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I0700247

IPL, 125 R, 2007-10, 545 01 43-40

125R

545 01 43-40

Replaces545014340 - 11/21/06 NOTE : Illustration may differ from actual model due to design changes.

545014340

12/21/06 Page:

PARTS LISTR

125R

1

Parts List No.

Date

MODEL

WARNINGAll repairs, adjustments and maintenance not described in the Operator’s Manual must be performed by Qualified Service Personnel.

Ref. Part No. Description Ref. Part No. DescriptionRef. Part No. Description

1. 545036401 Nose Cone - LH2. 545036501 Nose Cone - RH3. 530016448 Screw4. 530016449 Screw5. 503721003 Handle-Assist6. 503210745 Bolt7. 545056601 Clamp-Harness (lower)8. 530015940 Screw9. 545067101 Assy-Throttle Housing (Incl. 18,19,20,21,22,23, 24,25,26,27,28,29)10. 502199503 Handlebar11. 503804501 Cover-Assist Handle12. 502211201 Clip-Handlebar13. 545113301 Clamp-Harness (upper)14. 545006068 Kit-Driveshaft 15. 530015814 Screw16. 530058563 Clamp - Bracket17. 545058501 Clamp 1” Handlebar18. 537419001 Switch-Stop19. 537160701 Lockout-Starter Throttle20. 537174301 Spring - Lockout21. 503221013 Nut 22. 537160601 Lockout - Throttle23. 537160203 Housing - Throttle -LH

545135401 Decal-Warning 537312901 Guard - Transport 530031159 Wrench-Hex 502114602 Wrench-Spark Plug

= New Part Number For This IPL = Refer to the Service Reference Indicated for more information.(Located at the END of the IPL)

24. Assy - Cable Wire25. 537174201 Spring - Trigger26. 537160801 Trigger - Throttle27. 503216618 Screw28. 503200735 Screw29. 537160301 Housing-Throttle - RH30. Flexshaft31. 537216301 Harness w/o warning32. 545030901 Kit-Shield (Incl. 33,34)33. 530052286 Limiter - Line34. 530015814 Screw36. 503890101 Cup-Support37. 537285601 Support - Flange38. 503856301 Locknut - Blade39. 530016014 Screw 40. 530016301 Screw41. 537234901 Driver Disc 42. 530015771 Screw 43. 530057554 Bracket - Shield44. 502285901 Pin - Locking45. 530096295 Assy - Gearbox

45

44

394041

3334

3236

3837

3

2

1

9

10

4

8 171615

5

6

7

4243

14

13

11

12

27

28

2925

2623

21 24

20

22

30

31

18 19

545014340

12/21/06 Replaces545014340 - 11/21/06 Page:

PARTS LISTR

125R

2

Parts List No.

Date

MODEL

NOTE : Illustration may differ from actual model due to design changes.

Ref. Part No. Description Ref. Part No. DescriptionRef. Part No. Description

1. 530150253 Filter2. 530016101 Nut-Carb. Screw3. Air Box4. 530057844 Lever - Choke5. 545050402 Kit-Carb. Gasket (Incl 7,61)6. 530035596 Adaptor-Carb.7. 545030101 Kit-Gasket (foam)8. 530016400 Bolt9. 545001001 Cylinder10. 952030201 Plug-Spark (RCJ-8Y)11. 545050403 Kit-Crankshaft seal12. 530016475 Washer-Starter13. 530016450 Spring-Starter Cup14. 545102302 Assy-Starter Cup15. 530059800 Coupling-Starter16. 530095646 Assy-Fuel Filter17. 545030201 Kit-Fuel Line18. 530150350 Assy-Cap w/ret.(Incl. 19)19. 530019293 O-ring - Fuel Cap20. 545105102 Assy-Fuel Tank (Incl. 16,17,18,19)21. 530057851 Shroud-Rear22. 530016448 Screw 23. 545029901 Kit-Rope24. 530150318 Handle-Starter

48. 530403094 Nut49. 530016456 Screw50. 545017501 Assy-Fan Housing51. Assy-Clutch Drum52. 545050405 Kit-Clutch Assy. 53. 530057852 Spacer 54. 530039242 Flywheel 55. 545054601 Crankcase56. 545013401 Bearing 57. 545030001 Kit-Crankshaft 58. 530015162 Retainer-Piston Pin59. 530019283 Ring-Piston60. 545030301 Kit-Piston (Incl. 58,59)61. 545030101 Kit-Gasket (adaptor seal)62. 530015897 Screw63. 545113201 Guide - Cable 64. 545006062 Kit-Carb. (Incl. 4,5)65. 530057846 Cover-Air Box66. 530059796 Assy-Knob67. 545030101 Kit-Gasket (Incl. 5,7,11,19,39,61)

530058709 Bulb-Purge

= New Part Number For This IPL = Refer to the Service Reference Indicated for more information.(Located at the END of the IPL)

25. 530016426 Screw26. 545029603 Starter Hsg. w/eyelet27. 545029801 Kit-Starter Spring28. 545029701 Kit-Starter Pulley29. 530016468 Screw30. 545106301 Assy-Starter Hsg.(Incl. 23,24,26,27,28,29)31. 530059780 Isolator-Tank32. 530058982 Bolt-Muffler33. 530015496 Screw34. 530150440 Shield-Heat35. 530016449 Screw36. 545104901 Guard-Muffler37. 545030501 Kit-Spark Arrestor (Incl. 33)38. 545057502 Assy-Muffler39. 530057848 Gasket-Paper Metal40. 530015897 Screw 41. 545046701 Module42. 530039227 Assy-Leadwire 43. 530016456 Screw44. 530016030 Washer 45. 530094189 Washer-Clutch46. 530016469 Screw47. 530016470 Screw

Not Shown

12

3

18

17

16

151413

11

5756

60

61

62

64

6566

58

59

109

87

6

5

4

20

19

2122

242325

2627

2829

31

32

33

37

38

39

41

4445

4647

49

5051

67

GasketKit

5253

5455

48

42 43

40

3435

36

12

30

63

Replaces545014340 - 11/21/06 NOTE : Illustration may differ from actual model due to design changes.

545014340

12/21/06 Page:

PARTS LISTR

125R

3

Parts List No.

Date

MODEL

Service Reference

Note : Due to product improvements, your unit may have a different clutch drum assembly and flexshaft. Please refer to the serial number on your unit and order the parts below.

Serial Number - 2006-273N and lower, please use the following parts: Page 1, Ref.# 30 - 545081805 Kit - Clutch drum & flexshaft Page 2, Ref.# 51 - 545081805 Kit - Clutch drum & flexshaft

Serial Number - 2006-274N and higher, please use he following parts: Page 1, Ref.# 30 - 545007507 Flexshaft Page 2, Ref.# 51 - 530150039 Assy-Clutch drum with adapter

Service Reference

Note : Due to product improvements, your unit may have a different cable assembly and air box. Please refer to the serial number on your unit and order the parts below.

Serial Number - 2006-059N and lower, please use the following parts: Page 1, Ref.# 1 - 545050412 Kit - Air box with cable wire harness assembly Page 2, Ref.# 3 - 545050412 Kit - Air box with cable wire harness assembly

Serial Number - 2006-060N and higher, please use he following parts: Page 1, Ref.# 1 - 545125801 Assembly-cable wire harness Page 2, Ref.# 3 - 545084601 Air box