Page 4 - Instruction for use of parts catalogue; • This parts catalogue has been created as of July 20, 2004.; CONTENTS
1 2004.07.20 E 1 1 2 3 4 5 Instruction for use of parts catalogue • This parts catalogue has been created as of July 20, 2004. • Since this date, the sales practice for repair parts may have been changed or the parts may have been eliminated (listed for thosenot for sale). • The modified information...
Page 7 - When the parts were revised; • The following abbreviations are used in this parts catalogue.; Abbreviations used in the parts catalogue
4 1 2004.07.20 E When the parts were revised Be sure to check the serial number!! The number has been used from the initial model without revision. When shown at the left side, it is applicable to the models o f N o . 1 0 0 8 0 0 1 a n d t h e subsequent numbers. When shown at the right side, it is ...
Page 9 - Models, parts catalogue codes and applicable serial numbers
6 1 2004.07.20 E Models, parts catalogue codes and applicable serial Nos. given in this parts catalogue can be identified as follows.Parts with parts catalogue codes are exclusive for models destined for countries designated.If no area codes are listed, parts are for common use. * Of carburetor/thro...
Page 10 - Color label
7 1 2004.07.20 E • When ordering parts, check the model name, main color, and code by observing the “COLOR LABEL” on the vehicle.• When ordering a colored part, use the color chart in the instruction for use of parts catalogue. Color label VFR800FIW R-157 R157
Page 11 - Color chart
8 1 2004.07.20 E • When ordering a colored part, refer to the chart below and use a part number consisting of the relevant basic part number to which has been added a part color code. Color chart SCR100WH (SCR100WH 5 ) Pearl white Boss gray metallic Black NH-A20P NH-A21M NH-1 No. Name of colored par...
Page 12 - Fuel hose, general purpose hoses and vinyl hose
9 1 2004.07.20 E • The standard part fuel hose, general purpose hose and vinyl hose may be substituted by the coiled bulk part.• When ordering the standard part fuel hose, general purpose hose and vinyl hose use the bulk part number written in the parts catalogue in brackets ( ) underneath the part ...
Page 15 - • Bulk part number of fuel hose, general purpose hose and vinyl hose.
12 1 2004.07.20 E • Bulk part number of fuel hose, general purpose hose and vinyl hose. (Example) 9 5 0 0 1 - 7 5 0 0 1 - 5 0 M Bulk part number: Refers to the bulk part. Marking code (hose type): (fuel hose and general purpose hose)Change code (for added hose): (Vinyl hose) • Indicates number mark ...
Page 16 - Method of computing
13 1 2004.07.20 E This F.R.T. (Flat Rate Time) is used to determine the standard labortime allowed for replacement of parts covered by the warranty duringthe period the warranty is in effect. The F.R.T. for those parts whichare not listed herein should be determined from the operation closelyrelated...
Page 18 - Operations other than replacing parts
15 1 2004.07.20 E 4. Operations other than replacing parts a. Removal and installation b. Adjustment, measurement and cleaning Engine No. Service item F.R.T. 1 Engine 1.0 2 Cylinder head *1.6 3 Carburetor 0.4 4 Crankcase separation *3.0 No. Service item F.R.T. 1 Spark plug adjustment and cleaning 0....
Page 19 - ENGINE GROUP
16 2004.07.20 E 2 ENGINE GROUP E-1 SHROUD/FAN COVER E-2 CYLINDER HEAD COVER E-3 CYLINDER HEAD E-4 CAMSHAFT/VALVE E-5 CAM CHAIN/TENSIONER E-6 CYLINDER E-7 RIGHT CRANKCASE E-8 GENERATOR E-9 OIL PUMP
Page 21 - FRAME GROUP
18 2004.07.20 E 3 FRAME GROUP F-1 HEADLIGHT F-2 SPEEDOMETER F-3 HANDLE LEVER/SWITCH/CABLE F-4 FR. BRAKE MASTER CYLINDER F-5 HANDLE/HANDLE COVER F-6 FRONT FENDER/FRONT COVER F-7 INNER BOX F-8 FLOOR PANEL F-9 LUGGAGE BOX/BODY COVER
Page 26 - CYLINDER HEAD COVER
2004.07.20 E 23 2 E-2 CYLINDER HEAD COVER Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 11211-GCC-000 TUBE, BREATHER •••••••••••••• 1 2 12310-GCC-B50 COVER COMP., HEAD ••••••••••• 1 3 12391-GCC-C50 GASKET, CYLINDER HEAD COVER • 1 4 90017-GCC-000 BOLT, HEAD COVE...
Page 27 - CYLINDER HEAD
24 2004.07.20 E 2 E-3 CYLINDER HEAD Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 12200-GCC-B50 HEAD COMP., CYLINDER •••••••• 1 2 12204-GCC-306 GUIDE, VALVE (O.S.) ••••••••• 2 3 12211-GCC-000 HOLDER, CAMSHAFT •••••••••••• 1 4 12251-GCC-000 GASKET, CYLINDER HEAD...
Page 30 - CYLINDER
2004.07.20 E 27 2 E-6 CYLINDER Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 12100-GCC-C50 CYLINDER COMP. •••••••••••••• 1 2 12191-GCC-B50 GASKET, CYLINDER •••••••••••• 1 3 90701-GF6-000 DOWEL PIN, 8X14 ••••••••••••• 2 Service item F.R.T. GASKET, CYLINDER •••••...
Page 31 - RIGHT CRANKCASE
28 2004.07.20 E 2 E-7 RIGHT CRANKCASE Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 11100-GCC-B50 CRANKCASE COMP., R. ••••••••• 1 2 11102-GT8-B00 BUSH, ENGINE HANGER RUBBER •• 1 3 11192-GCC-B50 GASKET, CRANKCASE ••••••••••• 1 4 11361-GCC-000 COVER, OIL PUMP •••...
Page 32 - GENERATOR
2004.07.20 E 29 2 E-8 GENERATOR Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 19510-GCC-000 FAN COMP., COOLING •••••••••• 1 2 31110-GFC-870 FLYWHEEL COMP. •••••••••••••• 1 3 31120-GCC-B50 STATOR COMP. •••••••••••••••• 1 4 32907-GFC-890 CLIP, A.C. GENERATOR CORD...
Page 33 - OIL PUMP
30 2004.07.20 E 2 E-9 OIL PUMP Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 15100-GFC-900 PUMP ASSY., OIL ••••••••••••• 1 2 15133-GFC-901 GEAR, OIL PUMP DRIVEN (39T) • 1 3 15331-GFC-900 ROTOR, OIL PUMP INNER ••••••• 1 4 15332-GFC-900 ROTOR, OIL PUMP OUTER ••••...
Page 34 - STARTING MOTOR
2004.07.20 E 31 2 E-10 STARTING MOTOR Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 11205-GW3-980 BUSH, 8X12X6 •••••••••••••••• 1 2 28120-GCC-000 PINION ASSY., STARTER (14T/40T) 1 3 28150-GCC-000 HOLDER COMP., STARTER PINION 1 4 31210-GCC-000 MOTOR UNIT, STARTI...
Page 35 - LEFT CRANKCASE COVER
32 2004.07.20 E 2 E-11 LEFT CRANKCASE COVER Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 11206-GCC-000 CLAMPER, RR. BRAKE CABLE •••• 1 2 11341-GCC-C50 COVER, L. SIDE •••••••••••••• 1 3 11342-GCC-000 PLATE, L. COVER ••••••••••••• 1 4 11344-GW3-980 RUBBER, START...
Page 36 - DRIVE FACE
2004.07.20 E 33 2 E-12 DRIVE FACE Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 22011-GCC-000 PIECE SET, SLIDE •••••••••••• 1 2 22102-GCC-C50 FACE COMP., DRIVE ••••••••••• 1 3 22105-GCC-C50 BOSS, DRIVE FACE •••••••••••• 1 4 22109-GCC-C50 RATCHET, STARTER ••••••...
Page 37 - DRIVEN FACE
34 2004.07.20 E 2 E-13 DRIVEN FACE Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 22100-GW3-980 OUTER COMP., CLUTCH ••••••••• 1 2 22350-GW3-980 PLATE COMP., DRIVE •••••••••• 1 3 22401-GCC-000 SPRING, CLUTCH •••••••••••••• 3 4 22535-GW3-980 WEIGHT SET, CLUTCH •••...
Page 38 - TRANSMISSION
2004.07.20 E 35 2 E-14 TRANSMISSION Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 21200-GCC-B50 CASE COMP., TRANSMISSION •••• 1 2 21395-GFC-890 GASKET, TRANSMISSION COVER •• 1 3 23411-GCC-000 DRIVESHAFT •••••••••••••••••• 1 4 23421-GCC-000 COUNTERSHAFT (13T) ••...
Page 39 - LEFT CRANKCASE
36 2004.07.20 E 2 E-15 LEFT CRANKCASE Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 11102-GT8-B00 BUSH, ENGINE HANGER RUBBER •• 1 2 11200-GCC-B50 CRANKCASE COMP., L. ••••••••• 1 3 11203-GC7-300 BUSH, RR. CUSHION UNDER RUBBER 1 4 11204-GCC-000 PLATE, OIL SEAL ST...
Page 41 - CARBURETOR
38 2004.07.20 E 2 E-17 CARBURETOR Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 16010-GCC-770 GASKET SET •••••••••••••••••• 1 2 16012-GCC-B50 NEEDLE SET, JET ••••••••••••• 1 3 16013-KEW-900 FLOAT SET ••••••••••••••••••• 1 4 16015-GCC-B51 CHAMBER SET, FLOAT ••••...
Page 43 - HEADLIGHT
40 2004.07.20 E 3 F-1 HEADLIGHT Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 32920-GCC-B00 CLAMP, CORD ••••••••••••••••• 1 2 33100-GCC-B50 HEADLIGHT ASSY. (12V 40/40W) 1 3 33110-GCC-B50 HEADLIGHT UNIT •••••••••••••• 1 4 33113-GCC-B50 PIPE, CP •••••••••••••••••...
Page 44 - SPEEDOMETER
2004.07.20 E 41 3 F-2 SPEEDOMETER Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 34908-GCC-B50 BULB, WEDGE BASE (T10) (12V 3.4W) 2 2 34909-GCC-B50 BULB, WEDGE BASE (T10) (12V 1.7W) 3 3 37200-GCC-B50 SPEEDOMETER ASSY. (KPH) ••••• 1 4 37210-GCC-B50 SPEEDOMETER COM...
Page 47 - FR. BRAKE MASTER CYLINDER
44 2004.07.20 E 3 F-4 FR. BRAKE MASTER CYLINDER Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 32101-GCC-B50 SUB CORD, FR. STOP SWITCH ••• 1 2 35340-GW3-980 SWITCH ASSY., FR. STOP •••••• 1 3 45125-GCC-B50 HOSE COMP., FR. BRAKE ••••••• 1 4 45127-GCC-C50 CLAMPER A...
Page 50 - FRONT FENDER/FRONT COVER
2004.07.20 E 47 3 F-6 FRONT FENDER/FRONT COVER Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 61100-GCC-C50ZB FENDER, FR. *NHA23R*............BEST GRAY 1 61100-GCC-C50ZC *NHA24R*........ALASKAN WHITE 1 61100-GCC-C50ZD *NH1*...................BLACK 1 2 61110-GCC-...
Page 51 - INNER BOX
48 2004.07.20 E 3 F-7 INNER BOX Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 64309-KCW-850 COVER, LID HINGE •••••••••••• 2 2 75581-KCW-870 SPRING, LOCK KEY SETTING •••• 1 3 77239-GCC-B50 LOCK, INNER BOX ••••••••••••• 1 4 81131-GCC-C50ZA BOX, INNER *NH1*..........
Page 52 - FLOOR PANEL
2004.07.20 E 49 3 F-8 FLOOR PANEL Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 50611-GCC-C50 COVER, UNDER •••••••••••••••• 1 2 64310-GCC-C51ZA STEP, FLOOR *NH1*...................BLACK 1 3 64311-GCC-C51 PLATE, FLOOR STEP ••••••••••• 1 4 64320-GCC-C50ZA MAT, FL...
Page 53 - LUGGAGE BOX/BODY COVER
50 2004.07.20 E 3 F-9 LUGGAGE BOX/BODY COVER Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 77106-GAH-000 HOOK, HELMET •••••••••••••••• 1 2 80151-GCC-C50ZA COVER, CENTER *NH1*...................BLACK 1 3 80152-GCC-C50ZA LID, MAINTENANCE *NH1*...................B...
Page 55 - STEERING STEM/FRONT FORK
52 2004.07.20 E 3 F-10 STEERING STEM/FRONT FORK Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 50301-GM0-000 RACE, STEERING UPPER BALL ••• 1 2 50302-KCW-870 RACE, STEERING BOTTOM BALL •• 1 3 50306-196-010 NUT, STEERING STEM LOCK ••••• 1 4 51400-GCC-B50 FORK ASSY...
Page 57 - FRONT BRAKE CALIPER
54 2004.07.20 E 3 F-11 FRONT BRAKE CALIPER Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 06451-KEJ-900 SEAL SET, PISTON •••••••••••• 2 2 06455-GCC-B51 PAD SET, FR. •••••••••••••••• 1 3 43107-GCC-B50 PISTON •••••••••••••••••••••• 2 4 43352-GW3-980 BLEEDER ••••••...
Page 58 - FRONT WHEEL
2004.07.20 E 55 3 F-12 FRONT WHEEL Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 42753-GCC-B50 VALVE, RIM (KENDA) •••••••••• 1 42753-GCC-B70 VALVE, RIM (IRC) •••••••••••• 1 42753-KRV-910 VALVE, RIM (CHENG SHIN) ••••• 1 2 44301-GCC-C50 AXLE, FR. WHEEL ••••••••••...
Page 59 - REAR WHEEL
56 2004.07.20 E 3 F-13 REAR WHEEL Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 06430-GCC-B50 SHOE SET, BRAKE (JB) •••••••• 1 2 42650-GCC-B51ZA WHEEL SUB ASSY., RR. *NH168M*VERNIER GRAY METALLIC 1 3 42711-GCC-B50 TIRE, RR. (100/90-10 56J) (KENDA) 1 42711-GCC-B6...
Page 60 - SEAT
2004.07.20 E 57 3 F-14 SEAT Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 77115-GCC-C50 RUBBER, SEAL •••••••••••••••• 1 2 77200-GCC-B50ZA SEAT COMP., DOUBLE *TYPE1* •• 1 3 77235-GCC-C51 CATCH COMP., SEAT ••••••••••• 1 4 77236-GCC-C51 SPRING, SEAT CATCH ••••••••...
Page 61 - FUEL TANK
58 2004.07.20 E 3 F-15 FUEL TANK Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 16950-GCC-B50 COCK ASSY., FUEL AUTO ••••••• 1 2 16952-GCC-B50 SCREEN SET, FUEL STRAINER ••• 1 3 16958-KCW-870 GASKET, FUEL COCK BODY •••••• 1 4 17500-GCC-C50 TANK COMP., FUEL •••••••...
Page 62 - BATTERY
2004.07.20 E 59 3 F-16 BATTERY Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 31500-GCC-K70 BATTERY ASSY. (YTX5L-BS) •••• 1 31500-GCC-K90 BATTERY ASSY. (GTX5L-BS) •••• 1 2 95012-12001 BAND B1, BATTERY •••••••••••• 1 Service item F.R.T. BATTERY ASSY. ••••••••••••...
Page 63 - AIR CLEANER
60 2004.07.20 E 3 F-17 AIR CLEANER Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 15771-551-000 CLIP, OIL DRAIN TUBE •••••••• 1 2 15772-500-013 CLIP, BREATHER TUBE ••••••••• 1 3 17210-GCC-C51 ELEMENT COMP., AIR CLEANER •• 1 4 17212-GAH-000 SEAL, AIR CLEANER COVE...
Page 66 - EXHAUST MUFFLER
2004.07.20 E 63 3 F-18 EXHAUST MUFFLER Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 18292-GY1-610 GASKET, EX. PIPE •••••••••••• 1 2 18293-GZ5-000 RUBBER, PROTECTOR PACKING ••• 2 3 18300-GCC-C50 MUFFLER COMP., EX. •••••••••• 1 4 18318-GCC-C50 PROTECTOR, MUFFLER...
Page 68 - REAR CUSHION
2004.07.20 E 65 3 F-20 REAR CUSHION Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 52400-GCC-000 CUSHION ASSY., RR. •••••••••• 1 2 52485-GW3-980 BUSH, RUBBER •••••••••••••••• 1 3 52487-GW3-980 COLLAR, RUBBER BUSH ••••••••• 1 4 92201-08032-0A BOLT, HEX., 8X32 •••...
Page 69 - REAR FENDER
66 2004.07.20 E 3 F-21 REAR FENDER Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 33741-KV8-840 REFLECTOR, REFLEX ••••••••••• 1 2 64203-166-610 COLLAR, FAIRING STAY •••••••• 1 3 80104-GCC-000 PLATE, RR. FENDER SPLASH GUARD 1 4 80105-GCC-C50 FENDER, RR. •••••••••...
Page 70 - FRONT WINKER
2004.07.20 E 67 3 F-22 FRONT WINKER Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 33402-GCC-B00 LENS, R. FR. WINKER ••••••••• 1 2 33407-GCC-B00 SEAL, PACKING ••••••••••••••• 2 3 33410-GCC-B50 BASE COMP., FR. WINKER •••••• 1 4 33452-GCC-B00 LENS, L. FR. WINKER •...
Page 71 - REAR COMBINATION LIGHT
68 2004.07.20 E 3 F-23 REAR COMBINATION LIGHT Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 33105-GCC-B50 WASHER •••••••••••••••••••••• 2 2 33700-GCC-B50 LIGHT ASSY., RR. COMBINATION 1 3 33701-GCC-B00 LENS, TAILLIGHT ••••••••••••• 1 4 33702-GCC-B00 LENS, LICENS...
Page 72 - WIRE HARNESS
2004.07.20 E 69 3 F-24 WIRE HARNESS Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 30401-HA7-670 CUSHION, C.D.I. UNIT •••••••• 1 2 30410-GCC-B51 C.D.I. UNIT ••••••••••••••••• 1 3 30500-GCC-B50 COIL ASSY., IGNITION •••••••• 1 4 30700-GFC-890 CAP ASSY., NOISE SUPP...
Page 74 - FRAME BODY
2004.07.20 E 71 3 F-25 FRAME BODY Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 11345-GCC-000 DUCT, L. COVER •••••••••••••• 1 2 11346-KCW-870 BAND, L. COVER DUCT ••••••••• 1 3 19051-KA4-000 RUBBER, RADIATOR MOUNTING ••• 2 4 50100-GCC-C51 BODY COMP., FRAME •••••...
Page 75 - TOOLS
72 2004.07.20 E 3 F-26 TOOLS Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 77251-342-000 BAG, SERVICE BOOK ••••••••••• 1 2 89010-GCC-000 TOOL SET •••••••••••••••••••• 1 3 89101-063-000 BAG, TOOL ••••••••••••••••••• 1 4 89216-GY6-900 WRENCH, BOX (P16X10) •••••••...
Page 77 - MARK
74 2004.07.20 E 3 F-28 MARK Ref. No. Part No. Description Reqd. QTY Parts catalogue code SCR100WH 5 Serial No. 1 87515-GCC-C10ZA EMBLEM, BODY COVER *TYPE1* •• 2 2 87561-GCC-C50ZA MARK, FR. HANDLE COVER *TYPE1* 1 87561-GCC-C50ZB MARK, FR. HANDLE COVER *TYPE2* 1 87561-GCC-C50ZC MARK, FR. HANDLE COVER ...
Page 81 - PART NAME INDEX
78 2004.07.20 E Page Ref. Part name Page Ref. Part name Page Ref. Part name 5 [ A ] ARM ASSY., KICK STARTER •••••• 64 1 ARM COMP., RR. BRAKE LOCK •••• 42 21 ARM, RR. BRAKE ••••••••••••••• 56 7 ARM, VALVE ROCKER •••••••••••• 25 5 AXLE, FR. WHEEL •••••••••••••• 55 2 [ B ] BAG, SERVICE BOOK •••••••••••...
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