8–12176–00 sprocket, cam chain 2 4 90105–07006 bolt, flange 4 5 94591–60124 chain 1 6 4c8–12210–00 tensioner assy, cam chain 1 7 2d1–12213–00 gasket, tensione...

  • Page 14

    B 9 fig. 6 water pump ref. No. Part no. Description 4c 81 remarks 1 5vy–12469–00 joint 1 1 2 5vy–12576–00 hose 1 1 3 90450–38040 hose clamp assy 1 4 93210–47675 o-ring 1 5 95024–06025 bolt, flange 3 6 5vy–12637–00 stay 1 1 7 4c8–12420–00 water pump assy 1 8 93306–00106 .Bearing 2 9 93102–12372 .Oil ...

  • Page 15

    B 10 fig. 6 water pump ref. No. Part no. Description 4c 81 remarks 28 5vy–12481–10 pipe 1 1 29 93210–235a1 o-ring 1 30 93210–27370 o-ring 1 31 5vy–12588–00 hose 5 1 32 90467–200a0 clip 1 33 90450–32001 hose clamp assy 1 34 90110–06161 bolt, hexagon socket head 1 35 4c8–12484–00 pipe 4 1 36 90430–060...

  • Page 16

    B 11 fig. 7 radiator & hose ref. No. Part no. Description 4c 81 remarks 1 4c8–12485–00 pipe 5 1 2 4c8–1243a–00 hose 1 1 3 90467–11090 clip 2 4 93210–235a1 o-ring 1 5 90110–06168 bolt, hexagon socket head 1 6 90450–35001 hose clamp assy 1 7 5vy–12410–10 thermostat assy 1 8 5lp–12411–00 .Thermostat 1 ...

  • Page 17

    B 12 fig. 7 radiator & hose ref. No. Part no. Description 4c 81 remarks 28 90450–35001 hose clamp assy 1 29 4c8–12659–00 damper, air shroud 2 1 30 4c8–12668–00 damper, air shroud 3 2 31 5sl–12462–00 cap, radiator 1 32 90387–0700g collar 1 33 91317–06030 bolt 1 34 90201–06071 washer, plate 1 35 90201...

  • Page 18

    B 13 fig. 8 oil pump ref. No. Part no. Description 4c 81 remarks 1 94580–25078 chain (did25 78le) 1 2 4c8–13410–00 strainer housing assy 1 3 93210–22298 o-ring 1 4 90480–13010 grommet 1 5 5vy–13117–10 collar, distance 1 6 90110–06173 bolt, hexagon socket head 3 7 5vy–13416–00 pipe, oil 1 1 8 93210–1...

  • Page 19

    B 14 fig. 9 oil cleaner ref. No. Part no. Description 4c 81 remarks 1 90401–20145 bolt, union 1 2 5gh–13440–20 element assy, oil cleaner 1 3 5vy–13490–00 relief valve assy 1 4 93210–15566 o-ring 1 5 4c8–13417–00 cover, strainer 1 6 90340–14132 .Plug, straight screw 1 7 214–11198–01 .Gasket 1 8 99530...

  • Page 20

    B 15 fig. 10 intake ref. No. Part no. Description 4c 81 remarks 1 4c8–13595–00 joint 1 2 90450–62002 hose clamp assy 1 3 4c8–13596–00 joint, carburetor 2 1 4 90450–62002 hose clamp assy 2 5 4c8–13598–00 joint, carburetor 4 1 6 90450–62002 hose clamp assy 1 7 2c0–13881–00 cover 1 1 8 4c8–14411–00 cas...

  • Page 21

    C 2 fig. 10 intake ref. No. Part no. Description 4c 81 remarks 28 91312–06016 bolt 7.

  • Page 22

    C 3 fig. 11 intake 2 ref. No. Part no. Description 4c 81 remarks 1 4c8–13750–00 throttle body assy 1 2 8a7–14139–00 .Clip, pipe 4 3 895–14169–00 .Cap 4 4 4c8–13761–00 .Injector assy 4 5 5ps–14147–00 ..O-ring 1 6 8fp–13556–00 .Gasket, manifold 4 7 4c8–82386–00 .Extension, wire harness 1 8 4km–14137–0...

  • Page 23

    C 4 fig. 12 air induction system ref. No. Part no. Description 4c 81 remarks 1 4c8–14840–00 air cut valve assy 1 2 4c8–14881–00 hose, bend 1 1 3 4c8–14882–00 hose, bend 2 1 4 90467–18172 clip 2 5 4c8–14883–00 hose, bend 3 1 6 90467–18172 clip 1 7 90467–180a0 clip 2 8 90467–17128 clip 1 9 90464–28003...

  • Page 24

    C 5 fig. 13 exhaust ref. No. Part no. Description 4c 81 remarks 1 4c8–14610–00 exhaust pipe assy 1 1 2 4c8–14602–00 .Exhaust pipe comp. 1 3 4c8–14615–00 .Joint, exhaust 1 1 4 5vy–14816–00 .Plug, blind 1 5 5vy–14638–00 .Collar 2 6 5vy–14623–00 .Gasket, exhaust pipe 1 7 5vy–14821–00 .Arm, shaft (valve...

  • Page 25

    C 6 fig. 13 exhaust ref. No. Part no. Description 4c 81 remarks 28 90201–06079 .Washer, plate 4 29 90387–06188 .Collar 4 30 4fm–24181–00 .Damper, locating 1 1 31 4c8–8592a–00 .Sensor 1 32 4c8–21880–00 .Stay assy. ,1 1 33 90111–08021 .Bolt,hex. Socket button 1 34 90480–12021 .Grommet 4 35 4c8–14710–0...

  • Page 26

    C 7 fig. 13 exhaust ref. No. Part no. Description 4c 81 remarks 55 90387–08020 collar 2 56 95814–08045 bolt, flange 2 57 90201–08034 washer, plate 2 58 95604–08200 nut, u flange 2 59 4c8–1133e–00 cable, pulley 1 1 60 4c8–1133f–00 cable, pulley 2 1 61 4c8–14718–00–p0 protector, muffler 1 1 mbl2 62 90...

  • Page 27

    C 8 fig. 14 crankcase ref. No. Part no. Description 4c 81 remarks 1 4c8–15100–00 crankcase assy 1 2 5eb–15155–00 .Nozzle 3 4 3 93210–04092 .O-ring 4 4 99530–10014 .Pin, dowel 3 5 5vy–13418–10 pipe, oil 2 1 6 93210–14003 o-ring 2 7 90110–06161 bolt, hexagon socket head 2 8 90116–10032 bolt, stud 7 9 ...

  • Page 28

    C 9 fig. 15 crankcase cover 1 ref. No. Part no. Description 4c 81 remarks 1 5vy–15411–00 cover, crankcase 1 1 2 93306–20124 bearing 1 3 93605–10108 pin, dowel 2 4 5vy–15164–00 housing, bearing 2 1 5 5vy–15542–00 collar 2 1 6 90149–06064 screw 3 7 90201–06431 washer, plate 3 8 5px–15189–00 plug 1 9 9...

  • Page 29

    C 10 fig. 15 crankcase cover 1 ref. No. Part no. Description 4c 81 remarks 28 90340–32004 plug, straight screw 1 29 93210–32172 o-ring 1 30 90430–08143 gasket 1 31 92014–08016 bolt, button head 1 32 4c8–15456–00 gasket, oil pump cover 1 1 33 90109–06014 bolt 6 34 5vy–11165–00 plate, breather 1 35 90...

  • Page 30

    C 11 fig. 15 crankcase cover 1 ref. No. Part no. Description 4c 81 remarks 55 91380–06014 bolt 2.

  • Page 31

    C 12 fig. 16 starter ref. No. Part no. Description 4c 81 remarks 1 2d1–11537–00 gear, driven 1 2 5vy–16155–00 absorber 1 3 3 90201–20016 washer, plate 1 4 5vy–11478–00 collar 1 5 5vy–15570–00 starter clutch assy 1 6 5vy–15586–00 plate, starter clutch assy 1 7 5vy–15515–00 gear 3 1 8 5vy–11445–00 spa...

  • Page 32

    C 13 fig. 17 clutch ref. No. Part no. Description 4c 81 remarks 1 2d1–16382–00 axle, push lever 1 2 92907–08600 washer, plate 1 3 99001–07600 circlip 1 4 93317–11096 bearing 1 5 93102–15212 oil seal 1 6 93315–21570 bearing 1 7 4c8–16150–00 primary driven gear comp. 1 8 4c8–16154–00 plate, thrust 1 1...

  • Page 33

    C 14 fig. 17 clutch ref. No. Part no. Description 4c 81 remarks 25 4b1–16325–00 plate, clutch 2 1 ur (t2.3) 26 4c8–16377–00 nut, lock 1 27 93310–232r9 bearing 1 28 4xv–16356–01 rod, push 1 1 29 4c8–16340–00 push lever assy 1 30 90508–16041 spring, torsion 1 31 90201–10029 washer, plate 1 32 99009–10...

  • Page 34

    C 15 fig. 18 transmission ref. No. Part no. Description 4c 81 remarks 1 4c8–17411–00 axle, main (15t) 1 2 90387–28003 collar 1 3 4c8–17151–00 gear, 5th pinion (22t) 1 4 90209–25011 washer 2 5 93440–28184 circlip 2 6 2d1–17131–00 gear, 3rd pinion (21/23t) 1 7 90387–25007 collar 1 8 4c8–17161–00 gear,...

  • Page 35

    D 2 fig. 18 transmission ref. No. Part no. Description 4c 81 remarks 28 90214–28002 washer, claw 1 29 5vy–17231–00 gear, 3rd wheel (37t) 1 30 4c8–17251–00 gear, 5th wheel (30t) 1 31 90387–25008 collar 1 32 5vy–17211–00 gear,1st wheel (38t) 1 33 93102–40330 oil seal 1 34 93440–62032 circlip 1 35 4c8–...

  • Page 36

    D 3 fig. 19 shift cam & fork ref. No. Part no. Description 4c 81 remarks 1 5vy–18540–00 shift cam assy 1 2 136–18542–00 .Point, neutral 1 3 93306–00106 bearing 1 4 5vy–18511–01 fork, shift 1 1 5 2d1–18512–00 fork, shift 2 1 6 5vy–18513–01 fork, shift 3 1 7 5vy–18531–00 bar, shift fork guide 1 1 8 5v...

  • Page 37

    D 4 fig. 20 shift shaft ref. No. Part no. Description 4c 81 remarks 1 5vy–18144–00 hanger, spring 1 2 132–16346–00 hook, spring 1 3 5vy–18140–00 stopper lever assy 1 4 90387–0804s collar 1 5 5vy–18127–10 stopper, screw 1 6 93317–11295 bearing 2 7 93102–12106 oil seal (sd 12-22-5 hs) 1 8 99002–10600 ...

  • Page 38

    D 5 fig. 21 frame ref. No. Part no. Description 4c 81 remarks 1 4c8–2116j–00 bracket 7 1 2 90480–14005 grommet 2 3 90387–063e6 collar 2 4 95022–06020 bolt, flange 2 5 90201–06m31 washer, plate 2 6 95024–06012 bolt, flange 1 7 4c8–21110–00 frame comp. 1 8 4c8–21190–00 rear frame comp. 1 9 5vy–21268–0...

  • Page 39

    D 6 fig. 21 frame ref. No. Part no. Description 4c 81 remarks 28 90338–14007 plug 2 29 90338–17004 plug 2 30 90338–23004 plug 2 31 90338–08008 plug 1 32 5vy–21131–00 bracket 1 33 95822–06016 bolt, flange 4 34 4c8–2117m–00 cover 2 1 35 4c8–2174x–00 damper 1 36 4c8–21746–00 damper 1 37 4c8–2139x–00 da...

  • Page 40

    D 7 fig. 21 frame ref. No. Part no. Description 4c 81 remarks 55 4c8–2113d–00 .Sheet, 3 1 56 90109–06043 bolt 1 57 90111–05002 bolt,hex. Socket button 2 58 90269–06012 rivet 3 59 4c8–24121–00 seat, knee grip 1 1 60 4c8–24122–00 seat, knee grip 2 1 61 5sl–84753–00 damper 2.

  • Page 41

    D 8 fig. 22 fender ref. No. Part no. Description 4c 81 remarks 1 5pw–21511–00–p1 fender, front 1 ur for dpbmc 5pw–21511–00–p6 fender, front 1 ur for smx 5pw–21511–00–pb fender, front 1 ur for bwc1 2 90480–12072 grommet 6 3 90387–065j6 collar 6 4 90111–06043 bolt,hex. Socket button 4 5 90111–06030 bo...

  • Page 42

    D 9 fig. 22 fender ref. No. Part no. Description 4c 81 remarks 24 5vy–21669–00 seal 1 25 90465–04020 clamp 2 26 4c8–21639–00 damper 2 2 27 4c8–21735–00 seal 2 8 28 5vy–21732–00 seal 1 2 29 5pw–21732–00 seal 1 2 30 90269–06081 rivet 2 31 90269–06081 rivet 2 32 90269–07077 rivet 1 33 90465–04020 clamp...

  • Page 43

    D 10 fig. 22 fender ref. No. Part no. Description 4c 81 remarks 51 4c8–27498–00 .Seat 1 1 52 4c8–27499–00 .Seat 2 1 53 92017–05012 bolt, button head 1 54 90111–05011 bolt,hex. Socket button 1 55 4c8–28100–00 tool kit 1.

  • Page 44

    D 11 fig. 23 side cover ref. No. Part no. Description 4c 81 remarks 1 4c8–21710–00–p0 side cover assy 1 1 ur for dpbmc 4c8–21710–00–p1 side cover assy 1 1 ur for smx 4c8–y2171–00–p2 cover, side 1 1 ur for bwc1 2 5pw–2174x–00 .Damper 2 3 90338–06018 .Plug 2 4 4c8–21747–00 .Damper 1 5 4c8–2172p–00 .Se...

  • Page 45

    D 12 fig. 24 rear arm ref. No. Part no. Description 4c 81 remarks 1 4c8–22110–00 rear arm comp. 1 2 90101–08013 bolt 2 3 95302–08600 nut 2 4 90201–08057 washer, plate 2 5 4c8–22184–00 bush 1 6 93317–52865 bearing 1 7 93317–428u8 bearing 1 8 5vy–22128–00 cover, thrust 1 1 9 4c8–22128–00 cover, thrust...

  • Page 46

    D 13 fig. 24 rear arm ref. No. Part no. Description 4c 81 remarks 28 90105–10017 bolt, flange 1 29 95602–10200 nut, u flange 1 30 90387–1012a collar 2 31 90387–1013u collar 1 32 90105–10021 bolt, flange 1 33 95602–10200 nut, u flange 1 34 90387–1012a collar 1 35 90105–10017 bolt, flange 1 36 95602–1...

  • Page 47

    D 14 fig. 25 rear suspension ref. No. Part no. Description 4c 81 remarks 1 4c8–22210–00 shock absorber assy, rear 1 2 93315–31758 .Bearing 1 3 93109–17071 .Oil seal 2 4 90105–10018 bolt, flange 1 5 95602–10200 nut, u flange 1 6 4c8–22219–00 bracket, upper 1 7 4c8–22127–00 shim 1 8 95602–14200 nut, s...

  • Page 48

    D 15 fig. 26 steering ref. No. Part no. Description 4c 81 remarks 1 93399–99932 bearing 1 2 3fv–23462–00 seal, steering 1 3 4xv–23415–01 cover, ball race 1 1 4 90179–30691 nut 2 5 4xv–23418–00 washer, special 1 6 90202–30235 washer, plate 1 7 90170–28419 nut 1 8 90201–281u8 washer, plate 1 9 4c8–234...

  • Page 49

    E 2 fig. 27 front fork ref. No. Part no. Description 4c 81 remarks 1 4c8–23102–00 front fork assy (l.H) 1 ur for dpbmc,bwc1 4c8–23102–10 front fork assy (l.H) 1 ur for smx 2 4c8–23136–00 .Tube, outer 1 ur for dpbmc,bwc1 4c8–23136–10 .Tube, outer 1 ur for smx 3 5pw–23146–00 ..Washer, oil seal 1 4 4pu...

  • Page 50

    E 3 fig. 27 front fork ref. No. Part no. Description 4c 81 remarks 24 4pu–23144–00 ..Seal, dust 1 25 4c8–23120–00 .Inner tube comp.2 1 26 4c8–23170–00 .Cylinder comp., front fork 1 27 509–23158–l0 .Gasket 1 28 5ux–23181–00 .Bolt, hexagon socket head 1 29 4c8–23141–00 .Spring, front fork 1 30 5vy–122...

  • Page 51

    E 4 fig. 28 fuel tank ref. No. Part no. Description 4c 81 remarks 1 4c8–yk241–00–p0 fuel tank comp. 1 ur for dpbmc 4c8–yk241–00–p1 fuel tank comp. 1 ur for smx 4c8–y2410–00–01 fuel tank comp. 1 ur for bwc1 2 4c8–24245–00 .Graphic, fuel tank 2 1 for bwc1 3 91312–06016 bolt 2 4 5vy–24183–00 damper, lo...

  • Page 52

    E 5 fig. 28 fuel tank ref. No. Part no. Description 4c 81 remarks 26 90461–08003 clamp 1 27 90154–05012 screw, binding 1 28 5jw–24486–00 o-ring 1 29 90110–05014 bolt, hexagon socket head 6 30 5vy–24312–00 pipe 2 1 31 4c8–24316–00 pipe 6 1 32 90467–09006 clip 2 33 4c8–2171a–00–p0 cover, top 1 ur for ...

  • Page 53

    E 6 fig. 28 fuel tank ref. No. Part no. Description 4c 81 remarks 51 4c8–2414h–00 damper, plate 1 1 52 4c8–2414p–00 damper, plate 5 1 53 5pw–2411j–01 damper, side cover 1 54 90159–05015 screw, with washer 2 55 4c8–2414k–00 damper, plate 3 2 56 5vy–2414r–00 damper, plate 6 1 57 5sl–2413b–00 emblem 2 ...

  • Page 54

    E 7 fig. 29 seat ref. No. Part no. Description 4c 81 remarks 1 4c8–24710–00 single seat assy 1 ur for dpbmc,smx 4c8–24710–10 single seat assy 1 ur for bwc1 2 4c8–24711–00 .Cover, single seat 1 ur for dpbmc,smx 4c8–24711–10 .Cover, single seat 1 ur for bwc1 3 90110–06258 bolt, hexagon socket head 2 4...

  • Page 55

    E 8 fig. 30 front wheel ref. No. Part no. Description 4c 81 remarks 1 5vy–25168–00–98 cast wheel, front 1 lgb for dpbmc,smx 5vy–25168–00–0x cast wheel, front 1 lgb/htr for bwc1 2 4xv–25117–00 spacer, bearing 1 3 93306–07208 bearing 2 4 93106–28043 oil seal 2 5 * tire(120/70 zr17 m/c 58w) 1 ur lm pir...

  • Page 56

    E 9 fig. 31 front brake caliper ref. No. Part no. Description 4c 81 remarks 1 4c8–2581t–00 disk brake assy 2 2 90149–06043 screw 10 3 4c8–2580t–00 caliper assy (left) 1 4 4c8–w0057–00 .Piston assy, caliper 1 5 4c8–w0047–00 ..Caliper seal kit 1 6 4c8–w0045–00 .Brake pad kit 1 7 4sv–25924–00 .Pin, pad...

  • Page 57

    E 10 fig. 32 rear wheel ref. No. Part no. Description 4c 81 remarks 1 5vy–25338–00–98 cast wheel, rear 1 lgb for dpbmc,smx 5vy–25338–00–0x cast wheel, rear 1 lgb/htr for bwc1 2 93306–20531 bearing 1 3 93106–40013 oil seal 1 4 93317–43580 bearing 1 5 93420–61m07 circlip 1 6 5pw–25317–00 spacer, beari...

  • Page 58

    E 11 fig. 32 rear wheel ref. No. Part no. Description 4c 81 remarks 24 90110–05030 .Bolt, hexagon socket head 1 25 5vy–25389–00 puller, chain 2 1 26 4c8–25381–00 axle, wheel 1 27 90185–24007 nut, self-locking 1 28 90201–25020 washer, plate 1 29 94582–10118 chain (did50va8-118ll) 1 30 94682–05031 .Jo...

  • Page 59

    E 12 fig. 33 rear brake caliper ref. No. Part no. Description 4c 81 remarks 1 5sl–2582w–00 disk, rear brake 2 1 2 90149–08009 screw 5 3 5vy–2580w–11 caliper assy, rear 2 1 4 5vy–w0057–00 .Piston assy, caliper 1 5 5sl–w0047–00 ..Caliper seal kit 1 6 5sl–25917–00 .Boot, caliper 1 7 5sl–25838–00 .Sleev...

  • Page 60

    E 13 fig. 34 steering handle & cable ref. No. Part no. Description 4c 81 remarks 1 5vy–26121–00 handlebar (left) 1 2 5vy–26122–00 handlebar (right) 1 3 4xv–23434–00 holder, damper 2 4 5pw–26246–00 end, grip 2 5 91317–06025 bolt 2 6 91312–06025 bolt 2 7 91312–08030 bolt 2 8 2h9–23469–00 cap, bolt 2 9...

  • Page 61

    E 14 fig. 35 front master cylinder ref. No. Part no. Description 4c 81 remarks 1 5sl–w2587–00 master cylinder sub assy 1 2 5vy–w0041–00 .Cylinder kit, master 1 3 5vy–w0048–00 .Bleed screw kit 1 4 5vy–25975–00 ..Seal 1 1 5 5vy–2589f–01 bolt, lever 1 6 5vs–2586f–00 nut, cover 1 7 5sl–83922–10 lever 2 ...

  • Page 62

    E 15 fig. 36 stand & footrest ref. No. Part no. Description 4c 81 remarks 1 5vy–27311–01 stand, side 1 2 5jj–27321–00 bracket, side stand 1 3 4nx–27351–00 guide, side stand 1 4 5pw–27352–00 hook, side stand 1 5 90506–18008 spring, tension 1 6 90445–19002 hose (l60) 1 7 90201–081r9 washer, plate 1 8 ...

  • Page 63

    F 2 fig. 36 stand & footrest ref. No. Part no. Description 4c 81 remarks 28 91401–25015 pin, cotter 1 29 90109–083e0 bolt 1 30 90201–08103 washer, plate 1 31 4c8–2144g–00 stay, stop switch 1 32 90480–12607 grommet 1 33 90387–06023 collar 1 34 90159–06150 screw, with washer 1 35 4c8–27446–00 plate 2 ...

  • Page 64

    F 3 fig. 36 stand & footrest ref. No. Part no. Description 4c 81 remarks 55 4c8–27490–00 protector assy 1 56 90387–0603j .Collar 2 57 90183–05024 .Nut, spring 1 58 90183–05076 .Nut, spring 1 59 4c8–2749a–00 .Seat 3 1 60 4c8–2749b–00 .Seat 4 1 61 4c8–2749d–00 .Seat 6 1 62 4c8–21486–00 .Damper 2 1 63 ...

  • Page 65

    F 4 fig. 37 rear master cylinder ref. No. Part no. Description 4c 81 remarks 1 4c8–27211–00 pedal, brake 1 2 4c8–27434–00 bolt 1 3 90506–20193 spring, tension 1 4 90446–15386 hose 1 5 4c8–27813–00 pin, pedal crank 1 6 4c8–2583v–00 rr. Master cylinder assy. 1 7 5vx–w0042–60 .Cylinder kit, master 1 8 ...

  • Page 66

    F 5 fig. 37 rear master cylinder ref. No. Part no. Description 4c 81 remarks 28 90119–05019 bolt, with washer 1.

  • Page 67

    F 6 fig. 38 cowling 1 ref. No. Part no. Description 4c 81 remarks 1 4c8–y2881–00 windshield 1 2 4c8–28428–00 .Seal 1 1 3 4c8–28429–00 .Seal 2 1 4 4c8–2844e–00 .Seal 3 1 5 4c8–2846f–00 .Seal 4 1 6 4c8–2847f–00 .Seal 5 1 7 4c8–2848f–00 .Seal 6 1 8 4c8–2832p–00 .Graphic 18 1 9 4c8–2835g–00–p0 body, fro...

  • Page 68

    F 7 fig. 38 cowling 1 ref. No. Part no. Description 4c 81 remarks 26 90160–05006 screw, round tapping 6 27 90160–05007 screw, round tapping 3 28 4c8–2838n–00–p0 duct 1 1 ur for dpbmc 4c8–2838n–00–p1 duct 1 1 ur for smx 4c8–2838n–00–p2 duct 1 1 ur for bwc1 29 4c8–2834e–00 damper 3 1 30 1fk–2171h–00 g...

  • Page 69

    F 8 fig. 38 cowling 1 ref. No. Part no. Description 4c 81 remarks 49 4c8–2837w–00 grill, air outlet 2 1 50 5pw–2177l–00 plate, spring 1 51 90269–06001 rivet 2 52 4c8–26280–00 rear view mirror assy (left) 1 53 4c8–26290–00 rear view mirror assy (right) 1 54 4c8–26298–00 plate, mirror fitting 1 2 55 9...

  • Page 70

    F 9 fig. 39 cowling 2 ref. No. Part no. Description 4c 81 remarks 1 4c8–y283u–00–p0 panel assembly 1 1 ur for dpbmc 4c8–y283u–10–p1 panel assembly 1 1 ur for smx 4c8–y283u–20–p2 panel assembly 1 1 ur for bwc1 2 5pw–2177l–00 .Plate, spring 1 3 4c8–28219–00 .Cover 1 1 4 90183–05m02 .Nut, spring 2 5 4c...

  • Page 71

    F 10 fig. 39 cowling 2 ref. No. Part no. Description 4c 81 remarks 18 97702–50016 .Screw, tapping 3 19 4c8–283b4–00 .Graphic 20 1 for dpbmc 20 4c8–28392–00 .Graphic 2 1 ur for dpbmc 4c8–28392–10 .Graphic 2 1 ur for smx 4c8–28392–20 .Graphic 2 1 ur for bwc1 21 5pw–28386–00 head 4 22 2tk–21757–00 wash...

  • Page 72

    F 11 fig. 39 cowling 2 ref. No. Part no. Description 4c 81 remarks 37 5pw–2177l–00 .Plate, spring 3 38 90480–12596 .Grommet 2 39 90387–065j6 .Collar 2 40 4c8–2848m–00 .Seat 4 1 41 4c8–2848p–00 .Seat 6 1 42 5ta–21749–00 .Collar 1 43 4c8–2153e–00 .Emblem, yamaha 1 ur for dpbmc 4c8–2153e–10 .Emblem, ya...

  • Page 73

    F 12 fig. 39 cowling 2 ref. No. Part no. Description 4c 81 remarks 62 5pw–2177l–00 plate, spring 1 63 90119–06052 bolt, with washer 2 64 90464–13077 clamp 2.

  • Page 74

    F 13 fig. 40 generator ref. No. Part no. Description 4c 81 remarks 1 5vy–81450–00 rotor assy 1 2 2d1–81410–01 stator assy 1 3 90149–06067 screw 3 4 4c8–15191–00 plate 1 5 90105–06078 bolt, flange 1.

  • Page 75

    F 14 fig. 41 starting motor ref. No. Part no. Description 4c 81 remarks 1 4c8–81890–00 motor assy 1 2 4c8–81801–00 .Brush set 1 3 93210–25711 .O-ring 1 4 4c8–81846–00 .Screw 2 5 95302–06700 .Nut 1 6 90201–05021 .Washer, plate 2 7 4c8–81861–00 .Gasket 2 8 4c8–8183g–00 cord comp. 1 9 95302–06700 nut 1...

  • Page 76

    F 15 fig. 42 flasher light ref. No. Part no. Description 4c 81 remarks 1 2c0–83310–00 front flasher light assy 1 1 2 2c0–83311–00 .Bulb, flasher (12v-10w) 1 3 2c0–8333a–00 .Lens comp 1 4 97702–40010 .Screw, tapping 1 5 2c0–83320–00 front flasher light assy 2 1 6 2c0–83311–00 .Bulb, flasher (12v-10w)...

  • Page 77

    G 2 fig. 43 meter ref. No. Part no. Description 4c 81 remarks 1 4c8–83500–00 speedometer assy (km/h) 1 4c8–83500–10 speedometer assy (mph) 1 for gbr 2 4c8–8353e–00 .Case, meter upper 1 3 5vy–83572–01 .Case, speedometer lower 1 4 5pw–8352s–00 .Screw, panel ftting 11 5 90160–05006 screw, round tapping...

  • Page 78

    G 3 fig. 44 headlight ref. No. Part no. Description 4c 81 remarks 1 4c8–84303–00 headlight unit assy 1 4c8–84303–20 headlight unit assy 1 for gbr,irl,zaf 2 4sv–84314–00 bulb (12v-55w) 2 (h7)halogen 3 4sv–84347–00 bulb (12v-5w) 1 4 5sl–84397–00 cover, socket 1 5 5gj–84397–00 cover, socket 1 6 4c8–841...

  • Page 79

    G 4 fig. 45 taillight ref. No. Part no. Description 4c 81 remarks 1 4c8–84710–00 taillight unit assy 1 2 90269–06081 rivet 2 3 5pw–84717–00 cord, taillight 1 4 4c8–21629–00 guard, mud 1 5 5vx–84745–01 licence light unit assy 1 6 4hc–84744–00 .Bulb (12v-5w) 1 7 97706–04012 .Screw, tapping 2 8 95602–0...

  • Page 80

    G 5 fig. 46 handle switch & lever ref. No. Part no. Description 4c 81 remarks 1 4xv–82910–15 lever holder assy (left) 1 2 4xv–83912–11 .Lever 1 1 3 2c0–83945–00 .Bolt, lever 1 4 95607–06200 .Nut, self u-flange 1 5 95027–06020 .Bolt, flange 1 6 5lv–83951–00 .Bolt, cable adjusting 1 7 4xv–82917–01 .Sw...

  • Page 81

    G 6 fig. 47 electrical 1 ref. No. Part no. Description 4c 81 remarks 1 90201–12790 washer, plate 1 2 8cc–85790–01 thermosensor assy 1 3 2d1–81673–00 rotor 1 4 90282–03001 key, straight 1 5 90201–10039 washer, plate 1 6 90105–10290 bolt, flange 1 7 5vy–85820–10 servo motor assy 1 8 4c8–85829–00 cover...

  • Page 82

    G 7 fig. 47 electrical 1 ref. No. Part no. Description 4c 81 remarks 28 4c8–15589–00 plate, clutch cover 1 29 90110–06161 bolt, hexagon socket head 1 30 90465–08054 clamp 1 31 5vy–85896–00 sensor, cam position 1 32 90110–06175 bolt, hexagon socket head 1.

  • Page 83

    G 8 fig. 48 electrical 2 ref. No. Part no. Description 4c 81 remarks 1 1d0–81940–02 starter relay assy 1 2 36y–82151–00 .Fuse (15a-bl) 2 3 5ps–82576–01 lean angle sensor 1 4 91312–04025 bolt 2 5 90201–047a2 washer, plate 2 6 90183–04039 nut, spring 2 7 5vk–81950–30 relay assy 1 8 4c8–83350–00 flashe...

  • Page 84

    G 9 fig. 48 electrical 2 ref. No. Part no. Description 4c 81 remarks 28 5vy–82100–00 battery assy (yuasa ytz10s) 1 29 4c8–82590–00 wire harness assy 1 30 5jj–82151–70 .Fuse (25a-bl) 2 31 5jj–82151–10 .Fuse (15a-bl) 4 32 5jj–82151–00 .Fuse (7.5a-bl) 5 33 5jw–82151–10 .Fuse (50a) 1 34 5ea–81950–20 rel...

  • Page 85

    M 1 numerical index part no. Grid no. 4c8–11101–00 b – 2 5vy–1111g–00 b – 2 4c8–11133–10 b – 2 4c8–11134–10 b – 2 5vy–11165–00 c – 10 4c8–11181–00 b – 2 4c8–11191–00 b – 2 4c8–11193–00 b – 2 214–11198–01 b – 14 5vy–11311–10 b – 4 4c8–1133e–00 c – 7 4c8–1133f–00 c – 7 5vy–11351–00 b – 4 4c8–11411–00 ...

  • Page 86

    M 2 numerical index part no. Grid no. 4c8–2110m–10 d – 6 4c8–2110n–00 d – 6 4c8–2110p–00 d – 6 4c8–21110–00 d – 5 4c8–2111d–00 d – 5 4c8–2112b–00 d – 6 5vy–21131–00 d – 6 4c8–2113b–00 d – 6 4c8–2113c–00 d – 6 4c8–2113d–00 d – 7 4c8–2116j–00 d – 5 5vy–2117k–01 e – 7 4c8–2117m–00 d – 6 4c8–2117t–00 d ...

  • Page 87

    M 3 numerical index part no. Grid no. 5vy–27442–01 e – 15 4c8–27443–00 e – 15 4c8–27445–00 e – 15 4c8–27446–00 f – 2 5jj–27461–00 e – 15 4c8–27463–00 g – 8 4c8–27490–00 f – 3 4c8–27498–00 d – 10 4c8–27499–00 d – 10 4c8–2749a–00 f – 3 4c8–2749b–00 f – 3 4c8–2749d–00 f – 3 4c8–27813–00 f – 4 4c8–28100...

  • Page 88

    M 4 numerical index part no. Grid no. 90111–06064 f – 2 90111–08021 c – 6 90111–08038 f – 4 90111–08058 c – 6 90116–10023 c – 8 90116–10032 c – 8 90116–10485 e – 10 90119–05019 f – 5 90119–05193 d – 9 90119–05239 d – 9 90119–06052 f – 12 90119–06228 g – 9 90119–09003 c – 8 90149–06043 e – 9 90149–06...

  • Page 89

    M 5 numerical index part no. Grid no. 92012–06012 f – 3 92012–06014 b – 12 92012–06016 d – 12 92014–06012 c – 5 92014–06014 c – 9 92014–08016 c – 10 92017–05012 d – 10 92017–05035 g – 8 92017–06025 e – 7 92902–05600 b – 15 92902–06200 f – 4 92907–05200 g – 4 92907–08600 c – 13 92990–06200 c – 5 9310...