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CRF230F

CRF230F 3
CRF230F 4
CRF230F 5
CRF230F 6

4
13KPS3E4 © Honda Motor Co., Ltd. 2005
FOREWORD INDEX 1

ENGINE GROUP 2

FRAME GROUP 3

[CRF230F3] PART NUMBER INDEX 4

PART NAME INDEX 5


B1

CONTENTS Address
Instruction for use of parts catalogue Page No.

• Instruction for use of parts catalogue ......................... 1


• This parts catalogue has been created as of May 20, 2005.
• How to refer to the part information ............................ 2
B
B
1
2
1
1
• Since this date, the sales practice for repair parts may have been
changed or the parts may have been eliminated (listed for those
• Part catalogue structure ............................................. 3 B 3
not for sale). • When the parts were revised...................................... 4 B 4
• Abbreviations used in the parts catalogue.................. 4 B 4
• The modified information is reflected on the latest Electronic • Part block and serial number check ........................... 5 B 5
Parts Catalogue (EPC). • Color label attachment position check........................ 5 B 5
Also, refer to the parts catalogue news for any change.
• Models, parts catalogue codes and applicable
serial numbers ........................................................... 6 B 6
• See the parts catalogue news for any revision that is made after
May 20, 2005. • Color label .................................................................. 7 B 7
• Color chart .................................................................. 8 B 8
• Always specify the part number when ordering a part. • Fuel hose, general purpose hoses and vinyl
hose......................................................................... 12 B12
• Check the model, type, serial numbers, color, maker, and the • FLAT RATE SERVICE TIME.................................... 16 B16
size as needed before ordering a part.
• Illustrated index ........................................................ 21 C 5
• Note that the illustrations (part drawings) can differ from the ac- • ENGINE GROUP..................................................... 27 D 1 2
tual parts in shape. • FRAME GROUP...................................................... 48 F 1 3
They are given just to help you to refer to the parts. • PART NO. INDEX..................................................... 86 I 1 4
• PART NAME INDEX................................................. 90 J 1 5
• When modifications or additions to this parts catalogue are
made, a revised edition will be issued at an appropriate time,
with successively progressing revision numbers on the cov-
er. 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
your Honda distributor.

Initial version issue date


September 01, 2002
Honda Motor Co., Ltd.

1
2005.05.20 E
B 2

Reference with “Illustrated index”


How to refer to the part information

Reference with “Part number index”

Reference with “Part name index”

2
2005.05.20 E
B 3

Address number
Part catalogue structure • Address No. is provided (in place of the page No.) to help
you refer to the part with the part No. or part name.
Block title Block number
Service item/Flat rate time
1
Reference number
• Title number marked with the parenthesis or parentheses
indicates that it continues from the previous page.
Part number Honda color code
Description
Assemblies
• Sections framed with broken lines in the exploded view
drawings are available as complete assemblies. (Their in-
dividual parts can also be obtained.)
Color description
Note
• Notes are shown with the parentheses in the part name
column.
Required quantity
• Reqd. QTY shown in the parenthesis or parentheses indi-
cates the optional part.
• Reqd. QTY marked with “N” indicates the optional part that
should be selected as needed.
• Reqd. QTY indicates the number of the part used in the
block.
Serial number
Parts catalogue code
• When the parts catalogue code column is blank, it indi-
cates that the part is applicable to all codes.

• Parts enclosed within a dotted line are covered in a


different block.

• A hollow arrow indicates the block No. for the parts en-
closed within a dotted line .

• A solid arrow indicates the block No. the part in


question is connected to.
3
2005.05.20 E
B 4

When the parts were revised Abbreviations used in the parts catalogue

1
Be sure to check the
serial number!!
RIGHT is
abbreviated “L.” stands
as “R.” for LEFT

* “L.” or “R.” in the description of a part stands for the LEFT hand
side or the RIGHT hand side. Determine the left or right as if you
were in the motorcycle seat.

• The following abbreviations are used in this parts catalogue.


A ........... Ampere L. ............Left
ABS ....... Anti-lock brake L (100L) .Link (100 Links)
system L.E.D. .....Light emitted diode
A.C. ....... Alternating current MM .........Millimeter
The number has been When shown at the left side, When shown at the right side, A.M. ...... Attaching mark MPH .......Miles per hour
used from the initial model it is applicable to the models it is applicable to the models
without revision. o f N o . 1 0 0 8 0 0 1 a n d t h e up to No.1008000. ASSY. .... Assembly R. ...........Right
subsequent numbers. C.D.I. ..... Capacitive discharge RR. .........Rear
• The parts listed with "###" at the end of the parts name have limited supply period ignition STD. .......Standard
(parts not for sale).
COMP. ... Complete T (22T) ...Tooth (22 Teeth)
D.C. ....... Direct current TCS ........Traction control
EX. ........ Exhaust system
FR. ........ Front T.M. ........Transcript mark
G ........... Gram V ............Volt
HEX. ..... Hexagonal W ...........Watt
IN. ......... Inlet WL .........With labelling
KPH ...... Kilometers per hour WOL .......Without labelling

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2005.05.20 E
B 5

Part block and serial number check Color label attachment position check

Engine parts Carburetor parts Frame parts


1
Part block Colored parts
E-1~ E-15 F-1~

Required Engine serial Carburetor serial Frame serial Color label


serial number number number
number

Check
point

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2005.05.20 E
B 6

Models, parts catalogue codes and applicable serial numbers

1
Models, parts catalogue codes and applicable serial Nos. given in this parts catalogue can be identified as follows.
Parts with parts catalogue codes are exclusive for models destined for countries designated.
If no area codes are listed, parts are for common use.
Parts Applicable
Applicable engine Applicable frame
Model catalogue Type carburetor
serial No. serial No.
code serial No.

CRF230F3 U Australia ME09E-3700001~3799999 9C2ME09U*3R700001~3R799999 PD9CA A

CRF230F4 U Australia ME09E-4700001~4799999 9C2ME09U*4R700001~4R799999 PD9CA A

CRF230F5 U Australia ME09E-5700001~5799999 9C2ME09U*5R700001~5R799999 PD9CA A

CRF230F6 U Australia ME09E-6700001~ 9C2ME09U*6R700001~ PD9CA A

* Of carburetor/throttle body identification numbers, only the portions underlined in the example below are used for registration.

PD9CA KC

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2005.05.20 E
B 7

Color label

• When ordering parts, check the model name, main color, and code by observing the “COLOR LABEL” on the vehicle.
• When ordering a colored part, use the color chart in the instruction for use of parts catalogue.
1

VFR800FIW
R-157
R157

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2005.05.20 E
B 8

Color chart

1 • When ordering a colored part, refer to the chart below and use a part number consisting of the relevant basic part number to which has been
added a part color code.
CRF230F (CRF230F3)
MODEL CRF230F3
Fighting
COLOR
red Applicable model
Applicable
CODE R-134 Ref.
block
No.
Initial Final No.
No. Name of colored parts Basic part No. R134 applicable applicable
model model
1 BODY COMP., FRAME 50100-KPS-900 ZA F-25 1
2 BOOT, FR. FORK 51611-KR6-013 ZH F-7 18
3 CASE, HEADLIGHT 61301-KCZ-900 ZE F-1 9
4 COVER, AIR CLEANER CASE 17220-KPS-900 ZA F-15 8
5 COVER, BATTERY BOX 83601-KPS-900 ZB F-14 5
6 COVER, L. SIDE 83600-KPS-900 ZA F-14 4
7 COVER, R. SIDE 83500-KPS-900 ZA F-14 2
8 FENDER SET, RR. 80101-KPS-900 ZA F-22 6
9 FENDER, FR. 61100-KPS-900 ZA F-6 1
10 HOLDER, UPPER 53131-KBB-950 ZA F-4 6
11 LABEL, COLOR 87565-KPS-900 ZA F-27 5
12 MARK 87130-MBN-830 ZA F-28 3
13 PANEL COMP., RR. BRAKE 43100-KPS-900 ZA F-10 2
14 PIPE, STEERING HANDLE 53100-KPS-900 ZA F-4 5
15 PLATE SET, FR. NUMBER 61140-KCY-A30 ZA F-1 8
16 PLATE, SKID 50351-KPS-900 ZA F-25 4
17 PROTECTOR, EX. PIPE 18345-KPS-900 ZA F-16 8
18 SHROUD SET, L. TANK 17555-KPS-900 ZA F-12 10
19 SHROUD SET, R. TANK 17545-KPS-900 ZA F-12 9
20 STRIPE, L. TANK SHROUD 87127-KPS-900 ZA F-28 2
21 STRIPE, R. TANK SHROUD 87126-KPS-900 ZA F-28 1

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2005.05.20 E
B 9

CRF230F (CRF230F4)
MODEL CRF230F4

COLOR
Extreme
red Applicable model
Applicable
1
CODE R-292R Ref.
block
No.
Initial Final No.
No. Name of colored parts Basic part No. R292 applicable applicable
model model
1 BODY COMP., FRAME 50100-KPS-900 ZA F-25 1
2 BOOT, FR. FORK 51611-KR6-013 ZH F-7 18
3 CASE, HEADLIGHT 61301-KPS-880 ZA F-1 9
4 COVER, AIR CLEANER CASE 17220-KPS-900 ZA F-15 8
5 COVER, BATTERY BOX 83601-KPS-900 ZB F-14 5
6 COVER, L. SIDE 83600-KPS-900 ZA F-14 4
7 COVER, R. SIDE 83500-KPS-900 ZA F-14 2
8 FENDER SET, RR. 80101-KPS-860 ZA F-22 6
9 FENDER, FR. 61100-KPS-860 ZA F-6 1
10 HOLDER, UPPER 53131-KBB-950 ZA F-4 6
11 LABEL, COLOR 87565-KPS-860 ZA F-27 5
12 MARK 87130-MBN-830 ZA F-28 3
13 PANEL COMP., RR. BRAKE 43100-KPS-900 ZA F-10 2
14 PIPE, STEERING HANDLE 53100-KPS-900 ZA F-4 5
15 PLATE SET, FR. NUMBER 61140-KCY-A30 ZA F-1 8
16 PLATE, SKID 50351-KPS-900 ZA F-25 4
17 PROTECTOR, EX. PIPE 18345-KPS-900 ZA F-16 8
18 SHROUD SET, L. TANK 17555-KPS-860 ZA F-12 10
19 SHROUD SET, R. TANK 17545-KPS-860 ZA F-12 9
20 STRIPE, L. TANK SHROUD 87127-KPS-860 ZA F-28 5
21 STRIPE, R. TANK SHROUD 87126-KPS-860 ZA F-28 4

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2005.05.20 E
B10

CRF230F (CRF230F5)
MODEL CRF230F5

1 COLOR
Extreme
red Applicable model
Applicable
CODE R-292R Ref.
block
No.
Initial Final No.
No. Name of colored parts Basic part No. R292 applicable applicable
model model
1 BODY COMP., FRAME 50100-KPS-900 ZA F-25 1
2 BOOT, FR. FORK 51611-KR6-013 ZH F-7 18
3 COVER, AIR CLEANER CASE 17220-KPS-900 ZA F-15 8
4 COVER, BATTERY BOX 83601-KPS-900 ZB F-14 5
5 COVER, L. SIDE 83600-KPS-900 ZA F-14 4
6 COVER, R. SIDE 83500-KPS-900 ZA F-14 2
7 FENDER SET, RR. 80101-KPS-760 ZA F-22 6
8 HOLDER, UPPER 53131-KBB-950 ZA F-4 6
9 LABEL, COLOR 87565-KPS-760 ZA F-27 5
10 MARK 87130-MBN-830 ZA F-28 3
11 PANEL COMP., RR. BRAKE 43100-KPS-900 ZA F-10 2
12 PIPE, STEERING HANDLE 53100-KPS-901 ZA F-4 5
13 PLATE SET, FR. NUMBER 61140-KCY-A30 ZA F-1 8
14 PLATE, SKID 50351-KPS-900 ZA F-25 4
15 PROTECTOR, EX. PIPE 18345-KPS-900 ZA F-16 8
16 SHROUD SET, L. TANK 17555-KPS-760 ZA F-12 10
17 SHROUD SET, R. TANK 17545-KPS-760 ZA F-12 9
18 STRIPE, L. TANK SHROUD 87127-KPS-760 ZA F-28 7
19 STRIPE, R. TANK SHROUD 87126-KPS-760 ZA F-28 6

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2005.05.20 E
B11

CRF230F (CRF230F6)
MODEL CRF230F6

COLOR
Extreme
red Applicable model
Applicable
1
CODE R-292R Ref.
block
No.
Initial Final No.
No. Name of colored parts Basic part No. R292 applicable applicable
model model
1 BODY COMP., FRAME 50100-KPS-730 ZA F-25 1
2 BOOT, FR. FORK 51611-KR6-013 ZH F-7 18
3 COVER, AIR CLEANER CASE 17220-KPS-900 ZA F-15 8
4 COVER, BATTERY BOX 83601-KPS-900 ZB F-14 5
5 COVER, L. SIDE 83600-KPS-900 ZA F-14 4
6 COVER, R. SIDE 83500-KPS-900 ZA F-14 2
7 FENDER SET, RR. 80101-KPS-760 ZA F-22 6
8 HOLDER, UPPER 53131-KBB-950 ZA F-4 6
9 LABEL, COLOR 87565-KPS-730 ZA F-27 5
10 MARK 87130-MBN-830 ZA F-28 3
11 PANEL COMP., RR. BRAKE 43100-KPS-900 ZA F-10 2
12 PIPE, STEERING HANDLE 53100-KPS-901 ZA F-4 5
13 PLATE SET, FR. NUMBER 61140-KCY-A30 ZA F-1 8
14 PLATE, SKID 50351-KPS-900 ZA F-25 4
15 PROTECTOR, EX. PIPE 18345-KPS-901 ZA F-16 8
16 SHROUD SET, L. TANK 17555-KPS-730 ZA F-12 10
17 SHROUD SET, R. TANK 17545-KPS-730 ZA F-12 9
18 STRIPE, L. TANK SHROUD 87127-KPS-730 ZA F-28 9
19 STRIPE, R. TANK SHROUD 87126-KPS-730 ZA F-28 8

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2005.05.20 E
B12

Fuel hose, general purpose hoses and vinyl hose

1 • The standard part fuel hose, general purpose hose and vinyl hose may be substituted by the coiled bulk part.
• When ordering the standard part fuel hose, general purpose hose and vinyl hose use the bulk part number written in the parts catalogue in brackets ( ) underneath the part
name, or use the catalogue below.
(The bulk part standard length is 1 m, however, those displayed in the catalogue < > are available in 3 m and 8 m lengths.)
• When exchanging the hose, cut and use at the specified length as mentioned in the part name.
(For the method of cutting the bulk part, and method of filling out orders etc., please refer to the service manual and the instructions issued with the bulk part.)

• The list below is a catalogue of the standard part numbers and bulk part numbers. Note that those numbers are applicable to the listed replacement parts only.

Fuel hoses/Tubes Fuel hoses/Tubes


Bulk part Bulk part
Standard part No. Bulk part No. Inner Standard part No. Bulk part No. Inner
diameter Length diameter Length
(m) (m)
(mm) (mm)
95001-30xxx-2x 95001-30001-20M 3.0 1 95001-55001-60M 1
95001-30xxx-3x 95001-30001-30M 3.0 1 95001-55xxx-3x <95001-55003-60M> 5.5 3
<95001-55008-60M> 8
95001-30xxx-4x 95001-30001-40M 3.0 1
95001-55001-60M 1
95001-35001-50M 1 95001-55xxx-4x <95001-55003-60M> 5.5 3
95001-35xxx-2x <95001-35003-50M> 3.5 3 <95001-55008-60M> 8
95001-35001-60M 1 95001-55001-50M 1
95001-35xxx-3x <95001-35003-60M> 3.5 3 95001-55xxx-5x <95001-55003-50M> 5.5 3
95001-35001-60M 1 <95001-55008-50M> 8
95001-35xxx-4x <95001-35003-60M> 3.5 3 95001-55001-60M 1
95001-35001-50M 1 95001-55xxx-6x <95001-55003-60M> 5.5 3
95001-35xxx-5x <95001-35003-50M> 3.5 3 <95001-55008-60M> 8
95001-35001-60M 1 95001-75001-50M 1
95001-35xxx-6x 3.5 95001-75xxx-2x 7.5
<95001-35003-60M> 3 <95001-75003-50M> 3
95001-45001-50M 1 95001-75001-60M 1
95001-45xxx-2x <95001-45003-50M> 4.5 3 95001-75xxx-3x <95001-75003-60M> 7.5 3
<95001-75008-60M> 8
95001-45001-60M 1
95001-45xxx-3x <95001-45003-60M> 4.5 3 95001-75001-60M 1
<95001-45008-60M> 8 95001-75xxx-4x <95001-75003-60M> 7.5 3
<95001-75008-60M> 8
95001-45001-60M 1
95001-45xxx-4x <95001-45003-60M> 4.5 3 95001-75001-50M 1
95001-75xxx-5x <95001-75003-50M> 7.5 3
<95001-45008-60M> 8
95001-45001-50M 1 95001-75001-60M 1
95001-45xxx-5x 4.5 95001-75xxx-6x <95001-75003-60M> 7.5 3
<95001-45003-50M> 3
<95001-75008-60M> 8
95001-45001-60M 1
95001-45xxx-6x <95001-45003-60M> 4.5 3 95001-80xxx-2x 95001-80001-50M 8.0 1
<95001-45008-60M> 8 95001-80xxx-3x 95001-80001-60M 8.0 1
95001-55001-50M 1 95001-80xxx-4x 95001-80001-60M 8.0 1
95001-55xxx-2x <95001-55003-50M> 5.5 3
<95001-55008-50M> 8 95001-80xxx-5x 95001-80001-50M 8.0 1
95001-80xxx-6x 95001-80001-60M 8.0 1
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2005.05.20 E
B13

Vinyl tube Vinyl tube Vinyl tube


Bulk part Bulk part Bulk part

1
Standard part Inner Outer Standard part Inner Outer Standard part Inner Outer
Bulk part No. Length Bulk part No. Length Bulk part No. Length
No. dia- meter dia-meter No. dia- meter dia-meter No. dia- meter dia-meter
(m) (m) (m)
(mm) (mm) (mm) (mm) (mm) (mm)
95003-01001-60M 1 95003-14001-10M 1 95003-36001-10M 1
95003-01xxx-3x <95003-01003-60M> 2.9 6.8 95003-14xxx-1x <95003-14003-10M> 6.0 9.0
3 3 95003-36xxx-1x <95003-36003-10M> 11.0 13.0 3
<95003-36008-10M> 8
95003-01001-60M 1 95003-14001-10M 1
95003-01xxx-60 <95003-01003-60M> 2.9 6.8 95003-14xxx-20 <95003-14003-10M> 6.0 9.0
3 3 95003-36001-10M 1
95003-36xxx-20 <95003-36003-10M> 11.0 13.0 3
95003-03001-60M 1 95003-14001-60M 1 <95003-36008-10M> 8
95003-03xxx-3x <95003-03003-60M> 3.0 6.0 95003-14xxx-3x <95003-14003-60M> 6.0 9.0
3 3
95003-37001-60M 1
95003-03001-60M 1 95003-17001-10M 1 95003-37xxx-3x 95003-37003-60M> 11.0 15.0
95003-03xxx-60 <95003-03003-60M> 3.0 6.0 95003-17xxx-1x <95003-17003-10M> 7.0 9.0 3
3 3
95003-37001-60M 1
95003-05001-60M 1 95003-19001-10M 1 95003-37xxx-60 <95003-37003-60M> 11.0 15.0 3
95003-05xxx-3x <95003-05003-60M> 3.5 6.5 3 95003-19xxx-1x <95003-19003-10M> 7.0 11.0 3
<95003-05008-60M> 8 <95003-19008-10M> 8 95003-38001-10M 1
95003-38xxx-1x <95003-38003-10M> 12.0 13.0 3
95003-05001-60M 1 95003-19001-10M 1
95003-05xxx-60 <95003-05003-60M> 3.5 6.5 3 95003-19xxx-20 <95003-19003-10M> 7.0 11.0 3 95003-38001-10M 1
<95003-05008-60M> 8 95003-38xxx-20 <95003-38003-10M> 12.0 13.0
<95003-19008-10M> 8 3
95003-07001-10M 1 95003-19001-60M 1 95003-39001-10M 1
95003-39xxx-1x <95003-39003-10M> 12.0 14.0
95003-07xxx-1x <95003-07003-10M> 4.0 7.0 3 95003-19xxx-3x <95003-19003-60M> 7.0 11.0 3 3
<95003-07008-10M> 8 <95003-19008-60M> 8
95003-39001-10M 1
95003-39xxx-20 <95003-39003-10M> 12.0 14.0
95003-07001-10M 1 95003-19001-60M 1 3
95003-07xxx-20 <95003-07003-10M> 4.0 7.0 3 95003-19xxx-60 <95003-19003-60M> 7.0 11.0 3
<95003-07008-10M> 8 <95003-19008-60M> 8 95003-40001-10M 1
95003-40xxx-20 <95003-40003-10M> 12.0 16.0 3
95003-07001-60M 1 95003-21001-10M 1
95003-21xxx-1x <95003-21003-10M> 8.0 9.0 95003-40001-60M 1
95003-07xxx-3x <95003-07003-60M> 4.0 7.0 3 3 95003-40xxx-3x <95003-40003-60M> 12.0 16.0
<95003-07008-60M> 8 3
95003-21001-10M 1
95003-21xxx-20 <95003-21003-10M> 8.0 9.0 95003-40001-60M 1
95003-07001-60M 1 3 95003-40xxx-60 <95003-40003-60M> 12.0 16.0
95003-07xxx-60 <95003-07003-60M> 4.0 7.0 3 3
<95003-07008-60M> 8 95003-23001-10M 1
95003-23xxx-1x <95003-23003-10M> 8.0 12.0 95003-43001-10M 1
3
95003-07001-70M 1 95003-43xxx-1x <95003-43003-10M> 13.0 15.0 3
95003-07xxx-7x <95003-07003-70M> 4.0 7.0 3 95003-23001-10M 1 <95003-43008-10M> 8
95003-23xxx-20 <95003-23003-10M> 8.0 12.0
<95003-07008-70M> 8 3
95003-43001-10M 1
95003-08001-10M 1 95003-23001-60M 1 95003-43xxx-20 <95003-43003-10M> 13.0 15.0 3
95003-08xxx-1x <95003-08003-10M> 4.5 6.5 3 95003-23xxx-3x <95003-23003-60M> 8.0 12.0 3 <95003-43008-10M> 8
<95003-08008-10M> 8 <95003-23008-60M> 8
95003-45001-10M 1
95003-09001-60M 1 95003-23001-60M 1 95003-45xxx-1x <95003-45003-10M> 14.0 18.0 3
95003-09xxx-3x <95003-09003-60M> 4.5 8.0 95003-23xxx-60 <95003-23003-60M> 8.0 12.0 3 <95003-45008-10M> 8
3
<95003-23008-60M> 8
95003-09001-60M 1 95003-45001-10M 1
95003-09xxx-60 <95003-09003-60M> 4.5 8.0 95003-25001-10M 1 95003-45xxx-20 <95003-45003-10M> 14.0 18.0 3
3 95003-25xxx-1x <95003-25003-10M> 9.0 11.0 3 <95003-45008-10M> 8
95003-10001-10M 1
95003-10xxx-1x <95003-10003-10M> 5.0 8.0 95003-25001-10M 1 95003-50001-10M 1
3 95003-25xxx-20 <95003-25003-10M> 9.0 11.0 95003-50xxx-1x <95003-50003-10M> 16.0 19.0
3 3
95003-10001-10M 1
95003-10xxx-20 <95003-10003-10M> 5.0 8.0 95003-25001-60M 1 95003-50001-10M 1
3 95003-25xxx-3x <95003-25003-60M> 9.0 11.0 95003-50xxx-20 <95003-50003-10M> 16.0 19.0
3 3
95003-10001-60M 1
95003-10xxx-3x <95003-10003-60M> 5.0 8.0 95003-25001-70M 1 95003-50001-60M 1
3 95003-25xxx-7x <95003-25003-70M> 9.0 11.0 95003-50xxx-3x <95003-50003-60M> 16.0 19.0
3 3
95003-10001-60M 1
95003-10xxx-60 <95003-10003-60M> 5.0 8.0 95003-27001-10M 1 95003-55001-10M 1
3 95003-27xxx-1x <95003-27003-10M> 9.0 13.0 95003-55xxx-1x <95003-55003-10M> 17.5 20.5
3 3
95003-11001-60M 1
95003-11xxx-3x <95003-11003-60M> 5.0 9.0 3 95003-27001-10M 1 95003-55001-10M 1
95003-27xxx-20 <95003-27003-10M> 9.0 13.0 95003-55xxx-20 <95003-55003-10M> 17.5 20.5
<95003-11008-60M> 8 3 3

95003-11001-60M 1 95003-27001-60M 1 95003-60001-10M 1


95003-27xxx-3x <95003-27003-60M> 9.0 13.0 95003-60xxx-1x <95003-60003-10M> 22.0 27.0
95003-11xxx-60 <95003-11003-60M> 5.0 9.0 3 3 3
<95003-11008-60M> 8 95003-27001-60M 1 95003-60001-10M 1
95003-27xxx-60 <95003-27003-60M> 9.0 13.0 95003-60xxx-20 <95003-60003-10M> 22.0 27.0
95003-12001-10M 1 3 3
95003-12xxx-1x <95003-12003-10M> 5.0 7.0 3 95003-33001-10M 1 95003-60001-60M 1
<95003-12008-10M> 8 95003-33xxx-1x <95003-33003-10M> 10.0 14.0 95003-60xxx-3x <95003-60003-60M> 22.0 27.0
3 3
95003-12001-10M 1 95003-33001-10M 1 95003-60001-60M 1
95003-12xxx-20 <95003-12003-10M> 5.0 7.0 3 95003-33xxx-20 <95003-33003-10M> 10.0 14.0 95003-60xxx-60 <95003-60003-60M> 22.0 27.0
3 3
<95003-12008-10M> 8

13
2005.05.20 E
B14

General purpose hoses General purpose hoses


Bulk part Bulk part

1 Standard part No. Bulk part No. Inner


diameter Length
(m)
Standard part No. Bulk part No. Inner
diameter Length
(m)
(mm) (mm)
95005-11xxx-3x 95005-11001-30M 11.0 1 95005-45001-10M 1
95005-11xxx-5x 95005-11001-50M 11.0 1 95005-45xxx-4x <95005-45003-10M> 4.5 3
<95005-45008-10M> 8
95005-12001-10M 1
95005-12xxx-1x 12.0 95005-45xxx-5x 95005-45001-50M 4.5 1
<95005-12003-10M> 3
95005-12xxx-2x 95005-12001-20M 12.0 1 95005-50001-30M 1
95005-50xxx-3x <95005-50003-30M> 5.0 3
95005-12xxx-3x 95005-12001-30M 12.0 1
95005-50xxx-5x 95005-50001-50M 5.0 1
95005-12xxx-5x 95005-12001-50M 12.0 1
95005-55001-10M 1
95005-14xxx-1x 95005-14001-10M 14.0 1 95005-55xxx-1x <95005-55003-10M> 5.3 3
95005-14001-20M 1 <95005-55008-10M> 8
95005-14xxx-2x 14.0
<95005-14003-20M> 3 95005-55001-20M 1
95005-55xxx-2x 5.3
95005-14xxx-3x 95005-14001-30M 14.0 1 <95005-55003-20M> 3
95005-14xxx-5x 95005-14001-50M 14.0 1 95005-55001-10M 1
95005-55xxx-4x <95005-55003-10M> 5.3 3
95005-17xxx-1x 95005-17001-10M 17.0 1 <95005-55008-10M> 8
95005-17xxx-2x 95005-17001-20M 17.0 1 95005-65001-10M 1
95005-65xxx-1x 6.5
95005-17xxx-3x 95005-17001-30M 17.0 1 <95005-65003-10M> 3
95005-17xxx-5x 95005-17001-50M 17.0 1 95005-65xxx-2x 95005-65001-20M 6.5 1
95005-30xxx-3x 95005-30001-30M 3.0 1 95005-70001-30M 1
95005-70xxx-3x 7.0
<95005-70003-30M> 3
95005-30xxx-5x 95005-30001-50M 3.0 1
95005-70xxx-5x 95005-70001-50M 7.0 1
95005-35001-10M 1
95005-35xxx-1x <95005-35003-10M> 3.5 3 95005-75001-10M 1
95005-75xxx-1x <95005-75003-10M> 7.3 3
<95005-35008-10M> 8
95005-35xxx-2x 95005-35001-20M 3.5 1 95005-75xxx-2x 95005-75001-20M 7.3 1
95005-35xxx-3x 95005-35001-30M 3.5 1 95005-80xxx-1x 95005-80001-10M 8.0 1
<95005-80003-10M> 3
95005-35001-10M 1
95005-35xxx-4x <95005-35003-10M> 3.5 3 95005-80xxx-2x 95005-80001-20M 8.0 1
<95005-35008-10M> 8 95005-80xxx-3x 95005-80001-30M 8.0 1
95005-35xxx-5x 95005-35001-50M 3.5 1 95005-80xxx-5x 95005-80001-50M 8.0 1
95005-45001-10M 1 95005-91xxx-3x 95005-91001-30M 12.0 1
95005-45xxx-1x <95005-45003-10M> 4.5 3
<95005-45008-10M> 8 95005-91xxx-5x 95005-91001-50M 12.0 1
95005-45xxx-2x 95005-45001-20M 4.5 1 95005-92xxx-3x 95005-92001-30M 12.0 1
95005-45xxx-3x 95005-45001-30M 4.5 1 95005-92xxx-5x 95005-92001-50M 12.0 1
NOTE: X is displayed to represent the omitted numerals and letters of the
roman alphabet.

CAUTION: It is DANGEROUS to confuse the fuel hose with the general purpose hose or vinyl hose.
Never use a general purpose hose or vinyl hose in place of a fuel hose or vice versa. Always use the correct bulk part in the parts catalogue, according
to the service manual or the instructions issued with the bulk part.

14
2005.05.20 E
B15

• Bulk part number of fuel hose, general purpose hose and vinyl hose.

(Example)

95001-75001-50M
1
Bulk part number: Refers to the bulk part.

Marking code (hose type): (fuel hose and general purpose hose)
Change code (for added hose): (Vinyl hose)
• Indicates number mark or change sequence, however, the code for the bulk part must be strictly
0 (zero).

Types of code:
• Fuel hose 2: Red outside braid • Vinyl hose 1: Clear • General hose 1: Ash gray
(3 mm inside dia. only) 2: Black 2: Ash gray
5: Black inside braid 3: Light red 3: Black
3: Red (3 mm inside dia. only) 6: Light red 5: Black
4: Ash gray with red stripe 7: Pale black
(3 mm inside dia. only)
6: Black
Lengths: 001: 1 m (standard)
003: 3 m
008: 8 m

I.D code: (fuel hose and general purpose hose)


30: 3.0 mm 11: 11 mm
35: 3.5 mm 91: 12 mm (outside dia. 15) mm
45: 4.5 mm 92: 12 mm (outside dia. 16) mm
50: 5.0 mm 12: 12 mm (outside dia. 17) mm
55: 5.3 mm, 5.5 mm 14: 14 mm
65: 6.5 mm 17: 17 mm
70: 7.0 mm
75: 7.3 mm, 7.5 mm
80: 8.0 mm
ID./OD. code: (vinyl hose)
01: ID. 2.9, OD. 6.8 mm 14: ID. 6.0, OD. 9.0 mm 37: ID. 11.0, OD. 15.0 mm
03: ID. 3.0, OD. 6.0 mm 17: ID. 7.0, OD. 9.0 mm 38: ID. 12.0, OD. 13.0 mm
05: ID. 3.5, OD. 6.5 mm 19: ID. 7.0, OD. 11.0 mm 39: ID. 12.0, OD. 14.0 mm
07: ID. 4.0, OD. 7.0 mm 21: ID. 8.0, OD. 9.0 mm 40: ID. 12.0, OD. 16.0 mm
08: ID. 4.5, OD. 6.5 mm 23: ID. 8.0, OD. 12.0 mm 43: ID. 13.0, OD. 15.0 mm
09: ID. 4.5, OD. 8.0 mm 25: ID. 9.0, OD. 11.0 mm 45: ID. 14.0, OD. 18.0 mm
12: ID. 5.0, OD. 7.0 mm 27: ID. 9.0, OD. 13.0 mm 50: ID. 16.0, OD. 19.0 mm
10: ID. 5.0, OD. 8.0 mm 33: ID. 10.0, OD. 14.0 mm 55: ID. 17.5, OD. 20.5 mm
11: ID. 5.0, OD. 9.0 mm 36: ID. 11.0, OD. 13.0 mm 60: ID. 22.0, OD. 27.0 mm

Hose type: 1: Fuel hose


3: Vinyl hose
5: General hose

15
2005.05.20 E
B16

Editorial style
FLAT RATE SERVICE TIME
The service items shown in the text are listed with the exchange
work time for the repair sales parts as the subject. Other
1 Flat rate service time (FRT) means the standard time required to
service a MC, which is listed in this manual to help the dealers
representative service items not using repair parts (removal/
installation, adjustment, inspection/measuring, and other work) are
control the actual working process and calculate the service charge listed collectively in the list in the preface, classified according to the
by using it as a guide. work.

FRT setting system FRT setting standard


• Decimal system (in unit of 0.1) is adopted to set FRT as it is
Net service time
convenient to calculate the wage.
Removal, Disassembly/reassembly, Installation Example: (0.1) 6 minutes, (0.2) 12 minutes
Inspection, Measurement, Adjustment, Confirmation [Labor cost per hour] x [FRT] = [Wage]
• FRT is set with a hand tool.
Diagnosis/troubleshooting (Electric system)
• Service items and FRT can be subject to change depending on
Completion inspection development of tools and service equipment and improvement in
service procedure.
Float time
Preparation
(Process check, Confirmation arrangement for
necessary tools)
Related work (Transfer of vehicles)
* Float time is set by multiplying the net service time by a given
coefficient.

16
2005.05.20 E
C 1

Work procedure Service item whose FRT is not presented


• As the work procedure is set with the work time according to the • Accessories and service parts that are not listed to use in this
method in the separate Service Manual, refer to this Manual as manual.
required.
• Work methods permitting servicing in the shortest time still
• Locations with little aging deterioration or breakage during normal
use.
1
permitting assurance of safe work and product warranty are used • Service work that can be finished by one touch.
for the setting of service items not listed in the Service Manual.
• Service work that is seldom done (i.e. extremely small causes of
• Work basically is to be performed by one person, and when two or trouble and service frequency).
more people are required, setting is done as the total time for the
number of people. * When FRT is not presented, please calculate wages based on ap-
• The set value for the technological level of the workers uses a propriate actual work time
person with three years of experience in the repair of Honda
vehicles as the standard. Operation not included of FRT
• Special tools and service equipment used to set FRT are those • Oil and coolant water draining, Waiting time for warming up
specified or recommended in Service Manual. operation and etc..
• Additional operation that involves removal/installation of standard
exterior equipment.
• Indirect time spent for service by visiting the customer, trade-in,
and delivery of a MC.
• Indirect time required for ordering and delivery of parts.
• Cost for grease, adhesive agent, etc. used for service work.

17
2005.05.20 E
C 2

Explanation of FRT by using an example Indicating work contents that are included in the service
(The example may differ from the actual presented items) item.

1 Ref.
No.
L.O.N.
(Relative ref. Number)
Description
F.R.T.
Indicating a reference No. whose operation and time are
the same as FRT4.5 for the camshaft.
(1, 3, 4, 7)
(The application range is limited to the service items
2 111118 CAMSHAFT • • • • • • • • • • • • • • 4.5 without an LON setting within a same block.)

How to refer to the service item by using the sample


• Includes: Valve clearance adjustment (camshaft replacement)
111118A Replace rocker arm add
Open to the page of the block where the camshaft's
• • • • • • • • • • • • • • • • • • • • • • • • • 1.0
spare part illustration is shown.

Reference No. of the illustration of part that shows location


of the replacement work.
Look for the camshaft illustration, and refer to the ser-
FRT is an abbreviation of Flat Rate Time indicating the vice item and FRT that agree with the reference No.
standard service time required for the replacement.

LON is an abbreviation of Labor Operation Number, and it


is a classification of the service items by the work unit code.

The same operation code is used regardless of the models.

Standard operation is indicated with 6 digits code, and


additional operation is indicated with 7 digits code.

Indicating the camshaft replacement and FRT4.5.

Indicating FRT1.0 that will be added when additional


operation (replace rocker arm) is done in association with
camshaft replacement.

18
2005.05.20 E
C 3

Indication mark for the listing of service items that continues to


the following page
1 11 1 18 A
1
Ref. (Relative ref. Number)
L.O.N. F.R.T. a c
No. Description
a) Category codes and classification
2 111118 CAMSHAFT • • • • • • • • • • • • • • • 4.5
• • • Code Category

• • • 1 Engine
+ 2 Transmission
3 Fuel & Exhaust
Mark indicated at the last line.
4 Frame & Body

Indication of the block with no setting of FRT 5 Steering/Suspension


6 Electrical
Ref. (Relative ref. Number)
L.O.N. F.R.T. 7 Wheels/Brakes
No. Description
8 Controls/instrument
NO INFORMATION • • • • • • • • • • • • • • • • • • •
9 -
• LON code system
0 -

1 11 1 18 A c) Operation codes and classification


a b c d e Code Operation category
1 Replace, Removal/Installation, Change
a) Category code..................... Engine 2 Overhaul
b) Location/function code ........ Engine upper 3 Adjust, Balance
c) Operation code.................... Replace 4 (Paint-related work: Top-coat)
d) Operation sequence number (Unit code can be shown 5 Test, Inspect/diagnose, Measurment, Check
with alphabet)
6 (Overhaul-related work: Rebore)
......................... camshaft
(No regular rule of code) 7 (Overhaul-related work: Reseal)
8 (Resurface)
e) Additional code ................... replace rocker arm
(No regular rule of code) 9 (Paint-related work: Refinish)
0 Repair, Cleaning, Air bleeding
19
2005.05.20 E
C 4

Major service items without using spare parts


(1) Removal/Installation, (2) Adjustment, (3) Inspection/
Measurement, (4) Overhaul, (5) Other work

1 E: Engine, F: Frame

* OPERATIONS OTHER THAN REPLACING PARTS

(1) Removal and installation (3) Inspection, Measurement


Set for the configuration with the parts removed from the vehicle.
LON DESCRIPTION FRT
LON DESCRIPTION FRT 1115A0 COMPRESSION PRESSURE-MEASUREMENT 0.2
TILTING ENGINE ASSEMBLY-
1101E5 REMOVAL/INSTALLATION 1.7 CARBURETOR FLOAT LEVEL-
3115A0 0.6
INCLUDES: All necessary adjustment MEASUREMENT
E
CYLINDER HEAD ASSEMBLY- 6145A0 IGNITION TIMING-INSPECTION 0.2
1111K0 REMOVAL/INSTALLATION 2.7 ENGINE OIL-INSPECTION
E INCLUDES: Engine removal and installation 1135A0 0.1
EXCLUDES: Oil change
CARBURETOR ASSEMBLY-
3111D6 0.4 7115A0 BRAKE OPERATION-TEST 0.1
REMOVAL/INSTALLATION
CRANKCASE SEPARATION F BATTERY-CHECKING OF ELECTROLYTE
1101E6 4.3 6105A0 0.2
INCLUDES: Engine removal and installation LEVEL & GRAVITY

(2) Adjustment (4) Overhaul


Work condition: The required Measurements, inspections,
LON DESCRIPTION FRT adjustments, and cleaning/washing of each part are performed,
3113A0 CARBURETOR IDLE-ADJUSTMENT 0.1 including the main body removal/installation work and the
CLUTCH-ADJUSTMENT replacement of defective parts.
2123A0 0.1
INCLUDES: Clutch lever adjustment
E LON DESCRIPTION FRT
6143A1 SPARK PLUG-ADJUSTMENT/CLEANING 0.1
CARBURETOR-OVERHAUL
VALVE CLEARANCE-ADJUSTMENT E 311200 0.7
1113A0 0.5 INCLUDES: All necessary adjustment
NOTE: For 1 vehicle
2133A0 DRIVE CHAIN-ADJUSTMENT 0.1 (5) Other work
REAR BRAKE-ADJUSTMENT
F 7113A1 0.1 LON DESCRIPTION FRT
EXCLUDES: Rear brake shoe adjustment
3113A3 THROTTLE OPERATION-ADJUSTMENT 0.1 E 1130A1 OIL FILTER SCREEN-CLEANING 0.2
3120A0 CLEANER ELEMENT-CLEANING 0.2
F
7110A0 FRONT BRAKE-AIR BLEEDING 0.2

20
2005.05.20 E
ENGINE GROUP C 5
E-1 D 1 E-2 D 3 E-3 D 5
CYLINDER HEAD COVER/CYLINDER HEAD CAMSHAFT/VALVE CAM CHAIN/TENSIONER

2
E-4 D 6 E-5 D 7 E-6 D 8
CYLINDER RIGHT CRANKCASE COVER CLUTCH

E-7 D 9 E-8 D10 E-9 D11


OIL PUMP LEFT CRANKCASE COVER GENERATOR

21
2005.05.20 E
ENGINE GROUP C 6
E-10 D12 E-11 D13 E-12 D14
STARTING MOTOR CRANKCASE CRANKSHAFT/PISTON

2
E-13 D15 E-14 E 1 E-15 E 2
TRANSMISSION GEARSHIFT DRUM CARBURETOR

EOP-1 E 4 EOP-2 E 5
GASKET KIT A GASKET KIT B

22
2005.05.20 E
FRAME GROUP C 7
F-1 F 1 F-2 F 2 F-3 F 4
HEADLIGHT HANDLE LEVER/SWITCH/CABLE FR. BRAKE MASTER CYLINDER

F-4 F 5 F-5 F 6 F-6 F 7


HANDLE PIPE/TOP BRIDGE STEERING STEM FRONT FENDER

F-7 F 8 F-8 F10 F-9 F11


FRONT FORK FRONT BRAKE CALIPER FRONT WHEEL

23
2005.05.20 E
FRAME GROUP C 8
F-10 F13 F-11 F14 F-12 F16
REAR BRAKE PANEL REAR WHEEL FUEL TANK

F-13 G 2 F-14 G 3 F-15 G 4


SEAT SIDE COVER AIR CLEANER

F-16 G 6 F-17 G 8 F-18 G 9


EXHAUST MUFFLER PEDAL STEP

24
2005.05.20 E
FRAME GROUP C 9
F-19 G10 F-20 G11 F-21 G13
SIDE STAND SWINGARM/CHAIN CASE REAR CUSHION

F-22 G14 F-23 G15 F-24 H 1


REAR FENDER BATTERY WIRE HARNESS

F-25 H 2 F-26 H 4 F-27 H 5


FRAME BODY TOOLS CAUTION LABEL

25
2005.05.20 E
FRAME GROUP C10
F-28 H 6
MARK

26
2005.05.20 E
E-1 CYLINDER HEAD COVER/CYLINDER HEAD D 1
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 111106 HEAD, CYLINDER ••••••••••••••• 3.9
.INCLUDES: Engine removal and
installation
.INCLUDES: Valve clearance
adjustment and reface
2 1111L9 GUIDE, INTAKE VALVE(ONE) ••••• 3.5
.INCLUDES: Engine removal and
installation
.INCLUDES: Reaming
.INCLUDES: Valve clearance
adjustment and reface
1111M9 GUIDE, VALVE :FOR 1 VEHICLE •• 3.8
.INCLUDES: Engine removal and
installation
.INCLUDES: Reaming
.INCLUDES: Valve clearance
adjustment and reface
3 1111M0 GUIDE, EXHAUST VALVE(ONE) •••• 3.5
2
.INCLUDES: Engine removal and
installation
.INCLUDES: Reaming
.INCLUDES: Valve clearance
adjustment and reface
+ 4 111115 GASKET, CYLINDER HEAD •••••••• 2.7

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 12000-KPS-900 HEAD ASSY., CYLINDER •••••••• 1 1 1 1


2 12204-KW1-305 GUIDE, IN. VALVE (O.S) •••••• 1 1 1 1
3 12206-KW1-315 GUIDE, EX. VALVE (O.S) •••••• 1 1 1 1
4 12251-KT0-711 GASKET, CYLINDER HEAD ••••••• 1 1 1 1
5 12271-383-000 RUBBER, OIL SEAL •••••••••••• 1 1 1 1
6 12331-KPS-900 COVER, L. CYLINDER HEAD ••••• 1 1 1 1
7 12339-KT0-710 GASKET, PULSE GENERATOR BASE 1 1 1 1
8 12361-KPS-900 CAP, TAPPET ADJUSTING HOLE •• 2 2 2 2
9 16210-KPS-900 INSULATOR, CARBURETOR ••••••• 1 1 1 1
10 16214-KPS-900 GASKET, CARBURETOR INSULATOR 1 1 1 1
11 16223-KPS-900 BAND, INSULATOR ••••••••••••• 1 1 1 1
12 90003-KPS-900 BOLT, FLANGE, 6X22 •••••••••• 2 2 2 2
13 90004-GHB-700 BOLT, FLANGE, 6X35(NSHF) •••• 4 4 4 4
14 90041-KW1-900 BOLT, STUD, 7X35 •••••••••••• 2 2 2 2
15 90104-KPS-900 BOLT, FLANGE, 6X20 •••••••••• 2 2 2 2
16 90114-KPS-900 SCREW, PAN, 5X25 •••••••••••• 1 1 1 1
17 90442-KPS-900 WASHER, SEALING, 8MM •••••••• 4 4 4 4
18 90443-KPS-900 NUT, CAP, 8MM ••••••••••••••• 4 4 4 4
19 90702-KPS-900 DOWEL PIN, 8X14 ••••••••••••• 2 2 2 2
20 91301-KW1-900 O-RING, 10.5X1.5 •••••••••••• 2 2 2 2
21 91301-107-000 O-RING, 75X2.5 •••••••••••••• 1 1 1 1
22 91303-KK3-830 O-RING, 35X3(ARAI) •••••••••• 2 2 2 2
23 91304-HB3-003 O-RING, 33.5X3.0 •••••••••••• 1 1 1 1
24 94101-06000 WASHER, PLAIN, 6MM •••••••••• 1 1 1 1
25 96700-06125-10 BOLT, SOCKET, 6X125 ••••••••• 1 1 1 1
27
2005.05.20 E
E-1 CYLINDER HEAD COVER/CYLINDER HEAD D 2
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
+ 4 .INCLUDES: Engine removal and
installation
6 (7,21)
1111D0 COVER, CYLINDER HEAD SIDE
:LEFT ••••••••••••••••••••••• 0.2
9 (10,23)
311131 INSULATOR, THROTTLE BODY/
CARBURETOR •••••••••••••••••• 0.4
26 614130 PLUG, SPARK •••••••••••••••••• 0.1

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

26 98069-58916 PLUG, SPARK (DPR8EA-9)(NGK) • 1 1 1 1


98069-58926 PLUG, SPARK (X24EPR-U9)(DENSO) 1 1 1 1
98069-57916 PLUG, SPARK (DPR7EA-9)(NGK) • (1) (1) (1) (1)
98069-57926 PLUG, SPARK (X22EPR-U9)(DENSO) (1) (1) (1) (1)

28
2005.05.20 E
E-2 CAMSHAFT/VALVE D 3
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
2 111118 CAMSHAFT ••••••••••••••••••••• 2.3
.INCLUDES: Valve clearance
adjustment
.INCLUDES: Engine removal and
installation
3 1111K8 ARM, INTAKE VALVE ROCKER(ONE) 2.3
.INCLUDES: Engine removal and
installation
.INCLUDES: Valve clearance
adjustment
1111K9 ARM, EXHAUST VALVE ROCKER(ONE) 2.3
.INCLUDES: Engine removal and
installation
.INCLUDES: Valve clearance
adjustment
1111L8 ARM, VALVE ROCKER
:FOR 1 VEHICLE ••••••••••••••
.INCLUDES: Engine removal and
2.4 2
installation
.INCLUDES: Valve clearance
adjustment
6 1111N0 VALVE, INTAKE(ONE) ••••••••••• 3.0
.INCLUDES: Engine removal and
installation
+ .INCLUDES: Refacing
Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 12208-413-003 SEAL, VALVE STEM (ARAI) ••••• 2 2 2 2


2 14100-KPS-900 CAMSHAFT COMP. •••••••••••••• 1 1 1 1
3 14431-KPS-900 ARM, VALVE ROCKER ••••••••••• 2 2 2 2
4 14451-KPS-900 SHAFT, ROCKER ARM ••••••••••• 2 2 2 2
5 14456-KPS-900 PLATE, ROCKER ARM SHAFT
SETTING 1 1 1 1
6 14711-KBB-900 VALVE, IN. •••••••••••••••••• 1 1 1 1
7 14721-KBB-900 VALVE, EX. •••••••••••••••••• 1 1 1 1
8 14751-383-005 SPRING, VALVE OUTER
(NIPPON HATSUJO) 2 2 2 2
9 14761-383-005 SPRING, VALVE INNER
(NIPPON HATSUJO) 2 2 2 2
10 14771-107-020 RETAINER, VALVE SPRING •••••• 2 2 2 2
11 14775-KPS-900 SEAT, VALVE SPRING OUTER •••• 2 2 2 2
12 14776-KPS-900 SEAT, VALVE SPRING INNER •••• 2 2 2 2
13 14781-HA0-770 COTTER, VALVE ••••••••••••••• 4 4 4 4
14 90012-KN6-930 SCREW, TAPPET ADJUSTING ••••• 2 2 2 2
15 90206-250-000 NUT, TAPPET ADJUSTING ••••••• 2 2 2 2
16 90212-KPS-900 SCREW, FLAT, 6X16 ••••••••••• 1 1 1 1

29
2005.05.20 E
E-2 CAMSHAFT/VALVE D 4
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
+ 6 .EXCLUDES: Valve guide
replacement
1111P0 VALVE :FOR 1 VEHICLE ••••••••• 3.2
.INCLUDES: Engine removal and
installation
.INCLUDES: Refacing
.EXCLUDES: Valve guide
replacement
7 1111N1 VALVE, EXHAUST(ONE) •••••••••• 3.0
.INCLUDES: Engine removal and
installation
.INCLUDES: Refacing
.EXCLUDES: Valve guide
replacement
8 (1,9,10,11,12,13)

2 1111P2 SPRING, INTAKE VALVE(ONE) ••••


.INCLUDES: Engine removal and
installation
2.8

1111P3 SPRING, EXHAUST VALVE(ONE) ••• 2.8


.INCLUDES: Engine removal and
installation
1111Q2 SPRING, VALVE :FOR 1 VEHICLE • 2.9
.INCLUDES: Engine removal and
installation

30
2005.05.20 E
E-3 CAM CHAIN/TENSIONER D 5
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 1111Q4 SPROCKET, CAM •••••••••••••••• 0.7
2 110140 CHAIN, CAM ••••••••••••••••••• 1.6
3 111130 TENSIONER, CAM CHAIN ••••••••• 1.7
5 (6)
111133 LIFTER, TENSIONER •••••••••••• 0.4
8 111139 GUIDE, CAM CHAIN ••••••••••••• 2.7
.INCLUDES: Engine removal and
installation

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 14321-KEH-900 SPROCKET, CAM (34T) ••••••••• 1 1 1 1


2 14401-KFB-751 CHAIN, CAM (104L)(BORG WARNER) 1 1 1 1
3 14500-KBB-900 TENSIONER, CAM CHAIN •••••••• 1 1 1 1
4 14513-KPS-900 PLATE, CAM CHAIN SETTING •••• 1 1 1 1
5 14520-KCT-691 LIFTER ASSY., TENSIONER ••••• 1 1 1 1
6 14523-KBB-901 GASKET, TENSIONER LIFTER •••• 1 1 1 1
7 14535-KPS-900 BOLT, TENSIONER PIVOT ••••••• 1 1 1 1
8 14550-KFB-000 GUIDE, CAM CHAIN •••••••••••• 1 1 1 1
9 90002-KPS-900 BOLT, FLANGE, 6X10 •••••••••• 2 2 2 2
10 90005-KY7-000 SCREW, PAN, 6X6 ••••••••••••• 1 1 1 1
11 90071-MG8-000 BOLT, FLANGE SOCKET, 6X16 ••• 2 2 2 2
12 90475-703-000 WASHER C, 8MM ••••••••••••••• 1 1 1 1
13 90488-425-000 WASHER, SEALING, 6MM •••••••• 2 2 2 2
14 91306-105-690 O-RING, 1.5X9.5 ••••••••••••• 1 1 1 1
15 95701-06012-00 BOLT, FLANGE, 6X12 •••••••••• 1 1 1 1

31
2005.05.20 E
E-4 CYLINDER D 6
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 1111A5 CYLINDER ••••••••••••••••••••• 3.0
.INCLUDES: Engine removal and
installation
2 111102 GASKET, CYLINDER ••••••••••••• 2.9
.INCLUDES: Engine removal and
installation

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 12100-KFB-000 CYLINDER COMP. •••••••••••••• 1 1 1 1


2 12191-KCN-000 GASKET, CYLINDER •••••••••••• 1 1 1 1
3 90704-KPS-900 DOWEL PIN, 10X20 •••••••••••• 2 2 2 2

32
2005.05.20 E
E-5 RIGHT CRANKCASE COVER D 7
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 110159 COVER, CRANKCASE :RIGHT •••••• 0.7
2 110158 GASKET, CRANKCASE COVER :RIGHT 0.6
4 (5,9)
2121A7 LEVER, CLUTCH •••••••••••••••• 0.7

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 11330-KPS-900 COVER COMP., R. CRANKCASE ••• 1 1 1 1


2 11393-KGA-900 GASKET, R. COVER •••••••••••• 1 1 1 1
3 15650-KPS-900 GAUGE, OIL LEVEL •••••••••••• 1 1 1 1
4 22810-KPS-900 LEVER COMP., CLUTCH ••••••••• 1 1 1 1
5 22815-KPS-900 SPRING, CLUTCH LEVER •••••••• 1 1 1 1
6 22838-KRG-000 HOLDER, CLUTCH WIRE ••••••••• 1 1 1 1
7 90035-KG8-900 BOLT, FLANGE, 6X43 •••••••••• 2 2 2 2
8 90702-KPS-900 DOWEL PIN, 8X14 ••••••••••••• 2 2 2 2
9 91201-148-003 OIL SEAL, 12X22X5(ARAI) ••••• 1 1 1 1
10 91307-035-000 O-RING, 18X3 •••••••••••••••• 1 1 1 1
11 94305-30102 PIN, SPRING, 3X10 ••••••••••• 1 1 1 1
12 96001-06040-00 BOLT, FLANGE, 6X40 •••••••••• 8 8 8 8
13 96001-06050-00 BOLT, FLANGE, 6X50 •••••••••• 1 1 1 1

33
2005.05.20 E
E-6 CLUTCH D 8
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 2121A0 OUTER, CLUTCH •••••••••••••••• 1.0
2 212112 CENTER, CLUTCH ••••••••••••••• 1.0
5 (3,6,7,8,13)
2121A1 DISC, CLUTCH FRICTION •••••••• 1.0
.NOTE: Same time for two units
or more
9 2121A3 PLATE, CLUTCH PRESSURE ••••••• 1.0
10 (18)
2121A4 PLATE, CLUTCH LIFTER ••••••••• 0.7
11 2121B6 ROD, CLUTCH LIFTER ••••••••••• 0.6
12 212107 SPRING, CLUTCH ••••••••••••••• 0.7
.NOTE: Same time for two units
or more

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 22100-KPS-900 OUTER COMP., CLUTCH ••••••••• 1 1 1 1


2 22121-KPS-900 CENTER COMP., CLUTCH •••••••• 1 1 1 1
3 22125-KW7-900 SEAT, JUDDER SPRING ••••••••• 1 1 1 1
4 22131-KHA-940 GUIDE, CLUTCH OUTER ••••••••• 1 1 1 1
5 22201-KBW-900 DISK, CLUTCH FRICTION ••••••• 1 1 1 1
6 22201-KPM-850 DISK, CLUTCH FRICTION (4X8X45) 4 4 4 4
7 22201-MJ8-000 DISK, CLUTCH FRICTION ••••••• 1 1 1 1
8 22321-KPS-900 PLATE, CLUTCH ••••••••••••••• 5 5 5 5
9 22350-KPS-900 PLATE, CLUTCH PRESSURE •••••• 1 1 1 1
10 22361-KPS-900 PLATE, CLUTCH LIFTER •••••••• 1 1 1 1
11 22366-KHA-940 ROD, CLUTCH LIFTER •••••••••• 1 1 1 1
12 22401-KCJ-710 SPRING, CLUTCH •••••••••••••• 4 4 4 4
13 22402-KPM-850 SPRING, JUDDER •••••••••••••• 1 1 1 1
14 90050-KPS-900 BOLT, SPECIAL FLANGE, 6X22 •• 4 4 4 4
15 90231-KB5-720 NUT, LOCK, 16MM ••••••••••••• 1 1 1 1
16 90434-KPS-900 WASHER, 16MM •••••••••••••••• 1 1 1 1
17 90461-KPS-900 WASHER B, SPLINE, 20MM •••••• 1 1 1 1
18 91008-KPS-900 BEARING, RADIAL BALL, 16003 • 1 1 1 1

34
2005.05.20 E
E-7 OIL PUMP D 9
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 113105 PUMP ASSY., OIL •••••••••••••• 0.8
2 1131B8 GEAR, OIL PUMP DRIVE ••••••••• 0.7
4 (3)
1131C7 ROTOR, OIL PUMP •••••••••••••• 0.9
.NOTE: Same time for two units
5 1101L0 ROTOR, OIL FILTER •••••••••••• 0.8
6 1101L1 CAP, OIL FILTER ROTOR •••••••• 0.7
10 211105 GEAR, PRIMARY DRIVE •••••••••• 1.0

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 15100-KPS-900 OIL PUMP ASSY. •••••••••••••• 1 1 1 1


2 15131-KPS-900 GEAR, OIL PUMP DRIVE •••••••• 1 1 1 1
3 15331-KPS-900 ROTOR, OIL PUMP INNER ••••••• 1 1 1 1
4 15332-KPS-900 ROTOR, OIL PUMP OUTER ••••••• 1 1 1 1
5 15430-KPS-900 ROTOR COMP., OIL FILTER ••••• 1 1 1 1
6 15436-KPS-900 CAP, OIL FILTER ROTOR ••••••• 1 1 1 1
7 15441-KPS-900 THROUGH, OIL •••••••••••••••• 1 1 1 1
8 15446-KPS-900 SPRING, OIL THROUGH ••••••••• 1 1 1 1
9 15459-KT0-710 GASKET, OIL FILTER CAP •••••• 1 1 1 1
10 23121-KPS-900 GEAR, PRIMARY DRIVE (22T) ••• 1 1 1 1
11 90010-KPS-900 BOLT, HEX., 5X20 •••••••••••• 2 2 2 2
12 90112-KPS-900 SCREW, OVAL, 5X12 ••••••••••• 3 3 3 3
13 90211-KPS-900 SCREW, FLAT, 4X12 ••••••••••• 2 2 2 2
14 90213-KPS-900 SCREW, FLAT, 6X30 ••••••••••• 2 2 2 2
15 90231-KPS-900 NUT, LOCK, 16MM ••••••••••••• 1 1 1 1
16 90434-KPS-900 WASHER, 16MM •••••••••••••••• 1 1 1 1
17 90471-KGA-900 KEY, WOODRUFF, 25X18 •••••••• 1 1 1 1
18 90751-KPS-900 PIN, LOCK, 8MM •••••••••••••• 1 1 1 1
19 91304-KPS-900 O-RING, 9.4X2.4 ••••••••••••• 2 2 2 2

35
2005.05.20 E
E-8 LEFT CRANKCASE COVER D10
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 1101A6 COVER, CRANKCASE :LEFT ••••••• 0.7
2 (13)
2101D7 COVER, REDUCTION GEAR •••••••• 0.2
3 1101B0 COVER, CRANKCASE :LEFT REAR •• 0.1
4 1101A3 GASKET, CRANKCASE COVER :LEFT 0.6

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 11341-KPS-900 COVER, L. CRANKCASE ••••••••• 1 1 1 1


2 11355-KPS-900 COVER, REDUCTION GEAR ••••••• 1 1 1 1
3 11360-KPS-900 COVER, L. RR. CRANKCASE ••••• 1 1 1 1
4 11395-KCN-000 GASKET, L. COVER •••••••••••• 1 1 1 1
5 32976-KW1-900 CLAMPER, A.C. GENERATOR CORD 1 1 1 1
6 90001-KPS-900 BOLT, FLANGE, 6X14 •••••••••• 1 1 1 1
7 90084-KPS-900 CAP, 14MM ••••••••••••••••••• 1 1 1 1
8 90087-KPS-900 CAP, 30MM ••••••••••••••••••• 1 1 1 1
9 90104-KPS-900 BOLT, FLANGE, 6X20 •••••••••• 1 1 1 1
10 90703-KPS-900 DOWEL PIN, 10X14 •••••••••••• 2 2 2 2
11 91302-567-003 O-RING, 27.4X2.4(ARAI) •••••• 1 1 1 1
12 91303-377-000 O-RING, 13.8X2.5 •••••••••••• 1 1 1 1
13 91304-MN5-003 O-RING, 63X3(ARAI) •••••••••• 1 1 1 -
91304-KGA-940 O-RING, 63X3 •••••••••••••••• - - - 1
14 96001-06025-00 BOLT, FLANGE, 6X25 •••••••••• 2 2 2 2
15 96001-06040-00 BOLT, FLANGE, 6X40 •••••••••• 4 4 4 4
16 96001-06050-00 BOLT, FLANGE, 6X50 •••••••••• 1 1 1 1
17 96001-06060-00 BOLT, FLANGE, 6X60 •••••••••• 1 1 1 1
18 96001-06070-00 BOLT, FLANGE, 6X70 •••••••••• 2 2 2 2

36
2005.05.20 E
E-9 GENERATOR D11
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 612131 OUTER, STARTING CLUTCH ••••••• 0.8
2 613105 ROTOR OR FLYWHEEL •••••••••••• 0.8
3 6131A3 STATOR ••••••••••••••••••••••• 0.8

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 28125-KW3-006 CLUTCH COMP., STARTING ONE WAY 1 1 1 1


2 31110-KPS-901 FLYWHEEL COMP. •••••••••••••• 1 1 1 1
3 31120-KPS-940 STATOR COMP. •••••••••••••••• 1 1 1 -
31120-KPS-941 •••••••••••••••••••••••••••• - - - 1
4 32976-KN6-910 GUIDE, A.C. GENERATOR CORD •• 1 1 1 1
5 35750-GS3-003 CONTACT, NEUTRAL SWITCH ••••• 1 1 1 1
6 35752-028-300 SPACER, NEUTRAL SWITCH •••••• 1 1 1 1
7 90085-413-781 BOLT, SOCKET, 6MM ••••••••••• 6 6 6 6
8 90089-HB3-000 BOLT, SOCKET, 5X14 •••••••••• 2 2 2 2
9 90101-KBH-003 BOLT, FLANGE, 10X65 ••••••••• 1 1 1 1
10 90403-KPS-900 WASHER, 10X24 ••••••••••••••• 1 1 1 1
11 91312-107-000 O-RING, 7X1.7 ••••••••••••••• 1 1 1 1
12 96001-06032-00 BOLT, FLANGE, 6X32 •••••••••• 3 3 3 3

37
2005.05.20 E
E-10 STARTING MOTOR D12
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 612120 GEAR, STARTER DRIVEN ••••••••• 0.7
3 612125 GEAR, STARTER REDUCTION •••••• 0.2
5 612135 GEAR, STARTER IDLE ••••••••••• 0.6
7 612105 MOTOR, STARTING •••••••••••••• 0.3
8 6121A4 TERMINAL, BRUSH(STARTER) ••••• 0.5
11 6121A5 HOLDER, BRUSH(STARTER) ••••••• 0.5

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 28110-KBB-900 GEAR COMP., STARTER DRIVEN


(56T) 1 1 1 1
2 28114-KN6-930 COLLAR, STARTING DRIVEN GEAR 1 1 1 1
3 28130-KFB-000 GEAR, REDUCTION (16T/61T) ••• 1 1 1 1
4 28132-KPS-900 SHAFT, REDUCTION GEAR ••••••• 1 1 1 1
5 28140-KPS-900 GEAR, IDLE (16T/16T) •••••••• 1 1 1 1
6 28142-KW1-900 SHAFT, IDLE GEAR •••••••••••• 1 1 1 1
7 31200-KBB-901 MOTOR ASSY., STARTING
(MITSUBA) 1 1 1 1
8 31201-KS5-901 TERMINAL SET, BRUSH ••••••••• 1 1 1 1
9 31204-KS5-901 SPRING, CARBON BRUSH •••••••• 2 2 2 2
10 31205-MN4-008 BOLT, SETTING ••••••••••••••• 2 2 2 2
11 31206-KW1-901 HOLDER SET, BRUSH ••••••••••• 1 1 1 1
12 31207-KS5-901 RING •••••••••••••••••••••••• 2 2 2 2
13 90005-KPS-900 BOLT, FLANGE, 6X60 •••••••••• 1 1 1 1
14 90071-MB0-000 NUT-WASHER, 6MM ••••••••••••• 2 2 2 2
15 90401-KW1-900 WASHER, STEEL PLATE ••••••••• 2 2 2 2
16 91309-425-003 O-RING, 24.4X3.1(ARAI) •••••• 1 1 1 1
17 91320-MB0-000 O-RING •••••••••••••••••••••• 3 3 3 3
18 95801-06032-00 BOLT, FLANGE, 6X32 •••••••••• 1 1 1 1

38
2005.05.20 E
E-11 CRANKCASE D13
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 110120 CRANKCASE :RIGHT ••••••••••••• 4.8
.INCLUDES: Engine removal and
installation
1101A2 CRANKCASE :BOTH •••••••••••••• 6.1
.INCLUDES: Engine removal and
installation
2 110110 GASKET, CRANKCASE •••••••••••• 4.3
.INCLUDES: Engine removal and
installation
3 110115 CRANKCASE :LEFT •••••••••••••• 5.7
.INCLUDES: Engine removal and
installation
5 1131B5 SCREEN, OIL FILTER ••••••••••• 0.2
11 2101C8 BEARING, COUNTERSHAFT :RIGHT • 4.5
.INCLUDES: Engine removal and
installation
2101C9 BEARING, COUNTERSHAFT :BOTH ••
.INCLUDES: Engine removal and
4.7 2
installation
2101D4 BEARING, MAINSHAFT AND
COUNTERSHAFT :ALL ••••••••••• 4.9
.INCLUDES: Engine removal and
installation
12 1101F9 OIL SEAL, GEARSHIFT SPINDLE •• 1.0

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 11100-KPS-900 CRANKCASE COMP., R. ••••••••• 1 1 1 1


2 11191-KHA-940 GASKET, CRANKCASE ••••••••••• 1 1 1 1
3 11200-KPS-900 CRANKCASE COMP., L. ••••••••• 1 1 1 1
4 12361-KPS-900 CAP, TAPPET ADJUSTING HOLE •• 1 1 1 1
5 15421-KPS-900 SCREEN, OIL FILTER •••••••••• 1 1 1 1
6 15426-KPS-900 SPRING, OIL FILTER SCREEN ••• 1 1 1 1
7 90004-KPS-900 BOLT, FLANGE, 6X55 •••••••••• 1 1 1 1
8 90031-KFB-000 BOLT, CYLINDER STUD (A) ••••• 2 2 2 2
9 90032-KFB-000 BOLT, CYLINDER STUD (B) ••••• 2 2 2 2
10 90703-KPS-900 DOWEL PIN, 10X14 •••••••••••• 4 4 4 4
11 91008-KCN-003 BEARING, NEEDLE, 21MM ••••••• 1 1 1 1
12 91202-965-003 OIL SEAL, 14X28X7(ARAI) ••••• 1 1 1 1
13 91303-KK3-830 O-RING, 35X3(ARAI) •••••••••• 1 1 1 1
14 96001-06050-00 BOLT, FLANGE, 6X50 •••••••••• 10 10 10 10

39
2005.05.20 E
E-12 CRANKSHAFT/PISTON D14
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
2 1101B5 CRANKSHAFT ••••••••••••••••••• 4.5
.INCLUDES: Engine removal and
installation
1101B5A .Replace left crankshaft
bearing add ••••••••••••••••• 0.2
1101B5B .Replace right crankshaft
bearing add ••••••••••••••••• 0.2
1101B5C .Replace both crankshaft
bearing add ••••••••••••••••• 0.4
4 (3,5,6)
111103 RING, PISTON AND/OR PISTON
(ONE) ••••••••••••••••••••••• 3.1
.INCLUDES: Engine removal and
installation
11 1101B6 BEARING, CRANKSHAFT :LEFT •••• 4.7

2 .INCLUDES: Engine removal and


installation
1101G0 BEARING, CRANKSHAFT :BOTH •••• 4.9
.INCLUDES: Engine removal and
installation
12 1101B7 BEARING, CRANKSHAFT :RIGHT ••• 4.5
.INCLUDES: Engine removal and
installation

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 06381-KPS-900 ROD KIT, CONNECTING ••••••••• 1 1 1 1


2 13000-KPS-900 CRANKSHAFT COMP. •••••••••••• 1 1 1 1
3 13011-KFB-305 RING SET, PISTON (STD.) ••••• 1 1 1 1
4 13101-KFB-750 PISTON (STD.) ••••••••••••••• 1 1 1 1
5 13111-440-000 PIN, PISTON ••••••••••••••••• 1 1 1 1
6 13112-KPS-900 CLIP, PISTON PIN, 15MM •••••• 2 2 2 2
7 13311-KPS-900 CRANKSHAFT, R. •••••••••••••• 1 1 1 1
8 13321-KPS-900 CRANKSHAFT, L. •••••••••••••• 1 1 1 1
9 14311-KN6-931 SPROCKET, TIMING (17T) •••••• 1 1 1 1
10 90741-KFB-000 KEY, WOODRUFF, 4MM •••••••••• 1 1 1 1
11 91001-KBW-941 BEARING, RADIAL BALL, 6207 •• 1 1 1 1
12 91001-KCN-003 BEARING, RADIAL BALL, 28X72X18 1 1 1 1

40
2005.05.20 E
E-13 TRANSMISSION D15
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
2 (7,10,13,15)
210141 MAINSHAFT, TRANSMISSION •••••• 4.5
.INCLUDES: Engine removal and
installation
210141A .Replace countershaft add •••• 0.2
3 (4,8,11,12,14,16)
210142 COUNTERSHAFT, TRANSMISSION ••• 4.5
.INCLUDES: Engine removal and
installation
17 213135 SPROCKET, DRIVE •••••••••••••• 0.2
30 2101C5 BEARING, MAINSHAFT :RIGHT •••• 4.5
.INCLUDES: Engine removal and
installation
2101C6 BEARING, MAINSHAFT :BOTH ••••• 4.7
.INCLUDES: Engine removal and
installation
2101D4 BEARING, MAINSHAFT AND
COUNTERSHAFT :ALL ••••••••••• 4.9
2
.INCLUDES: Engine removal and
installation
31 2101C2 BEARING, MAINSHAFT :LEFT ••••• 4.5
.INCLUDES: Engine removal and
installation
+32 2101C7 BEARING, COUNTERSHAFT :LEFT •• 4.5

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 11108-KHA-940 PLATE, BEARING SETTING •••••• 1 1 1 1


2 23211-KPS-900 MAINSHAFT, TRANSMISSION (13T) 1 1 1 1
3 23221-KPS-900 COUNTERSHAFT, TRANSMISSION •• 1 1 1 1
4 23421-KPS-900 GEAR, COUNTERSHAFT FIRST (36T) 1 1 1 1
5 23427-KPS-900 COLLAR, COUNTERSHAFT FIRST •• 1 1 1 1
6 23431-437-000 BUSH, 20MM •••••••••••••••••• 1 1 1 1
7 23441-KPS-900 GEAR, MAINSHAFT SECOND (17T) 1 1 1 1
8 23451-KPS-900 GEAR, COUNTERSHAFT SECOND
(33T) 1 1 1 1
9 23452-KW1-900 BUSH, 20X23X9 ••••••••••••••• 2 2 2 2
10 23461-KPS-900 GEAR, MAINSHAFT THIRD & FOURTH
(20T/27T) 1 1 1 1
11 23471-KPS-900 GEAR, COUNTERSHAFT THIRD (29T) 1 1 1 1
12 23491-KPS-900 GEAR, COUNTERSHAFT FOURTH
(31T) 1 1 1 1
13 23501-KPS-900 GEAR, MAINSHAFT FIFTH (25T) • 1 1 1 1
14 23511-KPS-900 GEAR, COUNTERSHAFT FIFTH (24T) 1 1 1 1
15 23512-KPS-900 GEAR, MAINSHAFT TOP (32T) ••• 1 1 1 1
16 23513-KPS-900 GEAR, COUNTERSHAFT TOP (26T) 1 1 1 1
17 23801-KPS-900 SPROCKET, DRIVE (13T) ••••••• 1 1 1 1
18 23811-KPS-900 PLATE A2, FIXING •••••••••••• 1 1 1 1
19 90011-KPS-900 BOLT, HEX., 6X25 •••••••••••• 2 2 2 2
20 90451-KPS-900 WASHER, THRUST, 15MM •••••••• 1 1 1 1
21 90451-365-000 WASHER, THRUST, 15MM •••••••• 1 1 1 1
22 90452-KPS-900 WASHER, THRUST, 16.5MM •••••• 1 1 1 1
41
2005.05.20 E
E-13 TRANSMISSION D16
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
+32 .INCLUDES: Engine removal and
installation
2101C9 BEARING, COUNTERSHAFT :BOTH •• 4.7
.INCLUDES: Engine removal and
installation

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

23 90454-KPS-900 WASHER B, THRUST, 20MM •••••• 3 3 3 3


24 90455-KPS-900 WASHER A, SPLINE, 20MM •••••• 2 2 2 2
25 90463-437-000 WASHER, SPLINE, 22MM •••••••• 2 2 2 2
26 90464-360-000 WASHER, COUNTERSHAFT THIRD
SPLINE 1 1 1 1
27 90465-360-000 WASHER, LOCK •••••••••••••••• 1 1 1 1
28 90601-KPS-900 CIRCLIP, EXTERNAL, 22MM ••••• 2 2 2 2
29 90605-KPS-900 SET RING, 20MM •••••••••••••• 2 2 2 2
30 91005-KCN-003 BEARING, RADIAL BALL, 20X55X11 1 1 1 1
31 91015-KK6-003 BEARING, RADIAL BALL, 6202U • 1 1 1 1
32 91016-KPS-900 BEARING, RADIAL BALL, 6204 •• 1 1 1 1
33 91216-KGH-901 OIL SEAL, 20X37X7 ••••••••••• 1 1 1 1
34 96600-08018-18 BOLT, SOCKET, 8X18 •••••••••• 1 1 1 1

42
2005.05.20 E
E-14 GEARSHIFT DRUM E 1
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 (2,3,4)
210112 FORK, GEARSHIFT •••••••••••••• 4.5
.NOTE: Same time for two units
or more
.INCLUDES: Engine removal and
installation
5 2101A9 DRUM, GEARSHIFT •••••••••••••• 4.5
.INCLUDES: Engine removal and
installation
6 2101B0 CAM, SHIFT DRUM •••••••••••••• 1.0
7 (8)
210125 STOPPER OR SPRING, SHIFT DRUM 1.0
9 (10,12,17,21)
210122 SPINDLE, GEARSHIFT ••••••••••• 1.1

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 24211-KPS-900 FORK, R. GEARSHIFT •••••••••• 1 1 1 1


2 24221-KPS-900 FORK, L. GEARSHIFT •••••••••• 1 1 1 1
3 24231-KPS-900 FORK, CENTER GEARSHIFT •••••• 1 1 1 1
4 24241-KPS-900 SHAFT, GEARSHIFT FORK GUIDE • 1 1 1 1
5 24301-KPS-900 DRUM, GEARSHIFT ••••••••••••• 1 1 1 1
6 24411-KPS-900 CAM, GEARSHIFT •••••••••••••• 1 1 1 1
7 24430-KPS-900 STOPPER COMP., GEARSHIFT DRUM 1 1 1 1
8 24435-KPS-900 SPRING, SHIFT DRUM STOPPER •• 1 1 1 1
9 24610-KT0-000 SPINDLE COMP., GEARSHIFT •••• 1 1 1 1
10 24621-446-650 PLATE, GEARSHIFT •••••••••••• 1 1 1 1
11 24631-KPS-900 SPRING, GEARSHIFT PLATE ••••• 1 1 1 1
12 24651-437-000 SPRING, GEARSHIFT RETURN •••• 1 1 1 1
13 35753-KG2-951 ROTOR, NEUTRAL SWITCH ••••••• 1 1 1 1
14 90012-KPS-900 BOLT, HEX., 6X25 •••••••••••• 1 1 1 1
15 90023-KPS-900 PIVOT, GEARSHIFT DRUM STOPPER 1 1 1 1
16 90408-KPS-900 WASHER, 6MM ••••••••••••••••• 1 1 1 1
17 90453-KPS-900 WASHER, THRUST, 14MM •••••••• 2 2 2 2
18 90752-KPS-900 PIN, LOCK, 10MM ••••••••••••• 1 1 1 1
19 91102-KPS-900 ROLLER, 4X10 •••••••••••••••• 1 1 1 1
20 94510-12000 CIRCLIP, EXTERNAL, 12MM ••••• 1 1 1 1
21 94510-14000 CIRCLIP, EXTERNAL, 14MM ••••• 1 1 1 1

43
2005.05.20 E
E-15 CARBURETOR E 2
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
2 (4)
311120 FLOAT OR FLOAT VALVE ••••••••• 0.6
3 3111A3 NEEDLE, JET •••••••••••••••••• 0.9
5 3111A5 TOP SET, CARBURETOR •••••••••• 0.4
6 3111A6 CHAMBER, FLOAT ••••••••••••••• 0.4
8 3111F6 ARM SET, THROTTLE VALVE LINK • 0.7
12 3111M6 LINK SET, THROTTLE ••••••••••• 0.6
14 3111B8 VALVE, AIR CUT ••••••••••••••• 0.4
16 3111B5 CARBURETOR ASSEMBLY •••••••••• 0.6
17 3111A8 VALVE, THROTTLE •••••••••••••• 0.7
32 (20,31)
3111D4 JET, MAIN •••••••••••••••••••• 0.2

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 16010-KCE-670 GASKET SET •••••••••••••••••• 1 1 1 1


2 16011-KCK-910 VALVE SET, FLOAT •••••••••••• 1 1 1 1
3 16012-KPS-901 NEEDLE SET, JET ••••••••••••• 1 1 1 1
4 16013-KN4-A10 FLOAT SET ••••••••••••••••••• 1 1 1 1
5 16014-KCE-771 TOP SET ••••••••••••••••••••• 1 1 1 1
6 16015-KPS-901 CHAMBER SET, FLOAT •••••••••• 1 1 1 1
7 16016-393-701 SCREW SET ••••••••••••••••••• 1 1 1 1
8 16018-428-671 ARM SET, LINK ••••••••••••••• 1 1 1 1
9 16019-KPS-901 LEVER COMP., CHOKE •••••••••• 1 1 1 1
10 16028-KBW-901 SCREW SET B ••••••••••••••••• 1 1 1 1
11 16029-KCE-670 SCREW SET C ••••••••••••••••• 1 1 1 1
12 16032-KPS-901 LINK SET, THROTTLE •••••••••• 1 1 1 1
13 16037-KCE-670 STAY SET, WIRE •••••••••••••• 1 1 1 1
14 16048-KB7-901 VALVE SET, AIR CUT •••••••••• 1 1 1 1
15 16075-GHB-640 O-RING, 1.3X4.3 ••••••••••••• 1 1 1 1
16 16100-KPS-901 CARBURETOR ASSY. (PD9CA A) •• 1 1 1 1
17 16111-KBB-951 VALVE, THROTTLE ••••••••••••• 1 1 1 1
18 16119-429-771 PLATE, CHOKE LEVER SETTING •• 1 1 1 1
19 16163-KCS-920 GASKET, FLOAT CHAMBER ••••••• 1 1 1 1
20 16165-KEG-961 HOLDER, NEEDLE JET •••••••••• 1 1 1 1
21 16168-382-014 HOLDER, JET ••••••••••••••••• 1 1 1 1
22 16198-KPS-901 TUBE, AIR VENT •••••••••••••• 1 1 1 1
23 16199-KPS-901 TUBE •••••••••••••••••••••••• 1 1 1 1
24 93600-05010-1H SCREW, FLAT, 5X10 ••••••••••• 1 1 1 1
25 93892-03008-18 SCREW-WASHER, 3X8 ••••••••••• 2 2 2 2
44
2005.05.20 E
E-15 CARBURETOR E 3

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

26 93892-04010-18 SCREW-WASHER, 4X10 •••••••••• 1 1 1 1


27 93892-04012-18 SCREW-WASHER, 4X12 •••••••••• 2 2 2 2
28 93892-04014-18 SCREW-WASHER, 4X14 •••••••••• 2 2 2 2
29 93892-04016-18 SCREW-WASHER, 4X16 •••••••••• 3 3 3 3
30 95002-02659 CLIP, TUBE (B6.5) ••••••••••• 2 2 2 2
31 99103-KPS-0500 JET, SLOW, #50 •••••••••••••• (1) (1) (1) (1)
99103-KPS-0520 JET, SLOW, #52 •••••••••••••• (1) (1) (1) (1)
99103-MT2-0350 JET, SLOW, #35 •••••••••••••• (1) (1) (1) (1)
99103-MT2-0380 JET, SLOW, #38 •••••••••••••• (1) (1) (1) (1)
99103-MT2-0400 JET, SLOW, #40 •••••••••••••• (1) (1) (1) (1)
99103-MT2-0420 JET, SLOW, #42 •••••••••••••• 1 1 1 1
99103-MT2-0450 JET, SLOW, #45 •••••••••••••• (1) (1) (1) (1)
99103-MT2-0480 JET, SLOW, #48 •••••••••••••• (1) (1) (1) (1)
32 99113-GHB-0920 JET, MAIN, #92 •••••••••••••• (1) (1) (1) (1)
99113-GHB-0950 JET, MAIN, #95 •••••••••••••• (1) (1) (1) (1)
99113-GHB-0980 JET, MAIN, #98 •••••••••••••• (1) (1) (1) (1)
99113-GHB-1000 JET, MAIN, #100 ••••••••••••• (1) (1) (1) (1)
99113-GHB-1020 JET, MAIN, #102 ••••••••••••• 1 1 1 1
99113-GHB-1050 JET, MAIN, #105 ••••••••••••• (1) (1) (1) (1)
99113-GHB-1080 JET, MAIN, #108 ••••••••••••• (1) (1) (1) (1)
99113-GHB-1100 JET, MAIN, #110 ••••••••••••• (1) (1) (1) (1)
99113-GHB-1120 JET, MAIN, #112 ••••••••••••• (1) (1) (1) (1)

45
2005.05.20 E
EOP-1 GASKET KIT A E 4
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
NO INFORMATION •••••••••••••••

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 06113-KPS-900 GASKET SHEET KIT A ••••••••••


(COMPONENT PARTS) 1 1 1 -
12191-KCN-000 GASKET, CYLINDER •••••••••••• 1 1 1 -
12251-KT0-711 GASKET, CYLINDER HEAD ••••••• 1 1 1 -
12339-KT0-710 GASKET, PULSE GENERATOR BASE 1 1 1 -
14523-KBB-901 GASKET, TENSIONER LIFTER •••• 1 1 1 -
16214-KPS-900 GASKET, CARBURETOR INSULATOR 1 1 1 -
18291-MN5-650 GASKET, EX. PIPE •••••••••••• 1 1 1 -
18391-MB0-891 PACKING, EX. •••••••••••••••• 1 1 1 -
2 06114-KPS-900 WASHER O-RING KIT A •••••••••
(COMPONENT PARTS) 1 1 1 -
90442-KPS-900 WASHER, SEALING, 8MM •••••••• 4 4 4 -
90488-425-000 WASHER, SEALING, 6MM •••••••• 2 2 2 -
91301-107-000 O-RING, 75X2.5 •••••••••••••• 1 1 1 -
91303-KK3-830 O-RING, 35X3(ARAI) •••••••••• 2 2 2 -
91304-HB3-003 O-RING, 33.5X3.0 •••••••••••• 1 1 1 -
91306-105-690 O-RING, 1.5X9.5 ••••••••••••• 1 1 1 -

46
2005.05.20 E
EOP-2 GASKET KIT B E 5
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
NO INFORMATION •••••••••••••••

Reqd. QTY
Ref.
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 06115-KPS-900 GASKET SHEET KIT B ••••••••••


(COMPONENT PARTS) 1 1 1 -
11191-KHA-940 GASKET, CRANKCASE ••••••••••• 1 1 1 -
11393-KGA-900 GASKET, R. COVER •••••••••••• 1 1 1 -
11395-KCN-000 GASKET, L. COVER •••••••••••• 1 1 1 -
15459-KT0-710 GASKET, OIL FILTER CAP •••••• 1 1 1 -
2 06116-KPS-900 WASHER O-RING KIT B •••••••••
(COMPONENT PARTS) 1 1 1 -
91302-567-003 O-RING, 27.4X2.4(ARAI) •••••• 1 1 1 -
91303-KK3-830 O-RING, 35X3(ARAI) •••••••••• 2 2 2 -
91303-377-000 O-RING, 13.8X2.5 •••••••••••• 1 1 1 -
91304-KPS-900 O-RING, 9.4X2.4 ••••••••••••• 2 2 2 -
91307-035-000 O-RING, 18X3 •••••••••••••••• 1 1 1 -
91304-KGA-940 O-RING, 63X3 •••••••••••••••• 1 1 1 -

47
2005.05.20 E
F-1 HEADLIGHT F 1
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
5 6161A7 HEADLIGHT UNIT ••••••••••••••• 0.2
6 6161B1 SOCKET, HEADLIGHT •••••••••••• 0.2
7 616118 BULB, HEADLIGHT •••••••••••••• 0.1
9 616103 CASE, HEADLIGHT •••••••••••••• 0.2

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 19113-MB1-870 RUBBER, RADIATOR MOUNTING ••• 2 2 2 2


2 33103-KF0-670 SCREW, BEAM ADJUSTING ••••••• 1 1 1 1
3 33107-246-003 SPRING, HEADLIGHT BEAM
ADJUSTING 1 1 1 1
4 33117-KA2-003 NUT, BEAM ADJUSTING (STANLEY) 1 1 1 1
5 33123-KCY-670 HEADLIGHT UNIT •••••••••••••• 1 1 1 1
6 33130-KCY-670 SOCKET ASSY., HEADLIGHT ••••• 1 1 1 1
7 34901-MN1-671 BULB, HEADLIGHT (12V 35W)
(STANLEY) 1 1 1 1
8 61140-KCY-A30ZA PLATE SET, FR. NUMBER (WL)
*NH196*............ROSS WHITE 1 1 1 1
9 61301-KCZ-900ZE CASE, HEADLIGHT
*R134*...........FIGHTING RED 1 - - -
61301-KPS-880ZA *R292R*...........EXTREME RED - 1 - -
61301-KPS-780 •••••••••••••••••••••••••••• - - 1 1
10 90101-ML3-840 BOLT, SHROUD SETTING •••••••• 2 2 2 2
11 90201-MCG-000 NUT, CAP, 6MM ••••••••••••••• 2 2 2 2
12 93901-34210 SCREW, TAPPING, 4X10 •••••••• 2 2 2 2

48
2005.05.20 E
F-2 HANDLE LEVER/SWITCH/CABLE F 2
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 (3)
811100 CABLE, THROTTLE •••••••••••••• 0.5
.NOTE: Same time for two units
4 811115 CABLE, CLUTCH •••••••••••••••• 0.2
5 6151D8 SWITCH, ENGINE STOP •••••••••• 0.3
6 615116 SWITCH, STARTER •••••••••••••• 0.3
7 6151A9 SWITCH, CLUTCH ••••••••••••••• 0.1
8 810150 GRIP, THROTTLE ••••••••••••••• 0.2
9 8101C1 GRIP, HANDLE :RIGHT •••••••••• 0.2
10 8101C0 GRIP, HANDLE :LEFT ••••••••••• 0.1
11 810155 HOUSING, THROTTLE •••••••••••• 0.2
14 8101C8 BRACKET, HANDLE LEVER :LEFT •• 0.2
18 8101C6 LEVER, HANDLE :LEFT •••••••••• 0.1
8101F5 LEVER, HANDLE :BOTH •••••••••• 0.2

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 17910-KPS-900 CABLE COMP., THROTTLE ••••••• 1 1 1 1


2 17913-KB7-000 COVER, THROTTLE CABLE ••••••• 1 1 1 1
3 17920-KPS-900 CABLE COMP. B, THROTTLE ••••• 1 1 1 1
4 22870-KPS-900 CABLE COMP., CLUTCH ••••••••• 1 1 1 1
5 35130-KPS-900 SWITCH ASSY., ENGINE STOP ••• 1 1 1 1
6 35150-KPS-900 SWITCH ASSY., STARTER ••••••• 1 1 1 1
7 35330-MK5-003 SWITCH ASSY., CLUTCH •••••••• 1 1 1 1
8 53140-KPS-901 GRIP ASSY., THROTTLE •••••••• 1 1 1 1
9 53165-MK5-010 GRIP, R. HANDLE ••••••••••••• 1 1 1 1
10 53166-MK5-010 GRIP, L. HANDLE ••••••••••••• 1 1 1 1
11 53167-KPS-900 HOUSING, UPPER THROTTLE ••••• 1 1 1 1
12 53168-KPS-900 HOUSING, LOWER THROTTLE ••••• 1 1 1 1
13 53169-KPE-900 SLIDER, THROTTLE •••••••••••• 1 1 1 1
14 53172-KPS-900 BRACKET, L. HANDLE LEVER •••• 1 1 1 1
15 53174-KPS-900 HOLDER, L. LEVER BRACKET •••• 1 1 1 1
16 53174-116-670 PLUG, HANDLE LEVER BRACKET •• 1 1 1 1
17 53177-KS5-700 COVER, L. HANDLE LEVER •••••• 1 1 1 1
18 53178-KPS-900 LEVER, L. STEERING HANDLE ••• 1 1 1 1
19 53192-268-000 BOLT, WIRE ADJUSTING •••••••• 1 1 1 1
20 90113-HA0-770 BOLT, HANDLE LEVER PIVOT •••• 1 1 1 1
21 90120-KPS-900 SCREW, PAN, 4X32 •••••••••••• 1 1 1 1
22 90121-KPS-900 SCREW, PAN, 4X45 •••••••••••• 1 1 1 1
23 93901-32320 SCREW, TAPPING, 3X12 •••••••• 1 1 1 1
24 90321-315-670 NUT, FIXING ••••••••••••••••• 1 1 1 1
25 90520-KPS-900 WASHER, SPRING, 3MM ••••••••• 1 1 1 1
49
2005.05.20 E
F-2 HANDLE LEVER/SWITCH/CABLE F 3

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

26 90650-KW3-000 BAND, WIRE •••••••••••••••••• 5 5 5 5


27 93500-04012-1A SCREW, PAN, 4X12 •••••••••••• 1 1 1 1
28 93500-05016-0A SCREW, PAN, 5X16 •••••••••••• 2 2 2 2
29 93500-05016-0G SCREW, PAN, 5X16 •••••••••••• 2 2 2 2
30 94050-06000 NUT, FLANGE, 6MM •••••••••••• 1 1 1 1
31 94111-04000 WASHER, SPRING, 4MM ••••••••• 1 1 1 1

50
2005.05.20 E
F-3 FR. BRAKE MASTER CYLINDER F 4
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 7121A0 HOSE, FRONT BRAKE •••••••••••• 0.4
.INCLUDES: Bleed brakes
3 712105 CYLINDER, FRONT BRAKE MASTER • 0.4
.INCLUDES: Bleed brakes
7 7121G6 DIAPHRAGM, FRONT BRAKE MASTER
CYLINDER •••••••••••••••••••• 0.1
9 7121G9 PISTON SET, FRONT BRAKE MASTER 0.4
.INCLUDES: Bleed brakes
11 8101C7 LEVER, HANDLE :RIGHT ••••••••• 0.1
8101F5 LEVER, HANDLE :BOTH •••••••••• 0.2

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 45125-KPS-941 HOSE COMP., FR. BRAKE ••••••• 1 1 1 1


2 45504-KN5-006 BOOT COMP. •••••••••••••••••• 1 1 1 1
3 45510-KPS-901 CYLINDER SUB ASSY., FR. BRAKE
MASTER 1 1 1 1
4 45513-KCE-671 CAP, MASTER CYLINDER •••••••• 1 1 1 1
5 45517-GW0-751 HOLDER, MASTER CYLINDER ••••• 1 1 1 1
6 45518-KA3-731 SEPARATOR COMP. ••••••••••••• 1 1 1 1
7 45520-KA3-731 DIAPHRAGM ••••••••••••••••••• 1 1 1 1
8 45523-KA3-731 RING •••••••••••••••••••••••• 1 1 1 1
9 45530-KPS-901 CYLINDER SET, MASTER •••••••• 1 1 1 1
10 53174-KN5-006 SPRING, BRAKE LEVER ••••••••• 1 1 1 1
11 53175-KCE-670 LEVER, R. STEERING HANDLE ••• 1 1 1 1
12 53176-ML3-791 COVER, R. HANDLE LEVER •••••• 1 1 1 1
13 90111-ML3-791 BOLT SET, ADJUSTER •••••••••• 1 1 1 1
14 90114-166-006 BOLT, HANDLE LEVER PIVOT •••• 1 1 1 1
15 90145-MS9-612 BOLT, OIL, 10X22 •••••••••••• 2 2 2 2
16 90545-300-000 WASHER, OIL BOLT •••••••••••• 4 4 4 4
17 90651-MA5-671 CIRCLIP ••••••••••••••••••••• 1 1 1 1
18 93600-04012-1G SCREW, FLAT, 4X12 ••••••••••• 2 2 2 2
19 94050-06000 NUT, FLANGE, 6MM •••••••••••• 1 1 1 1
20 96001-06022-00 BOLT, FLANGE, 6X22 •••••••••• 2 2 2 -
90040-GHR-690 •••••••••••••••••••••••••••• - - - 2

51
2005.05.20 E
F-4 HANDLE PIPE/TOP BRIDGE F 5
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
2 615146 SWITCH, IGNITION ••••••••••••• 0.3
5 810100 PIPE, STEERING HANDLE •••••••• 0.4
7 510110 BRIDGE, FORK TOP ••••••••••••• 0.4

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

2 35100-KPS-900 SWITCH ASSY., COMBINATION ••• 1 1 1 1


3 35121-HF1-881 KEY, BLANK (TYPE 1)
(KEY NO. AXX / BXX) (1) (1) (1) (1)
35122-HF1-881 KEY, BLANK (TYPE 2)
(KEY NO. CXX / DXX) (1) (1) (1) (1)
4 45470-KPS-940 GUIDE COMP., BRAKE HOSE (TOP) 1 1 1 1
5 53100-KPS-900ZA PIPE, STEERING HANDLE
*NH146M*
ACCURATE SILVER METALLIC 1 1 - -
53100-KPS-901ZA *NH146M*
ACCURATE SILVER METALLIC - - 1 1
6 53131-KBB-950ZA HOLDER, UPPER
*NH146M*
ACCURATE SILVER METALLIC 2 2 2 2
7 53300-KPS-900 BRIDGE COMP., FORK TOP •••••• 1 1 - -
53300-KPS-760 •••••••••••••••••••••••••••• - - 1 1
10 61314-KPS-940 STAY, HEADLIGHT CASE R. UPPER 1 1 1 1
12 61317-KPS-940 STAY, HEADLIGHT CASE L. UPPER 1 1 1 1
13 61319-KPS-940 GUIDE, THROTTLE CABLE ••••••• 1 1 1 1
15 86150-MN8-300 EMBLEM, WING MARK ••••••••••• 1 1 - -
86150-KPG-902 EMBLEM, PRODUCT (UEHARA) •••• - - 1 1
16 90103-MBN-670 BOLT, FLANGE, 8X42 •••••••••• 4 4 4 4
18 90304-KPS-900 NUT, STEERING STEM •••••••••• 1 1 1 1
19 90503-KPS-900 WASHER, STEERING STEM ••••••• 1 1 1 1
21 90659-734-K51 CLIP, HARNESS (NIFUKO) •••••• 1 1 1 1
23 95701-06012-00 BOLT, FLANGE, 6X12 •••••••••• 1 1 1 1
24 96300-08035-00 BOLT, FLANGE, 8X35 •••••••••• 4 4 4 4
52
2005.05.20 E
F-5 STEERING STEM F 6
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
4 510100 STEM OR SHAFT ASSY., STEERING 0.7
5 5101B2 THREAD, STEERING HEAD TOP •••• 0.3
9 5101B6 BEARING, HEAD PIPE :UPPER •••• 0.7
5101C7 BEARING, HEAD PIPE :BOTH ••••• 0.9
10 5101B7 BEARING, HEAD PIPE :LOWER •••• 0.9

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 45460-KPS-900 GUIDE COMP., BRAKE HOSE BOTTOM 1 1 1 1


2 53214-KA3-732 DUST SEAL, STEERING HEAD
(ARAI) 1 1 1 1
3 53214-KA4-701 DUST SEAL, STEERING HEAD
(ARAI) 1 1 1 1
4 53219-KPS-900 STEM SUB ASSY., STEERING •••• 1 1 1 1
5 53229-KPS-900 THREAD, STEERING HEAD TOP ••• 1 1 1 1
6 61318-KPS-940 STAY, HEADLIGHT CASE LOWER •• 1 1 1 1
7 90107-KF0-000 BOLT, FLANGE, 8X40 •••••••••• 4 4 4 4
8 90201-415-000 NUT, CAP, 6MM ••••••••••••••• 2 2 2 2
9 91015-425-831 BEARING, HEAD PIPE UPPER (NTN) 1 1 1 1
10 91015-425-831 BEARING, HEAD PIPE UPPER (NTN) 1 1 1 1
91015-425-832 BEARING, HEAD PIPE UPPER
(NACHI) 1 1 1 1

53
2005.05.20 E
F-6 FRONT FENDER F 7
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 4131B7 FENDER, FRONT •••••••••••••••• 0.1

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 61100-KPS-900ZA FENDER, FR.


*R134*...........FIGHTING RED 1 - - -
61100-KPS-860ZA *R292R*...........EXTREME RED - 1 - -
61100-KPS-760 •••••••••••••••••••••••••••• - - 1 1
2 61104-KB7-900 COLLAR, FENDER MOUNTING ••••• 4 4 4 4
3 90023-KS4-000 BOLT, FLANGE, 6X32 •••••••••• 2 2 2 2
4 90511-KPS-900 WASHER, 6.5X20 •••••••••••••• 4 4 4 4
5 96300-06020-00 BOLT, FLANGE, 6X20 •••••••••• 2 2 2 2

54
2005.05.20 E
F-7 FRONT FORK F 8
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
2 5111C5 SPRING, FRONT FORK :LEFT ••••• 0.2
5111C6 SPRING, FRONT FORK :RIGHT •••• 0.2
5111C7 SPRING, FRONT FORK :BOTH ••••• 0.4
3 5111G2 PIPE, FRONT FORK :LEFT ••••••• 0.8
5111G3 PIPE, FRONT FORK :RIGHT •••••• 0.8
5111G4 PIPE, FRONT FORK :BOTH ••••••• 1.3
8 5111D2 CASE, BOTTOM :RIGHT •••••••••• 0.8
5111D3 CASE, BOTTOM :BOTH ••••••••••• 1.3
14 5111C3 FORK ASSY., FRONT :RIGHT ••••• 0.4
5111C4 FORK ASSY., FRONT :BOTH •••••• 0.6
15 5111E7 SEAL, FRONT FORK :LEFT ••••••• 0.8
5111E8 SEAL, FRONT FORK :RIGHT •••••• 0.8
5111E9 SEAL, FRONT FORK :BOTH ••••••• 1.3
16 5111D1 CASE, BOTTOM :LEFT ••••••••••• 0.8
17 5111C2 FORK ASSY., FRONT :LEFT •••••• 0.4
18 5111J9 BOOT, FRONT FORK :LEFT ••••••• 0.4
5111K0 BOOT, FRONT FORK :RIGHT •••••• 0.4
5111K1 BOOT, FRONT FORK :BOTH ••••••• 0.5

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 45461-KPS-900 CLAMPER A, BRAKE HOSE ••••••• 2 2 2 2


2 51401-KPS-901 SPRING, FR. FORK •••••••••••• 2 2 2 2
3 51410-KPS-901 PIPE COMP., FR. FORK •••••••• 2 2 2 2
4 51411-MG1-003 SPRING, FR. FORK REBOUND •••• 2 2 2 2
5 51412-461-003 RING, BACK UP ••••••••••••••• 2 2 2 2
6 51414-MN4-003 BUSH, GUIDE ••••••••••••••••• 2 2 2 2
7 51415-KS5-003 BUSH, SLIDER •••••••••••••••• 2 2 2 2
8 51420-KBB-903 CASE COMP., R. BOTTOM ••••••• 1 1 1 1
9 51432-KCN-003 PIECE, OIL LOCK ••••••••••••• 2 2 2 2
10 51437-ME4-003 RING, PISTON •••••••••••••••• 2 2 2 2
11 51440-KPS-901 PIPE, SEAT •••••••••••••••••• 2 2 2 2
12 51447-KR6-003 RING, OIL SEAL STOPPER •••••• 2 2 2 2
13 51450-KAS-901 BOLT COMP., FR. FORK •••••••• 2 2 2 2
14 51480-KPS-901 FORK SUB ASSY., R. FR. •••••• 1 1 1 1
15 51490-KR6-305 SEAL SET, FR. FORK •••••••••• 2 2 2 2
16 51520-KBB-903 CASE COMP., L. BOTTOM ••••••• 1 1 1 1
17 51580-KPS-901 FORK SUB ASSY., L. FR. •••••• 1 1 1 1
18 51611-KR6-013ZH BOOT, FR. FORK
*NH1*...................BLACK 2 2 2 2
19 51612-430-010 BAND, FR. FORK BOOT ••••••••• 2 2 2 2
20 51634-MA0-003 HOLDER, AXLE •••••••••••••••• 1 1 1 1
21 90116-KV3-701 BOLT, SOCKET, 8MM ••••••••••• 2 2 2 2
22 90301-473-003 NUT, U, 6MM ••••••••••••••••• 4 4 4 4
23 90544-283-000 WASHER, SPECIAL, 8MM •••••••• 2 2 2 2
24 91254-KR6-003 DUST SEAL ••••••••••••••••••• 2 2 2 2
55
2005.05.20 E
F-7 FRONT FORK F 9

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

25 91357-ME4-003 O-RING, 27.7X3.5 •••••••••••• 2 2 2 2


26 92900-06025-0E BOLT, STUD, 6X25 •••••••••••• 4 4 4 4
27 93500-03025-0A SCREW, PAN, 3X25 •••••••••••• 2 2 2 2
28 96500-06014-00 BOLT, FLANGE, 6X14 •••••••••• 2 2 2 -
90040-GHR-650 •••••••••••••••••••••••••••• - - - 2

56
2005.05.20 E
F-8 FRONT BRAKE CALIPER F10
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
2 (1)
7111D1 PISTON, FRONT BRAKE CALIPER •• 0.5
.INCLUDES: Bleed brakes
.NOTE: Same time for two units
5 711115 SHOE(PAD) SET, BRAKE :FRONT •• 0.1
12 711130 CALIPER, FRONT BRAKE ••••••••• 0.4
.INCLUDES: Bleed brakes
13 7111G0 BRACKET, FRONT CALIPER ••••••• 0.2

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 06431-MA3-405 SEAL SET, PISTON •••••••••••• 2 2 2 2


2 43107-MBG-006 PISTON, 27X27 ••••••••••••••• 2 2 2 2
3 43352-568-003 SCREW, BLEEDER (NISSIN) ••••• 1 1 1 1
4 43353-461-771 CAP, BLEEDER •••••••••••••••• 1 1 1 1
5 45105-MY6-405 PAD SET, FR. •••••••••••••••• 1 1 1 1
6 45108-MY1-006 SPRING, PAD ••••••••••••••••• 1 1 1 1
7 45112-KS6-701 RETAINER •••••••••••••••••••• 1 1 1 1
8 45131-HA5-672 BOLT A, PIN ••••••••••••••••• 1 1 1 1
10 45132-166-016 BOOT, PIN BUSH (NISSIN) ••••• 1 1 1 1
11 45133-MA3-006 BOOT B •••••••••••••••••••••• 1 1 1 1
12 45150-KZ4-J21 CALIPER SUB ASSY., L. FR.
BRAKE (NISSIN) 1 1 1 1
13 45190-KZ4-J21 BRACKET SUB ASSY., L. FR.
CALIPER 1 1 1 1
14 45203-MG3-016 PLUG, PIN ••••••••••••••••••• 1 1 1 1
15 45215-HA5-672 PIN, HANGER ••••••••••••••••• 1 1 1 1
16 90131-KPS-900 BOLT, FLANGE, 8X40 •••••••••• 2 2 2 2

57
2005.05.20 E
F-9 FRONT WHEEL F11
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
3 710151 AXLE, FRONT WHEEL •••••••••••• 0.2
8 710103 HUB, FRONT WHEEL ••••••••••••• 2.3
9 7101D4 FRONT WHEEL •••••••••••••••••• 0.9
10 710109 RIM, WHEEL :FRONT •••••••••••• 2.2
11 710139 FRONT TIRE(ONE) •••••••••••••• 0.8
12 710140 TUBE, FRONT TIRE ••••••••••••• 0.8
15 711120 DISC, FRONT BRAKE •••••••••••• 0.3
22 (7)
710115 BEARING, FRONT WHEEL(ONE) •••• 0.4
710115G .Replace 1 bearing add ••••••• 0.1

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 06441-KPS-900 SPOKE SET, FR. •••••••••••••• 36 36 36 -


06441-KPS-730 •••••••••••••••••••••••••••• - - - 36
2 42714-KA3-710 CAP, VALVE •••••••••••••••••• 1 1 1 1
3 44301-KPS-900 AXLE, FR. WHEEL ••••••••••••• 1 1 1 1
4 44311-KPS-900 COLLAR, FR. WHEEL ••••••••••• 1 1 1 1
5 44312-KPS-900 COLLAR, FR. WHEEL ••••••••••• 1 1 1 1
6 44610-KL3-770 COVER, FR. HUB •••••••••••••• 1 1 1 1
7 44620-KPS-900 COLLAR, FR. AXLE DISTANCE ••• 1 1 1 1
8 44635-KPS-900 HUB SUB ASSY., FR. •••••••••• 1 1 1 -
44635-KPS-730 •••••••••••••••••••••••••••• - - - 1
9 44650-KPS-900 WHEEL SUB ASSY., FR. •••••••• 1 1 1 -
44650-KPS-730 •••••••••••••••••••••••••••• - - - 1
10 44701-KPS-901 RIM, FR. WHEEL •••••••••••••• 1 1 1 1
11 44711-KPS-901 TIRE, FR. (PIRELLI)
(80/100 NHS MT320H) 1 1 1 1
12 44712-MAN-622 TUBE, TIRE (PIRELLI)(MA-21) • 1 1 1 1
13 44713-KW8-901 FLAP, TIRE (PIRELLI)(1.40-21) 1 1 1 1
14 44715-MA0-770 STOPPER, BEAD (1.60) •••••••• 1 1 1 1
15 45351-KPS-900 DISK, FR. BRAKE ••••••••••••• 1 1 1 1
16 90105-KAE-870 BOLT, DISK, 6X17 •••••••••••• 4 4 4 4
17 90204-KPS-900 SCREW-WASHER, 4X8 ••••••••••• 4 4 4 4
18 90755-229-003 OIL SEAL, 21X37X7(ARAI) ••••• 1 1 1 1
90755-229-005 OIL SEAL, 21X37X7(NOK) •••••• 1 1 1 1
19 91254-KA3-831 DUST SEAL, 22X50X5(NOK) ••••• 1 1 1 1
20 94001-08000-0S NUT, HEX., 8MM •••••••••••••• 1 1 1 1
58
2005.05.20 E
F-9 FRONT WHEEL F12

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

21 94111-08000 WASHER, SPRING, 8MM ••••••••• 1 1 1 1


22 96140-62020-10 BEARING, RADIAL BALL, 6202U • 2 2 2 2
91014-KPS-731 BEARING, BALL RADIAL, 6202U
(NACHI) - - - 2
91014-KPS-732 BEARING, BALL RADIAL, 6202U
(NSK) - - - 2

59
2005.05.20 E
F-10 REAR BRAKE PANEL F13
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 711140 SHOE(PAD) SET, BRAKE :REAR ••• 0.4
2 (3)
7111A9 PANEL, REAR BRAKE •••••••••••• 0.5
7 7111C4 ARM, REAR BRAKE •••••••••••••• 0.2

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 06430-GBJ-J10 SHOE SET, BRAKE (ASK) ••••••• 1 1 1 1


06430-GCE-900 SHOE SET, BRAKE (NK) •••••••• 1 1 1 1
2 43100-KPS-900ZA PANEL COMP., RR. BRAKE
*NH109MS*
SHOT SILVER METALLIC SPECIAL 1 1 1 1
3 43141-KFC-790 CAM, RR. BRAKE •••••••••••••• 1 1 1 1
4 43142-KPS-900 SEAT, RR. BRAKE CAM ••••••••• 1 1 1 1
5 43145-KB7-000 INDICATOR, RR. BRAKE •••••••• 1 1 1 1
6 43151-110-000 SPRING, BRAKE SHOE •••••••••• 2 2 2 2
7 43410-KPS-900 ARM, RR. BRAKE •••••••••••••• 1 1 1 1
8 43411-KHA-940 COVER, RR. BRAKE ARM •••••••• 1 1 1 1
9 45134-KB7-005 DUST SEAL, BRAKE CAM (NOK) •• 2 2 2 2
10 90117-KPS-900 BOLT, FLANGE, 6X35 •••••••••• 1 1 1 -
90032-GHR-740 •••••••••••••••••••••••••••• - - - 1
11 90301-473-003 NUT, U, 6MM ••••••••••••••••• 1 1 1 1

60
2005.05.20 E
F-11 REAR WHEEL F14
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
5 7101A0 SPROCKET, FINAL DRIVEN ••••••• 0.4
6 710160 AXLE, REAR WHEEL ••••••••••••• 0.3
9 710121 HUB, REAR WHEEL •••••••••••••• 2.4
10 710118 REAR WHEEL ••••••••••••••••••• 1.0
11 710127 RIM, WHEEL :REAR ••••••••••••• 2.3
12 710142 REAR TIRE(ONE) ••••••••••••••• 0.9
13 7101A7 TUBE, REAR TIRE •••••••••••••• 0.9
25 (8,26)
710133 BEARING, REAR WHEEL(ONE) ••••• 0.5
710133G .Replace 1 bearing add ••••••• 0.1

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 06420-KPS-900 SPOKE SET A, RR. ••••••••••••


(L. SIDE) 18 18 18 -
06420-KPS-730 ••••••••••••••••••••••••••••
(L. SIDE) - - - 18
2 06422-KPS-900 SPOKE SET C, RR. ••••••••••••
(R. SIDE) 18 18 18 -
06422-KPS-730 SPOKE SET B, RR. ••••••••••••
(R. SIDE) - - - 18
3 40544-KPS-900 ADJUSTER, R. CHAIN •••••••••• 1 1 1 -
40544-KPS-730 •••••••••••••••••••••••••••• - - - 1
4 40545-KPS-900 ADJUSTER, L. CHAIN •••••••••• 1 1 1 -
40545-KPS-730 •••••••••••••••••••••••••••• - - - 1
5 41201-KPS-900 SPROCKET, FINAL DRIVEN (50T) 1 1 1 1
6 42301-KPS-900 AXLE, RR. WHEEL ••••••••••••• 1 1 1 1
7 42312-KPS-900 COLLAR, RR. WHEEL ••••••••••• 1 1 1 1
8 42620-KPS-900 COLLAR, RR. AXLE DISTANCE ••• 1 1 1 1
9 42635-KPS-900 HUB SUB ASSY., RR. •••••••••• 1 1 1 -
42635-KPS-730 •••••••••••••••••••••••••••• - - - 1
10 42650-KPS-900 WHEEL SUB ASSY., RR. •••••••• 1 1 1 -
42650-KPS-730 •••••••••••••••••••••••••••• - - - 1
11 42701-KPS-901 RIM, RR. WHEEL •••••••••••••• 1 1 1 1
12 42711-KPS-901 TIRE, RR. (PIRELLI)
(100/100-18 NHS MT320H) 1 1 1 1
13 42712-KHA-941 TUBE, TIRE (PIRELLI)(MD-18) • 1 1 1 1
14 42713-KW8-901 FLAP, TIRE (PIRELLI)(1.85-18) 1 1 1 1
15 42714-KA3-710 CAP, VALVE •••••••••••••••••• 1 1 1 1
61
2005.05.20 E
F-11 REAR WHEEL F15

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

16 42715-KA2-680 STOPPER, BEAD (1.85) •••••••• 1 1 1 1


17 90125-KA4-000 SCREW, FLAT, 8X31 ••••••••••• 6 6 6 6
18 90305-GW2-711 NUT, U, 16MM •••••••••••••••• 1 1 1 1
19 90309-ML3-791 NUT, U, 8MM ••••••••••••••••• 6 6 6 6
20 90465-MC4-000 WASHER, 8MM ••••••••••••••••• 6 6 6 6
21 90559-KPS-900 WASHER, RR. AXLE •••••••••••• 1 1 1 1
22 91253-033-003 OIL SEAL, 25X47X6.5 ••••••••• 1 1 1 1
23 94001-08000-0S NUT, HEX., 8MM •••••••••••••• 1 1 1 1
24 94111-08000 WASHER, SPRING, 8MM ••••••••• 1 1 1 1
25 96140-62030-10 BEARING, RADIAL BALL, 6203U • 1 1 1 1
91013-KPS-731 BEARING, BALL RADIAL, 6203U
(NAHI) - - - 1
91013-KPS-732 BEARING, BALL RADIAL, 6203U
(NSK) - - - 1
26 96140-63030-10 BEARING, RADIAL BALL, 6303U • 1 1 1 1
91051-KPS-731 BEARING, BALL RADIAL, 6303U
(NACHI) - - - 1
91051-KPS-732 BEARING, BALL RADIAL, 6303U
(NSK) - - - 1

62
2005.05.20 E
F-12 FUEL TANK F16
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 310110 COCK ASSY., FUEL ••••••••••••• 0.2
6 310100 TANK, FUEL ••••••••••••••••••• 0.3
9 1151A0 SHROUD, RADIATOR :RIGHT •••••• 0.2
.NOTE: Same time for two units
1151A5 SHROUD, RADIATOR :BOTH ••••••• 0.2
10 115126 SHROUD, RADIATOR :LEFT ••••••• 0.2
.NOTE: Same time for two units

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3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 16950-GCF-671 COCK ASSY., FUEL •••••••••••• 1 1 1 1


2 16997-467-000 O-RING, 11.8X3.55 ••••••••••• 1 1 1 1
3 17506-KPS-900 RUBBER, TANK SETTING •••••••• 2 2 2 2
4 17508-GBF-830 RUBBER, TANK MOUNTING ••••••• 2 2 2 2
5 17509-KPS-900 COLLAR, TANK SETTING •••••••• 2 2 2 2
6 17510-KPS-900 TANK COMP., FUEL •••••••••••• 1 1 - -
17510-KPS-760 •••••••••••••••••••••••••••• - - 1 1
7 17516-KPS-900 BAND, TANK RR. •••••••••••••• 1 1 1 1
8 17521-429-000 TUBE, FUEL CAP BREATHER ••••• 1 1 1 1
9 17545-KPS-900ZA SHROUD SET, R. TANK *TYPE1*
(WL) 1 - - -
17545-KPS-860ZA •••••••••••••••••••••••••••• - 1 - -
17545-KPS-760ZA •••••••••••••••••••••••••••• - - 1 -
17545-KPS-730ZA •••••••••••••••••••••••••••• - - - 1
10 17555-KPS-900ZA SHROUD SET, L. TANK *TYPE1*
(WL) 1 - - -
17555-KPS-860ZA •••••••••••••••••••••••••••• - 1 - -
17555-KPS-760ZA •••••••••••••••••••••••••••• - - 1 -
17555-KPS-730ZA •••••••••••••••••••••••••••• - - - 1
11 17620-GEL-770 CAP ASSY., FUEL TANK •••••••• 1 1 1 1
12 17624-GEL-770 PACKING, FUEL CAP ••••••••••• 1 1 1 1
13 17626-KPS-900 COLLAR, TANK SETTING •••••••• 2 2 2 2
14 17634-KPS-900 BRACKET, FUEL TANK FR. •••••• 2 2 2 2
15 17681-KPS-900 TUBE, FUEL •••••••••••••••••• 1 1 1 1
16 84706-415-000 COLLAR •••••••••••••••••••••• 4 4 4 4
17 90103-KV3-830 SCREW A, COWL SETTING ••••••• 2 2 2 2
63
2005.05.20 E
F-12 FUEL TANK G 1

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3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

18 90137-KA3-830 BOLT, FLANGE, 6X40 •••••••••• 2 2 2 2


19 90503-898-000 WASHER, TANK CUSHION •••••••• 2 2 2 2
20 90522-KF0-000 COLLAR, SIDE COVER SETTING •• 1 1 1 1
21 90651-KPS-900 CLIP, TUBE (B10) •••••••••••• 2 2 2 2
22 90653-HC4-900 CLIP, MUDGUARD •••••••••••••• 4 4 4 4
23 93500-06018-0A SCREW, PAN, 6X18 •••••••••••• 1 1 1 1
24 96001-06016-00 BOLT, FLANGE, 6X16 •••••••••• 6 6 6 6

64
2005.05.20 E
F-13 SEAT G 2
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 4131E4 SEAT :DOUBLE ••••••••••••••••• 0.1

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3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 77200-KPS-900 SEAT COMP., DOUBLE •••••••••• 1 - - -


77200-KPS-860 •••••••••••••••••••••••••••• - 1 1 1
2 77213-KPS-900 LEATHER COMP., SEAT
(NO LETTERS PRINTED) 1 - - -
77213-KPS-860 •••••••••••••••••••••••••••• - 1 1 1
3 90306-KPS-900 NUT, FLANGE, 8MM •••••••••••• 2 2 2 2
4 95701-08025-00 BOLT, FLANGE, 8X25 •••••••••• 2 2 2 2

65
2005.05.20 E
F-14 SIDE COVER G 3
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
2 4111H9 COVER, SIDE :RIGHT ••••••••••• 0.1
.NOTE: Same time for two units
4111J0 COVER, SIDE :BOTH •••••••••••• 0.1
4 (5)
4111H8 COVER, SIDE :LEFT •••••••••••• 0.1
.NOTE: Same time for two units

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3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 52156-KAS-900 COLLAR, 6.5X4 ••••••••••••••• 1 1 1 1


2 83500-KPS-900ZA COVER, R. SIDE
*NH196*............ROSS WHITE 1 1 1 1
3 83551-376-000 GROMMET, SIDE COVER ••••••••• 2 2 2 2
4 83600-KPS-900ZA COVER, L. SIDE
*NH196*............ROSS WHITE 1 1 1 1
5 83601-KPS-900ZB COVER, BATTERY BOX
*NH1*...................BLACK 1 1 1 1
6 83601-MB0-000 GROMMET A, SIDE COVER ••••••• 2 2 2 2
7 90103-KV3-830 SCREW A, COWL SETTING ••••••• 2 2 2 2
8 90111-187-000 BOLT, FLANGE, 6MM ••••••••••• 1 1 1 1
9 93404-06025-07 BOLT-WASHER, 6X25 ••••••••••• 1 1 1 1
10 93913-24120 SCREW, TAPPING, 4X10 •••••••• 2 2 2 2

66
2005.05.20 E
F-15 AIR CLEANER G 4
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
3 312105 ELEMENT, AIR CLEANER ••••••••• 0.2
4 3121A8 BASE, AIR CLEANER ELEMENT •••• 0.1
9 3121B6 TUBE, AIR CLEANER CONNECTING • 0.6
10 3121A5 CASE, AIR CLEANER •••••••••••• 0.6
11 3121D3 DUCT, AIR INTAKE ••••••••••••• 0.2
13 4131A0 MUDGUARD, AIR CLEANER CASE ••• 0.1

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3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 15772-KPS-900 CLIP, BREATHER TUBE ••••••••• 1 1 1 1


2 15772-MN1-670 CLIP B, BREATHER TUBE ••••••• 3 3 3 3
3 17213-KPS-900 ELEMENT, AIR CLEANER •••••••• 1 1 1 1
4 17214-KPS-900 HOLDER, ELEMENT ••••••••••••• 1 1 1 1
5 17216-KPS-900 PLATE COMP., ELEMENT SETTING 1 1 1 1
6 17217-KPS-900 PLATE, FR. HOLDER ••••••••••• 1 1 1 1
7 17219-KPS-900 SEAL, AIR CLEANER COVER ••••• 1 1 1 1
8 17220-KPS-900ZA COVER, AIR CLEANER CASE
*NH1*...................BLACK 1 1 1 1
9 17222-KPS-900 TUBE, AIR CLEANER CONNECTING 1 1 1 1
10 17230-KPS-900 CASE, AIR CLEANER ••••••••••• 1 1 1 1
11 17240-KPS-900 DUCT, AIR CLEANER IN. ••••••• 1 1 1 1
12 17241-KPS-900 CAP, IN. DUCT ••••••••••••••• 1 1 1 1
13 17245-KPS-900 MUDGUARD •••••••••••••••••••• 1 1 1 1
14 17358-170-000 TUBE, DRAIN ••••••••••••••••• 1 1 1 1
15 17371-KPS-900 TUBE, BREATHER •••••••••••••• 1 1 1 1
16 83505-KPS-900 COLLAR, COVER MOUNTING •••••• 2 2 2 2
17 90104-KPS-900 BOLT, FLANGE, 6X20 •••••••••• 2 2 2 2
18 90111-KPS-900 BOLT, FLANGE, 6MM ••••••••••• 1 1 1 1
19 90311-KPS-900 NUT, CLIP, 6MM •••••••••••••• 3 3 3 3
20 90505-MC4-000 GROMMET A, AIR CLEANER CASE • 2 2 2 2
21 90520-134-000 WASHER, HEADLIGHT CASE SETTING 1 1 1 1
22 90652-KPS-900 BAND, AIR CLEANER CONNECTING
TUBE (52) 1 1 1 1
23 91463-KPS-900 JOINT, TUBE ••••••••••••••••• 1 1 1 1
67
2005.05.20 E
F-15 AIR CLEANER G 5

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3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

24 92101-05010-0A BOLT, HEX., 5X10 •••••••••••• 1 1 1 1


25 93500-05028-0G SCREW, PAN, 5X28 •••••••••••• 1 1 1 1
26 93891-05012-07 SCREW-WASHER, 5X12 •••••••••• 5 5 5 5
27 93903-25210 SCREW, TAPPING, 5X12 •••••••• 2 2 2 2
28 94001-05070-0S NUT, HEX., 5MM •••••••••••••• 6 6 6 6
29 94021-05020-0S NUT, CAP, 5MM ••••••••••••••• 1 1 1 1

68
2005.05.20 E
F-16 EXHAUST MUFFLER G 6
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
2 3131B4 GASKET, EXHAUST PIPE ••••••••• 0.2
4 313120 MUFFLER •••••••••••••••••••••• 0.1
5 313110 PIPE, EXHAUST •••••••••••••••• 0.2
7 3131C1 ARRESTER, SPARK •••••••••••••• 0.1
8 3131A6 PROTECTOR, EXHAUST PIPE •••••• 0.1

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3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 18291-KPS-900 GASKET, EX. MUFFLER ••••••••• 1 1 1 1


2 18291-MN5-650 GASKET, EX. PIPE •••••••••••• 1 1 1 1
3 18292-KBR-000 PACKING, PROTECTOR •••••••••• 2 2 2 2
4 18300-KPS-900 MUFFLER ASSY., EX. •••••••••• 1 1 1 -
18300-KPS-730 •••••••••••••••••••••••••••• - - - 1
5 18320-KPS-900 PIPE COMP., EX. ••••••••••••• 1 1 1 1
6 18328-KAE-000 RUBBER, CHAMBER RR. MOUNTING 1 1 1 1
7 18355-KPS-900 ARRESTER ASSY. •••••••••••••• 1 1 1 -
18355-KPS-730 •••••••••••••••••••••••••••• - - - 1
8 18345-KPS-900ZAPROTECTOR, EX. PIPE
*NH106*.......HEATPROOF BLACK 1 1 1 -
18345-KPS-901ZA *NH106*.......HEATPROOF BLACK - - - 1
9 18356-KAE-000 COLLAR, SILENCER MOUNTING ••• 1 1 1 1
10 18373-MN1-670 BAND, R. EX. PIPE ••••••••••• 1 1 1 -
18373-KRH-D20 BAND, EX. PIPE •••••••••••••• - - - 1
11 18391-MB0-891 PACKING, EX. •••••••••••••••• 1 1 1 1
12 18421-KFB-000 RUBBER, MUFFLER MOUNTING •••• 1 1 1 1
13 18422-KFB-000 COLLAR, MUFFLER MOUNTING •••• 1 1 1 1
14 83512-KA4-700 RUBBER, SIDE COVER •••••••••• 2 2 2 2
15 90101-KCE-000 BOLT, FLANGE, 6X10 •••••••••• 3 3 3 3
16 90305-KPS-900 NUT, HEX. CAP, 7MM •••••••••• 2 2 2 2
17 94050-08070 NUT, FLANGE, 8MM •••••••••••• 1 1 1 1
18 94103-08700 WASHER, PLAIN, 8MM •••••••••• 1 1 1 1
19 95701-08030-07 BOLT, FLANGE, 8X30 •••••••••• 1 1 1 1
20 95701-08040-07 BOLT, FLANGE, 8X40 •••••••••• 1 1 1 1
69
2005.05.20 E
F-16 EXHAUST MUFFLER G 7

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3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

21 95701-08045-07 BOLT, FLANGE, 8X45 •••••••••• 1 1 1 1


22 96001-06008-07 BOLT, FLANGE, 6X8 ••••••••••• 2 2 2 2

70
2005.05.20 E
F-17 PEDAL G 8
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 4101A1 PEDAL, GEAR CHANGE ••••••••••• 0.1
2 811135 ROD, REAR BRAKE •••••••••••••• 0.3
6 (17)
810160 PEDAL, REAR BRAKE •••••••••••• 0.3

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3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 24700-KPS-900 PEDAL ASSY., GEAR CHANGE •••• 1 1 1 1


2 43451-KPS-900 ROD COMP., RR. BRAKE •••••••• 1 1 1 1
3 43453-KPS-900 PIN C, JOINT •••••••••••••••• 1 1 1 1
4 43454-KPS-900 JOINT B, BRAKE ARM •••••••••• 1 1 1 1
5 43472-KPS-900 SPRING A, BRAKE ROD ••••••••• 1 1 1 1
6 46500-KPS-900 PEDAL COMP., BRAKE •••••••••• 1 1 1 -
7 46513-KPS-900 SPRING SET, BRAKE PEDAL ••••• 1 1 1 1
8 46515-KY7-000 TUBE, BRAKE PEDAL SPRING •••• 1 1 1 1
9 46525-KK0-003 DUST SEAL, 17X20X2.5 •••••••• 2 2 2 2
10 90010-ML0-720 BOLT, FLANGE, 6X20 •••••••••• 1 1 1 1
11 90105-KPS-900 BOLT, HEX., 6X20 •••••••••••• 1 1 1 1
12 90501-KPS-900 WASHER, BUSH •••••••••••••••• 1 1 1 -
90501-KRE-900 •••••••••••••••••••••••••••• - - - 1
13 94001-06000-0S NUT, HEX., 6MM •••••••••••••• 1 1 1 1
14 94201-20120 PIN, SPLIT, 2.0X12 •••••••••• 1 1 1 1
15 94201-30280 PIN, SPLIT, 3.0X28 •••••••••• 1 1 1 1
16 95015-42000 NUT B, BRAKE ROD ADJUSTING •• 1 1 1 1
17 46500-KPS-730 PEDAL COMP., BRAKE •••••••••• - - - 1

71
2005.05.20 E
F-18 STEP G 9
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
2 4101C6 BAR, MAIN STEP :RIGHT •••••••• 0.1
4101J1 BAR, MAIN STEP :BOTH ••••••••• 0.2
3 4101C4 BRACKET, STEP :RIGHT ••••••••• 0.2
4101N7 BRACKET, STEP :BOTH •••••••••• 0.4
5 4101C5 BAR, MAIN STEP :LEFT ••••••••• 0.1
6 4101C3 BRACKET, STEP :LEFT •••••••••• 0.2

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3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 50603-KPS-900 PIN, STEP BAR JOINT ••••••••• 2 2 2 2


2 50612-KPS-900 STEP COMP., R. •••••••••••••• 1 1 1 1
3 50615-KPS-900 ARM COMP., R. STEP •••••••••• 1 1 1 1
4 50617-466-000 SPRING, STEP RETURN ••••••••• 2 2 2 2
5 50642-KPS-900 STEP COMP., L. •••••••••••••• 1 1 1 1
6 50645-KPS-900 ARM COMP., L. STEP •••••••••• 1 1 1 1
7 90181-MCT-000 BOLT, SOCKET, 10X45 ••••••••• 4 4 4 4
8 90502-KPS-900 WASHER, PLAIN, 8MM •••••••••• 2 2 2 2
9 94201-20150 PIN, SPLIT, 2.0X15 •••••••••• 2 2 2 2

72
2005.05.20 E
F-19 SIDE STAND G10
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 410180 BAR, SIDE STAND •••••••••••••• 0.2
2 410182 SPRING, SIDE STAND ••••••••••• 0.1

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3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 50530-KPS-900 BAR COMP., SIDE STAND ••••••• 1 1 1 -


50530-KPS-730 •••••••••••••••••••••••••••• - - - 1
2 50535-KN5-670 SPRING, SIDE STAND •••••••••• 1 1 1 1
3 90108-MJ0-000 BOLT, SIDE STAND PIVOT •••••• 1 1 1 1
4 90203-MF9-710 NUT, SIDE STAND ••••••••••••• 1 1 1 1

73
2005.05.20 E
F-20 SWINGARM/CHAIN CASE G11
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 213165 CHAIN, DRIVE ••••••••••••••••• 0.2
4 5121H5 COLLAR, SWINGARM ••••••••••••• 0.7
6 4101E2 GUIDE, DRIVE CHAIN ••••••••••• 0.1
7 4101J2 SLIDER, CHAIN GUIDE •••••••••• 0.1
9 4101E5 SLIDER, CHAIN •••••••••••••••• 0.3
12 4101Q8 SLIDER, CHAIN :LOWER ••••••••• 0.1
13 5121B0 SWINGARM ASSEMBLY •••••••••••• 0.9
19 5121C8 BEARING, SWINGARM PIVOT :LEFT 1.0
5121C9 BEARING, SWINGARM PIVOT :RIGHT 1.0
5121D0 BEARING, SWINGARM PIVOT :BOTH 1.2

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3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 06405-KCR-P00 CHAIN SET, DRIVE (DAIDO)


(DID520-112L-120L)
(STANDARD LINK 110L) 1 1 1 1
06405-KCR-P10 CHAIN SET, DRIVE (RK EXCEL)
(RK520 112L-120L)
(STANDARD LINK 110L) 1 1 1 1
2 40535-KCR-305 JOINT SET, DRIVE CHAIN (DAIDO)
(SEAL TYPE) 1 1 1 1
40535-KCR-306 JOINT SET, DRIVE CHAIN
(RK EXCEL)(SEAL TYPE) 1 1 1 1
3 52101-KPS-900 BOLT, SWINGARM PIVOT •••••••• 1 1 1 1
4 52141-KPS-900 COLLAR, SWINGARM PIVOT CENTER
DISTANCE 1 1 1 1
5 52144-356-003 CAP, SWINGARM DUST SEAL (ARAI) 2 2 2 2
52144-356-005 CAP, SWINGARM DUST SEAL (NOK) 2 2 2 2
6 52146-KPS-900 GUIDE, CHAIN •••••••••••••••• 1 1 1 1
7 52147-MN1-670 SLIDER, CHAIN GUIDE ••••••••• 1 1 1 1
8 52159-KPE-900 COLLAR, CHAIN SLIPPER ••••••• 1 1 1 1
9 52170-KPS-900 SLIDER, CHAIN ••••••••••••••• 1 1 1 1
10 52171-KPS-900 WASHER, CHAIN SLIDER •••••••• 2 2 2 2
11 52175-KPS-900 ROLLER, CHAIN UPPER ••••••••• 1 1 1 1
12 52185-KPS-900 SLIDER, CHAIN LOWER ••••••••• 1 1 1 1
13 52200-KPS-900 SWINGARM SUB ASSY., RR. ••••• 1 1 1 1
14 90103-MY6-670 BOLT, FLANGE, 6X16 •••••••••• 2 2 2 2
15 90106-KPS-900 BOLT, FLANGE, 6X28 •••••••••• 1 1 1 1
16 90115-KPS-900 SCREW, PAN, 5X8 ••••••••••••• 2 2 2 2
74
2005.05.20 E
F-20 SWINGARM/CHAIN CASE G12

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3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

17 90301-473-003 NUT, U, 6MM ••••••••••••••••• 2 2 2 2


18 90305-GE8-003 NUT, U, 14MM •••••••••••••••• 1 1 1 1
19 91070-KPE-901 BEARING, NEEDLE, 20X26X20 ••• 2 2 2 2
20 93600-06045-0A SCREW, FLAT, 6X45 ••••••••••• 2 2 2 2
21 94102-08700 WASHER, PLAIN, 8MM •••••••••• 1 1 1 1
22 94201-20150 PIN, SPLIT, 2.0X15 •••••••••• 1 1 1 1

75
2005.05.20 E
F-21 REAR CUSHION G13
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 512115 CUSHION ASSY., REAR •••••••••• 0.5
5 (2,3,4)
512140 ARM, CUSHION ••••••••••••••••• 0.5
7 (6)
512145 ROD, CUSHION CONNECTING •••••• 0.3
15 (16,17)
5121D4 BEARING, CUSHION CONNECTING
ROD ••••••••••••••••••••••••• 0.5
5121D4A .Replace 1 bearing add ••••••• 0.1
512146 BEARING, CUSHION ARM ••••••••• 0.7
512146A .Replace 1 bearing add ••••••• 0.1
5121D3 BEARING, CUSHION ARM
:FOR 1 VEHICLE •••••••••••••• 1.0

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3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 52400-KPS-901 CUSHION ASSY., RR. •••••••••• 1 1 1 1


2 52462-KPS-900 COLLAR A, CUSHION ARM ••••••• 1 1 1 1
3 52463-KPE-900 COLLAR B, CUSHION ARM ••••••• 1 1 1 1
4 52464-KPE-900 COLLAR C, CUSHION ARM ••••••• 1 1 1 1
5 52465-KPS-900 ARM SUB ASSY., CUSHION •••••• 1 1 1 1
6 52472-KPS-900 COLLAR, CONNECTING ROD •••••• 1 1 1 1
7 52475-KPS-900 ROD SUB ASSY., CUSHION
CONNECTING 1 1 1 1
8 87516-KV6-610 LABEL, RR. DAMPER CAUTION ••• 1 1 1 1
9 90101-KPS-900 BOLT, FLANGE, 10X100 •••••••• 1 1 1 1
10 90102-KFB-000 BOLT, FLANGE, 12X78 ••••••••• 1 1 1 1
11 90102-KPS-900 BOLT, FLANGE, 10X118 •••••••• 1 1 1 1
12 90154-KPS-900 BOLT, FLANGE, 10X52 ••••••••• 2 2 2 2
13 90304-GE8-003 NUT, U, 10MM •••••••••••••••• 3 3 3 3
14 90306-KF0-003 NUT, FLANGE, 12MM ••••••••••• 1 1 1 1
15 91071-KV3-005 BEARING, NEEDLE (KOYO) •••••• 4 4 4 4
16 91071-MY1-005 BEARING, NEEDLE, 17X24X17 ••• 1 1 1 1
17 91072-MY1-005 BEARING, NEEDLE, 20X26X20 ••• 1 1 1 1
18 91254-KS6-003 DUST SEAL, 20X26X4.5(ARAI) •• 2 2 2 2
19 91262-KV3-831 DUST SEAL, 17X24X5(ARAI) •••• 6 6 6 6

76
2005.05.20 E
F-22 REAR FENDER G14
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
6 413102 FENDER, REAR ••••••••••••••••• 0.2

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

6 80101-KPS-900ZA FENDER SET, RR. (WL)


*R134*...........FIGHTING RED 1 - - -
80101-KPS-860ZA *R292R*...........EXTREME RED - 1 - -
80101-KPS-760ZA FENDER SET, RR. *TYPE1*(WL) • - - 1 1
7 83505-KM4-000 COLLAR, TOOL BOX SETTING •••• 2 2 2 2
9 90116-ME9-000 BOLT, FLANGE, 6MM ••••••••••• 2 2 2 2

77
2005.05.20 E
F-23 BATTERY G15
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 610100 BATTERY •••••••••••••••••••••• 0.2
3 610105 CABLE, POSITIVE BATTERY •••••• 0.2
4 612115 CABLE, STARTER MOTOR ••••••••• 0.3
9 610110 CABLE, NEGATIVE BATTERY •••••• 0.3
10 615113 SWITCH, STARTER MAGNETIC ••••• 0.3
13 410185 BOX, BATTERY ••••••••••••••••• 0.3

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 31500-KY4-905 BATTERY (YTX5L-BS)(YUASA) ••• 1 1 1 -


31500-KRP-981 BATTERY (YTX5L-BS)
(TIANJIN YUASA) - - - 1
2 31511-107-300 RUBBER, BATTERY CUSHION ••••• 3 3 3 3
3 32401-KPS-900 CABLE, STARTER MAGNETIC
BATTERY 1 1 1 1
4 32410-KPS-900 CABLE, STARTING MOTOR ••••••• 1 1 1 1
5 32411-253-000 COVER, STARTER MOTOR TERMINAL 1 1 1 1
6 32414-MJ6-720 COVER A, MAGNETIC SWITCH •••• 1 1 1 1
7 32414-MM9-000 COVER A, BATTERY TERMINAL ••• 1 1 1 1
8 32415-KS5-000 COVER B, MAGNETIC SWITCH •••• 1 1 1 1
9 32601-KPS-900 CABLE, BATTERY EARTH •••••••• 1 1 1 1
10 35851-MF5-751 SWITCH COMP., STARTER MAGNETIC 1 1 1 1
11 35855-MF5-751 HOLDER ASSY., FUSE •••••••••• 1 1 1 1
12 35856-MF5-751 RUBBER, SHOCK ••••••••••••••• 1 1 1 1
13 50320-KPS-900 BOX ASSY., BATTERY •••••••••• 1 1 1 1
14 50326-KPS-900 BAND, BATTERY ••••••••••••••• 1 1 1 1
15 66101-HA7-670 GROMMET, FR. FENDER SETTING • 1 1 1 1
16 80101-165-000 RUBBER, RR. FENDER CUSHION •• 1 1 1 1
17 83505-KPS-900 COLLAR, COVER MOUNTING •••••• 1 1 1 1
18 90104-KPS-900 BOLT, FLANGE, 6X20 •••••••••• 1 1 1 1
19 90311-KPS-900 NUT, CLIP, 6MM •••••••••••••• 1 1 1 1
20 90320-KPS-900 NUT, HEX., 6MM •••••••••••••• 2 2 2 2
21 90501-HA7-670 COLLAR, FENDER SETTING •••••• 1 1 1 1
22 90505-MC4-000 GROMMET A, AIR CLEANER CASE • 1 1 1 1
78
2005.05.20 E
F-23 BATTERY G16

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

23 90521-KPS-900 WASHER, SPRING, 6MM ••••••••• 2 2 2 2


24 90650-KW3-000 BAND, WIRE •••••••••••••••••• 1 1 1 1
25 98200-30750 FUSE, BLADE (7.5A) •••••••••• 2 2 2 2

79
2005.05.20 E
F-24 WIRE HARNESS H 1
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
3 6141A1 IGNITION CONTROL MODULE •••••• 0.4
4 614105 COIL, IGNITION ••••••••••••••• 0.4
6 6131B2 RECTIFIER, REGULATE •••••••••• 0.4
7 611100 HARNESS, WIRE •••••••••••••••• 0.5

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 15712-PD1-811 CLIP, BREATHER TUBE PROTECTOR 1 1 1 1


2 30401-KPS-900 CUSHION, C.D.I. UNIT •••••••• 1 1 1 1
3 30410-KPS-901 C.D.I. UNIT ••••••••••••••••• 1 1 1 1
4 30500-KPS-900 COIL ASSY., IGNITION •••••••• 1 1 1 1
5 30700-KN4-A60 CAP ASSY., NOISE SUPPRESSOR • 1 1 1 1
6 31600-GBL-871 RECTIFIER COMP., REGULATE
(SHINDENGEN) 1 1 - -
31600-GAG-K20 RECTIFIER COMP., REGULATE ••• - - 1 1
7 32100-KPS-940 HARNESS, WIRE ••••••••••••••• 1 1 1 1
8 32108-080-000 COVER, WIRE HARNESS CONNECTOR 1 1 1 1
9 50301-KPS-900 STAY, C.D.I. •••••••••••••••• 1 1 1 1
10 96001-06018-00 BOLT, FLANGE, 6X18 •••••••••• 2 2 2 2
11 90124-KPS-900 BOLT, HEX., 6X10 •••••••••••• 1 1 1 1
12 90620-SB2-003 BAND, WIRE HARNESS •••••••••• 1 1 1 1
13 90684-ZA0-601 CLIP, HARNESS ••••••••••••••• 1 1 1 1
14 91404-VM6-000 CLIP, WIRE HARNESS •••••••••• 2 2 2 2
15 91547-SF4-003 BAND, WIRE HARNESS (BLUE)
(123.5MM) 2 2 2 2
16 96001-06008-00 BOLT, FLANGE, 6X8 ••••••••••• 2 2 2 2

80
2005.05.20 E
F-25 FRAME BODY H 2
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
1 410100 BODY, FRAME •••••••••••••••••• 4.5
.INCLUDES: Engine removal and
installation
4 410135 PLATE, SKID •••••••••••••••••• 0.1

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 50100-KPS-900ZA BODY COMP., FRAME


*NH146M*
ACCURATE SILVER METALLIC 1 1 1 -
50100-KPS-730ZA *NH146M*
ACCURATE SILVER METALLIC - - - 1
2 50212-KPS-900 RUBBER, TANK GUARD •••••••••• 2 2 2 2
3 50318-GE2-000 COLLAR, ENGINE MOUNTING ••••• 1 1 1 1
4 50351-KPS-900ZA PLATE, SKID
*NH201R*...........HUSKY GRAY 1 1 1 1
5 50531-KPS-900 PLATE, R. UPPER ENGINE HANGER 1 1 1 1
6 50532-KPS-900 PLATE, L.
UPPER ENGINE HANGER 1 1 1 1
7 50533-KPS-900 PLATE, R.
FR. ENGINE HANGER • 1 1 1 1
8 50534-KPS-900 PLATE, L.
FR. ENGINE HANGER • 1 1 1 1
9 50535-KPS-900 PLATE, L.
RR. UPPER ENGINE
HANGER 1 1 1 1
10 80138-KPS-900 COLLAR, 14X5 •••••••••••••••• 1 1 1 1
11 84103-392-000 CAP, RR. BUMPER ••••••••••••• 2 2 2 2
12 90013-PL9-000 BOLT, FLANGE, 8X56 •••••••••• 2 2 2 2
13 90024-MV9-670 BOLT, FLANGE, 8X88 •••••••••• 1 1 1 1
14 90105-MG3-000 BOLT, FLANGE, 10X110 •••••••• 1 1 1 1
15 90107-KPS-900 BOLT, FLANGE, 8X16 •••••••••• 3 3 3 3
16 90111-162-000 BOLT, FLANGE, 6MM ••••••••••• 2 2 2 2
17 90152-MBN-671 BOLT, FLANGE, 10X109 •••••••• 1 1 1 1
18 90154-KB7-700 BOLT, FLANGE, 8X73 •••••••••• 2 2 2 2
19 90154-MA0-000 BOLT, FLANGE, 8X60 •••••••••• 1 1 1 1
20 90156-KK6-000 BOLT, FLANGE, 8X96 •••••••••• 1 1 1 1
81
2005.05.20 E
F-25 FRAME BODY H 3

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

21 90302-KPS-900 NUT, HEX., 10MM ••••••••••••• 1 1 1 1


22 90303-KPS-900 NUT, FLANGE, 10MM ••••••••••• 1 1 1 1
23 90306-KPS-900 NUT, FLANGE, 8MM •••••••••••• 7 7 7 7
24 90441-MT3-000 WASHER, 10MM •••••••••••••••• 1 1 1 1

82
2005.05.20 E
F-26 TOOLS H 4
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
NO INFORMATION •••••••••••••••

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 89010-KT0-830 TOOL SET •••••••••••••••••••• 1 1 1 1


2 89217-045-670 BAR, HANDLE ••••••••••••••••• 1 1 1 1
3 99004-18002 WRENCH, BOX (P18) ••••••••••• 1 1 1 1
4 99008-01600 BAG, TOOL, 160MM •••••••••••• 1 1 1 1

83
2005.05.20 E
F-27 CAUTION LABEL H 5
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
NO INFORMATION •••••••••••••••

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

3 87507-GAN-850 LABEL, DRIVE CHAIN •••••••••• 1 1 1 1


4 87560-GF8-690 LABEL, DRIVE •••••••••••••••• 1 1 1 1
5 87565-KPS-900ZA LABEL, COLOR *TYPE1*(R134) •• 1 - - -
87565-KPS-860ZA LABEL, COLOR *TYPE1*(R292) •• - 1 - -
87565-KPS-760ZA •••••••••••••••••••••••••••• - - 1 -
87565-KPS-730ZA •••••••••••••••••••••••••••• - - - 1
6 87586-GF8-640 LABEL, FUEL ••••••••••••••••• 1 - - -

84
2005.05.20 E
F-28 MARK H 6
Ref. (Relative ref. Number)
L.O.N. F.R.T.
No. Description
NO INFORMATION •••••••••••••••

Reqd. QTY
Ref.

3
Part No. Description CRF230F Serial No. Parts catalogue code
No. 3 4 5 6

1 87126-KPS-900ZA STRIPE, R. TANK SHROUD *TYPE1* 1 - - -


2 87127-KPS-900ZA STRIPE, L. TANK SHROUD *TYPE1* 1 - - -
3 87130-MBN-830ZA MARK *TYPE1*(HONDA) ••••••••• 2 2 2 2
4 87126-KPS-860ZA STRIPE, R. TANK SHROUD *TYPE1* - 1 - -
5 87127-KPS-860ZA STRIPE, L. TANK SHROUD *TYPE1* - 1 - -
6 87126-KPS-760ZA STRIPE, R. TANK SHROUD *TYPE1* - - 1 -
7 87127-KPS-760ZA STRIPE, L. TANK SHROUD *TYPE1* - - 1 -
8 87126-KPS-730ZA STRIPE, R. TANK SHROUD *TYPE1* - - - 1
9 87127-KPS-730ZA STRIPE, L. TANK SHROUD *TYPE1* - - - 1

85
2005.05.20 E
PART NO. INDEX I 1
Part Number Address Page Ref. Part Number Address Page Ref. Part Number Address Page Ref. Part Number Address Page Ref. Part Number Address Page Ref.

06000 13112-KPS-900 D14 40 6 16028-KBW-901 E2 44 10 18000 23491-KPS-900 D15 41 12


13311-KPS-900 D14 40 7 16029-KCE-670 E2 44 11 23501-KPS-900 D15 41 13
06113-KPS-900 E4 46 1 13321-KPS-900 D14 40 8 16032-KPS-901 E2 44 12 18291-KPS-900 G6 69 1 23511-KPS-900 D15 41 14
06114-KPS-900 E4 46 2 16037-KCE-670 E2 44 13 18291-MN5-650 E4 46 1 23512-KPS-900 D15 41 15
06115-KPS-900 E5 47 1 14000 16048-KB7-901 E2 44 14 G6 69 2 23513-KPS-900 D15 41 16
06116-KPS-900 E5 47 2 16075-GHB-640 E2 44 15 18292-KBR-000 G6 69 3 23801-KPS-900 D15 41 17
06381-KPS-900 D14 40 1 14100-KPS-900 D3 29 2 16100-KPS-901 E2 44 16 18300-KPS-730 G6 69 4 23811-KPS-900 D15 41 18
06405-KCR-P00 G11 74 1 14311-KN6-931 D14 40 9 16111-KBB-951 E2 44 17 18300-KPS-900 G6 69 4
06405-KCR-P10 G11 74 1 14321-KEH-900 D5 31 1 16119-429-771 E2 44 18 18320-KPS-900 G6 69 5 24000
06420-KPS-730 F14 61 1 14401-KFB-751 D5 31 2 16163-KCS-920 E2 44 19 18328-KAE-000 G6 69 6
06420-KPS-900 F14 61 1 14431-KPS-900 D3 29 3 16165-KEG-961 E2 44 20 18345-KPS-900ZA G6 69 8 24211-KPS-900 E1 43 1
06422-KPS-730 F14 61 2 14451-KPS-900 D3 29 4 16168-382-014 E2 44 21 18345-KPS-901ZA G6 69 8 24221-KPS-900 E1 43 2
06422-KPS-900 F14 61 2 14456-KPS-900 D3 29 5 16198-KPS-901 E2 44 22 18355-KPS-730 G6 69 7 24231-KPS-900 E1 43 3
06430-GBJ-J10 F13 60 1 14500-KBB-900 D5 31 3 16199-KPS-901 E2 44 23 18355-KPS-900 G6 69 7 24241-KPS-900 E1 43 4
06430-GCE-900 F13 60 1 14513-KPS-900 D5 31 4 16210-KPS-900 D1 27 9 18356-KAE-000 G6 69 9 24301-KPS-900 E1 43 5
06431-MA3-405 F10 57 1 14520-KCT-691 D5 31 5 16214-KPS-900 D1 27 10 18373-KRH-D20 G6 69 10 24411-KPS-900 E1 43 6
06441-KPS-730 F11 58 1 14523-KBB-901 D5 31 6 E4 46 1 18373-MN1-670 G6 69 10 24430-KPS-900 E1 43 7
06441-KPS-900 F11 58 1 E4 46 1 16223-KPS-900 D1 27 11 18391-MB0-891 E4 46 1 24435-KPS-900 E1 43 8
14535-KPS-900 D5 31 7 16950-GCF-671 F16 63 1 G6 69 11 24610-KT0-000 E1 43 9
11000 14550-KFB-000 D5 31 8 16997-467-000 F16 63 2 18421-KFB-000 G6 69 12 24621-446-650 E1 43 10
14711-KBB-900 D3 29 6 18422-KFB-000 G6 69 13 24631-KPS-900 E1 43 11
11100-KPS-900 D13 39 1 14721-KBB-900 D3 29 7 17000 24651-437-000 E1 43 12
11108-KHA-940 D15 41 1 14751-383-005 D3 29 8 19000 24700-KPS-900 G8 71 1
11191-KHA-940 D13 39 2 14761-383-005 D3 29 9 17213-KPS-900 G4 67 3
E5 47 1 14771-107-020 D3 29 10 17214-KPS-900 G4 67 4 19113-MB1-870 F1 48 1 28000
11200-KPS-900 D13 39 3 14775-KPS-900 D3 29 11 17216-KPS-900 G4 67 5
11330-KPS-900 D7 33 1 14776-KPS-900 D3 29 12 17217-KPS-900 G4 67 6 22000 28110-KBB-900 D12 38 1
11341-KPS-900 D10 36 1 14781-HA0-770 D3 29 13 17219-KPS-900 G4 67 7 28114-KN6-930 D12 38 2
11355-KPS-900 D10 36 2 17220-KPS-900ZA G4 67 8 22100-KPS-900 D8 34 1 28125-KW3-006 D11 37 1
11360-KPS-900 D10 36 3 15000 17222-KPS-900 G4 67 9 22121-KPS-900 D8 34 2 28130-KFB-000 D12 38 3
11393-KGA-900 D7 33 2 17230-KPS-900 G4 67 10 22125-KW7-900 D8 34 3 28132-KPS-900 D12 38 4
E5 47 1 15100-KPS-900 D9 35 1 17240-KPS-900 G4 67 11 22131-KHA-940 D8 34 4 28140-KPS-900 D12 38 5
11395-KCN-000 D10 36 4 15131-KPS-900 D9 35 2 17241-KPS-900 G4 67 12 22201-KBW-900 D8 34 5 28142-KW1-900 D12 38 6
E5 47 1 15331-KPS-900 D9 35 3 17245-KPS-900 G4 67 13 22201-KPM-850 D8 34 6
15332-KPS-900 D9 35 4 17358-170-000 G4 67 14 22201-MJ8-000 D8 34 7 30000
12000 15421-KPS-900 D13 39 5 17371-KPS-900 G4 67 15 22321-KPS-900 D8 34 8
15426-KPS-900 D13 39 6 17506-KPS-900 F16 63 3 22350-KPS-900 D8 34 9 30401-KPS-900 H1 80 2
12000-KPS-900 D1 27 1 15430-KPS-900 D9 35 5 17508-GBF-830 F16 63 4 22361-KPS-900 D8 34 10 30410-KPS-901 H1 80 3
12100-KFB-000 D6 32 1 15436-KPS-900 D9 35 6 17509-KPS-900 F16 63 5 22366-KHA-940 D8 34 11 30500-KPS-900 H1 80 4
12191-KCN-000 D6 32 2 15441-KPS-900 D9 35 7 17510-KPS-760 F16 63 6 22401-KCJ-710 D8 34 12 30700-KN4-A60 H1 80 5

4
E4 46 1 15446-KPS-900 D9 35 8 17510-KPS-900 F16 63 6 22402-KPM-850 D8 34 13
12204-KW1-305 D1 27 2 15459-KT0-710 D9 35 9 17516-KPS-900 F16 63 7 22810-KPS-900 D7 33 4 31000
12206-KW1-315 D1 27 3 E5 47 1 17521-429-000 F16 63 8 22815-KPS-900 D7 33 5
12208-413-003 D3 29 1 15650-KPS-900 D7 33 3 17545-KPS-730ZA F16 63 9 22838-KRG-000 D7 33 6 31110-KPS-901 D11 37 2
12251-KT0-711 D1 27 4 15712-PD1-811 H1 80 1 17545-KPS-760ZA F16 63 9 22870-KPS-900 F2 49 4 31120-KPS-940 D11 37 3
E4 46 1 15772-KPS-900 G4 67 1 17545-KPS-860ZA F16 63 9 31120-KPS-941 D11 37 3
12271-383-000 D1 27 5 15772-MN1-670 G4 67 2 17545-KPS-900ZA F16 63 9 23000 31200-KBB-901 D12 38 7
12331-KPS-900 D1 27 6 17555-KPS-730ZA F16 63 10 31201-KS5-901 D12 38 8
12339-KT0-710 D1 27 7 16000 17555-KPS-760ZA F16 63 10 23121-KPS-900 D9 35 10 31204-KS5-901 D12 38 9
E4 46 1 17555-KPS-860ZA F16 63 10 23211-KPS-900 D15 41 2 31205-MN4-008 D12 38 10
12361-KPS-900 D1 27 8 16010-KCE-670 E2 44 1 17555-KPS-900ZA F16 63 10 23221-KPS-900 D15 41 3 31206-KW1-901 D12 38 11
D13 39 4 16011-KCK-910 E2 44 2 17620-GEL-770 F16 63 11 23421-KPS-900 D15 41 4 31207-KS5-901 D12 38 12
16012-KPS-901 E2 44 3 17624-GEL-770 F16 63 12 23427-KPS-900 D15 41 5 31500-KRP-981 G15 78 1
13000 16013-KN4-A10 E2 44 4 17626-KPS-900 F16 63 13 23431-437-000 D15 41 6 31500-KY4-905 G15 78 1
16014-KCE-771 E2 44 5 17634-KPS-900 F16 63 14 23441-KPS-900 D15 41 7 31511-107-300 G15 78 2
13000-KPS-900 D14 40 2 16015-KPS-901 E2 44 6 17681-KPS-900 F16 63 15 23451-KPS-900 D15 41 8 31600-GAG-K20 H1 80 6
13011-KFB-305 D14 40 3 16016-393-701 E2 44 7 17910-KPS-900 F2 49 1 23452-KW1-900 D15 41 9 31600-GBL-871 H1 80 6
13101-KFB-750 D14 40 4 16018-428-671 E2 44 8 17913-KB7-000 F2 49 2 23461-KPS-900 D15 41 10
13111-440-000 D14 40 5 16019-KPS-901 E2 44 9 17920-KPS-900 F2 49 3 23471-KPS-900 D15 41 11
86
2005.05.20 E
PART NO. INDEX I 2
Part Number Address Page Ref. Part Number Address Page Ref. Part Number Address Page Ref. Part Number Address Page Ref. Part Number Address Page Ref.

32000 42635-KPS-730 F14 61 9 45215-HA5-672 F10 57 15 51447-KR6-003 F8 55 12 61000


42635-KPS-900 F14 61 9 45351-KPS-900 F11 58 15 51450-KAS-901 F8 55 13
32100-KPS-940 H1 80 7 42650-KPS-730 F14 61 10 45460-KPS-900 F6 53 1 51480-KPS-901 F8 55 14 61100-KPS-760 F7 54 1
32108-080-000 H1 80 8 42650-KPS-900 F14 61 10 45461-KPS-900 F8 55 1 51490-KR6-305 F8 55 15 61100-KPS-860ZA F7 54 1
32401-KPS-900 G15 78 3 42701-KPS-901 F14 61 11 45470-KPS-940 F5 52 4 51520-KBB-903 F8 55 16 61100-KPS-900ZA F7 54 1
32410-KPS-900 G15 78 4 42711-KPS-901 F14 61 12 45504-KN5-006 F4 51 2 51580-KPS-901 F8 55 17 61104-KB7-900 F7 54 2
32411-253-000 G15 78 5 42712-KHA-941 F14 61 13 45510-KPS-901 F4 51 3 51611-KR6-013ZH F8 55 18 61140-KCY-A30ZA F1 48 8
32414-MJ6-720 G15 78 6 42713-KW8-901 F14 61 14 45513-KCE-671 F4 51 4 51612-430-010 F8 55 19 61301-KCZ-900ZE F1 48 9
32414-MM9-000 G15 78 7 42714-KA3-710 F11 58 2 45517-GW0-751 F4 51 5 51634-MA0-003 F8 55 20 61301-KPS-780 F1 48 9
32415-KS5-000 G15 78 8 F14 61 15 45518-KA3-731 F4 51 6 61301-KPS-880ZA F1 48 9
32601-KPS-900 G15 78 9 42715-KA2-680 F15 62 16 45520-KA3-731 F4 51 7 52000 61314-KPS-940 F5 52 10
32976-KN6-910 D11 37 4 45523-KA3-731 F4 51 8 61317-KPS-940 F5 52 12
32976-KW1-900 D10 36 5 43000 45530-KPS-901 F4 51 9 52101-KPS-900 G11 74 3 61318-KPS-940 F6 53 6
52141-KPS-900 G11 74 4 61319-KPS-940 F5 52 13
33000 43100-KPS-900ZA F13 60 2 46000 52144-356-003 G11 74 5
43107-MBG-006 F10 57 2 52144-356-005 G11 74 5 66000
33103-KF0-670 F1 48 2 43141-KFC-790 F13 60 3 46500-KPS-730 G8 71 17 52146-KPS-900 G11 74 6
33107-246-003 F1 48 3 43142-KPS-900 F13 60 4 46500-KPS-900 G8 71 6 52147-MN1-670 G11 74 7 66101-HA7-670 G15 78 15
33117-KA2-003 F1 48 4 43145-KB7-000 F13 60 5 46513-KPS-900 G8 71 7 52156-KAS-900 G3 66 1
33123-KCY-670 F1 48 5 43151-110-000 F13 60 6 46515-KY7-000 G8 71 8 52159-KPE-900 G11 74 8 77000
33130-KCY-670 F1 48 6 43352-568-003 F10 57 3 46525-KK0-003 G8 71 9 52170-KPS-900 G11 74 9
43353-461-771 F10 57 4 52171-KPS-900 G11 74 10 77200-KPS-860 G2 65 1
34000 43410-KPS-900 F13 60 7 50000 52175-KPS-900 G11 74 11 77200-KPS-900 G2 65 1
43411-KHA-940 F13 60 8 52185-KPS-900 G11 74 12 77213-KPS-860 G2 65 2
34901-MN1-671 F1 48 7 43451-KPS-900 G8 71 2 50100-KPS-730ZA H2 81 1 52200-KPS-900 G11 74 13 77213-KPS-900 G2 65 2
43453-KPS-900 G8 71 3 50100-KPS-900ZA H2 81 1 52400-KPS-901 G13 76 1
35000 43454-KPS-900 G8 71 4 50212-KPS-900 H2 81 2 52462-KPS-900 G13 76 2 80000
43472-KPS-900 G8 71 5 50301-KPS-900 H1 80 9 52463-KPE-900 G13 76 3
35100-KPS-900 F5 52 2 50318-GE2-000 H2 81 3 52464-KPE-900 G13 76 4 80101-165-000 G15 78 16
35121-HF1-881 F5 52 3 44000 50320-KPS-900 G15 78 13 52465-KPS-900 G13 76 5 80101-KPS-760ZA G14 77 6
35122-HF1-881 F5 52 3 50326-KPS-900 G15 78 14 52472-KPS-900 G13 76 6 80101-KPS-860ZA G14 77 6
35130-KPS-900 F2 49 5 44301-KPS-900 F11 58 3 50351-KPS-900ZA H2 81 4 52475-KPS-900 G13 76 7 80101-KPS-900ZA G14 77 6
35150-KPS-900 F2 49 6 44311-KPS-900 F11 58 4 50530-KPS-730 G10 73 1 80138-KPS-900 H2 81 10
35330-MK5-003 F2 49 7 44312-KPS-900 F11 58 5 50530-KPS-900 G10 73 1 53000
35750-GS3-003 D11 37 5 44610-KL3-770 F11 58 6 50531-KPS-900 H2 81 5 83000
35752-028-300 D11 37 6 44620-KPS-900 F11 58 7 50532-KPS-900 H2 81 6 53100-KPS-900ZA F5 52 5
35753-KG2-951 E1 43 13 44635-KPS-730 F11 58 8 50533-KPS-900 H2 81 7 53100-KPS-901ZA F5 52 5 83500-KPS-900ZA G3 66 2
35851-MF5-751 G15 78 10 44635-KPS-900 F11 58 8 50534-KPS-900 H2 81 8 53131-KBB-950ZA F5 52 6 83505-KM4-000 G14 77 7
35855-MF5-751 G15 78 11 44650-KPS-730 F11 58 9 50535-KN5-670 G10 73 2 53140-KPS-901 F2 49 8 83505-KPS-900 G4 67 16
35856-MF5-751 G15 78 12 44650-KPS-900 F11 58 9 50535-KPS-900 H2 81 9 53165-MK5-010 F2 49 9 G15 78 17

4
44701-KPS-901 F11 58 10 50603-KPS-900 G9 72 1 53166-MK5-010 F2 49 10 83512-KA4-700 G6 69 14
40000 44711-KPS-901 F11 58 11 50612-KPS-900 G9 72 2 53167-KPS-900 F2 49 11 83551-376-000 G3 66 3
44712-MAN-622 F11 58 12 50615-KPS-900 G9 72 3 53168-KPS-900 F2 49 12 83600-KPS-900ZA G3 66 4
40535-KCR-305 G11 74 2 44713-KW8-901 F11 58 13 50617-466-000 G9 72 4 53169-KPE-900 F2 49 13 83601-KPS-900ZB G3 66 5
40535-KCR-306 G11 74 2 44715-MA0-770 F11 58 14 50642-KPS-900 G9 72 5 53172-KPS-900 F2 49 14 83601-MB0-000 G3 66 6
40544-KPS-730 F14 61 3 50645-KPS-900 G9 72 6 53174-116-670 F2 49 16
40544-KPS-900 F14 61 3 45000 53174-KN5-006 F4 51 10 84000
40545-KPS-730 F14 61 4 51000 53174-KPS-900 F2 49 15
40545-KPS-900 F14 61 4 45105-MY6-405 F10 57 5 53175-KCE-670 F4 51 11 84103-392-000 H2 81 11
45108-MY1-006 F10 57 6 51401-KPS-901 F8 55 2 53176-ML3-791 F4 51 12 84706-415-000 F16 63 16
41000 45112-KS6-701 F10 57 7 51410-KPS-901 F8 55 3 53177-KS5-700 F2 49 17
45125-KPS-941 F4 51 1 51411-MG1-003 F8 55 4 53178-KPS-900 F2 49 18 86000
41201-KPS-900 F14 61 5 45131-HA5-672 F10 57 8 51412-461-003 F8 55 5 53192-268-000 F2 49 19
45132-166-016 F10 57 10 51414-MN4-003 F8 55 6 53214-KA3-732 F6 53 2 86150-KPG-902 F5 52 15
42000 45133-MA3-006 F10 57 11 51415-KS5-003 F8 55 7 53214-KA4-701 F6 53 3 86150-MN8-300 F5 52 15
45134-KB7-005 F13 60 9 51420-KBB-903 F8 55 8 53219-KPS-900 F6 53 4
42301-KPS-900 F14 61 6 45150-KZ4-J21 F10 57 12 51432-KCN-003 F8 55 9 53229-KPS-900 F6 53 5 87000
42312-KPS-900 F14 61 7 45190-KZ4-J21 F10 57 13 51437-ME4-003 F8 55 10 53300-KPS-760 F5 52 7
42620-KPS-900 F14 61 8 45203-MG3-016 F10 57 14 51440-KPS-901 F8 55 11 53300-KPS-900 F5 52 7 87126-KPS-730ZA H6 85 8
87
2005.05.20 E
PART NO. INDEX I 3
Part Number Address Page Ref. Part Number Address Page Ref. Part Number Address Page Ref. Part Number Address Page Ref. Part Number Address Page Ref.

87126-KPS-760ZA H6 85 6 90102-KPS-900 G13 76 11 90305-GW2-711 F15 62 18 90659-734-K51 F5 52 21 91304-KPS-900 D9 35 19


87126-KPS-860ZA H6 85 4 90103-KV3-830 F16 63 17 90305-KPS-900 G6 69 16 90684-ZA0-601 H1 80 13 E5 47 2
87126-KPS-900ZA H6 85 1 G3 66 7 90306-KF0-003 G13 76 14 90702-KPS-900 D1 27 19 91304-MN5-003 D10 36 13
87127-KPS-730ZA H6 85 9 90103-MBN-670 F5 52 16 90306-KPS-900 G2 65 3 D7 33 8 91306-105-690 D5 31 14
87127-KPS-760ZA H6 85 7 90103-MY6-670 G11 74 14 H3 82 23 90703-KPS-900 D10 36 10 E4 46 2
87127-KPS-860ZA H6 85 5 90104-KPS-900 D1 27 15 90309-ML3-791 F15 62 19 D13 39 10 91307-035-000 D7 33 10
87127-KPS-900ZA H6 85 2 D10 36 9 90311-KPS-900 G4 67 19 90704-KPS-900 D6 32 3 E5 47 2
87130-MBN-830ZA H6 85 3 G4 67 17 G15 78 19 90741-KFB-000 D14 40 10 91309-425-003 D12 38 16
87507-GAN-850 H5 84 3 G15 78 18 90320-KPS-900 G15 78 20 90751-KPS-900 D9 35 18 91312-107-000 D11 37 11
87516-KV6-610 G13 76 8 90105-KAE-870 F11 58 16 90321-315-670 F2 49 24 90752-KPS-900 E1 43 18 91320-MB0-000 D12 38 17
87560-GF8-690 H5 84 4 90105-KPS-900 G8 71 11 90401-KW1-900 D12 38 15 90755-229-003 F11 58 18 91357-ME4-003 F9 56 25
87565-KPS-730ZA H5 84 5 90105-MG3-000 H2 81 14 90403-KPS-900 D11 37 10 90755-229-005 F11 58 18 91404-VM6-000 H1 80 14
87565-KPS-760ZA H5 84 5 90106-KPS-900 G11 74 15 90408-KPS-900 E1 43 16 91463-KPS-900 G4 67 23
87565-KPS-860ZA H5 84 5 90107-KF0-000 F6 53 7 90434-KPS-900 D8 34 16 91000 91547-SF4-003 H1 80 15
87565-KPS-900ZA H5 84 5 90107-KPS-900 H2 81 15 D9 35 16
87586-GF8-640 H5 84 6 90108-MJ0-000 G10 73 3 90441-MT3-000 H3 82 24 91001-KBW-941 D14 40 11 92000
90111-162-000 H2 81 16 90442-KPS-900 D1 27 17 91001-KCN-003 D14 40 12
89000 90111-187-000 G3 66 8 E4 46 2 91005-KCN-003 D16 42 30 92101-05010-0A G5 68 24
90111-KPS-900 G4 67 18 90443-KPS-900 D1 27 18 91008-KCN-003 D13 39 11 92900-06025-0E F9 56 26
89010-KT0-830 H4 83 1 90111-ML3-791 F4 51 13 90451-365-000 D15 41 21 91008-KPS-900 D8 34 18
89217-045-670 H4 83 2 90112-KPS-900 D9 35 12 90451-KPS-900 D15 41 20 91013-KPS-731 F15 62 25 93000
90113-HA0-770 F2 49 20 90452-KPS-900 D15 41 22 91013-KPS-732 F15 62 25
90000 90114-166-006 F4 51 14 90453-KPS-900 E1 43 17 91014-KPS-731 F12 59 22 93404-06025-07 G3 66 9
90114-KPS-900 D1 27 16 90454-KPS-900 D16 42 23 91014-KPS-732 F12 59 22 93500-03025-0A F9 56 27
90001-KPS-900 D10 36 6 90115-KPS-900 G11 74 16 90455-KPS-900 D16 42 24 91015-425-831 F6 53 9 93500-04012-1A F3 50 27
90002-KPS-900 D5 31 9 90116-KV3-701 F8 55 21 90461-KPS-900 D8 34 17 10 93500-05016-0A F3 50 28
90003-KPS-900 D1 27 12 90116-ME9-000 G14 77 9 90463-437-000 D16 42 25 91015-425-832 F6 53 10 93500-05016-0G F3 50 29
90004-GHB-700 D1 27 13 90117-KPS-900 F13 60 10 90464-360-000 D16 42 26 91015-KK6-003 D16 42 31 93500-05028-0G G5 68 25
90004-KPS-900 D13 39 7 90120-KPS-900 F2 49 21 90465-360-000 D16 42 27 91016-KPS-900 D16 42 32 93500-06018-0A G1 64 23
90005-KPS-900 D12 38 13 90121-KPS-900 F2 49 22 90465-MC4-000 F15 62 20 91051-KPS-731 F15 62 26 93600-04012-1G F4 51 18
90005-KY7-000 D5 31 10 90124-KPS-900 H1 80 11 90471-KGA-900 D9 35 17 91051-KPS-732 F15 62 26 93600-05010-1H E2 44 24
90010-KPS-900 D9 35 11 90125-KA4-000 F15 62 17 90475-703-000 D5 31 12 91070-KPE-901 G12 75 19 93600-06045-0A G12 75 20
90010-ML0-720 G8 71 10 90131-KPS-900 F10 57 16 90488-425-000 D5 31 13 91071-KV3-005 G13 76 15 93891-05012-07 G5 68 26
90011-KPS-900 D15 41 19 90137-KA3-830 G1 64 18 E4 46 2 91071-MY1-005 G13 76 16 93892-03008-18 E2 44 25
90012-KN6-930 D3 29 14 90145-MS9-612 F4 51 15 90501-HA7-670 G15 78 21 91072-MY1-005 G13 76 17 93892-04010-18 E3 45 26
90012-KPS-900 E1 43 14 90152-MBN-671 H2 81 17 90501-KPS-900 G8 71 12 91102-KPS-900 E1 43 19 93892-04012-18 E3 45 27
90013-PL9-000 H2 81 12 90154-KB7-700 H2 81 18 90501-KRE-900 G8 71 12 91201-148-003 D7 33 9 93892-04014-18 E3 45 28
90023-KPS-900 E1 43 15 90154-KPS-900 G13 76 12 90502-KPS-900 G9 72 8 91202-965-003 D13 39 12 93892-04016-18 E3 45 29
90023-KS4-000 F7 54 3 90154-MA0-000 H2 81 19 90503-898-000 G1 64 19 91216-KGH-901 D16 42 33 93901-32320 F2 49 23
90024-MV9-670 H2 81 13 90156-KK6-000 H2 81 20 90503-KPS-900 F5 52 19 91253-033-003 F15 62 22 93901-34210 F1 48 12

4
90031-KFB-000 D13 39 8 90181-MCT-000 G9 72 7 90505-MC4-000 G4 67 20 91254-KA3-831 F11 58 19 93903-25210 G5 68 27
90032-GHR-740 F13 60 10 90201-415-000 F6 53 8 G15 78 22 91254-KR6-003 F8 55 24 93913-24120 G3 66 10
90032-KFB-000 D13 39 9 90201-MCG-000 F1 48 11 90511-KPS-900 F7 54 4 91254-KS6-003 G13 76 18
90035-KG8-900 D7 33 7 90203-MF9-710 G10 73 4 90520-134-000 G4 67 21 91262-KV3-831 G13 76 19 94000
90040-GHR-650 F9 56 28 90204-KPS-900 F11 58 17 90520-KPS-900 F2 49 25 91301-107-000 D1 27 21
90040-GHR-690 F4 51 20 90206-250-000 D3 29 15 90521-KPS-900 G16 79 23 E4 46 2 94001-05070-0S G5 68 28
90041-KW1-900 D1 27 14 90211-KPS-900 D9 35 13 90522-KF0-000 G1 64 20 91301-KW1-900 D1 27 20 94001-06000-0S G8 71 13
90050-KPS-900 D8 34 14 90212-KPS-900 D3 29 16 90544-283-000 F8 55 23 91302-567-003 D10 36 11 94001-08000-0S F11 58 20
90071-MB0-000 D12 38 14 90213-KPS-900 D9 35 14 90545-300-000 F4 51 16 E5 47 2 F15 62 23
90071-MG8-000 D5 31 11 90231-KB5-720 D8 34 15 90559-KPS-900 F15 62 21 91303-377-000 D10 36 12 94021-05020-0S G5 68 29
90084-KPS-900 D10 36 7 90231-KPS-900 D9 35 15 90601-KPS-900 D16 42 28 E5 47 2 94050-06000 F3 50 30
90085-413-781 D11 37 7 90301-473-003 F8 55 22 90605-KPS-900 D16 42 29 91303-KK3-830 D1 27 22 F4 51 19
90087-KPS-900 D10 36 8 F13 60 11 90620-SB2-003 H1 80 12 D13 39 13 94050-08070 G6 69 17
90089-HB3-000 D11 37 8 G12 75 17 90650-KW3-000 F3 50 26 E4 46 2 94101-06000 D1 27 24
90101-KBH-003 D11 37 9 90302-KPS-900 H3 82 21 G16 79 24 E5 47 2 94102-08700 G12 75 21
90101-KCE-000 G6 69 15 90303-KPS-900 H3 82 22 90651-KPS-900 G1 64 21 91304-HB3-003 D1 27 23 94103-08700 G6 69 18
90101-KPS-900 G13 76 9 90304-GE8-003 G13 76 13 90651-MA5-671 F4 51 17 E4 46 2 94111-04000 F3 50 31
90101-ML3-840 F1 48 10 90304-KPS-900 F5 52 18 90652-KPS-900 G4 67 22 91304-KGA-940 D10 36 13 94111-08000 F12 59 21
90102-KFB-000 G13 76 10 90305-GE8-003 G12 75 18 90653-HC4-900 G1 64 22 E5 47 2 F15 62 24
88
2005.05.20 E
PART NO. INDEX I 4
Part Number Address Page Ref. Part Number Address Page Ref. Part Number Address Page Ref. Part Number Address Page Ref. Part Number Address Page Ref.

94201-20120 G8 71 14 99103-MT2-0350 E3 45 31
94201-20150 G9 72 9 99103-MT2-0380 E3 45 31
G12 75 22 99103-MT2-0400 E3 45 31
94201-30280 G8 71 15 99103-MT2-0420 E3 45 31
94305-30102 D7 33 11 99103-MT2-0450 E3 45 31
94510-12000 E1 43 20 99103-MT2-0480 E3 45 31
94510-14000 E1 43 21 99113-GHB-0920 E3 45 32
99113-GHB-0950 E3 45 32
95000 99113-GHB-0980 E3 45 32
99113-GHB-1000 E3 45 32
95002-02659 E3 45 30 99113-GHB-1020 E3 45 32
95015-42000 G8 71 16 99113-GHB-1050 E3 45 32
95701-06012-00 D5 31 15 99113-GHB-1080 E3 45 32
F5 52 23 99113-GHB-1100 E3 45 32
95701-08025-00 G2 65 4 99113-GHB-1120 E3 45 32
95701-08030-07 G6 69 19
95701-08040-07 G6 69 20
95701-08045-07 G7 70 21
95801-06032-00 D12 38 18
96000
96001-06008-00 H1 80 16
96001-06008-07 G7 70 22
96001-06016-00 G1 64 24
96001-06018-00 H1 80 10
96001-06022-00 F4 51 20
96001-06025-00 D10 36 14
96001-06032-00 D11 37 12
96001-06040-00 D7 33 12
D10 36 15
96001-06050-00 D7 33 13
D10 36 16
D13 39 14
96001-06060-00 D10 36 17
96001-06070-00 D10 36 18
96140-62020-10 F12 59 22
96140-62030-10 F15 62 25
96140-63030-10 F15 62 26
96300-06020-00 F7 54 5

4
96300-08035-00 F5 52 24
96500-06014-00 F9 56 28
96600-08018-18 D16 42 34
96700-06125-10 D1 27 25
98000
98069-57916 D2 28 26
98069-57926 D2 28 26
98069-58916 D2 28 26
98069-58926 D2 28 26
98200-30750 G16 79 25
99000
99004-18002 H4 83 3
99008-01600 H4 83 4
99103-KPS-0500 E3 45 31
99103-KPS-0520 E3 45 31
89
2005.05.20 E
PART NAME INDEX J 1
Part name Address Page Ref. Part name Address Page Ref. Part name Address Page Ref.

[A ] BOLT, FLANGE SOCKET, 6X16 ••••• D5 31 11 BOLT, FLANGE, 8X60•••••••••••• H2 81 19


BOLT, FLANGE, 10X100 •••••••••• G13 76 9 BOLT, FLANGE, 8X73•••••••••••• H2 81 18
ADJUSTER, L. CHAIN ••••••••••• F14 61 4 BOLT, FLANGE, 10X109 •••••••••• H2 81 17 BOLT, FLANGE, 8X88•••••••••••• H2 81 13
ADJUSTER, R. CHAIN ••••••••••• F14 61 3 BOLT, FLANGE, 10X110 •••••••••• H2 81 14 BOLT, FLANGE, 8X96•••••••••••• H2 81 20
ARM COMP., L. STEP ••••••••••• G9 72 6 BOLT, FLANGE, 10X118 •••••••••• G13 76 11 BOLT, HANDLE LEVER PIVOT•••••• F2 49 20
ARM COMP., R. STEP ••••••••••• G9 72 3 BOLT, FLANGE, 10X52 ••••••••••• G13 76 12 F4 51 14
ARM SET, LINK •••••••••••••••• E2 44 8 BOLT, FLANGE, 10X65 ••••••••••• D11 37 9 BOLT, HEX., 5X10•••••••••••••• G5 68 24
ARM SUB ASSY., CUSHION ••••••• G13 76 5 BOLT, FLANGE, 12X78 ••••••••••• G13 76 10 BOLT, HEX., 5X20•••••••••••••• D9 35 11
ARM, RR. BRAKE ••••••••••••••• F13 60 7 BOLT, FLANGE, 6MM••••••••••••• G3 66 8 BOLT, HEX., 6X10•••••••••••••• H1 80 11
ARM, VALVE ROCKER •••••••••••• D3 29 3 G4 67 18 BOLT, HEX., 6X20•••••••••••••• G8 71 11
ARRESTER ASSY. ••••••••••••••• G6 69 7 G14 77 9 BOLT, HEX., 6X25•••••••••••••• D15 41 19
AXLE, FR. WHEEL •••••••••••••• F11 58 3 H2 81 16 E1 43 14
AXLE, RR. WHEEL •••••••••••••• F14 61 6 BOLT, FLANGE, 6X10•••••••••••• D5 31 9 BOLT, OIL, 10X22•••••••••••••• F4 51 15
G6 69 15 BOLT, SETTING••••••••••••••••• D12 38 10
[B ] BOLT, FLANGE, 6X12•••••••••••• D5 31 15 BOLT, SHROUD SETTING•••••••••• F1 48 10
F5 52 23 BOLT, SIDE STAND PIVOT•••••••• G10 73 3
BAG, TOOL, 160MM ••••••••••••• H4 83 4 BOLT, FLANGE, 6X14•••••••••••• D10 36 6 BOLT, SOCKET, 10X45••••••••••• G9 72 7
BAND, AIR CLEANER CONNECTING F9 56 28 BOLT, SOCKET, 5X14•••••••••••• D11 37 8
TUBE G4 67 22 BOLT, FLANGE, 6X16•••••••••••• G1 64 24 BOLT, SOCKET, 6MM••••••••••••• D11 37 7
BAND, BATTERY •••••••••••••••• G15 78 14 G11 74 14 BOLT, SOCKET, 6X125••••••••••• D1 27 25
BAND, EX. PIPE ••••••••••••••• G6 69 10 BOLT, FLANGE, 6X18•••••••••••• H1 80 10 BOLT, SOCKET, 8MM••••••••••••• F8 55 21
BAND, FR. FORK BOOT •••••••••• F8 55 19 BOLT, FLANGE, 6X20•••••••••••• D1 27 15 BOLT, SOCKET, 8X18•••••••••••• D16 42 34
BAND, INSULATOR •••••••••••••• D1 27 11 D10 36 9 BOLT, SPECIAL FLANGE, 6X22•••• D8 34 14
BAND, R. EX. PIPE •••••••••••• G6 69 10 F7 54 5 BOLT, STUD, 6X25•••••••••••••• F9 56 26
BAND, TANK RR. ••••••••••••••• F16 63 7 G4 67 17 BOLT, STUD, 7X35•••••••••••••• D1 27 14
BAND, WIRE ••••••••••••••••••• F3 50 26 G8 71 10 BOLT, SWINGARM PIVOT•••••••••• G11 74 3
G16 79 24 G15 78 18 BOLT, TENSIONER PIVOT••••••••• D5 31 7
BAND, WIRE HARNESS ••••••••••• H1 80 12 BOLT, FLANGE, 6X22•••••••••••• D1 27 12 BOLT, WIRE ADJUSTING•••••••••• F2 49 19
15 F4 51 20 BOOT B•••••••••••••••••••••••• F10 57 11
BAR COMP., SIDE STAND •••••••• G10 73 1 BOLT, FLANGE, 6X25•••••••••••• D10 36 14 BOOT COMP.•••••••••••••••••••• F4 51 2
BAR, HANDLE •••••••••••••••••• H4 83 2 BOLT, FLANGE, 6X28•••••••••••• G11 74 15 BOOT, FR. FORK•••••••••••••••• F8 55 18
BATTERY •••••••••••••••••••••• G15 78 1 BOLT, FLANGE, 6X32•••••••••••• D11 37 12 BOOT, PIN BUSH•••••••••••••••• F10 57 10
BEARING, BALL RADIAL, 6202U •• F12 59 22 D12 38 18 BOX ASSY., BATTERY•••••••••••• G15 78 13
BEARING, BALL RADIAL, 6203U •• F15 62 25 F7 54 3 BRACKET SUB ASSY., L. FR.
BEARING, BALL RADIAL, 6303U •• F15 62 26 BOLT, FLANGE, 6X35•••••••••••• D1 27 13 CALIPER F10 57 13
BEARING, HEAD PIPE UPPER ••••• F6 53 9 F13 60 10 BRACKET, FUEL TANK FR.•••••••• F16 63 14
10 BOLT, FLANGE, 6X40•••••••••••• D7 33 12 BRACKET, L. HANDLE LEVER•••••• F2 49 14
BEARING, NEEDLE •••••••••••••• G13 76 15 D10 36 15 BRIDGE COMP., FORK TOP•••••••• F5 52 7
BEARING, NEEDLE, 17X24X17 •••• G13 76 16 G1 64 18 BULB, HEADLIGHT••••••••••••••• F1 48 7
BEARING, NEEDLE, 20X26X20 •••• G12 75 19 BOLT, FLANGE, 6X43•••••••••••• D7 33 7 BUSH, 20MM•••••••••••••••••••• D15 41 6
G13 76 17 BOLT, FLANGE, 6X50•••••••••••• D7 33 13 BUSH, 20X23X9••••••••••••••••• D15 41 9
BEARING, NEEDLE, 21MM •••••••• D13 39 11 D10 36 16 BUSH, GUIDE••••••••••••••••••• F8 55 6
BEARING, RADIAL BALL, 16003 •• D8 34 18 D13 39 14 BUSH, SLIDER•••••••••••••••••• F8 55 7
BEARING, RADIAL BALL, 20X55X11 D16 42 30 BOLT, FLANGE, 6X55•••••••••••• D13 39 7
BEARING, RADIAL BALL, 28X72X18 D14 40 12 BOLT, FLANGE, 6X60•••••••••••• D10 36 17 [C ]
BEARING, RADIAL BALL, 6202U •• D16 42 31 D12 38 13
F12 59 22 BOLT, FLANGE, 6X70•••••••••••• D10 36 18 CABLE COMP. B, THROTTLE••••••• F2 49 3
BEARING, RADIAL BALL, 6203U •• F15 62 25 BOLT, FLANGE, 6X8••••••••••••• G7 70 22 CABLE COMP., CLUTCH••••••••••• F2 49 4
BEARING, RADIAL BALL, 6204 ••• D16 42 32 H1 80 16 CABLE COMP., THROTTLE••••••••• F2 49 1
BEARING, RADIAL BALL, 6207 ••• D14 40 11 BOLT, FLANGE, 8X16•••••••••••• H2 81 15 CABLE, BATTERY EARTH•••••••••• G15 78 9
BEARING, RADIAL BALL, 6303U •• F15 62 26 BOLT, FLANGE, 8X25•••••••••••• G2 65 4 CABLE, STARTER MAGNETIC
BODY COMP., FRAME •••••••••••• H2 81 1 BOLT, FLANGE, 8X30•••••••••••• G6 69 19 BATTERY G15 78 3

5
BOLT-WASHER, 6X25 •••••••••••• G3 66 9 BOLT, FLANGE, 8X35•••••••••••• F5 52 24 CABLE, STARTING MOTOR••••••••• G15 78 4
BOLT A, PIN •••••••••••••••••• F10 57 8 BOLT, FLANGE, 8X40•••••••••••• F6 53 7 CALIPER SUB ASSY., L. FR.
BOLT COMP., FR. FORK ••••••••• F8 55 13 F10 57 16 BRAKE F10 57 12
BOLT SET, ADJUSTER ••••••••••• F4 51 13 G6 69 20 CAMSHAFT COMP.•••••••••••••••• D3 29 2
BOLT, CYLINDER STUD •••••••••• D13 39 8 BOLT, FLANGE, 8X42•••••••••••• F5 52 16 CAM, GEARSHIFT•••••••••••••••• E1 43 6
9 BOLT, FLANGE, 8X45•••••••••••• G7 70 21 CAM, RR. BRAKE•••••••••••••••• F13 60 3
BOLT, DISK, 6X17 ••••••••••••• F11 58 16 BOLT, FLANGE, 8X56•••••••••••• H2 81 12 CAP ASSY., FUEL TANK•••••••••• F16 63 11
90
2005.05.20 E
PART NAME INDEX J 2
Part name Address Page Ref. Part name Address Page Ref. Part name Address Page Ref.

CAP ASSY., NOISE SUPPRESSOR •• H1 80 5 COLLAR, RR. AXLE DISTANCE ••••• F14 61 8 DUST SEAL••••••••••••••••••••• F8 55 24
CAP, 14MM •••••••••••••••••••• D10 36 7 COLLAR, RR. WHEEL••••••••••••• F14 61 7 DUST SEAL, 17X20X2.5•••••••••• G8 71 9
CAP, 30MM •••••••••••••••••••• D10 36 8 COLLAR, SIDE COVER SETTING •••• G1 64 20 DUST SEAL, 17X24X5•••••••••••• G13 76 19
CAP, BLEEDER ••••••••••••••••• F10 57 4 COLLAR, SILENCER MOUNTING ••••• G6 69 9 DUST SEAL, 20X26X4.5•••••••••• G13 76 18
CAP, IN. DUCT •••••••••••••••• G4 67 12 COLLAR, STARTING DRIVEN GEAR•• D12 38 2 DUST SEAL, 22X50X5•••••••••••• F11 58 19
CAP, MASTER CYLINDER ••••••••• F4 51 4 COLLAR, SWINGARM PIVOT CENTER DUST SEAL, BRAKE CAM•••••••••• F13 60 9
CAP, OIL FILTER ROTOR •••••••• D9 35 6 DISTANCE G11 74 4 DUST SEAL, STEERING HEAD•••••• F6 53 2
CAP, RR. BUMPER •••••••••••••• H2 81 11 COLLAR, TANK SETTING •••••••••• F16 63 5 3
CAP, SWINGARM DUST SEAL •••••• G11 74 5 13
CAP, TAPPET ADJUSTING HOLE ••• D1 27 8 COLLAR, TOOL BOX SETTING•••••• G14 77 7 [E ]
D13 39 4 CONTACT, NEUTRAL SWITCH••••••• D11 37 5
CAP, VALVE ••••••••••••••••••• F11 58 2 COTTER, VALVE••••••••••••••••• D3 29 13 ELEMENT, AIR CLEANER•••••••••• G4 67 3
F14 61 15 COUNTERSHAFT, TRANSMISSION •••• D15 41 3 EMBLEM, PRODUCT••••••••••••••• F5 52 15
CARBURETOR ASSY. ••••••••••••• E2 44 16 COVER A, BATTERY TERMINAL ••••• G15 78 7 EMBLEM, WING MARK••••••••••••• F5 52 15
CASE COMP., L. BOTTOM •••••••• F8 55 16 COVER A, MAGNETIC SWITCH•••••• G15 78 6
CASE COMP., R. BOTTOM •••••••• F8 55 8 COVER B, MAGNETIC SWITCH•••••• G15 78 8 [F ]
CASE, AIR CLEANER •••••••••••• G4 67 10 COVER COMP., R. CRANKCASE ••••• D7 33 1
CASE, HEADLIGHT •••••••••••••• F1 48 9 COVER, AIR CLEANER CASE••••••• G4 67 8 FENDER SET, RR.••••••••••••••• G14 77 6
CENTER COMP., CLUTCH ••••••••• D8 34 2 COVER, BATTERY BOX•••••••••••• G3 66 5 FENDER, FR.••••••••••••••••••• F7 54 1
CHAIN SET, DRIVE ••••••••••••• G11 74 1 COVER, FR. HUB •••••••••••••••• F11 58 6 FLAP, TIRE•••••••••••••••••••• F11 58 13
CHAIN, CAM ••••••••••••••••••• D5 31 2 COVER, L. CRANKCASE ••••••••••• D10 36 1 F14 61 14
CHAMBER SET, FLOAT ••••••••••• E2 44 6 COVER, L. CYLINDER HEAD••••••• D1 27 6 FLOAT SET••••••••••••••••••••• E2 44 4
CIRCLIP •••••••••••••••••••••• F4 51 17 COVER, L. HANDLE LEVER•••••••• F2 49 17 FLYWHEEL COMP.•••••••••••••••• D11 37 2
CIRCLIP, EXTERNAL, 12MM •••••• E1 43 20 COVER, L. RR. CRANKCASE••••••• D10 36 3 FORK SUB ASSY., L. FR.•••••••• F8 55 17
CIRCLIP, EXTERNAL, 14MM •••••• E1 43 21 COVER, L. SIDE •••••••••••••••• G3 66 4 FORK SUB ASSY., R. FR.•••••••• F8 55 14
CIRCLIP, EXTERNAL, 22MM •••••• D16 42 28 COVER, REDUCTION GEAR••••••••• D10 36 2 FORK, CENTER GEARSHIFT•••••••• E1 43 3
CLAMPER A, BRAKE HOSE •••••••• F8 55 1 COVER, RR. BRAKE ARM •••••••••• F13 60 8 FORK, L. GEARSHIFT•••••••••••• E1 43 2
CLAMPER, A.C. GENERATOR CORD • D10 36 5 COVER, R. HANDLE LEVER•••••••• F4 51 12 FORK, R. GEARSHIFT•••••••••••• E1 43 1
CLIP B, BREATHER TUBE •••••••• G4 67 2 COVER, R. SIDE •••••••••••••••• G3 66 2 FUSE, BLADE••••••••••••••••••• G16 79 25
CLIP, BREATHER TUBE •••••••••• G4 67 1 COVER, STARTER MOTOR TERMINAL• G15 78 5
CLIP, BREATHER TUBE PROTECTOR H1 80 1 COVER, THROTTLE CABLE••••••••• F2 49 2 [G ]
CLIP, HARNESS •••••••••••••••• F5 52 21 COVER, WIRE HARNESS CONNECTOR• H1 80 8
H1 80 13 CRANKCASE COMP., L. ••••••••••• D13 39 3 GASKET SET•••••••••••••••••••• E2 44 1
CLIP, MUDGUARD ••••••••••••••• G1 64 22 CRANKCASE COMP., R. ••••••••••• D13 39 1 GASKET SHEET KIT A•••••••••••• E4 46 1
CLIP, PISTON PIN, 15MM ••••••• D14 40 6 CRANKSHAFT COMP.•••••••••••••• D14 40 2 GASKET SHEET KIT B•••••••••••• E5 47 1
CLIP, TUBE ••••••••••••••••••• E3 45 30 CRANKSHAFT, L. •••••••••••••••• D14 40 8 GASKET, CARBURETOR INSULATOR•• D1 27 10
G1 64 21 CRANKSHAFT, R. •••••••••••••••• D14 40 7 E4 46 1
CLIP, WIRE HARNESS ••••••••••• H1 80 14 CUSHION ASSY., RR.•••••••••••• G13 76 1 GASKET, CRANKCASE••••••••••••• D13 39 2
CLUTCH COMP., STARTING ONE WAY D11 37 1 CUSHION, C.D.I. UNIT •••••••••• H1 80 2 E5 47 1
COCK ASSY., FUEL ••••••••••••• F16 63 1 CYLINDER COMP. •••••••••••••••• D6 32 1 GASKET, CYLINDER•••••••••••••• D6 32 2
COIL ASSY., IGNITION ••••••••• H1 80 4 CYLINDER SET, MASTER •••••••••• F4 51 9 E4 46 1
COLLAR ••••••••••••••••••••••• F16 63 16 CYLINDER SUB ASSY., FR. BRAKE GASKET, CYLINDER HEAD••••••••• D1 27 4
COLLAR A, CUSHION ARM •••••••• G13 76 2 MASTER F4 51 3 E4 46 1
COLLAR B, CUSHION ARM •••••••• G13 76 3 C.D.I. UNIT••••••••••••••••••• H1 80 3 GASKET, EX. MUFFLER••••••••••• G6 69 1
COLLAR C, CUSHION ARM •••••••• G13 76 4 GASKET, EX. PIPE•••••••••••••• E4 46 1
COLLAR, 14X5 ••••••••••••••••• H2 81 10 [D ] G6 69 2
COLLAR, 6.5X4 •••••••••••••••• G3 66 1 GASKET, FLOAT CHAMBER••••••••• E2 44 19
COLLAR, CHAIN SLIPPER •••••••• G11 74 8 DIAPHRAGM ••••••••••••••••••••• F4 51 7 GASKET, L. COVER•••••••••••••• D10 36 4
COLLAR, CONNECTING ROD ••••••• G13 76 6 DISK, CLUTCH FRICTION••••••••• D8 34 5 E5 47 1
COLLAR, COUNTERSHAFT FIRST ••• D15 41 5 6 GASKET, OIL FILTER CAP•••••••• D9 35 9
COLLAR, COVER MOUNTING ••••••• G4 67 16 7 E5 47 1
G15 78 17 DISK, FR. BRAKE••••••••••••••• F11 58 15 GASKET, PULSE GENERATOR BASE•• D1 27 7

5
COLLAR, ENGINE MOUNTING •••••• H2 81 3 DOWEL PIN, 10X14•••••••••••••• D10 36 10 E4 46 1
COLLAR, FENDER MOUNTING •••••• F7 54 2 D13 39 10 GASKET, R. COVER•••••••••••••• D7 33 2
COLLAR, FENDER SETTING ••••••• G15 78 21 DOWEL PIN, 10X20•••••••••••••• D6 32 3 E5 47 1
COLLAR, FR. AXLE DISTANCE •••• F11 58 7 DOWEL PIN, 8X14••••••••••••••• D1 27 19 GASKET, TENSIONER LIFTER•••••• D5 31 6
COLLAR, FR. WHEEL •••••••••••• F11 58 4 D7 33 8 E4 46 1
5 DRUM, GEARSHIFT••••••••••••••• E1 43 5 GAUGE, OIL LEVEL•••••••••••••• D7 33 3
COLLAR, MUFFLER MOUNTING ••••• G6 69 13 DUCT, AIR CLEANER IN.••••••••• G4 67 11 GEAR COMP., STARTER DRIVEN•••• D12 38 1
91
2005.05.20 E
PART NAME INDEX J 3
Part name Address Page Ref. Part name Address Page Ref. Part name Address Page Ref.

GEAR, COUNTERSHAFT FIFTH ••••• D15 41 14 [J ] NUT, HEX., 5MM•••••••••••••••• G5 68 28


GEAR, COUNTERSHAFT FIRST ••••• D15 41 4 NUT, HEX., 6MM•••••••••••••••• G8 71 13
GEAR, COUNTERSHAFT FOURTH •••• D15 41 12 JET, MAIN,•••••••••••••••••••• E3 45 32 G15 78 20
GEAR, COUNTERSHAFT SECOND •••• D15 41 8 JET, SLOW,•••••••••••••••••••• E3 45 31 NUT, HEX., 8MM•••••••••••••••• F11 58 20
GEAR, COUNTERSHAFT THIRD ••••• D15 41 11 JOINT B, BRAKE ARM•••••••••••• G8 71 4 F15 62 23
GEAR, COUNTERSHAFT TOP ••••••• D15 41 16 JOINT SET, DRIVE CHAIN•••••••• G11 74 2 NUT, LOCK, 16MM••••••••••••••• D8 34 15
GEAR, IDLE ••••••••••••••••••• D12 38 5 JOINT, TUBE••••••••••••••••••• G4 67 23 D9 35 15
GEAR, MAINSHAFT FIFTH •••••••• D15 41 13 NUT, SIDE STAND••••••••••••••• G10 73 4
GEAR, MAINSHAFT SECOND ••••••• D15 41 7 [K ] NUT, STEERING STEM•••••••••••• F5 52 18
GEAR, MAINSHAFT THIRD & FOURTH D15 41 10 NUT, TAPPET ADJUSTING••••••••• D3 29 15
GEAR, MAINSHAFT TOP •••••••••• D15 41 15 KEY, BLANK•••••••••••••••••••• F5 52 3 NUT, U, 10MM•••••••••••••••••• G13 76 13
GEAR, OIL PUMP DRIVE ••••••••• D9 35 2 KEY, WOODRUFF, 25X18 •••••••••• D9 35 17 NUT, U, 14MM•••••••••••••••••• G12 75 18
GEAR, PRIMARY DRIVE •••••••••• D9 35 10 KEY, WOODRUFF, 4MM•••••••••••• D14 40 10 NUT, U, 16MM•••••••••••••••••• F15 62 18
GEAR, REDUCTION •••••••••••••• D12 38 3 NUT, U, 6MM••••••••••••••••••• F8 55 22
GRIP ASSY., THROTTLE ••••••••• F2 49 8 [L ] F13 60 11
GRIP, L. HANDLE •••••••••••••• F2 49 10 G12 75 17
GRIP, R. HANDLE •••••••••••••• F2 49 9 LABEL, COLOR•••••••••••••••••• H5 84 5 NUT, U, 8MM••••••••••••••••••• F15 62 19
GROMMET A, AIR CLEANER CASE •• G4 67 20 LABEL, DRIVE•••••••••••••••••• H5 84 4
G15 78 22 LABEL, DRIVE CHAIN•••••••••••• H5 84 3 [O ]
GROMMET A, SIDE COVER •••••••• G3 66 6 LABEL, FUEL••••••••••••••••••• H5 84 6
GROMMET, FR. FENDER SETTING •• G15 78 15 LABEL, RR. DAMPER CAUTION ••••• G13 76 8 OIL PUMP ASSY.•••••••••••••••• D9 35 1
GROMMET, SIDE COVER •••••••••• G3 66 3 LEATHER COMP., SEAT ••••••••••• G2 65 2 OIL SEAL, 12X22X5••••••••••••• D7 33 9
GUIDE COMP., BRAKE HOSE •••••• F5 52 4 LEVER COMP., CHOKE•••••••••••• E2 44 9 OIL SEAL, 14X28X7••••••••••••• D13 39 12
GUIDE COMP., BRAKE HOSE BOTTOM F6 53 1 LEVER COMP., CLUTCH ••••••••••• D7 33 4 OIL SEAL, 20X37X7••••••••••••• D16 42 33
GUIDE, A.C. GENERATOR CORD ••• D11 37 4 LEVER, L. STEERING HANDLE ••••• F2 49 18 OIL SEAL, 21X37X7••••••••••••• F11 58 18
GUIDE, CAM CHAIN ••••••••••••• D5 31 8 LEVER, R. STEERING HANDLE ••••• F4 51 11 OIL SEAL, 25X47X6.5••••••••••• F15 62 22
GUIDE, CHAIN ••••••••••••••••• G11 74 6 LIFTER ASSY., TENSIONER••••••• D5 31 5 O-RING•••••••••••••••••••••••• D12 38 17
GUIDE, CLUTCH OUTER •••••••••• D8 34 4 LINK SET, THROTTLE•••••••••••• E2 44 12 O-RING, 10.5X1.5•••••••••••••• D1 27 20
GUIDE, EX. VALVE ••••••••••••• D1 27 3 O-RING, 11.8X3.55••••••••••••• F16 63 2
GUIDE, IN. VALVE ••••••••••••• D1 27 2 [M ] O-RING, 13.8X2.5•••••••••••••• D10 36 12
GUIDE, THROTTLE CABLE •••••••• F5 52 13 E5 47 2
MAINSHAFT, TRANSMISSION••••••• D15 41 2 O-RING, 18X3•••••••••••••••••• D7 33 10
[H ] MARK•••••••••••••••••••••••••• H6 85 3 E5 47 2
MOTOR ASSY., STARTING••••••••• D12 38 7 O-RING, 1.3X4.3••••••••••••••• E2 44 15
HARNESS, WIRE •••••••••••••••• H1 80 7 MUDGUARD •••••••••••••••••••••• G4 67 13 O-RING, 1.5X9.5••••••••••••••• D5 31 14
HEADLIGHT UNIT ••••••••••••••• F1 48 5 MUFFLER ASSY., EX.•••••••••••• G6 69 4 E4 46 2
HEAD ASSY., CYLINDER ••••••••• D1 27 1 O-RING, 24.4X3.1•••••••••••••• D12 38 16
HOLDER ASSY., FUSE ••••••••••• G15 78 11 [N ] O-RING, 27.4X2.4•••••••••••••• D10 36 11
HOLDER SET, BRUSH •••••••••••• D12 38 11 E5 47 2
HOLDER, AXLE ••••••••••••••••• F8 55 20 NEEDLE SET, JET••••••••••••••• E2 44 3 O-RING, 27.7X3.5•••••••••••••• F9 56 25
HOLDER, CLUTCH WIRE •••••••••• D7 33 6 NUT-WASHER, 6MM••••••••••••••• D12 38 14 O-RING, 33.5X3.0•••••••••••••• D1 27 23
HOLDER, ELEMENT •••••••••••••• G4 67 4 NUT B, BRAKE ROD ADJUSTING •••• G8 71 16 E4 46 2
HOLDER, JET •••••••••••••••••• E2 44 21 NUT, BEAM ADJUSTING ••••••••••• F1 48 4 O-RING, 35X3•••••••••••••••••• D1 27 22
HOLDER, L. LEVER BRACKET ••••• F2 49 15 NUT, CAP, 5MM••••••••••••••••• G5 68 29 D13 39 13
HOLDER, MASTER CYLINDER •••••• F4 51 5 NUT, CAP, 6MM••••••••••••••••• F1 48 11 E4 46 2
HOLDER, NEEDLE JET ••••••••••• E2 44 20 F6 53 8 E5 47 2
HOLDER, UPPER •••••••••••••••• F5 52 6 NUT, CAP, 8MM••••••••••••••••• D1 27 18 O-RING, 63X3•••••••••••••••••• D10 36 13
HOSE COMP., FR. BRAKE •••••••• F4 51 1 NUT, CLIP, 6MM •••••••••••••••• G4 67 19 E5 47 2
HOUSING, LOWER THROTTLE •••••• F2 49 12 G15 78 19 O-RING, 75X2.5•••••••••••••••• D1 27 21
HOUSING, UPPER THROTTLE •••••• F2 49 11 NUT, FIXING••••••••••••••••••• F2 49 24 E4 46 2
HUB SUB ASSY., FR. ••••••••••• F11 58 8 NUT, FLANGE, 10MM••••••••••••• H3 82 22 O-RING, 7X1.7••••••••••••••••• D11 37 11
HUB SUB ASSY., RR. ••••••••••• F14 61 9 NUT, FLANGE, 12MM••••••••••••• G13 76 14 O-RING, 9.4X2.4••••••••••••••• D9 35 19

5
NUT, FLANGE, 6MM•••••••••••••• F3 50 30 E5 47 2
[I ] F4 51 19 OUTER COMP., CLUTCH••••••••••• D8 34 1
NUT, FLANGE, 8MM•••••••••••••• G2 65 3
INDICATOR, RR. BRAKE ••••••••• F13 60 5 G6 69 17 [P ]
INSULATOR, CARBURETOR •••••••• D1 27 9 H3 82 23
NUT, HEX. CAP, 7MM•••••••••••• G6 69 16 PACKING, EX.•••••••••••••••••• E4 46 1
NUT, HEX., 10MM••••••••••••••• H3 82 21 G6 69 11
92
2005.05.20 E
PART NAME INDEX J 4
Part name Address Page Ref. Part name Address Page Ref. Part name Address Page Ref.

PACKING, FUEL CAP •••••••••••• F16 63 12 RING•••••••••••••••••••••••••• F4 51 8 SCREW, PAN, 5X25•••••••••••••• D1 27 16


PACKING, PROTECTOR ••••••••••• G6 69 3 RING SET, PISTON•••••••••••••• D14 40 3 SCREW, PAN, 5X28•••••••••••••• G5 68 25
PAD SET, FR. ••••••••••••••••• F10 57 5 RING, BACK UP••••••••••••••••• F8 55 5 SCREW, PAN, 5X8••••••••••••••• G11 74 16
PANEL COMP., RR. BRAKE ••••••• F13 60 2 RING, OIL SEAL STOPPER•••••••• F8 55 12 SCREW, PAN, 6X18•••••••••••••• G1 64 23
PEDAL ASSY., GEAR CHANGE ••••• G8 71 1 RING, PISTON•••••••••••••••••• F8 55 10 SCREW, PAN, 6X6••••••••••••••• D5 31 10
PEDAL COMP., BRAKE ••••••••••• G8 71 6 ROD COMP., RR. BRAKE •••••••••• G8 71 2 SCREW, TAPPET ADJUSTING••••••• D3 29 14
17 ROD KIT, CONNECTING ••••••••••• D14 40 1 SCREW, TAPPING, 3X12•••••••••• F2 49 23
PIECE, OIL LOCK •••••••••••••• F8 55 9 ROD SUB ASSY., CUSHION SCREW, TAPPING, 4X10•••••••••• F1 48 12
PIN C, JOINT ••••••••••••••••• G8 71 3 CONNECTING G13 76 7 G3 66 10
PIN, HANGER •••••••••••••••••• F10 57 15 ROD, CLUTCH LIFTER•••••••••••• D8 34 11 SCREW, TAPPING, 5X12•••••••••• G5 68 27
PIN, LOCK, 10MM •••••••••••••• E1 43 18 ROLLER, 4X10•••••••••••••••••• E1 43 19 SEAL SET, FR. FORK•••••••••••• F8 55 15
PIN, LOCK, 8MM ••••••••••••••• D9 35 18 ROLLER, CHAIN UPPER ••••••••••• G11 74 11 SEAL SET, PISTON•••••••••••••• F10 57 1
PIN, PISTON •••••••••••••••••• D14 40 5 ROTOR COMP., OIL FILTER••••••• D9 35 5 SEAL, AIR CLEANER COVER••••••• G4 67 7
PIN, SPLIT, 2.0X12 ••••••••••• G8 71 14 ROTOR, NEUTRAL SWITCH••••••••• E1 43 13 SEAL, VALVE STEM•••••••••••••• D3 29 1
PIN, SPLIT, 2.0X15 ••••••••••• G9 72 9 ROTOR, OIL PUMP INNER••••••••• D9 35 3 SEAT COMP., DOUBLE•••••••••••• G2 65 1
G12 75 22 ROTOR, OIL PUMP OUTER••••••••• D9 35 4 SEAT, JUDDER SPRING••••••••••• D8 34 3
PIN, SPLIT, 3.0X28 ••••••••••• G8 71 15 RUBBER, BATTERY CUSHION••••••• G15 78 2 SEAT, RR. BRAKE CAM••••••••••• F13 60 4
PIN, SPRING, 3X10 •••••••••••• D7 33 11 RUBBER, CHAMBER RR. MOUNTING•• G6 69 6 SEAT, VALVE SPRING INNER•••••• D3 29 12
PIN, STEP BAR JOINT •••••••••• G9 72 1 RUBBER, MUFFLER MOUNTING•••••• G6 69 12 SEAT, VALVE SPRING OUTER•••••• D3 29 11
PIPE COMP., EX. •••••••••••••• G6 69 5 RUBBER, OIL SEAL•••••••••••••• D1 27 5 SEPARATOR COMP.••••••••••••••• F4 51 6
PIPE COMP., FR. FORK ••••••••• F8 55 3 RUBBER, RADIATOR MOUNTING ••••• F1 48 1 SET RING, 20MM•••••••••••••••• D16 42 29
PIPE, SEAT ••••••••••••••••••• F8 55 11 RUBBER, RR. FENDER CUSHION •••• G15 78 16 SHAFT, GEARSHIFT FORK GUIDE••• E1 43 4
PIPE, STEERING HANDLE •••••••• F5 52 5 RUBBER, SHOCK••••••••••••••••• G15 78 12 SHAFT, IDLE GEAR•••••••••••••• D12 38 6
PISTON ••••••••••••••••••••••• D14 40 4 RUBBER, SIDE COVER•••••••••••• G6 69 14 SHAFT, REDUCTION GEAR••••••••• D12 38 4
PISTON, 27X27 •••••••••••••••• F10 57 2 RUBBER, TANK GUARD•••••••••••• H2 81 2 SHAFT, ROCKER ARM••••••••••••• D3 29 4
PIVOT, GEARSHIFT DRUM STOPPER E1 43 15 RUBBER, TANK MOUNTING••••••••• F16 63 4 SHOE SET, BRAKE••••••••••••••• F13 60 1
PLATE A2, FIXING ••••••••••••• D15 41 18 RUBBER, TANK SETTING •••••••••• F16 63 3 SHROUD SET, L. TANK••••••••••• F16 63 10
PLATE COMP., ELEMENT SETTING • G4 67 5 SHROUD SET, R. TANK••••••••••• F16 63 9
PLATE SET, FR. NUMBER •••••••• F1 48 8 [S ] SLIDER, CHAIN••••••••••••••••• G11 74 9
PLATE, BEARING SETTING ••••••• D15 41 1 SLIDER, CHAIN GUIDE••••••••••• G11 74 7
PLATE, CAM CHAIN SETTING ••••• D5 31 4 SCREEN, OIL FILTER•••••••••••• D13 39 5 SLIDER, CHAIN LOWER••••••••••• G11 74 12
PLATE, CHOKE LEVER SETTING ••• E2 44 18 SCREW-WASHER, 3X8••••••••••••• E2 44 25 SLIDER, THROTTLE•••••••••••••• F2 49 13
PLATE, CLUTCH •••••••••••••••• D8 34 8 SCREW-WASHER, 4X10•••••••••••• E3 45 26 SOCKET ASSY., HEADLIGHT••••••• F1 48 6
PLATE, CLUTCH LIFTER ••••••••• D8 34 10 SCREW-WASHER, 4X12•••••••••••• E3 45 27 SPACER, NEUTRAL SWITCH•••••••• D11 37 6
PLATE, CLUTCH PRESSURE ••••••• D8 34 9 SCREW-WASHER, 4X14•••••••••••• E3 45 28 SPINDLE COMP., GEARSHIFT•••••• E1 43 9
PLATE, FR. HOLDER •••••••••••• G4 67 6 SCREW-WASHER, 4X16•••••••••••• E3 45 29 SPOKE SET A, RR.•••••••••••••• F14 61 1
PLATE, GEARSHIFT ••••••••••••• E1 43 10 SCREW-WASHER, 4X8••••••••••••• F11 58 17 SPOKE SET B, RR.•••••••••••••• F14 61 2
PLATE, L. FR. ENGINE HANGER •• H2 81 8 SCREW-WASHER, 5X12•••••••••••• G5 68 26 SPOKE SET C, RR.•••••••••••••• F14 61 2
PLATE, L. RR. UPPER ENGINE SCREW A, COWL SETTING••••••••• F16 63 17 SPOKE SET, FR.•••••••••••••••• F11 58 1
HANGER H2 81 9 G3 66 7 SPRING A, BRAKE ROD••••••••••• G8 71 5
PLATE, L. UPPER ENGINE HANGER H2 81 6 SCREW SET ••••••••••••••••••••• E2 44 7 SPRING SET, BRAKE PEDAL••••••• G8 71 7
PLATE, ROCKER ARM SHAFT SCREW SET B••••••••••••••••••• E2 44 10 SPRING, BRAKE LEVER••••••••••• F4 51 10
SETTING D3 29 5 SCREW SET C••••••••••••••••••• E2 44 11 SPRING, BRAKE SHOE•••••••••••• F13 60 6
PLATE, R. FR. ENGINE HANGER •• H2 81 7 SCREW, BEAM ADJUSTING••••••••• F1 48 2 SPRING, CARBON BRUSH•••••••••• D12 38 9
PLATE, R. UPPER ENGINE HANGER H2 81 5 SCREW, BLEEDER •••••••••••••••• F10 57 3 SPRING, CLUTCH•••••••••••••••• D8 34 12
PLATE, SKID •••••••••••••••••• H2 81 4 SCREW, FLAT, 4X12••••••••••••• D9 35 13 SPRING, CLUTCH LEVER•••••••••• D7 33 5
PLUG, HANDLE LEVER BRACKET ••• F2 49 16 F4 51 18 SPRING, FR. FORK•••••••••••••• F8 55 2
PLUG, PIN •••••••••••••••••••• F10 57 14 SCREW, FLAT, 5X10••••••••••••• E2 44 24 SPRING, FR. FORK REBOUND•••••• F8 55 4
PLUG, SPARK •••••••••••••••••• D2 28 26 SCREW, FLAT, 6X16••••••••••••• D3 29 16 SPRING, GEARSHIFT PLATE••••••• E1 43 11
PROTECTOR, EX. PIPE •••••••••• G6 69 8 SCREW, FLAT, 6X30••••••••••••• D9 35 14 SPRING, GEARSHIFT RETURN•••••• E1 43 12
SCREW, FLAT, 6X45••••••••••••• G12 75 20 SPRING, HEADLIGHT BEAM
[R ] SCREW, FLAT, 8X31••••••••••••• F15 62 17 ADJUSTING F1 48 3

5
SCREW, OVAL, 5X12••••••••••••• D9 35 12 SPRING, JUDDER•••••••••••••••• D8 34 13
RECTIFIER COMP., REGULATE •••• H1 80 6 SCREW, PAN, 3X25•••••••••••••• F9 56 27 SPRING, OIL FILTER SCREEN••••• D13 39 6
RETAINER ••••••••••••••••••••• F10 57 7 SCREW, PAN, 4X12•••••••••••••• F3 50 27 SPRING, OIL THROUGH••••••••••• D9 35 8
RETAINER, VALVE SPRING ••••••• D3 29 10 SCREW, PAN, 4X32•••••••••••••• F2 49 21 SPRING, PAD••••••••••••••••••• F10 57 6
RIM, FR. WHEEL ••••••••••••••• F11 58 10 SCREW, PAN, 4X45•••••••••••••• F2 49 22 SPRING, SHIFT DRUM STOPPER•••• E1 43 8
RIM, RR. WHEEL ••••••••••••••• F14 61 11 SCREW, PAN, 5X16•••••••••••••• F3 50 28 SPRING, SIDE STAND•••••••••••• G10 73 2
RING ••••••••••••••••••••••••• D12 38 12 29 SPRING, STEP RETURN••••••••••• G9 72 4
93
2005.05.20 E
PART NAME INDEX J 5
Part name Address Page Ref. Part name Address Page Ref. Part name Address Page Ref.

SPRING, VALVE INNER •••••••••• D3 29 9 VALVE, EX.•••••••••••••••••••• D3 29 7


SPRING, VALVE OUTER •••••••••• D3 29 8 VALVE, IN.•••••••••••••••••••• D3 29 6
SPROCKET, CAM •••••••••••••••• D5 31 1 VALVE, THROTTLE••••••••••••••• E2 44 17
SPROCKET, DRIVE •••••••••••••• D15 41 17
SPROCKET, FINAL DRIVEN ••••••• F14 61 5 [W ]
SPROCKET, TIMING ••••••••••••• D14 40 9
STATOR COMP. ••••••••••••••••• D11 37 3 WASHER A, SPLINE, 20MM•••••••• D16 42 24
STAY SET, WIRE ••••••••••••••• E2 44 13 WASHER B, SPLINE, 20MM•••••••• D8 34 17
STAY, C.D.I. ••••••••••••••••• H1 80 9 WASHER B, THRUST, 20MM•••••••• D16 42 23
STAY, HEADLIGHT CASE LOWER ••• F6 53 6 WASHER C, 8MM••••••••••••••••• D5 31 12
STAY, HEADLIGHT CASE L. UPPER F5 52 12 WASHER O-RING KIT A ••••••••••• E4 46 2
STAY, HEADLIGHT CASE R. UPPER F5 52 10 WASHER O-RING KIT B ••••••••••• E5 47 2
STEM SUB ASSY., STEERING ••••• F6 53 4 WASHER, 10MM•••••••••••••••••• H3 82 24
STEP COMP., L. ••••••••••••••• G9 72 5 WASHER, 10X24••••••••••••••••• D11 37 10
STEP COMP., R. ••••••••••••••• G9 72 2 WASHER, 16MM•••••••••••••••••• D8 34 16
STOPPER COMP., GEARSHIFT DRUM E1 43 7 D9 35 16
STOPPER, BEAD •••••••••••••••• F11 58 14 WASHER, 6MM••••••••••••••••••• E1 43 16
F15 62 16 WASHER, 6.5X20 •••••••••••••••• F7 54 4
STRIPE, L. TANK SHROUD ••••••• H6 85 2 WASHER, 8MM••••••••••••••••••• F15 62 20
5 WASHER, BUSH•••••••••••••••••• G8 71 12
7 WASHER, CHAIN SLIDER •••••••••• G11 74 10
9 WASHER, COUNTERSHAFT THIRD
STRIPE, R. TANK SHROUD ••••••• H6 85 1 SPLINE D16 42 26
4 WASHER, HEADLIGHT CASE SETTING G4 67 21
6 WASHER, LOCK•••••••••••••••••• D16 42 27
8 WASHER, OIL BOLT•••••••••••••• F4 51 16
SWINGARM SUB ASSY., RR. •••••• G11 74 13 WASHER, PLAIN, 6MM•••••••••••• D1 27 24
SWITCH ASSY., CLUTCH ••••••••• F2 49 7 WASHER, PLAIN, 8MM•••••••••••• G6 69 18
SWITCH ASSY., COMBINATION •••• F5 52 2 G9 72 8
SWITCH ASSY., ENGINE STOP •••• F2 49 5 G12 75 21
SWITCH ASSY., STARTER •••••••• F2 49 6 WASHER, RR. AXLE•••••••••••••• F15 62 21
SWITCH COMP., STARTER MAGNETIC G15 78 10 WASHER, SEALING, 6MM •••••••••• D5 31 13
E4 46 2
[T ] WASHER, SEALING, 8MM •••••••••• D1 27 17
E4 46 2
TANK COMP., FUEL ••••••••••••• F16 63 6 WASHER, SPECIAL, 8MM •••••••••• F8 55 23
TENSIONER, CAM CHAIN ••••••••• D5 31 3 WASHER, SPLINE, 22MM •••••••••• D16 42 25
TERMINAL SET, BRUSH •••••••••• D12 38 8 WASHER, SPRING, 3MM ••••••••••• F2 49 25
THREAD, STEERING HEAD TOP •••• F6 53 5 WASHER, SPRING, 4MM ••••••••••• F3 50 31
THROUGH, OIL ••••••••••••••••• D9 35 7 WASHER, SPRING, 6MM ••••••••••• G16 79 23
TIRE, FR. •••••••••••••••••••• F11 58 11 WASHER, SPRING, 8MM ••••••••••• F12 59 21
TIRE, RR. •••••••••••••••••••• F14 61 12 F15 62 24
TOOL SET ••••••••••••••••••••• H4 83 1 WASHER, STEEL PLATE ••••••••••• D12 38 15
TOP SET •••••••••••••••••••••• E2 44 5 WASHER, STEERING STEM••••••••• F5 52 19
TUBE ••••••••••••••••••••••••• E2 44 23 WASHER, TANK CUSHION •••••••••• G1 64 19
TUBE, AIR CLEANER CONNECTING • G4 67 9 WASHER, THRUST, 14MM •••••••••• E1 43 17
TUBE, AIR VENT ••••••••••••••• E2 44 22 WASHER, THRUST, 15MM •••••••••• D15 41 20
TUBE, BRAKE PEDAL SPRING ••••• G8 71 8 21
TUBE, BREATHER ••••••••••••••• G4 67 15 WASHER, THRUST, 16.5MM•••••••• D15 41 22
TUBE, DRAIN •••••••••••••••••• G4 67 14 WHEEL SUB ASSY., FR. •••••••••• F11 58 9
TUBE, FUEL ••••••••••••••••••• F16 63 15 WHEEL SUB ASSY., RR. •••••••••• F14 61 10
TUBE, FUEL CAP BREATHER •••••• F16 63 8 WRENCH, BOX••••••••••••••••••• H4 83 3

5
TUBE, TIRE ••••••••••••••••••• F11 58 12
F14 61 13
[V ]
VALVE SET, AIR CUT ••••••••••• E2 44 14
VALVE SET, FLOAT ••••••••••••• E2 44 2
94
2005.05.20 E
1 FOREWORD INDEX

2 ENGINE GROUP

3 FRAME GROUP

4 PART NUMBER INDEX

5 PART NAME INDEX


Published by Honda Motor Co., Ltd.
E.2005.05 Printed in Japan
June 27,2005
CODE NO. 13KPS3E4

PARTS CATALOGUE NEWS CRF230F


CRF230F3/4/5/6
PARTS
Honda Motor Co., Ltd. Service Division CATALOGUE
TITLE

PARTS CATALOGUE - CORRECTED


Printed in Japan NEWS NO. 001
(BR-KD)KPS
Reqd.QTY
Block Ref.
No. No. Note Part No. Description Serial No. Parts catalogue code
CRF230F
3 4 5 6
F-23 3 T 32401-KPS-900 CABLE, STARTER MAGNETIC
BATTERY 1 1 - -

D 32401-KPS-901 .............................. - - 1 1

NOTE A:PART NO.CHANGE D:NEWLY PROVIDED E:PART NO.DELETION K:REQUIRED NO.CORRECTION L:APPLICATION SERIAL NO.CORRECTION
T:APPLICATION CORRECTION Z:REMARKS CHANGE
1/1
July 03,2005
CODE NO. 13KPS3E4

PARTS CATALOGUE NEWS CRF230F


CRF230F3/4/5/6
PARTS
Honda Motor Co., Ltd. Service Division CATALOGUE
TITLE

PARTS CATALOGUE - CORRECTED


Printed in Japan NEWS NO. 002
(BR-KD)KPS
Reqd.QTY
Block Ref.
No. No. Note Part No. Description Serial No. Parts catalogue code
CRF230F
3 4 5 6
F-2 11 E 53167-KPS-900 *PARTS NO. DELETION

D 53168-KPS-900 HOUSING, LOWER THROTTLE ...... 1 1 1 1

12 D 53167-KPS-900 HOUSING, UPPER THROTTLE ...... 1 1 1 1

E 53168-KPS-900 *PARTS NO. DELETION

NOTE A:PART NO.CHANGE D:NEWLY PROVIDED E:PART NO.DELETION K:REQUIRED NO.CORRECTION L:APPLICATION SERIAL NO.CORRECTION
T:APPLICATION CORRECTION Z:REMARKS CHANGE
1/1
November 27,2005
CODE NO. 13KPS3E4

PARTS CATALOGUE NEWS CRF230F


CRF230F3/4/5/6
PARTS
Honda Motor Co., Ltd. Service Division CATALOGUE
TITLE

PARTS CATALOGUE - CORRECTED


Printed in Japan NEWS NO. 003
(BR-KD)KPS
Reqd.QTY
Block Ref.
No. No. Note Part No. Description Serial No. Parts catalogue code
CRF230F
3 4 5 6
EOP-1 1 T 06113-KPS-900 GASKET SHEET KIT A
(COMPONENT PARTS) 1 1 1 1

T 12191-KCN-000 GASKET, CYLINDER ............. 1 1 1 1

T 12251-KT0-711 GASKET, CYLINDER HEAD ........ 1 1 1 1

T 12339-KT0-710 GASKET, PULSE GENERATOR BASE . 1 1 1 1

T 14523-KBB-901 GASKET, TENSIONER LIFTER ..... 1 1 1 1

T 16214-KPS-900 GASKET, CARBURETOR INSULATOR . 1 1 1 1

T 18291-MN5-650 GASKET, EX. PIPE ............. 1 1 1 1

T 18391-MB0-891 PACKING, EX. ................. 1 1 1 1

2 T 06114-KPS-900 WASHER O-RING KIT A


(COMPONENT PARTS) 1 1 1 1

T 90442-KPS-900 WASHER, SEALING, 8MM ......... 4 4 4 4

T 90488-425-000 WASHER, SEALING, 6MM ......... 2 2 2 2

T 91301-107-000 O-RING, 75X2.5 ............... 1 1 1 1

T 91303-KK3-830 O-RING, 35X3(ARAI) ........... 2 2 2 2

T 91304-HB3-003 O-RING, 33.5X3.0 ............. 1 1 1 1

NOTE A:PART NO.CHANGE D:NEWLY PROVIDED E:PART NO.DELETION K:REQUIRED NO.CORRECTION L:APPLICATION SERIAL NO.CORRECTION
T:APPLICATION CORRECTION Z:REMARKS CHANGE
1/2
PARTS CATALOGUE NEWS
BOOKNo.:13KPS3E4
Reqd.QTY
Block Ref.
Note Part No. Description Serial No. Parts catalogue code
No. No. CRF230F
3 4 5 6
T 91306-105-690 O-RING, 1.5X9.5 .............. 1 1 1 1

EOP-2 1 T 06115-KPS-900 GASKET SHEET KIT B


(COMPONENT PARTS) 1 1 1 1

T 11191-KHA-940 GASKET, CRANKCASE ............ 1 1 1 1

T 11393-KGA-900 GASKET, R. COVER ............. 1 1 1 1

T 11395-KCN-000 GASKET, L. COVER ............. 1 1 1 1

T 15459-KT0-710 GASKET, OIL FILTER CAP ....... 1 1 1 1

2 T 06116-KPS-900 WASHER O-RING KIT B


(COMPONENT PARTS) 1 1 1 1

T 91302-567-003 O-RING, 27.4X2.4(ARAI) ....... 1 1 1 1

T 91303-KK3-830 O-RING, 35X3(ARAI) ........... 2 2 2 2

T 91303-377-000 O-RING, 13.8X2.5 ............. 1 1 1 1

T 91304-KPS-900 O-RING, 9.4X2.4 .............. 2 2 2 2

T 91307-035-000 O-RING, 18X3 ................. 1 1 1 1

T 91304-KGA-940 O-RING, 63X3 ................. 1 1 1 1

NOTE A:PART NO.CHANGE D:NEWLY PROVIDED E:PART NO.DELETION K:REQUIRED NO.CORRECTION L:APPLICATION SERIAL NO.CORRECTION
T:APPLICATION CORRECTION Z:REMARKS CHANGE
2/2