PARTS LIST and SCHEMATICS

400cc DUNE BUGGY

TABLE OF CONTENTS

CHAPTER
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21

DESCRIPTION
FRONT SUSPENSION ASSY
REAR SUSPENSION ASSY
FRAME AND REAR RACK ASSY
BRAKING SYSTEM
STEERING ASSY
ENGINE ASSY
TRANSMISSION BOX ASSY
ELECTRIC ELEMENT ASSY
CYLINDER HEAD ASSY
VALVE ASSY
CRANK CONNECT ROD MECHANISM
CRANKCASE BODY PART
CLUTCH
CONTROL SHIFT CAM MECHANISM
GEAR MECHANISM
OUTPUT SHAFT ASSY
OIL COOLING MECHANISM
EXHAUST SYSTEM
INTAKE SYSTEM
PULL STARTER
STARTER MOTOR MECHANISM

PAGE
NUMBER
3
6
9
11
13
15
19
21
23
25
27
29
31
33
35
38
40
42
44
46
48

 PART 1THE FRONT SUSPENSION SYSTEM

 PART 1 THE FRONT SUSPENSION ASSY

REF
NO.
PART NO.
CHINESE
ENGLISH
M10x1.25 NUT M10x1.25
1
A0211.ZLM12*1.25

FRONT WHEEL RIM

2
260L00295

FRONT TIRE
3
260L00303
M5x12 SREW M5*12
4
SLM5*10
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

260L00257
KLM16*1.5
A021108.01J
ZC30204
YF45*2.65
A021108.07Z.01F
YZM8
HLM12*1.25*35

M16x1.5

30204
O 45x1.8

M8x1

ZC30205
YF35*55*8

25
26
27
28

21500035
ZYDQ38
KLM12*1.25
KKX3*30

29
30
31
32

FLM10*1.25*75
260L00257
260L00027
A0211.10.001

LM8*16
K1001.00.054P
K100108.03Z.01FH
FLM8*10
TDM8
PDM8
K100108.0301ZP
K100108.0401ZP

REGD
NO.
8
2
2
6

M12x1.25x35

DUSTPROOF COVER
CASTLE NUT M16*1.5
SPACER
BEARING30204
O RING 45*1.8
FRONT WHEEL HUB
OIL NIB M8*1
SPLINE BOLT M12*1.25*35

2
2
2
2
2
2
2
8

30205
FB35-55-8

M8x16

M8x20
M8
M8

BEARING 30205
OIL SEAL 35-55-8
FRONT BRAKE DISC
BOLT M8*16
FENDER SUPPORTING PLATE
LEFT TURNING KNURL COMP
BOLT M8*20
SPRING WASHER M8
FLAT WASHER M8
FRONT UPPER ROCKER LEFT
FRONT UPPER ROCKER RIGHT

2
2
2
16
2
1
4
8
8
1
1

BALL HEAD
%%C38 CIRCLIP38
M12x1.25-1 CASTLE NUT M12x1.25-1
3x22
COTTER PIN3*22
M10x1.25x75

FLANGE BOLT M10*1.25*75

%%c10
OIL SEAL 10
%%C15
SPINDLE COVER15
%%C15
PIPE15

Unit
price

4
4
5
5
8
16
16
8

33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52

NZM10*1.25
YZM6
TAM6
K100108.0101ZP
K100108.0201ZP
K1001.00.019
FLM10*1.25*40
NZM10*1.25
K1001.00.003
K1001.00.015
K1001.00.015
K1001.00.031
K100109.0101ZP
ZC61903-2Z
ZYDQ17
K100109.01Z.01S
K100109.0102Z
K100109.04Z
K100109.03Z
K100109.05Z

M10x1.25

LOCK NUT M10x1.25

M6
M6

OIL NIB M6
SPRING WASHER M6

53
54
55
56
57
58
59
60

K1001.00.108
ZC.ZS87-7/ZC.FS87-7
FLM8*30
LM8
PDM8
K10010.10P
K1001.00.059
K100122.0101ZP

M8x30
M8
M8
U

61

K100122.0201ZP

62
63

SBLM6*16
NZM6

M6x20
M6

M10x1.25x40
M10x1.25

/
/

61903
%%C17

FRONT LOWER ROCKER LEFT

FRONT LOWER ROCKER RIGHT

FRONT SHOCK ABSORBER

FLANGE BOLT M10*1.25
LOCK NUT M10*1.25

STEERING WHEEL
STEERING MACHINE
STEERING MACHINE COVER
IGNITION SWITCH
STEERING STAFF WELDING UNIT

BEARING61903
CIRCLIP
STEERING STAFF COVER
UPPER CONNECTING SHAFT
DOUBLE HEAD STEERING MACHINE

LOWER CONNECTING SHAFT

SINGLE
HEAD
STEERING
MACHINE
CONNECTING STAFF
TURNING BALL AND SOCKET
FLANGE BOLT M8*30
ROUND NUT M8
FLAT WASHER M8
U CARD
FRONT PLASTIC FENDER
FRONT FENDER SUPPORTING
UNIT LEFT
FRONT FENDER SUPPORTING
UNIT RIGHT
CROSS SCREW M6*20
NYLON LOCK NUT M6

12
8
8
1
1
2
4
12
1
1
1
1
1
1
1
1
1
1
1
1
2
2
8
8
8
4
2
1
1
6
6

PART 2 REAR SUSPENSION ASSY

 PART 2THE REAR SUSPENSION ASSY

REF
REGD Unit
NO.
PART NO.
CHINESE
ENGLISH
NO. price
M10x1.25
LOCKNUT M10*1.25
1
A0211.ZLM12*1.25
8

REAR
WHEEL
RIM
2 260L00296
2

REAR TIRE
3 260L00304
2

RUBBER DECORATE COVER

4 21500022
2
M22x1.5
CASTLE
NUT
M22x1.5
5 KKX22*1.5
2
4x28
COTTER PIN 4x28
6 KKX4/28
2

REAR WHEEL HUB

7 A021110.07Z.01F
2
M12x1.25x35
SPLINE
BOLT
M12x1.25x35
8 HLM12*1.25*35
8

DISC BRAKE
9
2
M8x16
BOLT M8x16
10 LM8*16
12
FB 42-62-8
OIL SEAL FB 42-62-8
11 YF45*62*8
1
6007-Z
BEARING 6007-Z
12 6007-Z
4
%%c35
SPACER35
13 A0211.10.015E
2

BEARING HOLDER WELDING COMP

14 K1001.00.047
1
M4x10
CROSS SCREW M4x10
15 STLM4*10
2
FB 50-68-8
OIL SEAL FB 50-68-8
16 YF50*68*8
2
YH-8001
BALL CAGE YH-8001
17 K1001.00.001
2

TRANSMISSION BOX
18 A0211.00.112
1
M12x25
BOLT M12x25
19 LM12*1.75*25
8
M12
SPRING WASHER M12
20 TDM12
8
M12
FLAT
WASHER
12
21 PDM12
8
HALF
SHAFT
COMP
FOR
CONNECTING ENGIIE
22 K100107.0401Z.01F
1
HALF
SHAFT
COMP
FOR

CONNECTING
23 K100107.04Z.01F
1
()
ELASTOMER
24 260L00216
1

HALF SHAFT COMP SPACER

25 A0211.00.039D
1
LOCK NUT M14
M14
1
26 KLM14*1.5
REAR LOWER ROCKER ,LEFT

1
27 K100110.0101ZP

REAR LOWER ROCKER ,RIGHT

28 K100110.0201ZP
1
M12x1.25x168 FLANGE M12*1.25*168
29 FLM12*1.25*165
4
M12x1.25

LOCK NUT M12*1.25

8
30 FLM12*1.25
17
AXES COVER 17
31 A0211.00.006
16
PIPE17
17
8
32 A021110.01Z.02J

33

260L0003

12

34
35

FLM10*1.25*75
NZM10*1.25

M10x1.25x75
M10x1.25

36

260L00027

37

A0211.10.001

15
15

38
39
40
41
42
43
44
45
46
47
48

YZM6
TDM6
K100110.0301ZP

49

7.010.003

50

K100117.13Z.01J

22
16
12

51
52

SBLM6*16
NZM6

M6x20
M6

K100110.0401ZP
LM12*50
K1001.00.020
K1001.00.060

K10022.0301ZP/0401ZP
LM8*45
NZM8*1.25
K100317.13Z.02S

M6
M6

M12x1.25x55

()
M8x40
M8

OIL SEAL12
FLANGE BOLT M10*1.25*75
LOCK NUT M10*1.25

16

AXES COVER15

16

PIPE15
OIL NIB M6
SPRING WASHER M6
REAR UPPER ROCKER ,LEFT
REAR UPPER ROCKER ,RIGHT
FLANGE BOLT M12*1.25*55
REAR SHOCK ABSORBER
REAR PLASTIC FENDER
REAR FENDER
SPRING WASHER M8
NYLON LOCK NUT M8

8
8

AXES COVER22

16
16
1
1
4
2
2
2
2
2
2

AXES COVER16

PIPE12
CROSS SCREW M6*20
NYLON LOCK NUTM6

2
6
6


PART 3THE FRAME AND REAR RACK ASSY

 THE FRAME AND REAR RACK ASSY

REF
NO.
1
2
3

REGD
NO.
1
1
4

PART NO.
K100107P
K1001.01P
LM8*16

CHINESE

M8X30

ENGLISN
THE FRAME ASSY
FRONT DECORATE PLATE
HEXAD FLANGE BOLT M8X30

K1001.00.010Z

REAR VIEW MIRROR L

5
6
7
8
9
10
11
12
13
14
15
16
17

K1001.00.010Y
LM10*1.25
7.020.012
K100117.03Z.01P
K100120P
LM8*35
NZM8*1.25
A0211.00.014F
A021130.01Z
YZX6*10
LM18*40
TDM18
PDM18

M10

M8x35
M8

6x10
M18X40
M18
M18
M10x1.25x55

M10x1.25

M8x20
32
M832
M832

REAR VIEW MIRROR R

HEXAD LOCKNUT M8
FOOT PAD
REAR DECORATE PLATE
REAR RACK ASSY
BOLT M8*35
HEXAD COLUMN BOLT M18X40
HITCH HOOK
HITCH TOWER
AXLE PIN6x10
BOLT M18*40
SPRING WASHER M18
FLATWASHER M18

1
2
4
1
1
4
12
1
1
1
1
1
1

FLANGE BOLT M10*1.25*55

LOCK NUT M10*1.25

LEFT SEAT
RIGHT SEAT
BOLT M8*20

2
1
1
8
6
12
6
2
1
1
1

18

FLM10*1.25*55

19
20
21
22
23
24
25
26
27
28
29
30

FLM10*1.25
K1001.00.040X
K1001.00.040X
LM8*20
21500115
7.010.049
7.010.050
K100119.03P
K100119.01GP
K100119.02GP
K100119.01ZP

CUSTOM BAR CAGE CAP32

WASHER M8 MATCH32 PIPE

NUT M8 MATCH32 PIPE
CUSTOM CROSS BAR
CUSTOM BAR CAGE. L
CUSTOM BAR CAGE.R
CUSTOM CROSS BAR TOP

Unit
price

10


PART 4THE BRAKING SYSTEM

11

 Part 4: THE BRAKING SYSTEM

REF
NO.

PART NO.

K100115.0201ZP

LM6*30

CHINESE

M6x30
M6

NZM6

M8x105

12
8
M8
8.010.015

NZM8*1.25

M6x25
FLM6*25
M6
PDM6
M6
TDM6

21500074
(
)
21500074

21500074
M8x30
LM8*30

7.020.012
21500074 8x40
M8X20
LM8*20
M8x60
LM8*60
21500074

K1001.00.058
(1300mm)
(1300mm)
(700mm)

6
7
8
9
10
11
12
13
14
15
16
17
18
19
20

FLM8*105
7.010.003

REGD
NO.

ENGLISH
BRAKE PEDAL JOINTING COMP
BOLT M6*30
LOCK NUT M6
BOLT M8*105

AXES COVER12
PIPE8
LOCK NUT M8
BRAKE PUMP
CALIPER ASSYF,L
BRAKE PAD,F,L
FLANGE M6*25
FLATWASHER M6
SPRINGWASHER M6
CALIPER ASSYF,R
BRAKE PAD,F,R
CALIPER ASSYR,L
BRAKE PAD ,R ,L
CALIPER ASSYR,R
BRAKE PAD ,R,R
PARKING HANDLE JOINTING COMP

1
1
1

1
4
1
1
2

1
2
1
2
1
2

(700mm)

PARKING HANDLE RUBBER COVER

PARKING HOLDER
BOLT M8*30
FEET RUBBER PAD
PIPE8x40
BOLT08*20
BOLT M8*60
SPRING CAP
SPRING
BRAKE HOSE FL(1300mm)
BRAKE HOSE FR(1300mm)
BRAKE HOSE RL(700mm)
BRAKE HOSE RR(700mm)

34

(1000mm)

BRAKE CUPRUM PIPE R.L1000MM

35

(1000mm)

BRAKE CUPRUM PIPERR(1000MM

36

(1250mm)
(1250mm)

BRAKE HOSE RL(1250mm)

BRAKE HOSE RR(1250mm)

37

PARKING CABLE

21
22
23
24
25
26
27
28
29
30
31
32
33

38

K1001.00.007

Unit
price

1
1
1
1
1
1
2
1
1
1
1

12


PART 5THE STEERING SYSTEM

13

 PART 5THE STEERING ASSY

REF
NO.
01Z
02Z
03Z

PART NO.
K100109.0102Z
K100109-02Z
K100109.03Z

CHINESE

04Z

K100109.04Z

05Z
06Z
01J

K100109.05Z
K100109.06Z.01C
K100101.01.02D
K1001.00.031
SLM6*12

M6x12

ENGLISH
REGD NO. Unit price
STEERING STAFF ASSY
1
UPPER UNIVERSAL COUPLING
1
LOWER UNIVERSAL COUPLING
1
DOUBLE
HEAD
STEERING
MACHINE
1
SINGLE
HEAD
STEERING
MACHINE
1
HORN CONNECTING COMP
1
STEERING WHEEL HOLDER
1
HORN BUTTON
1
BOLT M6*12
6

LM12
K1001.00.003
SLM4*10
K10011010P
FLM8*30
PDM8
NZM8*1.25

M12

M4x10
U
M8x30
M8
M8

FLANGE NUT M12

STEERING WHEEL
BOLT M4*10
U CARD
FLANGE BOLT M8*30
FLATWASHER M8
FLANGE NUT M8

01B
02B
03B
04B
05B
06B

1
1
3
4
8
8
8

14

PART 6THE ENGINE SYSTEM

15

 PART 6 THE ENGINE SYSTEM

REF NO.

PART NO.

1
2
3

A040114.00.015

KG51-70
K1001.00.030

K1001.00.041

O RING

M8x25

THROAT PIPE CLIP

BOLT M8*25
AIR CLEANER CONNECTING PIPE
CLIP
AIR CLEANER CONNECTING PIPE
PLASTIC BREATHER PIPE
AIR CLEANER BREATHER FOAM
GASKET
PLASTIC BOLT
FILTER CLIP COMP
FILTER COMP
AIR CLEANER CRUST
AIR CLEANER CAP
AIR CLEANER GASKET
AIR CLEANER INTAKE ADJUSTING
PLATE
AIR
CLEANER
INTAKE
FOAM
GASKET
AIR CLEANER INTAKE THROAT
PIPE
AIR CLEANER INTAKE COVER
SCREW M5
AIR CLEANER COVER LOCK
RUBBER CLIP
RUBBER
INTEGRATE DUST PIPE CLIP
INTEGRATE DUST PIPE
INTEGRATE DUST PIPE PLUG
AIR CLEANER BRACKET
AIR CLEANER HOOP

1
2

17

18

19
20
21
22
23
24
25
26
27
28
29

20

REGD
NO.

1
1
1

10
11
12
13
14
15
16

ENGLISH

ENGINE
ENGINE THROAT PIPE
CARBURETOR

JS183FMQ.M

5
6
7
8
9

CHINESE

M5

K100117.0501ZP
K100117.05Z.01D

Unit price

2
1
1
1
1
1
1
1
1
1
1
1
1
1
4
6
2
1
2
1
1
1
1

16

30
31
32
33
34
35
36
37
38
39
40
41
42

M8x16
LM8*16
M8
TDM8
M8
PDM8
M6x20
LM6*20
M6
PDM6
M6
NZM6
K100117.05Z.01D
K100117.05Z.02D
M8x25
LM8*25
M8
NZM8
K100312.0101Z

K1003.00.003
M6x25
LM6*25

43

K040112.02S
260L00081K31
10MM

260L00081K32
60MM

260L00014
K1001.00.045P
K1001.00.044P

260L00132

K100113.01J
M8x40
LM8*40
A040114.00.113

K1001.00.034

K1001.00.035

K1001.00.013

K1001.00.032

K1001.00.032

44
45
46
47
48
49
50
51
52
53
54
55
56
58
59
60
61

XZ4*30
KKX1.6*12
K100121.02C
SLM6*16

B%%c4x30

1.6x12

M6x20

BOLT M8*16
SPRING WASHER M8
FLAT WASHER M8
BOLT M6*20
FLAT WASHER M6
LOCK NUT M6
AIR CLEANER SUSPEND PLATE ,L
AIR CLEANER SUSPEND PLATE ,R
BOLT M8*25
LOCK NUT M8
FUEL TANK
FUEL TANK CAP
BOLT M6*25
FUEL TANK SHOCKPROOF RUBBER
GASKET

4
4
18
2
2
3
1
1
2

FUEL TANK OUTFLOW HOSE

FUEL TANK INFLOW HOSE

THREE CONNECTING COMP
MUFFLER
EXHAUST PIPE
MUFFLER SPRING
MUFFLER CONNECTING PIPE
BOLT M8*40
OIL COOLING COMP
OIL COOLING HOSE ,L
OIL COOLING HOSE ,R
GEARS SHIFT HANDGRIP
GEARS SHIFT HANDGRIP HOLDER
REVERSE HANDGRIP
AXLE PIN 4x30
COTTER PIN 1.6*12
COTTER BLOCK PLATE
CROSS SCREW M6*20

1
1
1
1
2
1
2
1
1
1
1
1
1
1
1
1
1

1
1
4
8

17

62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79

K1001.00.066
K1001.00.006
K100121.0101ZP
LM8*30
LM8*50
K1001.00.053P
K100121.01GD
LM8*60
7.010.003
K100121.01D
K100121.02Z
K100121.0401ZP
FLM8*110
8.010.105
K100121.03Z
K100121.05ZD
XZ8*25
KKX3*16

80
81
82

K100107.0101ZP
FLM10*1.25*55
NZM10*1.25

83
84
85

FLM10*1.25*85
K100107.0102ZP
FLM10*1.25*60

M8x30
M8x50

%%C12x1.5-32
M8x60

%%C12x2-42

M8x155
%%C12x2-86

B8x24
3x16

GEARS SHIFT HOLDER JACKET

REVERSE CONTROL CABLE
GEARS SHIFT HANDGRIP COMP
BOLT M8*30
BOLT M8*50
GEARS SHIFT HOLDER
SPACER 12x1.5-32
BOLT M8*60
NYLON BUSH
BUSH PIPE 12x2-42
FRONT TIF-ROD
MIDDLE ROCKER
BOLT M8*155
BUSH PIPE 12x2-86
REAR TIF-ROD
REAR ROCKER
AXLE PIN 8x24
COTTER PIN 3x16
ENGINE
LOWER
FASTEN
BRACKET ,F
M10x1.25x55 FLANGE BOLT M10*1.25*55
M10x1.25 LOCK NUT M10*1.25
ENGINE
UPPER
FASTEN
BRACKET ,F

M10x1.25x60 FLANGE BOLT M10*1.25*60

1
1
1
3
2
1
2
1
4
1
1
1
1
1
1
1
1
1
1
5
7
1
1
1

18


PART 7. THE TRANSMISSION BOX ASSY

19

 PART 7THE TRANSMISSION BOX ASSY

REF
NO.
1
2
3

PART NO.
K1001.
00.099 GB13871-1992
GB/T 5783-2000
GB/T 5783-2000

4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24

CHINESE

ENGLISH

REGD NO. Unit price

M8x30
M8x40

OIL SEAL 50-%%c70

BOLT M8*30
BOLT M8*40

2
6
2

A0211-10-01-01

TRANSMISSION BOX COVER

GB/T3452.1-1992
GB/T3452.1-1992
GB/T276-1994
GB/T894.1-1986
GB/T894.1-1986
A0211-10-01-04
GB/T 5783-2000
GB/T 95-1985
GB/T93-1987
GB/T 5783-2000
GB/T 5783-2000
GB13871-1992
A0211-10-01-06
GB/T3452.1-1992
GB/T276-1994
GB/T 893.1-1986
GB/T894.1-1986
GB/T276-1994
GB/T 5783-2000
GB/T5801-1994

%%c170X2.65
6010

%%C38

M12x12
M12
M12
M12x25
M8x20
FW-25-47-7

%%c80X2.65
6205
52
%%C50
6306-Z()

RNA4901

BREATHER JOINT
GASKET 170X2.65
BEARING 6010
BEVEL GEAR (2)
CIRCLIP %%C38
TRANSMISSION BOX BODY
BOLT M12*12
FLAT WASHER M12
SPRING WASHER M12
BOLT M12*25
BOLT M8*20
OIL SEAL FW-25-47-7
SIDE COVER
GASKET %%c80X2.65
BEARING 6205
CIRCLIP 52
CIRCLIP %%C50
BEARING 6306-Z
BEVEL GEAR (1)
NEEDLE BEARING RNA4901

1
1
2
1
1
1
2
8
8
8
4
1
1
1
1
1
1
1
1
1

FW-%%c50-%%c70

20


PART 8 THE ELECTRIC ELEMENT ASSY

21

 PART 8THE ELECTRIC ELEMENT ASSY

REF
NO.
1

PART NO.
K1001.00.005

CHINESE

2
3

K1001.00.016
K1001.00.015

()

ENGLISH
REGD NO. Unit price
MAIL WIRE
1
COMBINED
SPEEDOMETER
COVER
1
COMBINED SWITCH
1

K1001.00.043

HORN

5
6

260L00139
260L00139

HEAD LIGHT ,F,L

HEAD LIGHT ,F,R

1
1

TURNING LIGHT ,F
BRAKE SWITCH
HORN BUTTON
MANUAL
FAN SWITCH
IGNITION LOCK
EMERGENCY STOP SWITCH
FAN CONTROLLER
RECTIFIER&REGULATOR
IGNITION
FLASHER REALY
START RELAY
ELECTRIC PLATE
ELECTRIC COVER
GEAR SWITCH
BATTERY
BATTERY BOX
BATTERY COVER
COOLING FAN
FAN COVER
REAR BRAKE LIGHT

2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26

K1001.00.009Z/0
09Y

K1001.00.031
()
K0405.00.009

21500090
()
K0405.00.009
SSC5-501000-0

260L00042

F3-D10000-0

260L00279

260L00284
K1001.00.077H

K1001.00.040

A040114.00.002

K1001.00.012

K1001.00.029

K1001.00.042

260L00060

22

PART 9. CYLINDER HEAD ASSY

23

 CYLINDER HEAD ASSY

Ref.no
1
2
3

Part.no
2

4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

F3-111000-0
F3-111701-0
F3-111751-0
Q/JR YP802000
FR-100405-0
F3-100604-0
F3-102000-0
Q/JR YP96-2000

F3-100603-0
F3-101000-0
F3-100403-0
GB/T 70.1
F3-103000-0
FG-102000-0
F3-100605-0
FG-100701-0
Q/JR YP80-2000

F3-100602-0
GB/T70.1
F3-100202-0
FG-100201-0
FG-100601-0
F3-100601-0

Description

Cylinder cap assy

Steel wire circlip
Guide pipe of valve

1
2
2

95026-06010

Bolt 95026-06010

99510-14016
14*17.5*8

Washer
Damper
Cylinder cap shim unit

1
12
1
2
1
4
4
2
1
1
1
1
2
1
2
1
1
1
1

M8*50-10.9-Zn5.D

95026-06012
O107.1*2.4

Alignment pin 99510-14016

Oil seal
Cap nut
Copper washer
Screw M8*50-10.9-Zn5.D
Sprocket chamber cover unit

Oil fender cover unit

Air drain
Hoop
Bolt 95026-06012
O ring

M6*25-10.9-Zn5.D

Screw M6*25-10.9-Zn5.D

Upper valve cover

Lower valve cover
O-ring
O ring

24

GB/T 70.1

O
O57.8*2.4
M6*16-10.9Zn5.D

25
26
27
28
29

F3-110403-0
GB/T 5783
F3-110402-0
DR8EA
FB-110851-0

M6*12-Zn5.D

60

QTY

Screw M6*20-10.9Zn5.D

Pressure plate
Bolt M6*12--Zn5.D
Stop plate
Spark plug
Double-head bolt

1
2
1
1
2

UNIT
PRICE

1
1

24

PART 10. VALVE MECHANISM

25

PENEUMATIC MECHANISM
Ref.no

Part.no

1
2
3
4
5
6
7
8
9
10

F3-114201-0
F3-100401-0
FG-100001-0
GB/T5786
FG-100402-0
F3-100402-0
GB/T 276-94
F3-114001-0
F3-130000-0
F3-140000-0

11

F3-150000-0

12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

F3-120000-0
F3-100801-0
Q/JR YP80-2000
Q/JR YP80-2000
F3-113000-0
F3-110303-0
F3-110304-0
F3-110306-0
F3-110701-0
F3-110702-0
F3-112000-0
F3-110301-0
F3-110302-0
F3-110601-0
F3-110001-0
F3-110305-0
F3-110851-0
F3-110852-0
F3-110401-0
F3-114000-0

2
2

Description

QTY

Pneumatic cam shaft

Timing sprocket
Driving pin

M10*1.25*25-Zn5.D

Bolt M10*1.25*25-Zn5.D

6005-RS/C3

Washer
Throw oil plate

95026-06025
95026-06014

Rolling bearing 6005-RS/C3

Bush
Timing chain
Lower guide plate assy

Upper guide plate

assy
Chain tensioner
Shim of tensioner
Bolt 95026-06025
Bolt 95026-06014
Needle bearing
Air intake valve
Air exhaust valve
Valve spring seat
Valve innerspring
Valve outer spring
Valve stem oil seal
Valve spring cover
Valve lock clip
o-ring
Rocker arm shaft
Valve rocker arm
Adjusting screw
Locking nut
Elastic washer
Camshaft unit

UNIT
PRICE

1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
1
1
1
2
2
2
2
2
4
2
2
2
2
2
2
1

26

PART 11. CRANK CONNECT ROD MECHANISM

27

(CRANK CONNECT ROD MECHANISM)

Ref.n
o
1
2
3
4
5
6
7
8
9
10
11
12
13

Part.no
F3-210000-0
F3-200702-0
F3-200004-0
F3-200302-0
F3-200401-0
GB/T819.1
F3-200402-0
GB/T276
F3-202000-0
F3-230000-0
GB/T276
F3-200301-0
F3-200003-0

14

GB/T819.1

15
16
17
18
19
20
21
22
23
24
25
26
27

F3-200403-0
F3-200404-0
F3-200851-0
F3-200002-0
F3-220201-0
F3-220001-0
F3-220002-0
F3-221000-0
F3-200001-0
F3-200701-0
F3-201000-0
F3-100604-0
F3-200801-0

28

Q/JR YP96-2000

29
30

F3-200002-0
F3-200601-0

31

GB/T70.1

32

F3-600301-0

Crank connect rod assy

Spring
Spring pin
Balance shaft driving gear
Washer
Screw M6*18-Zn6.D
Pressure plate 1
Bearing 6203
Oil seal
Balance shaft
Bearing 6205
Balance shaft gear
Flat key

QT
Y
1
6
3
1
1
3
1
1
1
1
2
1
1

Screw M6*16-Zn5.D

12

Pressure plate2
Locking washer
Nut
Woodruff key
Piston
Piston ring 1
Piston ring 2
Oil ring assy
Piston pin
Circlip
Cylinder unit
Damper
Cylinder shim

1
1
1
1
1
1
1
1
1
2
1
12
1

Alignment pin 99510-14016

Alignment pin
Alignment pin o ring

1
1

Screw M6*10-9-Zn.5D

Oil pump driving gear

Description

M6*18-Zn5.D
1
6203

6205

M6*16-Zn
5.D
2

1
2

9951014016

O
M6*30-10.9Zn.5D

UNIT
PRICE

28

PART 12. CRANKCASE BODY PART

29

(CRANKCASE BODY PART)

Ref.n
o
1
2
3
4
5

Part.no
F3-300801-0
F3-300001-0
F3-330000-0
ZAI-300203-0
ZAI-300604-0

Q/JR YP80-2000

7
8
9

Q/JR YP80-2000
Q/JR YP80-2000
Q/JR YP80-2000

10

GB/T 70.1

11

F3-300401-0

12

F3-300802-0

13
14
15
16
17
18
19
20

F3-340000-0
F3-301000-0
ZAI-300601-0
F3-310000-0
F3-200000-0
F3-300851-0
F3-300852-0

Description

10*14

9502606030
95026-06040
95026-06060
95026-06050
M8*10-9Zn.5D

QTY

Left crankcase cover gasket

Alignment pin 10*14
Left crankcase cover assy
Observe hole cover
o-ring

1
6
1
1
1

Bolt 65026-06030

27

Bolt 95026-06040
Bolt 95026-06060
Bolt 95026-06050

2
2
9

Screw M8*60-10.9-Zn5.D

Bracket of reverse gear rope

Right crankcase cover
gasket
Right crankcase cover assy
Oil dipstick
o-ring
Left crankcase assy
Right crankcase assy
Double head screw
Double head screw

UNIT
PRICE

1
1
1
1
1
1
2
2

30

PART 13. CLUTCH

31

(CLUTCH)
Ref.no
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28

Part.no
F3-400401-0
F3-411000-0
F3-413000-0
F3-414000-0
F3-400851-0
GB6170
GB/T 97.1
FG-400601-0
F3-400852-0
F3-404000-0
F3-403000-0
F3-402000-0
F3-400501-0
F3-401000-0
GB/T 308
F3-421000-0
F3-420402-0
F3-423000-0
F3-400402-0
F3-200851-0
F3-400601-0
F3-400301-0
F3-420401-0
F3-422000-0
F3-420201-0
F3-420701-0
F3-424000-0

Description

M8-Zn5.D
8-Zn8.D
O

8.731 G100b

Main clutch washer

Main clutch case assy
Overreach clutch
Pin clutch shoe assy
Nut
Nut M8-Zn5.D
Washer 8-Zn8.D
O-ring
Clutch adjusting screw
Lower cam plate assy
Steel ball bracket assy
Upper cam plate assy
Assistant bush
Rod push ass y
Steel ball 8.731G100b
Clutch gear assy
Spline washer
Clutch hub assy
Locking washer
Nut
o-ring
Post rod
Clutch plate
Friction disc
Pressure disc
Clutch spring
Bolt with washer

QTY

UNIT
PRIC
E

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
6
7
1
5
5

32

CONTROL SHIFT CAM

MECHANISM
PART 14. CONTROL SHIFT CAM MECHANISM

33

Ref.n
o
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31

Part.no
GB/T5789
F3-500402-0
F3-500401-0
GB/T894.2
F3-500701-0
F3-501000-0
F3-540201-0
F3-500751-0
GB/7 819.1
F3-500404-0
F3-550702-0
F3-530000-0
CY80.01-69
F3-500703-0
F3-560000-0
F3-500851-0
F3-550000-0
F3-500408-0
F3-500852-0
F3-500302-0
F3-500002-0
F3-500303-0
F3-500301-0
F3-500001-0
GB/T276
FG-505000-0
ZAI-402000-0
F3-500406-0
F3-540851-0
F3-540701-0
F3-540001-0

32

F3-540002-0

33
34
35
36
37

F3-540751-0
F3-540401-0
F3-D70000-0
GB/T97.1
GB/T70.1

Description
M6*12-Zn5.D

Bolt M6*12-Zn5.D

12

M6*20-Zn5.D

Reverse control lever

Washer
Circlip 12
Spring
Reverse shift bracket
Shift cam
Shift cam segment
Bolt M6*20-Zn5.D
Washer
Spring
Shift shaft
Spring broaching
Return spring
Stopper lever
Bolt
Shift lever assy

Torque spring pin tension gasket

Torque spring pin tension gasket

3R
1L

6003

6-Zn8.D
M6*16-Zn5.D

Shift fork 2
Short shift fork axle
Shift fork 3
Shift fork 1
Long shift fork axle
Bearing 6003
Oil seal
Oil seal
Press wire plate
Shaft contact
Spring
Star gear dowel pin
Reverse limit cam dowel
pin
Reverse limit cam
Fender
Fender signal
Washer 6-Zn8.D
Screw M6*46- Zn5.D

QT
Y
1
1
1
1
1
1

UNIT
PRICE

1
1
1
1
1
1
1
1
1

1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1

PART 15. GEAR MECHANISM

34

35

SHIFT GEAR MECHANISM

Ref.
no
1
2
3
4
5
6
7
8
9
10
11
12

Part.no
F3-503000-0
GB/T 276
F3-510302-0
F3-510001-0
F3-510305-0
F3-510303-0
F3-510401-0
F3-510402-0
F3-510304-0
F3-510301-0
F3-505000-0
GB/T 819.1

Description

6203

50*22*
14
M6*16Zn5.D

13

F3-500403-0

14
15
16

GB/T276
F3-520405-0
F3-520406-0

17

F3-524000-0

6204

26
6304

6004

26

18
19
20
21
22
23
24
25
26
27
28

F3-524000-0
F3-520307-0
F3-520404-0
F3-520001-0
F3-520305-0
F3-520304-0
F3-520402-0
F3-520302-0
F3-520303-0
F3-521000-0
F3-520401-0

29

F3-522000-0

30
31
32
33
34
35
36
37

F3-520306-0
GB/T894.2
GB/T276
F3-504000-0
GB/T276
F3-570301-0
GB/T894.2
F3-570302-0

QTY

Main axle oil seal

Bearing 6203
Shift 2 driving gear
Axle cover
Shift 5 driving gear
Shift 3 driving gear
Circlip
Spline washer
Shift 4 driving gear
Main axle

1
1
1
1
1
1
1
1
1
1

Bearing (50*22*14)

Screw M6*16-Zn5.D

Main axle bearing pressure

plate
Bearing 6204
Circlip
Washer

1
1
1

Shift 2 driven gear unit

Shift fork paurcirclip

Circlip
Spline washer
Spline bush
Reverse gear
Shift 5 driven gear
Ringent circlip
Shift 3 driven gear
Shift 4 driven
Drive axle unit
Washer

1
1
1
1
1
1
1
1
1
1
1

Shift 1 driven gear

Drive gear
Circlip26
Bearing 6304
Driving axle oil seal
Bearing 6004
Middle drive gear
Circlip 26
Middle drive shaft

1
1
1
1
1
1
1
1

UNIT
PRICE

36

38
39
40
41
42
43
44
45
46
47
48
49

GB/T276
F3-500202-0
F3-500409-0
GB/T819.1
F3-580307-0
F3-580852-0
F3-580410-0
F3-500004-0
GB/T894.2
F3-500405-0
F3-500306-0
F3-500003-0

50

GB/T5789

51
52
53
54

F3-500304-0
F3-500305-0
F3-500601-0
F3-500201-0

55

Q/JR YP80-2000

56
57
58
59
60

F3-500407-0
F3-502000-0
F3-570001-0
F3-570701-0
GB/T5782

6202C2

Bearing 6202C2
Wheel axle bearing base
Pressure plate

M8*25-Zn5.D

Screw M8*25-Zn5.D

M22*1

15

M8*3010.9-Zn5.D

9502606015

M6*30

Driving gear
Nut M22*1
Adjusting gaskets
Reverse axle
Circlip 15
Washer
Reverse wheel gear 2
Bush

1
1
2
4
1
1
1
1
1
2
1
1

Screw M8*30-10.9-Zn5.D

Speed driving gear

Speed driven gear
o-ring
Speed gear base

1
1
1
1

Bolt 95026-06015

Washer
Speed gear oil seal
Driving pin
Steel Circlip
Bolt M6*30

1
1
1
1
1

37

PART 16. OUTPUT SHAFT

38

OUTPUT SHAFT MECHANISM

Ref.
no

Part.no

Description

GB/T6186

F3-580402-0

F3-580303-0

4
5
6
7
8
9
10
11

F3-580300-0
F3-581201-0
F3-580405-0
GB97.1-85
F3-581601-0
GB/T 276
F3-581851-0
GB/T276

M14*
1.5

8-Zn8.D
O
6305

6207C3

12

F3-581301-0

13
14
15
16

F3-580301-0
F3-580701-0
F3-580001-0
GB/T 276

17

F3-580302-0

18

GB/T 276

6006C3

6205

19

F3-580851-0

20
21

F3-582000-0
F3-580401-0

22

F3-580305-0

23

F3-580601-0

24

GB/T5782

25

F3-580304-0

26

F3-584000-0

27

F3-586000-0

28
29
30

FG-580402-0
FG-586000-0
FG-580305-0

O
M8*3010.9-Zn5.D

QTY

Nut M14*1.5

Washer
Universal front joint
yoke (rear driving )
Oil seal
Bearing housing
Adjusting gasket
Washer
o-ring
Bearing 6305
Abnormal screw sleeve
Bearing 6207C3
Middle driven pinion
gear
Connection paw
Spring
Bushing
Bearing 6006C3

2
1
1
1
1
4
1
1
1
1
1
1
1
1
1

Middle driven shaft

Bearing 6205
Abnormal screw sleeve
(front driving )
Oil seal
Dust proof cove r
Universal front joint
yoke (front driving )
O-ring

1
1

Bolt M8*30-10.9-Zn5.D

Universal front joint

yoke (real driving )
Cross axle unit
Universal real joint yoke
(front driving )
Clip
Roll needle bearing
Transmission fork

UNIT
PRIC
E

1
2

1
1
1
8
8
1

39

PART 17. LUBRICATION COOLING MECHANISEM

40

LUBRICATION COOLING MECHANISEM

Ref.
no
1
2
3
4
5
6
7
8
9
10
11
12

Part.no
F3-610000-0
F3-611000-0
F3-610001-0
FG-600801-0
GB/T819.1
FG-620000-0
FG-600701-0
FG-600601-0
F3-610000-0
F3-630000-0
F3-600601-0
F3-670000-0

13

GB/T70.3

14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32

F3-600401-0
F3-600853-0
F3-640000-0
F3-650000-0
F3-660000-0
GB/T5786
GB/T97.1
GB/T6187
F3-D90000-0
F3-600851-0
F3-601000-0
F3-600402-0
F3-D80000-0
F3-600852-0
F3-602000-0
Q/TR YP802000
F3-603000-0
F3-6006020-0
FG-500405-0

Description

6*30-Zn5.D

M6*30-10.9Zn5.D

4
5

M6*12-Zn5.D
6-Zn5.D
M6-9-Zn5.D

M8*20
1

M8*22
2
95026-06012
3
O

QTY

UNIT
PRICE

Engine oil pump

Oil pump gear unit
Transmission pin
Oil pump pad
Screw M6*30-Zn5.D
Engine oil coarse strainer
Compressing spring
o-ring
Oil drain plug screw
Engine oil fine strainer
o-ring
Engine oil fine strainer
Screw M6*30-10.9-Zn5.D
Gasket
Contact
Oil delivery pipe 4
Oil delivery pipe 5
Oil cooler assy
Nut M6*12-Zn5.D
Washer 6-Zn8.D
Nut M6-9-Zn5.D
Cooler fan motor
Bolt M8*20
Oil pipe unit 1
Gasket
Oil temperature sensor
Bolt
Oil pipe unit 2
Bolt 95026-06012
Oil pipe unit 3
o-ring
Washer

41

PART 18. EXHAUST SYSTEM

42

EXHAUST SYSTEM
Ref.n
o

Part.no

Description

1
2
3
4
5
6

F3-740000-0
F3-702000-0
F3-700851-0
F3-730401-0
F3-730402-0
GB/T 5789

1
2
M6*12

F3-750801-0

8
9
10

F3-750000-0
F3-730403-0

Exhaust pipe unit

Exhaust pipe washer
Nut
Defend plate 1
Defend plate 2
Bolt M6*12
Seal ring of the exhaust
pipe
Silencer assy
Defend plate

QT
Y

UNIT
PRIC
E

1
1
2
1
1
7
1
1
1

43

PART 19. INTAKE SYSTEM

44

INTAKE SYSTEM
Ref.n
o
1
2
3
4
5
6
7

Part.no

Description

F3-701000-0
F3-700601-0
GB/T 70.1
F3-700401-0
F3-703000-0
F3-720000-0
F3-712000-0

O
M8*25

F3-701000-0

9
10
11

F3-701000-0
FG-710504-0
FG-710701-0

12

FG-710401-0

13
14
15
16
17
18

FG-710501-0
FG-710801-0
FG-710603-0
FG-711000-0
FG-710502-0
FG-710503-0

Carburetor seat unit

o-ring
Screw M8*25
Washer
Pipe clamp unit
Carburetor
Intake pipe clamp unit
Connecting pipe of
carburetor
Pipe clamp unit
Dust cup
Steel wire clamp
Locking plate if air filter
cover
Intake pipe
Thermal pad
Sealing ring
Filter core unit
Air filter cove r
Air filter body

QTY

UNIT
PRICE

1
1
2
2
1
1
2
1
1
1
1
3
1
2
1
1
1
1

45

PART 20. PULL STARTER

46

PULL STARTER
Ref.
no

Part.no

Description

1
2
3

F3-870000-0
F3-872000-0
FG-870801-0

FG-873000-0

5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23

F3-871000-0
F3-870802-0
FG-870702-0
FG-870851-0
GB/T896
FG-870701-0
F3-8704010-0
FG-870001-0
FG-870601-0
FG-870402-0
Q/JR YP80-93
F3-801000-0
F3-800601-0
FG-870000-0
GB/T93
GB/T5785
F3-800404-0
GB/T93
F3-584000-0

95026-06020

24

GB/T819.1

25
26

F3-800801-0

M1O*1.25*40

M5*16Zn5.D

QTY

Hand starting device

Left side cover unit
Shim
Bottom board unit of
winding spring
Drive plate unit
Tension line
Torsion spring
Drive paw
Circlip 6
Compressing spring
Guide board
Screw pin
Start lever
Start lever cover
Bolt 95026-06020
Starting ratchet
o-ring
Washer
Washer

1
1
1
1

Pressing plate
Oil seal
Bearing

1
2
2
2
1
1
1
1
1
1
6
1
1
1
1
1
1
1
1

Screw M5816-Zn5.D

Washer

Bolt M10*1.25*40

UNIT
PRICE

47

PART 21. STARTER MOTOR MECHANISM

48

STARTER MOTOR MECHANISM

Ref.no

Part.no

QT
Y

Description

F3-800301-0

Start idle gear 1

F3-803000-0

Bearing

3
4
5
6
7
8
9

F3-800401-0
GB/T894.1
F3-800001-0
F3-800002-0
F3-800302-0
F3-804000-0
F3-800402-0

Washer
Circlip 12
Go gear axle 1
Go gear axle 2
Starter idle gear 2
Bearing
Washer

2
2
1
1
1
1
1

10

F3-860000-0

Gear unit of electric starter

11
12
13

F3-800003-0
F3-830000-0
F3-D50000-0
Q/JR YP812000
F3-800403-0
Q/JR YP812000
GB/T93
Q/JR YP802000

12
1
2
2

M8*15-10Zn5.D
1

Starter clutch plate

Starter clutch
Magneto

1
1
1

Screw M8*15-10-Zn5.D

Lead holder

Bolt 98512-06030

Washer 6-Zn8.D

Bolt 95026-06030

Screw M5*12-10.9-Zn5.D

Starting motor

14
15
16
17
18
19

GB/T70.1

20
21

F3-D60000-0

98512-06030
6-Zn8.D
95026-06030
M5*12-10.9Zn5.D

UNIT
PRIC
E

49

NOTES

XATVUSA Inc.
7940 Silverton Ave. Suite 107
San Diego, CA 92126
Main (858) 689 8889
Fax (858) 689 6588
Email usa.xatv@gmail.com

50