Discovery XLT Parts Catalog - 500 Engine V08.08

DIAMO Discovery XLT
®
PARTS CATALOG - 500 Engine
First Edition August 2008
Copyright © 2007-2008 LS MotorSports, LLC. Reproduction without written permission is completely forbidden.
The information and diagrams included in this catalog are the exclusive property of LS MotorSports, LLC
and may not be reproduced in any media without the express written consent of LS MotorSports, LLC.
For more information contact:
LS MotorSports, LLC
10215 S Sam Houston Parkway W
Houston, TX 77071
281-277-6140
Information contained in this publication is subject to change without notice.
For the most up to date information please contact DIAMO USA or an Authorized Dealer
Copyright © 2007-2008 LS MotorSports, LLC. Reproduction without written permission is completely forbidden.
CONTENTS
PAGE
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
TITLE
Cylinder Head
Valve
Cylinder
Cam and Cam Chain
Crankshaft and Piston
Crankcase
Crankcase Cover
Transmission
Middle Drive Gear
Clutch
Shift Cam Fork
Oil Pump
Starter and Starter Clutch
Magneto
Water Pump
Carburetor
Oil Pipe
Cooling Fan
Engine Assembly
Fig. 34
Cylinder Head
Ref
Code
1 12200-F18-0000
2 GB/T 70.1-2000
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
90612-F12-0000
GB/T16674-1996
90601-F11-0000
GB/T 899-1988
91403-F12-0000
90802-F11-0000
GB/T16674-1996
GB/T16674-1996
90602-F11-0000
GB/T70.1-2000
12331-F12-0000
91202-F11-0000
GB/T70.1-2000
12361-F11-0000
91201-F11-0000
GB/T70.1-2000
12206-F18-0000
GB/T 5783-2000
12207-F18-0000
33300-F11-0000
14800-F11-0000
91221-F11-0000
Part Number
08-042-3401
Description
Cylinder Head Assy
08-042-3402
Screw M8X20
08-042-3403
Gasket 8X14X1
08-042-3404
Bolt M6X14
08-042-3405
Gasket 6X13X1.5
08-042-3406
Stud
08-042-3407
Clip
08-042-3408
Pin 14X16
08-042-3409
Bolt M10X223
08-042-3410
Bolt M10X250
08-042-3411
Washer 10X20X2
08-042-3412
Screw M8X40
08-042-3413
Cover
08-042-3414
O-Ring 107X2.4
08-042-3415
Screw M6X25
08-042-3416
Valve Cover
08-042-3417
O-Ring 58X2.4
08-042-3418
Screw M6X20
08-042-3419
Plate
08-042-3420
Bolt M6X12
08-042-3421
Plate
08-042-3422
Spark Plug (NGK DR8EA)
08-042-3423
Intake Manifold
O-Ring 43.2X2
08-042-3424
Fig. 35
Valve
Ref
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Code
14711-F11-0000
14721-F11-0000
14771-F11-0000
14761-F11-0000
14751-F11-0000
12209-F11-0000
14775-F11-0000
14781-F11-0000
14401-F18-0000
14451-F11-0000
91211-F11-0000
90012-F11-0000
90206-F11-0000
14400-F18-0000
Part Number
08-042-3501
08-042-3502
08-042-3503
08-042-3504
08-042-3505
08-042-3506
08-042-3507
08-042-3508
08-042-3509
08-042-3510
08-042-3511
08-042-3512
08-042-3513
08-042-3514
Description
Valve, Intake
Valve, Exhaust
Seat, Valve Spring
Spring, Valve Inner
Spring, Valve Outer
Seal, Valve Stem
Retainer, Valve Spring
Cotter
Rocker Arm
Shaft, Rocker Arm
O-Ring 9X2
Adjusting Screw ,Valve
Nut
Rocker Arm Assy
Fig. 36
Cylinder
Ref
1
2
3
4
5
6
7
8
9
10
11
12
Code
12250-F18-0000
90801-F39-0000
GB/T 16674-1996
90601-F18-0000
14508-F11-0000
91207-F39-0000
12150-F18-0000
90801-F39-0000
GB/T 70.1-2000
GB/T 70.1-2000
14500-F11-0000
12100-F18-0000
Part Number
08-042-3601
08-042-3602
08-042-3603
08-042-3604
08-042-3605
08-042-3606
08-042-3607
08-042-3608
08-042-3609
08-042-3610
08-042-3611
08-042-3612
Description
Gasket, Cylinder Head
Pin 14X16
Bolt M6X14
Washer 6X13X1.5
Gasket, Tensioner
O-Ring 90X3
Gasket, Cylinder
Pin 14X16
Bolt M6X25
Bolt M6X30
Tensioner
Cylinder
Fig. 37
Cam and Cam Chain
Ref
1
2
3
4
5
6
7
8
Code
14100-F18-0000
14320-F18-0000
14334-F39-0000
GB/T 5789-1986
M7-6.35-124
14630-F18-0000
14520-F39-0000
GB/T 9074.14-88
Part Number
08-042-3701
08-042-3702
08-042-3703
08-042-3704
08-042-3705
08-042-3706
08-042-3707
08-042-3708
Description
Camshaft Assy
Sproket, Cam Chain
Plate
Bolt M7X11
Cam Chain
Guide 1, Cam Chain
Guide 2, Cam Chain
Bolt M6X16
Fig. 38
Crankshaft and Piston
Ref
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Code
13200-F18-0000
13304-F39-0000
13305-F39-0000
13302-F39-0000
13303-F39-0000
90701-F39-0000
90618-F12-0000
GB/T 5783-2000
91207-F39-0000
GB/T 276-1994
13101-F18-0000
13120-F18-0000
13111-F18-0000
91301-F18-0000
13401-F39-0000
13402-F39-0000
13300-F18-0000
13320-F39-0000
GB/T 1095-2003
GB/T6172.1-2000
13321-F39-0000
GB/T 276-1994
GB/T 276-1994
91101-F39-0000
13201-F39-0000
Part Number
08-042-3801
08-042-3802
08-042-3803
08-042-3804
08-042-3805
08-042-3806
08-042-3807
08-042-3808
08-042-3809
08-042-3810
08-042-3811
08-042-3812
08-042-3813
08-042-3814
08-042-3815
08-042-3816
08-042-3817
08-042-3818
08-042-3819
08-042-3820
08-042-3821
08-042-3822
08-042-3823
08-042-3824
08-042-3825
Description
Crankshaft Assy
Gear, Drive
Washer, Bearing Cover
Spring
Dowel Pin 6X9.4
Circlip 35
Washer 10X30X3.2
Bolt M10X40
O-Ring 16.1X3.1
Bearing
Piston
Piston Ring Set
Piston Pin
Circlip
Spacer
Seal, Crankshaft
Weight 1
Balancer Weight Gear
Straight Key B5X12.4
Nut M18X1
Washer, Lock
Bearing 6305
Bearing 6304R
Oil Seal 20X30X7
Woodruff Key
Fig. 39
Crankcase
Ref
1
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
38
39
Code
11200-F39-0000
90803-F11-0000
GB/T 16674-1996
11100-F39-0000
GB/T 16674-1996
GB/T 5789-1986
GB/T 70.1-2000
91202-058-0000
91503-058-0000
15651-F39-0000
91216-F39-0000
11111-F39-0000
GB/T 16674-1996
21240-F39-0000
21241-F39-0000
90803-F11-0000
GB/T 16674-1996
GB/T 16674-1996
GB/T 276-1994
91102-F39-0000
90704-F39-0000
17115-F39-0000
GB/T 5789-1986
GB/T 5789-1986
11330-F39-0000
90801-F39-0000
GB/T 5789-1986
GB/T 5789-1986
GB/T 276-1994
91101-F12-0000
11331-F12-0000
GB/T 16674-1996
37180-F12-0000
90603-F12-0000
37120-F39-0000
91208-F39-0000
GB/T 9074.14-88
43611-F39-0000
90609-F39-0000
Part Number
08-043-3901
08-043-3902
08-043-3903
08-043-3904
08-043-3905
08-043-3906
08-043-3907
08-043-3908
08-043-3909
08-043-3910
08-043-3911
08-043-3912
08-043-3913
08-043-3914
08-043-3915
08-043-3916
08-043-3917
08-043-3918
08-043-3919
08-043-3920
08-043-3921
08-043-3922
08-043-3923
08-043-3924
08-043-3925
08-043-3926
08-043-3927
08-043-3928
08-043-3929
08-043-3930
08-043-3931
08-043-3932
08-043-3933
08-043-3934
08-043-3935
08-043-3936
08-043-3937
08-043-3938
08-043-3939
Description
Left Crankcase
Dowel Pin 10X15.7
Bolt M6X30
Right Crankcase
Bolt M6X40
Bolt M6X55
Bolt M8X40
Pipe, Breather 1
Clip
Oil Level Dipstick
O-Ring 20X2.3
Plate, Bearing Cover
Bolt M6X14
Housing, Bearing 1
Gasket
Dowel Pin 10X16
Bolt M6X30
Bolt M6X40
Bearing 16010
Oil Seal 35X65X8
Circlip 80
Bracket
Bolt M6X16
Bolt M6X20
Housing, Bearing
Dowel Pin 10X16
Bolt M6X30
Bolt M6X40
Bearing 6201RD
Oil Seal 12X32X6
Plate, Bearing Cover
Bolt M6X12
Neutral Switch
Washer 10X16X1
Gear Position Sensor
O-Ring 29.6X2.4
Bolt M6X16
Parking State Bolt
Gasket 14X20X1.5
Fig. 40
Crankcase Cover
Ref
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
Code
11321-F39-0000
11323-F39-0000
91501-F39-0000
91601-F39-0000
90803-F11-0000
GB/T 16674-1996
GB/T 16674-1996
11322-F39-0000
GB/T 16674-1996
GB/T 276-1994
91103-F12-0000
11324-F11-0000
GB/T819.1-2000
11325-F19-0000
91209-F39-0000
11450-F39-0000
11411-F39-0000
11412-F39-0000
GB/T 5789-1986
11400-F39-0000
11413-F39-0000
GB/T 5789-1986
GB/T 5789-1986
11403-F12-0000
11404-F12-0000
Part Number
08-043-4001
08-043-4002
08-043-4003
08-043-4004
08-043-4005
08-043-4006
08-043-4007
08-043-4008
08-043-4009
08-043-4010
08-043-4011
08-043-4012
08-043-4013
08-043-4014
08-043-4015
08-043-4016
08-043-4017
08-043-4018
08-043-4019
08-043-4020
08-043-4021
08-043-4022
08-043-4023
08-043-4024
08-043-4025
Description
Cover, Crankcase 1
Gasket, Crankcase Cover 1
Clamp
Clamp
Dowel Pin
Bolt M6X30
Bolt M6X40
Plate
Bolt M6X14
Bearing 60/28
Oil Seal 28X52X8.2
Thrust Washer
Screw M5X16
Inspection Hole Cover
O-Ring 13.4X2.35
Cover, Crankcase 2
Gasket 1, Clutch Cover
Gasket 2, Clutch Cover
Bolt M6X30
Cover, Crankcase 3
Gasket, Crankcase Cover 3
Bolt M6X25
Bolt M6X16
Grommet
Drain Plug
Fig. 41
Transmission
Ref
1
2
3
4
5
6
7
8
9
10
11
12
Code
22211-F39-0000
GB/T 276-1994
GB/T 276-1994
22203-F12-0000
91218-F39-0000
91104-F12-0000
22220-F39-0000
GB/T 276-1994
GB/T 276-1994
M9-9.525-34
22400-F39-0000
GB/T 276-1994
Part Number
08-043-4101
08-043-4102
08-043-4103
08-043-4104
08-043-4105
08-043-4106
08-043-4107
08-043-4108
08-043-4109
08-043-4110
08-043-4111
08-043-4112
Description
Shaft, Secondary
Bearing 6203
Bearing 6006C3
Collar
O-Ring 26.1X2.4
Oil Seal 42X55X8
Middle Axle Assy
Bearing 6202
Bearing 6203DLA8
Chain (23RH302-34ASM)
Middle Gear Assy
Bearing 6305
Fig. 42
Middle Drive Gear
Ref
1
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
Code
22140-F39-0000
GB/T 276-1994
22142-F12-0000
GB/T 819.2-1997
GB/T 5789-1986
90606-F39-0000
GB/T 6172.1-2000
22141-F39-0000
22150-F39-0000
GB/T 276-1994
22158-F39-0000
GB/T 276-1994
91106-F12-0000
22160-F39-0000
90607-F39-0000
90301-F39-0000
91201-F11-0000
GB/T 9074.14-88
22151-F39-0000
22152-F39-0000
22156-F39-0000
GB/T 276-1994
22190-F39-0000
90618-F39-0000
90301-F12-0000
22159-F12-0000
91103-F39-0000
Part Number
08-043-4201
08-043-4202
08-043-4203
08-043-4204
08-043-4205
08-043-4206
08-043-4207
08-043-4208
08-043-4209
08-043-4210
08-043-4211
08-043-4212
08-043-4213
08-043-4214
08-043-4215
08-043-4216
08-043-4217
08-043-4218
08-043-4219
08-043-4220
08-043-4221
08-043-4222
08-043-4223
08-043-4224
08-043-4225
08-043-4226
08-043-4227
Description
Housing, Bearing
Bearing 6305
Plate, Bearing Cover
Screw M8X24
Bolt M6X30
Shim 26X38X（0.10-0.60）
Nut M22
Middle Pinion Gear
Middle Ring Gear
Bearing 6207
Nut, Special
Bearing 63/22
Oil Seal 30X46X8
U-Joint
Washer 16.5X28X4
Nut M16
O-Ring 88X2.8
Bolt M8X30
Housing, Bearing
Shim 26X38X（0.10-0.60）
Shaft
Bearing 6205
Flange, Coupling
Washer 14.2X32X5
Nut M14
Nut, Special
Oil Seal 44X60X7
Fig. 43
Clutch
Ref
1
2
3
4
5
6
7
8
9
Code
21200-F39-0000
90705-F39-0000
GB/ T6172.1-2000
21300-F39-0000
25300-F39-0000
90609-F12-0000
GB/ T6172.1-2000
21400-F39-0000
GB/ T6172.1-2000
Part Number
08-043-4301
08-043-4302
08-043-4303
08-043-4304
08-043-4305
08-043-4306
08-043-4307
08-043-4308
08-043-4309
Description
Clutch Assy
Circlip
Nut M22X1
Primary Sheave
V-Belt
Washer 19.2X35X3.2
Nut M16X1
Secondary Sheave
Nut M16X1
Fig. 44
Shift Cam Fork
Ref
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Code
23200-F39-0000
23101-F39-0000
23102-F39-0000
23103-F39-0000
23104-F39-0000
23105-F39-0000
23106-F39-0000
90702-F39-0000
23300-F39-0000
90617-F39-0000
23340-F39-0000
GB/T 5789-1986
91111-F12-0000
23311-F39-0000
23312-F39-0000
91602-F39-0000
GB/T 16674-1996
GB/T 16674-1996
90803-F39-0000
23301-F39-0000
23302-F39-0000
Part Number
08-043-4401
08-043-4402
08-043-4403
08-043-4404
08-043-4405
08-043-4406
08-043-4407
08-043-4408
08-043-4409
08-043-4410
08-043-4411
08-043-4412
08-043-4413
08-043-4414
08-043-4415
08-043-4416
08-043-4417
08-043-4418
08-043-4419
08-043-4420
08-043-4421
Description
Shift Cam Assy
R Fork
H-L Fork
Fork Shaft
Spring, Compression
Spring, Compression
Cap, Spring
Circlip
Bolt, Gear Station
Gasket 14X22X1
Shift Guide Assy
Bolt M6X35
Oil Seal 15X25X5
Cover, Shift Shaft
Gasket, Shift Shaft Cover
Wire Clip
Bolt M6X20
Bolt M6X30
Dowel Pin 8X11.7
Spring, Gear Station
Ball, Gear Station
Fig. 45
Oil Pump
Ref
1
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
Code
15100-F39-0000
15101-F39-0000
GB/T 16674-1996
15300-F39-0000
91210-F39-0000
GB/T 16674-1996
GB/T 5789-1986
90612-F39-0000
15200-F39-0000
15201-F39-0001
15202-F39-0000
90703-F39-0000
04CH-70
15301-F39-0000
90613-F39-0000
15304-F39-0000
15302-F39-0000
15305-F39-0000
90609-F39-0000
15307-F39-0000
90609-F39-0000
15303-F39-0000
15306-F39-0000
90614-F39-0000
GB/T 70.1-2000
15360-F39-0000
91211-F39-0000
15361-F39-0000
GB/T 16674-1996
Part Number
08-043-4501
08-043-4502
08-043-4503
08-043-4504
08-043-4505
08-043-4506
08-043-4507
08-043-4508
08-043-4509
08-043-4510
08-043-4511
08-043-4512
08-043-4513
08-043-4514
08-043-4515
08-043-4516
08-043-4517
08-043-4518
08-043-4519
08-043-4520
08-043-4521
08-043-4522
08-043-4523
08-043-4524
08-043-4525
08-043-4526
08-043-4527
08-043-4528
08-043-4529
Description
Oil Pump Assy
Gasket, Oil Pump
Bolt M6X40
Strainer Housing Assy
O-Ring 14X2.3
Bolt M6X14
Bolt M14X1.5-6H-16
Washer 14X22X1
Oil Filter
Bolt, Oil Filter Fitting
Sprocket, Driven
Circlip
Oil Pump Chain
Pipe, Oil Delivery 1
Washer 8.4X15X2
Bolt, Special 1 M8X20
Pipe, Oil Delivery 2
Bolt, Special 2 M14X28.5
Washer 14X20X1.5
Bolt, Special 4 M14X50
Washer 14X20X1.5
Pipe, Oil Delivery 3
Bolt, Special 3 M14X50
Washer 10.2X16X1.2
Bolt M6X12
Relief Valve Assy
O-Ring 10X2.45
Plate
Bolt M6X12
Fig. 46
Starter and Starter Clutch
Ref
1
2
3
4
5
6
7
8
9
Code
31220-F39-0000
31230-F39-0000
31250-F39-0000
31240-F39-0000
90615-F39-0000
31100-F11-0000
GB/T 70.1-2000
31200-F39-0000
GB/T 16674-1996
Part Number
08-043-4601
08-043-4602
08-043-4603
08-043-4604
08-043-4605
08-043-4606
08-043-4607
08-043-4608
08-043-4609
Description
Idler Gear 1
Shaft, Idler Gear
Bearng KBK121618
Idler Gear 2
Washer 25X39X1
Starter Clutch One Way Assy
Bolt M8X16
Starter Motor
Bolt M6X30
Fig. 47
Magneto
Ref
1
2
3
4
Code
31100-F39-0000
31101-F39-0000
GB/T 9074.5-1988
GB/T 70.1-2000
Part Number
08-043-4701
08-043-4702
08-043-4703
08-043-4704
Description
Stator Assy
Rotor Assy
Screw
Bolt M5X12
Fig. 48
Water Pump
Ref
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Code
19700-F39-0000
GB/T 16674-1996
GB/T 16674-1996
GB/T 70.1-2000
19272-F39-0000
91213-F39-0000
19273-F39-0000
90405-F39-0000
19210-F39-0000
GB/T 70.1-2000
91214-F39-0000
19271-F39-0000
90404-F39-0000
91502-F39-0000
GB/T 16674-1996
19410-F39-0000
Part Number
08-043-4801
08-043-4802
08-043-4803
08-043-4804
08-043-4805
08-043-4806
08-043-4807
08-043-4808
08-043-4809
08-043-4810
08-043-4811
08-043-4812
08-043-4813
08-043-4814
08-043-4815
08-043-4816
Description
Water Pump Assy
Bolt M6X45
Bolt M6X65
Bolt M6X10
Water Pipe 1
O-Ring 20.7X2.6
Water Pipe 2
Clip, Water Pipe
Joint, Water Pipe
Bolt M6X20
O-Ring 33.4X2.4
Water Pipe 1
Clip
Clip, Water Pipe
Bolt M6X20
Thermostat Cover
Fig. 49
Carburetor
Ref
1
Code
16100-F11-0000
Part Number
08-042-4901
Description
CARBURETOR ASSY - 500
Fig. 50
Oil Pipe
Ref
1
2
3
4
5
6
7
8
9
10
11
12
Code
91223-F39-0000
15311-F39-0000
GB/T5789-1986
91222-F39-0000
15202-F39-0000
15310-F39-0000
90619-F39-0000
15363-F39-0000
90620-F39-0000
15365-F39-0000
15309-F39-0000
15308-F39-0000
Part Number
08-043-5001
08-043-5002
08-043-5003
08-043-5004
08-043-5005
08-043-5006
08-043-5007
08-043-5008
08-043-5009
08-043-5010
08-043-5011
08-043-5012
Description
O-Ring 11X2
Clip, Oil Pipe
Bolt M6X16
O-Ring 56.7X3.2
Adapter Plate, Oil Filter
Bracket, Oil Pipe
Washer 10X2
Spring
Washer 6X11X1.5
circlip
Oil Pipe 4
Oil Pipe 5
Fig. 51
Cooling Fan
Ref
1
2
3
4
5
6
7
8
Code
GB/T5789-1986
19102-F39-0001
90621-F39-0000
91221-F39-0000
19101-F39-0000
22140-F39-0001
19103-F39-0001
19104-F39-0001
Part Number
08-043-5101
08-043-5102
08-043-5103
08-043-5104
08-043-5105
08-043-5106
08-043-5107
08-043-5108
Description
Bolt M6X20
Base, Air Shroud
Washer 6.2X11.8X1
O-Ring 64.4X3.1
Plate, Cooling Fan
Boss, Cooling Fan
Cooling Fan
Air Shroud, Cooling Fan
Fig. 52
Engine Assembly
Ref
1
Code
Part Number
08-042-5201
Description
Engine Assy - 500