engine assembly bom id part number description qty t1110.1b7a

engine assembly bom id part number description qty t1110.1b7a

ENGINE ASSEMBLY
BOM ID PART NUMBER
1
T1110.1B7A
1­01
1­02
1­03
1­04
1­05
1­06
1­07
1­08
1­09
1­10
1­11
1­12
1­13
1­14
1­15
DESCRIPTION
POWERTRAIN ASSEMBLY
CRANKCASE
OIL PUMP
CRANKSHAFT & BALANCE DRIVE
CYLINDER & PISTON
FRONT CYLINDER HEAD, CAMSHAFTS & VALVES
REAR CYLINDER HEAD, CAMSHAFTS & VALVES
CAM DRIVE SYSTEM
VALVE COVER
WATER PUMP
TRANSMISSION GEARS
GEAR SHIFTER
CLUTCH
CLUTCH COVER
ROTOR, STATOR & STARTER MOTOR
IGNITION COVER
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
SV0001.1B7 REV A
VSS PLUG ONLY FOR VEHICLES BEFORE VIN 546AAAG27EE000007
CRANKCASE
13
11 Nm
3
1
20
AF...LOCTITE SUPERFLEX BLUE RTV
B ....LOCTITE 243
P.....JET-LUBE MP-50 MOLY PASTE
Y.....ASSEMBLY LUBE
20 Nm
12 Nm
8
12
11
APPLY LOCTITE SUPERFLEX BLUE RTV
TO CASE GASKET EDGES BEFORE
INSTALLING CYLINDER BASE GASKETS
21
11 Nm
29 Nm
5
2
5 Nm
7
5
9
14
7
12 Nm
23
8
BOM ID
6
18
11 Nm
10
1
1
17
4
1
19
3
12 Nm
11 Nm
22
16
7
20 Nm
12
15
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
PART NUMBER
CA0032.1B6
CA0041.1B6A
CA0060.1B6
CA0066.1B6A
CA0068.1B6
CA0069.1B6
CC0001.1B6
CC0002.1B6
CC0003.1B6
CC0005.1B6
CF0050.1B7
E0027.1B6
Q0015.1B6
Q0041.1B6A
Q0075.1B6
Q0095.08AZ
Q0270.1B6
Q0271.1B6
Q0309.1B6
T0121.1B7
W0001.1B7AYDX
W0005.1B6
W0101.1B6
DESCRIPTION
BOLT, PLUG M10X1
BOLT M16X1.5
BOLT, M6X16
BOLT, 6X45
BOLT, M6X85
BOLT, M6X105
PIN 8X12
PIN 5X10
PIN 6X40
PIN 4X15.8
O-RING, 12.5X1.8
BEARING HALF
JET, OIL, REAR ASSY
NIPPLE M14X1.5
JET, OIL, FRONT ASSY
JET 70
GLASS, INSPECTION
GASKET, INSPECTION GLASS
PLATE, INSPECTION GLASS RETAINING
PLUG, VSS BLOCK-OFF
CRANKCASE, ASSY, GUNSMOKE
GASKET, CRANKCASE
PIN, NEEDLE
QTY
4
1
3
8
17
2
6
4
1
2
1
4
1
1
1
1
1
1
1
1
1
1
1
SV0002.1B7 REV A
OIL PUMP
5
35
18
11 Nm
B...LOCTITE 243
Y...ASSEMBLY LUBE
2
13
BOM ID
22
1
4
1
20
14
11 Nm
11 Nm
26
16
21
3
28
25 Nm
4
31
30
24
11 Nm
7
23
11
19
29
8
25
17
12
27
32
33
9
6
11 Nm
15
10
15 Nm
25
27
15 Nm
37
34
15 Nm
36
11 Nm
4
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
PART NUMBER
CA0033.1B6
CA0040.1B6
CA0049.1B6
CA0061.1B6A
CA0063.1B6A
CA0064.1B6
CC0004.1B6
CC0005.1B6
CC0006.1B6
CE0001.1B6
CF0001.1B6
CF0002.1B6
CF0003.1B6
CG0001.1B6
Q0054.1B6
Q0062.1B6
Q0063.1B6
Q0064.1B6
Q0065.1B6
Q0080.1B6
Q0081.1B6
Q0082.1B6
Q0083.1B6
Q0084.1B6
Q0091.1B6
Q0092.1B6
Q0096.1B6
Q0097.1B6
Q0111.1B7
Q0360.1B6
Q0361.1B6
Q0362.1B6
Q0363.1B6
R0007.1B6
R0024.1B6YDX
R0025.1B6YDX
Y0382.1B6
DESCRIPTION
BOLT, PLUG, M16X1.5
DISTANCE SCREW M6
TAPTITE SCREW M6X16
BOLT, M6X20
BOLT, M6X30
BOLT, M6X35
PIN, 5X16.8
PIN, 4X15.8
PIN, 4X29.8
RING, RETAINING, 12X1
O-RING, OIL STRAINER
O-RING, 17X3
O-RING, OIL FILTER
SPRING, L46
GEAR, OIL PUMP 37T
COVER, OIL DUCT
STRAINER, OIL (INCLUDES O-RING)
FILTER, OIL
COVER, OIL PUMP
VALVE, PRESSURE RETAINING
ADAPTER, OIL SUCTION
COVER, OIL DUCT
COLLECTOR, OIL
BAFFLE, OIL SUMP
SEALING RING, OIL DRAIN PLUG 1, M12
SEALING RING, OIL DRAIN PLUG 2, M18
BOLT, PLUG, M12
PLUG, M18
PLUG, OIL FILLER
SHAFT, OIL PUMP
ROTOR SET, SCAVENGE
HOUSING, OIL PUMP
ROTOR SET, PRESSURE
GASKET, OIL STRAINER COVER
COVER, OIL FILTER
COVER, OIL STRAINER
SWITCH, OIL PRESSURE
QTY
1
1
2
9
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1
SV0003.1B7 REV A
SEE IGNITION COVER FOR
E0016.1B6 AND CJ0002.1B6
CRANKSHAFT & BALANCE DRIVE
AH...LOCTITE 272
U.....CONROD LUBE C0711.14A0
Y.....ASSEMBLY LUBE
8
2
7
SEE NOTE FOR TORQUE PROCEDURE
AND LUBE INSTRUCTIONS
3
1
10
6
CONNECTINGROD BOLT TORQUE PROCEDURE:
1) CLEAN CONROD THREADS, BOLT THREADS, AND UNDER BOLT HEAD
2) APPLY CONROD ASSEMBLY LUBE C0711.14A0 TO BOLT THREADS
AND UNDER BOLT HEAD
3) TORQUE BOTH BOLTS TO 15Nm
4) LOOSEN FIRST BOLT AND SET ELONGATION GAUGE
5) TIGHTEN FIRST BOLT TO AN ELONGATION OF 0.130mm ­ 0.140mm
4
NOTE: DO NOT EXCEED 60Nm
5
6) REPEAT STEPS 4 AND 5 FOR SECOND BOLT
7) REPEAT STEPS 1­6 FOR SECOND CONNECTING ROD
220 Nm
9
BOM ID PART NUMBER
1
CA0034.1B7
2
CB0028.1B6
3
CB0034.1B6
4
CC0007.1B6
5
CD0033.1B6
6
U0001A.1B7
7
U0002A.1B7
8
U0010.1B6
9
U0040.1B6
10
U0041.1B6
DESCRIPTION
BOLT, CONNECTING ROD
WASHER, THRUST, 15.2/30/1
WASHER, THRUST, 22.2/38/1
DRIVE PIN, 5X11.8
NUT, M24
CRANKSHAFT ASSY
CONNECTING ROD, ASSY
BEARING, PLAIN
GEAR SET, BALANCER, BOTTOM
GEAR SET, BALANCER, TOP
QTY
4
1
1
1
1
1
2
4
1
1
SV0004.1B7 REV A
Y...ASSEMBLY LUBE
O...ENGINE OIL
CYLINDER & PISTON
11
1
3
1
6
4
7
9
5
8
9
2
4
7
8
2
10
BOM ID PART NUMBER
1
CC0002.1B6
2
CE0005.1B7
3
T1001.1B7
4
V0025.1B6
5
V0040.1B7A
6
V0041.1B7A
7
V0050.1B7
8
V0061.1B7
9
V0200.1B7
10
V0240.1B7
11
V0241.1B7
DESCRIPTION
PIN 5X10
CIRCLIP, WRIST PIN
GASKET KIT, COMPLETE
GASKET, CYLINDER BASE
CYLINDER, FRONT
CYLINDER, REAR
PISTON RING SET
WRIST PIN
PISTON ASSY
CYLINDER & PISTON, FRONT ASSY
CYLINDER & PISTON, REAR ASSY
QTY
4
4
1
2
1
1
2
2
2
1
1
SV0005.1B7 REV A
FRONT CYLINDER HEAD, CAMSHAFTS & VALVES
17
14
12
15
3
10 Nm
8
7
27
10
11
3
21
23
18
13
7
22
24
11 Nm
14
5
9
15 Nm
32
40 Nm
5 Nm
1) 40 Nm
2) 80 DEGREES
16
30
20
19
15
2
4
28
6
1
1) 35 Nm
2) 54 Nm
3) 75 Nm
4) 95 Nm
29
10 Nm
VALVE LASH ADJUSTMENT
INTAKE.........0.006"­0.007" (0.152­0.178mm)
EXHAUST.....0.012"­0.013" (0.305­0.330mm)
ADJUSTMENT
SHIM TABLE
31
25
AD...LOCTITE 592
B.....LOCTITE 243
C.....LOCTITE 648
O.....ENGINE OIL
Y.....ASSEMBLY LUBE
26
BOM ID PART NUMBER
1
CA0035.1B7
2
CA0036.1B6
3
CA0067.1B6
4
CA0069.1B6
5
CA0111.1B6A
6
CB0070.10B5
7
CC0008.1B6
8
CC0009.1B6
9
F1040.1B7
10
F0050A.1B7
11
F0052A.1B7
12
F0060.1B6
13
F0061.1B6
14
F0070.1B6
15
F0080.1B6
16
F0085.1B6
17
F0086.1B6
18
F0087.1B6
19
F0100.1B6
20
F0101.1B6
21
F0121.1B6
22
F0122.1B6
23
F0123.10B5
24
F0124.10B5
25
F0140.1B6
26
F0141.1B6
27
28
P0743F.1B7
29
V0001.1B7
30
V0026.1B6
31
V0170.1B6
32
Y0605.1B7
DESCRIPTION
BOLT, M11
BOLT, M12X1X65
BOLT, M6X55
BOLT, M6X105
BOLT, M8X18
WASHER, SEALING, 8X11.5X1
PIN, 6X8
PIN, 4X8
GEAR SET, CAMSHAFT
CAMSHAFT, INTAKE, FRONT
CAMSHAFT, EXHAUST, FRONT
BRACKET, CAMSHAFT 2 FRONT
BRACKET, CAMSHAFT 1 FRONT
FINGER FOLLOWER
SHAFT, FINGER FOLLOWER
SPROCKET, CAMSHAFT
SPACER, INTAKE
SPACER, EXHAUST
SUPPORT, VALVE SPRING
SLEAL, VALVE STEM
RETAINER, VALVE SPRING
KEEPER, VALVE SPRING
SPRING, VALVE, INNER
SPRING, VALVE, OUTER
VALVE, INTAKE
VALVE, EXHAUST
SEE SHIM TABLE
ORIFICE, BYPASS PORT
CYLINDER HEAD, FRONT
GASKET, CYLINDER HEAD
STUD
SENSOR, COOLANT TEMP
QTY
1
2
2
1
1
1
4
2
1
1
1
1
1
4
2
1
1
1
4
4
4
8
4
4
2
2
4
1
1
1
4
1
SV0006.1B7 REV B
REAR CYLINDER HEAD, CAMSHAFTS & VALVES
ADJUSTABLE EHAUST CAM
GEAR SET ONLY OFFERED
AS RACE ACCESSORY
5
2
MATCHED EXHAUST
CAMSHAFT MUST BE USED
WITH FIXED CAM GEAR SET
AD...LOCTITE 592
B.....LOCTITE 243
C.....LOCTITE 648
O.....ENGINE OIL
Y.....ASSEMBLY LUBE
40 Nm
1) 40 Nm
2) 80 DEGREES
9
16
11 Nm
3
4
10 Nm
BOM ID
22
13
1
1
24
1) 35 Nm
2) 54 Nm
3) 75 Nm
4) 95 Nm
27
15
21
18
20
14
5 Nm
10
8
7
3
23
28
19
14
11
10 Nm
17
6
15
12
31
7
29
25
30
VALVE LASH ADJUSTMENT
INTAKE.........0.006"-0.007" (0.152-0.178mm)
EXHAUST.....0.012"-0.013" (0.305-0.330mm)
ADJUSTMENT
SHIM TABLE
26
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
PART NUMBER
CA0035.1B7
CA0036.1B6
CA0067.1B6
CA0069.1B6
CA0111.1B6A
CB0070.10B5
CC0008.1B6
CC0009.1B6
F0040.1B6
F0051A.1B7
F0053A.1B7A
F0062.1B6
F0063.1B6
F0070.1B6
F0080.1B6
F0085.1B6
F0086.1B6
F0087.1B6
F0100.1B6
F0101.1B6
F0121.1B6
F0122.1B6
F0123.10B5
F0124.10B5
F0140.1B6
F0141.1B6
P0743F.1B7
V0002.1B7
V0026.1B6
V0170.1B6
DESCRIPTION
BOLT, M11
BOLT, M12X1X65
BOLT, M6X55
BOLT, M6X105
BOLT, M8X18
WASHER, SEALING, 8X11.5X1
PIN, 6X8
PIN, 4X8
GEAR SET, CAMSHAFT
CAMSHAFT, INTAKE, REAR
CAMSHAFT, EXHAUST, REAR
BRACKET, CAMSHAFT 2 REAR
BRACKET, CAMSHAFT 1 REAR
FINGER FOLLOWER
SHAFT, FINGER FOLLOWER
SPROCKET, CAMSHAFT
SPACER, INTAKE
SPACER, EXHAUST
SUPPORT, VALVE SPRING
SEAL, VALVE STEM
RETAINER, VALVE SPRING
KEEPER, VALVE SPRING
SPRING, VALVE, INNER
SPRING, VALVE, OUTER
VALVE, INTAKE
VALVE, EXHAUST
SEE SHIM TABLE
ORIFICE, BYPASS PORT
CYLINDER HEAD, REAR
GASKET, CYLINDER HEAD
STUD
QTY
4
2
8
2
3
1
4
2
1
1
1
1
1
4
2
1
1
1
4
4
4
8
4
4
2
2
4
1
1
1
4
SV0007.1B7 REV A
VALVE ADJUSTMENT SHIMS
EACH KIT CONTAINS 5 SHIMS
F2200.1B6 CONTAINS 2 OF
EVERY KIT = 10 OF EVERY SHIM
BACK TO REAR CYLINDER HEAD,
CAMSHAFTS & VALVES
VALVE LASH ADJUSTMENT
INTAKE.........0.006"-0.007" (0.152-0.178mm)
EXHAUST.....0.012"-0.013" (0.305-0.330mm)
BACK TO FRONT CYLINDER HEAD,
CAMSHAFTS & VALVES
BOM ID
27
27-01
27-02
27-03
27-04
27-05
27-06
27-07
27-08
27-09
27-10
27-11
27-12
27-13
27-14
27-15
27-16
27-17
27-18
27-19
27-20
27-21
27-22
27-23
27-24
27-25
27-26
27-27
27-28
27-29
27-30
27-31
27-32
27-33
27-34
27-35
27-36
27-37
27-38
27-39
27-40
PART NUMBER
F2200.1B6
F1188.1B6
F1189.1B6
F1190.1B6
F1191.1B6
F1192.1B6
F1193.1B6
F1194.1B6
F1195.1B6
F1196.1B6
F1197.1B6
F1198.1B6
F1199.1B6
F1200.1B6
F1201.1B6
F1202.1B6
F1203.1B6
F1204.1B6
F1205.1B6
F1206.1B6
F1207.1B6
F1208.1B6
F1209.1B6
F1210.1B6
F1211.1B6
F1212.1B6
F1213.1B6
F1214.1B6
F1215.1B6
F1216.1B6
F1217.1B6
F1218.1B6
F1219.1B6
F1220.1B6
F1221.1B6
F1222.1B6
F1223.1B6
F1224.1B6
F1225.1B6
F1226.1B6
F1227.1B6
DESCRIPTION
KIT, VALVE ADJUSTMENT SHIMS
KIT, ADJUSTMENT SHIM 2.025 (5 PACK)
KIT, ADJUSTMENT SHIM 2.075 (5 PACK)
KIT, ADJUSTMENT SHIM 2.125 (5 PACK)
KIT, ADJUSTMENT SHIM 2.175 (5 PACK)
KIT, ADJUSTMENT SHIM 2.225 (5 PACK)
KIT, ADJUSTMENT SHIM 2.275 (5 PACK)
KIT, ADJUSTMENT SHIM 2.000 (5 PACK)
KIT, ADJUSTMENT SHIM 2.050 (5 PACK)
KIT, ADJUSTMENT SHIM 2.100 (5 PACK)
KIT, ADJUSTMENT SHIM 2.150 (5 PACK)
KIT, ADJUSTMENT SHIM 2.200 (5 PACK)
KIT, ADJUSTMENT SHIM 2.250 (5 PACK)
KIT, ADJUSTMENT SHIM 2.300 (5 PACK)
KIT, ADJUSTMENT SHIM 2.325 (5 PACK)
KIT, ADJUSTMENT SHIM 2.350 (5 PACK)
KIT, ADJUSTMENT SHIM 2.375 (5 PACK)
KIT, ADJUSTMENT SHIM 2.400 (5 PACK)
KIT, ADJUSTMENT SHIM 2.425 (5 PACK)
KIT, ADJUSTMENT SHIM 2.450 (5 PACK)
KIT, ADJUSTMENT SHIM 2.475 (5 PACK)
KIT, ADJUSTMENT SHIM 2.500 (5 PACK)
KIT, ADJUSTMENT SHIM 2.525 (5 PACK)
KIT, ADJUSTMENT SHIM 2.550 (5 PACK)
KIT, ADJUSTMENT SHIM 2.575 (5 PACK)
KIT, ADJUSTMENT SHIM 2.600 (5 PACK)
KIT, ADJUSTMENT SHIM 2.625 (5 PACK)
KIT, ADJUSTMENT SHIM 2.650 (5 PACK)
KIT, ADJUSTMENT SHIM 2.675 (5 PACK)
KIT, ADJUSTMENT SHIM 2.700 (5 PACK)
KIT, ADJUSTMENT SHIM 2.725 (5 PACK)
KIT, ADJUSTMENT SHIM 2.750 (5 PACK)
KIT, ADJUSTMENT SHIM 2.775 (5 PACK)
KIT, ADJUSTMENT SHIM 2.800 (5 PACK)
KIT, ADJUSTMENT SHIM 2.825 (5 PACK)
KIT, ADJUSTMENT SHIM 2.850 (5 PACK)
KIT, ADJUSTMENT SHIM 2.875 (5 PACK)
KIT, ADJUSTMENT SHIM 2.900 (5 PACK)
KIT, ADJUSTMENT SHIM 2.925 (5 PACK)
KIT, ADJUSTMENT SHIM 2.950 (5 PACK)
KIT, ADJUSTMENT SHIM 2.975 (5 PACK)
QTY
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
F2200.1B6 REV A
B...LOCTITE 243
O...ENGINE OIL
CAM DRIVE SYSTEM
9
5
30 Nm
1
3
6
1
3
6
7
4
2
5
7
4
11 Nm
8
BOM ID
8
1
2
9
11 Nm
2
3
4
5
6
7
8
9
PART NUMBER
CA0039.1B6A
CA0061.1B6A
CJ0003.1B6
E0029.1B6
F0020.1B6
F0021.1B6
F0055.1B6
F0058.1B6
F0059.1B6
DESCRIPTION
BOLT, M16X1.5
BOLT, 6X20
RING, SEALING, 16X22
SLEEVE
GUIDE, CHAIN TENSION
TENSIONER, CHAIN ASSY
CHAIN, CAMSHAFT
GUIDE, CHAIN
GUIDE, CHAIN
QTY
2
4
2
2
2
2
2
2
2
SV0008.1B7 REV A
VALVE COVER
2
11 Nm
7
6
8.5 Nm
5
2
11 Nm
1
4
5
6
7
1
8.5 Nm
3
4
BOM ID
1
3
2
3
4
5
6
7
PART NUMBER
CA0037.1B6
CA0060.1B6
R0002.1B6
R0012.1B6
R0111.1B6
V0075.1B6
Y0300.1B6
DESCRIPTION
BOLT, M6X23
BOLT, M6X16
GASKET, VALVE COVER
GASKET, SPARK PLUG
COVER, VALVE
SPARK PLUG CR9EKB
COIL, IGNITION
QTY
10
2
2
2
2
2
2
SV0009.1B7 REV A
WATER PUMP
Y...ASSEMBLY LUBE
P...JET-LUBE MP-50 MOLY PASTE
SEE CLUTCH COVER FOR
Q0430.1B6 AND E0015.1B6
4
8
6
7
9
2
5
3
HAND TIGHTENED
1
11 Nm
BOM ID
1
2
3
4
5
6
7
8
9
PART NUMBER
CA0062.1B6A
CB0028.1B6
CJ0001.1B6
E0028.1B6
Q0425.1B7YDX
Q0426.1B6
Q0427.1B6
Q0428.1B6
Q0431.1B6
DESCRIPTION
BOLT, M6X25
WASHER, THRUST, 15.2/30/1
RING, SEALING, 6X10
BUSHING, NEEDLE, 12X16X10
HOUSING, WATER PUMP, GUNSMOKE
GASKET, WATER PUMP
IMPELLER, WATER PUMP
SHAFT, WATER PUMP ASSY
ROTARY SEAL, WATER PUMP
QTY
4
1
1
1
1
1
1
1
1
SV0010.1B7 REV A
TRANSMISSION GEARS
P...JET-LUBE MP-50 MOLY PASTE
Y...ASSEMBLY LUBE
11 Nm
1
24
11
9
17
5
18
12
6
6
19
5
BOM ID
1
6
20
21
10
5
16
3
22
6
6
5
23
14
2
13
7
8
25
1
11 Nm
4
12
15
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
PART NUMBER
CA0058.1B6
CB0022.1B6
CB0023.1B6
CE0002.1B6
CE0003.1B6
E0018.1B6
E0019.1B6
E0020.1B6
E0021.1B6
E0022.1B6
X0009.1B6
X0040.1B6
X0041.1B6
X0042.1B6
X0043.1B6
X0044.1B6
X0045.1B6
X0046.1B6
X0047.1B6
X0048.1B6
X0049.1B6
X0050.1B6
X0062.1B6
X0070.1B6
X1008.1B6
DESCRIPTION
BOLT, M6X13
WASHER, THRUST
WASHER, THRUST
RING, SNAP 28X2
RING, RETAINING 29X2
BEARING, NEEDLE
BEARING 6304
BEARING 6206
BEARING 4306
BEARING 6205
SHAFT, OUTPUT
GEAR BOX, ASSY
GEAR 24T 5TH GEAR INPUT
GEAR 21/23T 3/4 INPUT
GEAR 25T 6TH GEAR INPUT
GEAR 16T 2ND GEAR INPUT
GEAR 28T 2ND GEAR OUTPUT
GEAR 24T 6TH GEAR OUTPUT
GEAR 27T 4TH GEAR OUTPUT
GEAR 29T 3RD GEAR OUTPUT
GEAR 25T 5TH GEAR OUTPUT
GEAR 32T 1ST GEAR OUTPUT
SHIM
SEAL, OIL, 40X52X7
SHAFT, INPUT
QTY
2
1
1
1
4
5
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
SV0011.1B7 REV A
AD...LOCTITE 592
B......LOCTITE 243
P.....JET-LUBE MP-50 MOLY PASTE
Y.....ASSEMBLY LUBE
GEAR SHIFTER
15
9
2.5 Nm
16
1
17
7
11 Nm
14
14
11
6
2
BOM ID
9
1
12
4
5
8
10
3
13
11 Nm
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
PART NUMBER
CA0038.1B6
CA0058.1B6
CA0059.1B6
CA0214.1B7
CG0003.1B6
E0023.1B6
E0024.1B6
E0026.1B6
X0007.1B6
X0010.1B6
X0061.1B6
X0066.1B6A
X0068.1B6
X0076.1B6
X0090.1B6
X0091.1B6
X0092.1B6
DESCRIPTION
NEUTRAL SWITCH
BOLT, M6X13
BOLT, M6X16
BOLT, M6X25
SPRING, INDEX
BEARING 6006
BEARING 61805
STEP RING
SPINDLE, FORK
LEVER, INDEX, ASSY
SHIFT DRUM
SHIM, INDEX
SHAFT, GEARSHIFT, ASSY
SEAL, OIL, 12X22X7
FORK, SHIFT, 2/4
FORK, SHIFT, 1/3
FORK, SHIFT, 5/6
QTY
1
1
1
1
1
1
1
1
2
1
1
1
1
2
1
1
1
SV0012.1B7 REV A
15
CLUTCH
AH...LOCTITE 272
B.....LOCTITE 243
C.....LOCTITE 648
O.....ENGINE OIL
7
24
3
16
8
25
1) 12 Nm
2) 30 Nm
12
23
9
18
17
5
1
10
2
26
13
4
6
14
19
22
170 Nm
20
ALL FIBER PLATES MUST
BE PRE-SOAKED IN OIL
11
27
21
1
X0014.1B6 (WITH NOTCH)
INSTALLED FIRST WITH
SHARP SIDE FACING OUT
ALL OTHER STEEL PLATES
SHARP SIDE FACING IN
1) TIGHTEN ALL SIX EVENLY
UNTIL BOTTOMED OUT
2) 10 Nm
28
BOM ID
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
PART NUMBER
CA0080.1B7
CA0083.1B6
CB0024.1B6
CB0025.1B6
CB0026.1B6A
CD0034.1B7
CD0035.1B6
CG0005.1B6
CG0006.1B6
CG0008.1B6
CG0020.1B7
CH0006.1B6
CK0001.1B6
CK0002.1B7
Q0053.1B6
X0011.1B6
X0012.1B6
X0013.1B7
X0014.1B6
X0015.1B6
X0019.1B7
X0030.1B6
X0100.1B6
X0101.1B6
X0102.1B6
X0103.1B6
X0104.1B7
X1035.1B6
DESCRIPTION
BOLT, M6X45
BOLT, 8X25
WASHER, THRUST, 30.2/50/2.5
WASHER, THRUST
RING, THRUST, 25/43.6/5
NUT, M24X1.5
NUT, M8
SPRING, COMPRESSION
SPRING, COMPRESSION
SPRING, COMPRESSION
SPRING, CLUTCH
SLEEVE
SPRING, DISK
WASHER, SPRING, 24.5/40/1.8
GEAR, OIL PUMP
DRIVE, PRIMARY, ASSY
CLUTCH DRUM
HUB, CLUTCH
PLATE, CLUTCH
PLATE, CLUTCH
PIN, CLUTCH RELEASE
PLATE, CLUTCH FRICTION
PLATE, SUPPORT, INNER
PLATE, SUPPORT, OUTER
RETAINER, SPRING
RETAINER, SPRING
WASHER, STEP
PRESSURE PLATE, CLUTCH ASSY
QTY
6
3
1
1
1
1
3
2
4
4
6
3
1
1
1
1
1
1
1
9
1
9
1
1
4
8
6
1
SV0013.1B7 REV A
CLUTCH COVER
K...DOT 4 BRAKE FLUID
Y...ASSEMBLY LUBE
P...JET-LUBE MP-50 MOLY PASTE
19
14
18
4
16
BOM ID
17
1
26
23
12
15
2
15 Nm
11 Nm
13
5 Nm
20
29
24
28
6
27
7
31
11
8
32
22
10
14 Nm
34
33
5
21
9
9 Nm
34
30
1
3
25
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
PART NUMBER
CA0063.1B6A
CA0064.1B6
CB0027.1B7
CC0004.1B6
CD0020.1B6
CD0031.1B7
CE0006.1B6
CF0007.1B6
CF0020.1B6
CF0023.1B6
CG0009.1B6
CJ0001.1B6
CN0047.1B7
E0015.1B6
H0403.1B6
Q0430.1B6
R0001.1B6
R0009.1B6
R0022A.1B6YDX
R0027.1B7YDX
R0028.1B7
R0029A.1B6YDX
X0060.1B7
X0069.1B7
X0071.1B7
X0072.1B7
X0073.1B6
X0074.1B6
X0077.1B6
X0086.1B6A
X0087.1B6A
X0205.1B6
X0206.1B6
X0207.1B6
DESCRIPTION
BOLT, M6X30
BOLT, M6X35
WASHER, THRUST, 12.2/32/2
PIN, 5X16.8
NUT, M10
NUT, M12
RING, RETAINING, 50X2
O-RING, 45X2
O-RING, OUTER PLUG
O-RING, 17X2
SPRING, 2X32X40
RING, SEALING, 6X10
CLAMP, 9.6-11.3MM
BUSHING, NEEDLE, 15X21X12
CLAMP, CUSHIONED
OIL SEAL, WATER PUMP
GASKET, CLUTCH COVER
GASKET, DIAPHRAGM COVER
COVER, CLUTCH, INNER, ASSY, GUNSMOKE
COVER, DIAPHRAGM, INNER, GUNSMOKE
PLUG, CLUTCH COVER, OUTER
COVER, CLUTCH, OUTER
HOSE, LOW PRESSURE
DIAPHRAGM, CLUTCH
PLATE, OUTER DISK
PLATE, INNER DISK
BLEED SCREW
CAP, RUBBER
SEAL, OIL, 12X22X7
PISTON
SLEEVE
O-RING, .674X.103
O-RING, 1.299X.103
RING, BACKUP, .702X.086
QTY
8
15
1
2
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
SV0014.1B7 REV A
ROTOR & STATOR
AF...LOCTITE SUPERFLEX BLUE RTV
AH...LOCTITE 272
B.....LOCTITE 243
C.....LOCTITE 648
Y.....ASSEMBLY LUBE
1
4 Nm
30 Nm
4
14
APPLY LOCTITE SUPERFLEX BLUE RTV
TO STATOR WIRING HARNESS AND PLUG
8
3
13
5
11 Nm
1) 285 Nm
2) LOOSEN NUT
3) 407 Nm
9
10
11
BOM ID
12
2
1
7
11 Nm
6
2
3
4
5
6
7
8
9
10
11
12
13
14
PART NUMBER
CA0048.1B6
CA0062.1B6A
CA0065.1B7
CA0081.1B6
CD0032.1B6
CF0016.1B6
Y0383.1B6A
Y0442.1B7
Y0533.1B7
Y0536.1B6
Y0537.1B6
Y0538.1AY
Y0539.1AY
Y1012.1B6
DESCRIPTION
SCREW, M4X8
BOLT, M6X25
BOLT, M6X40
BOLT, M8X18
NUT, M24
O-RING, STARTER
STARTER
STATOR ASSY
FLYWHEEL, ASSY
CLUTCH, ONE-WAY
HOUSING, ONE-WAY CLUTCH
GEAR, IDLER, STARTER
GEAR, FREEWHEEL, STARTER
HOLDER, CABLE, INNER
QTY
2
2
3
6
1
1
1
1
1
1
1
1
1
1
SV0015.1B7 REV A
11 Nm
IGNITION COVER
Y...ASSEMBLY LUBE
P...JET-LUBE MP-50 MOLY PASTE
11 Nm
1
2
14
7
11
6
4
12
13
8
3
5
9
11 Nm
2
BOM ID
1
10
2
3
4
5
6
7
8
9
10
11
12
13
14
PART NUMBER
CA0060.1B6
CA0064.1B6
CE0007.1B6
CF0010.1B6
CF0011.1B6
CF0018.1B6
CJ0001.1B6
CJ0002.1B6
E0016.1B6
R0008.1B6
R0021.1B6
R0026.1B6YDX
U0014.1B6
Y0640.1B6
DESCRIPTION
BOLT, M6X16
BOLT, M6X35
RING, RETAINING, 30X1.2
O-RING, OUTER PLUG
O-RING, 25X2
O-RING
RING, SEALING, 6X10
SEAL, OIL, 12X20X5
BUSHING, NEEDLE, 15X21X16
GASKET, STATOR COVER
PLUG, STATOR COVER, OUTER
COVER, IGNITION, ASSY, GUNSMOKE
SLEEVE, SEALING
TRIGGER, CRANK POSITION
QTY
1
13
1
1
1
1
1
1
1
1
1
1
1
1
SV0016.1B7 REV A