COMPLETE ENGINE PARTS LIST

Transkript

1 COMPLETE ENGINE PARTS LIST for CRF50F Please confirm engine spec. CODE NO, TRANSMISSION GENERATOR 3a CH NO-IGNITION TYPE 3b CH SPEED CLOSED TRANSMISSION INNER ROTOR KIT TYPE-1 3c CH STOCK FLYWHEEL TYPE 4a CH NO-IGNITION TYPE 4b CH SPEED TRANSMISSION INNER ROTOR KIT TYPE-1 4c CH STOCK FLYWHEEL TYPE 5a CH NO-IGNITION TYPE 5b CH SPEED CLOSED TRANSMISSION INNER ROTOR KIT TYPE-1 5c CH STOCK FLYWHEEL TYPE 1A XXX These marks are included in below kits ULTRA-SE BIG BORE KIT 124cc ULTRA CLUTCH KIT for 3 SPEED TRANSMISSION ULTRA CLUTCH KIT for 4 SPEED TRANSMISSION ULTRA CLUTCH KIT for 5 SPEED TRANSMISSION SPEED CLOSED TRANSMISSION INNER ROTOR KIT TYPE-1 1A XXX Basic specifications ULTRA-SE 124cc BIG BORE KIT + ULTRA OIL PUMP KIT + ULTRA CLUTCH KIT warning 5 SPEED MOTOR IS ONLY FOR ROAD USE.

2 FIG.1 CYLINDER HEAD COVER / CYLINDER / PISTON 1A SPL CAP NUT M B SEALING WASHER 6mm C SEALING COPPER WASHER A 6mm D CAP BOLT E CAM SPROCKET ULTRA-SE CAM SHAFT(#30) F ULTRA-SE CAM SHAFT(#35) OP OP OP 1G SE ROCKER ARM SET H TI-NUT M I ROCKER ARM ADJUST SCREW A CYLINDER HEAD COVER WITH CYLINDER HEAD COVER GASKET A Ф 54.0 HARD PLATING CYLINDER (For 124cc) B Ф 54.0 SS PISTON(For ULTRA-SE 124cc)3R( ) C Ф 54.0 PISTON RING 3R( ) D PISTON PIN A SD CAM CHAIN 25SD-86L B STUD BOLT M6 203mm C STUD BOLT M6 210mm D PLUG CAP 70B E DENSO IRIDIUM PLUG IY F PLUG WRENCH GASKET SET-A (For 124cc) 1SET 1SET 1SET 5A CYLINDER HEAD COVER GASKET B R HEAD SIDE COVER GASKET C L HEAD SIDE COVER GASKET D O-RING 30.8mm E MANIFOLD GASKET F EX GASKET (XH-1) G HEAD GASKET (For 124cc) H BASE GASKET (For 124cc) I RUBBER GASKET 16mm J PISTON PIN CLIP CH Block 1 1SET 1SET 1SET 6A FLANGE BOLT M B SEALING WASHER C FLANGE BOLT M D R SIDE COVER E TAPPET CAP F L SIDE COVER CH Block 3 1SET 1SET 1SET 7A ROCKER ARM SHAFT CH Block 2 1SET 1SET 1SET 8A BOLT 6mm 2 2 2

3 FIG.2 CYLINDER HEAD ULTRA-SE CYLINDER HEAD ASSY WITH VALVE GUIDE 1SET 1SET 1SET 1A ULTRA-SE CYLINDER HEAD COMP ULTRA-SE VALVE SET IN VALVE ULTRA-SE (1) (1) (1) 1B EX VALVE ULTRA-SE (1) (1) (1) ULTRA-SE TITANIUM VALVE SET OP OP OP IN VALVE ULTRA-SE TITANIUM (OP) (OP) (OP) EX VALVE ULTRA-SE TITANIUM (OP) (OP) (OP) 1C ULTRA VALVE COTTER D ULTRA VALVE SPRING TITANIUM RETAINER SET E ULTRA-SE VALVE SPRING SET ULTRA-SE OUTER VALVE SPRING (2) (2) (2) INNER VALVE SPRING (2) (2) (2) 1F ULTRA VALVE STEM SEAL G OUTER VALVE SPRING SEAT H IN/EX VALVE GUIDE 2 2 2

4 FIG.3 CAM CHAIN TENSIONER 1 CH Block 4 1SET 1SET 1SET 1A GUIDE ROLLER B GUIDE ROLLER PIN C SEALING WASHER 8mm D FLANGE BOLT M E SEALING WASHER F SEALING BOLT 14mm G SEALING WASHER 14mm H TENSIONER SPRING I TENSIONER ROD J TENSIONER ROD HEAD K TENSIONER PIVOT L TENSIONER ARM M TENSIONER ROLLER N CAM CHAIN GUIDE SPROCKET 25T FIG.4 DOWEL PIN 1 CH Block 5 1SET 1SET 1SET 1A DOWEL PIN B DOWEL PIN

5 FIG.5 OIL PUMP ULTRA OIL PUMP KIT 1SET 1SET 1SET 1A OIL PUMP BODY GASKET CH Block 8 1SET 1SET 1SET 2A OIL FILTER SCREEN B PANHEAD SCREW M C PANHEAD SCREW M FIG.6 L CRANKCASE COVER 1 CH Block 9 1SET 1SET 1SET 1A L CRANKCASE COVER B FLANGE BOLT M C FLANGE BOLT M

6 FIG.7 CLUTCH / R CRANKCASE COVER / PRIMARY GEAR 1A / 3/ 4 CAP BOLT M B / 3/ 4 CAP BOLT M C / 3/ 4 CAP BOLT M D / 3/ 4 CAP BOLT M E CLUTCH CABLE RECEIVER F / 3/ 4 BUTTON CAP BOLT M G / 3/ 4 OIL FILTER COVER H / 3/ 4 O-RING I / 3/ 4 OIL FILTER J / 3/ 4 OIL FILTER SPRING K / 3/ 4 OIL LEVEL GAUGE Ф L / 3/ 4 UNION BOLT M M / 3/ 4 ALUMINIUM WASHER N / 3/ 4 OIL GALLERY O / 3/ 4 OIL SEAL P / 3/ 4 CLUTCH LEVER COMP Q / 3/ 4 O-RING 9mm R / 3/ 4 CLUTCH LEVER SPRING S / 3/ 4 R CRANK CASE COVER COMP T / 3/ 4 OIL SEAL U / 3/ 4 INTERNAL CLIP V / 3/ 4 CLUTCH LIFTER ROD A L SHORT LEVER & HOLDER SET B CLUTCH CABLE (OUTER LENGTH :950mm) A / 3/ 4 SPECIAL FLANGE BOLT M B / 3/ 4 CLUTCH LIFTER PLATE C / 3/ 4 REINFORCED CLUTCH SPRING D / 3/ 4 EXTERNAL CLIP 17mm E / 3/ 4 CLUTCH CENTER F / 3/ 4 CLUTCH(FRICTION)DISK G / 3/ 4 CLUTCH PLATE H / 3/ 4 CLUTCH PRESSURE PLATE I / 3/ 4 SPLINE WASHER-B J / 3/ 4 COLLAR ( ) K / 3/ 4 CLUTCH OUTER COMP-A 66T L / 3/ 4 THRUST WASHER ( ) M / 3/ 4 THRUST BEARING ( ) N / 3/ 4 THRUST BEARING RETAINER ( ) A / 3/ 4 OIL PASS NUT B / 3/ 4 CLUTCH LOCK WASHER C / 3/ 4 PRIMARY DRIVE GEAR 18T A / 3/ 4 RIGHT SIDE CRANKCASE GASKET B / 3/ 4 CRANKCASE GASKET CH Block 6 1SET 1SET 1SET 6A OIL LEVEL GAUGE B O-RING CH Block 7 1SET 1SET 1SET 7A BEARING # B COLLAR 17mm A UNION NIPPLE(SOLD EACH) OP OP OP

7 FIG.8 3 SPEED TRANSMISSION / KICK STARTER SPINDLE / SHIFT SPINDLE 3a 3b 3c 1A MAINSHAFT 1st 13T A COUNTERSHAFT 1st GEAR 34T A KICK STARTER PINION 24T A GEARSHIFT SPINDLE SET CH Block 13 1SET 1SET 1SET 5A MAINSHAFT 2nd GEAR 15T B MAINSHAFT 3rd GEAR 21T C THRUST WASHER 14mm D SPLINE WASHER 17mm E EXTERNAL CIRCLIP 17mm F BEARING G COUNTERSHAFT H COUNTERSHAFT 2nd GEAR 25T I COUNTERSHAFT 3rd GEAR 25T J THRUST WASHER 17mm K BUSH L SPLINE WASHER M EXTERNAL CIRCLIP 20mm N SPLINE WASHER 20mm O THRUST WASHER B P THRUST WASHER 13.5mm Q OIL SEAL CH Block 14 1SET 1SET 1SET 6A GEARSHIFT DRUM B SHIFT FORK C SHIFT FORK GUIDE PIN D SHIFT FORK GUIDE PIN CLIP E WASHER 13.2mm F PLUG 19mm G HEXAGON HEAD BOLT M H SHIFT DRUM SIDE WASHER I KNOCK BOLT 6mm J SHIFT DRUM STOPPER PLATE K ROLLER L SHIFT DRUM PIN M SHIFT DRUM STOPPER ARM BOLT N SHIFT DRUM STOPPER ARM O SHIFT DRUM STOPPER ARM SPRING P GEARSHIFT RETURN SPRING PIN Q OIL SEAL CH Block 15 1SET 1SET 1SET 7A KICK STARTER SPINDLE B THRUST WASHER 20mm C SET RING 20mm D STARTER DRIVE RATCHET E STARTER PINION SPRING F WASHER 17mm G EXTERNAL CIRCLIP 16mm H KICK SPRING RETAINER I KICK STARTER SPRING 1 1 1

8 FIG.9 4 SPEED TRANSMISSION / KICK STARTER SPINDLE / SHIFT SPINDLE 4a 4b 4c 1A MAINSHAFT 1st 11T A GEAR SHIFT SPINDLE SET CH A Block13A 1SET 1SET 1SET 3A MAINSHAFT 2nd GEAR 16T B MAINSHAFT 3rd GEAR 20T C MAINSHAFT 4th GEAR 23T D THRUST WASHER 14mm E SPLINE WASHER 17mm F EXTERNAL CLIP 17mm G SPLINE WASHER B 17mm H COUNTERSHAFT I COUNTERSHAFT 1st GEAR 36T J COUNTERSHAFT 2nd GEAR 31T K COUNTERSHAFT 3rd GEAR 27T L COUNTERSHAFT 4th GEAR 24T M COUNTERSHAFT 1st GEAR BUSH N THRUST WASHER 17.2mm O THRUST WASHER 13.5mm P BEARING Q OIL SEAL CH A Block14A 1SET 1SET 1SET 4A SHIFT DRUM B L SHIFT FORK C R SHIFT FORK D SHIFT FORK GUIDE PIN E SHIFT FORK GUIDE PIN CLIP F WASHER 13.2mm G PLUG 19mm H BOLT M I SHIFT DRUM SIDE WASHER J KNOCK BOLT 6mm K SHIFT DRUM SIDE PLATE L ROLLER M SHIFT DRUM PIN N SHIFT DRUM STOPPER ARM SET O SHIFT RETURN SPRING PIN P OIL SEAL CH Block 15 1SET 1SET 1SET 5A KICK STARTER SPINDLE B THRUST WASHER 20mm C SET RING 20mm D STARTER DRIVE RATCHET E STARTER PINION SPRING F WASHER 17mm G EXTERNAL CLIP 16mm H KICK SPRING RETAINER I KICK STARTER SPRING CH Block16 1SET 1SET 1SET 6A KICK STARTER PINION 21T 1 1 1

9 FIG.10 5 SPEED TRANSMISSION / KICK STARTER SPINDLE / SHIFT SPINDLE 5a 5b 5c 1A MAINSHAFT 1st 14T A MAINSHAFT 5th GEAR 24T B MAINSHAFT 3rd/4th GEAR 21/23T C MAINSHAFT 2nd GEAR 18T D SPLINE WASHER 17mm E EXTERNAL CRIP 17mm F SPLINE WASHER -B 17mm G THRUST WASHER 14mm A COUNTERSHAFT B COUNTERSHAFT 1st GEAR 31T C COUNTERSHAFT 5th GEAR 23T D COUNTERSHAFT 3rd GEAR 26T E COUNTERSHAFT 4th GEAR 24T F COUNTERSHAFT 2nd GEAR 29T G THRUST WASHER 13.5mm (Large) A GEAR SHIFT DRUM B L GEAR SHIFT FORK C C GEAR SHIFT FORK D R GEAR SHIFT FORK E NEUTRAL SWITCH ROTOR F GEAR SHIFT FORK GUIDE PIN G SHIFT FORK PIN LOCK WASHER A KICK STARTER PINION 25T A FLAT SCREW M B SHIFT DRUM STOPPER PLATE C SHIFT DRUM SIDE PLATE D SIDE PLATE SETTING PIN E GEAR SHIFT DRUM PIN A STOPPER ARM PIPOT BOLT B SHIFT DRUM STOPPER ARM C SHIFT DRUM STOPPER ARM SPRING A GEAR SHIFT SPINDLE SET CH B Block14B 1SET 1SET 1SET 9A PLUG 19mm B BOLT M C SHIFT DRUM SIDE WASHER D SHIFT RETURN SPRING PIN E OIL SEAL CH B Block13B 1SET 1SET 1SET 10A BEARING B OIL SEAL CH Block 15 1SET 1SET 1SET 11A KICK STARTER SPINDLE B THRUST WASHER 20mm C SET RING 20mm D STARTER DRIVE RATCHET E STARTER PINION SPRING F WASHER 17mm G EXTERNAL CLIP 16mm H KICK STARTER RETAINER I KICK STARTER SPRING 1 1 1

10 FIG.11 CRANKSHAFT / CRANKCASE 1A mm LONG STROKE CRANKSHAFT COMP B OIL PUMP SPINDLE SET(12V) C R CRANKCASE COVER GASKET D CRANKCASE GASKET CH Block 11 1SET 1SET 1SET 2A R CRANKCASE COMP B L CRANKCASE COMP C DOWEL PIN D FLANGE BOLT M E FLANGE BOLT M F FLANGE BOLT M CH Block 12 1SET 1SET 1SET 3A WOODRUFF KEY 4mm ALUMINIUM DRAIN BOLT 1SET 1SET 1SET 4A DRAIN BOLT SEALING WASHER φ

11 FIG.12 GENERATOR 3c 4c 5c 1 CH A Block 10A 1A FLANGE NUT 10mm B WASHER 10mm C FLYWHEEL D BOLT E BOLT F STATOR COMP G CLAMPER PULSAR H BOLT I CLAMPER ACG J FLAT SCREW K STATOR BASE L O-RING M O-RING N OIL SEAL

12 FIG.13 INNER ROTOR KIT TYPE-1 3b 4b 5b 1A MAGNET ASSY B CAP BOLT M C FLAT WASHER 6mm D CAP BOLT M E STATOR BASE F O-RING G OIL SEAL H O-RING A CDI UNIT B KILL SWITCH C RUBBER CUSHION D TIELAP BAND 250mm SUPER IGNITION COIL SET 1SET 1SET 1SET 3A SUPER IGNITION COIL B IGNITION COIL STAY C GROUND WIRE D CAP BOLT M E CAP BOLT M CH Block 10 1SET 1SET 1SET 4A FLANGE NUT M B WASHER 10mm 1 1 1