manual desarme elite125

7/22/2019 Manual Desarme Elite125

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PART NUMBER INDEX

FOREWORD INDEX

ENGINE GROUP

FRAME GROUP

PART NAME INDEX

19KSY5S1.FM Page 2 Wednesday, August 25, 2004 5:48 PM


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Instruction for use of parts catalogue

This parts catalogue has been created as of August 10, 2004.

2004 8 10

Since this date, the sales practice for repair parts may have beenchanged or the parts may have been eliminated (listed for those not forsale).

The modified information is reflected on the latest Electronic PartsCatalogue (EPC).Also, refer to the parts catalogue news for any change.

EPC

See the parts catalogue news for any revision that is made after August

10, 2004.2004 810

Always specify the part number when ordering a part.

Check the model, type, serial numbers, color, maker, and the size asneeded before ordering a part.

Note that the illustrations (part drawings) can differ from the actualparts in shape.

They are given just to help you to refer to the parts.

When modifications or additions to this parts catalogue are made, a

revised edition will be issued at an appropriate time, withsuccessively progressing revision numbers on the cover.Werecommend obtaining such revisions in order to keep your partscatalogue up-to-date at all times.To check whether a parts cataloguerevision has been issued, please contact your Honda distributor.

How to refer to the part information ....................................... 2

Part catalogue structure ................................................ ........ 3

When the parts were revised................................................. 4

Abbreviations used in the parts catalogue ........................... 4

Part block and serial number check ..................................... 5

Color label attachment position check... ............................... 5

Models, parts catalogue codes and applicable serialnumbers ................................................ ................................ 6

Color label ............................................. ................................ 7

Color chart........... ................................................. ................. 8

Fuel hose, general purpose hoses and vinyl hose.............. 10

How to use the flat rate time (F.R.T.)........... ........................ 14

F.R.T

Illustrated index ........................................... ........................ 17

ENGINE GROUP ................................................................ 23

FRAME GROUP.................................................................. 42

PART NO. INDEX................................... .............................. 77

PART NAME INDEX................. ............................................ 80

CONTENTS

Page



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Reference with Part number index

Reference with Part name index

How to refer to the part information

Reference with Illustrated index



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Part catalogue structure

Block title Block number

Service item/Flat rate time

Reference number Title number marked with the parenthesis or parentheses

indicates that it continues from the previous page.

Part number Honda color code

Description

As semblies Sections framed with broken lines in the exploded view drawings

are available as complete assemblies.

(Their individual 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 indicates the

optional part.

Reqd.QTY marked with N indicates the optional part thatshould be selected as needed.

N

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 indicates that

the part is applicable to all codes.

Parts enclosed within a dotted line are covered in adifferent block.

A hollow arrow indicates the block No. for the parts enclosedwithin a dotted line .

A solid arrow indicates the block No. the part in questionis connected to.



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When the parts were revised

Be sure to checkthe serial number!!

The number has beenused from the initialmodel without revision.

When shown at the left side,i t i s appl icable to themodels of No.1008001 andthe subsequent numbers. 1008001

When shown at the right side,it is applicable to the modelsup to No.1008000. 1008000

The parts listed with "###" at the end of the parts name have limited supply period

(parts not for sale). ###

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

motorcycle seat.L R

The following abbreviations are used in this parts catalogue.

A ...........Ampere

ABS ......Anti-lock brake

system

A.C. ......Alternating current

A.M. ......Attaching mark

ASSY. ....Assembly

C.D.I. ....Capacitive discharge

ignition

COMP....Complete

D.C. ......Direct current

EX..........Exhaust

FR. ........Front

G ..........Gram

HEX. ......Hexagonal

IN. .........Inlet

KPH ......Kilometers per hour

L. ..........Left

L (100L) Link (100 Links)

L.E.D. ...Light emitted diode

MM .......Millimeter

MPH .....Miles per hour

R. .........Right

RR.........Rear

STD....... Standard T (22T) . Tooth (22 Teeth)

TCS ...... Traction control system

T.M. ......Transcript mark

V ...........Volt

W ..........Watt

WL ........With labelling

WOL .....Without labelling

Abbreviations used in the parts catalogue

RIGHT isabbreviated ssR.

L.standsfor LEFT

R L



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Part block and serial number check

Requiredserialnumber

Engine parts

E-1~

Engine serialnumber

Carburetor parts

E-17

Carburetor serialnumber

Frame parts

F-1~

Frame serialnumber

Part block

Check point

Color label attachment position check

Colored parts

Color label



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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.

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

VE49E KC

Models, parts catalogue codes and applicable serial numbers

Area Parts catalogue Applicable engine Applicable frame Applicable carburetor

code code serial No. serial No. identification No.

SC125SH5 CH China 1CH




VE49E A

Model Type



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When ordering parts, check the model name, main color, and code by observing the OLOR LABELon the vehicle.

When ordering a colored part, use the color chart in the instruction for use of parts catalogue.

Color label

VFR800FIW

R-157

R157



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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.

Color chart

Pearl procyon

black

Pearl cancer

white

Clean silver

metallic

Bake red

metallic

Sirius blue

metallic

NH-A06P NH-495P NH-A05M R-283M B-178M

No. Name of colored parts Basic part No. NHA06 NH495 NHA05 R283 B178

Initial

applicable

model

Final

applicable

model

1 BOX, INNER 64304-KSY-900 ZA ZA ZA ZA ZA F-7 1

2 COVER COMP., HANDLE 53250-KSY-900 ZA ZA ZA ZA ZA F-5 7

3 COVER SET, FR. HANDLE 53204-KSY-900 ZC ZD ZB ZE ZA F-5 4

4 COVER SET, FR. HANDLE 53204-KSY-910 ZC ZD ZB ZE ZA F-5 4

5 COVER SET, L. BODY 83550-KSY-900 ZC ZD ZB ZE ZA F-9 7

6 COVER SET, R. BODY 83450-KSY-900 ZC ZD ZB ZE ZA F-9 5

7 COVER SET, RR. CENTER 83700-KSY-900 ZC ZD ZB ZE ZA F-9 9

8 COVER, BATTERY BOX 64312-KSY-900 ZA ZA ZA ZA ZA F-8 3

9 COVER, CENTER 80152-KSY-900 ZA ZA ZA ZA ZA F-9 2

10 COVER, FR. 64301-KSY-900 ZC ZD ZB ZE ZA F-6 4

11 COVER, FR. LOWER 61100-KSY-900 ZB ZA ZA ZB ZB F-6 1

12 COVER, L. FR. FORK 51104-KSY-900 ZA ZA ZA ZA ZA F-10 6

13 COVER, L. SIDE 83601-KSY-900 ZB ZA ZA ZB ZB F-9 8

14 COVER, R. FR. FORK 51103-KSY-900 ZA ZA ZA ZA ZA F-10 5

15 COVER, R. SIDE 83501-KSY-900 ZB ZA ZA ZB ZB F-9 6

16 COVER, RR. CENTER LOWER 83751-KSY-900 ZB ZA ZA ZB ZB F-9 10

17 EMBLEM, BODY COVER 87554-KSY-900 ZA ZA ZA ZA ZA F-30 1

18 EMBLEM, FR. HANDLE COVER 87563-KSY-900 ZA ZA ZA ZA ZA F-30 3

19 HOOK, LUGGAGE 81132-GAH-000 ZW ZW ZW ZW ZW F-7 6

20 LABEL, COLOR 87565-KSY-900 ZA ZB ZC ZD ZE F-29 3




Applicable

block

No.

Ref.No.CODE

SC125SH5/SC1252SH5/SC1253SH5/SC1254SH5

SC125SH(SC125SH5)

SC1252SH(SC1252SH5)

SC1253SH(SC1253SH5)SC1254SH(SC1254SH5)

MODEL

COLORApplicable model



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Pearl procyon

black

Pearl cancer

white

Clean silver

metallic

Bake red

metallic

Sirius blue

metallic

NH-A06P NH-495P NH-A05M R-283M B-178M

No. Name of colored parts Basic part No. NHA06 NH495 NHA05 R283 B178

Initial

applicable

model

Final

applicable

model

24 LABEL, DRIVE 87560-MW0-670 ZB ZB ZB ZB ZB F-29 2

25 LID, BRAKE FLUID MAINTENANCE 53207-KSY-900 ZC ZD ZB ZE ZA F-5 5

26 LID, INNER BOX 64308-KSY-900 ZA ZA ZA ZA ZA F-7 2

27 MARK, RR. CENTER COVER 87561-KSY-900 ZA ZB ZB ZA ZB F-30 2

28 MAT, FLOOR 64320-KSY-900 ZA ZA ZA ZA ZA F-8 4

29 MAT, FLOOR 64320-KSY-910 ZA ZA ZA ZA ZA F-8 4

30 SEAT COMP., DOUBLE 77200-KSY-900 ZA ZA ZA ZA ZA F-14 3

31 SKIRT, L. SIDE 83620-KSY-900 ZB ZA ZA ZB ZB F-8 6

32 SKIRT, R. SIDE 83520-KSY-900 ZB ZA ZA ZB ZB F-8 5

33 STEP, FLOOR 64310-KSY-900 ZA ZA ZA ZA ZA F-8 2

34 WHEEL SUB ASSY., FR. 44650-KSY-880 ZA ZA ZA ZA ZA F-12 5

35 WHEEL SUB ASSY., RR. 42650-KSY-880 ZA ZA ZA ZA ZA F-13 2

SC1254SH(SC1254SH5)MODEL SC125SH5/SC1252SH5/SC1253SH5/SC1254SH5

COLORApplicable model

Applicable

block

No.

Ref.No.CODE

SC125SH(SC125SH5)

SC1252SH(SC1252SH5)

SC1253SH(SC1253SH5)



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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.)

1 < > 3 8 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 l ist 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 hose, general purpose hoses and vinyl hose

Fuel hoses/Tubes

Standard part No.

Bulk part No.

Bulk part

Inner diameter mm

Length m

95001-30xxx-2x 95001-30001-20M 3.0 195001-30xxx-3x 95001-30001-30M 3.0 1

95001-30xxx-4x 95001-30001-40M 3.0 1

95001-35xxx-2x 95001-35001-50M 3.5

13

95001-35xxx-3x 95001-35001-60M

3.5 1

3

95001-35xxx-4x 95001-35001-60M

3.5 1

3

95001-35xxx-5x 95001-35001-50M

3.5 1

3

95001-35xxx-6x 95001-35001-60M

3.5 1

3

95001-45xxx-2x 95001-45001-50M

4.5 1

3

95001-45xxx-3x95001-45001-60M

4.513

8

95001-45xxx-4x95001-45001-60M

4.5138

95001-45xxx-5x 95001-45001-50M

4.5 1

3

95001-45xxx-6x95001-45001-60M

4.5138

95001-55xxx-2x95001-55001-50M

5.5138

95001-55xxx-3x 95001-55001-60M

5.5 138

95001-55xxx-4x95001-55001-60M

5.5138

95001-55xxx-5x95001-55001-50M

5.5138

95001-55xxx-6x95001-55001-60M

5.5138

95001-75xxx-2x 95001-75001-50M

7.5 13

95001-75xxx-3x95001-75001-60M

7.5138

95001-75xxx-4x95001-75001-60M

7.5138

95001-75xxx-5x 95001-75001-50M

7.5 1

3

95001-75xxx-6x95001-75001-60M

7.5138

95001-80xxx-2x 95001-80001-50M 8.0 1

95001-80xxx-3x 95001-80001-60M 8.0 1

95001-80xxx-4x 95001-80001-60M 8.0 1

95001-80xxx-5x 95001-80001-50M 8.0 1

95001-80xxx-6x 95001-80001-60M 8.0 1

Fuel hoses/Tubes

Standard part No.

Bulk part No.

Bulk part

Inner diameter mm

Length m



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Vinyl Itube

Standard partNo.

Bulk part No.

Bulk part

Inner dia-metermm

Outer dia-metermm

Lengthm

95003-01xxx-3x 95003-01001-60M

2.9 6.8 1

3

95003-01xxx-60 95003-01001-60M

2.9 6.8 1

3

95003-03xxx-3x 95003-03001-60M

3.0 6.0 1

3

95003-03xxx-60 95003-03001-60M

3.0 6.0 1

3

95003-05xxx-3x95003-05001-60M

3.5 6.5138

95003-05xxx-6095003-05001-60M

3.5 6.5138

95003-07xxx-1x95003-07001-10M

4.0 7.0138

95003-07xxx-2095003-07001-10M

4.0 7.0138

95003-07xxx-3x95003-07001-60M

4.0 7.0138

95003-07xxx-6095003-07001-60M

4.0 7.0138

95003-07xxx-7x95003-07001-70M

4.0 7.0138

95003-08xxx-1x95003-08001-10M

4.5 6.5138

95003-09xxx-3x 95003-09001-60M

4.5 8.0 1

3

95003-09xxx-60 95003-09001-60M

4.5 8.0 1

3

95003-10xxx-1x 95003-10001-10M

5.0 8.0 1

3

95003-10xxx-20 95003-10001-10M

5.0 8.0 1

3

95003-10xxx-3x 95003-10001-60M 5.0 8.0

13

95003-10xxx-60 95003-10001-60M

5.0 8.0 1

3

95003-11xxx-3x95003-11001-60M

5.0 9.0138

95003-11xxx-6095003-11001-60M

5.0 9.0138

95003-12xxx-1x95003-12001-10M

5.0 7.0138

95003-12xxx-2095003-12001-10M

5.0 7.0138

95003-14xxx-1x 95003-14001-10M

6.0 9.0 1

3

95003-14xxx-20 95003-14001-10M

6.0 9.0 1

3

95003-14xxx-3x 95003-14001-60M

6.0 9.0 1

3

95003-17xxx-1x 95003-17001-10M

7.0 9.0 1

3

95003-19xxx-1x95003-19001-10M

7.0 11.0138

95003-19xxx-2095003-19001-10M

7.0 11.0138

95003-19xxx-3x95003-19001-60M

7.0 11.0138

95003-19xxx-6095003-19001-60M

7.0 11.0138

95003-21xxx-1x 95003-21001-10M

8.0 9.0 1

3

95003-21xxx-20 95003-21001-10M

8.0 9.0 1

3

95003-23xxx-1x 95003-23001-10M

8.0 12.0 1

3

95003-23xxx-20 95003-23001-10M

8.0 12.0 1

3

95003-23xxx-3x95003-23001-60M

8.0 12.0138

95003-23xxx-6095003-23001-60M

8.0 12.0138

95003-25xxx-1x 95003-25001-10M

9.0 11.0 1

3

95003-25xxx-20 95003-25001-10M

9.0 11.0 1

3

95003-25xxx-3x 95003-25001-60M

9.0 11.0 1

3

95003-25xxx-7x 95003-25001-70M 9.0 11.0 13

95003-27xxx-1x 95003-27001-10M

9.0 13.0 1

3

95003-27xxx-20 95003-27001-10M

9.0 13.0 1

3

95003-27xxx-3x 95003-27001-60M

9.0 13.0 1

3

95003-27xxx-60 95003-27001-60M

9.0 13.0 1

3

95003-33xxx-1x 95003-33001-10M

10.0 14.0 1

3

95003-33xxx-20 95003-33001-10M

10.0 14.0 1

3

Vinyl Itube

Standard partNo.

Bulk part No.

Bulk part

Inner dia-metermm

Outer dia-metermm

Lengthm

95003-36xxx-1x95003-36001-10M

11.0 13.0138

95003-36xxx-2095003-36001-10M

11.0 13.0138

95003-37xxx-3x 95003-37001-60M95003-37003-60M>

11.0 15.0 1

3

95003-37xxx-60 95003-37001-60M

11.0 15.0 1

3

95003-38xxx-1x 95003-38001-10M

12.0 13.0 1

3

95003-38xxx-20 95003-38001-10M

12.0 13.0 1

3

95003-39xxx-1x 95003-39001-10M

12.0 14.0 1

3

95003-39xxx-20 95003-39001-10M 12.0 14.0 13

95003-40xxx-20 95003-40001-10M

12.0 16.0 1

3

95003-40xxx-3x 95003-40001-60M

12.0 16.0 1

3

95003-40xxx-60 95003-40001-60M

12.0 16.0 1

3

95003-43xxx-1x95003-43001-10M

13.0 15.0138

95003-43xxx-2095003-43001-10M

13.0 15.0138

95003-45xxx-1x95003-45001-10M

14.0 18.0138

95003-45xxx-2095003-45001-10M

14.0 18.0138

95003-50xxx-1x 95003-50001-10M

16.0 19.0 1

3

95003-50xxx-20 95003-50001-10M

16.0 19.0 1

3

95003-50xxx-3x 95003-50001-60M 16.0 19.0 13

95003-55xxx-1x 95003-55001-10M

17.5 20.5 1

3

95003-55xxx-20 95003-55001-10M

17.5 20.5 1

3

95003-60xxx-1x 95003-60001-10M

22.0 27.0 1

3

95003-60xxx-20 95003-60001-10M

22.0 27.0 1

3

95003-60xxx-3x 95003-60001-60M

22.0 27.0 1

3

95003-60xxx-60 95003-60001-60M

22.0 27.0 1

3

Vinyl Itube

Standard partNo.

Bulk part No.

Bulk part

Inner dia-metermm

Outer dia-metermm

Lengthm



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NOTE: X is displayed to represent the omitted numerals and letters of the romanalphabet.

X

General purpose hoses

Standard part No.

Bulk part No.

Bulk part

Innerdiameter

mm

Lengthm

95005-11xxx-3x 95005-11001-30M 11.0 1

95005-11xxx-5x 95005-11001-50M 11.0 1

95005-12xxx-1x 95005-12001-10M

12.0 1

3

95005-12xxx-2x 95005-12001-20M 12.0 1

95005-12xxx-3x 95005-12001-30M 12.0 1

95005-12xxx-5x 95005-12001-50M 12.0 1

95005-14xxx-1x 95005-14001-10M 14.0 1

95005-14xxx-2x 95005-14001-20M

14.0 13

95005-14xxx-3x 95005-14001-30M 14.0 1

95005-14xxx-5x 95005-14001-50M 14.0 1

95005-17xxx-1x 95005-17001-10M 17.0 195005-17xxx-2x 95005-17001-20M 17.0 1

95005-17xxx-3x 95005-17001-30M 17.0 1

95005-17xxx-5x 95005-17001-50M 17.0 1

95005-30xxx-3x 95005-30001-30M 3.0 1

95005-30xxx-5x 95005-30001-50M 3.0 1

95005-35xxx-1x95005-35001-10M

3.5138

95005-35xxx-2x 95005-35001-20M 3.5 1

95005-35xxx-3x 95005-35001-30M 3.5 1

95005-35xxx-4x95005-35001-10M

3.5138

95005-35xxx-5x 95005-35001-50M 3.5 1

95005-45xxx-1x95005-45001-10M

4.5138

95005-45xxx-2x 95005-45001-20M 4.5 1

95005-45xxx-3x 95005-45001-30M 4.5 1

95005-45xxx-4x95005-45001-10M

4.5138

95005-45xxx-5x 95005-45001-50M 4.5 1

95005-50xxx-3x 95005-50001-30M

5.0

13

95005-50xxx-5x 95005-50001-50M 5.0 1

95005-55xxx-1x95005-55001-10M

5.3138

95005-55xxx-2x 95005-55001-20M

5.3 1

3

95005-55xxx-4x95005-55001-10M

5.3138

95005-65xxx-1x 95005-65001-10M

6.5

13

95005-65xxx -2x 95005-65001-20M 6.5 1

95005-70xxx-3x 95005-70001-30M

7.0

13

95005-70xxx -5x 95005-70001-50M 7.0 1

95005-75xxx-1x 95005-75001-10M

7.3

13

95005-75xxx -2x 95005-75001-20M 7.3 1

95005-80xxx-1x 95005-80001-10M

8.0

13

95005-80xxx -2x 95005-80001-20M 8.0 1

95005-80xxx -3x 95005-80001-30M 8.0 1

95005-80xxx -5x 95005-80001-50M 8.0 1

95005-91xxx-3x 95005-91001-30M 12.0 1

95005-91xxx-5x 95005-91001-50M 12.0 1

95005-92xxx-3x 95005-92001-30M 12.0 1

95005-92xxx-5x 95005-92001-50M 12.0 1

General purpose hoses

Standard part No.

Bulk part No.

Bulk part

Innerdiameter

mm

Lengthm

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 theservice manual or the instructions issued with the bulk part.



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

(Example)

9 5 0 0 1 - 7 5 0 0 1 - 5 0 M

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). 0

Types of code: Fuel hose 2: Red outside braid

(3 mm inside dia. only) 3 mm5: Black inside braid 3: Red (3 mm inside dia. only) 3 mm4: Ash gray with red stri pe (3 mm inside dia. only) 3 mm6: Black

Vinyl hose 1: Clear 2: Black

3: Light red 6: Light red 7: Pale black

General hose 1: Ash gray 2: Ash gray

3: Black 5: Black

Lengths: 001: 1 m (standard) 003: 3 m008: 8 m

I.D code:(fuel hose and general purpose hose) 30: 3.0 mm 11:11 mm35: 3.5 mm 91:12 mm (outside dia. 12 mm 15 mm45: 4.5 mm 92:12 mm (outside dia. 12 mm 16 mm50: 5.0 mm 12:12 mm (outside dia. 12 mm 17 mm55: 5.3 mm, 5.5 mm 14:14 mm65: 6.5 mm 17:17 mm70: 7.0 mm75: 7.3 mm, 7.5 mm80: 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 mm03: ID . 3.0, OD. 6.0 mm 17: ID. 7.0, OD. 9.0 mm 38:ID. 12.0 , OD. 13.0 mm05: 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 mm08: ID . 4.5, OD. 6.5 mm 23: ID. 8.0, OD. 12 .0 mm 43:ID. 13.0 , OD. 15.0 mm09: ID . 4.5, OD. 8.0 mm 25: ID. 9.0, OD. 11 .0 mm 45:ID. 14.0 , OD. 18.0 mm12: ID . 5.0, OD. 7.0 mm 27: ID. 9.0, OD. 13 .0 mm 50:ID. 16.0 , OD. 19.0 mm10: ID . 5.0, OD. 8.0 mm 33: ID. 10.0, OD. 14 .0 mm 55:ID. 17.5 , OD. 20.5 mm11: 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



16/88

14

1

2004.08.10

This F.R.T. (Flat Rate Time) is used to determine the standard labor

time allowed for replacement of parts covered by the warranty

during the period the warranty is in effect.F.R.T. The F.R.T. for those

parts which are not listed herein should be determined from the

operation closely related to the replacement of that part.

F.R.T. F.R.T.

1. The F.R.T. is based on the following servicing conditions

F.R.T.

a.A liberal allowance is added to the net servicing time.

b.Standard times specified are based on the condition that the

necessary servicing tools listed in the service manual

(motorcycle) which describes the Honda service policy are

available close at hand and the work performed by a

mechanic with normal skill.

c.Time required for inspection and operational test following the

servicing is included in the F.R.T.

F.R.T.

How to use the flat rate time (F.R.T.)

F.R.T.

2. Method of computing

The job times are listed in tenth of an hour to simplify

computation.

(Example) 0.3 = 18 minutes5.6 = 5 hours and 36 minutes

0 .3 18

5.6 5 36

CONVERSION CHART

Hours

Minutes

Hours

Minutes

0.1 6 0.6 36

0.2 12 0.7 42

0.3 18 0.8 48

0.4 24 0.9 54

0.5 30 1.0 60



17/88

15

1

2004.08.10

3. Computing the F.R.T.

F.R.T.

The following are only examples and do not reflect the actualF.R.T. for this product.

F.R.T.When several jobs are performed at the same time, make the

calculation in the following manner.

a.Jobs of non duplicated nature

The F.R.T. for the job is obtained by totalling the F.R.T. for

each part replaced.

F.R.T. F.R.T. (Example) Replacement of head cover gasket and oil filter.

b.Jobs of duplicated nature

Take the F.R.T. for the last part to be replaced.

F.R.T. (Example) Replacement of piston and cylinder head gasket.

Service item

F.R.T.

Packing, cylinder head cover

0.5

Cartridge, oil filter

0.5

The F.R.T. for the job is: 0.5 + 0.5 = 1.0 F.R.T. 0.5 + 0.5 = 1.0

Service item

F.R.T.

Gasket comp., cylinder head

3.0

Piston

*5.0

The F.R.T. for the job is: 5.0 F.R.T. 5.0

c.Jobs of partially related nature

Total up the F.R.T. for all of the parts replaced and thensubtract the F.R.T. for the duplicated operation (i.e., cylinder

head gasket service).

F.R.T. F.R.T.

(Example) Replacement of valve and cylinder head.

The F.R.T. shown with (*) includes engine removal andinstallation.

* F.R.T. The parts, having the same number of man-hour, are

identified by a mark #, and classified under the title of their

representative work.

#

Service item

F.R.T.

Valve

*3.0

Head assy., cylinder

*4.0

Gasket comp., cylinder head

*2.5

The F.R.T. for the job is: (3.0 + 4.0) - 2.5 = 4.5 F.R.T. (3.0 + 4.0) - 2.5 = 4.5



18/88

16

1

2004.08.10

4. Operations other than replacing parts

a.Removal and installation

b.Adjustment, measurement and cleaning

Engine

No.

Service item

F.R.T.

1 Engine

1.0

2 Cylinder head

*1.5

3 Carburetor

0.4

4 Crankcase separation

*3.0

No.

Service item

F.R.T.

1 Spark plug adjustment and cleaning

0.1

2 Carburetor idle adjustment

0.1

3 Engine oil inspection

0.1

4 Compression-pressure measurement

0.2

5 Carburetor float level measurement

0.5

6 Throttle operation adjustment

0.1

7 Ignition timing inspection

0.2

8 Oil filter screen cleaning

0.2

9 Valve clearance adjustment

0.4

Frame

c.Overhaul

No.

Service item

F.R.T.

1 Front brake air bleeding

0.2

2 Front brake adjustment

0.1

3 Brake operation test

0.1

4 Headlight aiming

0.1

No.

Service item

F.R.T.

1 Carburetor

0.7



19/88

2004.08.1017

2

ENGINE GROUP

E-1

FAN COVER/SHROUD

E-2

CYLINDER HEAD COVER

E-3

CYLINDER HEAD

E-4

CAMSHAFT/VALVE

E-5

CAM CHAIN/TENSIONER

E-6

CYLINDER

E-7

RIGHT CRANKCASE COVER

E-8

GENERATOR

E-9

OIL PUMP



20/88

182004.08.10

ENGINE GROUP

2

E-10

STARTER MOTOR

E-11

LEFT CRANKCASE COVER

E-12

DRIVE FACE

E-13

DRIVEN FACE

E-14

TRANSMISSION

E-15

CRANKCASE

E-16

CRANKSHAFT/PISTON

E-17

CARBURETOR



21/88

2004.08.1019

3

FRAME GROUP

F-1

HEADLIGHT

F-2

SPEEDOMETER

F-3

HANDLE LEVER/SWITCH/CABLE

F-4

FR. BRAKE MASTER CYLINDER

F-5

STEERING HANDLE/HANDLE COVER

F-6

FRONT FENDER/FRONT COVER

F-7

INNER BOX

F-8

FLOOR PANEL

F-9

LUGGAGE BOX/BODY COVER



22/88

202004.08.10

FRAME GROUP

3

F-10

FRONT FORK

F-11

FRONT BRAKE CALIPER

F-12

FRONT WHEEL

F-13

REAR WHEEL

F-14

SEAT

F-15

FUEL TANK

F-16

BATTERY

F-17

AIR CLEANER

F-18

AIR SUCTION VALVE



23/88

2004.08.1021

FRAME GROUP

3

F-19

EXHAUST MUFFLER

F-20

STAND/KICK PEDAL

F-21

BRAKE PEDAL

F-22

REAR CUSHION

F-23

REAR FENDER

F-24

FRONT WINKER

F-25

REAR COMBINATION LIGHT

F-26

WIRE HARNESS

F-27

FRAME BODY



24/88

222004.08.10

FRAME GROUP

3

F-28

TOOLS

F-29

CAUTION LABEL

F-30

MARK


19KSY5S1 FM P 23 W d d A t 25 2004 5 48 PM


25/88

2004.08.1023

2

E-1 FAN COVER/SHROUD

Ref.No.

Part No.

Description

Reqd. QTY

SC125 5

Serial No.

Parts catalogue code

1 11384-KSY-900 CLAMPER, BREATHER TUBE .................................. .................................. ................... 12 19610-KSY-900 COVER COMP., FAN ............................. ..................................... ............................... 13 19613-KRW-900 CLAMPER, STARTING MOTOR CORD ............................... ................................ ....................... 14 19615-KRW-900 DUCT, CARBURETOR COOLING ........................... ............................... ............................... .. 15 19621-KSY-900 SHROUD A ............................. ................................ ..................................... ................... A 1

6 19624-KSY-900 GUIDE, CARBURETOR DRAIN TUBE ............................ ................................ ....... 17 19625-KSY-900 SEAL, SHROUD A ............................... .................................. ................................ ............... A 18 19630-KSY-900 SHROUD COMP. B ............................... ................................... ................................. ........ B 19 19632-KRW-900 CLIP, HIGHTENSION CORD ............................ ............................... ................................... ..... 1

10 19635-KSY-900 SEAL, SHROUD B ............................... .................................. ................................ ............... B 1

11 70529-657-670 GROMMET B, SIDE PANEL ............................. .................................... ......................... B 112 93904-35380 SCREW, TAPPING, 5X16 ............................ ..................................... ............................ 5X16 713 96001-06025-00 BOLT, FLANGE, 6X25 ............................. ................................... ................................. 6X25 3

Service item

F.R.T.

COVER COMP., FAN ............................. ......

0.2

SHROUD COMP. B ............................... ......

B

*1.1

SHROUD A ...................................................A

*1.2


19KSY5S1 FM Page 24 Wednesday August 25 2004 5:48 PM


26/88

242004.08.10

2

E-2 CYLINDER HEAD COVER

Ref.

No.

Part No.

Description

Reqd. QTY

SC125 5

Serial No.


1 11211-KSY-900 TUBE, BREATHER ............................. ................................... ................................. .................... 12 12310-KSY-900 COVER COMP., CYLINDER HEAD ............................ ................................ .................. 13 12391-KRW-900 GASKET, HEAD COVER ............................... .................................... ........................ 14 9500 2- 0212 0 CLIP, TUBE (B12) ............................. ................................... ................................. .......... B12 15 95002-41250-08 CLAMP, TUBE (D12.5) ............................... ..................................... ............................ D12.5 1

6 95701-06025-00 BOLT, FLANGE, 6X25 ............................. ................................... ................................. 6X25 37 95701-06050-00 BOLT, FLANGE, 6X50 .............................. .................................. ................................ 6X50 1

Service item

F.R.T.

COVER COMP., CYLINDER HEAD ............

0.2

.GASKET, HEAD COVER




27/88

2004.08.1025

2

E-3 CYLINDER HEAD

Ref.

No.

Part No.

Description

Reqd. QTY

SC125 5

Serial No.


1 12200-KSY-880 HEAD COMP., CYLINDER ............................. .................................. ................................ . 12 12211-KRW-900 HOLDER, CAMSHAFT ............................ ..................................... ............................... ... 13 12237-KRW-305 GUIDE, IN. VALVE (O.S.) ................................. ................................ ................... O.S. 24 12245-KRW-305 GUIDE, EX. VALVE (O.S.) ................................ .................................... ............... O.S. 24 12251-KSY-880 GASKET, CYLINDER HEAD ................................ ................................. ............................ 1

5 16201-KRW-910 GASKET, CARBURETOR INSULATOR .......................... ............................. ...................... 16 16211-KRW-900 INSULATOR, CARBURETOR ............................. ............................... .............................. 17 17110-KSY-900 PIPE COMP., INLET ............................... .................................... ................................ ........ 18 17256-KSY-900 BAND, INSULATOR ............................... ................................. ................................ .............. 19 18640-KSY-900 PIPE COMP., AIR FEED ............................. ..................................... .......................... 1

10 18646-GFC-900 GASKET, AIR INTAKE PIPE ............................. .................................... ............................. 111 31916-KRW-910 PLUG, SPARK, 56 ................................. ................................. ............................... ............... 56 (1)12 31917-KRW-910 PLUG, SPARK, 57 ................................. ................................. ............................... ............... 57 113 90033-KSY-900

BOLT, SPECIAL STUD, 37.5MM ................................ ................................ .....

37.5MM 2

14 90465-KRW-901 WASHER, 8MM .................................. ................................... ................................. ...............8MM 415 90482-KSB-900 WASHER, 4.5MM ............................... ................................. ................................... ............4.5MM 1

16 91301-028-000 O-RING, 27X2.0 ............................ .................................... ................................... ......... O 27X2.0 117 91305-028-900 O-RING, 9X1.6 .............................. ................................... ................................. .............. O 9X1.6 218 92900-06055-0B BOLT, STUD, 6X55 ................................ ................................ .................................. .... 6X55 219 93500-04025-0A SCEW, PAN, 4X25 .............................. ................................... .................................... ..... 4X25 120 94050-06000 NUT, FLANGE, 6MM ............................... ................................... ................................ .. 6MM 2

21 94050-08000 NUT, FLANGE, 8MM ............................... ................................... ................................ .. 8MM 422 94301-10160 DOWEL PIN, 10X16 ............................... ..................................... ............................... ....10X16 423 96001-06016-00 BOLT, FLANGE, 6X16 ............................. ................................... ................................. 6X16 324 96001-06100-00 BOLT, FLANGE, 6X100 .............................. ..................................... .......................... 6X100 2

Service item

F.R.T.

PLUG, SPARK, 56 .......................... .............56

0.1

PIPE COMP., AIR FEED .............................

0.2

PIPE COMP., INLET ....................................

0.4

GASKET, CYLINDER HEAD ........................

*1.5

.HOLDER, CAMSHAFTGUIDE, EX. VALVE .............................. ........

(INC. REAMING)

ADD 0.3 FOR EACH.0.3

EXC. VALVE REFACING

ADD MORE 0.2 IF PERFORMED. 0.2

*2.1

HEAD COMP., CYLINDER ..........................

*2.2

g y, g ,



28/88

262004.08.10

2

E-4 CAMSHAFT/VALVE

Ref.

No.

Part No.

Description

Reqd. QTY

SC125 5

Serial No.


1 12209-GFC-890 SEAL, VALVE STEM ............................... .................................... ................................ ........ 22 14100-KSY-900 CAMSHAFT COMP............... ................................... ............................... ............................ 13 14150-KRW-900 PLATE COMP., STOPPER ................................ .................................... ............................. 14 14431-KRW-900 ARM, VALVE ROCKER ............................... .................................... ................................. ..... 25 14450-KRW-900 SHAFT COMP., IN. ROCKER ARM ........................... ................................ ................ 1

6 14452-KRW-900 SHAFT, EX. ROCKER ARM .............................. .................................... ............................ 17 14711-KRW-900 VALVE, IN. .............................. .................................. ................................... .............................. 18 14721-KRW-900 VALVE, EX. .............................. ................................ ..................................... ............................ 19 14751-GBG-900 SPRING, VALVE OUTER .............................. .................................... ................................ .. 2

10 14761-GBG-900 SPRING, VALVE INNER ................................ ................................... ................................ .. 2

11 14771-KRS-830 RETAINER, VALVE SPRING ............................... .................................. ............................. 2

12 14775-MA6-000 SEAT, VALVE SPRING OUTER ............................... ................................... ................... 213 14781-KSY-900 COTTER, VALVE ................................ .................................... ................................ ................ 414 90012-KRW-900 SCREW, TAPPET ADJUSTING .................................. ................................. .................. 215 90206-KRW-900 NUT, TAPPET ADJUSTING ............................. ................................. .............................. 2

Service item

F.R.T.

ARM, VALVE ROCKER ................................

(SAME TIME FOR TWO UNITS)

*1.5

.CAMSHAFT COMP..PLATE COMP., STOPPERSPRING, VALVE OUTER .............................

ADD 0.1 FOR EACH.0.1INC. RELATIVE PART

*1.7

VALVE, EX. ...................................................

ADD 0.2 FOR EACH.0.2INC. REFACINGEXC. VALVE GUIDE REPLACEMENT

*1.8

1E__05__.FM Page 27 Thursday, August 26, 2004 2:27 PM


29/88

2004.08.1027

2

E-5 CAM CHAIN/TENSIONER

Ref.

No.

Part No.

Description

Reqd. QTY

SC125

5

Serial No.


1 14401-KSY-880 CHAIN, CAM ................................ ................................ .................................. ........................ 12 14510-KSB-900 TENSIONER COMP., CAM CHAIN ............................ ................................ ...................... 13 14520-KSY-900 LIFTER ASSY., TENSIONER ............................. .................................... ..................... 14 14523-KRW-910 GASKET, TENSIONER LIFTE ................................. ............................... ..................... 15 14531-KSB-900 PIVOT, CAM CHAIN TENSIONER .................................. ................................ .......... 1

6 14610-KRW-900 GUIDE COMP., CAM CHAIN ............................... ................................ ............................... 17 90004-GHB-660 BOLT, FLANGE, 6X22(NSHF) ................................ ..................................... .6X22 NSHF 28 90005-KW1-900 SCREW, PAN, 6X6 ............................... .................................. .................................. ......... 6X6 19 91301-HM5-630 O-RING, 15.2X1.5 .............................. ................................... ................................. .....O15.2X1.5 1

10 91306-MG3-000 O-RING, 1.5X9.5 ................................ ................................... ................................. ...... O1.5X9.5 1

Service item

F.R.T.

LIFTER ASSY., TENSIONER ........................

*1.2

GUIDE COMP., CAM CHAIN .....................

*1.5

TENSIONER COMP., CAM CHAIN .............

*2.0

CHAIN, CAM ................................ ................

*3.0



30/88

282004.08.10

2

E-6 CYLINDER

Ref.

No.

Part No.

Description

Reqd. QTY

SC125 5

Serial No.


1 12100-KRW-900 CYLINDER COMP. ............................. .................................. .................................. ............ 12 12191-KRW-910 GASKET, CYLINDER .............................. ..................................... ............................... ....... 13 90004-GHB-610 BOLT, FLANGE, 6X12(NSHF) ................................ ..................................... .6X12 NSHF 14 90461-KRW-900 WASHER, SEALING, 6.5MM ............................. .................................... .................... 6.5MM 15 9430 1- 1016 0 DOWEL PIN, 10X16.......................... ................................ ................................. ............ 10X16 2

Service item

F.R.T.

GASKET, CYLINDE........ ...............................

*1.8

CYLINDER COMP. .......................................

*1.9



31/88

2004.08.1029

2

E-7 RIGHT CRANKCASE COVER

Ref.

No.

Part No.

Description

Reqd. QTY

SC125 5

Serial No.


1 11331-KSY-900 COVER, R. CRANKCASE ................................. ............................... .................................. 12 11394-KRW-910 GASKET, R. COVER .............................. .................................... ................................ 13 12361-035-000 CAP, TAPPET ADJUSTING HOLE ............................. ................................ ............................. 14 15421-GFC-900 SCREEN, OIL FILTER ............................ .................................. .................................. ........... 15 15426-KCW-880 SPRING, OIL FILTER SCREEN ............................... ................................... ................... 1

6 15651-KSB-900 GAUGE, OIL LEVEL ............................... .................................. .................................. ........... 17 32961-KSY-900 CLAMPER, A.C. GENERATOR CORD ................................ ................................. .. 18 91201-KSB-900 OIL SEAL, 19.8X30X5 ................................. ..................................... .......................... 19.8X30X5 19 91302-KCC-900 O-RING, 30.8MM ............................... .................................. .................................. ......O 30.8MM 1

10 91307-035-000 O-RING, 18X3 ............................... ................................ .................................... ................O 18X3 1

11 94301-08140 DOWEL PIN, 8X14 ................................. ................................ ................................. .........8X14 2

12 96001-06032-00 BOLT, FLANGE, 6X32 ............................. ................................... ................................. 6X32 113 96001-06040-00 BOLT, FLANGE, 6X40 ............................. ................................... ................................. 6X40 114 96001-06095-00 BOLT, FLANGE, 6X95 ............................. ................................... ................................. 6X95 415 96001-06100-00 BOLT, FLANGE, 6X100 .............................. ..................................... .......................... 6X100 1

16 96001-06110-00 BOLT, FLANGE, 6X110 .............................. ..................................... .......................... 6X110 2

Service item

F.R.T.

SCREEN, OIL FILTER ............................ ......

0.2

GASKET, R. COVER ....................................

0.9

COVER, R. CRANKCASE ............................

1.1

.OIL SEAL, 19.8X30X519.8X30X5



32/88

302004.08.10

2

E-8 GENERATOR

Ref.

No.

Part No.

Description

Reqd. QTY

SC125 5

Serial No.


1 19510-KSY-900 FAN COMP., COOLING .............................. ..................................... ............................. 12 31110-KSB-880 FLYWHEEL COMP. ................................ ................................. ................................... ........... 13 31120-KSY-880 STATOR COMP. ................................ .................................... ................................ ............... 14 90439-KRW-901 WASHER, 24X12X2.3 .................................. ..................................... .......................... 24X12X2.3 15 92101-050120A BOLT, HEX., 5X12 ............................ ..................................... .................................. .... 5X12 2

6 9405 0- 1200 0 NUT, FLANGE, 12MM ............................. ................................... ................................ 12MM 17 96001-06018-00 BOLT, FLANGE, 6X18 ............................. ................................... ................................. 6X18 48 96001-06020-00 BOLT, FLANGE, 6X20 ............................. ................................... ................................. 6X20 2

Service item

F.R.T.

FAN COMP., COOLING ..............................

0.3

FLYWHEEL COMP. .............................. ........

0.6

STATOR COMP. ................................ ...........

1.2



33/88

2004.08.1031

2

E-9 OIL PUMP

Ref.

No.

Part No.

Description

Reqd. QTY

SC125 5

Serial No.


1 15100-KRW-900 PUMP ASSY., OIL .................................. .................................... ................................ ........ 12 15133-KRW-900 SPROCKET, OIL PUMP DRIVEN(23T)..................................... .................... 23T 13 15141-KSY-880 CHAIN, OIL PUMP ................................. ................................ .................................. .. 14 15331-KRW-900 ROTOR, OIL PUMP INNER ................................. ................................. ......................... 15 15332-KRW-900 ROTOR, OIL PUMP OUTER .............................. ................................... ......................... 1

6 15711-KRW-900 SEPARATOR, OIL .............................. ................................. ................................... ............ 17 93500-03010-1A SREW, PAN, 3X10 ............................. .................................... ................................ ......... 3X10 18 94050-06000 NUT, FLANGE, 6MM ............................... ................................... ................................ .. 6MM 19 94303-04065 PIN C, DOWEL, 4X6.5 ............................... .................................... ............................ C 4X6.5 1

10 96001-06012-00 BOLT, FLANGE, 6X12 ............................. ................................... ................................. 6X12 2

11 96001-06025-00 BOLT, FLANGE, 6X25 ............................. ................................... ................................. 6X25 2

Service item

F.R.T.

SPROCKET, OIL PUMP DRIVEN ................

1.0

CHAIN, OIL PUMP ............................... .......

1.1

PUMP ASSY., OIL .................................. ......

INC. RELATIVE PART

1.2



34/88

322004.08.10

2

E-10 STARTER MOTOR

Ref.

No.

Part No.

Description

Reqd. QTY

SC125 5

Serial No.


1 28101-KRW-900 GEAR, STARTER REDUCTION(17/49T)...................... ................................ 17/49T 1

2 28102-KRW-900 SHAFT, STARTER REDUCTION GEAR ........................... ................................... ....... 13 28110-KRW-900 GEAR COMP., STARTING CLUTCH(60T)................ ............................ 60T 1

4 28120-KRW-900 OUTER COMP., STARTING CLUTCH .................................. ............................. 15 28125-KRW-900 FLANGE, STARTING CLUTCH ................................ ................................... ................ 1

6 28126-KRW-900 CAP, STARTING ROLLER SPRING ........................... .................................. .............. 37 28127-KRW-900 SPRING, ROLLER .............................. ................................... ................................. ................ 38 31201-KRW-900 BRACKET SET, FR. ........................... ................................... ................................. ............. 19 31202-KRW-900 YOKE SET ............................... ................................ ..................................... .............................. 1

10 31205-KRW-900 BOLT SET ............................... ................................ ..................................... .......................... 1

11 31210-KRW-900 MOTOR UNIT, STARTING ................................... ................................. ......................... 1

12 32106-KRW-900 O-RING ............................... ................................. ................................... ................................ ... O 113 32410-KSB-880 CABLE, STARTER MOTOR ............................... .................................... ......................... 114 32411-KRW-900 COVER, TERMINAL ............................... ................................. ................................ ................... 115 32414-KSB-900 COVER A, MAGNETIC SWITCH ................................ ................................ ................... A 1

16 32603-KSB-880 CABLE, EARTH ............................. .................................. .................................. .................... 117 90001-KRW-900 BOLT, SOCKET, 6X10 ............................... ................................. .............................. 6X10 318 90201-KRW-900 NUT, LOCK, 22MM ................................ ................................ .................................. .. 22MM 119 90403-KRW-900 WASHER, THRUST, 22.2X31X2.5 ................................. ................................... 22.2X31X2.5 120 90701-KRW-900 KEY, WOODRUFF, 25X14X4 ................................. ................................. ...................25X14X4 1

21 90702-KRW-900 DOWEL PIN, 5X6 .............................. .................................... ................................ .............5X6 1

Service item

F.R.T.

BRACKET SET, FR. ........................... ..........

0.8

.MOTOR UNIT, STARTINGCABLE, STARTER MOTOR .........................

0.9

.GEAR, STARTER REDUCTIONCABLE, EARTH ............................. ...............

1.0

GEAR COMP., STARTING CLUTCH ..........

1.1

OUTER COMP., STARTING CLUTCH ........

INC. RELATIVE PART

1.3



35/88

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E-10

33

STARTER MOTOR

2

22 91105-KRW-900 BEARING, NEEDLE, 28X32X17 .............................. .................................... ......... 28X32X17 123 91107-KRW-900 ROLLER, 10X10 ............................. ................................... ................................. ................ 10X10 324 91309-KCW-870 O-RING ............................... ................................. ................................... ................................. .. O 125 91981-KN7-670 SCREW-WASHER, 5X8 ......................................................................................................................... 1

26 93892-04006-08 SCREW-WASHER, 4X6 ......................................................................................................................... 2

27 94111-05000 WASHER, SPRING, 5MM ............................ ..................................... ............................ 5MM 228 96001-06016-00 BOLT, FLANGE, 6X16 ............................. ................................... ................................. 6X16 2

Ref.

No.

Part No.

Description

Reqd. QTY

SC125 5

Serial No.




36/88

342004.08.10

2

E-11 LEFT CRANKCASE COVER

Ref.

No.

Part No.

Description

Reqd. QTY

SC125 5

Serial No.


1 11340-KSY-900 COVER COMP., L. ................................. ................................ .................................... ........... 1

2 11342-KSY-900 PLATE, L. COVER ............................. .................................. .................................. .................... 1

3 11382-KSY-900 CLAMPER, BRAKE CABLE ........................... .............................. ............................... . 1

4 11386-KSY-900 STAY, MAIN STAND STOPPER ................................. ................................. ................. 1

5 11395-KSY-880 GASKET, L. COVER ............................... ................................... ................................. 1

6 90004-GHB-710 BOLT, FLANGE, 6X40(NSHF) ................................ ..................................... .6X40 NSHF 6

7 90004-GHB-760 BOLT, FLANGE, 6X65(NSHF) ................................ ..................................... .6X65 NSHF 2

8 9390 3- 3412 0 SCREW, TAPPING, 4X8 .............................. ..................................... ......................... M 4X8 4

9 9430 1- 0814 0 DOWEL PIN, 8X14 ................................. ................................ ................................. .........8X14 2

10 96001-06014-00 BOLT, FLANGE, 6X14 ............................. ................................... ................................. 6X14 1

Service item

F.R.T.

COVER COMP., L. .............................. .........

0.3

.GASKET, L. COVER

1E__12__.FM Page 35 Wednesday, August 25, 2004 6:08 PM


37/88

2004.08.1035

2

E-12 DRIVE FACE

Ref.

No.

Part No.

Description

Reqd. QTY

SC125

5

Serial No.


1 11206-KSY-900 PLATE, KICK RETURN STOPPER ................................ .................................. ....... 12 22011-KRW-900 PIECE SET, SLIDE ............................... .................................. ................................ .... 13 22102-KRW-900 FACE, DRIVE ................................ .................................. .................................. ......................... 14 22105-KRW-900 BOSS, DRIVE FACE ............................... ..................................... ............................... ........ 15 22110-KSY-900 FACE COMP., MOVABLE DRIVE ................................. ................................... .......... 1

6 22123-KRW-900 ROLLER SET, WEIGHT ............................... ..................................... .............................. 17 22131-KSB-900 PLATE, RAMP ............................... ................................. ................................... ............................. 18 28221-KRW-900 GEAR, KICK STARTER DRIVEN(20T) ................................ ......................... 20T 19 28223-KRW-900 SPRING, FRICTION STARTER GEAR...................... ................................... ....... 1

10 28230-KRW-900 GEAR COMP., STARTER IDLE ................................ .................................. ............ 1

11 28241-KRW-900 SHAFT, STARTER IDLE .............................. ..................................... ................................. . 112 28242-KRW-900 SPRING, STARTER IDLE ............................. .................................... .............................. 113 28250-KSB-900 SPINDLE COMP., KICK STARTER ................................ ................................. .............. 1

14 28254-KRW-900 BUSH, KICK SPINDLE (14X18X16)....................................... ............................... ..... 14X18X16 115 28255-KRW-900 BUSH, 12X16X12 .................................... .................................. .................................. .12X16X12 1

16 28281-KRW-900 SPRING, KICK STARTER ............................. .................................... ................................ . 117 28282-KRW-900 PIN, SPECIAL, 4.5MM ................................ ................................ .................................. .... 118 90441-KRW-901 WASHER, 12.2X29X2.5 ............................... .................................... ........................12.2X29X2.5 119 90451-KRW-900 WASHER, 14MM ................................ .................................. .................................. .............14MM 120 90452-KG8-000 WASHER, 12.5MM .................................. .................................. .................................. .....12.5MM 1

21 94030-12200 NUT, HEX., 12MM ............................. .................................... ................................ .....12MM 122 96001-06014-00 BOLT, FLANGE, 6X14 ............................. ................................... ................................. 6X14 123 96220-30085 ROLLER, 3X8.5 .................................. .................................. .................................. .............3X8.5 1

Service item

F.R.T.

FACE, DRIVE ................................ ................

0.5

.SPINDLE COMP., KICK STARTER

INC. RELATIVE PART

FACE COMP., MOVABLE DRIVE ...............

0.6

.GEAR COMP., STARTER IDLE

INC. RELATIVE PART

.ROLLER SET, WEIGHTGEAR, KICK STARTER DRIVEN .................

0.7

1E__13__.FM Page 36 Thursday, August 26, 2004 2:28 PM


38/88

36

2004.08.10

2

E-13 DRIVEN FACE

Ref.

No.

Part No.

Description

Reqd. QTY

SC125

5

Serial No.


1 22101-KRW-900 OUTER, CLUTCH ................................ ................................... ............................... ............. 12 22350-KRW-900 PLATE COMP., DRIVE ............................... ................................. ............................... 13 22361-KRW-900 PLATE, CLUTCH SIDE ................................ ................................ ........................... 14 22401-KRW-900 SPRING, CLUTCH ............................. .................................. .................................. ............. 35 22535-KRW-900 WEIGHT SET, CLUTCH ................................ .................................. ............................ 1

6 22804-GB2-000 RUBBER, CLUTCH DAMPER ................................. ................................... ................ 37 23100-KRW-900 BELT, DRIVE ............................ .................................... ................................ .......................... 18 23205-KRW-910 FACE SET, DRIVEN ............................... .................................... ................................ ........ 19 23210-KRW-900 FACE COMP., DRIVEN ................................ .................................... ................................ .. 1

10 23223-KRW-900 FACE SET, MOVABLE DRIVEN ................................. ................................ ................ 1

11 23225-KSY-900 PIN, ROLLER GUIDE ............................. ..................................... ............................... ........ 312 23226-KRW-900 ROLLER, GUIDE ................................ ................................... ................................. ............... 313 23233-GW3-010 SPRING, DRIVEN FACE ............................. .................................... ................................. .. 1

14 23237-KRW-900 COLLAR, SEAL ............................. ................................... ................................. .................... 115 23238-KRW-900 COLLAR, SPRING ............................. .................................... ................................ ....................... 1

16 90202-KRW-900 NUT, SPECIAL, 28MM ................................ ................................ ............................... 28MM 117 90441-KRW-901 WASHER, 12.2X29X2.5 ............................... .................................... ........................12.2X29X2.5 118 90605-166-720 CIRCLIP, 7MM .............................. ................................... ................................. ....................7MM 319 91004-KCW-880 BEARING, RADIAL BALL, 6902U ............................... .................................... ...6902U 120 91005-KCW-880 BEARING, NEEDLE, 20X29X18 .............................. .................................... .........20X29X18 1

21 91211-KCW-880 SEAL, DRIVEN FACE, 34X41X4 ................................ ................................ ....34X41X4 222 91384-KRW-900 O-RING, 38.8X1.9 .............................. ................................... ................................. .....O38.8X1.9 223 94030-12200 NUT, HEX., 12MM ............................. .................................... ................................ .....12MM 124 94520-28000 CIRCLIP, INTERNAL, 28MM ............................... .................................. .........................28MM 1

Service item

F.R.T.

OUTER, CLUTCH .............................. ...........

0.4

BELT, DRIVE ................................................

0.5

BEARING, NEEDLE, 20X29X18 ..................20X29X18

0.6

.BEARING, RADIAL BALL, 6902U6902U.FACE SET, DRIVEN

INC. RELATIVE PART

.FACE SET, MOVABLE DRIVEN.SPRING, DRIVEN FACEFACE COMP., DRIVEN ............................... .

0.7

.WEIGHT SET, CLUTCH

INC. RELATIVE PART



39/88

2004.08.1037

2

E-14 TRANSMISSION

Ref.

No.

Part No.

Description

Reqd. QTY

SC125 5

Serial No.


1 21301-KSY-900 COVER, MISSION .............................. ................................... ................................. ................... 12 21395-KSY-880 GASKET, TRANSMISSION COVER ............................... .................................. .............. 13 23411-KSB-900 SHAFT, DRIVE (15T) .............................. ................................... ................................. .. 15T 14 23420-KRW-900 GEAR COMP., COUNTERSHAFT LOW(13/42T)................................................... ............ 15 23431-KSB-900 SHAFT, FINAL ............................... ................................ .................................... ........................ 1

6 23432-KRW-900 GEAR, FINAL (40T) ............................ .................................... ................................ .............. 17 90004-GHB-680 BOLT, FLANGE, 6X28(NSHF) ................................ ..................................... .6X28 NSHF 38 90004-GHB-700 BOLT, FLANGE, 6X35(NSHF) ................................ ..................................... .6X35 NSHF 39 90103-KN8-000 BOLT, SPECIAL, 8MM ............................... ................................. ................................. 8MM 2

10 90474-333-000 WASHER, SEALING, 8MM ................................. ................................... ....................... 8MM 2

11 91202-KRW-900 OIL SEAL, 20X32X6 ............................... ................................... ................................. ... 20X32X6 112 94301-08140 DOWEL PIN, 8X14 ................................. ................................ ................................. .........8X14 2

13 94510-20000 CIRCLIP, EXTERNAL, 20MM ................................. ............................... ......................... 20MM 114 96100-62020-00 BEARING, RADIAL BALL, 6202 ................................ ................................ .......... 6202 115 96100-62030-00 BEARING, RADIAL BALL, 6203 ................................ ................................ .......... 6203 1

16 96100-62043-00 BEARING, RADIAL BALL, 6204 ................................ ................................ .......... 6204 1

Service item

F.R.T.

GASKET, TRANSMISSION COVER .............

0.6

.GEAR COMP., COUNTERSHAFT LOWE

.GEAR, FINALBEARING, RADIAL BALL, 6202 .................6202

ADD 0.1 FOR EACH.0.1

0.7

BEARING, RADIAL BALL, 6204 .................6202

0.9

.OIL SEAL, 20X32X620X32X6.SHAFT, DRIVESHAFT, FINAL ................................... ...........

1.0

COVER, MISSION ........................................

1.1



40/88

382004.08.10

2

E-15 CRANKCASE

Ref.

No.

Part No.

Description

Reqd. QTY

SC125 5

Serial No.


1 11100-KSY-880 CRANKCASE COMP., R. ............................. .................................... .............................. 12 11102-GW3-980 BUSH, ENGINE HANGER RUBBER ............................... ................................ ... 23 11191-KRW-910 GASKET, CRANKCASE ............................... ..................................... ................................ .. 14 11200-KSY-880 CRANKCASE COMP., L. ............................. .................................... .............................. 15 11203-GC7-300 BUSH, RR. CUSHION UNDER RUBBER.............. ............................... ............. 1

6 11221-KSB-900 TUBE, MISSION BREATHER ................................. ............................... ........................ 17 90031-KSB-900 BOLT A, CYLINDER STUD(8X187.5).................................................... A 8X187.5 28 90032-KSB-900 BOLT B, CYLINDER STUD.... ................................... .................................. ............... B 29 91003-KCW-880 BEARING, RADIAL BALL, 6301 ................................ ................................ .......... 6301 1

10 91009-GW3-980 BEARING, RADIAL BALL, 6004UU ................................ ................................ 6004UU 1

11 91201-KSB-900 OIL SEAL, 19.8X30X5 ................................. ..................................... .......................... 19.8X30X5 112 91255-KRW-900 OIL SEAL, 27X42X7 ............................... ................................... ................................. ... 27X42X7 113 92800-12000

BOLT, DRAIN PLUG, 12MM ................................. ................................. ................12MM 114 94109-12000 WASHER, DRAIN PLUG, 12MM ................................ .................................. ..........12MM 115 94301-08140 DOWEL PIN, 8X14 ................................. ................................ ................................. .........8X14 2

16 96001-06050-00 BOLT, FLANGE, 6X50 .............................. .................................. ................................. 6X50 217 96100-60020-00 BEARING, RADIAL BALL, 6002 ................................ ................................ .......... 6202 1

Service item

F.R.T.

BEARING, RADIAL BALL, 6301 .................

6301ADD 0.1 FOR EACH.0.1

0.8

OIL SEAL, 27X42X7 .............................. ......27X42X7

1.0

BEARING, RADIAL BALL, 6004UU ............6004UU

1.2

BOLT A, CYLINDER STUD .........................

AADD 0.1 FOR EACH.0.1

*1.9

GASKET, CRANKCASE ................................

*3.0

OIL SEAL, 19.8X30X5 ............................... ..

19.8X30X5

*3.2

CRANKCASE COMP., R. ............................ .

*3.4

CRANKCASE COMP., L. ............................ .

*3.9



41/88

2004.08.1039

2

E-16 CRANKSHAFT/PISTON

Ref.

No.

Part No.

Description

Reqd. QTY

SC125 5

Serial No.


1 13000-KSY-900 CRANKSHAFT COMP. ............................. .................................... ............................... ... 12 13011-KSY-880 RING SET, PISTON (STD) ................................ .................................... ........... 1

13021-KSY-880 RING SET, PISTON (0.25) ............................... .................................... ............... 0.25 (1)13031-KSY-880 RING SET, PISTON (0.50) ............................... .................................... ............... 0.50 (1)13041-KSY-880 RING SET, PISTON (0.75) ............................... .................................... ............... 0.75 (1)13051-KSY-880 RING SET, PISTON (1.00) ............................... .................................... ............... 1.00 (1)

3 13101-KRW-900 PISTON (STD.) ................................... ................................. ................................... ... 113102-KRW-900 PISTON (0.25) .................................... ................................ .................................... ......... 0.25 (1)13103-KRW-900 PISTON (0.50) .................................... ................................. ................................... ......... 0.50 (1)13104-KRW-900 PISTON (0.75) .................................... ................................. ................................... ......... 0.75 (1)13105-KRW-900 PISTON (1.00) .................................... ................................ .................................... ......... 1.00 (1)

4 13111-KRW-900 PIN, PISTON ............................ .................................... ................................ .............................. 15 14311-KSY-900 SPROCKET, TIMING (17T) ............................... .................................... ................... 17T 1

6 15131-KRW-900 SPROCKET, OIL PUMP DRIVE (17T) ............................... .......................... 17T 17 90701-KRW-900 KEY, WOODRUFF, 25X14X4 ................................. ................................. ...................25X14X4 18 91002-KRW-900 BEARING, RADIAL BALL (63/22) ................................ ................................. 63/22 29 9460 1- 1500 0 CLIP, PISTON PIN, 15MM ............................... .................................... .................. 15MM 2

Service item

F.R.T.

PIN, PISTON ........................... ......................

1.9

PISTON ..........................................................

2.0

.RING SET, PISTONCRANKSHAFT COMP. .................................

*3.1

SPROCKET, OIL PUMP DRIVE ..................

*3.2

SPROCKET, TIMING .............................. ......

*3.4

BEARING, RADIAL BALL ............................

R. SIDE 3.33.3

*3.5



42/88

402004.08.10

2

E-17 CARBURETOR

Ref.

No.

Part No.

Description

Reqd. QTY

SC125 5

Serial No.


1 16010-KRW-910 GASKET SET ................................ ................................. ................................... ................. 12 16012-KSY-880 NEEDLE SET, JET ............................. ................................... ................................. ............... 13 16013-KSB-880 FLOAT SET ................................... ................................ .................................... ..................... 14 16015-KRW-910 CHAMBER SET, FLOAT ................................ ................................... ................................ .. 15 16016-KRW-910 SCREW SET A .................................. .................................. .................................. ..... 1

6 16028-KRW-910 SCREW SET B .................................. .................................. .................................. ..... 17 16037-KSB-880 PLATE SET, VALVE ............................. ................................... ................................. ....... 18 16046-KSY-880 BYSTARTER ASSY., AUTO ............................... .................................... ............. 19 16048-KRW-910 VALVE SET, AIR CUT ................................ ................................ .................................. .... 1

10 16050-KRW-910 SPRING, COMPRESSION COIL ................................. ................................ ................................. 1

11 16080-KRW-910 SCREW, PAN, 5X12 ............................... ..................................... ............................... ..... 5X12 212 16100-KSY-880 CARBURETOR ASSY. (VE49E A) .............................. ................................ ... VE49EA 1

13 16107-KEJ-C30 TOP .................................... ................................ .................................... ................................ ....... 114 16111-KRW-910 PISTON COMP., VACUUM ................................... ................................ ..................... 115 16119-KSB-880 STAY, WIRE .................................. ................................. ................................... ..................... 1

16 16131-KSB-880 PLATE, SET ................................... ................................. ................................... ................. O 117 16140-KSB-880 BODY COMP., BYSTARTER ............................. .................................... ...................... 118 16155-GCC-B50 VALVE COMP., FLOAT ............................... ..................................... ................................ .. 119 16165-KRW-910 HOLDER, NEEDLE JET ................................ ................................... ................................ ........ 120 16178-KSB-880 BINDER .............................. ................................ .................................... ................................ ....... 1

21 16179-KSB-880 BINDER .............................. ................................ .................................... ................................ ....... 1

Service item

F.R.T.

PISTON COMP., VACUUM ..........................

0.3

CHAMBER SET, FLOAT ............................. .

0.4

BYSTARTER ASSY., AUTO .........................

0.5

.FLOAT SET.JET, MAIN,.VALVE COMP., FLOATCARBURETOR ASSY. ..................................

0.6

.NEEDLE SET, JET



43/88

2004.08.10

E-17

41

CARBURETOR

2

22 16190-GCC-B50 CAP, HOLDER .............................. .................................. .................................. ........................ 123 16199-KRW-910 TUBE, AIR VENT ............................... .................................... ................................ ................... 124 93500-04008-1H SCREW, PAN, 4X8 ............................... .................................. .................................. ......... 4X8 225 93500-04014-1H SCREW, PAN, 4X14 ............................... ..................................... ............................... ..... 4X14 426 93892-04008-18 SCREW-WASHER, 4X8 ............................... ................................. .................................. 4X8 227 93892-04010-18 SCREW-WASHER, 4X10 .............................. ..................................... ........................... 4X10 228 93892-05012-18 SCREW-WASHER, 5X12 .............................. ..................................... ........................... 5X12 229 95002-02079 CLIP, TUBE (B7) ............................... .................................... ................................ ............ B7 230 95002-02089 CLIP, TUBE (B8) ............................... .................................... ................................ ............ B8 2

31 95005-35170-20 TUBE, 3.5X170(95005-35001-20M)............................................ 3.5X170 95005-35001-20M 132 95005-45270-50 TUBE, 4.5X270(95005-45001-50M)............................................ 4.5X270 95005-45001-50M 133 99101-KSB-0000 JET, #102 ................................ ..................................... ................................ .........................#102 134 99103-KCW-0000 JET, SLOW, #80 ................................ ................................... ................................. ......... #80 1

Ref.

No.

Part No.

Description

Reqd. QTY

SC125 5

Serial No.




44/88

422004.08.10

3

F-1 HEADLIGHT

Ref.

No.

Part No.

Description

Reqd. QTY

SC125 5

Serial No.


1 33110-KSY-880 HEADLIGHT UNIT ............................. ................................... ................................. ............. 1

2 33112-KSY-880 COVER, SOCKET .............................. ................................... ................................. .................... 1

3 33120-KSY-880 SOCKET COMP. ................................ .................................. .................................. ..... 1

4 33301-KSY-880 BULB, POSITION LIGHT ............................ ..................................... ................................ .. 1

5 34901-KSY-880 BULB, HEADLIGHT (12V 35/35W) ............................... ......................... 12V 35/35W 1

6 9390 3- 2522 0 SCREW, TAPPING, 5X12 ............................ ..................................... ........................... 5X12 5

7 9410 3- 0580 0 WASHER, PLAIN, 5MM ............................... ..................................... ................................ 5MM 5

Service item

F.R.T.

BULB, HEADLIGHT .............................. ........

0.2

.BULB, POSITION LIGHT

.SOCKET COMP.HEADLIGHT UNIT ........................................

0.3



45/88

2004.08.1043

3

F-2 SPEEDOMETER

Ref.

No.

Part No.

Description

Reqd. QTY

SC125 5

Serial No.


1 34908-GW3-780 BULB, WEDGE BASE (T10)(12V 3.4W) ................................ ................................... ........... 2

2 34908-GW3-980 BULB, WEDGE BASE (12V 3W) ................................ ................................... 1 2V 3W 3

3 37200-KSY-880 SPEEDOMETER ASSY. .............................. ..................................... .......................... 1 -------- --------1CH,3CH37200-KSY-890 .............................................................................................................................................................. 1 -------- --------2CH,4CH

4 37210-KSY-880 SPEED & FUEL METER COMP. ................................. ............................... 1

5 37211-KSY-880 LENS .................................. ................................ .................................... ................................ ....... 1

6 37215-KSB-880 CLAMP, CORD ............................. ................................. ................................... ..................... 1

7 37220-KSY-880 CASE COMP. ............................... ................................ .................................... ..................... 1

8 37224-KSY-880 SOCKET COMP. ............................... ................................... ................................. ................ 1 -------- --------1CH,3CH37224-KSY-890 .............................................................................................................................................................. 1 -------- --------2CH,4CH

9 37305-GW3-780 SCREW-WASHER, 3X22 ............................. .................................... ............................. 3X22 3

10 38307-KSY-900 STAY, WINKER RELAY ............................... .................................... ...................... 1

11 44830-KSB-900 CABLE ASSY., SPEEDOMETER ................................. ................................ ...................... 112 90035-GW3-980 SCREW-WASHER, SPECIAL, 4X10 ............................... .................................. .... 4X10 2

13 90109-GFH-930 SCREW, TAPPING, 4X14 ................................ ................................ ............................ 4X14 1

14 91301-027-000 O-RING, 6.8X1.9 ............................... ................................. ................................... ....... O 6.8X1.9 1

15 93700-05018-0A SCREW, OVAL, 5X18 ............................ .................................... ................................ .. 5X18 1

16 93903-22420 SCR

manual desarme elite125

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