CUT HERE
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Occupation: Name
Dealership
Street
Department
City
2003 Firebolt XB9R Parts Catalog 99574-03Y
State
Clip out and mail to: Buell Distribution Corporation P.O. Box 653 Milwaukee, WI 53201
Zip
GENERAL INFORMATION This Parts Catalog has been prepared for your convenience when ordering parts for the 2003 Firebolt XB9R motorcycle. Prices of parts listed in this catalog are published separately. The following instructions should be followed carefully when ordering parts. • An asterisk (*) in the “MODELS” column indicates the part is used through the current model year. • When a part is revised during the model year the early version part will be marked in the MODELS column with ‘E’ followed by the model year in which the change occurred. This indicates the part was used early in the model year.The latest version of the part will be marked in the MODELS column with ‘L’ followed by the model year in which the change occurred. This indicates the part was used late in the model year • Index numbers shown in the illustrations correspond to index numbers in parts lists. The number in parenthesis following the description of parts is the quantity needed for complete assembly. If there is no number in parenthesis, only one is used. • Specify the correct part number for each item. Check the "MODELS" column of the parts list which shows the model on which the part fits. Whenever in doubt, refer to the Vehicle Identification Number (V.I.N.) stamped on the frame and engine crankcase. • VEHICLE IDENTIFICATION NUMBER The full 17 digit serial or Vehicle Identification Number (V.I.N.) is stamped on the steering head and on an information plate at the same location. A Motor Identification Number is stamped on the left side crankcase near the front of the engine.
Manufacturer: Buell Motorcycle Company Type Designation - Firebolt XB9R 12 = World 57 = California
Engine
Horsepower Code 3 = Model Year - 2003 3 = Manufactured in East Troy, WI Sequential Number
4 MZ AX 12 *Varies - can be 0 thru 9 or X
J
*
3
3
400001-420000 = World 420001-425000 = CA
400001
Sample V.I.N. as it appears on the steering head - 4MZAX12J133400001 Sample abbreviated V.I.N. as it appears on the left side crankcase- AX123400001
Orders may be placed via your computer for all parts. Please review your system documentation for details on placing orders electronically. All non-warranty replacement crankcase orders require return of the complete left crankcase half with V.I.N. All non-warranty replacement frame orders require return of the steering neck with V.I.N. Non-compliance will result in a fine. See non-warranty frame and crankcase policy or contact your SPOC team for details. THIS IS NOT AN ASSEMBLY MANUAL AND SHOULD NOT BE USED AS SUCH. PATENT NOTICE Buell products are manufactured under one or more of the following patents: U.S. Patents - 4776432, 4951774, 4964484, 4959696, 5209319, 5294702, 5303795, 5332246, 5435584, 6105701, 6213238, 6213240, 6267193, D440190. To the best knowledge of Buell Motorcycle Co., the material contained herein is accurate as of the date this publication was approved for printing. Buell Motorcycle Co. reserves the right to change specifications, equipment, or designs at any time without notice and without incurring obligation. ©COPYRIGHT 2002 BY BUELL DISTRIBUTION CORPORATION, ALL RIGHTS RESERVED Printed in U.S.A.
1
ALPHABETICAL INDEX DESCRIPTION
PAGE
Air Cleaner............................................................... 21 Air Scoop ................................................................. 77 Alternator................................................................. 23 Axle, front ................................................................ 41 Axle, rear ................................................................. 43 Battery ..................................................................... 75 Battery Cables ......................................................... 75 Belt Guard, lower..................................................... 59 Belt Guard, upper .................................................... 59 Belt, rear .................................................................. 35 Bracket, fairing support........................................... 81 Brake Caliper, front.................................................. 37 Brake Caliper, rear................................................... 39 Brake Control, front ................................................. 37 Brake Control, rear .................................................. 39 Brake Line, front ...................................................... 37 Brake Line, rear ....................................................... 39 Brake Pads ........................................................ 37, 39 Brake Rotor, front .................................................... 41 Brake Rotor, rear ..................................................... 43 Bulb, taillight ............................................................ 79 Cable, clutch control ................................................ 57 Cable, throttle control .............................................. 57 California Evaporative Emissions Components....... 91 Cam Bushings ......................................................... 15 Cam Gears .............................................................. 15 Carrier, fuse block.................................................... 65 Chain, primary ......................................................... 35 Chin Fairing, center ................................................. 63 Chin Fairing, LH....................................................... 63 Chin Fairing, RH ...................................................... 63 Circuit Breakers ....................................................... 89 Clutch ...................................................................... 33 Clutch Cable ............................................................ 57 Clutch Lever............................................................. 57 Connecting Rod & Bearings ...................................... 9 Cover, clutch ............................................................ 13 Covers, rocker arm .................................................... 7 Crankcase ............................................................... 11 Cylinder Head............................................................ 5 Cylinder, engine......................................................... 5 Decals...................................................................... 67 Electrical Connectors .............................................. 89 Electrical Switches .................................................. 89 Engine Control Module ............................................ 25 Engine Mounts......................................................... 53 Engine, complete....................................................... 5 Exhaust System....................................................... 73 Fairing, front ............................................................ 65 Fan .......................................................................... 77 Fan Shroud, LH ....................................................... 77 Fan Shroud, RH....................................................... 77 Fender, front ............................................................ 63 Fender, rear ............................................................. 59 Filter, air................................................................... 21 Filter, engine oil ....................................................... 71 Flasher, turn signals ................................................ 79 Flywheel .................................................................... 9 Footpeg ................................................................... 51
2
DESCRIPTION
PAGE
Fork, front ................................................................ 47 Frame ...................................................................... 51 Fuel Pump ............................................................... 69 Fuel Tank ................................................................. 69 Fuses....................................................................... 89 Gasket Kits ............................................................ 5, 7 Gearcase, cams ...................................................... 15 Glossary .................................................................. 90 Handlebars .............................................................. 57 Hardware Listing ............................................... 85, 86 Headlights ............................................................... 77 Horn ........................................................................ 77 Hydraulic Lifters......................................................... 7 Idler Pulley............................................................... 35 Ignition Coil.............................................................. 25 Ignition Switch ......................................................... 89 Induction Module ..................................................... 19 Instrument Cluster ................................................... 81 Intake Air Cover....................................................... 63 Intake Manifold ........................................................ 19 Keys, ignition ........................................................... 89 Lever, front master cylinder ..................................... 37 Lever, transmission gear shift.................................. 31 License Plate Bracket.............................................. 79 Lock, ignition ........................................................... 89 Master Cylinder, front .............................................. 37 Master Cylinder, rear ............................................... 39 Mirrors ..................................................................... 65 Muffler ..................................................................... 73 Numerical Index .......................................... 93, 94, 95 Oil Filter ................................................................... 71 Oil Pressure Switch ................................................. 71 Oil Pump.................................................................. 17 Oil Tank Filler Plug................................................... 55 PCV Valve ................................................................. 7 Piston & Piston Rings............................................ 5, 9 Primary Cover ......................................................... 13 Push Rods & Cover ................................................... 7 Reflectors ................................................................ 79 Regulator................................................................. 23 Relay, ignition .......................................................... 89 Relay, starter ........................................................... 89 Rocker Arms & Cover................................................ 7 Seat ......................................................................... 61 Sensor, bank angle.................................................. 89 Sensor, vehicle speed ............................................. 89 Shifter ...................................................................... 31 Shock Absorber, rear............................................... 49 Side Stand............................................................... 51 Spark Plug............................................................... 25 Speedometer........................................................... 81 Sprocket Covers ...................................................... 59 Sprockets........................................................... 33, 35 Starter Motor ........................................................... 27 Steering Head ......................................................... 45 Swingarm ................................................................ 55 Switch, front brake................................................... 37 Switch, rear brake light ............................................ 39 Switches .................................................................. 89
ALPHABETICAL INDEX DESCRIPTION
PAGE
DESCRIPTION
PAGE
Switches, handlebar ................................................57 Switches, ignition .....................................................89 Switches, sidestand .................................................51 Tail Lamp .................................................................79 Tail Section ..............................................................61 Throttle Control ........................................................57 Throttle Position Sensor ..........................................25 Timer Cover .............................................................25 Transmission Gears .................................................29 Turn Signals.............................................................79 Valves & Guides ........................................................5 Voltage Regulator ....................................................23 Wheel, front .............................................................41 Wheel, rear ..............................................................43 Windscreen..............................................................65 Wiring & electrical connectors .................................89 Wiring harness, main.........................................83, 85 Wiring harness, rear lamps......................................79
3
CYLINDER HEAD & VALVES 1 2 16 15 14 10 13 11
8 5 4
12
17
18 3
9 6 7
4
CYLINDER, HEAD & VALVES
b0029c
INDEX NO.
1 2 3 4 5 6 7 8 9
10 11
12 13 14 15 16 17 18
PART NO.
DESCRIPTION
MODELS
16032-02 16478-85A 16480-92 16573-83 16715-83 16770-84D 16774-86D 16832-86C 16872-02 16875-02 17058-02 17059-02 17036-91 18094-02 18020-83 18011-86 18690-02 18691-02 16461-02 18245-02 18258-02 18260-02 22710-02 26432-76A
ENGINE ASM. w/out front isolator mount attached (not illustrated) SCREW, internal thread (4) SCREW, internal thread (4) INSERT, cylinder stud (4) STUD, exhaust port (4) GASKET, cylinder head (2) GASKET, cylinder base (2) STUD, cylinder base (8) HEAD ASM., front cylinder - w/ valve guides & seats HEAD ASM., rear cylinder - w/ valve guides & seats GASKET KIT, engine overhaul GASKET KIT, top overhaul GASKET KIT, rocker covers COLLAR/SEAL, valve stem (4) SEAT, intake valve (2) SEAT, exhaust valve (2) VALVE, intake (2) VALVE, exhaust (2) VALVE GUIDE, intake & exhaust (4) SPRING, valve (4) COLLAR, valve spring - upper (4) RETAINER, valve collar (8) CYLINDER w/ piston & rings O-RING, cylinder stud insert (4)
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
16032-02
INTERNATIONAL ONLY ENGINE ASM. w/ out front isolator mount attached (not illustrated) (AUS, ENG, EUR, JPN)
2003-XB9R
5
ROCKER ARMS, COVERS & PUSH RODS 16 17 1 24
2 6
15
4 6 10
2 6
19
11 13 5 19 6
20 14
21
12 7
8 22
3
23
6
18
9
ROCKER ARMS, COVERS & PUSH RODS
b0030b
INDEX 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
PART NO. 882 1039 3299Y 3997A 4718A 6736 11190 16800-84 17036-91 17353-89 17358-84A 17360-83A 17375-83A 17598-97Y 17605-00YA 17606-00Y 17607-00Y 17608-00Y 17611-83 17642-02 17649-02 17908-02 17909-02 17979-02 17986-00Y 18532-00A 18538-99B 63858-49
DESCRIPTION
MODELS
SCREW (8) SCREW, hex flange head w /locker (8) SCREW w/ washer (8) BOLT (6) BOLT w/ washer (8) WASHER (6) O-RING, push rod cover - upper (4) GASKET, rocker cover/cylinder head, valve & push rod sides (2) GASKET KIT, rocker covers w/ # 8,11, 12 & 26 GASKET, rocker cover - lower (2) GASKET, rocker cover - inner (2) ROCKER ARM ASM., w/ bushing, front intake & rear exhaust (2) ROCKER ARM ASM., w/ bushing, rear intake & front exhaust (2) ROCKER COVER, inner (2) ROCKER COVER, top front GROMMET (2) PCV VALVE (2) GASKET, push rod cover front SHAFT, rocker arm (4) ROCKER COVER, top rear (not illustrated) GASKET, rear push rod cover (not illustrated) PUSH ROD, exhaust (2) PUSH ROD, intake (2) COVER, push rod, rear (not illustrated) COVER, push rod, front SCREW, tappet anti-rotation (2) HYDRAULIC LIFTER (2) GASKET (10)
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
7
PISTON & FLYWHEEL ASSEMBLY
3
4
9
5 9 7
1 8 2
8
6
PISTON & FLYWHEEL ASSEMBLY
b0031c
INDEX NO. 1 2 3 4 5 6 7 8 9
PART NO. 8973 11177A 21948-02 22707-02 22765-02 24213-02 24331-36 24332-36 24658-87 22589-83B
DESCRIPTION
MODELS
THRUST WASHER RETAINING RING PISTON RING SET - standard (2) PISTON & RINGS ASM. - standard (2) PISTON PIN (2) FLYWHEEL & CONNECTING ROD ASM. BUSHING, piston pin - standard (2) BUSHING, piston pin - 0.01 oversize (2) INNER RING LOCK RING, piston pin (2)
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
9
CRANKCASE 17
18
4 6 23
7 1
26
12 9
28 3 10 30
18
1
24
14
31 19
34 24
5 21
20
22 16 11 8
13 2
15
27 25 33
10
32
29
CRANKCASE
b0032b
INDEX 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 29 30 31 32 33 34
PART NO. 358 720 1028 879A 1044 4091 6314W 8881 8973 10080 11177A 12068 16899-02 22265-00Y 24604-00B 24647-87 24650-87 24659-87 24660-87 24754-75 24439-02 26921-02 26922-02 26923-02 26924-02 29950-91 32617-00Y 35114-02 40254-02 45830-48 62340-01Y 26365-02 63533-41A AA0636.2CZ BA0613.2Z DA0600.11CZ L0178.K
DESCRIPTION
MODELS
DOWEL PIN (4) PLUG, timing SCREW, w/ washer (9) SCREW (5) SCREW SCREW (2) WASHER (5) BEARING RACE WASHER, thrust CLAMP, hose (3) RETAINING RING OIL SEAL STUD, tap end (2) OIL JET ASM., complete BEARING BEARING, gear shaft (blue) BEARING, gear shaft (red) BEARING, gear shaft (white/gray) BEARING, gear shaft (green) DOWEL PIN (2) CRANKCASE SET w/ bushings & bearings (silver) REED VALVE ASM VALVE, reed STOP, reed valve REED BLOCK COVER, stator wires SCREW, self-tapping (6) RING, retaining SPACER, sprocket shaft PLUG HOSE, preformed FITTING, connector - straight FITTING, connector - vent SCREW WASHER LOCKNUT SPACER
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
11
PRIMARY COVER & CHAIN TENSIONER
9 8 5
7
1
1 10
6
11 2 13 4 12
14 3
12
PRIMARY COVER & CHAIN TENSIONER
b0033b
INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14
PART NO. 961 4820A 7804 11105 25351-00Y 25378-02 25521-02 34772-00Y 34912-02 34763-02 37101-84A 40039-02 34076-02 60328-98A
DESCRIPTION
MODELS
SCREW, sems (5) SCREW, sems (14) NUT, chain adjustment O-RING GASKET, clutch cover GASKET, primary cover PRIMARY COVER w/ 34076-02 (painted black) COVER, clutch COVER, inspection GASKET, inspection cover OIL SEAL, shifter shaft ADJUSTER ASM., chain w/ shoe, collar, plate & screw BUSHING DRAIN PLUG KIT w/ 11105
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
13
CAM SHAFTS & CAM COVER
7
8
7 7
8
10 10
7 8
9 10 7 12 10 5 13 11 4 10 2
14
10
3
6 8
8
1
CAMSHAFTS & CAM COVER
b0034b
INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12
13
PART NO.
DESCRIPTION
MODELS
215 4820A 7916A 11124 11317 24047-00 24439-02 25188-02 25353-00Y 25782-02 26318-88A 62376-02
DOWEL PIN (2) SCREW, sems (7) NUT SEAL, oil KEY, square PINION GEAR CRANKCASE SET w/ bearings & bushings “E” CAM GEAR SET w/ pinion gear GASKET, camshaft cover GEAR COVER ASM. w/ bushings, oil seal & fitting (painted black) DRIVE GEAR, oil pump FITTING, oil vent hose
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
62352-94B
NOTE: Hoses are sold in bulk length under the following part number. Cut to required length. HOSE, drain/feed
2003-XB9R
15
OIL PUMP
13
9
Oil Line Return
15
8
7 3 4 10 Oil Line Feed
12 16
11 6 14 5 1 2
16
Oil Line to Oil Cooler
OIL PUMP
b0025b
INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
PART NO. 4132 4765 6157 11002 26357-02 26358-02 26359-02 26361-02 26434-91 26488-98 26491-98 26492-91 26493-91 26495-89A HS0008.02A8 L2116.02A8 L2118.02A8
DESCRIPTION
MODELS
SCREW (2) SCREW, sems (2) THRUST WASHER RETAINING RING OIL PUMP, complete FITTING, connector FITTING, connector - 45 degree FITTING, 90 degree O-RING GEAR SHAFT GEROTOR SET, return GEROTOR SET, feed SEPARATOR PLATE GASKET, pump mounting OIL LINE, cooler feed OIL LINE, return OIL LINE, feed
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
17
INDUCTION MODULE - ELECTRONIC FUEL INJECTION
16
2
5
10 14
6
13
15
15 8
11 4
1
3
9
4
7 6
12 3
18
INDUCTION MODULE - ELECTRONIC FUEL INJECTION
b0035a
INDEX NO. 1 2 3 4 5 6 7 8
9 10 11 12 13 14 15 16
PART NO. 3322Y 3323Y 3275 3987 6090Y 26995-86B 27009-86A 27010-86A 27337-99Y 27338-99Y 27425-02 29533-99Y 29537-99Y 29539-99Y 29803-02 29804-02 29805-02 29806-02 A0508.2CSS P0025.02A8
DESCRIPTION
MODELS
SCREW (2) BOLT (2) BOLT (2) BOLT (2) WASHER (2) SEAL, intake manifold (2) MOUTNING FLANGE, front intake MOUNTING FLANGE, rear intake O-RING, fuel injector (not illustrated) O-RING, fuel injector (not illustrated) FUEL INDUCTION MODULE (complete) FUEL INJECTOR (2) THROTTLE POSITION SENSOR RING SEAL MANIFOLD ASM., injector w/ #1, 9, 12 & 13 INTAKE MANIFOLD FUEL RAIL ASM. THROTTLE BODY ASM. SCREW (2) VELOCITY STACK
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
19
AIR CLEANER
6
5
4
9 7 1
1
1 8 3
2
20
AIR CLEANER
b0007a
INDEX NO. 1 2 3 4 5 6 7 8 9
PART NO. CA0018.02A8 HS0014.02A8 HS0016.02A8 HS0455.02A8 P0144.02A8 P0213.02A8 P0215.02A8 P0138.K P0139.K P0700.02A8 P0851.02A8
DESCRIPTION
MODELS
SCREW, shoulder (4) SLEEVE (not illustrated) BREATHER HOSE, front w/ sleeve BREATHER HOSE, rear SEAL, airbox FILTER ELEMENT COVER, airbox SENSOR, air intake (not illustrated) GOMMET BASEPLATE ASM., includes base plate & seal SNORKEL, intake
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
21
ALTERNATOR & REGULATOR
4 1
2
3
12 7
9
5 6 8
10 11
22
ALTERNATOR & REGULATOR
b0019a
INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12
PART NO. 3029 4751 40241-02 29971-02Y 72233-94 72238-94 72691-01 C0043.02A8 DN1000.2FZ Y0126.02A8 Y0135.02A8 Y0302.02A8
DESCRIPTION
MODELS
SCREW (4) SCREW (8) ROTOR HOUSING STATOR ASM. CONNECTOR LOCK, secondary CONNECTOR, stator wire SLEEVE, protective NUT, nylock (3) TERMINAL & Set, voltage regulator TERMINAL (5.0 - 3.0mm cable range) VOLTAGE REGULATOR
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
23
ELECTRONIC IGNITION SYSTEM 14 20 21
18 22 23
20 5 15 16
6
2
6
12
11
13
1
4 3
19 10 7 17 9
24
8
ELECTRONIC IGNITION SYSTEM
b0010a
INDEX NO.
PART NO.
DESCRIPTION
MODELS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
1601 2445 2611C 11124 16357-02 27671-01K 32400-94 32473-02 32504-80A 32606-82 72103-94BK 72143-94 72190-94 AA0414.2CXZB AA0608.2CXZB BA0613.2Z C0044.02A8 N0306.02A8 T0111.02A8 Y0204.02A8 Y0300.02A8
SCREW (2) SCREW SCREW SEAL MOUNT, cylinder brace/throttle body SPARK PLUG (2) SENSOR ASM. CUP, trigger rotor COVER, timer - inner STUD (2) RECEPTACLE, 3 pin SECONDARY LOCK, 3 pin receptacle TERMINAL, single socket SCREW, coil mount (2) SCREW, brace WASHER, brace RIVET, black (2) ENGINE CONTROL MODULE COVER, timer - outer WIRE, spark plug (2) IGNITION COIL
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
22 23
N0316.02A8 N0326.02A8
INTERNATIONAL ONLY ENGINE CONTROL MODULE (AUS) ENGINE CONTROL MODULE (ENG, EUR, JPN)
2003-XB9R 2003-XB9R
25
STARTER MOTOR 3
20 12 30 36 19
5
21 9
2
7
27 31 4
36
29 29 34 6
22
10
29
33
23
8
29
28
26 24
29 13 35 14
1 16 15 17 11
37 25 18
26
32
STARTER MOTOR
b0026
INDEX 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 29 30 31 32 33 34 35 36 37
PART NO. 928 929A 3350 3403 3559 6217 8871 8879 8883 9077 11116 31322-91 31323-91 31324-91 31325-91 31327-91 31328-91 31390-91B 31488-81A 31515-90 31518-90 31521-98 31525-90 31530-90 31537-98 31539-91 31556-91A 31599-91 31600-90 31603-91 31661-90 31662-90 31663-90 31688-90 31689-90 31692-90 31695-90 45902-00
DESCRIPTION
MODELS
BOLT, starter (2) SCREW with o-ring (2) BOLT, through FLANGE NUT BOLT, through WASHER BALL BEARING BALL BALL BEARING CLUTCH ROLLER (5) O-RING COVER SHAFT RETAINER, snap PINION, starter NUT, pinion stop RING, snap STARTER MOTOR, complete (black) GASKET, starter motor ARMATURE ASM. HOLDER ASM., starter brush YOKE ASM. GEAR, idler RETAINER, idler SWITCH ASM., magnetic HOUSING ASM. CLUTCH SUB-ASM. FRAME, starter end SPRING, return STARTER SOLENOID REPAIR KIT SPRING, starter (4) CAP TERMINAL, rubber CLUTCH, starter COVER, solenoid BOLT w/ washer (3) SPRING O-RING, yoke (2) SCREW w/ washer (2)
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
27
TRANSMISSION GEARS 11 12
9
8 5 17
10
30 7
19
2
19 4
7 21 31
3
2
7
27 3
7
24
7
28 3
2 2
20 22
26 23
2 7 2 25
3 7 29 15
28
6
14 13 1
16 18
33
32
TRANSMISSION GEARS
b0027
INDEX 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 29 30 31 32 33
PART NO. 3675 6003 8876A 8977 8996A 8998 11067 11161 11165 12030 12067A 33344-94 35020-89 35021-89 35022-89A 35030-89 35034-94 35038-89A 35051-89 35063-89 35633-94 35640-89 35641-89 35762-02 35763-89A 35771-94 35772-94 35773-94 35775-94 35796-00 35797-00 37495-91 37870-91
DESCRIPTION
MODELS
SCREW THRUST WASHER (6) BEARING (4) BEARING, closed end BEARING, ball BEARING RETAINING RING (7) RETAINING RING QUAD SEAL OIL SEAL OIL SEAL SPACER RETAINER, countershaft RETAINING RING SPACER BEARING GEAR ASM., fifth-mainshaft w/ oil seal & needle bearing RETAINING RING BEARING, needle (2) SPACER GEAR, fifth-countershaft MAINSHAFT COUNTERSHAFT GEAR, first-mainshaft GEAR, first-countershaft GEAR, third-countershaft GEAR, third-mainshaft GEAR, fourth-mainshaft GEAR, fourth-countershaft GEAR, second-mainshaft GEAR, second-countershaft NUT, mainshaft SPRING WASHER
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
29
SHIFTER 20
14 17 19 18 24
23
15
21
22 16
11 25 21
26
6
9
14
7 8 8 2 3
12
5
13 1 4 10 12
30
8
SHIFTER
b0012d
INDEX 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
PART NO. 3997A 9187 11360 33540-02 33634-02 33900-99 34014-02 34064-00B 34144-02 34163-02 34483-02 34491-02 34981-02 34982-02 AN1006.2CXZB AN1008.2CXZB CA0015.02A8 CD0007.02A8 DN1000.4FZB N0320.02A8 N0507.01A1A N0513.T N0599.02A8 N0600.02A8 N0606.02A8A N0630.02A8 T0225.01A1
DESCRIPTION
MODELS
SCREW BEARING RING, retaining SPRING SLEEVE ASM., detent SHIFTER CAM ASM. SWITCH, neutral (not illustrated) SHIFTER LEVER ASM. SPRING, shifter return FORK ASM, shifter (3) PIN, shifter stop SPRING, detent SPRING, extension (2) SHAFT, shifter forks (2) BUSHING, RH crankcase BOLT (2) BOLT BOLT, flange head (2) JAM NUT JAM NUT, thin LINKAGE ASM., shifter w/ #17, 18, 20 & 24 ROD END, shift linkage, male RH thread BEARING, pedal (2) SLEEVE, shift/brake lever TOE PEG, shift lever ROD END, shift linkage, male LH thread SHIFT PEDAL ASM., w/ toe peg and bearings LEVER, engine
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
31
CLUTCH 17
25
3
24
18
16
14
21
13 20 23 29 28
22
7 2 4
30 26
5
15
9 1
27 8 6 12 11
10
32
19
CLUTCH
b0028b
INDEX 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 29 30
PART NO. 8873 8885 9214 11046 11250 11730A 11765Y 25409-94B 25453-87A 34920-86A 36715-94 36802-84B 37495-91 37870-91 37872-90 37890-02 37891-02 37892-02 37893-02 37894-02 37895-02 37896-02 37897-02 37898-02 37899-02 37908-90 37909-90 37911-90 37913-90 37918-91
DESCRIPTION
MODELS
BALL (3) BALL BEARING NEEDLE BEARING RETAINING RING RETAINING RING NUT ADJUSTMENT SCREW RAMP, outer RAMP, inner COUPLING, clutch cable SPRING, clutch adjustment LOCKPLATE, well type NUT, main shaft SPRING WASHER SEAT, spring - inner THRUSTWASHER, inner THURSTWASHER, outer INNER RACE, needle bearing SPRING. diaphragm SPRING, damper SEAT, damper spring PRESSURE PLATE FRICTION PLATE, narrow CLUTCH HUB CLUTCH SHELL & SPROCKET w/ ball bearing & retaining ring RETAINING RING RETAINING RING FRICTION PLATE (paper) (7) STEEL PLATE (7) RELEASE PLATE
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
33
BELTS & SPROCKETS
17 13 11
9
18 3 1
15 7
12
20 14 4
19
5 8 2 6
34
12 16
10
BELTS & SPROCKETS
b0011e
INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
PART NO. 3594 7839 35211-91A 40005-57B 40039-02 40241-02 40251-92A 40254-02 40343-02 6400HB AA0609.11CXZB BA0511.2Z BA0613.2Z CA0020.02A8 DA0500.2CZ DA0600.12FAZB G0400.02A8 G0500.02A8F G0604.02A8C G0614.02A8C
DESCRIPTION
MODELS
SCREW (2) NUT, engine sprocket NUT, transmission sprocket PRIMARY CHAIN ADJUSTER ASM., chain w/ shoe, collar, plate & screw ENGINE SPROCKET, triple row, 35T LOCK PLATE SPACER, sprocket shaft SPROCKET ASM., transmission, 30T WASHER (2) SCREW (6) WASHER (2) WASHER (6) SCREW LOCKNUT NUT, flange (2) REAR SPROCKET, 27T DRIVE BELT, 155T IDLER PULLEY ASM., w/ pulley wheel and bracket WHEEL, idler pulley
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
35
FRONT BRAKE CONTROL & CALIPER
4 22 10 21 1 19 26
16
24
5
15
13
18
23
2 21
11 12
25 5
14
20 13
3
6 17 9 8 7
36
16 15
FRONT BRAKE CONTROL & CALIPER
b0022c
INDEX NO.
PART NO.
DESCRIPTION
MODELS
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
91960-97Y AA0404.11CDBL AA0608.2CXZB CA0200.R H0020.02A8 H0021.02A8 H0022.F H0031.02A8 H0032.02A8 H0035.9 H0054.9 H0055.9 H0110.02A8 H0300.02A8 H0405.9B H0412.01A0 H0418.02A8 H1531.02A8 N0200.02A8 N0202.02A8 N0203.9 N0210.R N0220.F N0259.9 Y0820.9
PLUG, mirror mounting hole plug SCREW BOLT, front brake caliper (2) SCREW, front master cylinder cover (2) PISTON SET PAD SPRING, caliper BLEEDER SET PIN HANGER SET, caliper STOPPER, front caliper DIAPHRAM COVER, front master cylinder CIRCLIP, brake piston BOOT, brake piston BRAKE CALIPER ASM., front BRAKE PAD (2) BANJO BOLT, master cylinder (2) WASHER (4) WIRE FORM, brake line BRAKE LINE ASM., front MASTER CYLINDER ASM, front w/ lever LEVER, front master cylinder PIVOT BOLT KIT, w/ nut CAP SET REPAIR KIT, front master cylinder CLAMP, front master cylinder SWITCH KIT, brake lever
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
26
N0096.02A8
INTERNATIONAL ONLY MASTER CYLINDER ASM.w/ label (JPN)
2003-XB9R
37
REAR BRAKE CONTROL & CALIPER
16
3
20
22
21
11
23
19
10 13
5
1
18
9 14 19 15
12
4
13 2 6
17
24
7
8
38
26
24
25
REAR BRAKE CONTROL & CALIPER
b0006a
INDEX 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
PART NO. 5407Y A0620.5CZB AA0406.11CDBL AA0620.2CZB B0613.1Z C0148.T C0232.TA CA0015.02A8 D0600.2CZ H0022.F H0024.F H0026.F H0027.02A8 H0030.T H0033.T H0034.T H0040.F H0041.F H0053.T H0102.02A8 H0105.F H0106.F H0107.F H0203.02A8 H0205.02A8 H0206.02A8 H0212.02A8 H0301.T H0405.9B H0412.01A0 H0417.02A8 H1522.02A8A N0505.T N0513.T N0516.T N0517.T N0530.02A8 N0599.02A8
DESCRIPTION
MODELS
BOLT SCREW (2) SCREW SCREW (2) WASHER COTTER PIN CLEVIS PIN, rear master cylinder BOLT, flange head LOCK NUT FITTING, brake bleeder w/ cap CLIP (not illustrated) PIN HOSE SET, rear master cylinder PISTON SET, rear caliper (not illustrated) BRACKET, rear caliper (not illustrated) BOOT SET, flange bolt (not illustrated) PISTON SET, rear master cylinder (not illustrated) CONNECTOR, rear master cylinder (not illustrated) BOOT, bracket pin (not illustrated) CALIPER & CARRIER, rear BOLT, flange caliper (not illustrated) PIN BOLT, rear caliper RETAINER, rear caliper SWITCH, rear brake light MASTER CYLINDER, rear TANK ASM. SET, master cylinder RESERVOIR, rear master cylinder (not illustrated) BRAKE PAD ASM., rear BANJO BOLT, rear master cylinder WASHER (4) WIRE FORM, rear brake line BRAKE LINE ASM., rear w/ switch, banjo bolt & washers (4) ROD ASM., rear master cylinder (not illustrated) BEARING, pedal (2) CIRCLIP (not illustrated) BOOT, brake piston (not illustrated) PEDAL ASM. SLEEVE, shift/brake lever
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
39
FRONT WHEEL 7 4 3 9
6 3
5
10
2 1
40
8
FRONT WHEEL
b0001
INDEX NO. 1 2 3 4 5 6 7 8 9 10
PART NO. CA0014.02A8 CB0006.02A8 E0004.02A8 G0120.02A8 G0313.02A8 G0325.02A8 G0110.02A8WAX H1201.02A8 H0505.02A8 H0506.02A8
DESCRIPTION
MODELS
BOLT, front rotor (6) WASHER, drive bushing (6) BEARING (2) AXLE, front VALVE STEM ASM. AXLE SPACER, front WHEEL ASM., front w/ bearings, center spacer & valve stem (stardust silver) BRAKE ROTOR KIT, front w/ rotor, bolts, bushings, springs & washers SPRING, front rotor (6) DRIVE BUSHING, front rotor mount (6)
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
41
REAR WHEEL
1
2
3 6
7
2
5
4
42
REAR WHEEL
b0002
INDEX NO. 1 2 3 4 5 6 7
PART NO. CA0005.T E0005.02A8 G0309.02A8WAX G0313.02A8 G0321.02A8 G0323.02A8 H0150.02A8
DESCRIPTION
MODELS
BOLT, rear brake rotor (6) WHEEL BEARINGS (2) WHEEL ASM., rear w/ bearings, center spacer & valve stem (stardust silver) VALVE STEM w/ cap AXLE, rear AXLE SPACER, rear BRAKE ROTOR, rear
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
43
STEERING HEAD 7 6 3 5 3
3
1
2 4
2
44
STEERING HEAD
b0003a
INDEX NO. 1 2 3 4 5 6 7
PART NO. E0002.02A8 AA0508.2CXZB AA0608.2CXZB J0106.02A8 J0135.02A8 J1050.02A8 M0675.02A8
DESCRIPTION
MODELS
ROLLER BEARING w/ cup BOLT (4) BOLT (3) TRIPLE CLAMP ASM., lower - w/ stem CAPNUT TRIPLE CLAMP ASM., w/ graphic GRAPHIC PANEL, upper triple
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
45
FRONT FORK 10
15 23 21
9
17
16
8 22 19 11
4
18 13 12 1 14
17 20
5 6 7
3
24
46
2
FRONT FORK
b0036b
INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
PART NO. 46047-97Y AA0512.2CZB J0107.02A8 C3009.E J0113.02A8 J0114.02A8 J0115.02A8 J0116.02A8 J0117.02A8 J0121.02A8 J0122.02A8 J0124.02A8 J8124.02A8 J8127.02A8 J8128.02A8 J8130.02A8 J8135.02A8 J8138.02A8 J8139.02A8
21
J8140.02A8 J8141.02A8 J8142.02A8 J8143.02A8 J8144.02A8
22 23 24
J8145.02A8 J9147.02A8 M0106.02A8
DESCRIPTION
MODELS
OIL SEAL STOPPER RING (2) PINCH BOLT, axle (4) OUTER TUBE (2) PAD, protective (2) (not illustrated) SPRING, fork (2) CENTERING PLATE (2) WASHER, fork (2) BOLT, center (2) SPRING JOINT, fork (2) FRONT FORK ASM. LH FRONT FORK ASM. RH STOPPER RING (2) SNAP RING (2) OIL SEAL (2) SEAL SPACER (2) DUST SEAL (2) SPRING COLLAR, fork (2) SLIDE BUSHING (2) DAMPER ASM., includes rebound adjuster asm., damper locknut, damper asm. (2) GUIDE BUSHING (2) SLIDER PISTON (2) SLIDER COMPONENT ASM. LH, fork SLIDER COMPONENT ASM. RH, fork PRELOAD ADJUSTMENT ASM., includes fork cap asm. & rebound adjuster(2) WASHER, preload (2) O-RING SET (2) REFLECTOR ASM., amber (2)
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
47
REAR SHOCK ABSORBER
2 5
8
4 7
6
8 11
4 3
10 10 9
48
1
REAR SHOCK ABSORBER
b0016a
INDEX NO.
PART NO.
DESCRIPTION
MODELS
1 2 3 4 5 6 7 8 9 10
A1065.2CZB AA0406.21CZB CA0020.02A8 BA0511.2Z C0025.02A8 DA0500.10CZ K0402.02A8 K0410.02A8 K0424.02A8 K0425.02A8
SCREW SCREW (2) SCREW WASHER (2) CLAMP, rear shock reservoir NUT SLEEVE, shock mount REAR SHOCK ASM., includes shock spring & retainer kit SPRING, rear shock RETAINER KIT, shock
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
11
K0001.02A8
INTERNATIONAL ONLY REAR SHOCK KIT w/ labels (JPN)
2003-XB9R
49
FRAME
17
15
16 7 5 24
5
22 33
14
25 27 14 28
8
26
6
2
3 30
23 31
8
15
9 4
25
13
1
10 29
11 32 19 21 12
50
18
20
FRAME
b0004d
INDEX 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 29 30 31 32
33
PART NO.
DESCRIPTION
MODELS 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
L0605.02A8 M0300.YBD M0310.YBD N0401.02A8 N0402.02A8 N0405.02A8 N0406.02A8 N0425.02A8 N0427.02A8 N0428.02A8 N0429.02A8 N0520.02A8 N0521.02A8 N0552.02A8 N0553.02A8 N0554.02A8 N0555.02A8 Y0800.02A8
SPRING, sidestand SCREW BOLT (5) BOLT, LH rider heel guard (not illustrated) BOLT (4) SCREW (4) BOLT (4) BOLT, passenger heel guards (4) CLIP, LH rider heel guard (not illustrated) PIN, footpeg (2) SPRING RH, rider footpeg SPRING LH, rider footpeg (not illustrated) WEAR PEG, rider footpeg (2) BOLT (1) BOLT (2) THREAD, insert WASHER (4) BEARING, race (2) HEEL GUARD LH, passenger (not illustrated) HEEL GUARD RH, passenger SUBFRAME TAIL ASM. BRACKET ASM., sidestand PIVOT BOLT, sidestand SIDESTAND ASM. PLATE, sidestand spring extension FRAME/FUEL TANK ASM. KIT, front w/ bearing races & labels (See FUEL TANK & PUMP pages for more information on kit) FRAME/FUEL TANK ASM. KIT, front w/ bearing races & labels (CAL) PAINT, touch-up frame, silver 0.5oz. (not illustrated) PAINT, touch-up frame, silver aerosol (not illustrated) BRACKET RH, footpeg mount, rider BRACKET LH, footpeg mount, rider (not illustrated) BRACKET LH, footpeg mount, passenger (not illustrated) BRACKET RH, footpeg mount, passenger CLIP, footpeg (2) DETENT PLATE, passenger (2) SPRING, passenger footpeg (2) BALL, passenger (2) FOOTPEG LH, rider w/ wear peg (not illustrated) FOOTPEG RH, rider w/ wear peg FOOTPEG LH, passenger (not illustrated) FOOTPEG RH, passenger HEEL GUARD LH, rider (not illustrated) HEEL GUARD RH, rider SWTICH, sidestand
L0601.02A8 L0602.02A8 L0603.02A8 L0604.02A8 N0097.02A8 N0098.02A8
INTERNATIONAL ONLY FRAME/FUEL TANK ASM. KIT, front w/ bearing races & labels (CAN) FRAME/FUEL TANK ASM. KIT, front w/ bearing races & labels (ENG, EUR) FRAME/FUEL TANK ASM. KIT, front w/ bearing races & labels (AUS) FRAME/FUEL TANK ASM. KIT, front w/ bearing races & labels (JPN) BRACKET LH, footpeg mount, rider w/ label (AUS) (not illustrated) BRACKET LH, footpeg mount, rider w/ label (JPN) (not illustrated)
50005-85A AA0404.11CDBL AA0406.2CZB AA0409.5CZB AA0404.5CZB AA0508.2CXZB AA0608.2CXZB 2533 C0098.02A8 C0235.02A8 C0249.02A8 C0250.02A8 C0255.02A8 CA0010.02A8 CA0015.02A8 C0028.02A8 CB0002.T E0002.02A8 L0078.02A8 L0079.02A8 L0090.02A8 L0152.02A8 L0174.02A8 L0194.02A8A L0203.02A8 L0600.02A8
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
51
ENGINE MOUNTS
9 20 7 14
9 7
1
1
17 6
1 3
10
3
18
9 14
15
8
8
12
2
5
11 13 14
4
9
52
16
9 9
19
ENGINE MOUNTS
b0005d
INDEX NO.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
PART NO. 10059A 10112 AA0405.2CXZB AA0508.2CZB AA0615.2CZB AA0634.2CZB AA0712.2CZB AN0805.5CSS BA0511.2Z BA0613.2Z CA0015.02A8 C0028.02A8 CB0002.T DA0500.2CZ L0160.02A8 L0500.02A8 L0501.02A8 L0502.02A8 L0506.02A8 L0511.02A8 L0512.02A8 Y0307.02A8
DESCRIPTION
MODELS
CLAMP (not illustrated) CLAMP (not illustrated) SCREW (3) BOLT (4) SCREW (2) SCREW SCREW (2) SCREW WASHER (2) WASHER (2) BOLT, flange head (6) THREAD INSERT WASHER (4) LOCK NUT MOUNT, center tiebar TIEBAR ASM. (3) ISOLATOR ASM., front ISOLATOR ASM., rear SNUBBER, front isolator upper “W” BRACKET ASM. BOLT, front isolator CABLE, negative battery
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
53
SWINGARM 21
13 9 22
13
11
8
3
10 5
6
8 1 2
17 4 14 4
12
19 15
54
7
18
20
16
SWINGARM
b0017d
INDEX NO.
PART NO.
DESCRIPTION
MODELS
21
11105 60328-98A AA0507.2CZB AA0520.2CXZB AA0522.2CZB AA0712.2CZB CB0002.T CD0002.T E0006.02A8 K0003.02A8 K0101.02A8 K0158.02A8 K0200.02A8 K0403.02A8 M0567.02A8 Q0011.02A8 Q0012.02A8 Q0013.02A8 Q0102.02A8 Q0104.02A8 Q0107.02A8 Q0109.02A8 Q0127.02A8
O-RING, oil drain plug (not illustrated) PLUG, oil drain BOLT (2) SCREW SCREW (2) PINCH BOLT, axle head WASHER, pinch bolt NUT BEARING, swingarm (2) SWINGARM w/ label(s) BRACE, swingarm SPACER, swingarm bearing SHAFT, swingarm pivot BUSHING, rear shock (2) SPACER, belt guard O-RING, oil breather fitting O-RING, oil return fitting O-RING, oil feeder fitting FITTING ASM., oil feeder w/ o-ring TUBE ASM., oil return w/ o-ring TUBE ASM., oil breather w/ o-ring O-RING, oil filler plug (not illustrated) OIL FILLER PLUG ASM. w/ o-ring
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
22
K0002.02A8
INTERNATIONAL ONLY SWINGARM w/ label(s) (JPN)
2003-XB9R
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
55
HANDLEBARS & HAND CONTROLS 15 3 6 10 9 16 12 11 8
1 2 14 19 4
13
7
13
7
14 18 20
21 15
56
5
17
HANDLEBARS & HAND CONTROLS
b0023a
INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
PART NO. 11179 38627-02A 91960-97Y A0525.2CBL A0540.2CBL A0622.21CBL AA0508.2CXZB C0145.T C0149.T CA0002.T CA0006.T CD0001.T N0002.02A8 N0010.02A8 N0050.K N0051.K N0102.02A8 N0104.02A8 N0158.TA N0159.TA N0307.02A8 N0308.02A8
DESCRIPTION
MODELS
O-RING CLUTCH CABLE PLUG, mirror mount SCREW (3) SCREW BOLT, clutch lever pinch SCREW (2) SWITCH, clutch lever BRACKET, clutch lever BOLT, switch lever asm. SCREW, switch mounting NUT, clutch lever asm. HANDLEBAR, clip-on (2) END CAP (2) HAND GRIP LH HAND GRIP RH CLUTCH LEVER CLUTCH LEVER ASM. SWITCH GEAR RH SWITCH GEAR LH CABLE, throttle control CABLE, idle control
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
57
REAR FENDER & BELT GUARDS
7 3
10
6
14
11 1 13
6
15
6
5
12
8
9
6
4 7 2
58
REAR FENDER & BELT GUARDS
b0018c
INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
PART NO. AA0404.10CSS AA0404.11CDBL AA0406.11CXDBL AA0412.11CDBL AA0522.2CZB AN1005.3CBBL BA0409.6BL CA0012.02A8 G0555.02A8A M0550.02A8 M0564.02A8 M0565.02A8 M0566.02A8 M0567.02A8 M0568.02A8
DESCRIPTION
MODELS
SCREW (2) SCREW, sprocket cover (2) SCREW, rear inner fender (2) SCREW, sprocket cover SCREW SCREW (9) WASHER (6) WASHER SPROCKET COVER, front REAR INNER FENDER BELT GUARD, inner panel BELT GUARD, outer bottom panel BELT GUARD, top outer panel SPACER, belt guard DEFLECTOR, stone
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
59
SEAT, TAIL SECTION & TRUNK
11 9 10
2
4 3 15 17
4 12
3
4 3 5 8
1
7 6
14
13
2 2
60
16
16
SEAT, TAIL SECTION & TRUNK
b0042b
INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17
PART NO.
DESCRIPTION
MODELS
A0620.2CZB AA0406.11CDBL BA0509.6 CA0018.02A8 M0066.02A8 M0067.02A8 M0068.02A8 M0069.02A8 M0087.02A8MAW M0087.02A8MBB M0090.02A8 M0091.02A8 M0704.02A8 M0756.02A8 M0905.02A8 M1664.02A8MAW M1664.02A8MBB Y0725.02A8
BOLT (2) SCREW (6) WASHER(5) SCREW, shoulder (5) CABLE, seat lock RETAINER, seat lock PLATE, seal lock LATCH, seat lock COWL, passenger seat (arctic white) COWL, passenger seat (battle blue) SEAT, rider, complete SEAT, passenger, complete GROMMET, bodywork, rubber (3) TRUNK LINER, trunk TAIL SECTION KIT w/ orange/white decal (arctic white) TAIL SECTION KIT w/ orange/white decal (battle blue) SEAT LOCK w/ key(s)
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
M1665.02A8MAW M1665.02A8MBB
INTERNATIONAL ONLY TAIL SECTION KIT w/ orange/white decal (arctic white) (JPN) TAIL SECTION KIT w/ orange/white decal (battle blue) (JPN)
2003-XB9R 2003-XB9R
61
INTAKE COVER, FRONT FENDER & CHIN FAIRING 3
8
7 7
3 6
3 7
3 11
3 9 6
7
4 3
10 12 7 5
3 2
62
1
INTAKE COVER, FRONT FENDER & CHIN FAIRING
b0020
INDEX NO. 1 2 3 4 5 6 7 8
9 10 11 12
PART NO. AA0404.11CXDBL BA0409.6BL BA0509.6 BN1000.1BL C0520.02A8 CA0012.02A8 CA0018.02A8 M1224.02A8MAW M1224.02A8MBB M1225.02A8MAW M0662.02A8MAW M0662.02A8MBB M1647.02A8MAW M1647.02A8MBB M1648.02A8MAW M1648.02A8MBB M0698.02A8
DESCRIPTION
MODELS
SCREW (2) WASHER (2) WASHER, nylon (13) WASHER, black (4) RIVET, black (4) SCREW, shoulder (5) SCREW, shoulder (8) INTAKE COVER ASM. w/ trim & orange/white decal (arctic white) INTAKE COVER ASM. w/ trim & orange/white decal (battle blue) INTAKE COVER ASM. w/ trim & blue/orange decal (battle blue) FENDER, front (arctic white) FENDER, front (battle blue) CHIN FAIRING KIT, RH w/ silver/blue decal (arctic white) CHIN FAIRING KIT, RH w/ silver/white decal (battle blue) CHIN FAIRING, LH w/ silver/blue decal (arctic white) CHIN FAIRING, LH w/ silver/white decal (battle blue) CHIN FAIRING, center (black)
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
63
FRONT FAIRING, WINDSCREEN & MIRRORS
9
12 11 5
5
11 2 8
4
1 8
3
1 13 6
10
64
7
FRONT FAIRING, WINDSCREEN & MIRRORS
b0014
INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13
PART NO. AA0406.21CRZ AN1005.3CBBL AN1010.3FSS CB0009.02A8 D0600.2CZ M0064.02A8 M0065.02A8 M0073.02A8 M0600.02A8 M1646.02A8MAW M1646.02A8MBB M0703.02A8 N0161.02A8 N0162.02A8
DESCRIPTION
MODELS
SCREW (4) SCREW (4) SCREW (2) WASHER, nylon (6) NUT (4) BEZEL LH, front fairing, black w/ tape BEZEL RH, front fairing, black w/ tape FUSE BLOCK CARRIER (2) WINDSCREEN FAIRING ASM., front w/ LH/RH bezels & blue/orange decal (arctic white) FAIRING ASM., front w/ LH/RH bezels & orange/white decal (battle blue) WELL NUT (6) MIRROR, LH MIRROR, RH
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
65
DECALS & LABELS
4 7
5 6
10 11
8 9
WARNING 3
WARNING – DISCONNECT BATTERY (NEGATIVE
2
TERMINAL FIRST) BEFORE PERFORMING ANY MECHANICAL SERVICE. ACCIDENTAL STARTER OPERATION COULD CAUSE INJURY.
1
66
DECALS & LABELS
b0008a
INDEX NO. 1 2
3 4 5 6 7 8 9 10 11
PART NO.
DESCRIPTION
MODELS
66042-79A C0315.T L0360.02A8 L0361.02A8 L1011.02A8 M0725.02A8 M0726.02A8 M0745.02A8 M0750.02A8 M0766.02A8 M0772.02A8 M0784.02A8 M0820.02A8
WARNING LABEL, battery WARNING LABEL, general DECAL, fuse block, fuse position (not illustrated) DECAL, fuse block, fuse position (not illustrated) WARNING LABEL, frame modifications (AUS, CAL, ENG, EUR) DECAL, intake cover, orange/white DECAL, tail/fairing, blue/orange DECAL, tail/fairing, orange/white DECAL, intake cover, blue/orange DECAL, tail vent, silver/white DECAL, tail vent, silver/blue DECAL, chin fairing, silver/white DECAL, chin fairing, silver/blue
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
14270-92 65948-00 C0317.02A8
INTERNATIONAL ONLY LABEL, shift pattern (JPN) (not illustrated) WARNING LABEL, battery (JPN) (not illustrated) LABEL, noise (AUS) (not illustrated)
2003-XB9R 2003-XB9R 2003-XB9R
67
FUEL TANK & PUMP 15 28
5 2
25
14
10
23 24
9 3
4 27
11 21 22
19 12 26
22
19
13 20 8 1
8
7
68
18
17 6
16
FUEL TANK & PUMP
b0037c
INDEX 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.
DESCRIPTION
MODELS 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
L0605.02A8 P0002.02A8 P0045.02A8 P0100.02A8 P0104.02A8 P0115.02A8 P0119.02A8 P0121.02A8 P0125.02A8 P0127.02A8 P0128.02A8 P0130.02A8 P0153.02A8 P0166.K P0177.K P0178.K P0187.02A8 P0189.02A8 P0191.02A8 P0194.02A8 P0198.02A8 P0228.02A8 P0229.02A8 P0464.02A8 P0806.K
SCREW (4) SCREW (2) NUT SLEEVE (not illustrated) FRAME/FUEL TANK ASM KIT, Fuel pump & lines not included. See FRAME pages for more information on kit FRAME/FUEL TANK ASM. KIT, front w/bearing races & labels (CAL) SCREW (5) CLIP, regulator FUEL FILTER, in line w/ hoses CLAMP (5) FUEL CELL VENT w/ fuel cell vent o-ring RETAINING PLATE, fuel cell vent O-RING (2) O-RING (3) O-RING RETAINING RING, fuel cap FUEL PUMP ASM. CAP, fuel tank w/ key(s) REGULATOR w/ o-rings O-RING, small regulator O-RING, large regulator E-CLIPS (4) DRAIN PLUG w/ o-rings SENSOR ASM., w/ screw kit WIRE ASM., w/ screw kit O-RING KIT, banjo stud (not illustrated) O-RING, fuel cap retaining ring O-RING, fuel cell vent FUEL LINE ASM. FILTER, fuel pump, internal
L0601.02A8 L0602.02A8 L0603.02A8 L0604.02A8 P0099.02A8
INTERNATIONAL ONLY FRAME/FUEL TANK ASM. KIT, front w/ bearing races & labels (CAN) FRAME/FUEL TANK ASM. KIT, front w/ bearing races & labels (ENG, EUR) FRAME/FUEL TANK ASM. KIT, front w/ bearing races & labels (AUS) FRAME/FUEL TANK ASM. KIT, front w/ bearing races & labels (JPN) CAP, fuel tank w/ label and key(s) (AUS)
AA0406.2CZB AN1004.2CZ DA0500.8FZ HS0015.02A8 L0600.02A8
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
69
OIL FILTER & HOSES
8 22 12 8 12
9 13
23
16 20 17 14
12 17
8
10
Oil Line Vent
2 15 11
21
5
18
3
Oil Cooler Return
19
6
1 7
70
Oil Cooler Feed
4
OIL FILTER & HOSES
b0038b
INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23
PART NO. 26359-02 26554-77 33117-91A 33154-00Y 33155-00Y 62376-02 63806-00Y AA0405.2CXZB AA0406.2CZB AN1005.14FZB AN1006.14FZB B0613.1Z BA0410.3Z C0034.02A8 C0035.02A8 C0529.M DN1000.10FZB HS0008.02A8 HS0009.02A8 L0077.02A8 L2117.02A8 M0070.02A8 Q0002.02A8
DESCRIPTION
MODELS
FITTING, connector - 45 degree SWITCH, oil pressure ADAPTER, oil filter SPRING BALL FITTING OIL FILTER SCREW (2) SCREW SCREW SCREW WASHER (2) WASHER CLAMP, 3/8” routing holes CLAMP, 1/2” routing holes CLAMP NUT (2) HOSE, oil cooler feed HOSE, oil cooler return BRACKET, stabilizer HOSE, oil line vent SCOOP, oil cooler OIL COOLER
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
71
EXHAUST SYSTEM 5 7 15 13 13 4 17 6
8 6
16
11 18 9 12 3
2
1 1 2
9
3
10
14
72
EXHAUST SYSTEM
b0039a
INDEX NO.
PART NO.
DESCRIPTION
MODELS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
65324-83A 65325-83A 65328-83 AA0522.2CZB AA0624.1CZB BA0511.2Z BA0613.2Z DA0500.10CZ DA0500.12FZ S0101.02A8 S0110.02A8 S0116.02A8 S0123.02A8 S0127.8 S0133.02A8 S0135.02A8 S0136.02A8
GASKET, exhaust port (2) RETAINING RING, exhaust (2) CLAMP, exhaust ring (2) SCREW SCREW (2) WASHER (2) WASHER, flat (2) NUT NUT FLANGE (4) HEADER MUFFLER (DOM, CAL) MUFFLER STRAP, front MUFFLER STRAP, rear (2) CLAMP, 2” torca MUFFLER BRACKET, rear MUFFLER MOUNT, front BUSHING, front muffler mount (2)
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
18
S0111.02A8
INTERNATIONAL ONLY MUFFLER (AUS, CAN, ENG, EUR, JPN)
2003-XB9R
73
BATTERY 1
1 6
12
10 11
8 9 2 13
4
5
9 8 7
74
3
BATTERY
b0013b
INDEX NO.
PART NO.
DESCRIPTION
MODELS
1 2 3 4 5 6 7 8 9 10 11 12
4312 65948-00 70578-89 BA0409.4Z B0613.1Z C0032.02A8 C0041.02A8 D0600.2CZ Y0101.02A8 Y0103.02A8 Y0320.02A8 Y0321.02A8
SCREW (2) BATTERY BOOT, starter WASHER, star WASHER BOOT, battery terminal BRACKET, battery strap LOCKNUT PAD, battery (4) STRAP, battery (rubber) CABLE, positive CABLE, negative
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
13
Y0024.02A8
INTERNATIONAL ONLY BATTERY w/ label (JPN)
2003-XB9R
75
HEADLIGHTS, HORN & FAN
13 5
16
9
6
4
14 17 19
1
2
8
15 18
8
12 7
3
10
7 3
11
7 3 3
76
7
HEADLIGHTS, HORN & FAN
b0024d
INDEX NO. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
17
18 19
PART NO.
DESCRIPTION
MODELS
68918-98 AA0404.10CSS AA0406.11CDBL AA0406.21CZB AA0406.5CZB AA0408.21CRZ BA0409.6BL CA0017.02A8 DA0400.2CZ M0902.02A8 M0903.02A8 Y0050.02A8 Y0308.TA Y0400.02A8 Y0421.02A8 Y0435.02A8 Y0438.02A8 YH401.02A8
BULB, 55W headlight (2) SCREW (4) SCREW (6) SCREW (2) SCREW (2) SCREW (2) WASHER (6) SCREW (8) LOCK NUT (2) AIR SCOOP ASM., ram ENGINE SCOOP ASM. RH FAN ASM. HORN HEADLIGHT, low beam TRAFFIC HEADLIGHT ASM RH - complete (CAN) (not illustrated) HEADLIGHT, high beam BRACKET/SUPPORT HEADLIGHT ASM. WIRE HARNESS, headlight (not illustrated)
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
Y0026.02A8 Y0406.02A8 Y0422.02A8 Y0426.02A8 Y0427.02A8 Y0428.02A8 YH402.02A8
INTERNATIONAL ONLY BULB, position (not illustrated) HEADLIGHT ASM., low beam (EUR) TRAFFIC HEADLIGHT ASM RH - complete (EUR) (not illustrated) TRAFFIC HEADLIGHT ASM LH - complete (AUS, ENG, JPN) (not illustrated) HEADLIGHT ASM., high beam (AUS, ENG, EUR, JPN) HEADLIGHT ASM., low beam (AUS, ENG, JPN) WIRE HARNESS, headlight (AUS, ENG, EUR, JPN) (not illustrated)
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
77
TAIL LAMP & TURN SIGNALS
5
15
19
16 8 7 18 3
2
12
4 10 20 9
1 21
17
78
11 1 22
6
17 14 13
8
TAIL LAMP & TURN SIGNALS
b0021b
INDEX NO.
PART NO.
DESCRIPTION
MODELS
17 18 19
59259-90 AA0404.10CSS AA0404.11CDBL AA0406.11CDBL AN0808.14CSS B0800.4Z BA0511.2Z D0800.4FZ DA0400.8CZ L0542.02A8 L0544.02A8 L0545.02A8 M0755.02A8 Y0039.K Y0040.K Y0041.K Y0042.K Y0043.02A8 Y0401.02A8 Y0401B.2U Y0504.02A8 Y0503.02A8 Y0621.M YH350.02A8
REFLECTOR, red (3) SCREW (2) SCREW SCREW (2) SCREW (2) LOCK WASHER, turnsignal mounting (4) WASHER (2) NUT, jam (4) LOCK NUT (2) BRACKET, rear reflector BRACKET LH, rear side reflector (not illustrated) BRACKET RH, rear side reflector BRACKET, license plate LENS, outer turnsignal LENS, inner turnsignal (not illustrated) SCREW, turnsignal lens (not illustrated) BULB, turnsignal (4) LENS, taillight (not illustrated) TAIL LIGHT BULB, tail light TURNSIGNAL LH rear/RH front (not illustrated) TURNSIGNAL RH rear/LH front FLASHER, turnsignal HARNESS, tail light wiring
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
20 21 22
L0541.02A8 59259-90 59256-84A
INTERNATIONAL ONLY BRACKET, rear reflector (AUS, CAN, ENG, EUR, JPN) REFLECTOR, red (2) (AUS, ENG, EUR, JPN) REFLECTOR, amber (AUS, ENG, EUR, JPN)
2003-XB9R 2003-XB9R 2003-XB9R
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16
79
INSTRUMENT CLUSTER 10 11
7
4 4
8
7 4 5 4 1 9 3 9 3 2
6
9 3 6
80
6
INSTRUMENT CLUSTER
b0009a
INDEX NO.
PART NO.
DESCRIPTION
MODELS
10
AA0522.2CZB AA0524.2CZB B0510.1Z BA0511.2Z C0039.02A8 D0500.1CZ DA0500.10CZ L0940.02A8 M0649.01A3 Y0303.2B Y0500.02A8
SCREW (2) SCREW (2) WASHER (3) WASHER (5) CLAMP, main wire harness JAM NUT (3) NUT, spring lock (2) BRACKET, fairing support GROMMET, rubber (3) WIRE TIE (not illustrated) INSTRUMENT CLUSTER - mph (ENG)
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
11
Y0501.02A8
INTERNATIONAL ONLY INSTRUMENT CLUSTER - kph (AUS, CAN, EUR, JPN)
2003-XB9R
1 2 3 4 5 6 7 8 9
81
MAIN WIRE HARNESS RELAY CENTER
63 64 65
1 29 35
LH TURN SIGNAL
FLASHER
BANK ANGLE SENSOR
39 40
SPEEDOMETER
57 58 60
HORN
23 25
70
20
RH TURN SIGNAL
HORN
RH CONTROLS
25 70
70 DATA LINK
RH TURN SIGNAL
EMC
EMC
7 10 13 14 44
25 41
70
28 30 31 34 68
20
LH TURN SIGNAL
LH CONTROLS
5 8 11 12
FUSE & DIODE ASY
4 10 13 44
27 59 IGNITION SWIITCH
HEAD LAMP SWITCH REAR INJECTOR
FRONT INJECTOR
HEAD TEMP SENSOR
60 61
60 61
54 GROUND
66 67
49 50
STARTER SOLENOID 02 SENSOR
47 48 2 17
18 19
22 25
SIDESTAND SWITCH
46
TPS SENSOR
CLUTCH SWITCH
BRAKE SWITCH
42 43
24 26
COOLING FAN
IAT
STARTER FUEL PUMP
IGNITION COIL
OIL PRESSURE SWITCH
22
3 9 13
NEUTRAL SWITCH CAM POSITION SENSOR
15 16 62 63
6 9 13
VEHICLE SPEED SENSOR
23 25 41
45 51 52
70 69 BATTERY
VOLTAGE REGULATOR
82
GROUND
TAIL LAMP HARNESS
FOOT BRAKE SWITCH
33 36 37 38 55 56
22 25 J-FUSE ASY
53 TAIL FRAME GROUND
MAIN WIRE HARNESS
b0043a
INDEX 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 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
PART NO.
DESCRIPTION
MODELS
Y0136.02A8
MAIN WIRE HARNESS includes the following items
2003-XB9R
31522-00B 72033-93 72113-94BK 72119-94BK 72124-94GY 72133-94GY 72139-94GY 72144-94 72153-94 72159-94 72164-94 72190-94 72191-94 72195-94 72234-94 72238-94 72280-95 72291-94 72295-94 72405-98BK 72405-98GN 73102-96BK 73108-96BK 73152-96BK 73158-96BK 73190-96 73191-96 C0152.02A8 L0073.02A8 L0074.02A8 Y0011.K Y0016.T Y0021.02A8 Y0023.02A8 Y0028.02A8 Y0029.02A8 Y0033.02A8 Y0034.02A8 Y0035.02A8 Y0045.02A8 Y0046.02A8 Y0049.02A8 Y0053.02A8 Y0054.02A8 Y0056.02A8
DIODE (3) TERMINAL (3) CONNECTOR, sealed CONNECTOR, sealed CONNECTOR CONNECTOR, sealed CONNECTOR, sealed SPACER SOCKET LOCK (2) SOCKET LOCK (2) SEAL, connector TERMINAL TERMINAL (6) SEAL PIN CONNECTOR ASM., black w/ seal TPA, black (2) CONNECTOR, sensor 3-way w/ seal TERMINAL, female spade (14-16 gauge) HOUSING, starter connector TERMINAL, insulated INSULATED TERMINAL CONNECTOR PIN, housing 8-way (2) CONNECTOR CONNECTOR (not illustrated) TERMINAL (24) TERMINAL (7) IGNITION SWITCH/CONNECTOR TOP COVER, fuse block TOP COVER, relay FUSE, 15A FUSE, 7.5A (4) BOOT, instrument cluster harness MAIN FUSE, 30A BASE COVER, fuse block BRACKET, fuse/relay block COVER, fuse holder FUSE HOLDER, inner, red BRACKET, j-fuse CONNECTOR TERMINAL CLIP CONNECTOR, 2-pin black TERMINAL (2) TERMINAL (14 gauge) (3)
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
83
MAIN WIRE HARNESS (CONTINUED) RELAY CENTER
63 64 65
1 29 35
LH TURN SIGNAL
FLASHER
BANK ANGLE SENSOR
39 40
SPEEDOMETER
57 58 60
HORN
23 25
70
20
RH TURN SIGNAL
HORN
RH CONTROLS
25 70
70 DATA LINK
RH TURN SIGNAL
EMC
EMC
7 10 13 14 44
25 41
70
28 30 31 34 68
20
LH TURN SIGNAL
LH CONTROLS
5 8 11 12
FUSE & DIODE ASY
4 10 13 44
27 59 IGNITION SWIITCH
HEAD LAMP SWITCH REAR INJECTOR
FRONT INJECTOR
HEAD TEMP SENSOR
60 61
60 61
54 GROUND
66 67
49 50
STARTER SOLENOID 02 SENSOR
47 48 2 17
46
18 19
22 25
SIDESTAND SWITCH TPS SENSOR
CLUTCH SWITCH
BRAKE SWITCH
42 43
24 26
COOLING FAN
IAT
STARTER FUEL PUMP
IGNITION COIL
OIL PRESSURE SWITCH
22
3 9 13
NEUTRAL SWITCH CAM POSITION SENSOR
15 16 62 63
6 9 13
VEHICLE SPEED SENSOR
23 25 41
45 51 52
70 69 BATTERY
VOLTAGE REGULATOR
84
GROUND
TAIL LAMP HARNESS
FOOT BRAKE SWITCH
33 36 37 38 55 56
22 25 J-FUSE ASY
53 TAIL FRAME GROUND
MAIN WIRE HARNESS (CONTINUED)
b0043a
INDEX NO.
45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70
PART NO.
DESCRIPTION
MODELS
Y0136.02A8
MAIN WIRE HARNESS (CONTINED) includes the following items
2003-XB9R
Y0060.02A8 Y0061.02A8 Y0066.02A8 Y0067.02A8 Y0071.02A8 Y0072.02A8 Y0076.02A8 Y0077.02A8 Y0081.02A8 Y0082.02A8 Y0093.02A8 Y0094.02A8 Y0095.02A8 Y0096.02A8 Y0097.02A8 Y0119.02A8 Y0120.02A8 Y0126.02A8 Y0129.02A8 Y0130.02A8 Y0132.02A8 Y0133.02A8 Y0134.02A8 Y0211.K Y0320.02A8 Y0357.3A
CONNECTOR, fuel pump CONNECTOR, 3-pin black CONNECTOR, 2-pin black w/ seal TERMINAL (2) CONNECTOR, single black w/ seal TERMINAL SECONDARY LOCK PINS (4) TERMINAL, eye TERMINAL FUSE HOLDER, main, black TERMINAL, pin, j-fuse holder (2) CONNECTOR, black TERMINAL, socket (12) CONNECTOR, black w/ seal CONNECTOR, injector w/ seal (2) TERMINAL(4) TERMINAL SET, voltage regulator CONNECTOR TERMINAL, socket (3) PLUG, black (3) CONNECTOR, 2-pin black TERMINAL, socket (2) FUSE & DIODE ASM. CABLE, battery TERMINAL
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
85
SWITCHES, SWITCHES,CIRCUIT CIRCUIT BREAKERS, BREAKERS & CONNECTORS ELECTRICAL &CONNECTOR SENSORS
5
4 6
18
21 1
20
3
13 19 17
10
15
2
8
16 14
7 12
86
11
11
9
SWITCHES, CIRCUIT BREAKERS & ELECTRICAL CONNECTORS
b0040a
INDEX NO. 1 2 3 4 5 6 7
8 9 10 11
12 13 14 15 16 17 18
19 20 21
PART NO.
DESCRIPTION
MODELS
6288 31522-00B 33900-99 70227-99 74431-01 32564-99YB AN0808.3CBBL C0026.02A8 C0033.02A8 C0036.02A8 C0042.02A8 C0045.02A8 C0152.02A8 C2024.02A8 CA0007.T CA0016.02A8 CB0008.02A8 L0073.02A8 L0074.02A8 M0072.02A8 P0138.K S0130.02A8 S0131.02A8 Y0011.K Y0016.T Y0211.K Y0303.2B Y0349.02A8 Y0356.4 Y0357.3A Y0602.02A8 Y0723.T Y0724.02A8 Y0732.T
WASHER RELAY, start ignition SWITCH, neutral indicator JUMPER, neutral indicator SENSOR, vehicle speed SENSOR, engine temperature SCREW (2) CLIP, wire tie (2) (not illustrated) FASTENERS, tree, black plastic (7) (not illustrated) CLAMP, nylon loop (not illustrated) TUBING, heat shrink, side stand switch covering (not illustrated) STRAP, rear wire harness mount (not illustrated) BODY, electrical, ignition switch TOOL KIT (not illustrated) SCREW SCREW WASHER COVER, fuse block, top w/ label (not illustrated) COVER, fuse block relay, top w/ label (not illustrated) WIRE GUARD, routing (not illustrated) SENSOR, air intake SENSOR, O2 SENSOR, bank angle FUSE, 15A, EMC FUSE, 7.5A DIODE (2) CABLE STRAP (25) CONCUIT ASM., main harness (not illustrated) CONNECTOR, single bullet (10) (not illustrated) TERMINAL (10) (not illustrated) COMPLETE VEHICLE LOCK SET, w/ seat, ignition, fuel cap & key(s) HOUSING, ignition switch IGNITION ASM., w/ key(s) KEY SET, ignition (specify four - digit key code)
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
P0098.02A8
INTERNATIONAL ONLY COMPLETE VEHICLE LOCK SET, w/ seat, ignition, fuel cap w/ label & key(s) 2003-XB9R (AUS) (not illustrated)
87
CALIFORNIA EVAPORATIVE EMISSIONS COMPONENTS
1
2
4 3
88
CALIFORNIA EVAPORATIVE EMISSIONS COMPONENTS
b0015b
INDEX NO.
1 2 3 4
PART NO.
27016-00 27042-84A HS0025.02A8 HS0020.02A8 HS0021.02A8
DESCRIPTION
MODELS
These components are used on 2003 Firebolt XB9R model motorcycles sold in the state of California. HOSE, reducer (not illustrated) CARBON CANISTER HOSE ASM., 3/8” I.D. nylon, carbon canister HOSE ASM., standard (all except CAL) HOSE ASM., fuel vent w/ reducer (CAL ONLY)
2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R 2003-XB9R
89
GLOSSARY
A
N
ADJ ..........................................................................Adjuster AMP ..................................................................... Amperage ASM ...................................................................... Assembly AUS ......................................................................... Australia
NO ............................................................................Number
O
C
O.D.............................................................Outside Diameter O.S.......................................................................Over Sized OZ............................................................................... Ounce
CAL. .......................................................................California CAN.......................................................................... Canada CYL ..........................................................................Cylinder
R
D DIA ......................................................................... Diameter DOM....................................................................... Domestic
E
RD .............................................................................. Round RH ...................................................................... Right Hand
S SPEEDO.......................................................... Speedometer STD ........................................................................ Standard
ENG .........................................................................England EUR........................................................................... Europe
T
F
TACH ..................................................................Tachometer TEMP................................................................ Temperature THD ........................................................................... Thread THK .............................................................................. Thick TM ........................................................................Trademark
FT...................................................................................Foot
G GAL .............................................................................Gallon GR............................................................................... Grade
V V ......................................................................................Volt
H
W
HD ................................................................................ Head
W/ .................................................................................. With
I I.D.................................................................Inside Diameter
J JPN ............................................................................. Japan
K KPH.......................................................Kilometers Per Hour
L LG ................................................................................. Long LH............................................................................ left hand
M MM .........................................................................Millimeter MPH .............................................................. Miles Per Hour
90
HARDWARE LISTING 882 961 1039 1601 2445 2533 3029 3275 3350 3403 3594 3675 3987 4091 4132 4312 4751 4765 6736 7839 2611C 3997A 4718A 4820A 4820A 6314W 7916A 879A A0508.2CSS A0620.2CZB
SCREW, 1/4-20 X 7/8, hex socket hd., sems, zinc, gr. 8 SCREW, 1/4-20 X 1/2 pan hd. torx w/ washer, gr. 8 SCREW, 5/16-18 X 2-1/2 hex flange hd., phosphatized SCREW, No. 8-32 X 1/2 pozidriv flat hd., zinc SCREW, 1/4-20 X 9/16 button hd. SCREW, No. 10-16 X 1/2 hex socket button hd., gr. 8 SCREW, No. 10-24 X 1-1/8 socket hd. torx SCREW, 5/16-18 X 3/4, hex socket hd., zinc, gr. 8 BOLT, M5-0.8 X 115 mm, hex flange hd. LOCKNUT, M8-1.25 X 12 mm, hex flange, zinc SCREW, 1/4-20 X 5/8, hex socket hd., gr. 8 SCREW, 5/16-18 X 1 torx socket flat hd., locking, phosphatized, gr. 8 BOLT, 5/16-18 X 3/4 hex hd., gr. 5 SCREW, No. 10-24 X 1/2 hex washer hd., self tapping, zinc SCREW, 1/4-20 X 1-1/8, torx socket button hd., black zinc, gr. 5 BOLT, M6-1.0 X 12 mm, flange hd., stainless steel BOLT, 1/4-20 X 3/4, hex hd., w/lockpatch, zinc, gr. 8 SCREW, 1/4-20 X 2-5/8, hex socket hd., sems, w/lock patch, zinc, gr. 8 WASHER, 9/32 X 5/8 X 1/16, zinc NUT, 3/4-16, hex hd. SCREW, No. 10-32 X 5/8, hex washer hd. w/lockpatch, zinc, gr. 5 BOLT, 1/4-20 X 1-1/4, hex socket hd. w/ sealant, zinc SCREW, 1/4-20 X 1-1/2, hex socket hd., sems, zinc SCREW, 1/4-20 X 2, hex socket hd., sems, locking, zinc SCREW, 1/4-20 X 2, hex socket hd., sems, locking, zinc WASHER, 21/64 X 9/16 X 1/8, zinc JAMNUT, 5/8-18, zinc SCREW, 5/16-18 X 3-1/2 knurled socket hd. SCREW, M5 X 8 socket hd., stainless steel BOLT, M6 X 1 X 20 socket hd., clear zinc., gr.12
A0620.5CZB
SCREW, M6-1 X 20 flat hd., counter sink, clear zinc gr. 12 A0622.21CBL BOLT, M6-1.25 X 22, hex flange hd., black zinc A1065.2CZB SCREW, M10 X 65 socket hd., clear zinc, gr. 12 AA0404.10CSS SCREW, 1/4-20 X 1/2 button hd., torx,stainless steel AA0404.11CDBL SCREW, 1/4-20 X 1/2 trusshead torx, black chromate, gr. 2 AA0404.11CXDBLSCREW, 1/4-20 X 1/2 trusshead torx, black chromate, scotch grip, gr. 2 AA0404.5CZB SCREW, 1/4-20 X 1/2 flat hd., allen, gr. 8 AA0405.2CXZB SCREW, 1/4-20 X 5/8, hex socket hd., zinc AA0406.11CXDBLSCREW, 1/4-20 X 3/4 truss torx, black chromate, scotch grip, gr. 2 AA0406.21CRZ SCREW,1/4X3/4 hex flange hd., thread cutting, zinc AA0406.21CZB SCREW, 1/4-20 X 3/4 hex flange hd., bright zinc AA0406.2CZB BOLT, 1/4-20 X 3/4, hex socket hd., zinc AA0406.5CZB SCREW, 1/4-20 X 3/4 flat hd. allen, bright zinc AA0408.21CRZ SCREW, 1/4-20 X 1, hex flange hd., zinc AA0409.5CZB SCREW, 1/4-20 X 1-1/8 flat hd. counter sink, bright zinc AA0412.11CDBL SCREW, 1/4-20 X 1.5 trusshead torx, black chromate, gr. 2 AA0414.2CXZB SCREW, 1/4-20 X 1-3/4 socket hd allen scotch grip, bright zinc AA0507.2CZB SCREW, 5/16-18 X 7/8 socket hd., bright zinc AA0508.2CXZB BOLT, 5/16-18 X 1.0 socket hd., scotch grip, bright zinc AA0508.2CZB BOLT, 5/16-18 1 socket hd., bright zinc AA0520.2CXZB SCREW, 5/16-18 X 2-1/2 socket hd., scotch grip, bright zinc AA0522.2CZB SCREW, 5/16-18 X 2-3/4 socket hd., bright zinc AA0524.2CZB SCREW, 5/16-18 X 3 socket hd. allen bright zinc AA0608.2CXZB BOLT, 3/8-16 X 1.0 socket hd. bright zinc AA0609.11CXZB SCREW, 3/8-16 X 1-1/8 trusshead torx, scotch grip, bright zinc AA0615.2CZB SCREW, 3/8-16 X 1-7/8 socket hd., bright zinc AA0620.2CZB SCREW, 3/8-16 X 2.5 socket hd., bright zinc AA0624.1CZB SCREW, 3/8-16 X 3 hex hd., bright zinc
91
HARDWARE LISTING AA0634.2CZB
SCREW, 3/8-16 X 4-1/4 socket hd., zinc
AA0636.2CZ
SCREW, 3/8-16 X4-1/2 socket hd., zinc
AA0712.2CZB
SCREW, 7/16-14 X 1-1/2 socket hd., bright zinc
AN0805.5CSS
SCREW, 8-32 X 5/8 flat hd. allen, countersink, stainless steel
AN0808.14CSS SCREW, 8-32 X 1, pan hd. phillips, stainless steel AN0808.3CBBL SCREW, 8-32 X 1 button hd., black AN1004.2CZ
SCREW, 10-24 X 1/2 socket hd., zinc
AN1005.14FZB
SCREW, 10-32 X 5/8 pan hd. phillips, bright zinc
AN1005.3CBBL SCREW, 10-24 X 5/8 button hd., black AN1006.14FZB
SCREW, 10-32 X 3/4 pan hd. phillips, bright zinc
AN1010.3FSS
SCREW, 10-32 X 1-1/4 button hd, stainless steel
B0510.1Z
WASHER, 5mm I.D. X 1mm. O.D. flat
B0613.1Z
WASHER, 6 mm I.D. X 13 mm O.D., std., zinc
B0800.4Z
LOCKWASHER, 8 mm I.D., star, zinc
BA0409.6BL
WASHER, 1/4 I.D. X 9/16 O.D., black nylon
BA0410.3Z
WASHER, 1/4 I.D. X 11/16 O.D. flat zinc
BA0509.6
WASHER, 5/16 I.D. X 9/16 O.D. nylon
BA0511.2Z
WASHER, 5/16 I.D. X 11/16 O.D. flat, hardened, zinc
BA0613.2Z
WASHER, 3/8 I.D. X 13/16 O.D. flat, clear zinc
BN1000.1BL
WASHER, #10, black
D0500.1CZ
NUT, M5 X 10 hex zinc
D0600.2CZ
LOCKNUT, M6 X 1.0, nylock, zinc
D0800.4FZ
LOCKNUT, M8 X 1.025, nylock, zinc
DA0400.2CZ
LOCKNUT, 1/4-28 X 20, hex, nylock, zinc
DA0400.8CZ
NUT, 1/4-20 thin, nylock
DA0500.10CZ
LOCKNUT, 5/16-18, hex, spring lock, zinc
DA0500.12FZ
FLANGENUT, 5/16-24, hex, zinc
DA0500.2CZ
LOCKNUT, 5/16-18 nylock, clear zinc
DA0500.8FZ
NUT, 5/16-24, thin nylock zinc
DA0600.11CZ
LOCKNUT, 3/8-16 jam clear zinc
DA0600.12FAZB FLANGENUT, 3/8-24, gr. 5 DN1000.4FZB
92
LOCKNUT, No.10-32, hex, thin/jam, zinc, gr. 12
NUMERICAL INDEX Part No. 10059A 10080 10112 1028 1039 1044 11002 11046 11067 11105 11105 11116 11124 11124 11161 11165 11177A 11177A 11179 11190 11250 11317 11360 11730A 11765Y 12030 12067A 12068 14270-92 1601 16032-02 16032-02 16357-02 16461-02 16478-85A 16480-92 16573-83 16715-83 16770-84D 16774-86D 16800-84 16832-86C 16872-02 16875-02 16899-02 17036-91 17036-91 17058-02 17059-02 17353-89 17358-84A 17360-83A 17375-83A 17598-97Y 17605-00YA 17606-00Y 17607-00Y 17608-00Y 17611-83 17642-02
Page
Part No.
Page
53 11 53 11 7 11 17 33 29 13 55 27 15 25 29 29 11 9 57 7 33 15 31 33 33 29 29 11 67 25 5 5 25 5 5 5 5 5 5 5 7 5 5 5 11 5 7 5 5 7 7 7 7 7 7 7 7 7 7 7
17649-02 17908-02 17909-02 17979-02 17986-00Y 18011-86 18020-83 18094-02 18245-02 18258-02 18260-02 18532-00A 18538-99B 18690-02 18691-02 215 21948-02 22265-00Y 22589-83B 22707-02 22710-02 22765-02 24047-00 24213-02 24331-36 24332-36 24439-02 24439-02 2445 24604-00B 24647-87 24650-87 24658-87 24659-87 24660-87 24754-75 25188-02 2533 25351-00Y 25353-00Y 25378-02 25409-94B 25453-87A 25521-02 25782-02 2611C 26318-88A 26357-02 26358-02 26359-02 26359-02 26361-02 26365-02 26432-76A 26434-91 26488-98 26491-98 26492-91 26493-91 26495-89A
7 7 7 7 7 5 5 5 5 5 5 7 7 5 5 15 9 11 9 9 5 9 15 9 9 9 11 15 25 11 11 11 9 11 11 11 15 51 13 15 13 33 33 13 15 25 15 17 17 17 71 17 11 5 17 17 17 17 17 17
Part No. 26554-77 26921-02 26922-02 26923-02 26924-02 26995-86B 27009-86A 27010-86A 27016-00 27042-84A 27337-99Y 27338-99Y 27425-02 27671-01K 29533-99Y 29537-99Y 29539-99Y 29803-02 29804-02 29805-02 29806-02 29950-91 29971-02Y 3029 31322-91 31323-91 31324-91 31325-91 31327-91 31328-91 31390-91B 31488-81A 31515-90 31518-90 31521-98 31522-00B 31522-00B 31525-90 31530-90 31537-98 31539-91 31556-91A 31599-91 31600-90 31603-91 31661-90 31662-90 31663-90 31688-90 31689-90 31692-90 31695-90 32400-94 32473-02 32504-80A 32564-99YB 32606-82 32617-00Y 3275 3299Y
Page
Part No.
Page
Part No.
Page
71 11 11 11 11 19 19 19 89 89 19 19 19 25 19 19 19 19 19 19 19 11 23 23 27 27 27 27 27 27 27 27 27 27 27 83 87 27 27 27 27 27 27 27 27 27 27 27 27 27 27 27 25 25 25 87 25 11 19 7
33117-91A 33154-00Y 33155-00Y 3322Y 3323Y 33344-94 3350 33540-02 33634-02 33900-99 33900-99 34014-02 3403 34064-00B 34076-02 34144-02 34163-02 34483-02 34491-02 34763-02 34772-00Y 34912-02 34920-86A 34981-02 34982-02 35020-89 35021-89 35022-89A 35030-89 35034-94 35038-89A 35051-89 35063-89 35114-02 35211-91A 3559 35633-94 35640-89 35641-89 35762-02 35763-89A 35771-94 35772-94 35773-94 35775-94 35796-00 35797-00 358 3594 36715-94 3675 36802-84B 37101-84A 37495-91 37495-91 37870-91 37870-91 37872-90 37890-02 37891-02
71 71 71 19 19 29 27 31 31 31 87 31 27 31 13 31 31 31 31 13 13 13 33 31 31 29 29 29 29 29 29 29 29 11 35 27 29 29 29 29 29 29 29 29 29 29 29 11 35 33 29 33 13 29 33 29 33 33 33 33
37892-02 37893-02 37894-02 37895-02 37896-02 37897-02 37898-02 37899-02 37908-90 37909-90 37911-90 37913-90 37918-91 38627-02A 3987 3997A 3997A 40005-57B 40039-02 40039-02 40241-02 40241-02 40251-92A 40254-02 40254-02 40343-02 4091 4132 4312 45830-48 45902-00 46047-97Y 4718A 4751 4765 4820A 4820A 50005-85A 5407Y 59256-84A 59259-90 59259-90 6003 60328-98A 60328-98A 6090Y 6157 6217 62340-01Y 62352-94B 62376-02 62376-02 6288 6314W 63533-41A 63806-00Y 63858-49 6400HB 65324-83A 65325-83A
33 33 33 33 33 33 33 33 33 33 33 33 33 57 19 31 7 35 13 35 23 35 35 11 35 35 11 17 75 11 27 47 7 23 17 13 15 51 39 79 79 79 29 13 55 19 17 27 11 15 15 71 87 11 11 71 7 35 73 73
93
NUMERICAL INDEX Part No.
Page
65328-83 65948-00 65948-00 66042-79A 6736 68918-98 70227-99 70578-89 720 72033-93 72103-94BK 72113-94BK 72119-94BK 72124-94GY 72133-94GY 72139-94GY 72143-94 72144-94 72153-94 72159-94 72164-94 72190-94 72190-94 72191-94 72195-94 72233-94 72234-94 72238-94 72238-94 72280-95 72291-94 72295-94 72405-98BK 72405-98GN 72691-01 73102-96BK 73108-96BK 73152-96BK 73158-96BK 73190-96 73191-96 74431-01 7804 7839 7916A 879A 882 8871 8873 8876A 8879 8881 8883 8885 8973 8973 8977 8996A 8998 9077
73 67 75 67 7 77 87 75 11 83 25 83 83 83 83 83 25 83 83 83 83 25 83 83 83 23 83 23 83 83 83 83 83 83 23 83 83 83 83 83 83 87 13 35 15 11 7 27 33 29 27 11 27 33 11 9 29 29 29 27
94
Part No.
Page
9187 31 91960-97Y 37 91960-97Y 57 9214 33 928 27 929A 27 961 13 A0508.2CSS 19 A0525.2CBL 57 A0540.2CBL 57 A0620.2CZB 61 A0620.5CZB 39 A0622.21CBL 57 A1065.2CZB 49 AA0404.10CSS 59 AA0404.10CSS 77 AA0404.10CSS 79 AA0404.11CDBL 37 AA0404.11CDBL 51 AA0404.11CDBL 59 AA0404.11CDBL 79 AA0404.11CXDBL63 AA0404.5CZB 51 AA0405.2CXZB 53 AA0405.2CXZB 71 AA0406.11CDBL 39 AA0406.11CDBL 61 AA0406.11CDBL 77 AA0406.11CDBL 79 AA0406.11CXDBL59 AA0406.21CRZ 65 AA0406.21CZB 49 AA0406.21CZB 77 AA0406.2CZB 51 AA0406.2CZB 69 AA0406.2CZB 71 AA0406.5CZB 77 AA0408.21CRZ 77 AA0409.5CZB 51 AA0412.11CDBL 59 AA0414.2CXZB 25 AA0507.2CZB 55 AA0508.2CXZB 45 AA0508.2CXZB 51 AA0508.2CXZB 57 AA0508.2CZB 53 AA0512.2CZB 47 AA0520.2CXZB 55 AA0522.2CZB 55 AA0522.2CZB 59 AA0522.2CZB 73 AA0522.2CZB 81 AA0524.2CZB 81 AA0608.2CXZB 25 AA0608.2CXZB 37 AA0608.2CXZB 45 AA0608.2CXZB 51 AA0609.11CXZB 35 AA0615.2CZB 53 AA0620.2CZB 39
Part No. AA0624.1CZB AA0634.2CZB AA0636.2CZ AA0712.2CZB AA0712.2CZB AN0805.5CSS AN0808.14CSS AN0808.3CBBL AN1004.2CZ AN1005.14FZB AN1005.3CBBL AN1005.3CBBL AN1006.14FZB AN1006.2CXZB AN1008.2CXZB AN1010.3FSS B0510.1Z B0613.1Z B0613.1Z B0613.1Z B0800.4Z BA0409.4Z BA0409.6BL BA0409.6BL BA0409.6BL BA0410.3Z BA0509.6 BA0509.6 BA0511.2Z BA0511.2Z BA0511.2Z BA0511.2Z BA0511.2Z BA0511.2Z BA0613.2Z BA0613.2Z BA0613.2Z BA0613.2Z BA0613.2Z BN1000.1BL C0025.02A8 C0026.02A8 C0028.02A8 C0028.02A8 C0032.02A8 C0033.02A8 C0034.02A8 C0035.02A8 C0036.02A8 C0039.02A8 C0041.02A8 C0042.02A8 C0043.02A8 C0044.02A8 C0045.02A8 C0098.02A8 C0145.T C0148.T C0149.T C0152.02A8
Page 73 53 11 53 55 53 79 87 69 71 59 65 71 31 31 65 81 39 71 75 79 75 59 63 77 71 61 63 35 49 53 73 79 81 11 25 35 53 73 63 49 87 51 53 75 87 71 71 87 81 75 87 23 25 87 51 57 39 57 83
Part No.
Page
C0152.02A8 C0232.TA C0235.02A8 C0249.02A8 C0250.02A8 C0255.02A8 C0315.T C0317.02A8 C0520.02A8 C0529.M C2024.02A8 C3009.E CA0002.T CA0005.T CA0006.T CA0007.T CA0010.02A8 CA0012.02A8 CA0012.02A8 CA0014.02A8 CA0015.02A8 CA0015.02A8 CA0015.02A8 CA0015.02A8 CA0016.02A8 CA0017.02A8 CA0018.02A8 CA0018.02A8 CA0018.02A8 CA0020.02A8 CA0020.02A8 CA0200.R CB0002.T CB0002.T CB0002.T CB0006.02A8 CB0008.02A8 CB0009.02A8 CD0001.T CD0002.T CD0007.02A8 D0500.1CZ D0600.2CZ D0600.2CZ D0600.2CZ D0800.4FZ DA0400.2CZ DA0400.8CZ DA0500.10CZ DA0500.10CZ DA0500.10CZ DA0500.12FZ DA0500.2CZ DA0500.2CZ DA0500.8FZ DA0600.11CZ DA0600.12FAZB DN1000.10FZB DN1000.2FZ DN1000.4FZB
87 39 51 51 51 51 67 67 63 71 87 47 57 43 57 87 51 59 63 41 31 39 51 53 87 77 21 61 63 35 49 37 51 53 55 41 87 65 57 55 31 81 39 65 75 79 77 79 49 73 81 73 35 53 69 11 35 71 23 31
Part No.
Page
E0002.02A8 45 E0002.02A8 51 E0004.02A8 41 E0005.02A8 43 E0006.02A8 55 G0110.02A8WAX 41 G0120.02A8 41 G0309.02A8WAX 43 G0313.02A8 41 G0313.02A8 43 G0321.02A8 43 G0323.02A8 43 G0325.02A8 41 G0400.02A8 35 G0500.02A8F 35 G0555.02A8A 59 G0604.02A8C 35 G0614.02A8C 35 H0020.02A8 37 H0021.02A8 37 H0022.F 37 H0022.F 39 H0024.F 39 H0026.F 39 H0027.02A8 39 H0030.T 39 H0031.02A8 37 H0032.02A8 37 H0033.T 39 H0034.T 39 H0035.9 37 H0040.F 39 H0041.F 39 H0053.T 39 H0054.9 37 H0055.9 37 H0102.02A8 39 H0105.F 39 H0106.F 39 H0107.F 39 H0110.02A8 37 H0150.02A8 43 H0203.02A8 39 H0205.02A8 39 H0206.02A8 39 H0212.02A8 39 H0300.02A8 37 H0301.T 39 H0405.9B 37 H0405.9B 39 H0412.01A0 37 H0412.01A0 39 H0417.02A8 39 H0418.02A8 37 H0505.02A8 41 H0506.02A8 41 H1201.02A8 41 H1522.02A8A 39 H1531.02A8 37 HS0008.02A8 17
NUMERICAL INDEX Part No. HS0008.02A8 HS0009.02A8 HS0014.02A8 HS0015.02A8 HS0016.02A8 HS0020.02A8 HS0021.02A8 HS0025.02A8 HS0455.02A8 J0106.02A8 J0107.02A8 J0113.02A8 J0114.02A8 J0115.02A8 J0116.02A8 J0117.02A8 J0121.02A8 J0122.02A8 J0124.02A8 J0135.02A8 J1050.02A8 J8124.02A8 J8127.02A8 J8128.02A8 J8130.02A8 J8135.02A8 J8138.02A8 J8139.02A8 J8140.02A8 J8141.02A8 J8142.02A8 J8143.02A8 J8144.02A8 J8145.02A8 J9147.02A8 K0001.02A8 K0002.02A8 K0003.02A8 K0101.02A8 K0158.02A8 K0200.02A8 K0402.02A8 K0403.02A8 K0410.02A8 K0424.02A8 K0425.02A8 L0073.02A8 L0073.02A8 L0074.02A8 L0074.02A8 L0077.02A8 L0078.02A8 L0079.02A8 L0090.02A8 L0152.02A8 L0160.02A8 L0174.02A8 L0178.K L0194.02A8A L0203.02A8
Page 71 71 21 69 21 89 89 89 21 45 47 47 47 47 47 47 47 47 47 45 45 47 47 47 47 47 47 47 47 47 47 47 47 47 47 49 55 55 55 55 55 49 55 49 49 49 83 87 83 87 71 51 51 51 51 53 51 11 51 51
Part No.
Page
L0360.02A8 67 L0361.02A8 67 L0500.02A8 53 L0501.02A8 53 L0502.02A8 53 L0506.02A8 53 L0511.02A8 53 L0512.02A8 53 L0541.02A8 79 L0542.02A8 79 L0544.02A8 79 L0545.02A8 79 L0600.02A8 51 L0600.02A8 69 L0601.02A8 51 L0601.02A8 69 L0602.02A8 51 L0602.02A8 69 L0603.02A8 51 L0603.02A8 69 L0604.02A8 51 L0604.02A8 69 L0605.02A8 51 L0605.02A8 69 L0940.02A8 81 L1011.02A8 67 L2116.02A8 17 L2117.02A8 71 L2118.02A8 17 M0064.02A8 65 M0065.02A8 65 M0066.02A8 61 M0067.02A8 61 M0068.02A8 61 M0069.02A8 61 M0070.02A8 71 M0072.02A8 87 M0073.02A8 65 M0087.02A8MAW61 M0087.02A8MBB 61 M0090.02A8 61 M0091.02A8 61 M0106.02A8 47 M0300.YBD 51 M0310.YBD 51 M0550.02A8 59 M0564.02A8 59 M0565.02A8 59 M0566.02A8 59 M0567.02A8 55 M0567.02A8 59 M0568.02A8 59 M0600.02A8 65 M0649.01A3 81 M0662.02A8MAW63 M0662.02A8MBB 63 M0675.02A8 45 M0698.02A8 63 M0703.02A8 65 M0704.02A8 61
Part No.
Page
M0725.02A8 67 M0726.02A8 67 M0745.02A8 67 M0750.02A8 67 M0755.02A8 79 M0756.02A8 61 M0766.02A8 67 M0772.02A8 67 M0784.02A8 67 M0820.02A8 67 M0902.02A8 77 M0903.02A8 77 M0905.02A8 61 M1224.02A8MAW63 M1224.02A8MBB 63 M1225.02A8MAW63 M1646.02A8MAW65 M1646.02A8MBB 65 M1647.02A8MAW63 M1647.02A8MBB 63 M1648.02A8MAW63 M1648.02A8MBB 63 M1664.02A8MAW61 M1664.02A8MBB 61 M1665.02A8MAW61 M1665.02A8MBB 61 N0002.02A8 57 N0010.02A8 57 N0050.K 57 N0051.K 57 N0096.02A8 37 N0097.02A8 51 N0098.02A8 51 N0102.02A8 57 N0104.02A8 57 N0158.TA 57 N0159.TA 57 N0161.02A8 65 N0162.02A8 65 N0200.02A8 37 N0202.02A8 37 N0203.9 37 N0210.R 37 N0220.F 37 N0259.9 37 N0306.02A8 25 N0307.02A8 57 N0308.02A8 57 N0316.02A8 25 N0320.02A8 31 N0326.02A8 25 N0401.02A8 51 N0402.02A8 51 N0405.02A8 51 N0406.02A8 51 N0425.02A8 51 N0427.02A8 51 N0428.02A8 51 N0429.02A8 51 N0505.T 39
Part No. N0507.01A1A N0513.T N0513.T N0516.T N0517.T N0520.02A8 N0521.02A8 N0530.02A8 N0552.02A8 N0553.02A8 N0554.02A8 N0555.02A8 N0599.02A8 N0599.02A8 N0600.02A8 N0606.02A8A N0630.02A8 P0002.02A8 P0025.02A8 P0045.02A8 P0098.02A8 P0099.02A8 P0100.02A8 P0104.02A8 P0115.02A8 P0119.02A8 P0121.02A8 P0125.02A8 P0127.02A8 P0128.02A8 P0130.02A8 P0138.K P0138.K P0139.K P0144.02A8 P0153.02A8 P0166.K P0177.K P0178.K P0187.02A8 P0189.02A8 P0191.02A8 P0194.02A8 P0198.02A8 P0213.02A8 P0215.02A8 P0228.02A8 P0229.02A8 P0464.02A8 P0700.02A8 P0806.K P0851.02A8 Q0002.02A8 Q0011.02A8 Q0012.02A8 Q0013.02A8 Q0102.02A8 Q0104.02A8 Q0107.02A8 Q0109.02A8
Page 31 31 39 39 39 51 51 39 51 51 51 51 31 39 31 31 31 69 19 69 87 69 69 69 69 69 69 69 69 69 69 21 87 21 21 69 69 69 69 69 69 69 69 69 21 21 69 69 69 21 69 21 71 55 55 55 55 55 55 55
Part No. Q0127.02A8 S0101.02A8 S0110.02A8 S0111.02A8 S0116.02A8 S0123.02A8 S0127.8 S0130.02A8 S0131.02A8 S0133.02A8 S0135.02A8 S0136.02A8 T0111.02A8 T0225.01A1 Y0011.K Y0011.K Y0016.T Y0016.T Y0021.02A8 Y0023.02A8 Y0024.02A8 Y0026.02A8 Y0028.02A8 Y0029.02A8 Y0033.02A8 Y0034.02A8 Y0035.02A8 Y0039.K Y0040.K Y0041.K Y0042.K Y0043.02A8 Y0045.02A8 Y0046.02A8 Y0049.02A8 Y0050.02A8 Y0053.02A8 Y0054.02A8 Y0056.02A8 Y0060.02A8 Y0061.02A8 Y0066.02A8 Y0067.02A8 Y0071.02A8 Y0072.02A8 Y0076.02A8 Y0077.02A8 Y0081.02A8 Y0082.02A8 Y0093.02A8 Y0094.02A8 Y0095.02A8 Y0096.02A8 Y0097.02A8 Y0101.02A8 Y0103.02A8 Y0119.02A8 Y0120.02A8 Y0126.02A8 Y0126.02A8
Page 55 73 73 73 73 73 73 87 87 73 73 73 25 31 83 87 83 87 83 83 75 77 83 83 83 83 83 79 79 79 79 79 83 83 83 77 83 83 83 85 85 85 85 85 85 85 85 85 85 85 85 85 85 85 75 75 85 85 23 85
95
NUMERICAL INDEX Part No.
Page
Y0129.02A8 Y0130.02A8 Y0132.02A8 Y0133.02A8 Y0134.02A8 Y0135.02A8 Y0136.02A8 Y0136.02A8 Y0204.02A8 Y0211.K Y0211.K Y0300.02A8 Y0302.02A8 Y0303.2B Y0303.2B Y0307.02A8 Y0308.TA Y0320.02A8 Y0320.02A8 Y0321.02A8 Y0349.02A8 Y0356.4 Y0357.3A Y0357.3A Y0400.02A8 Y0401.02A8 Y0401B.2U Y0406.02A8 Y0421.02A8 Y0422.02A8 Y0426.02A8 Y0427.02A8 Y0428.02A8 Y0435.02A8 Y0438.02A8 Y0500.02A8 Y0501.02A8 Y0503.02A8 Y0504.02A8 Y0602.02A8 Y0621.M Y0723.T Y0724.02A8 Y0725.02A8 Y0732.T Y0800.02A8 Y0820.9 YH350.02A8 YH401.02A8 YH402.02A8
85 85 85 85 85 23 83 85 25 85 87 25 23 81 87 53 77 75 85 75 87 87 85 87 77 79 79 77 77 77 77 77 77 77 77 81 81 79 79 87 79 87 87 61 87 51 37 79 77 77
96
Part No.
Page
Part No.
Page
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Page
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