hfdawn-130511034451-phpapp01

While every care is taken in publishing this catalogue, the

company will not be responsible for any error and omission.

This catalogue is the property of Hero MotoCop Ltd.

Copy right of this catalogue is reserved.

21

3

4

5

INDEX

INSTRUCTIONS(Use of Parts Catalogue)

BLOCK INDEX

PART NO. INDEX

ENGINE GROUP

FRAME GROUP

3

Function and

component No.

1

INSTRUCTION FOR USE OF PARTS CATALOGUE

This parts catalogue is compiled of all service parts and Flat Rate Time (F.R.T.) for

-DAWN Motorcycle.

I. How to order parts

1. Information required

Replacement parts orders must contain both the part number and the

stamped number(s) as described below. This is because any changes and

modifications of parts are registered at with the pertinent parts

and stamped numbers.

Numbers needed

(a) Carburettor parts : Part number and

Stamped carburettor identification number.

(b) Engine parts : Part number and Stamped engine number.

(c) Frame parts : Part number and Stamped frame number.

2. Revision

When modifications or additions to this Parts Catalogue are made, a news

letters/revised edition will be issued at an appropriate time, with sucessively

progressing revision numbers. 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 SPARE PARTS

DEPARTMENTS, LTD.

Hero MotoCorp HF

Hero MotoCorp

Hero MotoCorp

II. How to read this Parts Catalogue

1. Make-up of the part number

(Example) (General Parts)

Colour Code

Subcontractor designation

Modification designation

Parts classification No.

(Example) Bolts, nuts and other standard parts

Function and

type No.

Dimension Chemical surface treatment

ISO

COLOUR CODE COLOUR DESCRIPTION

COLOUR REF. CODE MAIN BODY COLOUR

(NH-1) ZA BLACK (TYPE-1)

(NH-1) ZB BLACK (TYPE-2)

(R-184M) ZC CLASSY MAROON METALLIC

(R-195C) ZD CANDY BLAZING RED

NH-373M ZE BOON SILVER METALLIC

2. Colour codes

The colour code at the end of the part number indicates the colour. Code below ZA

in alphabetical order (such as ZA, ZB, ZC, etc.) do not indicate the colour directly,

but reference must be made to the code given in the description

column of this Parts Catalogue.

Hero MotoCorp

5

COLOUR REF. COLOUR DESCRIPTION

(NH-35M) CLOUD SILVER METALLIC

(NH-268M) VERNIER GREY METALLIC

(NH-1) BLACK

Hero MotoCop NON BODY COLOUR CODE

3. Abbreviations

The following abbreviations are used in this Parts Catalogue.

ASSY. .........Assembly L (100L).........Link (100 Links)

COMP.........Complete A.C. ...............Alternating current

R.................Right D.C................Direct current

L. ...............Left IN ..................Inlet

STD. ...........Standard EXH...............Exhaust

MM. ............Millimeter FR. ...............Front

G. ...............Gram RR.................Rear

T (22T). ......Tooth (22Teeth) Hex................Hexagonal

A.................Ampere A.M................Attaching Mark

V. ................Volt T.M. ...............Transcript Mark

W. ...............Watt C.D.I. .............Capacitive Discharge ignition

KMPH.........Kilometers per hour INC................Including

L.E.D. .........Light emitting diode

4. Dimensions

All dimensions are given in millimeters (mm) except in the case of steel balls,

tyres and tyre tubes and wheel rims.

Parts Example Interpretation

Bolt (Screw) 6 x 12 6mm diameter, 12mm length

Pin 8 x 14 8mm diameter, 14mm length

O-Ring 9.5 x 1.6 9.5mm diameter, 1.6mm thickness

Oil Seal 14 x 24 x 5 14mm inside diameter, 24mm outside

diameter, 5mm thickness

Tube 5 x 130 5mm inside diameter, 130mm length

5. Supercedence of parts

Part numbers given under the part name in the Description column indicate that

the part number has been superceded by that part number. may

make such supercedence without notice.

6. Assemblies

Sections framed with broken lines in the exploded view drawings are available as

complete assemblies. (Their individual parts can also be obtained.)

Hero MotoCorp

7. Required Quantity

The number given in the Reqd. No. column indicates the quantity of parts used in

the section described in that block.

Parts with quantities in ( ) represent optional parts.

Part whose required number is N, is a part whose required number can be

selected at need.

8. Part modifications and applicable serial numbers

In case where a part has been modified, the serial number of the first vehicle

(or frame, engine, carburettor) bearing the modification is listed in the

Serial No. Column.

9. Illustration

Illustration of parts given in parts catalogue diagrams are provided for

convenience identifying parts and may differ from the actual configuration of parts.

10. Models, area codes and applicable serial numbers

Models, area codes and applicable serial Nos. given in this parts catalogue can be

identified as follows.

Example

Applicable Applicable ApplicableArea

Model Type Engine Frame carburettorcode

serial No. serial No. identification No.

6

CD

DAWN

XXXX

ECYZXYYYYY

MBLXXXX

ELYZXYYYYY

ID 70B A 4LCLIndia

11. Location of stamped serial number

12. Selection table for lock or blank key

Refer to the following selection table to select the lock or blank key.

FRAME SERIAL NUMBER

ENGINE SERIAL NUMBER

CARBURETTOR IDENTIFICATION NUMBER

Type Key No.

TYPE 1 A** B**

TYPE 2 C** D**

Where ** is from 00~99

7

III. How to use the Flat Rate Time (F.R.T.)

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

for replacement of parts covered by the warranty during the period the warranty is

in effect. 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.

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

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 HERO HONDA service policies are available close at hand and the

work is 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.

2. Method of computing

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

(Example) 0.3 = 18 minutes

5.6 = 5 hours and 36 minutes

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

3. Computing the 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 totaling the F.R.T. for each part replaced.

(Example) Replacement of cylinder and clutch spring.

SERVICE ITEM F.R.T.

Cylinder 1.1

Clutch spring 0.7

The F.R.T. For the job is : 1.1+0.7=1.8

b. Jobs of duplicated nature

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

(Example) Replacement of piston and cylinder head gasket.

SERVICE ITEM F.R.T.

Cylinder head gasket 0.9

Piston 1.3

The F.R.T. for the job is : 1.3

c. Jobs of partially related nature

Total up the F.R.T. For all of the parts replaced and then subtract the F.R.T. for

the duplicated operation.

(Example) Replacement of gearshift drum and crankshaft assembly.

SERVICE ITEM F.R.T.

Gear Shift Drum *3.3

Crank Shaft *3.7

Crankcase Disassembly *3.2

The F.R.T. for the job is : (3.3+3.7)-3.2=3.8

Crankcase disassembly is the duplicated operations.

*The F.R.T. Shown with (*) includes engine removal and installation.

8

NO. SERVICE ITEM F.R.T.

1. Engine 1.3

2. Cylinder head 0.9

3. Carburettor 0.3

4. Operations other than replacing parts

a.Removed and installation

b. Adjustment, measurement and cleaning

Engine


1. Ignition timing - inspection 0.2

2 Spark plug adjustment and cleaning 0.1

3 Tappet adjustment 0.2

4 Carburettor idle adjustment 0.1

5 Engine oil inspection (excluding oil change) 0.1

6 Clutch adjustment 0.1

7 Cleaner element cleaning 0.2

8 Compression pressure measurement 0.1

9 Battery checking of electrolyte level and gravity 0.1

10 Carburettor float level measurement 0.5

11 Oil filter cleaning 0.5

12 Throttle operation adjustment 0.1

Frame


1 Front brake adjustment 0.1

2 Rear brake adjustment 0.1

3 Brake operation test 0.1

4 Headlight aimings 0.1

5 Drive chain (includes tension adjustment

however, does not include sprocket) 0.1

c. Overhaul


1 Carburettor 0.5

9

11

BLOCK INDEX ENGINE GROUP

2E-1 CYLINDER HEAD COVER/INLET PIPE. . . . . . . 19

E-2 CYLINDER/CYLINDER HEAD . . . . . . . . . . . . . . 20

E-3 CAMSHAFT/VALVE . . . . . . . . . . . . . . . . . . . . . . 21

E-4 CAM CHAIN TENSIONER . . . . . . . . . . . . . . . . . 22

E-5 RIGHT CRANKCASE COVER . . . . . . . . . . . . . . 23

E-6 CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24-25

E-7 LEFT CRANKCASE COVER/

A.C. GEN. ASSY... . . . . . . . . . . . . . . . . . . . . . 26-27

E-8 CRANK CASE/OIL PUMP . . . . . . . . . . . . . . . . . . 28

E-9 CRANK SHAFT/PISTON . . . . . . . . . . . . . . . . 29-30

E-10 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . 31-32

E-11 KICK STARTER. . . . . . . . . . . . . . . . . . . . . . . . . . 33

E-12 GEAR SHIFT . . . . . . . . . . . . . . . . . . . . . . . . . 34-35

E-13 CARBURETTOR . . . . . . . . . . . . . . . . . . . . . . . . . 36

BLOCK INDEX FRAME GROUP

12

F-1 HEAD LIGHT . . . . . . . . . . . . . . . . . . . . . . . . . 39-40

F-2 SPEEDOMETER/CABLE/KEY SET. . . . . . . . 41-42

F-3 HANDLE LEVER/SWITCH/. . . . . . . . . . . . . . . . . . .

CONTROL CABLE. . . . . . . . . . . . . . . . . . . . . 43-44

F-4 HANDLE PIPE/TOP BRIDGE . . . . . . . . . . . . . . . 45

F-5 STEERING STEM. . . . . . . . . . . . . . . . . . . . . . . . 46

F-6 FRONT FENDER . . . . . . . . . . . . . . . . . . . . . . . . 47

F-7 FRONT FORK. . . . . . . . . . . . . . . . . . . . . . . . . . . 48

F-8 FRONT BRAKE PANEL . . . . . . . . . . . . . . . . . . . 49

F-9 FRONT WHEEL . . . . . . . . . . . . . . . . . . . . . . . . . 50

F-10 REAR BRAKE PANEL. . . . . . . . . . . . . . . . . . . . . 51

F-11 REAR WHEEL . . . . . . . . . . . . . . . . . . . . . . . . 52-53

F-12 SEAT ASSY./CARRIER REAR . . . . . . . . . . . . . . 54

F-13 FUEL TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

F-14 SIDE COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

F-15 AIR CLEANER . . . . . . . . . . . . . . . . . . . . . . . . 57-58

F-16 MUFFLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

F-17 STEP ASSY/KICK STARTER/GEAR CHANGE

PADEL/SIDE STAND/PILLION STEP. . . . . . . 60-61

F-18 MAIN STAND/PEDAL BRAKE . . . . . . . . . . . . . . 62

F-19 REAR FORK/CHAIN CASE . . . . . . . . . . . . . . . . 63

F-20 REAR CUSHION. . . . . . . . . . . . . . . . . . . . . . . . . 64

F-21 REAR FENDER . . . . . . . . . . . . . . . . . . . . . . . . . 65

F-22 WINKERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

F-23 TAILLIGHT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

F-24 WIRE HARNESS/BATTERY . . . . . . . . . . . . . . . . 68

F-25 FRAME BODY/UTILITY BOX . . . . . . . . . . . . . . . 69

F-26 TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

F-27 STRIPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71-82

F-28 GUARD ENGINE (OPTIONAL). . . . . . . . . . . . . . 83

F-29 GUARD SARI (OPTIONAL) . . . . . . . . . . . . . . . . 84

F-30 MARK, CAUTION . . . . . . . . . . . . . . . . . . . . . . . . 85

BLOCK INDEX - ENGINE GROUP

E-1 17

2323

2323

2626

1212

2222

2222

66

1818

1616

1010

2525

11

15151717

171777

44

55

2121

1313

1414

1919

2424

22

33

88

99

1111

2020

99

1313

1919

2

18

17

20

15

15

18

13

5

7

9

6

8

19

14

16

3

1

4

4

19

19

19

11

1110

1012

10

10

11

E-2 18

3

16

16

9

9

10

12

11

17

13

13

13

1314

10

2

15

1

8

6

7

4

5

E-3 19

1312

11

11

9

3

8

7

10

5

6103

8

7

11

1

12

13 119

4

2

4

1

E-4 20

12

2

4

9

1

18

14

14

17

10

11

5

6

15

13

16

7

8

19

3

E-5 21

13

6

10

11

11

11

11

11

12

12

81

4

5

9

72

7

3

E-6 22

8

8

9

8

7

7

7

75

20 15

15

13

16

6

11

1111

19

18 10

2625

25 23

23

22

3

2

21

17

191

24

24

14

22

124

11

E-7 24 E-8 26

15 15

13 17

17

9

13

14

12

16

4

5

3

8

2

67

1

18

19

20

2020

19

20

10

11

10

11

E-9 27

53

4

5

6 7

10

111

9

10

8

2

13

2413

1018

18

16

14

4

3

2

23

1

5

17

17

19

19

7

9

25

25

21 11

12

22

22

15

6

20

20

8

13

8

7

911

12

12

6

5

4

2

11

101

3

12

10

185

25

25

7 6 6

66

8 9

1

14

11

13

21

3 3

4

1619

23

15

22

1724

202

1

2

BLOCK INDEX - ENGINE GROUP

E-10 29 E-11 30 E-12 30

E-13 32

14

BLOCK INDEX - FRAME GROUP

F-1 35 F-2 37 F-3 39

F-4 40 F-5 41 F-6 42

F-7 43

22

5544

33

1919

11

11 11

1188

1 1 11

66

2020

2020

77 002020

40406060

8080

100 100

120 120410410

k/h mk/h m

22

kmkm

ro Picl ro Picl

1111

9999

99

2222

2121

2323

2323

1010

2222

2121

2222

2121

SLD

SLD

LD

SLD

S

SLD

SLD

SLD SLD

21682168

82168

216

SLD SLD

LSDLSD

11A11A

SLDSLD

SLDSLD

20202020

2020

20202020

1414

1717

1313

1515

1616

1818

1212

F-8 45 F-9 46

1

8

2

7

4

9

9

10

1167

12

12

13

13

3

3

35

8

1918

2

3

1

4

4

4

4

5

6

7

9

10

11

12

14

17

16

21

20

22

2123

24 24

26

26

15

13

25

20

22

25

8

128

12

12

4

3

3

2

2

6

6

45

59

9

13

7

10

111

8

128

13

7

2

13

8

3

17

17

4

5

6

1

1

9

11

16

16

15

13

10

15

12

1214

14 14

4

2

5

7

76

6

3

5

12

10

11

6 2

25

4

3

20

12

21

15

17

5

14

22

19

21

15

2416

18 18

7

9

8

1

13

23

17

16

18

20

10

13

148

6

9

2

1

1

3

3

8

57

415

11 12

19

1210

13

1514

13

115

3

2

9

14

6

8

7

15


F-10 47 F-11 48 F-12 49

F-13 50 F-14 51 F-15 52

F-16 54 F-17 55 F-18 57

5

14

11

10

1

3

2

16

15

19

18

17

13

798

16

15

16

1516

15

13

6

4

12

1516

4

7

4

7

12

9

2

3

16

8

19

610

13

13

1

15

18

1114

17

5

2020

16

21

18

2

10

9

5

3

31222

24

8

23

15

1422

16 7

13

11

3

3

19

17

4

142

15

12

12

13

10

11

11

3

7

1

4

4

44

4

5

8

6

6

6

5

9

10

11

13

5

5

6

4

9

9

12

12

8

2

31

7

SLD

SLD

SDL SDL

2168

3

2 1

4

4

1

9

11

4

1

33

8

5

10

7

6

12

8

2

9

11

4

7

14

15

9

10

1718

37

37

22

28 31

31

32

32

28

19

29

29

20

21

24

30

20

21

22

23

35

17

10

38

26

8

11

112

639

5

34

4

3

36

25

25

71

38

33

12

2713

14

15

16

1

3

5

6

4

8

2

10

16

9

13

1415

11

7 12

15

15

88

22

1010

1919

1414

1212

44

1717

1919

1919

33

1111

11

19 19 1919

16161616

1515

1313

1515

77

55

66

1818

55

1818

99

88

22

77

66

55

33

12121010

1111

1313

1313

11

4499

1414

1515

1515

1414


F-19 58 F-20 59 F-21 60

F-22 61 F-23 63 F-24 64

F-25 66 F-26 68 F-27 69

14

16

13

11

11

11

11

15

17

1

23

4

5

9

10

7

15

20

18

19

8

12

13

9

1

1

2

9

7

9

7

8

4

5

4

5

3

6

3

6

8

7

9

9

7

3

2

6

5

7

8 7

9

1

4

8

6

9

1

12

17

17

214

21

21

21

18

18

1818

12

12

13

11 1412

36

7

7

8

10

9 11

6

5

5

15

20

16

4

2

1920

19

4

4

8

6

2

12

11

11

59

12

5

9

121

12

5

7

4

10

3

3

1

5

2

10

12

4

1EH

B

A BC EEC

B

H H

3

5

7

122

2

2

3

1

4

2

3


F-28 78 F-29 79

15

ENGINE GROUP

12

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

12301-GB6-911 COVER, CYLINDER HEAD ........................................................................ 1

12331-GB0-910 COVER R CYLINDER HEAD SIDE........................................................... 1

12341-KST-870 COVER L CYLINDER HEAD SIDE ........................................................... 1

12361-035-000 CAP, TAPPET ADJUSTING HOLE.............................................................. 1

12391-GW8-681 GASKET, CYLINDER HEAD COVER......................................................... 1

12394-GW8-681 GASKET, R CYLINDER HEAD SIDE COVER .......................................... 1

12395-GW8-681 GASKET, L CYLINDER HEAD SIDE COVER ........................................... 1

16211-459-750 INSULATOR, CARBURETTOR................................................................... 1

17111-198-900 PIPE INLET................................................................................................. 1

90201-GF6-000R NUT CAP, 7MM........................................................................................... 4

90442-GF6-000 WASHER, SEALING, 7MM......................................................................... 3

90443-GF6-010 WASHER, A SEALING, 7MM...................................................................... 1

90461-357-000 WASHER, SEALING, 12MM....................................................................... 1

91301-028-000 O-RING, 27X2............................................................................................. 1

91302-KEV-900 O-RING, 30.8X3.......................................................................................... 2

91304-GB1-900 O-RING, 25X2.4.......................................................................................... 1

95701-06110-00 BOLT, FLANGE, 6X110............................................................................... 1

Service Item F.R.T. Ref. Part No. Description Reqd. No./Model

No. HF-DAWN

19

* COVER, CYLINDER HEAD .................. 0.3

* GASKET, CYLINDER HEAD COVER ...

* COVER, R CYLINDER HEAD SIDE ... 0.1

* COVER, L CYLINDER HEAD SIDE .... 0.2

* S PARK PLUG ...................................... 0.1

* INSULATOR, CARBURETTOR ............ 0.2

* PIPE, INLET......................................... 0.3

E - 1

CYLINDER HEAD COVER/

INLET PIPE

3

FR

.

2

18

17

20

15

15

18

13

5

7

9

6

8

19

14

16

3

1

4

4

19

19

19

11

1110

1012

10

10

11

18

19

20

96001-06020-00 BOLT, FLANGE, SH.6X20........................................................................... 2

96001-06025-00 BOLT, FLANGE, SH.6X25........................................................................... 4

98056-57718-00 SPARK, PLUG CR7HSA(NGK)................................................................... 1


No. HF-DAWN

20

* COVER, CYLINDER HEAD .................. 0.3

* GASKET, CYLINDER HEAD COVER ...

* COVER, R CYLINDER HEAD SIDE ... 0.1

* COVER, L CYLINDER HEAD SIDE .... 0.2

* S PARK PLUG ...................................... 0.1

* INSULATOR, CARBURETTOR ............ 0.2

* PIPE, INLET......................................... 0.3

E - 1

CYLINDER HEAD COVER/

INLET PIPE

FR

.

2

18

17

20

15

15

18

13

5

7

9

6

8

19

14

16

3

1

4

4

19

19

19

11

1110

1012

10

10

11

12

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

12101-GF6-000 CYLINDER.................................................................................................. 1

12191-GS4-762 GASKET, CYLINDER.................................................................................. 1

12200-KST-940 HEAD COMP. CYLINDER........................................................................... 1

12237-GB4-305 GUIDE, IN VALVE ....................................................................................... 1

12245-GB4-305 GUIDE, EXH. VALVE .................................................................................. 1

12250-GF6-000 GASKET, ASSY. CYLINDER HEAD............................................................ 1

12251-GF6-000 GASKET, CYLINDER HEAD....................................................................... 1

12255-GF6-000 SEAS, CAM CHAIN CHAMBER ................................................................. 1

90033-041-020 BOLT, STUD, 6X32 ..................................................................................... 2

90082-035-000 BOLD, HS, 6MM ......................................................................................... 2

90602-BGO-900 COLLAR, 9.5MM......................................................................................... 1

90603-GF6-000 COLLAR, 14.8 MM...................................................................................... 1

90701-GF6-000 PIN, DOWL, 8X14....................................................................................... 4

91301-GF6-000 O-RING, 14.5MM ........................................................................................ 1

91303-GF6-000 PACKING, RUBBER, 16MM ....................................................................... 1

91305-028-150 O-RINGG, 9X1.6......................................................................................... 2

91306-GF6-000 GASKET, RUBBER, 9MM........................................................................... 1


No. HF-DAWN

21

E - 2

CYLINDER/CYLINDER HEAD

FR.

* CYLINDER ........................................... 1.2

* GASKET, CYLINDER ........................... 1.1

* HEAD, COMP., CYLINDER .................. 1.6

(INC. REAMING) .................................

* GUIDE, VALVE ....................................

(ADD 0.3 FOR EACH) .........................

(EXC. VALVE REFACING) ...................

(ADD MORE 0.2 IF PERFORMED) ......

* GASKET, CYLINDER HEAD ................ 0.9

* BOLT, STUD, 6 X 32 ............................ 0.3

(ADD 0.1 FOR EACH) .........................

3

16

16

9

9

10

12

11

17

13

13

13

1314

10

2

15

1

8

6

7

4

5

12

3

4

5

6

7

8

9

10

11

12

13

12209-GB4-685 SEAL, VALVE STEM (HITECH ARAI)......................................................... 2

14100-AAH-H41 SHAFT COMP., CAM .................................................................................. 1

14431-KST-940 ARM, VALVE ROCKER............................................................................... 2

14451-KST-940 SHAFT, ROCKER ARM............................................................................... 2

14711-GN5-910 VALVE, INLET............................................................................................. 1

14721-GF6-010 VALVE, EXHAUST ...................................................................................... 1

14751-GBG-900 SPRING, VALVE OUTER............................................................................ 2

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

14771-GB4-680 RETAINER, VALVE SPRING ...................................................................... 2

14775-MA6-000 SEAT, VALVE SPRIN OUTER..................................................................... 2

14781-MA6-000 COTTER, VALVE ........................................................................................ 4

90012-333-000 SCREW, TAPPET ADJUSTING .................................................................. 2

90206-001-000 NUT, TAPPET ADJUSTING ........................................................................ 2


No. HF-DAWN

22

E - 3

CAMSHAFT/VALVE

FR.

* CAMSHAFT COMP., ............................ 0.7

* ARM, VALVE ROCKER ........................ 1.1

(ONE OR ALL) .....................................

* VALVE .................................................. 1.4

(ADD 0.2 FOR EACH) .........................

(INC. REFACING) ................................

(EXC. VALVE GUIDE REPLACEMENT)

* SPRING, VALVE INNER ...................... 1.2

(ADD 0.1 FOR EACH) .........................

(INC. RELATIVE PART) ........................

1312

11

11

9

3

8

7

10

5

6103

8

7

11

1

12

13 119

4

2

4

1

12

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

14321-GB6-900 SPROCKET, CAM (28T) ............................................................................. 1

14401-178-000 CHAIN, CAM (84L)...................................................................................... 1

14500-035-020 ARM COMP., CAM CHAIN TENSIONER.................................................... 1

14502-086-000R ROLLER, CAM CHAIN TENSIONDER....................................................... 1

14531-035-000 PIVOT, CAM CHAIN TENSIONER.............................................................. 1

14541-GB4-681 SPRING, TENSIONER ............................................................................... 1

14550-GBO-910 PUSH ROD, COMP., TENSIONER............................................................. 1

14566-086-030 HEAD, CAM CHAIN TENSIONER, PUSH ROD......................................... 1

14610-086-000R ROLLER COMP., CAM CHAIN GUIDE....................................................... 1

14615-035-010 PIN, GUIDE ROLLER ................................................................................. 1

14670-035-030 SPROCKET, CAM CHAIN GUIDE (25T)..................................................... 1

14675-178-000 SPINDLE, CAM CHAIN GUIDE SPROCKET ............................................. 1

90081-035-000 BOLT, SEALING, 14MM.............................................................................. 1

90083-KVH-900 BOLT, KNOCK, 5MM................................................................................... 2



90481-035-000 WASHER, 8MM .......................................................................................... 1

90702-GB6-910 PIN, DOWEL, 8X12..................................................................................... 1

95701-08035-08 BOLT, FLANGE, 6X35................................................................................. 1


No. HF-DAWN

E - 4

CAM CHAIN TENSIONER

FR.

* SPROCKET, CAM(28T) ....................... 0.4

* ARM COMP., CAM CHAIN TENSIONER

* ROLLER, CAM CHAIN TENSIONER ...

* CHAIN, CAM (84L) .............................. 1.4

* PUSH ROD COMP., TENSIONER ....... 0.3

* ROLLER COMP., CAM CHAIN GUIDE 1.0

* SPROCKET, CAM CHAIN GUIDE ....... 1.6

* SPINDLE, CAM CHAIN GUIDE ...........

12

2

4

9

1

18

14

14

17

10

11

5

6

15

13

16

7

8

19

3

23

12

3

4

5

6

7

8

9

10

11

12

13

11330-AAH-H00 COVER COMP., R CRANK CASE (NH-3M).............................................. 1

11394-GW8-681 GASKET, R CRANK CASE COVER.......................................................... 1

15651-AAC-H00 GAUGE, OIL LEVEL ................................................................................... 1

22810-198-000 LEVER COMP., CLUTCH ........................................................................... 1

22815-166-000 SPRING, CLUTCH LEVER......................................................................... 1

32906-028-000 CLIP, HIGH TENSION CORD ..................................................................... 1

90702-GB6-910 PIN, DOWEL, 8X12..................................................................................... 2

91202-302-010 OIL SEAL, 13.8X24X5 ................................................................................ 1

91303-719-000 O-RING, 9MM ............................................................................................. 1

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

96001-06040-00 BOLT, FLANGE, SH. 6X40.......................................................................... 5

96001-06065-00 BOLT, FLANGE, SH. 6X65.......................................................................... 2

96001-06080-00 BOLT, FLANGE, SH. 6X80.......................................................................... 1


No. HF-DAWN

24

* COVER COMP., R CRANCK CASE ... 0.8

* GASKET, R CRANK CASE COVER ... 0.6

* LEVER COMP., CLUTCH ..................... 0.7


* OIL SEAL, 13.8 X 24 X 5 .....................

E - 5

RIGHT CRANKCASE COVER

FR.

13

6

10

11

11

11

11

11

12

12

81

4

5

9

72

7

3

12

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

15431-198-000 ROTOR, OIL FILTER .................................................................................. 1

15439-198-691 GASKET, OIL FILTER ROTOR ................................................................... 1

15441-198-000 COVER, OIL FILTER ROTOR..................................................................... 1

15661-198-000 PLATE, OIL SEPARATOR........................................................................... 1

22110-KST-940 OUTER, COMP., CLUTCH.......................................................................... 1

22121-198-900 CENTER, CLUTCH..................................................................................... 1

22201-GF6-000 DISK CLUTCH FRICTION .......................................................................... 4

22311-107-000 PLATE, CLUTCH ........................................................................................ 3

22350-115-020 PLATE, CLUTCH PRESURE...................................................................... 1

22361-KST-940 PLAGE, CLUTCH LIFTER .......................................................................... 1

22401-GF6-000 SPRING, CLUTCH...................................................................................... 4

22847-KCC-900 ROD, CLUTCH LIFTER .............................................................................. 1

23112-198-010 COLLAR, DRIVEN GEAR........................................................................... 1

23121-KST-901 GEAR, PRIMARY DRIVE (18T) .................................................................. 1

23216-GF6-000 COTTER, MAIN SHAFT.............................................................................. 2

23217-GF6-000 SET RING, MAIN SHAFT COTTER............................................................ 1

90231-087-0110 NUT, LOCK, 14MM ..................................................................................... 1

90231-198-000 NUT, B LOCK, 14MM ................................................................................ 1

90432-086-000 WASHER B LOCK..................................................................................... 2

90461-GF6-000 WASHER, SPLINE, 17MM.......................................................................... 1

91205-350-000 OIL SEAL, 6X25X6 ..................................................................................... 1


No. HF-DAWN

25

E - 6

CLUTCH

* ROTOR, OIL FILTER ............................ 0.9

* COVER, OIL FILTER ROTOR .............. 0.7

* PLATE, OIL SEPERATOR .................... 1.1

* OUTER COMP., CLUTCH .................... 1.2

* CENTER CLUTCH ...............................

* DISK, CLUTCH FRICTION ..................

(ONE OR ALL) .....................................


* PLATE, CLUTCH PRESSURE .............

* PLATE, CLUTCH LIFTER ....................

* SPRING CLUTCH (ONE OR ALL) .......

8

8

9

8

7

7

7

75

20 15

15

13

16

6

11

1111

19

18 10

2625

25 23

23

22

3

2

21

17

191

24

24

14

22

124

11

FR.

22

23

24

25

26

92020-06020-0A BOLT, HEX, 6X20........................................................................................ 2

92025-06025-0H BOLT, HEX 6X25......................................................................................... 4

93600-05012-1H SCREW, FLAT, 5X12 .................................................................................. 4

94101-06000 WASHER PLAIN, 6MM ............................................................................... 4

96100-60010-00 BEARING, RADIAL, BALL, 6001 ................................................................ 1


No. HF-DAWN

26

E - 6

CLUTCH

* ROTOR, OIL FILTER ............................ 0.9

* COVER, OIL FILTER ROTOR .............. 0.7

* PLATE, OIL SEPERATOR .................... 1.1

* OUTER COMP., CLUTCH .................... 1.2

* CENTER CLUTCH ...............................

* DISK, CLUTCH FRICTION ..................

(ONE OR ALL) .....................................


* PLATE, CLUTCH PRESSURE .............

* PLATE, CLUTCH LIFTER ....................

* SPRING CLUTCH (ONE OR ALL) .......

8

8

9

8

7

7

7

75

20 15

15

13

16

6

11

1111

19

18 10

2625

25 23

23

22

3

2

21

17

191

24

24

14

22

124

11

FR.

*COVER L CRANK CASE .................... 0.1

*A.C.GEN.ASSY., ................................... 0.5

*STATOR, COMP., .................................

*FLYWHEEL, COMP., ............................ 0.3

*OIL SEAL, 18.9 X 30 X 5 ......................

*O-RING, 107 X 2 ..................................

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

11321-KST-940 PLATE OIL SEPERATOR .............................................................................. 1

11341-AAH-H00 COVER L CRANK CASE ............................................................................ 1

11360-KST-941 COVER RR L., CRANK CASE ...................................................................... 1

31100-KWA-931 A.C.GEN. ASSY. ............................................................................................ 1

31110-KWA-931 FLYWHEEL, COMP. ...................................................................................... 1

31120-KWA-931 STATOR, COMP............................................................................................. 1

32961-KST-940 CLAMPER ACG CORD ................................................................................. 1

32981-GB4-780 GROMMET NEUTRAL SWITCH CORD........................................................ 1

90083-KVH-900 BOLT KNOCK 5MM....................................................................................... 2

90084-KST-850 CAP 14MM..................................................................................................... 1

90087-KST-850 CAP 30 MM.................................................................................................... 1

90410-HC4-000 WASHER 10MM ............................................................................................ 1

90702-GB6-910 PIN, DOWEL 8 X12 ....................................................................................... 2

91202-KTL-741 OIL SEAL 19X30X5 ....................................................................................... 1

91301-035-000 O-RING 107X2 .............................................................................................. 1

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

91317-171-000 O-RING 6X1.7 ............................................................................................... 2

91356-KGH-901 O-RING 30 MM.............................................................................................. 1

93600-06016-OA SCREW, FLAT, 6 X16 .................................................................................... 2


No. HF-DAWN

E - 7

LEFT CRANKCASE COVER/

A.C. GEN. ASSY.

FR. 23

23

26

12

22

22

6

18

16

10

25

1

1517

177

4

5

21

13

14

19

24

2

3

8

9

11

20

9

13

19

27

Ref. Part No. Description Reqd. No./Model

No. HF-DAWN

Service Item F.R.T.

*COVER L CRANK CASE .................... 0.1

*A.C.GEN.ASSY., ................................... 0.5

*STATOR, COMP., .................................

*FLYWHEEL, COMP., ............................ 0.3

*OIL SEAL, 18.9 X 30 X 5 ......................

*O-RING, 107 X 2 ..................................

20

21

22

23

24

25

26

94050-10000 NUT, FLANGE, 10 MM ................................................................................. 1

96001-06016-00 BOLT, FLANGE, SH., 6X16.......................................................................... 1

96001-06020-00 BOLT, FLANGE, SH. 6X20........................................................................... 2

96001-06028-00 BOLT, FLANGE, SH. 6X28........................................................................... 2

96001-06032-00 BOLT FLANGE, SH. 6X32............................................................................ 1

96001-06060-00 BOLT, FLANGE, SH. 6X60........................................................................... 1

96001-06070-00 BOLT, FLANGE SH. 6X70............................................................................ 1

E - 7

LEFT CRANKCASE COVER/

A.C. GEN. ASSY.

FR. 23

23

26

12

22

22

6

18

16

10

25

1

1517

177

4

5

21

13

14

19

24

2

3

8

9

11

20

9

13

19

28

12

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

11100-198-900 CRANK CASE COMP., R .......................................................................... 1

11191-GW8-681 GASKET, CRANK CASE............................................................................. 1

11200-KST-940 CRANK CASE COMP., L ........................................................................... 1

15100-KCC-900 PUMP ASSY., OIL ....................................................................................... 1

15119-178-000 GASKET, OIL PUMP BODY........................................................................ 1

15384-178-000 PIVOT, OIL PUMP....................................................................................... 1

15421-035-010 SCREEN, OIL FILTER ................................................................................ 1

16236-045-010 CLAMPER, OVER FLOW PIPE.................................................................. 1

17371-KWA-940 TUBE, BREATHER ..................................................................................... 1

90031-GF6-000 BOLT A, CYLINDER STUD, 6X198X7 ...................................................... 2

90032-GF6-000 BOLT B, CYLINDER STUD, 6X205.5X7 .................................................... 2

90407-259-000 PACKING, DRAIN COCK, 12.5X20 ............................................................ 1

90704-035-000 PIN, DOWEL............................................................................................... 2

92800-12000-00 BOLT, DRAIN PLUG, 12MM ....................................................................... 1

93500-05016-1H SCREW, PAN, 6X16 ................................................................................... 2

93500-06022-1H SCREW, PAN, 6X22 ................................................................................... 1

95002-02100 CLIP, B-10 TUBE ........................................................................................ 2

96001-06050-00 BOLT, FLANGE, SH. 6X50.......................................................................... 1

96001-06060-00 BOLT, FLANGE, SH. 6X60.......................................................................... 2

96001-06065-00 BOLT, FLANGE, SH. 6X65.......................................................................... 4


No. HF-DAWN

Service Item F.R.T.

29

E - 8

CRANK CASE/OIL PUMP

FR.

* CRANK CASE COMP., R ................... *4.0

* GASKET, CRANK CASE ...................... *3.6

* CRANK CASE COMP., L .................... *4.4

* SCREEN, OIL FILTER .......................... 0.6

* BOLT, CYLINDER STUD ...................... 1.1

(ADD 0.1 FOR EACH)

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


15 15

13 17

17

9

13

14

12

16

4

5

3

8

2

67

1

18

19

20

2020

19

20

10

11

10

11

12

3

4

5

6

7

8

9

10

11

13000-AAC-H40 CRANK SHAFT COMP., ............................................................................. 1

13011-KCC-941 RING SET, PISTON (STD)(TP)................................................................... 1

13012-KCC-941 RING SET, PISTON (O/S 0.25)(TP)............................................................ (1)

13013-KCC-942 RING SET, PISTON (O/S 0.50)(RIK) .......................................................... (1)

13014-KCC-941 RING SET, PISTON (O/S 0.75)(TP)............................................................ (1)

13015-KCC-942 RING SET, PISTON (O/S 1.00)(RIK) .......................................................... (1)

13101-KCC-901 PISTON....................................................................................................... 1

13102-KCC-315 PISTON OVER SIZE (0.25) ........................................................................ (1)




13111-087-000 PIN, PISTON............................................................................................... 1

13115-001-000 CLIP, PISTON PIN ...................................................................................... 2

13201-GF6-300 ROD, CONNECTING.................................................................................. 1

13381-KCC-900 PIN, CRANK................................................................................................ 1

14311-035-000 SPROCKET, TIMING (14T)......................................................................... 1

90741-KFB-000 KEY, WOODRUFF, 4MM............................................................................. 1

91001-GF6-000 BEARING, RADIAL BALL, 6304 ................................................................. 2

91101-AAC-H40 BEARING, CONNECTING ROD (RED) OR ............................................... 1

91102-AAC-H40 BEARING, CONNECTING ROD (BLUE) OR.............................................. (1)

91103-AAC-H40 BEARING, CONNECTING ROD (WHITE).................................................. (1)


No. HF-DAWN

Service Item F.R.T.

30

E - 9

CRANKSHAFT/PISTON

FR.

* CRANK SHAFT COMP., ....................... 4.0

* RING SET, PISTON ............................. 1.3

* PISTON

* PIN, PISTON ....................................... 1.2

* ROD, CONNECTING (ACTUAL TIME)


* BEARING, RADIAL BALL, 6304 .......... 4.2

(ADD 0.2 FOR EACH) .........................

53

4

5

6 7

10

111

9

10

8

2

SELECTION TABLE OF CONNECTING ROD BIG END BEARING

a

Crank Pin

CODE

(Colour)

Connecting

rod code

0.001

0.003

1 2 3 4 5

0.001+0.001(Green)

91102-GF6-003

Blue

+0.001+0.003(Yellow)

+0.003+0.005(White)

+0.005+0.007(Blue)

+0.007+0.009(Brown)

91103-GF6-003

White

91102-GF6-003

Blue

91103-GF6-003

White

91103-GF6-003

White

91102-GF6-003

Blue

91102-GF6-003

Blue

91102-GF6-003

Blue

91101-GF6-003

Red

91101-GF6-003

Red

91101-GF6-003

Red

91101-GF6-003

Red

91101-GF6-003

Red

+0.001

0.001

+0.003

+0.001

+0.005

+0.003

+0.007

+0.005

+0.009

+0.007

+0.011

+0.009

A

B

C

D

E

F

12

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

23211-GF6-000 MAIN SHAFT (11T) ..................................................................................... 1

23221-GF6-000 COUNTER SHAFT...................................................................................... 1

23421-GB4-770 GEAR, COUNTER SHAFT LOW (35T)....................................................... 1

23422-GB4-770 BUSH, 20X9................................................................................................ 1

23431-GN5-910 GEAR, M2 (17T) ......................................................................................... 1

23441-GB4-770 GEAR, COUNTER SHAFT SECOND (29T) ............................................... 1

23451-GK4-761 GEAR, M3 (21T) ......................................................................................... 1

23461-GK4-760 GEAR, COUNTER SHAFT THIRD (26T).................................................... 1

23471-GN5-910 GEAR, MAIN SHAFT FOURTH (24T)......................................................... 1

23481-HF7-000 GEAR, COUNTER SHAFT FOURTH (23T)................................................ 1

23801-178-000 SPROCKET, DRIVE (14T) .......................................................................... 1

23802-040-000 PLATE, DRIVE SPROCKET FIXING .......................................................... 1

90451-GF6-000 WASHER, THRUST, 12MM ........................................................................ 1

90451-198-000 WASHER, THRUST, 17MM ........................................................................ 1

90452-GB4-770 WASHER, THRUST, 17MM ........................................................................ 1

90461-GB4-770 WASHER, SPLINE, 20X1.2 ........................................................................ 1

90461-035-000 WASHER, SPLINE, 17MM.......................................................................... 2

90461-459-000 WASHER, SPLINE, 20MM.......................................................................... 2

90601-001-000 CIRCLIP, 17MM .......................................................................................... 2

90601-459-000 CIRCLIP, 20MM .......................................................................................... 2

91203-GB5-760 OIL SEAL, 17X29X5 ................................................................................... 1


No. HF-DAWN

Service Item F.R.T.

31

E - 10

TRANSMISSION

FR.

* MAINSHAFT ........................................ *3.8

(INC. RELATIVE PART)

* COUNTERSHAFT ...............................


(WHEN SERVICING COMP., UNIT) .....

F.R.T. IS 4.0 ..........................................

* SPROCKET, DRIVE ............................. 0.2

2413

1018

18

16

14

4

3

2

23

1

5

17

17

19

19

7

9

25

25

21 11

12

22

22

15

6

20

20

8

21

22

23

24

92000-06008-OH BOLT HEX., 6X8 ......................................................................................... 2

96100-60010-00 BEARING, RADIAL BALL, 6001 ................................................................. 1




No. HF-DAWN

Service Item F.R.T.

32

E - 10

TRANSMISSION

FR.

* MAINSHAFT ........................................ *3.8

(INC. RELATIVE PART)

* COUNTERSHAFT ...............................


(WHEN SERVICING COMP., UNIT) .....

F.R.T. IS 4.0 ..........................................

* SPROCKET, DRIVE ............................. 0.2

2413

1018

18

16

14

4

3

2

23

1

5

17

17

19

19

7

9

25

25

21 11

12

22

22

15

6

20

20

8

12

3

4

5

6

7

8

9

10

11

12

13

28211-GF6-000 PINION, KICK STARTER............................................................................ 1

28221-198-010 RATCHET, KICK STARTER........................................................................ 1

28251-GF6-000 SPINDLE, KICK STARTER......................................................................... 1

28253-397-000 SPRING, KICK STARTER RATCHET......................................................... 1

28254-198-000 RETAINER, RATCHET SPRING................................................................. 1

28256-198-000 PLATE, RATCHET GUIDE.......................................................................... 1

28261-198-000 SPRING, KICK STARTER .......................................................................... 1

28262-198-000 RETAINER, KICK SPRING......................................................................... 1

90452-115-000 WASHER, 17MM ........................................................................................ 1

90454-107-000 WASHER, THRUST, 20MM ........................................................................ 1

90601-459-000 CIRCLIP, 20MM .......................................................................................... 2

92020-06020-0A BOLT, HEX., 6X20....................................................................................... 2

94510-16000 CIRCLIP, EXTARNAL, 16MM...................................................................... 1


No. HF-DAWN

Service Item F.R.T.

33

E - 11

KICK STARTER

FR.

* PINION, KICK STARTER ..................... *3.7

* SPINDLE, KICK STARTER ..................


* SPRING, KICK STARTER .................... 1.1


13

8

7

911

12

12

6

5

4

2

11

101

3

12

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

24211-GF6-000 FORK, GEAR SHIFT................................................................................... 2

24261-121-742 PIN, GEAR SHIFT FORK GUIDE ............................................................... 2

24263-028-000 CLIP, GEAR SHIFT FORK GUIDE PIN....................................................... 2

24301-KWA-930 DRUM, GEAR SHIFT.................................................................................. 1

24411-198-900 PLATE, SHIFT DRUM STOPPER............................................................... 1

24421-200-000 PIN, GEAR SHIFT DRUM........................................................................... 4

24425-198-900 PLATE, SHIFT DRUM SIDE ....................................................................... 1

24430-198-900 ARM COMP., SHIFT DRUM STOPPER...................................................... 1

24435-GB4-770 SPRING, GEAR SHIFT DRUM STOPPER................................................. 1

24610-KST-940 SPINDLE COMP., GEAR SHIFT................................................................. 1

24639-035-000 COLLAR, 12.2MM....................................................................................... 1

24641-041-000 SPRING, GEAR SHIFT ARM...................................................................... 1

24651-035-000 SPRING, GEAR SHIFT, RETURN .............................................................. 1

24652-035-000 PIN, SHIFT RETURN SPRING................................................................... 1

35750-001-000 CONTACT ASSY., NEUTRAL SWITCH ...................................................... 1

35753-035-010 ROTOR, NEUTRAL SWITCH ..................................................................... 1

35755-001-000 PLATE, CONTACT FIXING......................................................................... 1

90071-171-010 BOLT, KNOCK, 6MM................................................................................... 1

90417-041-000 WASHER, GEAR SHIFT DRUM SIDE........................................................ 1

90801-035-000 PLUG, RUBBER, 19MM ............................................................................. 1

91208-KB4-670 OIL SEAL, 11.6X24X10............................................................................... 1


No. HF-DAWN

Service Item F.R.T.

34

E - 12

GEARSHIFT

FR.

* FORK GEARSHIFT.............................. *3.8

(ONE OR ALL) .....................................

* DRUM, GEARSHIFT............................

* PLATE, SHIFT DRUM STOPPER ........

* ARM COMP., SHIFT DRUM STOPPER


* SPINDLE COMP., GEARSHIFT ........... 1.2


* CONTACT ASSY., ................................

NEUTRAL SWITCH ............................. 0.2

12

10

185

25

25

7 6 6

66

8 9

1

14

11

13

21

3 3

4

1619

23

15

22

1724

202

1

2

22

23

24

25

91312-107-000 O-RING, 7X1.7............................................................................................ 1

92000-06016-0A BOLT, HEX., 6X16....................................................................................... 1

93500-05016-1H SCREW, PAN, 5X16 ................................................................................... 1

96220-30085 ROLLER, 3X8.5 .......................................................................................... 2


No. HF-DAWN

Service Item F.R.T.

35

E - 12

GEARSHIFT

FR.

* FORK GEARSHIFT.............................. *3.8

(ONE OR ALL) .....................................

* DRUM, GEARSHIFT............................

* PLATE, SHIFT DRUM STOPPER ........

* ARM COMP., SHIFT DRUM STOPPER


* SPINDLE COMP., GEARSHIFT ........... 1.2


* CONTACT ASSY., ................................

* NEUTRAL SWITCH ............................. 0.2

12

10

185

25

25

7 6 6

66

8 9

1

14

11

13

21

3 3

4

1619

23

15

22

1724

202

1

2

12

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

16010-198-901 GASKET, SET ...................................................................................... 1

16012-KST-A11 NEEDLE SET, JET ............................................................................... 1

16013-KRB-901 FLOAT, SET.......................................................................................... 1

16014-KPH-901 TOP, SET.............................................................................................. 1

16015-KVW-921 CHAMBER SET, FLOAT....................................................................... 1

16016-KPH-651 SCREW SET,........................................................................................ 1

16022-KWA-931 VALVE SET, THROTTLE ...................................................................... 1

16028-KPH-901 SCREW SET, B................................................................................... 1

16100-AAJ-A12 CARBURETTOR ASSY. ....................................................................... 1

16118-KST-901 CAP, CABLE SEALING ........................................................................ 1

16148-KPL-901 CAP, DUST........................................................................................... 1

16155-KRS-861 VALVE COMP., FLOAT......................................................................... 1

16165-KST-901 HOLDER NEEDLE JET........................................................................ 1

16199-KWA-931 TUBE, OVER FLOW ............................................................................ 1

93892-04010-10 SCREW, WASH, 4 X 14 ....................................................................... 2

95002-02659 CLIP, B, 6.5 TUBE ................................................................................ 2

99101-KWA-105 JET, MAIN # 105................................................................................... 1

99103-KTC-035 JET SLOW # 35.................................................................................... 1


No. HF-DAWN

Service Item F.R.T.

36

E - 13

CARBURETTOR

FR.

* NEEDLE SET, JET............................... 0.5

* CARBURETTOR ASSY.

* FLOAT SET.......................................... 0.4

* VALVE COMP., FLOAT JET, MAIN .......

* TOP SET.............................................. 0.2

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

* VALVE SET, THROTTLE ...................... 0.3


No. HF-DAWN

39

* HEADLIGHT ASSY., ............................. 0.1

* RIM COMP., HEADLIGHT....................

* UNIT, HEADLIGHT ..............................


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

* BULB, WEDGE BASE .........................

* SOCKET COMP., HEADLIGHT............ 0.2

* SOCKET COMP., POSITION LIGHT....

* CASE COMP., HEADLIGHT ................

F - 1

HEAD LIGHT

FR.

4

1

8

2

7

4

9

9

10

1167

12

12

13

13

3

3

35

1

2

3

4

5

6

7

8

9

10

11

12

13

3310B-AAJ-H01 LIGHT ASSY., HEAD..................................................... ................. 1

33101-KST-900 RIM COMP., HEADLIGHT............................................. ................. 1

33108-KGA-900 SPRING, UNIT HOLDER............................................... ................ 3

33108-KST-900 SPRING, BULB HOLDER.............................................. ................ 1

33112-KTN-921 SOCKET COVER........................................................................... 1

33120-KST-900 UNIT, HEADLIGHT....................................................... .................. 1

34901-MJ6-732 BULB, HEAD LIGHT....................................................................... 1

6130A-198-D00 CASE, COMP., HEADLIGHT......................................... ................. 1

61302-471-000 COLLAR, HEADLIGHT CASE........................................................ 2

61303-198-D00 NUT R HEADLIGHT CASE........................................................... 1

61304-198-D00 NUT L HEADLIGHT CASE.......................................... ................. 1

91508-GN2-000 SCREW, PAN, 5X10.5.................................................................... 2

95701-08020-02 BOLT, FLANGE, 8X20.................................................................... 2


No. HF-DAWN

*KEY SET............................................... 1.1

*SWITCH ASSY., COMB........................ 0.4

*SPEEDOMETER ASSY......................... 0.3

*SPEEDOMETER COMP., ..................... 0.5

*CASE, UPPER ASSY.,..........................

*CASE, UNDER ASSY., .........................

*SOCKET COMP.,..................................

*CABLE COMP., SPEEDOMETER ........

*CABLE, COMP., INNER ....................... 0.1

34908-KVE-900 BULB, WEDGE BASE (12V - 1.7 W)................................................... 6

35010-AAJ-H40 KEY SET ............................................................................................. 1

35100-KTC-900 LIST KEY NO....................................................................................... 1

35121-AAJ-H20 KEY BLANK (TYPE-1)......................................................................... 1

35122-AAJ-H20 KEY BLANK (TYPE-2)......................................................................... 1

37200-AAJ-H12 SPEEDOMETER ASSY. ...................................................................... 1

37210-AAJ-H12 SPEEDOMETER COMP.,.................................................................... 1

37215-MB6-830 CLAMP ................................................................................................ 1

37215-KST-940 RUBBER METER SET ........................................................................ 1

37246-KST-940 STAY, METER SET.............................................................................. 1

37610-AAJ-H42 CASE, UPPER ASSY. ......................................................................... 1

37612-AAJ-H12 CASE, UNDER ASSY. ......................................................................... 1

37612-KST-920A SEAL PACKING, (UNDER CASE) ...................................................... 1

37614-KST-941 COVER, UNDER CASE ...................................................................... 1

37619-KST-941 SOCKET COMP................................................................................... 1

44830-KST-940 CABLE, COMP., SPEEDOMETER...................................................... 1

44831-KST-940 CABLE, INNER.................................................................................... 1

84706-AAJ-H50 MARK, SPEEDOMETER..................................................................... 1

91352-GAZ-930 O-RING, 8.5 X 1.5 ............................................................................... 1

93500-04010-1H SCREW, PAN, 4 X 10.......................................................................... 1

93903-34420 SCREW, TAPING, 4 X 16 .................................................................... 7

1

2

3

4

5

6

7

8

9

10

11

11A

12

13

14

15

16

17

18

19

20

4

F - 2

SPEEDOMETER/CABLE/

KEY SET

40

FR.

2

54

3

19

1

1 1

18

1 1

6

20

20

7 002

4060

80

100

120140

m/ kh

2

km

Pricol

11

99

9

22

21

23

23

10

22

21

22

21

LD

S

SLD

SLD

LD SLD S

8216

2168

11A

2020

20

2020

14

17

13

15

16

18

12


No. HF-DAWN

94001-06070-0S NUT, HEX., 6 MM................................................................................ 3

94103-06700 WASHER, PLAIN, 6 MM. .................................................................... 3

96001-06016-07 BOLT, FLANGE, SH. 6 X 16 MM......................................................... 2

21

22

23

F - 2

SPEEDOMETER/CABLE/

KEY SET

*KEY SET............................................... 1.1

*SWITCH ASSY., COMB........................ 0.4

*SPEEDOMETER ASSY......................... 0.3

*SPEEDOMETER COMP., ..................... 0.5

*CASE, UPPER ASSY.,..........................

*CASE, UNDER ASSY., .........................

*SOCKET COMP.,..................................

*CABLE COMP., SPEEDOMETER ........

*CABLE, COMP., INNER ....................... 0.1

41

FR.

2

54

3

19

1

1 1

18

1 1

6

20

20

7 002

4060

80

100

120140

m/ kh

2

km

Pricol

11

99

9

22

21

23

23

10

22

21

22

21

LD

S

SLD

SLD

LD SLD S

8216

2168

11A

2020

20

2020

14

17

13

15

16

18

12


No. HF-DAWN

42

F - 3

HANDLE LEVER/SWITCH/

CONTROL CABLE

FR.

* CABLE COMP., THROTTLE ................ 0.3

* CABLE COMP., CLUTCH ..................... 0.2

* SWITCH ASSY., WINKER .................... 0.5

* SWITCH ASSY., FR. STOP..................

* CABLE COMP., FR. BRAKE .................

* GRIP COMP., R HANDLE .................. 0.6

* GRIP L HANDLE ................................ 0.6

* HOUSING UPPER, THROTTLE ..........

* HOUSING UNDER, THROTTLE ..........

* BRACKET R HANDLE LEVER ...........

* BRACKET L HANDLE LEVER ...........

* COVER R HANDLE LEVER ...............

* COVER L HANDLE LEVER ...............

17910-KVH-760 CABLE COMP., THROTTLE.................................................................... 1

22870-KWA-910 CABLE COMP., CLUTCH ........................................................................ 1

22871-116-670 BOOT, CLUTCH CABLE.......................................................................... 1

32161-404-000 BAND, B-1, WIRE .................................................................................... 2

35150-KST-900 SWITCH ASSY. START ........................................................................... -

35340-KCC-900 SWITCH ASSY., FR. STOP ..................................................................... 1

45450-KST-920 CABLE COMP., FR. BRAKE.................................................................... 1

53140-KST-940 GRIP COMP., THROTTLE ....................................................................... 1

53166-KTC-900 GRIP LEFT HANDLE............................................................................... 1

53167-GE4-000 HOUSING UNDER, THROTTLE............................................................. 1

53168-166-000 HOUSING UPPER, THROTTLE.............................................................. 1

53171-198-900 BRACKET R. HANDLE LEVER ............................................................... 1

53171-KCC-900 COVER R HANDLE LEVER................................................................... 1

53172-KTC-900 BRACKET L. HANDLE LEVER................................................................ 1

53172-KCC-900 COVER R HANDLE LEVER................................................................... 1

53175-AAF-H00 LEVER COMP., R STEERING HANDLE................................................ 1

53178-AAF-H00 LEVER COMP., L STEERING HANDLE................................................. 1

88110-AAJ-H00 MIRROR ASSY., R. BACK ....................................................................... 1

88120-AAJ-H00 MIRROR ASSY., L. BACK........................................................................ 1

90003-MY5-720 BOLT ADPT. 10 MM................................................................................. 2

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

8

1918

2

3

1

4

4

4

4

5

6

7

9

10

11

12

14

17

16

21

20

22

2123

24 24

26

26

15

13

25

20

22

25


No. HF-DAWN

43

F - 3

HANDLE LEVER/SWITCH/

CONTROL CABLE

FR.

* CABLE COMP., THROTTLE ................ 0.3

* CABLE COMP., CLUTCH ..................... 0.2

* SWITCH ASSY., WINKER .................... 0.5

* SWITCH ASSY., FR. STOP..................

* CABLE COMP., FR. BRAKE .................

* GRIP COMP., R HANDLE .................. 0.6

* GRIP L HANDLE ................................ 0.6

* HOUSING UPPER, THROTTLE ..........

* HOUSING UNDER, THROTTLE ..........

* BRACKET R HANDLE LEVER ...........

* BRACKET L HANDLE LEVER ...........

* COVER R HANDLE LEVER ...............

* COVER L HANDLE LEVER ...............

90114-310-000 BOLT, HANDLE LEVER PIVOT............................................................... 2

90201-KST-900 NUT, HEX., 10 MM .................................................................................. 2

92101-06025-0G BOLT, HEX., 6 X 25 ................................................................................. 2

93500-05022-1G SCREW, PAN, 5 X 22. ............................................................................. 2

94001-06090-0S NUT, HEX, 6 MM ..................................................................................... 2

94050-06000 NUT, FLANGE, 6MM ............................................................................... 2

21

22

23

24

25

26

8

1918

2

3

1

4

4

4

4

5

6

7

9

10

11

12

14

17

16

21

20

22

2123

24 24

26

26

15

13

25

20

22

25


No. HF-DAWN

44

FR.

* PIPE, STEERING HANDLE ................. 0.5

* BRIDGE COMP., FORK TOP ...............

* HOLDER, HANDLE PIPE UNDER ....... 0.2

(ADD 0.1 FOR EACH) .........................

8

128

12

12

4

3

3

2

2

6

6

45

59

9

13

7

10

111

8

128

13

F - 4

HANDLE PIPE/TOP BRIDGE

53100-KST-870 PIPE, STEERING HANDLE ................................................................... 1

53132-124-000 HOLDER, HANDLE PIPE UNDER......................................................... 2

53133-198-900 RUBBER, HANDLE CUSHION UPPER................................................. 2

53134-028-000 RUBBER, HANDLE CUSHION UNDER................................................. 2

53135-198-900 WASHER, HANDLE CUSHION.............................................................. 2

53136-198-900 PLATE, HANDLE CUSHION .................................................................. 2

53230-KST-940 BRIDGE COMP., FORK TOP ................................................................. 1

90023-GB4-770 BOLT SPECIAL 6X28 ............................................................................. 4

90304-438-000 NUT HEX6 MM...................................................................................... 2

90304-KSP-900 NUT, STEERING STEM ......................................................................... 1

94101-06000 WASHER, PLAIN 6MM........................................................................... 1

90503-KTR-900 WASHER, STEERING STEM NUT ........................................................ 1

95014-21101 HOLDER A1, HANDLE UPPER ............................................................. 1

1

2

3

4

5

6

7

8

9

10

11

12

13


No. HF-DAWN

45

F - 5

STEERING STEM

FR.

* HORN COMP., .....................................

* RACE, STEERING BALL ..................... 0.8

(ONE OR ALL) .....................................

* STEM COMP., STEERING ................... 0.9

* RACE, STEERING TOP CONE ........... 0.5

* THREAD, STEERING HEAD TOP .......

7

2

13

8

3

17

17

4

5

6

1

1

9

11

16

16

15

13

10

15

12

1214

14

50301-KTR-900 RACE, (STRG. TOP) BALL............................................................... 2

53200-AAJ-H40 STEM, COMP., STEERING................................................................ 1

53211-268-010 RACE, STEERING TOP CONE ......................................................... 1

53212-200-000 RACE, STEERING BOTTOM CONE ................................................. 1

53214-200-000 DUST SEAL, STEERING HEAD ........................................................ 1

53215-001-000 WASHER STEERING HEAD DUST SEAL ........................................ 2

53221-KTR-900 THREAD, STEERING TOP................................................................ 1

53222-KTR-900 MUD GUARD, STEERING (HEAD TOP) ........................................... 1

53600-AAJ-H01 LOCK, STRG. HANDLE..................................................................... 1

64310-198-D20A PLATE FR., NUMBER........................................................................ 1

64311-198-D20 BRKT. COMP., FR. NO PLATE .......................................................... 1

93500-05010-1A SCREW, PAN, 5 X 10......................................................................... 2

94101-05000 WASHER, PLAIN,5MM ...................................................................... 2

94101-08000 WASHER, PLAIN,8MM ...................................................................... 2

95701-08040-08 BOLT, HEX 8X40................................................................................ 2

95701-06022-07 BOLT, FLANGE 6X22......................................................................... 2

96211-06000 BALL STEEL, 6 MM ........................................................................... 16

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17


No. HF-DAWN

46

F - 6

FRONT FENDER

FR.

* FENDER COMP., FRONT. .................... 0.2

14

4

2

5

7

76

6

3

5

45451-KE6-920 GUIDE, FR. (FENDER) CABLE........................................................... 1

61100-AAJ-H00 FENDER COMP., FRONT (CHROME PLATED) ................................. 1

61100-AAJ-H00 FENDER COMP., FRONT (BLACK-1.) ................................................ 1

61100-AAJ-H00 FENDER COMP., FRONT (BLACK-1.) ................................................ 1

61150-AAJ-000 MUD GUARD FR. FENDER ................................................................ 1

9010-P26-900 SCREW, MUD GUARD........................................................................ 2

9200-06016-0A BOLT HEX. 6X16 ................................................................................. 2

94101-06000 WASHER PLAIN 6MM......................................................................... 1

94111-06000 WASHER SPRING 6 MM..................................................................... 1

1

2

3

4

5

6

7


No. HF-DAWN

F - 7

FRONT FORK

FR.

* FORK ASSY., FR.................................. 0.5

(ADD 0.2 FOR EACH) .........................

* SPRING, FR. CUSHION ......................

(ADD 0.2 FOR EACH) .........................

* PIPE COMP., FR. FORK ...................... 0.8

(ADD 0.5 FOR EACH) .........................

* CASE FR. BOTTOM ............................ 0.9

(ADD 0.5 FOR EACH) .........................

12

10

11

6 2

25

4

3

20

12

21

15

17

5

14

22

19

21

15

2416

18 18

7

9

8

1

13

23

51400-KST-A11 FORK ASSY., R FORNT .................................................................... 1

51401-KST-941 SPRING, FR. FORK ............................................................................ 2

51403-447-730 COLLAR, SPRING .............................................................................. 2

51403-447-730 JOINT, SPRING................................................................................... 2

51410-KWA-941 PIPE COMP., FR. FORK ..................................................................... 2

51403-KCC-900 COLLAR SPRING ............................................................................... 1

51412-KAG-900 SPRING, REBOUN ............................................................................. 2

51420-KST-A11 CASE, R FR. BOTTOM...................................................................... 1

51425-KST-901 SEAL, DUST........................................................................................ 2

51432-KST-901 PIECE, OIL LOCK ............................................................................... 2

51437-KVN-901 RING, PISTON .................................................................................... 2

51440-KTR-901 PIPE, SEAT ......................................................................................... 2

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