CONTENTS

FIG. 1 COVER COMP CYLINDER HEAD

FIG. 2 CAMSHAFT COMP
FIG. 3 HOLDER CAMSHAFT COMP
FIG. 4 CYLINDER HEAD COMP
FIG. 5 CARBURETOR
FIG. 6 AIR CLEANER
FIG. 7 LEFT CRANKCASE COVER
FIG. 8 DRIVE PULLEY
FIG. 9 CYLINDER COMP
FIG. 10 CRANKSHAFT COMP
FIG. 11 FAN COVER SHROUD
FIG. 12 GENERATOR COMP
FIG. 13 STARTING MOTOR/MOTOR STARTER COMP
FIG. 14 RIGHT CRANKCASE COVER COMP
FIG. 15 CRANKCASE COMP
FIG. 16 TRANSMISSION COMP
FIG. 17 PUMP COMP
FIG. 18 CHAIN CAM COMP
FIG. 19 BRUSH GUARD
FIG. 20 FRAME GROUP
FIG. 21 FRONT SUSPENSION
FIG. 22 STEERING
FIG. 23 REAR SUSPENSION/AXLE
FIG. 24 MUFFLER & IGNITION
FIG. 25 CONTROLS
FIG. 26 WARNING/GRAPHIC DECALS
FIG. 27 ELECTRICAL SCHEMATIC

1. COVER COMP CYLINDER HEAD

REF#
1-1
1-2
1-3
1-4

TPG#
GK05823
GK05824
GK05825
BS00075

DESCRIPTION
TUBE BREATHER
CYLINDER HEAD COVER
GASKET HEAD COVER
BOLT FLANGE M6X25

QTY
1
1
1
4

2. CAMSHAFT COMP

REF#
2-1

TPG#
GK05827

DESCRIPTION
CAMSHAFT

QTY
1

3. HOLDER CAMSHAFT COMP

REF#
3-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10

TPG#
GK05828
GK05829
GK05830
GK05831
GK05832
GK05833
GK05834
GK05835
GK05836
GK05837

DESCRIPTION
SHAFT EX ROCKER ARM
ARM VALVE ROCKER
HOLDER CAMSHAFT
NUT TAPPET ADJUSTING
SCREW TAPPET ADJUSTING
WASHER M8
NUT FLANG M8
SHAFT COMP IN ROCKER ARM
PLATE COMP STOPPER
HOLDER CAMSHAFT ASSY

QTY
1
2
1
2
2
4
4
1
1
1

4. CYLINDER HEAD COMP

REF#
4-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
4-11
4-12
4-13
4-14
4-15
4-16
4-17
4-18
4-19
4-20
4-21

TPG#
GK05838
GK05839
GK05840
GK05841
GK05842
GK05843
GK05844
GK05845
GK05846
GK05847
GK05848
GK05849
GK05850
GK05851
GK05852
GK05853
GK05854
GK05855
GK05856
GK05857
GK05858

DESCRIPTION
HEAD COMP CYLINDER
SEAL VALVE STEM
PLUG SPARK
BOLT FLANGE M6X100
GASKET CYLINDER HEAD
GASKET CARBURETOR INSULATOR
INSULATOR CARBURETOR
PIPE COMP IN
BAND INSULATER
NUT FLANGE M6
O-RING 28.5X1.8
PIN DOWEL 10X16
BOLT 2 STUD M6X35
BOLT 2 STUD M6X50
VALVE EX
VALVE IN
SEAT VALVE SPRING OUTER
SPRING VALVE OUTER
SPRING VALVE INNER
RETAINER VALVE SPRING
COTTER VALVE

QTY
1
2
1
2
1
1
1
1
1
2
1
4
2
2
1
1
2
2
2
2
4

5. CARBURETOR

REF#
5-1

TPG#
GK05859

DESCRIPTION
CARBURETOR ASSY

QTY
1

DESCRIPTION

QTY

6. AIR CLEANER

REF#

TPG#

6-1
6-2

GK05860
GK05861

AIR CLEANER
ELEMENT COMP AIR CLEANER

1
1

7. LEFT CRANKCASE COVER

REF#
7-1
7-2
7-3
7-4
7-5
7-6
7-7
7-8
7-9
7-10
7-11

TPG#
GK05862
GK05863
GK05864
GK05865
GK05866
GK05867
GK05868
GK05869
GK05878
GK05879
GK05880

DESCRIPTION
COVER LEFT
CLAMPER BREATHER DRAIN TUBE
GASKET LEFT COVER
PLATE LEFT COVER
SCREW TAPPING 4X6
BOLT FLANGE 6X40
BOLT FLANGE 6X65
BOLT FLANGE 6X16
AIR STRAINER
BRAND COVER
GASKET BRAND COVER

QTY
1
1
1
1
4
6
2
3
1
1
1

8. DRIVE PULLEY

REF#
8-1
8-2
8-3
8-4
8-5
8-6
8-7

TPG#
GK05881
GK05882
GK05883
GK05884
BS00076
GK05885
GK05887

DESCRIPTION
PULLEY ASSY DRIVEN
BELT DRIVE
PULLEY ASSY.MOVEABLE DRIVEN
WASHER PLAIN 12MM
NUT FLANGE 12X1.25MM
NUT FLANGE 12X1.25MM
GEAR KICK

QTY
1
1
1
2
1
1

9. CYLINDER COMP

REF#
9-1
9-2
9-3
9-4
9-5

TPG#
GK05888
GK05889
GK05890
BS00077
GK05892

DESCRIPTION
CYLINDER COMP
GASKET CYLINDER
WASHER SEALING 6.5MM
PIN DOWEL 10X16
BOLT FLANGE6X12

QTY
1
1
1
2
1

DESCRIPTION
CRANK SHAFT COMP
KEY WOODRUFF
PISTON
CLIP PISTON PIN 15MM
PIN PISTON
PISTON RING

QTY
1
2
1
2
1
1

10. CRANKSHAFT COMP

REF#
10-1
10-2
10-3
10-4
10-5
10-6

TPG#
GK05893
GK05894
GK05895
GK05896
GK05897
GK05898

11. FAN COVER SHROUND

REF#
11-1
11-2
11-3
11-4
11-5
11-6
11-7

TPG#
GK05899
GK05900
GK05901
GK05902
GK05903
GK05904
GK05905

DESCRIPTION
UP SHROUD COMP
DOWN SHROUD COMP
DUCT CARBURETOR COOLING
COVER COMP FAN
BOLT FLANGE 6X25
SCREW TAPPING ST4.8X16
CLAMPER CARB DRAIN TUBE

QTY

DESCRIPTION
COIL ASSY IGNITION
GENERATOR ASSY FLYWHEEL TYPE A.C
BOLT FLANGE 6X20
BOLT FLANGE 5X12
PAN COMP COOLING
BOLT FLANGE 6X18
NUT FLANGE 12X1.25
WASHER PLAIN 12MM

QTY
1
1
2
2
1
4
1
1

1
1
3
4
1

12. GENERATOR COMP

REF#
12-1
12-2
12-3
12-4
12-5
12-6
12-7
12-8

TPG#
GK05906
GK05907
GK05908
GK05909
GK05910
GK05911
BS00078
GK05913

13. STARTING MOTOR\MOTOR STARTER COMP

REF#
13-1
13-2
13-3
13-4
13-5
13-6
13-7
13-8
13-9
13-10

TPG#
GK05929
GK05930
GK05931
GK05932
GK05933
GK05934
BS00079
BK00037
BS00081
BK00038

DESCRIPTION
GEAR STARTER REDUCTION
SHAFT STARTER REDUCTION GEAR
MOTOR ASSY STARTER
STARTER CLUTCH
WASHER THRUST
NUT LOCK
BOLT FLANGE 6X16
GEAR COMP. STARTING CLUTCH
BEARING NEEDLE 28X32X17
FLANGE STARTING CLUTCH

QTY
1
1
1
1
1
1
2
1
1
1

14. RIGHT CRANKCASE COVER COMP

REF#
14-1
14-2
14-3
14-4
14-5
14-6
14-7
14-8
14-9
14-10
14-11
14-12
14-13
14-14
14-15

TPG#
GK05914
GK05915
GK05916
GK05917
GK05918
GK05919
GK05920
GK05921
GK05922
GK05923
GK05924
GK05925
GK05926
GK05927
BS00081

DESCRIPTION
RIGHT CRANK CASE COVER
GASKET R CRANKCASE COVER
CAP TAPPET ADJUSTING HOLE
SCREEN OIL FILTER
SPRING OIL FILTER SCREEN
GAUGE OIL LEVEL
CLAMPER A.C. GENERATOR CORD
OIL SEAL 19.8X30X5
O-RING 18X3
O-RING
BOLT FLANGE 6X35
BOLT FLANGE 6X32
BOLT FLANGE 6X95
BOLT FLANGE 6X110
BOLT FLANGE 6X100

QTY
1
1
1
1
1
1
1
1
1
1
1
1
4
2
1

15. CRANKCASE COMP

REF#
15-1
15-2
15-3
15-4
15-5
15-6
15-7
15-8
15-9
15-10
15-11
15-12
15-13
15-14
15-15
15-16
15-17
15-18
15-19
15-20
15-21
15-22

TPG#
GK05951
GK05952
GK05953
GK05954
GK05955
GK05956
GK05957
GK05958
GK05959
BS00082
BS00083
BS00084
GK05963
GK05964
BS00085
BS00086
GK05967
GK05968
BS00087
GK05970
GK05971
GK05972

DESCRIPTION
CRANKCASE ASSY RIGHT
BUSH ENGINE HANGER RUBBER
GASKET CRANKCASE
CRANKCASE ASSY LEFT
AIR CLEANER CONNECT FRONT
BUSH RR CUSHION UNDER RUBBER
TUBE BREATHER
BOLT STUD 8X187
BOLT STUD 8X195
BEARING RADIAL BALL 102
BEARING RADIAL BALL 180104
OIL SEAL 19.8X30X5
OIL SEAL 27X42X7
PIN DOWEL 8X14
BOLT FLANGE 6X50
BEARING RADIAL BALL 301
PIN BRAKE SHOE ANCHOR
O-RING 7.5X1.5
NUT FLANGE M8
BOLT DRAIN PLUG 12MM
WASHER DRAIN PLUG 12MM
AIR CLEANER CONNECT REAR

QTY
1
1
1
1
1
1
1
2
2
1
1
1
1
8
2
1
1
1
1
1
1
1

16. TRANSMISSION COMP

REF#
16-1
16-2
16-3
16-4
16-5
16-6
16-7
16-8
16-9
16-10
16-11
16-12
16-13
16-14
16-15

TPG#
GK05936
GK05937
GK05938
GK05939
GK05940
GK05941
BS00088
GK05943
GK05944
GK05945
GK05946
GK05947
GK05948
GK05949
GK05950

DESCRIPTION
COVER MISSION ASSY
GASKET MISSION COVER
SHAFT DRIVE
SHAFT COMP COUNTER
SHAFT FINAL
GEAR FINAL
BOLT FLANGE 6X35
BOLT FLANGE 6X28
BOLT DRAIN PLUG M8
WASHER 8MM
OIL SEAL 20X32X16
CIR CLIP EXTERNAL 20MM
BEARING RADIAL 204
BEARUING RADIAL 202
BEARUING RADIAL 203

QTY
1
1
1
1
1
1
3
3
2
2
1
1
1
1
1

17. OIL PUMP COMP

REF#
17-1
17-2
17-3
17-4
17-5
17-6
17-7

TPG#
GK05973
BS00075
GK05975
BS00089
GK05977
GK05978
BS00090

DESCRIPTION
OIL PUMP COMP
BOLT FLANGE 6X25
SPROCKET OIL PUMP DRIVEN
NUT FLANGE M6
CHAIN OIL PUMP
SEPARTOR OIL
BOLT FLANGE 6X12

QTY
1
2
1
1
1
1
2

18. CHAIN CAM COMP

REF#
18-1
18-2
18-3
18-4
18-5
18-6
18-7
18-8

TPG#
GK05980
GK05981
GK05982
GK05983
GK05984
GK05985
GK05986
GK05987

DESCRIPTION
CHAIN CAM
TENSIONER CAM CHAIN COMP
LIFTER ASSY TENSIONER
GASKET TENSIONER LIFTER
BOLT FLANGE 6X22
O-RING 15.2X1.5
PIVOT CAM CHAON TENSIONER
GUIDE COMP CAM CHAIN

QTY
1
1
1
1
2
1
1
1

19. BRUSH GUARD

REF#
19-1.1
19-1.2
19-2
19-3
19-4
19-5
19-6
19-7.1
19-7.2
19-8
19-9
19-10
19-11
19-12
19-13
19-14
19-15
19-16
19-17
19-18

TPG#
BP00003
BP00002
BS00091
BS00092
BS00093
BS00094
BS00095
BL00040
BL00041
BR00053
BL00085
BL00135
BK00035
NA
NA
NA
BL00083
BL00135
BL00137
BL00138

DESCRIPTION
GUARD SIDE RAIL LH
GUARD SIDE RAIL RH
BOLT M8 X 45
WASHER LOCK M8
WASHER SPHERICAL M8-32
NUT M8
WASHER SPHERICAL M8-25
GUARD VERTICAL RAIL LH
GUARD VERTICAL RAIL RH
PADDING FRAME LONG
FRAME CROSS MEMBER T-BAR
FRAME BRAKE LIGHT MNT TUBE
BRAKE LIGHT
BOLT M4 X 25 (Included in 19-11)
WASHER LOCK M4 (Included in 19-11)
NUT M4 (Included in 19-11)
FRAME CROSS MEMBER UPPER
FRAME END CAP SEAT, LARGE
FRAME CROSS MEMBER UPPER
FRAME END CAP SEAT, SMALL

QTY
1
1
13
13
16
5
2
1
1
3
1
1
1
2
2
2
1
6
1
4

20. FRAME GROUP

REF#
20-1
20-2
20-3
20-4
20-5
20-6
20-7
20-8
20-9
20-10
20-11
20-12
20-13
20-14
20-15
20-16

TPG#
BL00072
BL00131
BR00054
BR00052
BK00030
BK00033
BS00100
BS00102
BS00099
BS00092
BS00093
BS00091
BS00094
BM00003
BM00006
BM00005

DESCRIPTION
MAIN FRAME
FRONT BRUSHGUARD
PADDING FRAME 6"
PADDING FRAME SHORT
HEADLIGHT SET
HEADLIGHT BULB
BOLT M6 X 40
NUT LOCKING FLANGE M6
BOLT HHCS M8 X 50
WASHER LOCK M8
WASHER SPHERICAL M8
BOLT HHCS M8 X 45
NUT M8
SEAT, DRIVER, ADJUSTABLE
SEAT, PASSENGER, NON-ADJUSTABLE
SEAT BELT

QTY
1
1
2
2
1
2
2
2
2
10
12
6
2
1
1
2

20-17
20-18
20-19
20-20
20-21
20-22
20-23
20-24

BE00004
BE00005
BS00101
BS00103
BS00104
BE00007
BE00008
BE00011

GAS TANK
GAS TANK CAP
BOLT-WASHER M8x1.25x25
RUBBER MOUNT WASHER FLAT
NUT, FLANGE LOCK M8
COCK, FUEL SA
TUBE COMP. FUEL. #1
FUEL FILTER (not shown)

1
1
4
4
4
1
1
1

21. FRONT SUSPENSION

REF#
21-1
21-2.1
21-2.2
21-3
21-4
21-5
21-6
21-7
21-8
21-9
21-10.1
21-10.2
21-11
21-12
21-13
21-14

TPG#
BJ00005
BJ00006
BJ00026
BS00105
BS00106
BJ00021
BS00107
BS00087
BJ00047
BS00109
BB00015
BB00013
BB00028
BS00110
BS00111
BS00112

DESCRIPTION
A-ARM UPPER
A-ARM LOWER LH
A-ARM LOWER RH
BOLT HHFS M12 X 40
NUT FLANGE M12
SHOCK FRONT
BOLT HHFS M8 X 40
NUT FLANGE M8
BALL JOINT
PIN SPLIT 3.2 X 25
SPINDLE FRONT LH
SPINDLE FRONT RH
WHEEL HUB WITH STUDS
BEARING
BEARING SEAL
BUSHING BRASS

QTY
2
1
1
8
8
2
2
2
4
2
1
1
2
2
2
2

21-15
21-16
21-17
21-18
21-19
21-20
21-21
21-22
21-23

BS00113
BS00114
BS00115
BS00116
BS00117
BA00026
BA00022
BA00028
BJ00051

BEARING
BEARING SEAL
BUSHING BRASS
NUT CASTLE M14
NUT M10
WHEEL
TIRE FRONT
CAP, HUB
ROD END BEARING M12

2
2
2
2
8
2
2
2
8

22. STEERING

REF#
22-1
22-2
22-3
22-4
22-5
22-6
22-7
22-8
22-9
22-10
22-11
22-12
22-13
22-14
22-15

TPG#
BG00017
BS00119
BS00120
BG00029
BG00021
BS00063
BS00121
BS00122
BG00016
BG00018
BG00022
BJ00048
BJ00049
BS00101
BS00094

DESCRIPTION
STEERING WHEEL
BOLT HHCS M6x12
WASHER LOCK M6
COVER. STEERING BOLT
STEERING SHAFT
BUSH. STEERING SHAFT
CIRCLIP 20
BOLT HHCS M8x25
STEERING KNUCKLE
STEERING GEAR
STEERING COLUMN MOUNT SUPPORT
TIE ROD
ROD END ASSY.
BOLT HHCS M8x60
NUT M8

QTY
1
3
3
1
1
2
1
2
1
1
1
2
2
2
2

23. REAR SUSPENSION / AXLE

REF#
23-1
23-2
23-3
23-4
23-5
23-6
23-7
23-8
23-9
23-10
23-11
23-12
23-13
23-14
23-15
23-16
23-17
23-18
23-19
23-20

TPG#
BL00038
BJ00050
BB00034
BS00132
NA
NA
BB00035
BS00092
BJ00029
BS00126
NA
BK00039
BK00040
BK00041
BK00042
BK00043
BK00044
BS00135
NA
BS00137

DESCRIPTION
RR. SWINGARM
RUBBER BUSH, RR. SWINGARM
BRAKE SYSTEM: Caliper, Master Cyl. & Hose
STRAP BOLT M8x1.25x156
FLANGE BOLT M10x1.25x40
LOCKING FLANGE NUT M10
BRAKE PADS
LOCKING WASHER M8
REAR SHOCK
NUT FLANGE M10X1.25
BATTERY (SOURCED LOCALLY FROM SERVICE CENTER ONLY-YTX7L-BS)
BATTERY COVER
BATTERY STRAP
RESISTER
CDI
RECTIFIER COMP., REGULATE
STARTING RELAY
FLANGE BOLT M10x1.25x45
RR. ENGINE BRACKET

QTY
1
2
1
2
4
2
2
2
2
4
1
1
1
1
1
1
1
1
1
1

23-21
23-22
23-23
23-24
23-25
23-26
23-27
23-28
23-29
23-30
23-31
23-32
23-33
23-34
23-35
23-36
23-37
23-38
23-39
23-40
23-41
23-42
23-43
23-44
23-45
23-46
23-47
23-48
23-49
23-50
23-51
23-52
23-53
23-54
23-55
23-56
23-57
23-58

BS00168
BS00138
BS00140
BS00141
BS00142
BS00106
BK00045
BK00046
BS00143
BK00047
BS00144
BS00145
BB00036
BS00146
BS00147
NA
BB00016
BS00148
BB00018
BS00104
BS00149
BB00019
BB00022
BS00150
BS00151
BS00152
BA00023
BA00027
BC00158
BC00159
BC00157
BK00036
BC00162
BS00153
BS00104
BS00075
BS00076
BA00028

LOCKNUT M10X1.25
JAM NUT M12
ENGINE MOUNT SPACER LINK
ENGINE MOUNT CUSHION LINK
FLAT WASHER M12
NUT FLANGE M12X1.25
WIRING HARNESS
ELECTRICAL BOX (NO COMPONENTS)
BOLT STUD M5X15
COVER, ELECTRICAL BOX
WASHER M4
BOLT STUD M4X10
REAR DISC COVER
FLANGE BOLT M6x16
LOCKING NYLON NUT, M6
BRAKE LINE REAR (SEE 23-3)
AXLE
BOLT HHFS M8 X 25
BRAKE DISK
NUT FLANGE M9
BEARING
BEARING BASE
WHEEL HUB WITH STUDS
WASHER 16
NUT FLANGE M16X1.5
PIN SPECIAL4X35
RR. TIRE
RR. RIM
SPROCKET, DRIVEN
CHAIN, DRIVE (O-RING)
SPROCKET, DRIVE
CHARGER, BATTERY
GUARD, CHAIN
BOLT, HHFS M8X60
NUT, FLANGE LOCK M8
BOLT, HHFS M6X25
NUT, FLANGE LOCK M6
CAP, HUB

1
2
1
1
1
1
1
1
3
1
1
1
1
2
2
1
1
8
1
8
4
2
2
2
2
2
2
2
1
1
1
1
1
1
1
2
2
2

24. MUFFLER

REF#
24-1
24-2
24-3
24-4
24-5
24-6
24-7
24-8
24-9
24-10
24-11
24-12
24-13
24-14

TPG#
BC00163
BF00012
BF00009
BF00010
BS00119
BS00123
BS00124
BS00127
BS00128
BS00129
BF00011
BS00125
BS00130
BS00131

DESCRIPTION
ENGINE
MUFFLER MOUNT
MUFFLER
PROTECTOR MUFFLER
BOLT HHCS M6 X 12
BOLT-WASHER M10 X 1.25 X 20
WASHER LOCK M10
WASHER, FLAT M10
BUSHING, ISOLATOR, RUBBER
BUSHING, SPACER
GASKET EXHAUST PIPE
BOLT STUD M6X25
FR. FIXING COLLAR, ENGINE
FR. HANGED BOLT, ENGINE

QTY
1
1
1
1
1
1
1
2
1
1
1
1
1
1

24-15
24-16

BS00126
BK00048

NUT FLANGE M10X1.25

IGINTION COIL

1
1

25. CONTROLS

REF#
25-1
25-2
25-3
25-4
25-5
25-6
25-7
25-8
25-9
25-10
25-11
25-12
25-13
25-14
25-15
25-16
25-17
25-18
25-19
25-20
25-21
25-22
25-23
25-24

TPG#
BH00006
BH00008
BS00154
BS00155
BS00156
BS00157
BS00158
BS00159
BH00025
BB00030
BS00160
BS00161
BS00162
BS00163
BS00164
NA
NA
BS00167
BS00104
BH00005
BH00024
BH00007
BK00034
BT00047

DESCRIPTION
BRAKE PEDAL
BRAKE ROD
NUT , JAM M6
BRAKE GEMEL 6MM
PIN
WASHER, FLAT
PIN, COTTER
BRAKE ARM
BRAKE SPRING
MASTER CYL ROD
BRAKE GEMEL 8MM
NUT, JAM M8
PIN B 6X16
WASHER, FLAT M6
PIN SPECIAL2X24
MASTER CYLINDER (SEE 23-3)
BRAKE, PRESSURE SWITCH (SEE 23-3)
BOLT STUD M8X30
NUT, FLANGE M8
THROTTLE PEDAL
THROTTLE SPRING
THROTTLE CABLE
ENGINE STOP SWITCH
KEY SWITCH

QTY
1
1
4
2
2
2
2
1
1
1
1
4
1
1
1
1
1
2
2
1
1
1
1
1

25-25
25-26
25-27
25-28

BH00023
BH00020
BH00022
BT00050

RUBBER COVER, KEY SET

BRAKE, PARKING, SA
BOOT, PARK BRAKE
EXTRA KEYS (2)

1
1
1
2

26. WARNING/GRAPHIC DECALS

REF#
26-1
26-2
26-3
26-4
26-5
26-6
26-7
26-8
26-9

TPG#
SW30321
SW30318
SW30319
SW30317
SW30320
SW30316
BT00049
BT00043
BT00045

DESCRIPTION
LABEL, CAUTION
LABEL, NO LONG HAIR
LABEL, CHAIN GUARD
LABEL, NO RIDING
LABEL, SEAT BELT
LABEL, WARNING
LABEL, PARKING BRAKE
LABEL, CROSSFIRE SET
LABEL, CROSSFIRE FLOOR

QTY
1
1
1
1
1
1
1
1
1

27. ELECTRICAL SCHEMATIC