1. 1. While every care is taken in publishing this catalogue, the company 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. 2 1 3 5 INDEX INSTRUCTIONS (Use of Parts Catalogue) BLOCK INDEX ENGINE GROUP FRAME GROUP PART NO. INDEX 3 4
4. 4. Hero MotoCorp NON BODY COLOUR CODE COLOUR REF. COLOUR DESCRIPTION NH-35M CLOUD SILVER METALLIC NH-303M MAT AXIS GRAY METALLIC NH-1 BLACK INSTRUCTION FOR USE OF PARTS CATALOGUE This parts catalogue is compiled of all service parts and Flat Rate Time (F.R.T.) For Hero MotoCorp KARIZMA Motorcycle. I. How to order parts 1. Information required Replacement parts orders must contain both the part number and the stamped number(s) as described below. This is because any changes and modifications of parts are registered at Hero MotoCorp with the pertinent parts and stamped numbers. Numbers needed (a) Carburettor parts : Part number and Stamped carburettor identification number. (b) Engine parts : Part number and Stamped engine number. (c) Frame parts : Part number and Stamped frame number. 2. Revision When modifications or additions to this Parts Catalogue are made, a news letters/revised edition will be issued at an appropriate time, with sucessively progressing revision numbers. We recommend obtaining such revisions in order to keep your Parts Catalogue up-to-date at all times. To check whether a Parts Catalogue revision has been issued, please contact SPARE PARTS DEPARTMENTS, Hero MotoCorp Ltd. II. How to read this Parts Catalogue 1. Make-up of the part number (Example) (General Parts) Colour Code Subcontractor designation Modification designation Parts classification No. (Example) Bolts, nuts and other standard parts Function and type No. Dimension Chemical surface treatment ISO 2. Colour codes The colour code at the end of the part number indicates the colour. Code below ZA in 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 description column of this Parts Catalogue. COLOUR CODE COLOUR DESCRIPTION COLOUR REF. CODE MAIN BODY COLOUR NH-1 ZA BLACK R-321 ZB SPORTS RED NH-341P ZC PEARL FADELESS WHITE Y-153 ZD MOON YELLOW NH-A63M ZE EBONY GRAY METALLIC 5 1
5. 5. 6 3. Abbreviations The following abbreviations are used in this Parts Catalogue. ASSY. .........Assembly L.E.D. ............Light emitting diode COMP.........Complete L (100L).........Link (100 Links) R.................Right A.C. ...............Alternating current L. ...............Left D.C................Direct current STD............Standard IN ..................Inlet MM. ............Millimeter EXH...............Exhaust G. ...............Gram FR. ...............Front T (22T). ......Tooth (22Teeth) RR.................Rear A.................Ampere Hex................Hexagonal V. ................Volt A.M................Attaching Mark W................Watt T.M. ...............Transcript Mark KPH........... Kilometers per hour C.D.I..............Capacitive Discharge ignition INC............... Including 4. Dimensions All dimensions are given in millimeters (mm) except in the case of steel balls, tyres and tyre tubes and wheel rims. .............. Parts Example Interpretation Bolt (Screw) 6 x 12 6mm diameter, 12mm length Pin 8 x 14 8mm diameter, 14mm length O-Ring 9.5 x 1.6 9.5mm diameter, 1.6mm thickness Oil Seal 14 x 24 x 5 14mm inside diameter, 24mm outside diameter, 5mm thickness Tube 5 x 130 5mm inside diameter, 130mm length 5. Supercedence of parts Part numbers given under the part name in the Description column indicate that the part number has been superceded by that part number. may make such supercedence without notice. 6.Assemblies Sections framed with broken lines in the exploded view drawings are available as complete assemblies. (Their individual parts can also be obtained.) Hero MotoCorp 7. Required Quantity The number given in the Reqd. No. column indicates the quantity of parts used in the 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 be selected at need. 8. Part modifications and applicable serial numbers In 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. Illustration Illustration of parts given in parts catalogue diagrams are provided for convenience identifying parts and may differ from the actual configuration of parts. 10. Models, area codes and applicable serial numbers Models, area codes and applicable serial Nos. given in this parts catalogue can be identified as follows. Example VE3EA A 2MCU Model Area code Type Applicable Engine serial No. Applicable Frame serial No. Applicable carburettor identification No. KARIZMA ID India XXXXEDYZX YYYYY MBLXXXXEFYZX YYYYY
6. 6. 7 11. Location of stamped serial number CARBURETTOR IDENTIFICATION NUMBER ENGINE SERIAL NUMBER re miu m FRAME SERIAL NUMBER (ON FRAME BODY)
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 allowed for replacement of parts covered by the warranty during the period the warranty is in effect. The F.R.T. for those parts which are not listed herein should be determined 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 necessary servicing tools listed in the service manual (motorcycle) which describes the service policies are available close at hand and the work is performed by a mechanic with normal skill. c. Time required for inspection and operational test following the servicing is included in the F.R.T. 2. Method of computing The job times are listed in tenth of an hour to simplify computation. (Example) 0.3 = 18 minutes 5.6 = 5 hours and 36 minutes Hero MotoCorp CONVERSION CHART Hours Minutes Hours Minutes 0.1 6 0.6 36 0.2 12 0.7 42 0.3 18 0.8 48 0.4 24 0.9 54 0.5 30 1.0 60 3. Computing the F.R.T. When several jobs are performed at the same time, make the calculation in the following manner. a. Jobs of non duplicated nature The F.R.T. for the job is obtained by totaling the F.R.T. for each part replaced. (Example) Replacement of cylinder and clutch spring. SERVICE ITEM F.R.T. Cylinder 3.1* Clutch spring 0.8 The F.R.T. For the job is : 3.1+0.8=3.9 b. Jobs of duplicated nature Take the F.R.T. For the last part to be replaced. (Example) Replacement of piston and cylinder head gasket. SERVICE ITEM F.R.T. Cylinder head gasket 2.8* Piston 3.2* The F.R.T. for the job is : 3.2 c. Jobs of partially related nature Total up the F.R.T. For all of the parts replaced and then subtract the F.R.T. for the duplicated operation. (Example) Replacement of gearshift drum and crankshaft assembly. SERVICE ITEM F.R.T. Gear Shift Drum 4.4* Crank Shaft 5.3* Crankcase Disassembly 4.4* The F.R.T. for the job is : (4.4+5.3)-4.4=5.3 Crankcase disassembly is the duplicated operations. *The F.R.T. Shown with (*) includes engine removal and installation. 8
8. 8. NO. SERVICE ITEM F.R.T. 1. Engine 1.8 2. Cylinder head 2.8* 3. Carburettor 0.6 4. Operations other than replacing parts a. Removed and installation b. Adjustment, measurement and cleaning Engine NO. SERVICE ITEM F.R.T. 1. Engine oil - inspection (excluding oil change) 0.1 2 Oil filter screen cleaning 0.1 3 Cleaner element cleaning 0.2 4 Compression pressure measurement 0.1 5 Spark plug - adjustment and cleaning 0.1 6 Ignition timing - inspection 0.2 7 Valve clearance-adjustment 0.4 8 Throttle operation-adjustment 0.1 9 Carburettor idle - adjustment 0.1 10 Carburettor-float level measurement 0.5 11 Clutch-adjustment 0.1 Frame NO. SERVICE ITEM F.R.T. 1 Front brake - air bleeding 0.2 2 Front brake - adjustment 0.2 3 Rear brake - adjustment 0.1 4 Brake - operation test 0.1 5 Headlight - aimings 0.1 6 Drive chain (includes tension adjustment however, does not include sprocket) 0.1 c. Overhaul NO. SERVICE ITEM F.R.T. 1 Carburettor 1.0 9
9. 9. 2 E-1 CYLINDER HEAD COVER . . . . . . . . . . . . . . 17-18 E-2 CYLINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 E-3 CAM SHAFT/VALVE . . . . . . . . . . . . . . . . . . . 20-21 E-4 CAM CHAIN TENSIONER.. . . . . . . . . . . . . . . 22-23 E-5 RIGHT CRANK CASE COVER . . . . . . . . . . . . . . 24 E-6 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 E-7 LEFT CRANKCASE COVER.. . . . . . . . . . . . . 22-23 E-7A A.C. GEN. FLYWHEEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 E-7B STARTER MOTOR . . . . . . . . . . . . . . . . . . . . . . . 26 E-8 CRANK CASE . . . . . . . . . . . . . . . . . . . . . . . . 26-27 E-8A OIL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 E-9 CRANK SHAFT/PISTON. . . . . . . . . . . . . . . . . . . 35 E-10 TRANSMISSION (MAIN SHAFT/COUNTER SHAFT/GEARS) . . . . . . . . . . . . . . . . . . . . . . . . . 36 E-11 SPINDLE KICK STARTER . . . . . . . . . . . . . . . . . 37 E-12 GEAR SHIFT DRUM . . . . . . . . . . . . . . . . . . . . . . 38 E-13 CARBURETTOR . . . . . . . . . . . . . . . . . . . . . . . . . 39
10. 10. BLOCK INDEX FRAME GROUP F-1 HEAD LIGHT. . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 F-1A FRONT COWL. . . . . . . . . . . . . . . . . . . . . . . . 44-46 F-2 SPEEDOMETER . . . . . . . . . . . . . . . . . . . . . . 47-48 F-3 FRONT BRAKE MASTER CYLINDER . . . . . 49-50 F-3A HANDLE LEVER/SWITCH/CABLE . . . . . . . . 51-52 F-4 HANDLE PIPE/TOP BRIDGE/KEY SET . . . . 53-54 F-5 STEERING STEM. . . . . . . . . . . . . . . . . . . . . . . . 55 F-6 FRONT FENDER . . . . . . . . . . . . . . . . . . . . . . . . 56 F-7 FRONT FORK . . . . . . . . . . . . . . . . . . . . . . . . 57-58 F-8 CALIPER ASSY. RIGHT FRONT . . . . . . . . . . . . . 59 F-9 FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . 60-61 F-10 REAR BRAKE PANEL . . . . . . . . . . . . . . . . . . . . . 62 F-11 REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . 63-64 F-12 SEAT ASSY./COWL REAR . . . . . . . . . . . . . . 65-66 F-13 FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . 67-68 F-14 SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 F-15 AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . 70-71 F-16 EXHAUST MUFFLER. . . . . . . . . . . . . . . . . . 72-73 F-17 STEP PILLION. . . . . . . . . . . . . . . . . . . . . . . . . . 74 F-18 GEAR CHANGE PEDAL/KICK STARTER . . 75-76 F-18AMAIN STAND/SIDE STAND . . . . . . . . . . . . . . . 77 F-19 SWINGARM/CHAIN CASE . . . . . . . . . . . . . 78-79 F-20 REAR CUSHION . . . . . . . . . . . . . . . . . . . . . . . . 80 F-21 REAR FENDER . . . . . . . . . . . . . . . . . . . . . . . . . 81 F-22 WINKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . 82-83 F-23 TAILLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 F-24 WIRE HARNESS . . . . . . . . . . . . . . . . . . . . . . . . 85 F-24ABATTERY ASSY.. . . . . . . . . . . . . . . . . . . . . . . . . 86 F-25 FRAME BODY. . . . . . . . . . . . . . . . . . . . . . . . 87-88 F-26 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89 F-27 STRIPES/MARKS . . . . . . . . . . . . . . . . . . . . 90-106 F-28 SAREE GUARD . . . . . . . . . . . . . . . . . . . . . . . . 107 F-29 CAUTION LABEL . . . . . . . . . . . . . . . . . . . . . . . 108 12 e imr um e um mr i e imr um e imr um e imr um e imr um
11. 11. BLOCK INDEX ENGINE GROUP E-1 19 E-2 21 E-3 22 E-5 24 E-6 25 13 E-4 23 *Ref. No. on the index illustration may be different From that on the text E-7A 28 E-7B 29E-7 26 14 14 2 22 26 27 22 27 1 20 10 13 3 3 16 13 17 10 30 16 20 13 13 16 16 17 17 19 4 25 11 21 29 23 18 8 28 3 3 28 9 24 6 7 15 12 17 3 3 19 5 25 15 2 1 4 4 3 3 3 3 3 3 1 1 12 12 2 3 3 4 4 5 16 11 11 8 9 9 10 10 13 1313 13 14 14 15 15 8 67 2 31 8 8 6 5 4 12 10 10 9 12 13 11 7 2 11 11 1 12 12 13 12 12 12 9 12 10 3 4 8 5 6 12 12 12 12 12 7 7 14 12 10 18 16 17 13 15 5 8 7 7 7 9 9 9 9 11 8 10 11 9 7 12 1 2 12 6 4 5 3 12 1 23 23 23 26 19 2 25 21 25 8 9 24 20 23 6 17 11 10 17 13 18 12 5 15 7 7 3 16 16 4 22 22 15 14 1 4 4 6 5 3 3 2 12 11 7 7 10 10 8 108 9 6
12. 12. BLOCK INDEX ENGINE GROUP E-8 30 E-8A 32 E-9 33 E-11 36 E-12 37E-10 34 *Ref. No. on the index illustration may be different From that on the text E-13 39 14 21 21 17 719 5 3 14 15 21 21 21 22 21 9 20 18 6 13 21 21 21 102 13 13 12 11 8 1 1211 13 4 21 16 14 14 14 15 12 12 13 13 11 11 1 8 9 2 7 8 10 4 5 3 6 2 13 13 10 10 7 4 3 5 1 12 11 9 8 6 1 24 2 10 22 12 23 14 6 7 18 27 1716 26 28 21 21 15 19 9 3 8 25 27 13 22 23 1120 45 22 23 29 7 6 8 3 1 11 14 4 2 9 5 10 13 12 17 6 4 1 18 11 12 16 16 10 9 3 5 7 14 15 13 8 2 19 3 4 13 28 28 28 28 25 27 25 30 28 22 27 28 32 34 20 33 31 14 23 23 7 92 6 5 1 8 19 17 26 10 15 11 26 24 24 2429 21 12 18 16
13. 13. BLOCK INDEX FRAME GROUP F-1 17 F-1A 18 F-2 20 F-4 26 F-6 28 F-7 29 F-12 31 F-3 22 F-3A 24 13 2323 2424 2222 2222 1515 2727 2020 99 66 1010 1111 66 77 88 1212 1414 2525 2828 1313 2828 2626 1818 1717 2121 1919 1616 1717 1919 2121 44 22 11 11 33 55 NN PPAASSSSIINNGG 9 17 17 16 16 10 11 11 13 13 13 13 14 7 8 6 5 4 15 8 2 3 1 12 12 9 17 11 10 8 21 21 23 23 16 19 19 181818 18 18 14 18 18 19 19 19 20 19 19 12 12 15 1 6 7 2 22 4 4 20 22 13 5 3 7 66 5 3 4 6 1 6 5 2 3 4 3 4 4 3 14 16 11 1 4 3 2 7 13 10 8 17 5 20 18 19 15 12 21 9 6 2 4 22 3 1 7 9 17 22 17 16 17 17 16 6 18 13 8 10 15 19 12 23 23 11 19 21 20 14 5 2513 13 11 16 19 6 710989 22 22 2323 2424 17 12 1 2 25 14 12 20 18 25 14 12 20 18 15 7 10 9 8 9 25 5 4 3 17 21 21 21 21 RF . 14 20 11 4 22 22 20 15 21 21 21 21 21 21 21 21 21 16 19 21 2121 21 21 10 18 18 18 21 6 8 7 5 17 9 2 12 13 9 3 3 1 1 1 e u r mime u r mim 23 57 6 19 19 19 19 24 20 23 23 181623 18 14 19 20 19 17 19 22 22 15 12 12 1111 8 9 10 10 13 2 25 26 4 3 21
14. 14. BLOCK INDEX FRAME GROUP F-14 35 F-17 36F-13 33 14 F-18A 39 F-19 40F-18 37 F-24 45F-22 42 F-23 44 8 4 4 13 3 13 4 4 10 2 2 7 11 8 8 10 18 15 18 615 29 8 9 10 10 11 3 3 13 13 312 14 17 16 2 17 16 16 17 17 16 4 5 2 1 7 6 8 3 9 13 10 12 17 13 15 11 8 6 20 20 208 5 2510 13 10 10 3 4 1 2 25 25 7 13 12 23 16 22 21 24 14 19 18 18 19 20 15 15 13 11 16 13 11 1 1 11 13 1 4 2 6 5 8 3 10 14 14 7 11 14 12 9 10 1 7 4 8 3 8 8 2 5 8 8 6 8 4 1 7 5 13 11 23 10 22 21 17 12 24 24 14 6 25 25 181 3 2 9 7 20 4 8 20 15 16 19 21 22 23 12 14 8 15 15 15 10 10 9 9 9 13 15 9 16 16 17 18 2 3 6 4 7 5 1 11 19 10 10 9 16 16 16 5 7 14 21 12 17 15 11 18 3 2 6 1 4 20 20 8 16 16 19 19 19 13 19 32 13 3 14 1 23 18 21 26 27 28 25 31 29 25 2519 16 17 15 20 20 34 24 33 6 5 2 4 5 22 8 7 9 11 12 30 30 10 35
15. 15. BLOCK INDEX FRAME GROUP F-25 47 15 F-24A 46 F-27 49 F-28 68 26 26 26 16 35 18 1 8 31 25 28 1 27 3 5 4 4 20 20 19 34 34 35 35 30 27 3 25 28 33 33 2 6 2 24 36 29 29 1213 32 21 30 10 10 17 15 1 4 24 23 23 8 7 830 9 11 30 11 22 36 22 1 ST.MAG. ST.MAG. WITH ST.MOTOR WITH ST.MOTOR BATT.+ BATT.- 9 16 10 16 15 11 16 3 2 12 12 6 7 84 8 5 13 13 14 14 1 2 2 4 4 5 6 3 5 em m r iuA B C 2 E C B A D B 19 C E B B A 17 I J E A 4 E 15 1 14 E F F 7 E E G BDA C 11 E C A13 E D B D E 9 B A C B
16. 16. ENGINE GROUP
17. 17. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) 17 * HEAD ASSY., CYLINDER......................*4.0 * GUIDE, VALVE......................................*3.8 (INC. REAMING) (ADD 0.3 FOR EACH) (ADD 0.7 FOR EACH) (ADD MORE 0.2 IF PERFORMED) * GASKET, CYLINDER HEAD.................*2.8 * COVER 'L' CYLINDER HEAD................0.2 * INSULATOR, CARBURETTOR..............0.3 * BOLT, STUD, II 7X35.............................. (ADD 0.1 FOR EACH) * SPARK, PLUG........................................0.1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 11105-KFB-750 PIPE COMP. AIR SUCTION ..................................................... 1 12000-KRY-960 HEAD ASSY., CYLINDER......................................................... 1 12195-KRC-920 RUBBER, INSERT.................................................................... 1 12204-439-305 GUIDE, INLET VALVE (O.S.).................................................... 1 12206-KCN-305 GUIDE, EXH. VALVE (O.S.) ..................................................... 1 12251-KT0-711 GASKET, CYLINDER HEAD .................................................... 1 12271-383-000 RUBBER, OIL SEAL................................................................. 1 12331-KRY-960 COVER LEFT CYL. HEAD (NH-35M) ...................................... 1 12339-KT0-711 GASKET, PULSE GEN. BASE ................................................. 1 12361-KEZ-900 HOLE CAP, TAPPET ADJUSTING ........................................... 2 16210-KFB-000 INSULATOR, CARBURETTOR ................................................ 1 16219-MN4-000 BAND C INSULATOR ............................................................. 1 90004-GHB-700 BOLT, FLANGE, NSHF, 6X35................................................... 4 90041-KW1-900 BOLT, STUD, II 7X35................................................................ 2 90091-MM5-640 BOLT, FLANGE, SOCKET, 6X22.............................................. 2 90442-028-000 WASHER, SEALING, 8MM....................................................... 4 90443-107-000 NUT, CAP, 8MM........................................................................ 4 91301-107-000 'O'-RING, 75X2.5...................................................................... 1 91301-200-000 'O'-RING, 10X1.6...................................................................... 2 91303-KCS-920 'O'-RING, 35X3......................................................................... 2 E - 1 FR. CYLINDER HEAD/ COVER 26 248 8 31 19 24 16 20 2 28 9 30 11 6 29 29 7 27 4 5 18 10 23 3 13 15 16 16 16 18 19 19 19 20 20 20 21 22 23 25 26 28 1 14 17 12 3
18. 18. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) 18 * HEAD ASSY., CYLINDER......................*4.0 * GUIDE, VALVE......................................*3.8 (INC. REAMING) (ADD 0.3 FOR EACH) (ADD 0.7 FOR EACH) (ADD MORE 0.2 IF PERFORMED) * GASKET, CYLINDER HEAD.................*2.8 * COVER 'L' CYLINDER HEAD................0.2 * INSULATOR, CARBURETTOR..............0.3 * BOLT, STUD, II 7X35.............................. (ADD 0.1 FOR EACH) * SPARK, PLUG........................................0.1 21 22 23 24 25 26 27 28 29 30 91304-KCS-920 'O'-RING, 33.5X3...................................................................... 1 91305-KFN-900 'O'-RING, 9.8X1.9..................................................................... 1 93500-05032-0G SCREW, PAN 5X32 .................................................................. 1 94101-06000 WASHER, PLAIN 6MM............................................................. 1 94301-08140 DOWEL, PIN. 8X14 .................................................................. 2 94301-10120 DOWEL, PIN. 10X12 ................................................................ 2 96001-06016-00 BOLT, FLANGE, SH. 6X16 ....................................................... 2 96001-06025-00 BOLT, FLANGE, SH. 6X25 ....................................................... 2 96700-06125-00 SOCKET, BOLT, 6X125 ............................................................ 1 98069-58916-M0 SPARK PLUG (DPR8EA-9) ...................................................... 1 E - 1 FR. CYLINDER HEAD/ COVER 26 248 8 31 19 24 16 20 2 28 9 30 6 29 29 7 27 4 5 18 23 3 13 15 16 16 16 18 19 19 19 20 20 20 21 22 23 25 26 28 1 14 12 11 10 17
19. 19. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) E - 2 FR. 19 CYLINDER * CYLINDER COMP..................................*3.1 * GASKET, CYLINDER ............................*3.0 1 2 3 4 12100-KRY-960 CYLINDER COMP.,................................................................. 1 12191-KCN-010 GASKET, CYLINDER.............................................................. 1 12195-KRC-920 RUBBER, INSERT .................................................................. 6 94301-10200 DOWEL PIN, 10 X 20.............................................................. 2 2 1 4 4 3 3 3 3 3 3
20. 20. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) E - 3 FR. 20 CAM SHAFT/VALVE 12208-KCS-920 SEAL, VALVE STEM ............................................................... 2 14100-KRY-900 CAM SHAFT COMP................................................................ 1 14431-KEH-900 ARM, VALVE ROCKER........................................................... 2 14451-437-000 SHAFT, ROCKER ARM........................................................... 2 14456-KG2-950 SET PLATE, ROCKER ARM ................................................... 1 14711-KBB-900 VALVE, INLET ......................................................................... 1 14721-KBB-900 VALVE, EXHAUST .................................................................. 1 14751-KEH-910 SPRING, VALVE OUTER........................................................ 2 14761-KEH-910 SPRING, VALVE INNER ......................................................... 2 14771-107-020 RETAINER, VALVE SPRING................................................... 2 14775-107-000 SEAT, VALVE SPRING OUTER .............................................. 2 14776-107-010 SEAT, VALVE SPRING INNER................................................ 2 14781-HA0-770 COTTER, VALVE..................................................................... 4 90012-KN6-930L SCREW, TAPPET ADJUSTING .............................................. 2 90206-250-000 NUT, TAPPET ADJUSTING..................................................... 2 93600-06016-OA SCREW, FLAT, 6 X 16............................................................. 1 1 1 12 12 2 3 3 4 4 5 16 11 11 8 9 9 10 10 13 1313 13 14 14 15 15 8 67 * CAM SHAFT COMP...............................*2.8 * ARM, VALVE ROCKER..........................*2.4 (ADD 0.1 FOR EACH) * VALVE....................................................*3.6 (INC. REFACING) (EXC. VALVE GUIDE REPLACEMENT) * SPRING, VALVE....................................*3.4 (ADD 0.1 FOR EACH) (INC. RELATIVE PART) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
21. 21. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) E - 4 FR. 21 CAM CHAIN TENSIONER * SPROCKET, CAM...................................0.7 * CHAIN CAM............................................1.6 * TENSIONER., CAM CHAIN....................1.7 * LIFTER ASSY., TENSIONER..................0.4 * GASKET, TENSIONER LIFTER........... * GUIDE, CAM CHAIN.............................*2.8 1 2 3 4 5 6 7 8 9 10 11 12 13 14321-KEH-900 SPROCKET, CAM................................................................... 1 14401-KFB-751 CHAIN, CAM ........................................................................... 1 14500-KBB-900 TENSIONER, CAM CHAIN ..................................................... 1 14520-KRY-971 LIFTER ASSY., TENSIONER (PRICOL) ................................. 1 14523-KEH-910 GASKET, TENSIONER LIFTER.............................................. 1 14535-437-000 BOLT, TENSIONER PIVOT..................................................... 1 14550-KFB-000 GUIDE, CAM CHAIN............................................................... 1 90002-KW1-900 BOLT, FLANGE, 6X10............................................................. 2 90005-KY7-000 SCREW, PAN, 6X6.................................................................. 1 90071-MG8-000 BOLT, FLANGE, SOCKET, 6X16 ............................................ 2 90475-703-000 WASHER 'C'8MM.................................................................... 1 90488-425-000 WASHER, SEALING, 6 MM .................................................... 2 91306-MG3-000 'O'-RING, 1.5X9.5.................................................................... 1 2 31 8 8 6 5 4 12 10 10 9 12 13 11 7
22. 22. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) 22 11330-AAP-H00 COVER COMP R CRANK CASE ..................................................... 1 11393-KCN-010 GASKET, RIGHT COVER................................................................. 1 15650-KCN-000 GAUGE, OIL LEVEL......................................................................... 1 22810-KBB-900 LEVER COMP., CLUTCH................................................................. 1 22815-428-000 SPRING, CLUTCH LEVER............................................................... 1 90701-KFN-850 PIN, SPRING, 3 X 10........................................................................ 1 91053-719-005 BRG., NEEDLE, 12 X 16 X 10.......................................................... 2 91201-KCS-920 OIL SEAL, 20 X 34 X 7 ..................................................................... 1 91206-KCS-920 OIL SEAL, 14 X 28 X 4 ..................................................................... 1 91307-035-000 'O'-RING, 18 X 3............................................................................... 1 94301-08140 DOWEL PIN, 8 X 14 ......................................................................... 2 96001-06040-00 BOLT, FLANGE, SH., 6 X 40 ............................................................ 11 96001-06050-00 BOLT, FLANGE, SH. 6 X 50 ............................................................ 1 1 2 3 4 5 6 7 8 9 10 11 12 13 * COVER COMP., R CRANKCASE ........ 0.8 * LEVER COMP., CLUTCH .................... GASKET, R CRANKCASE COVER...... 0.7 * OIL SEAL ,12 X22 X 5.......................... * OIL SEAL ,16 X28 X 7.......................... 0.6 E - 5 RIGHT CRANK CASE COVER F .R 9 3 4 8 5 6 7 7 10 2 11 11 11 11 11 11 11 11 11 11 11 1 10 12
23. 23. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) E - 6 FR. 23 CLUTCH * OUTER COMP., CLUTCH..................1.1 * CENTER COMP., CLUTCH................. * DISK, CLUTCH FRICTION................. (ONE OR ALL) INC. RFELATIVE PART PLATE, CLUTCH PRESSURE * ROD, CLUTCH CH LIFTER.................07 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 15451-KRY-970 WASHER, LOCK 16MM.......................................................... 1 22100-KRY-900 OUTER COMP., CLUTCH....................................................... 1 22121-KPK-900 CENTER COMP., CLUTCH..................................................... 1 22125-KW7-900 SEAT, JUDDER SPRING ........................................................ 1 22131-KPM-850 GUIDE, CLUTCH OUTER....................................................... 1 22201-KBW-900 DISC, CLUTCH FRICTION ..................................................... 1 22201-KPM-850 DISK, CLUTCH FRICTION, 4 X 8 X 45................................... 3 22201-MJ8-000 DISK, CLUTCH FRICTION ..................................................... 1 22321-KE8-000 PLATE, CLUTCH..................................................................... 4 22355-KPK-900 PLATE, CLUTCH PRESSURE................................................ 1 22361-KPK-900 PLATE, CLUTCH LIFTER ....................................................... 1 22366-KFB-000 ROD, CLUTCH LIFTER .......................................................... 1 22401-KRY-900 SPRING, CLUTCH.................................................................. 4 22402-KPM-850 SPRING, JUDDER.................................................................. 1 90050-357-000 SPECIAL BOLT, FLANGE, 6 X 22........................................... 4 90231-KB5-720 NUT, LOCK, 16MM.................................................................. 1 90461-KPK-900 WASHER, 20 MM.................................................................... 1 91008-KK6-000 BEARING, BALL RADIAL, 16003............................................ 1 14 12 10 18 16 17 13 15 5 8 7 7 7 9 9 9 9 11
24. 24. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) E - 7 FR. 24 LEFT CRANK CASE COVER * COVER LEFT CRANK CASE.................0.9 * COVER, REDUCTION GEAR............... * COVER, LEFT RR., CRANK CASE........0.1 * GASKET, LEFT COVER.........................0.6 * GEAR, REDUCTION............................. * SHAFT, IDLE GEAR............................... 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 11341-KRY-960 COVER,'L'CRANK CASE ....................................................... 1 11355-KRY-960 COVER, REDUCTION GEAR................................................. 1 11361- 00 COVER, 'L' REAR. CRANK CASE.......................................... 1 11363-437-620 RUBBER, REAR COVER MOUNT ......................................... 1 11370-KRY-900A GUIDE COMP., DRIVE CHAIN ............................................... 1 11395-KCN-010 GASKET 'L' COVER................................................................ 1 17622-GB7-900 RUBBER, CUSHION............................................................... 2 28130-KFB-000 GEAR, REDUCTION............................................................... 1 28132-KN6-930 SHAFT, REDUCTION GEAR .................................................. 1 28140-KFB-000 GEAR, IDLE (16T)................................................................... 1 28142-KW1-900 SHAFT, IDLE GEAR................................................................ 1 35752-KRY-900A RUBBER, NEUTRAL SW. ....................................................... 1 90084-KVE-930 CAP, 14 MM ........................................................................... 1 90087-KTC-A20 CAP, 30 MM ........................................................................... 1 90417-041-000 WASHER, SHIFT DRUM SIDE ............................................... 2 90502-KEZ-900 COLLAR, RUBBER CUSHION ............................................... 2 90703-HC4-000 DOWEL PIN, 10 X 14.............................................................. 2 91303-377-000 'O'-RING, 13.8X2.5.................................................................. 1 91304-MZ0-760 'O'-RING, 63 X 3...................................................................... 1 91356-KEH-910 'O'-RING, 30 MM ..................................................................... 1 AAP-H 23 23 23 26 19 2 25 21 25 8 9 20 2 246 17 11 10 17 13 18 12 5 15 7 7 3 16 16 4 22 22 15 14 1
25. 25. E - 7 FR. 25 LEFT CRANK CASE COVER * COVER LEFT CRANK CASE.................0.9 * COVER, REDUCTION GEAR............... * COVER, LEFTOR RR., CRANK CASE..0.1 * GASKET, LEFT COVER.........................0.6 * GEAR, REDUCTION............................. * SHAFT, IDLE GEAR............................... 21 22 23 24 25 26 96001-06020-00 BOLT, FLANGE, SH., 6 X 20................................................... 1 96001-06028-00 BOLT, FLANGE, SH., 6 X 28................................................... 1 96001-06040-00 BOLT, FLANGE, SH., 6 X 40................................................... 4 96001-06060-00 BOLT, FLANGE, SH., 6 X 60................................................... 1 96001-06070-00 BOLT, FLANGE, SH., 6 X 70................................................... 2 96001-06080-00 BOLT, FLANGE, SH., 6 X 80................................................... 1 23 23 23 26 19 2 25 21 25 8 9 20 2 246 17 11 10 17 13 18 12 5 15 7 7 3 16 16 4 22 22 15 14 1 Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA)
26. 26. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) E - 7A FR. 26 A.C. GEN. FLYWHEEL * GEAR COMP., STARTER DRIVEN * COLLAR STARTER DRIVEN GEAR * OUTER COMP., ST CLUTCH..................0.7 * A.C. GEN. FLYWHEEL............................0.9 1 2 3 4 5 6 7 8 9 10 11 12 28110-KEW-900 GEAR COMP., STARTER DRIVEN......................................... 1 28114-KN6-930 COLLAR, STARTER DRIVEN GEAR...................................... 1 28125-KFC-791 OUTER COMP., STARTING CLUTCH.................................... 1 31100-KRY-901 A.C. GEN., FLWHEEL............................................................. 1 31110-KRY-901 FLY WHEEL COMP., .............................................................. 1 31120-KRY-901 STATOR COMP., ..................................................................... 1 32975-KFB-000 GUIDE, ACG CORD................................................................ 1 90089-KAS-900 BOLT, FLANGE, SOCKET, 5X14 ............................................ 2 90092-KE5-000 BOLT, STOPPER TENSIONER SHAFT.................................. 3 90101-KBH-003 BOLT, FLANGE, 10 X 65......................................................... 1 90403-KN6-930 WASHER, 10 X 24 .................................................................. 1 96700-06032-10 BOLT, SOCKET, 6 X 32........................................................... 6 8 10 11 9 7 12 1 2 12 4 5 3 12 6 9 9 8
27. 27. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) E - 7B FR. 27 STARTER MOTOR * MOTOR ASSY., STARTER....................0.7 1 2 3 4 5 6 7 8 9 10 11 12 31200-KPS-A11 MOTOR ASSY., STARTER ....................................................... 1 31201-MEW-921 CARBON BRUSH SET A ........................................................ 1 31202-MEW-921 CARBON BRUSH SET A ........................................................ 1 31203-MEW-921 BRUSH HOLDER .................................................................... 1 31204-MEW-921 SPRING CARBON BUSH......................................................... 4 31205-HP5-601 BOLT, SET ................................................................................ 2 31206-MEW-921 TERMINAL BOLT...................................................................... 1 31207-HP5-601 RING......................................................................................... 2 90071-MB0-000 NUT, WASHER, 6 MM .............................................................. 1 91309-425-003 'O'-RING 24.4 X 3.1.................................................................. 1 91320-MB0-000 'O'-RING ................................................................................... 1 93892-05012-08 SCREW WASH, 5X12 .............................................................. 1 1 2 3 4 5 5 5 5 6 6 7 9 8 8 9 10 12 11
28. 28. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) E - 8 FR. 28 CRANK CASE * CRANK CASE COMP., RIGHT...............*4.9 * GASKET, CRANK CASE........................*4.4 * CRANK CASE COMP., LEFT.................*5.8 * SCREEN, OIL FILTER............................0.1 (INC. RELATIVE PART) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 11100-KRY-960 CRANK CASE COMP., RIGHT ............................................... 1 11191-KCN-010 GASKET, CRANK CASE......................................................... 1 11200-KRY-960 CRANK CASE COMP., LEFT.................................................. 1 12361-KEZ-900 HOLE CAP, TAPPET ADJUSTING.......................................... 1 14513-KBB-900 PLATE CAM CHAIN SET ........................................................ 1 15421-107-000 SCREEN, OIL FILTER............................................................. 1 15426-107-000 SPRING, OIL FILTER SCREEN.............................................. 1 22838-437-000 HOLDER, CLUTCH WIRE ...................................................... 1 32976-KCT-690 CLAMPER, WIRE HARNESS ................................................. 1 35750-KCS-920 CONTACT, NEUTRAL SWITCH.............................................. 1 90031-KFB-000 BOLT 'A' STUD CYLINDER..................................................... 2 90032-KFB-000 BOLT 'B' STUD CYLINDER..................................................... 2 90703-HC4-000 DOWEL PIN, 10 X 14.............................................................. 4 91008-KCN-003 BEARING, NEEDLE, 21 MM................................................... 1 91106-KB4-003 BEARING, NEEDLE, 15 MM................................................... 1 91206-KCS-920 OIL SEAL, 14 X 28 X 4............................................................ 1 91303-KCS-920 'O'-RING, 35 X 3...................................................................... 1 91312-107-000 'O'-RING, 7 X 1.7..................................................................... 1 21 21 17 719 5 3 14 15 21 21 21 22 21 9 20 18 6 13 21 21 21 102 13 13 12 11 8 1 1211 13 4 21 16
29. 29. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) E - 8 FR. 29 CRANK CASE * CRANK CASE COMP., RIGHT...............*4.9 * GASKET, CRANK CASE........................*4.4 * CRANK CASE COMP., LEFT.................*5.8 * SCREEN, OIL FILTER............................0.1 (INC. RELATIVE PART) 19 20 21 22 95701-06012-08 BOLT, FLANGE, 6 X 12........................................................... 1 96001-06014-00 BOLT, FLANGE, SH. 6 X 14.................................................... 1 96001-06050-00 BOLT, FLANGE, SH. 6 X 50.................................................... 10 96001-06060-00 BOLT, FLANGE, SH. 6 X 60.................................................... 1 21 21 17 719 5 3 14 15 21 21 21 22 21 9 20 18 6 13 21 21 21 102 13 13 12 11 8 1 1211 13 4 21 16
30. 30. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) E - 8A FR. 30 OIL PUMP * OIL PUMP ASSY......................................0.9 * ROTOR COMP., OIL FILTER.................. * CAP, OIL FILTER ROTOR...................... * GEAR, PRIMARY DRIVE........................1.1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 15100-KFB-000 OIL PUMP ASSY.,.............................................................. ..... 1 15430-440-030 ROTOR COMP., OIL FILTER .................................................. 1 15436-107-000 CAP, OIL FILTER ROTOR....................................................... 1 15441-KCS-650 OIL, THROUGH ...................................................................... 1 15446-107-000 SPRING, OIL THROUGH........................................................ 1 15459-KWK-900 GASKET, OIL FILTER CAP..................................................... 1 23121-KBB-900 GEAR, PRIMARY DRIVE (22T) .............................................. 1 90101-440-000 SCREW, FLAT. 6 X 30............................................................. 2 90231-KCS-920 NUT, LOCK, 16 MM................................................................. 1 90434-KN6-930 WASHER, 16 MM.................................................................... 1 91304-KK3-830 'O'-RING, 9.4 X 2.4.................................................................. 2 92101-05020-0A BOLT, HEX., 5 X 20................................................................. 2 93600-04012-0A SCREW, FLAT, 4 X 12............................................................. 2 93700-05012-0A SCREW, OVAL, 5 X 12 ........................................................... 3 94251-08000 PIN LOCK, 8 MM..................................................................... 1 14 14 14 15 12 12 13 13 11 11 1 8 9 2 7 8 10 4 5 3 6
31. 31. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) E - 9 FR. 31 CRANK SHAFT/PISTON * CRANK SHAFT COMP..........................*5.3 * RING SET, PISTON.............................. *3.2 * PISTON.................................................. * PIN, PISTON.........................................*3.1 * ROD, CONNECTING (ACTUAL TIME) (INC. RELATIVE PART) * BRG. BALL RADIAL, 72 X 28 X 18.........*4.6 1 2 3 4 5 6 7 8 9 10 11 12 13 13000-KRY-903 CRANK SHAFT, COMP........................................................... 1 13011-KRY-900 RING SET, PISTON (STD)...................................................... 1 13101-KRY-901 PISTON (STD)......................................................................... 1 13111-440-000 PIN, PISTON ........................................................................... 1 13201-KFB-300 ROD, CONNECTING .............................................................. 1 13380-KCN-300 PIN COMP., CRANK ............................................................... 1 14311-KN6-931 SPROCKET, TIMING .............................................................. 1 90471-KW1-900 KEY WOODRUFF, 25 X 18 ..................................................... 1 90741-KFB-000 KEY WOODRUFF, 4 MM ........................................................ 1 91001-KCN-003 BRG. BALL RADIAL, 28 X 72 X 18 ......................................... 2 91102-KC6-003 ROLLER, 4 X 14.8 A ............................................................... 18 91103-KC6-003 ROLLER, 4 X 14.8 B ............................................................... (18) 91104-KC6-003 ROLLER, 4 X 14.8 C............................................................... (18) 91105-KW3-003 RETAINER, CONROD L END................................................. 1 94601-15000 CLIP, PISTON PIN, 15 MM...................................................... 2 2 13 13 10 10 7 4 3 5 1 12 11 9 8 6
32. 32. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) E - 10 FR. 32 TRANSMISSION (MAIN SHAFT/COUNTER SHAFT/GEARS) * MAIN SHAFT.........................................*5.3 (INC. RELATIVE PART) * COUNTER SHAFT................................*4.8 (INC. RELATIVE PART) (WHEN SERVICING COMP., UNIT) * SPROCKET, DRIVE...............................0.2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 11108-KHA-940 PLATE, BEARING SET ........................................................... 1 23211-KHA-940 SHAFT MAIN, TRANSMISSION ............................................. 1 23221-KRY-900 SHAFT COUNTER, TRANSMISSION..................................... 1 23426-KBB-900 GEAR C1 (36T) ...................................................................... 1 23427-KW1-900 BUSH, 16.5 X 19.5 X 9............................................................ 1 23431-KRY-900 BUSH, 20 MM ......................................................................... 1 23441-KBB-900 GEAR, M2 (18T)...................................................................... 1 23451-KRY-970 GEAR C-2 (31T)...................................................................... 1 23452-KW1-900 BUSH, 20 X 23 X 9.................................................................. 1 23461-KBB-900 GEAR, M3 (19T)...................................................................... 1 23471-KBB-900 GEAR, C3 (24T)...................................................................... 1 23481-KBB-900 GEAR, M4 (22T)...................................................................... 1 23491-KBB-900 GEAR, C4 (22T)...................................................................... 1 23501-KRY-900 GEAR, M5 (27T)...................................................................... 1 23511-KRY-970 GEAR, C-5 (22T)..................................................................... 1 23801-KCN-000 SPROCKET, DRIVE (13T) ...................................................... 1 23811-KR3-600 PLATE, A2 FIXING .................................................................. 1 90451-107-000 WASHER, THRUST, 15 MM.................................................... 1 90451-365-000 WASHER, THRUST, 15 MM.................................................... 1 90452-437-000 WASHER, THRUST, 16.5 MM................................................. 1 1 24 2 10 22 12 23 14 6 7 18 27 1716 26 28 21 21 15 19 9 3 8 25 27 13 22 23 1120 45 22 23 29
33. 33. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) E - 10 FR. 33 TRANSMISSION (MAIN SHAFT/COUNTER SHAFT/GEARS) * MAIN SHAFT.........................................*5.3 (INC. RELATIVE PART) * COUNTER SHAFT................................*4.8 (INC. RELATIVE PART) (WHEN SERVICING COMP., UNIT) * SPROCKET, DRIVE...............................0.2 21 22 23 24 25 26 27 28 29 90454-107-000 WASHER, THRUST, 20 MM.................................................... 2 90455-107-000 WASHER, SPLINE, 'A' 20MM ................................................. 3 90605-KTC-900 CIRCLIP 20MM ....................................................................... 3 91005-KCN-003 BRG. BALL RADIAL, 20 X 55 X 11 ......................................... 1 91015-KEH-910 BRG. BALL RADIAL, 6202U ................................................... 1 91201-KCS-920 OIL SEAL, 20 X 34 X 7............................................................ 1 92101-06010-0A BOLT, HEX., 6 X 10................................................................. 2 96100-62040-00 BRG. BALL RADIAL, 6204...................................................... 1 96600-08018-18 BOLT, SOCKET, 8 X 18........................................................... 1 1 24 2 10 22 12 23 14 6 7 18 27 1716 26 28 21 21 15 19 9 3 8 25 27 13 22 23 1120 45 22 23 29
34. 34. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) 13 6 1 12 9 8 14 10 2 10 7 4 5 11 15 15 3 28211-KHA-940 PINION, KICK STARTER ................................................................ 1 28221-KCJ-710 RATCHET, KICK STARTER ............................................................ 1 28251-KFN-850 SPINDLE, KICK STARTER ............................................................. 1 28253-KCJ-710 SPRING, KICK STARTER RATCHET ............................................. 1 28254-437-000 SET RATCHET SPRING ................................................................. 1 28261-KCJ-710 SPG., KICK STARTER.................................................................... 1 28262-437-000 COLLAR, KICK SPINDLE ............................................................... 1 28263-KCJ-710 RETAINER, STARTER SPRING ..................................................... 1 90004-437-000 BOLT KICK RATCHET .................................................................... 2 90401-KCJ-710 WASHER, 12 MM............................................................................ 1 90453-107-000 WASHER, THURST, 20 MM A....................................................... 2 90459-107-000 WASHER, THURST, 12 MM............................................................ 2 94510-16000 CIRCLIP, EXTERNAL, 16 MM......................................................... 1 94510-20000 CIRCLIP, EXTERNAL, 20 MM......................................................... 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 * SPINDLE, KICK STARTER.................. 0.7 (INC. RELATIVE PART) * SPRING, KICK RETURN * GEAR, KICK STARTER IDLE .............. 0.8 E - 11 SPINDLE KICK STARTER FR. 12 34
35. 35. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) E - 12 FR. 38 GEAR SHIFT DRUM * FORK GEAR SHIFT..............................*4.4 (ONE OR ALL) * DRUM, GEAR SHIFT............................ * CAM, GEAR SHIFT.................................1.2 * STOPPER COMP., GEAR SHIFT DRUM...............................0.8 (INC. RELATIVE PART)........................... * PLATE GEAR SHIFT............................... * SPINDLE COMP., GEAR SHIFT.............0.9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 24211-KW1-900 FORK RIGHT, GEAR SHIFT................................................... 1 24221-KBB-900 FORK LEFT, GEAR SHIFT ..................................................... 1 24231-KW1-900 FORK CENTER, GEAR SHIFT............................................... 1 24241-KCS-650 SHAFT, GEAR SHIFT FORK GUIDE ...................................... 1 24301-KCN-000 DRUM, GEAR SHIFT.............................................................. 1 24411-KCN-000 CAM, GEAR SHIFT................................................................. 1 24430-KW1-900 STOPPER COMP., GEAR SHIFT DRUM................................ 1 24435-KCN-000 SPRING, SHIFT DRUM STOPPER ........................................ 1 24610-KC6-000 SPINDLE COMP., GEAR SHIFT ............................................. 1 24621-107-760 PLATE, GEAR SHIFT.............................................................. 1 24631-107-000 SPRING, GEAR SHIFT PLATE............................................... 1 24651-107-000 SPRING, GEAR SHIFT RETURN ........................................... 1 35753-KCS-920 ROTOR, NEUTRAL SW. ......................................................... 1 90023-KW1-900 PIVOT SHIFT DRUM STOPPER ............................................ 1 90408-KW1-900 WASHER, 6MM....................................................................... 1 90451-001-000 WASHER, THRUST, 14 MM.................................................... 2 92000-06025-0A BOLT, HEX., 6 X 25................................................................. 1 94510-12000 CIRCLIP, EXTERNAL, 12 MM................................................. 1 94510-14000 CIRCLIP, EXTERNAL, 14 MM................................................. 1 96220-40100 ROLLER, 4 X 10...................................................................... 1 17 6 4 1 18 11 12 16 16 10 9 3 5 7 14 15 13 8 2 19
36. 36. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) 39 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 16010-KRY-901A O-RING ................................................................................... 1 16012-KRY-901 NEEDLE, SET JET ................................................................... 1 16013-KRY-901 FLOAT, SET.............................................................................. 1 16015-KRY-901 CHAMBER, SET FLOAT .......................................................... 1 16016-KRY-902 SCREW SET ............................................................................ 1 16028-KRY-901 SCREW SET ............................................................................ 1 16037-KRY-901 PLATE SET VALVE................................................................... 1 KRY 8 KRY AIR CUT KRY 60 KRY 0 SENSOR SET THROTTLE 16046- -901 VALVE, SET, STARTER............................................................ 1 1604 - -901 VALVE, SET, .............................................................. 1 16050- -901 SPG., COMPRESSION COIL................................................... 1 160 - -9 1 ...................................................... 1 16076-ND5-004 O RING, 1.3X4.3 ..................................................................... 1 16100-KRY-901 CARBURETTOR, ASSY........................................................... 1 16107-KRY-901 TOP COMP., ............................................................................. 1 16111-KRY-901 PISTON COMP., VACUUM....................................................... 1 16119-KRY-901 STAY, WIRE.............................................................................. 1 16145-KRY-901 JOINT, CONNECTOR .............................................................. 1 16155-KRY-901 VALVE COMP., FLOAT ............................................................. 1 16163-KRY-901 GASKET, FLOAT CHAMBER ................................................... 1 16165-KRY-901 HOLDER, NEEDLE JET........................................................... 1 3 FR. 12 1 1 19 29 2 2 7 13 4 1 5 6 9 10 14 15 17 18 20 11 22 23 25 25 2724 28 26 26 1 16 21 8 23 F-3 E - 13 CARBURETTOR * 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.............................. 0.6
37. 37. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) 39 21 22 23 24 25 26 27 28 29 30 31 32 33 34 16198-KRY-902 TUBE ........................................................................................ 1 17201-KRY-901 JOINT A VACUUM TUBE.......................................................... 1 93500-04008-1A SCREW, PAN 4X8 .................................................................... 2 93500-04014-1A SCREW, PAN 4X14 .................................................................. 2 93500-05010-1A SCREW, PAN 5X10 .................................................................. 2 93500-05010-1H SCREW, PAN 5X10 .................................................................. 2 93892-04010-18 SCREW, WASH 4X10............................................................... 2 95002-02079 CLIP, B1 7 TUBE ...................................................................... 1 95002-02089 CLIP, B1 8 TUBE ...................................................................... 1 95005-35055-20 TUBE, 3.5X55........................................................................... 1 95005-35090-20 TUBE, 3.5X90........................................................................... 1 95005-35190-20 TUBE, 3.5X190......................................................................... 1 99101-KRY-1250 JET MAIN # 125 ....................................................................... 1 99103-KRY-0350 JET SLOW # 35........................................................................ 1 3 FR. 12 1 1 19 29 2 2 7 13 4 1 5 6 9 10 14 15 17 18 20 11 22 23 25 25 2724 28 26 26 1 16 21 8 23 F-3 E - 13 CARBURETTOR * 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.............................. 0.6
38. 38. FRAME GROUP 15
39. 39. * LIGHT ASSY., HEAD............................ * SOCKET COMP., ................................. * BULB, HEAD LIGHT............................ * BULB, WEDGE BASE ......................... * PLATE, FRONT NUMBER ................... * STAY FR., NUMBER PLATE ................ F - 1 HEAD LIGHT FR. 9 17 17 16 16 10 11 11 13 13 13 13 14 7 8 6 5 4 15 8 2 3 1 12 12 17 Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) 3310B-AAP-H61 LIGHT ASSY., HEAD ................................................................ 1 33108-KRY-900 SPRING SPC............................................................................ 1 33110-AAP-H00 UNIT FR., COMB...................................................................... 1 33119-KRY-901 CLIP CORD .............................................................................. 1 33126-S05-003 COVER, RUBBER.................................................................... 1 33150-KRY-861 SOCKET COMP.,...................................................................... 1 34901-KSP-910 BULB, HEAD LIGHT, (HS1) 12 V-35/35W................................ 1 34908-GBG-840 BULB, WEDGE BASE T10....................................................... 2 64310-198-D20A PLATE, FR. NUMBER .............................................................. 1 64315-KRY-900 STAY FR., NUMBER PLATE .................................................... 1 90344-KEV-900 NUT C CLIP, 6 MM.................................................................. 2 93500-05010-1A SCREW, PAN, 5 X 10............................................................... 2 93500-06012-1A SCREW, PAN, 6 X 12............................................................... 2 93901-44220 SCREW, TAPPING, 4 X 10....................................................... 4 93903-25310 SCREW, TAPPING, 5 X 16....................................................... 1 94101-05000 WASHER, PLAIN, 5 MM........................................................... 2 95701-06012-07 BOLT, FLANGE, 6 X 12 ............................................................ 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 4
40. 40. 1 2 3 4 5 6 33603-053-650 COLLAR, RR. WINKER .......................................................... 2 61301-KRY-900ZA COWL CENTER FRONT (BLACK) ......................................... 1 61301-KRY-960ZB COWL CENTER FRONT (SPORTS RED).............................. 1 61301-KRY-860ZC COWL CENTER FRONT (PEARL FADELESS WHITE) ......... 1 61301-KRY-900ZE COWL CENTER FRONT (MOON YELLOW).......................... 1 61301-KRY-860ZE COWL CENTER FRONT (EBONY GRAY ME..) ..................... 1 61317-KCC-900 GUIDE, A................................................................................. 2 6410A-AAP-H60 SCREEN FRONT SUB ........................................................... 1 64201-AAP-H60ZA SET, R. FR. SIDE COWL (BLACK)......................................... 1 64201-AAP-H60ZB SET, R. FR. SIDE COWL (SPORTS RED) ............................. 1 64201-AAP-H60ZC SET, R. FR. SIDE COWL (PEARL FADELESS WHITE)......... 1 64201-AAP-H60ZD SET, R. FR. SIDE COWL (MOON YELLOW).......................... 1 64201-AAP-H60ZE SET, R. FR. SIDE COWL (EBONY GREY ME)....................... 1 64202-AAP-H60ZA SET, L. FR. SIDE COWL (BLACK) ......................................... 1 64202-AAP-H60ZB SET, L. FR. SIDE COWL (SPORTS RED).............................. 1 64202-AAP-H60ZC SET, L. FR. SIDE COWL (PEARL FADELESS WHITE) ......... 1 64202-AAP-H60ZD SET, L. FR. SIDE COWL (MOON YELLOW) .......................... 1 64202-AAP-H60ZE SET, L. FR. SIDE COWL (EBONY GREY ME.) ...................... 1 18 F - 1A FRONT COWL * COWL, CENTER FR. ........................... * SCREEN, FRONT ................................ * SET, R/L FR. SIDE COWL ................... * COWL, R/L INNER LWR ...................... * COWL, R/L INNER UPPER.................. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) FR. 14 20 11 4 22 22 20 15 21 21 21 21 21 21 21 21 21 16 19 21 2121 21 21 10 18 18 18 21 6 8 7 5 17 9 2 12 13 9 3 3 1 1
41. 41. 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 64211-KRY-900 SILENCER, SEAT 'A' RIGHT FR. COWL................................ 1 64212-KRY-900 SILENCER, SEAT 'A' LEFT FR. COWL.................................. 1 64213-KRY-900 SILENCER, SEAT 'B' FR. COWL............................................ 2 64301-KRY-860 COWL, R. INNER LWR........................................................... 1 64302-KRY-900 COWL, L. INNER LWR. .......................................................... 1 64303-KRY-900 COWL, R. INNER UPPER ...................................................... 1 64304-KRY-900 COWL, L. INNER UPPER....................................................... 1 77209-KAG-900 RUBBER, SEAT STAY MOUNT .............................................. 2 90101-GE0-000 SCREW, HINGE PATCH......................................................... 2 90109-SB6-000 SCREW, TRUSS, 5 X 16 ........................................................ 5 90111-KW3-000 NUT, COWL SET, M5X0.8 ...................................................... 5 90344-KEV-900 NUT, C. CLIP, 6 MM................................................................ 6 90504-964-000 WASHER, THRUST, 5 MM ..................................................... 5 90563-355-000 WASHER, WHEEL, 6 MM...................................................... 2 93903-25210 SCREW, TAPPING, 5 X 12 ..................................................... 20 95701-06025-00 BOLT, FLANGE, 6 X 25........................................................... 2 * COWL, CENTER FR. ........................... * SCREEN, FRONT ................................ * SET, R/L FR. SIDE COWL ................... * COWL, R/L INNER LWR ...................... * COWL, R/L INNER UPPER.................. 19 Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) F - 1A FRONT COWL FR. 14 20 11 4 22 22 20 15 21 21 21 21 21 21 21 21 21 16 19 21 2121 21 21 10 18 18 18 21 6 8 7 5 17 9 2 12 13 9 3 3 1 1
42. 42. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 37100-KRY-861 METER ASSY., COMB. ........................................................... 1 37110-KRY-861 SP.TA.LCD, METER ASSY. ..................................................... 1 37112-KRY-861 COVER, UPPER...................................................................... 1 37215-ML0-008 RUBBER, METER SET ........................................................... 3 37612-KRY-901 CASE, UNDER ASSY.............................................................. 1 37613-KRY-861 CASE, UPPER ASSY............................................................... 1 37613-KRY-900A RUBBER, SWITCH.................................................................. 2 37700-KRY-900 SPEED, SENSOR ASSY......................................................... 1 44830-KRY-960 CABLE ASSY., SPEEDOMETER ............................................ 1 44831-KRY-900 CABLE COMP., INNER ........................................................... 1 50354-428-000 STOPPER, RUBBER 'B'.......................................................... 1 61304-KRY-900 RUBBER, LIGHT CASE MOUNT ............................................ 2 61317-KCC-900 GUIDE 'A'................................................................................. 1 64313-KRY-900 RUBBER, 'R' METER SIDE..................................................... 1 64314-KRY-900 RUBBER, 'L' METER SIDE ..................................................... 1 64510-KRY-860 STAY, FRONT COWL UPPER................................................. 1 90235-KCZ-000 NUT, LOCK, 18 MM................................................................. 1 93903-22420 SCREW, TAPPING, 3 X 16...................................................... 7 93903-24420 SCREW, TAPPING, 4 X 16...................................................... 7 F .R F - 2 SPEEDOMETER * METER ASSY., COMB. ........................ * COVER UPPER ................................... * CASE UNDER ASSY............................ * CASE UPPER ASSY. ........................... * CABLE ASSY., SPEEDOMETER ......... * CABLE COMP., INNER ........................ 9 17 11 10 8 21 21 23 23 16 19 181818 18 18 14 18 18 19 19 19 20 19 19 12 12 15 1 6 7 2 22 4 4 20 22 13 20 Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) 5 7 19 3
43. 43. 21 * METER ASSY., COMB. ........................ * COVER UPPER ................................... * CASE UNDER ASSY............................ * CASE UPPER ASSY. ........................... * CABLE ASSY., SPEEDOMETER ......... * CABLE COMP., INNER ........................ 20 21 22 23 94001-05090-0S NUT, HEX., 5 MM ................................................................... 3 94021-08000-0S NUT, HEX., CAP 8 MM ........................................................... 2 94103-06000 WASHER, PLAIN, 6 MM......................................................... 3 95801-08040-00 BOLT, FLANGE, 8 X 40 .......................................................... 2 F - 2 SPEEDOMETER Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) F .R 9 17 11 10 8 21 21 23 23 16 19 181818 18 18 14 18 18 19 19 19 20 19 19 12 12 15 1 6 7 2 22 4 4 20 22 13 5 7 19 3
44. 44. F - 3 FRONT BRAKE MASTER CYL. RF . * SWITCH ASSY., FR. STOP.................. 0.1 * DIAPHRAGM. ...................................... * LEVER, R STEERING HANDLE ........ * HOSE COMP., FR. BRAKE. ................. 0.4 * CYL. SUB ASSY., FR. BRAKE MASTER. * CYLINDER SET, MASTER ................... . 22 35340-MA5-670L SWITCH ASSY., FR. STOP ..................................................... 1 45126-KRY-860 HOSE COMP., FR. BRAKE ..................................................... 1 45155-KRY-860 CLAMPER, FR. BRAKE .......................................................... 1 45156-KRY-900 CLAMPER, BRAKE HOSE...................................................... 1 45159-KRY-860 STAY, COMP., CLAMPER BRAKE HOSE ............................... 1 45160-KRY-860 STAY, COMP., CLAMPER BRAKE HOSE ............................... 1 45504-410-003 BOOT, COMP .......................................................................... 1 45510-KRY-971 CYLINDER SUB. ASSY., FR. BRAKE MASTER ..................... 1 45512-MA6-006 PROTECTOR .......................................................................... 1 45513-HA2-006 CAP MASTER CYLINDER ...................................................... 1 45517-166-000 HOLDER MASTER CYLINDER............................................... 1 45520-MG7-006L DIAPHRAGM........................................................................... 1 45521-HA2-006 PLATE, DIAPHRAGM.............................................................. 1 45530-471-831 CYLINDER SET, MASTER...................................................... 1 53175-KFN-850L LEVER RIGHT, STEERING HANDLE ..................................... 1 90114-166-000L BOLT, HANDLE LEVER........................................................... 1 90145-MS9-610 OIL, BOLT, 10 X 22.................................................................. 2 90545-300-000 WASHER, OIL BOLT ............................................................... 4 90651-MA5-671 CIR CLIP.................................................................................. 1 93600-04012-1G SCREW, FLAT 4 X 12.............................................................. 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) 2 4 23 3 1 8 10 18 23 18 17 18 18 17 7 19 14 9 11 16 20 13 24 24 12 20 22 21 15 6 5
45. 45. RF . F - 3 FRONT BRAKE MASTER CYL. * SWITCH ASSY., FR. STOP.................. 0.1 * DIAPHRAGM. ...................................... * LEVER, R STEERING HANDLE ........ * HOSE COMP., FR. BRAKE. ................. 0.4 * CYL. SUB ASSY., FR. BRAKE MASTER. * CYLINDER SET, MASTER ................... . 23 93893-04012-17 SCREW, WASHER, 4 X 12 ..................................................... 1 94050-06000 NUT, FLANGE, 6 MM .............................................................. 1 96001-06012-07 BOLT, FLANGE, SH., 6 X 12 ................................................... 2 96001-06022-07 BOLT, FLANGE, SH., 6 X 22 ................................................... 2 21 22 23 24 Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) 2 4 23 3 1 8 10 18 23 18 17 18 18 17 7 19 14 9 11 16 20 13 24 24 12 20 22 21 15 6 5
46. 46. * CABLE COMP., A THROTTLE ........... * CABLE COMP., B THROTTLE ........... * CABLE COMP., CHOKE ...................... * CABLE COMP., CLUTCH ..................... * SW. COMP., FR. LEVER ...................... * GRIP COMP., THROTTLE. .................. 0.6 * GRIP L HANDLE ................................ 0.6 * LEVER COMP., L HANDLE 24 16150-KFB-000 COVER, THROTTLE CABLE ................................................... 1 17910-KRY-860 CABLE COMP., A THROTTLE.................................................. 1 17920-KRY-860 CABLE COMP., B THROTTLE ................................................. 1 17950-KRY-900 CABLE COMP., CHOKE........................................................... 1 22870-KRY-860 CABLE COMP., CLUTCH ......................................................... 1 22871-437-000 BOOT, CLUTCH WIRE............................................................. 1 32161-404-000 BAND B1 WIRE........................................................................ 2 35150-KRY-900 SWITCH ASSY., LIGHTING ST. ............................................... 1 35200-KRY-900 SWITCH ASSY., WINKER ........................................................ 1 35330-413-003 SWITCH COMP., FR. LEVER................................................... 1 45517-166-000 HOLDER, MASTER CYLINDER............................................... 1 53140-KRY-900 GRIP COMP., THROTTLE........................................................ 1 53166-KRY-900 GRIP L. HANDLE ..................................................................... 1 53172-KRC-900 BRKT, HANDLE LEVER ........................................................... 1 53174-116-670 PLUG HANDLE LEVER............................................................ 1 53178-KFN-850 LEVER COMP., L. HANDLE..................................................... 1 53182-KFN-850 BOOT L. HANDLE COVER ...................................................... 1 88110-AAM-H51 MIRROR ASSY., R. BACK........................................................ 1 88114-KFN-950 CAP, LOCK NUT....................................................................... 2 ASSY.,88120-AAM-H51 MIRROR L. BACK ....................................................... 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) F - 3A HANDLE LEVER/ SWITCH/CABLE RF . 25 26 24 24 17 29 22 10 7 11 12 7 9 8 13 16 27 30 14 30 28 20 19 23 21 18 19 21 23 5 3 2 1 4 6 N PASSING 15
47. 47. * CABLE COMP., A THROTTLE ........... * CABLE COMP., B THROTTLE ........... * CABLE COMP., CHOKE ...................... * CABLE COMP., CLUTCH ..................... * SW. COMP., FR. LEVER ...................... * GRIP COMP., THROTTLE. .................. 0.6 * GRIP L HANDLE ................................ 0.6 * LEVER COMP., L HANDLE 25 90003-MY5-720 BOLT, ADPT, 10MM .................................................................. 2 90113-438-000 BOLT, HNDL. LEVER PIVOT.................................................... 1 90201-MW3-620 NUT, HEX., 10 MM ................................................................... 2 93500-04020-0G SCREW, PAN 4 X 20................................................................ 2 93892-05020-07 SCREW WASHER 5X20 .......................................................... 1 93892-05025-07 SCREW WASHER 5X25 .......................................................... 1 93892-05035-07 SCREW WASHER 5X35 .......................................................... 1 93892-05045-07 SCREW WASHER 5X45 .......................................................... 1 94050-06000 NUT FLANGE 6MM .................................................................. 1 96001-06022-07 BOLT, FLANGE SH 6X22 ......................................................... 2 21 22 23 24 25 26 27 28 29 30 Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) F - 3A HANDLE LEVER/ SWITCH/CABLE RF . 25 26 24 24 17 29 22 10 7 11 12 7 9 8 13 16 27 30 14 30 28 20 19 23 21 18 19 21 23 5 3 2 1 4 6 N PASSING 15
48. 48. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 35010-AAP-H60 KEY SET................................................................................. 1 35100-AAP-H61 SWITCH ASSY., COMB. & LOCK.......................................... 1 35105-KRY-900 COVER, COMB. SWITCH ...................................................... 1 35121-AAP-H61 BLANK KEY NO.1................................................................... 1 35122-AAP-H61 BLANK KEY NO.2................................................................... 1 53100-KFN-850 PIPE, STEERING HANDLE.................................................... 1 53104-KFN-850 WEIGHT, 'A' STEERING HANDLE ......................................... 2 53105-KFN-850 WEIGHT, 'B' STEERING HANDLE ......................................... 2 53107-MB6-630 RUBBER, HANDLE WT. 'B'..................................................... 4 53108-KR3-770 SNAPRING, HANDLE WT....................................................... 2 53127-KRY-900 GUIDE, CABLE....................................................................... 1 53132-KRY-900 HOLDER, HANDLE UNDER................................................... 2 5313A-AAP-H60 HOLDER, HANDLE UP SUB .................................................. 2 53133-KRY-900 RUBBER, HANDLE CUSHION............................................... 4 53230-KRY-931 BRIDGE FORK, TOP .............................................................. 1 90304-159-000 NUT, STEERING STEM.......................................................... 1 90100-KRY-930 BOLT, SOCKET, 8 MM............................................................ 2 90309-KF0-000 NUT, FLANGE, 8 MM.............................................................. 2 90503-051-870 WASHER, STEERING STEM NUT......................................... 1 90535-292-000 WASHER, HANDLE CUSHION .............................................. 2 F - 4 HANDLE PIPE/ TOP BRIDGE/KEY SET * KEY SET,.............................................. * SW. ASSY., COMB.& LOCK................. * PIPE STEERING HANDLE .................. * BRIDGE, FORK TOP ........................... 26 Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) FR. 2513 13 11 16 19 6 710989 22 22 2323 2424 17 12 1 2 25 14 12 20 18 25 14 12 20 18 15 7 10 9 8 9 25 5 4 3 17 21 21 21 21
49. 49. 21 22 23 24 25 91455-KL8-710 CAP SOC BOLT 8 MM............................................................ 4 93700-06065-0G SCREW, OVAL, 6 X 65 ........................................................... 2 93903-25210 SCREW, TAPPING, 5 X 12 ..................................................... 2 95701-06010-08 BOLT, FLANGE, 6 X 10........................................................... 2 96600-08032-00 BOLT, FLANGE, 8 X 32........................................................... 4 27 * KEY SET,.............................................. * SW. ASSY., COMB.& LOCK................. * PIPE STEERING HANDLE .................. * BRIDGE, FORK TOP ........................... F - 4 HANDLE PIPE/ TOP BRIDGE/KEY SET Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) FR. 2513 13 11 16 19 6 710989 22 22 2323 2424 17 12 1 2 25 14 12 20 18 25 14 12 20 18 15 7 10 9 8 9 25 5 4 3 17 21 21 21 21
50. 50. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) F - 5 STEERING STEM RF . * RACE, STEERING BALL ..................... 1.0 (ONE OR ALL) * RACE, STEERING BOTTOM CONE ... * STEM COMP., STEERING ................... 1.1 * RACE, STEERING TOP CONE ........... 0.5 * THREAD COMP., STRG.HD. TOP ....... 9 8 7 11 10 15 16 5 6 2 13 13 54 45160-KRY-860 STAY COMP., CLAMPER BRACKT. HOSE.............................. 1 50301-041-010 RACE, STEERING BALL ......................................................... 2 53200-KRY-900 STEM COMP., STEERING ....................................................... 1 53211-028-010 RACE, STEERING TOP CONE................................................ 1 53212-030-010 RACE, STEERING BOTTOM CONE........................................ 1 53214-001-010 DUST SEAL, STRG. HEAD...................................................... 1 53215-001-000 WASHER, STRG. HEAD DUST SEAL ..................................... 2 53220-074-000 THREAD COMP., STEERING HD. TOP................................... 1 95801-08030-07 BOLT, FLANGE,8X30 ............................................................... 1 96001-06012-07 BOLT, FLANGE, SH., 6 X 12 .................................................... 1 96211-06000 BALL STEERING 6 MM............................................................ 16 1 2 3 4 5 6 7 8 9 10 11 12 1 3 4 5 15 12 14 10
51. 51. 1 2 3 4 5 6 61100-KRY-900ZA FENDER, FRONT (BLACK) ..................................................... 1 61100-KRY-960ZB FENDER FRONT (SPORTS RED)........................................... 1 61100-KRY-860ZC FENDER FRONT (PEARL FADELESS WHITE) ...................... 1 61100-KRY-900ZE FENDER, FRONT (MOON YELLOW)...................................... 1 61100-KRY-860ZE FENDER FRONT (EBONY GREY ME.)................................... 1 61102-KRY-900 STAY, FR. FENDER.................................................................. 1 61103-KRY-900 COLLAR, 'A' FR. FENDER....................................................... 4 61105-KRY-900 RUBBER, FR. FENDER ........................................................... 4 90450-ZA0-000 WASHER, PLAIN, 6 X 1.2 ........................................................ 2 95801-06032-00 BOLT, FLANGE, 6 X 32 ............................................................ 4 F - 6 FRONT FENDER FR. * FENDER, FRONT ................................ 0.1 66 5 3 4 6 1 6 5 2 3 4 3 4 4 3 28 Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA)
52. 52. F - 7 FRONT FORK RF . * FORK ASSY., FR.................................. 0.5 (ADD 0.2 FOR EACH) * SPRING, FR. FORK ............................. 0.2 (ADD 0.5 FOR EACH) * SEAL SET, FR. FORK (ADD 0.5 FOR EACH) * CASE COMP.,R/L BOTTOM ................ 0.9 (ADD 0.6 FOR EACH) 14 16 11 1 4 3 2 7 13 10 8 17 5 20 18 19 15 12 21 9 51400-KRY-861 FORK ASSY., R FRONT ....................................................... 1 51401-KRY-901 SPRING, FRONT FORK ........................................................ 2 51410-KRY-861 PIPE COMP., FRONT FORK.................................................. 2 51412-369-000 SPRING, REBOUND.............................................................. 2 51412-KK4-003 RING, BACKUP...................................................................... 2 51414-KK4-003 BUSH, GUIDE ........................................................................ 2 51420-KRY-971 CASE COMP., R FR. BOTTOM ........................................... 1 51432-KFN-851 PIECE, OIL LOCK .................................................................. 2 51437-KVN-901 RING, PISTON ....................................................................... 2 51440-KFN-851 PIPE, SEAT ............................................................................ 2 51455-198-900 BOLT, FRONT FORK.............................................................. 2 51500-KRY-861 FORK ASSY., L FRONT........................................................ 1 51520-KRY-861 CASE COMP., L FRONT BOTTOM....................................... 1 90116-KAG-900 BOLT, SOCKET, 8 MM ........................................................... 2 90123-KAG-900 BOLT, A FRONT, FORK ........................................................ 2 90521-292-000 WASHER, PLAIN 10.3 MM..................................................... 2 90544-KFN-851 WASHER, SPECIAL 8 MM..................................................... 2 90601-KFN-851 RING, OIL SEAL STOP .......................................................... 2 91254-GAA-003 SEAL, DUST........................................................................... 2 91255-KRM-852 SEAL, OIL 31X43X10.3.......................................................... 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) 6 29
53. 53. F - 7 FRONT FORK RF . * FORK ASSY., FR.................................. 0.5 (ADD 0.2 FOR EACH) * SPRING, FR. FORK ............................. 0.2 (ADD 0.5 FOR EACH) * SEAL SET, FR. FORK (ADD 0.5 FOR EACH) * CASE COMP.,R/L BOTTOM ................ 0.9 (ADD 0.6 FOR EACH) 30 91255-KRM-852 O-RING ................................................................................... 220 Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) 14 16 11 1 4 3 2 7 13 10 8 17 5 20 18 19 15 12 21 9 6
54. 54. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) F - 8 CALIPER ASSY. R FR. * PAD SET, FR. ....................................... 0.2 * BRACKET, RIGHT * PISTON ............................................... 0.5 (ADD 0.1 FOR EACH) (INC. RELATIVE PART) * CALIPER ASSY., R. FR ........................ 0.4 RF . 58 12 13 12 13 15 16 16 14 11 4 3 1 1 8 5 9 5 7 10 2 06451-GE2-405 SEAL SET, PISTON ................................................................ 2 06455-GCR-016 PAD SET, FRONT ................................................................... 1 43352-568-003 SCREW, BLEEDER ................................................................ 1 43353-461-771 CAP, BLEEDER....................................................................... 1 45107-MN5-006 PISTON ................................................................................... 2 45108-ML4-006 PAD, SPRING.......................................................................... 1 45131-GZ0-006 PIN, BOLT ............................................................................... 1 45132-166-016 BUSH, BOOT PIN ................................................................... 1 45133-MA3-006 BOOT, 'B'................................................................................. 1 45200-KRY-901 CALIPER ASSY., RIGHT FR., ................................................ 1 45201-GT4-691 BODY, CALIPER FR................................................................ 1 45203-MG3-016 PLUG, PIN............................................................................... 2 45215-KA3-732 PIN, HANGER ......................................................................... 2 45216-166-006 WASHER, WAVE..................................................................... 1 45250-KRY-901 CALIPER SUB ASSY., 'R' FR.................................................. 1 45290-KGB-611 BRKT. SUB ASSY., 'R' FR. CALIPER...................................... 1 90155- KY4-900 BOLT, FLANGE, 8 X 25........................................................... 2 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 6
55. 55. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 42704-MER-D00 WEIGHT, BALANCE 10.................................................................... 1 42705-MER-D00 WEIGHT, BALANCE 20.................................................................... (1) 42706-MER-D00 WEIGHT, BALANCE 30.................................................................... (1) 42712-KFN-850 TUBE, TYRE .................................................................................... 1 44301-KPL-900 AXLE, FRONT WHEEL.................................................................... 1 44311-KRY-900 COLLAR, FR. WHEEL SIDE ............................................................ 1 44601-AAP-H00 WHEEL, FRONT (NH-303 M) .......................................................... 1 44601-AAP-H00 WHEEL, FRONT (NH-303 M) .......................................................... 1 44620-400-000 COLLAR, FRONT DISTANCE.......................................................... 1 44680-410-000 RETAINER GEAR BOX ................................................................... 1 44711-KFN-850R TYRE FR., 2.75 X 18-42P................................................................ 1 44800-KRC-910 GEAR BOX ASSY. SPDMT.............................................................. 1 44803-150-000 BUSH PINION.................................................................................. 1 44804-KFN-850 GEAR SPDMT.................................................................................. 1 44805-150-010 PINION SPDMT ............................................................................... 1 44807-001-000 WASHER GEAR BOX PINION ........................................................ 1 44809-170-000 WASHER SPDMT GEAR ................................................................ 1 45251-KRY-971 DISC, FRONT BRAKE ..................................................................... 1 90105-KL8-741 BOLT, FR. DISK, 8 X 24................................................................... 5 90306-KF0-000 NUT. FLANGE, 12MM...................................................................... 1 23 F - 9 FRONT WHEEL F .R * AXLE, FR. WHEEL............................... 0.3 * GEAR BOX ASSY., SPDMT ................. * TUBE, TYRE ........................................ 0.9 * TYRE, FR. ............................................ * COLLAR, FR. AXLE DISTANCE .......... 0.4 * DISC, FR. BRAKE................................ * BEARING, RADIAL BALL..................... (ADD. 0.1 FOR EACH) * WHEEL FRONT ................................... 3 4 11 12 14 13 8 6 1 5 7 15 12 12 12 12 16 2 16 9 10
56. 56. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) 19 20 21 22 23 90755-229-000 OIL SEAL, 21 X 37 X 07................................................................... 1 91256-096-650 OIL SEAL, 4.8 X 14.5 X 4................................................................. 1 91258-KEJ-900 DUST SEAL, 40 X 50 X 5................................................................. 1 93700-05020-0A SCREW, OVAL, 5 X 20 .................................................................... 2 96150-63010-10 BEARING, BALL RADIAL, 6301(UU)............................................... 2 23 F - 9 FRONT WHEEL F .R * AXLE, FR. WHEEL............................... 0.3 * GEAR BOX ASSY., SPDMT ................. * TUBE, TYRE ........................................ 0.9 * TYRE, FR. ............................................ * COLLAR, FR. AXLE DISTANCE .......... 0.4 * DISC, FR. BRAKE................................ * BEARING, RADIAL BALL..................... (ADD. 0.1 FOR EACH) * WHEEL FRONT ................................... 3 4 11 12 14 13 8 6 1 5 7 15 12 12 12 12 16 2 16 9 10
57. 57. Service Item F.R.T. Ref. Part No. Description Reqd. No./Model (KARIZMA) 42313-KRY-930 COLLAR, RR. BRAKE PANEL SIDE................................................ 1 43100-KRY-930 PANEL COMP., RR BRAKE ............................................................. 1 43141-KTC-900 CAM, RR., BRAKE ........................................................................... 1 43145-149-000 INDICATOR, RR BRAKE................................................................. 1 43410-KRY-930 ARM, RR BRAKE ............................................................................. 1 43434-ME1-670 RUBBER, STOPPER ARM............................................................... 1 43125-KRP-981 SHOE COMP., BRAKE..................................................................... (2) 45133-KCC-900 SPRING, FR. BRAKE SHOE............................................................ 2 45134-250-000 BRAKE CAM, DUST SEAL .............................................................. 1 90301-473-000 NUT, U, 6 MM................................................................................... 1 90505-425-000 WASHER, 8 MM............................................................................... 1 92811-10000 BOLT A, BRAKE STOPPER............................................................ 1 94001-08000-0S NUT, HEX, 8 MM .............................................................................. 1 94201-20150 PIN, SPLIT, 2X15 MM....................................................................... 1 95701-06035-00 BOLT, FLANGE, 6X35 ...................................................................... 1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 66 F - 10 REAR BRAKE PANEL RF . 1 5 10 15 9 12 14 13 11 6 2 3 7 7 8 4 3 *PANEL COMP., RR. BRAKE................. 0.5 * SHOE COMP., BRAKE......................... 0.4 (ONE OR ALL) * ARM, RR. BRAKE ................................ 0.1 (INC. RELATIVE PART)
58. 58. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 41201-KRY-900 SPROKET, FINAL DRIVEN (40 T).................................................... 1 41241-KSP-900 DAMPER, REAR WHEEL................................................................. 4 42301-KRY-900 AXLE, REAR WHEEL....................................................................... 1 42303-KRY-900 SLEEVE, REAR AXLE...................................................................... 1 42311-KRY-930 COLLAR, REAR WHEEL SIDE ........................................................ 1 42601-AAP-H31 WHEEL COMP. REAR...................................................................... 1 42611-KRY-931 FLANGE FINAL DRIVEN.................................................................. 1 42620-KSP-900 COLLAR, REAR AXLE DISTANCE................................................... 1 42704-MER-D00 WEIGHT, BALANCE, 10 ................................................................... 1 42705-MER-D00 WEIGHT, BALANCE, 20 ................................................................... (1) 42706-MER-D00 WEIGHT, BALANCE, 30 ................................................................... (1) 42711-KFN-850R TYRE, REAR 100/90-18, 56P........................................................... 1 42712-KFN-850 TUBE, TYRE .................................................................................... 1 90304-KCS-920 NUT, 'U' 10 MM................................................................................. 4 90504-KFN-850 WASHER PLAIN 22 MM................................................................... 1 90504-KR3-000 WASHER REAR AXLE ..................................................................... 1 91253-KSP-901 DUST, SEAL, 30 X 47 X 8 ................................................................ 1 91352-KSP-900 O-RING 42 MM................................................................................. 1 92915-10025-0E BOLT, STUD, II 10 X 25.................................................................... 4 95020-15100 NUT, 'E' STEM.................................................................................. 1 * SPROCKET FINAL DRIVEN ................ 0.5 * DAMPER, RR. WHEEL ........................ 0.4 (ONE OR ALL) * AXLE, RR. WHEEL .............................. 0.3 * SLEEVE, RR. AXLE ............................. 0.5 * WHEEL COMP., REAR......................... * FLANGE, FINAL DRIVEN .................... 0.8 * BEARING, BALL RADIAL..................... (ADD 0.1 FOR EACH) * TYRE, REAR........................................ 24 Service Item F.R.T. No. Ref. Part No. Description Reqd. No./Model KARIZMA F - 11 REAR WHEEL F .R 15 16 2 4 7 1 12 15 13 3 8 2 2 5 18 9 610 14 20 2 19 17 21 17 11
59. 59. 25 19 20 21 96150-60050-10 BEARING, BALL RADIAL, 6005....................................................... 1 96150-60050-10 BEARING, BALL RADIAL, 6005....................................................... 1 96150-63020-10 BEARING, BALL RADIAL, 6302(UU) ............................................... 1 * SPROCKET FINAL DRIVEN ................ 0.5 * DAMPER, RR. WHEEL .........