2. CYLINDER HEAD - Crossfire Motorcyclescrossfiremotorcycles.com/wp/wp-content/uploads/2015/08/...1...

No. PART No. DESCRIPTION QTY

1 1220A-010-0100 Cylinder Head Assembly Cylinder (1) 1

2 1220A-010-0000 Cylinder Head Assembly Cylinder (2) 1


1 90032-010-0000 Cylinder bolts M10×1.25×175 4

2 90031-010-0000 Cylinder bolts M10×1.25×145 4

3 90604-010-0000 Copper Washer 10×18×3 8

4 33300-010-0000 Spark Plug Ngk Dcpr7E 2

5 93107-0601-2060 Hexagon Flange Bolts M6×12 2

6 90601-002-0000 Aluminum Washer 6×12×1.5 2

7 12200-010-0100 Cylinder Head assy Cylinder (1) 1

8 93140-0804-5060 Stud M8×45(Sus) 4

9 93432-0608-0060 Hexagon socket head cap screws M6×100 4

10 91215-010-0000 Seal 1PK-N769C-4 2

11 12301-010-0000 Cover,Cylinder Head 2

12 90612-004-0000 Aluminum Washer 14×22×1.5 4

13 91105-010-0000 Gasket,Cylinder Head Cover Bolts 4

14 93017-010-0000 Bolts M6×25 4

15 12200-010-0000 Cylinder Head assy Cylinder (2) 1

800GT Engine Parts Manual1. CYLINDER HEAD

2. CYLINDER HEAD


1 14711-010-0000 Intake Valve 4

2 14721-010-0000 Exhaust Valve 4

3 14775-010-0000 Valve Spring Seat 8

4 91225-010-0000 Valve Stem Seal 8

5 14751-010-0000 Spring,Valve 8

6 14771-010-0000 Retainer,Valve Spring 8

7 14781-010-0000 Valve Lock Keeper 16

8 90611-010-0000 Washer 12.5×17×0.5 8

9 14430-010-0000 Intake Valve Rocker 2

10 14440-010-0000 Exhaust Valve Rocker 2

11 14451-010-0000 Valve Rockershaft 4


1 90802-002-0000 Pin,Dowel 14×16 8

2 12250-012-0000 Gasket,Cylinder Head 2

3 12120-010-0000 Cylinder Body assy Cylinder (2) 1

4 12150-010-0000 Gasket,Cylinder Base 2

5 12110-010-0000 Cylinder Body assy Cylinder (1) 1

4. CYLINDER

3. VALVE TRAIN


1 14120-010-0000 Camshaft Ⅱ 1

2 93102-010-0000 Camshaft Limiting Plate 2


4 14321-012-0000 Timing Driven Sprocket 2

5 90604-002-0000 Washer 10×22×2.5 2

6 93103-1002-0060 Hexagon Head Bolts M10×1.25×20 2

6 14000-002-0000 Timing Chain M7-6.35-112 2

7 14508-001-0000 Gasket,Tensioner 2

8 14500-001-0000 Tensioner Assy. 2


10 14520-010-0000 Timing Chain Tensioner Guide 2

11 14630-010-0000 Timing Chain Guide 2

12 93018-010-0000 Tensioner bolts M6×12 2

13 14110-010-0000 CamshaftⅠ 1

14 14631-010-0000 Chain Plate 2


1 13200-010-0000 Crankshaft Assy 1

2 13120-010-0000 Piston Ring Set 2

3 91301-010-0000 Circlip,Piston Pin 4

4 13111-010-0000 Piston Pin 2

5 13101-010-0000 Piston 2

6 13201-010-0000 Key 1

6. CRANKSHAFT & PISTON

5. VALVE ACTUATING MECHANISM


1 11200-010-0000 Right Crankcase Assy 1

2 11101-012-0000 Gasket,Crankcase 1

3 92201-010-0000 Crankshaft Bearing RB9173KU 2

4 92204-010-0000 Crankshaft Bearing RB9173KL 2

5 90803-010-0000 Pin,Dowel 10×16 2

6 11107-002-0000 Blind Nut,Oil Drainage 1

7 91203-002-0000 O-Ring 36×3.5 1

8 15204-002-0000 Filter Spring 1

9 15203-002-0000 Oil Filter Strainer 1

10 15101-010-0000 Gasket,Oil Pump 1

11 15100-010-0000 Oil Pump Assy 1

12 93405-0603-0060 Cross recessed countersunk head screw M6×30 3

13 93338-1000-0000 Circlip for shaft ∅10 1

14 19714-010-0001 Water pump driven gear 1

15 19722-010-0000 Pin ∅4×21 1

16 19709-010-0001 Water Pump ShaftⅠ 1

17 90618-003-0000 Washer 10.3×17×1 1

18 19712-010-0000 Water Pump driving gear 1

19 15160-010-0001 Oil Pump Middle Gear 1

20 31230-010-0000 Duplicate Gear Shaft ∅10×50 2

21 93706-2003-2000 Bearing 6200RS 1

22 15320-010-0000 Oil Separator 1

23 91214-010-0000 Seal 1PK-VS-0020C-A-4 1

24 93107-0607-0060 Hexagon flange bolts M6×70 1







25 93801-0108-0000 Screw Plug NPT1/8 1

32 19723-010-0000 Bushing ∅10×∅20×11 1

33 90803-001-0000 Pin ∅4×16 1


1 12362-007-0000 Cover,Exhaust Valve 1

2 91201-007-0000 O-Ring 32.7×3.1 1


4 35404-010-0000 Holder,Drive sprocket 1


6 21241-010-0000 Gasket,Right Crankcase Cover 1

7 90812-004-0000 Pin,Dowel 8×12 2

8 11400-010-0100 Right Crankcase Cover Assy 1

9 92007-010-0000 Oil Plug M10×1.25×12,Crankcase 1

10 22727-010-0000 Oil Pipe Joint 2


12 92202-010-0000 Crankcase Cover Bearing MB9340KS 2

13 91104-010-0000 Oil Seal 34×52×7 1


2 93136-010-0000 Press Plate,Valve piece 1

16 15306-010-0000 Valve Piece 1

14 90411-010-0000 Spring Clamp G ∅14 1

15 18631-010-0000 Exhaust Pipe 1


17 15500-010-0000 Oil Pump Assy 1

21 15321-010D-0000 Rubber Oil Pipe 1750 1

22 11402-010-0000 Joint,Breathing Pipe 1

23 91228-010-0000 O-Ring 6×2 2

24 90402-010-0000 Hose Clamp Assy ∅12～∅20 2

7. RIGHT CRANKCASE & OIL PUMP

8. RIGHT CRANKCASE COVER


1 11100-012-0000 Left Crankcase Assy 1

2 93801-0108-0000 Screw Plug NPT1/8 1

3 15200-010-0000 Oil Filter 1

4 91204-010-0000 O-Ring 61.5×2.4 1

5 15202-010-0000 Oil Filter Cover 1


7 36560-010-0000 Oil Pressure Sensor 1

8 15134-012-0000 Pressure Relief Plunger 1

9 15103-003-0000 Spring ∅8×∅1×32.5 1

10 90613-010-0000 Aluminum Washer 12.5×20×2 1

11 23304-012-0000 Hollow Bolts M12×1.25×15 1

12 11323-010-0100 Gasket, Stator Case Cover 1

13 90812-004-0000 Pin,Dowel 8×12 2

14 91212-004-0000 O-Ring 34.2×2.5 1

15 91216-010-0000 Seal,Water Pump cover 1PK-N771C-4 2

16 19700-010-0000 Water Pump Assy 1

17 91212-004-0000 O-Ring 34.2×2.5 1

18 19714-010-0001 Water pump driven gear 1

19 93701-0103-5000 Needle Bearing HK1010 1


21 90601-002-0000 Aluminum Washer 6×12×1.5 1



24 90803-001-0000 Pin ∅4×16 1


1 11300-012-0000 Stator Case Cover 1

2 91210-010-0000 O-Ring 24×2.5 1

3 11325-010-0000 Big Peep Hole Cover 1


5 93432-0801-6060 Hexagon Socket Head Cap Screws M8×16 6

6 91219-010-0000 O-Ring 18×1.8 1

7 36500-012-0000 Crankcase speed Sensor 1


9 15651-010-0000 Oil Dipstck 1

10 91207-001-0000 O-Ring 18×3.5 1

11 31120-012-0000 Generator Stator Assy L460 1

31120-012-0100 Generator Stator Assy L1000

12 93141-010-0000 Stator Wire Guard Plate 1

13 93404-0400-8060 Cross recessed Pan head screws M4×8 3

14 90101-010-0000 Generator Rotor Bolt M16×35 1

15 31250-010-0000 One Way Bearing Starter 1

16 31110-012-0000 Generator Rotor Assy 1

17 90603-010-0000 Washer 17.2×30×3 1

18 93315-0800-0000 Spring Washer ∅8 6


20 31240-010-0000 Starter Disk Gear Assy 1

9. LEFT CRANKCASE & WATER PUMP

10. LEFT CRANKCASE COVER & GENERATOR


1 31200-010-0000 Starter Motor Assy 1


3 31230-010-0000 Duplicate Gear Shaft ∅10×50 2

4 31220-010-0000 Starter Idler Gear 1

5 31210-010-0000 Middle Gear 1

6 31240-010-0000 Starter Disk Gear Assy 1


1 2216A-010-0000 Cross U-Joint Assy (∅22） 1

2 91103-010-0000 Oil Seal 25×47×7 1


4 22151-010-0000 Y Shaft Bearing Block 2

5 91226-010-0000 Gasket,Y Shaft Bearing Block 2

6 93706-0050-0000 Bearing 6005 1

7 22157-012-0000 Output Shaft Y 1

8 93706-9060-0000 Bearing 6906 1

9 91207-013-0000 O-Ring 45×2.5 1

10 91101-010-0000 Oil Seal 30×47×7 1

11 22172-010-0000 Shift Sleeve,Shaft Y 1

12 22159-010-0000 Transmission Shaft Spring 1

13 93706-2060-0000 Bearing 6206 1

14 P012000224100200 Transmission Shaft Y 1

15 90606-010-0000 Washer 30×40×0.5 1

16 22454-010-0000 Bushing ∅30×∅42×22.5 1

17 93706-3050-0000 Bearing 6305 1

18 91201-004-0000 O-Ring 90×3 1

19 22153-010-0000 Y Shaft Bearing Block Ⅱ 1


21 91205-010-0000 O-Ring 25×2.4 1

22 22215-010-0000 Bushing ∅25×∅32×18 1

23 91102-010-0000 Oil Seal 32×47×7 1

24 91205-010-0000 O-Ring 25×2.4 1

25 90608-002-0000 Washer 10×32×5 2

26 93103-1002-5060 Hexagon Head Bolts M10×1.25×25 1

27 93107-1002-5060 Hexagon flange bolts M10×1.25×25 1

28 46194-119-0000 Coupling，Rear Drive 1

29 22158-012-0000 Bushing,Coupling 1

30 22161-010-0000 Yoke A(∅22） 1

31 22165-010-0000 Yoke B(∅22） 1

32 22163-010-0000 Snap Ring ∅22 4

33 22160-010-0000 U-Joint （∅22） 1

11. STARTER

12. SHAFT TRANSMISSIONS


1 22720-010-0000 Gearbox Cover 1

2 93706-3050-0000 Bearing 6305 1

3 93103-010-0000 Press Plate,Main Shaft Bearing 1


5 22211-010-0000 Transmission Main Shaft 1

6 22739-010-0000 Pin ∅2×18 1

7 92301-010-0000 Needle Bearing 25×29×12.6 2

8 22212-012-0000 H Driving Gear 1

9 22230-010-0000 Circlip for shaft ∅27×∅32×2 3

10 22213-012-0000 L Driving Gear 1

11 93706-2044-0000 Bearing 6204 DU 1

12 93706-4030-0000 Bearing 6403 1

13 22234-010-0000 Washer 17.3×34×2 1

14 22224-012-0000 R Driven Gear 1

15 22233-010-0000 Washer 25.4×33×1 1

16 22222-012-0000 H Driven Gear 1

17 22223-012-0000 L Driven Gear 1

18 92302-010-0000 Needle Bearing 25×29×9.6 2

19 P012000222020200 Transmision Countershaft 1

20 92303-010-0000 Needle Bearing AXK15×28×2 1

21 22235-010-0000 Washer 15.3×32×1.5 1

22 93719-2716-3600 Needle Bearing NBI19×27×16 1

23 22242-010-0000 R Idle Gear 1

24 22241-010-0000 R Idle Gear Shaft 1

25 22511-010-0000 Reverse Gear-shaft 12×56 1

26 21401-010-0000 Bracket,Clutch Outer Cover 1



29 22218-010-0000 Bushing ∅25×∅32×11.5 1

30 91205-010-0000 O-Ring 25×2.4 1

31 91102-010-0000 Oil Seal 32×47×7 1


33 93315-0800-0000 Spring Washer ∅8 4



1 22750-012-0000 Gearbox Casing Assy 1

2 22711-010-0000 Gearbox Gasket 1

3 90803-010-0000 Pin,Dowel 10×16 2

4 91207-001-0000 O-Ring 18×3.5 1

5 15651-010-0000 Oil Dipstck 1

6 25162-010-0001 Exhaust Pipe joint 1

7 90632-002-0000 Copper Washer 8.4×15×1.2 4

8 93011-004-0000 Bolts For Oil Tube M8×25 2

9 22730-010-0000 Gearbox Cover 1

10 90812-004-0000 Pin,Dowel 8×12 2



13 90120-010-0000 Hexagon flange Screw Plug M20×1.5×12 1




17 90613-003-0000 Copper Washer 12×20×2 1


19 15302-012-0000 Oil Tube Welding Assy B 1

20 15301-012-0000 Oil Tube Welding Assy A 1



23 15400-010C-0000 Oil Pump Assy (Gear Box) 1


25 92004-010-0001 Stud M10×1.25×50 1

26 93233-1000-0040 Self-locking Nut M10×1.25 1

27 90622-004-0000 Aluminum Washer 14×20×1.5 1

28 90135-010-0000 Screw Plug M14×1.5×16 1


30 35404-010-0000 Holder,Drive sprocket 1


32 91202-002-0000 O-Ring 18×2.4 1

33 90402-010-0000 Hose Clamp Assy ∅12～∅20 2

34 19071-119-0005 Rubber Oil Pipe 460 1

15321-010-0000 Rubber Oil Pipe 1280 1

15307-010-0000 Rubber Oil Pipe 760 1

35 91207-002-0000 O-Ring 44×2 1

36 91228-010-0000 O-Ring 6×2 2

13. GEAR BOX TRANSMISSION

14. GEAR BOX


1 11420-010-0000 Cover,Clutch,Outer 1


3 11423-010-0000 Seal,Clutch Cover 1

4 25300-012-0003 Cvt Belt 1

5 15313-012-0000 Bolts M12×145 1

6 90103-010-0000 Bolts M10×110 1

7 90612-010-0000 Washer 12×30×3 1


9 21402-010-0000 Bushing ∅11×∅30×8 1

10 P012000211000000 Driver Pulley Assy（red） 1

P012000211000100 Driver Pulley Assy（green）11 P010000212000000 Driven Pulley Assy（orange） 1

12 11450-010-0000 Cover,Clutch,Inner 1

13 91201-010-0000 O-Ring 56.75×3.53 1

14 91202-010-0000 O-Ring 50×4 2

15 93232-0600-0040 Self-Locking Nut M6 9

16 93315-0600-0000 Spring Washer ∅6 1

17 11404-003-0000 Drain Plug,Clutch Cover 1

18 11403-003-0000 Damper


1 23320-004-0000 Shift Mechanism Assy 1

2 23330-012-0000 Fan Gear Shift Assy 1

3 23312-004-0000 Gasket,Shiftshaft Cover 1

4 23311-004-0000 Shiftshaft Cover 1


6 91111-002-0000 Oil Seal 15×25×5 1


8 90812-004-0000 Pin,Dowel 8×12 1

9 37120-012-0000 Sensor,Gear Shift Indicator 1

10 91208-004-0000 O-Ring 29.6×2.4 1

11 93146-0601-6060 Hexagon Head Bolt And Plain Washer Assemblies M6×16 2

12 23200-010C-0000 Drum,Shift 1

13 90614-004-0000 Aluminum Washer 10×16×1.2 1

14 93107-1001-6060 Hexagon Flange Bolts M10×1.25×16 1

15 23304-003-0000 Hollow Bolts M14×1.5×21 1

16 90617-003-0000 Copper Washer 14×21×1 1

17 23303-002-0000 Spring 24×1 1

18 23302-002-0000 Steel Ball 9.5 1

19 23102-010-0000 Shifting Fork Ⅰ 1

20 23101-010-0000 Shifting Fork Ⅱ 1

21 22232-010-0002 Shift Rail 1

22 23109-010-0000 Spring,Gear R&L 1

23 23108-010-0000 Spring,Gear H 1

24 93135-004-0000 Spring Seat,Shift Rail 2

25 93338-1200-0000 Circlip For Shaft ∅12 2

15. CLUTCH

16. SHIFTCAM & FORK


1 16100-010-0000 Throttle Body Assy（D46-1） 1

2 90402-007-0000 Hose Clamp Assy ∅50～∅70 2

3 14801-010-0000 Intake-Tube Joint 1

14801-007C-0000 Intake-Tube Joint 1

4 91217-010-0000 Seal,intake-tube 1PK-N862C-4 2


6 14800-010-0000 Intake-Tube Assy 1


8 16723-010-0000 Temperature/Pressure Sensor 1

9 93404-0400-8060 Cross recessed Pan head screws M4×8 1

10 16701-010-0000 Press Plate,Temp 1

11 15311-010-0000 Fuel Pipe ∅8×∅14×80 1

12 90401-010-0000 Clamp ∅14 4

13 15305-010-0000 Three-way Pipe 1

14 16400-010-0000 Fuel Injector（25377440） 2

15 15312-010C-0000 Fuel Pipe ∅8×∅14×43 1

16 16430-010-0000 Fuel injector fixed seat 2


1 36540-010-0000 Water Temperature Sensor 2

2 90610-010-0000 Aluminum Washer 20.5×30×1 2

3 91213-010-0000 Seal,thermostat cover 2

4 19410-010-0000 Cover,Thermostat 1

5 19412-010-0000 Cover,ThermostatⅡ 1



8 90601-002-0000 Aluminum Washer 6×12×1.5 2


10 90405-004-0000 Hose Clamp Assy ∅20～∅32 4

11 19003-010-0000 Three-way Pipe 1

12 19005-012-0000 Hose,Cylinder Ⅱ,Outlet 1

13 19004-012-0000 Hose,Cylinder Ⅰ,Water Out 1

14 90613-010-0000 Aluminum Washer 12.5×20×2 1

17. DUCTING DAMPERS

18. COOLING WATER PIPE

2. CYLINDER HEAD - Crossfire Motorcyclescrossfiremotorcycles.com/wp/wp-content/uploads/2015/08/...1...

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Transcript of 2. CYLINDER HEAD - Crossfire Motorcyclescrossfiremotorcycles.com/wp/wp-content/uploads/2015/08/...1...