aeon overland 180
TRANSCRIPT
DRAWING INDEXD-1: FAN COVER D-2: CYLINDER HEAD COVER D-3: CYLINDER HEAD/CAM SHAFT
page 7 D-4: CHAIN TENSIONER
page 8 D-5: CYLINDER
page 9 D-6: RIGHT CRANKCASE COVER/RADIATOR
page 10
page 11 1
page 12
DRAWING INDEXD-7: OIL PUMP ASSEMBLY D-8: LEFT CRANKCASE COVER D-9: DRIVE CLUTCH/STARTER
page 13 D-10: DRIVEN CLUTCH
page 14 D-11: TRANSMISSION LEVER
page 15 D-12: CRANKCASE
page 16
page 17-18 2
page 19
DRAWING INDEXD-13: CRANKSHAFT D-14: AIR CLEANER D-15: EXHAUST PIPE/CARBURETOR
page 20 D-16: FRAME BODY
page 21 D-17: BUMPER/RACKS
page 22 D-18: SWING ARM/FOOTREST
page 23
page 24 3
page 25
DRAWING INDEXD-19: FENDER D-20: SEAT D-21: FUEL TANK
page 26 D-22: SUSPENSION
page 27 D-23: FRONT WHEEL
page 28 D-24: REAR WHEEL
page 29
page 30 4
page 31
DRAWING INDEXD-25: FRONT BRAKE D-26: REAR BRAKE D-27: HANDLEBAR
page 32 D-28: CHAIN
page 33 D-29: CHAIN
page 34 D-30: STEERING
page 35
page 36 5
page 37
DRAWING INDEXD-31: LIGHTS D-32: GENERATOR/STARTING MOTOR D-33: ELECTRICAL PARTS
page 38-39 D-34: DECALS
page 40
page 41-42
page 43 6
D-1: FAN COVERITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 DESCRIPTION Asm., Shroud, Upper Screw, Tappinmg Clamp Plug, Rubber Elbow, Outlet Bolt Cover Set, Fly Wheel Cap Cap Clamp Asm., Shroud, Lower Gasket, Shroud, Lower Gasket, Shroud, Upper P/N 19623119-000 93904-3050168-00K 19628119-000 19633119-000 19615201-000 96000-060258-08C 19610119-001 19529119-000 19611156-000 19629119-000 19621119-000 19625119-000 19635119-000 Q'TY 1 4 1 1 1 3 1 1 1 1 1 1 1
7
D-2: CYLINDER HEAD COVERITEM 1 2 3 4 DESCRIPTION Bolt Asm., Head Cover Cover, Cylinder Head O-Ring, Head Cover P/N 96000-060258-08C 12310158-000 12309158-000 12391119-000 Q'TY 4 1 1 1
8
D-3: CYLINDER HEAD/CAM SHAFTITEM 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 DESCRIPTION Asm., Manifold, Intake Nut Clamp, Manifold, Intake O-Ring Plug, Spark Insulator, Manifold Gasket, Manifold Stud Pin, Dowel Gasket, Cylinder Head Valve, Intake Valve, Exhaust Head, Cylinder O-Ring Guide, Valve Intake Guide, Valve Exhaust Seal, Valve Seat, Valve, Spring, Outer Spring, Valve, Outer Spring, Valve, Inner Retainer, Valve, Spring Clip, Retainer Asm., Cam Shaft Bracket, Cam Shaft Nut Washer Nut, Tappet Adj. Screw, Tappet Adj. Shaft, Exhaust, Rocker Arm Arm, Valve, Rocker Asm., Decomp. Release Shaft, Intake, Rocker Arm Bolt Stud P/N 17100179-000 94050-06000-00C 14111119-000 93210-00227 98076119-00A 17112119-000 17113119-000 91001-060728-00C 94301-10140 12251158-000 14711122-000 14721122-000 12201158-000 93210-00915 12204119-000 12206119-000 12209119-000 14775119-000 14751119-000 14761119-000 14771119-000 14781119-000 14400122-000 12211158-000 94050-08000-00C 94101-0818023-00U 90206-05000-00A 90012-06015 14453158-000 14431119-000 14456119-000 14452158-000 96000-061008-08C 91001-080328-00C Q'TY 1 2 1 1 1 1 1 2 4 1 1 1 1 2 1 1 2 2 2 2 2 4 1 1 4 4 2 2 1 2 1 1 2 2
9
D-4: CHAIN TENSIONERITEM 1 2 3 4 5 6 7 8 9 DESCRIPTION Screw Bolt O-Ring Tensioner Gasket, Tensioner Guide, Cam Chain, RH Chain, Cam Guide, Cam Chain, LH Pivot, Guide P/N 93000-060068-00K 96000-060228-14C 93210-00915 14521119-000 14523119-000 14550119-000 14401119-000 14500119-000 14535119-000 Q'TY 1 2 1 1 1 1 1 1 1
10
D-5: CYLINDERITEM 1 2 3 DESCRIPTION Cylinder Gasket, Cylinder Pin, Dowel P/N 12101158-000 12191158-000 94301-10140 Q'TY 1 1 2
11
D-6: RIGHT CRANKCASE COVER/RADIATORITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 DESCRIPTION Dipstick O-Ring Bolt Pin, Dowel Gasket, Crankcase, RH Seal, Oil Cover, Crankcase, RH Screen Spring, Screen O-Ring Plug, Drain, Oil Washer Bolt, Banjo Hose, Inlet Hose, Outlet Radiator Washer ,Rubber Bolt Bolt Bolt Bolt Clamp, Wire, Stator P/N 15651201-000 93210-01835 96000-060408-08C 94301-08140 11393156-000 96501-19300500000 11330156-002 15421119-000 15426119-000 93210-03132 11334119-000 94101-1221320-00L 45456156-604 19220158-001 19230158-001 19215156-001 19235156-000 92005-060258-00K 96000-060958-08C 96000-061108-08C 96000-061008-08C 32961119-000 Q'TY 1 1 1 2 1 1 1 1 1 1 1 8 4 1 1 1 2 2 5 2 1 1
12
D-7: OIL PUMP ASS'YITEM 1 2 3 4 5 6 7 DESCRIPTION Bolt Cover, Oil Pump Chain, Oil Pump Nut Sprocket, Oil Pump Screw Asm., Pump, Oil P/N 96000-060128-08C 15711119-000 15141119-000 94050-06000-00C 15150119-000 93902-060308-00B 15100158-000 Q'TY 2 1 1 1 1 2 1
13
D-8: LEFT CRANKCASE COVERITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 DESCRIPTION Gasket Pin, Dowel Bolt Cover, Clutch Bolt Bolt Washer, Spring Asm., Kick Start Bolt Clamp Duct, Inlet Screw Cap Hook, Hose P/N 11359119-000 94301-08140 96000-060408-08C 11341156-001 96000-061008-08C 96000-060258-00K 94111-0611020-00K 28300156-000 93500-040258-00K 89669-119-001 11345179-000 93903-1040168-00K 11349156-000 11351119-000 Q'TY 1 2 7 1 1 1 1 1 1 1 1 1 1 1
14
D-9: DRIVE CLUTCH/STARTERITEM 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 DESCRIPTION Asm., Shaft, Starter Bushing Rollor Arresting Bolt Bushing Washer Recoil, Kick Start Asm., Shaft, Kick Start Idler Shaft, Starter Pin Spring Spring, Kick Start Gear Gear, Kick Start, Driven Washer Asm., Idle Gear, Starter Bushing, Kick Start Bushing, Slider Plate, Sheave Roller Clip, Cir Sheave Bushing Bushing Sheave, moveable Washer Nut Asm., Drive Clutch P/N 28251119-000 96401-121612 96220-30085 28252119-000 96000-060128-08C 96401-141816 94101-1422012-00K 28281119-000 28250119-000 28241119-000 28282119-000 28242119-000 28223119-000 28230119-000 94101-1225023-000 28231119-000 28211119-000 22132156-000 22131158-000 22121158-000 94512-2800R 22110156-000 96401-242830 96401-172451 22102156-000 94101-1225023-000 94050-12000-00C 22103160-000 Q'TY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 1 6 2 1 1 1 1 1 1 1
15
D-10: DRIVEN CLUTCHITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 DESCRIPTION Asm., Drive Clutch Clip, Cir Plate, Drive, Side Spring, Clutch Weight, Clutch Bushing, Rubber Plate, Drive, Inner Nut Clutch, Outer Nut Seal, Collor Spring, Clutch Seal, Collor O-Ring Seal, Oil Sheave, Moveable Roller, Guide Pin, Guide Asm., Sheave, Driven Sheave, Driven Bearing, Ball Clip, Cir Bearing, Needle Belt, Driven P/N 22001156-000 94511-0700E 22351119-000 22401119-000 22535156-000 22804119-000 22350119-000 90202-28000-00C 22100119-000 94050-12000-00C 23238119-000 23233158-000 23237119-000 93210-03920 96500-34410400000 23220119-000 23226119-000 23225119-000 23200119-000 23210119-000 96100-69020-U0000 94512-280IR 96200-202918 23100122-000 Q'TY 1 3 1 3 3 3 1 1 1 1 1 1 1 2 2 1 3 3 1 1 1 1 1 1
16
D-11: TRANSMISSION LEVERITEM 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 17 DESCRIPTION Bolt Bracket, Sprocket Sprocket, Drive Bushing, Rubber Hose Breather, Crankcase, Lower Cover, Transmission Pin, Dowel Gasket, Transmission Cover Bearing, Ball Seal, Oil Shaft Gear , Shift Bearing, Ball Seal, Oil Bearing, Ball Retainer Washer, Spline Ratchet, Shift Bearing, Ball Asm.,Idler Shaft Asm., Reverse Shaft Shaft, Drive Bearing, Ball Nut Washer Fork, Shift Gear Pin, Shift Gear Washer Retainer O-Ring Bracket, Shift Washer Bolt Fork, Shift Bolt Nut Rod End Bolt Lever, Shift P/N 92000-060108-00C 23811201-000 23801159-001 96400-082223 94408-05007-170 11610113-000 21301158-002 94301-08140 21395156-000 96100-60050-U0000 96500-304707A7271 23431156-002 23434201-000 96100-62020-00000 96500-203206T3034 96100-62030-00000 23436201-000 23435201-000 22430201-000 96100-62040-JR2C3 23433156-000 23420156-000 23411119-000 96100-TMB30-10000 90350-08000-0UK 94101-0816015-00C 21312156-000 21311156-000 23437156-000 23438156-000 93210-01425 21313156-000 94101-0510010-00B 91000-050098-00K 21314156-000 96000-060128-10C 90350-06000-00K 21316201-000 91000-060258-00K 21317156-000 Q'TY 2 1 1 2 1 1 1 2 1 1 1 1 2 4 1 1 3 3 1 1 1 1 1 1 1 3 1 1 1 1 1 1 1 1 1 2 2 1 2 1
D-11: TRANSMISSION LEVERITEM 41 42 43 44 45 46 47 48 49 50 51 52 53 54 DESCRIPTION Bracket, Shift Lever Bolt Lever, Shift Pin, Lever, Shift Spring, Shift Pin, Cotter Bolt Gate, Shift Knob, Transmission Lever Cover Bolt Asm., Positioner Spring Pin P/N 21318156-000 96000-060258-00K 21319201-000 21321156-000 21320201-000 94201-25190 96000-060128-10K 21323156-000 21328158-000 21327158-000 96000-060168-00K 21315156-000 21325156-000 21324156-000 Q'TY 1 1 1 1 1 1 2 1 1 1 1 1 1 1
18
D-12: CRANKCASEITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 DESCRIPTION Nut Washer Bushing, Rubber Pin, Dowel Gasket Bolt Bracket. Air Cleaner Bolt Nut Bushing, Rubber Bracket, Carburator Tube Washer Bolt Bolt Bolt Washer Seal, Oil Spacer, Collar Crankcase, LH Stud Crankcase, RH Stud Bolt P/N 90350-10000-00C 94101-1022020-00C 96400-102822 94301-08140 11191122-000 96000-101978-14C 17237201-000 96000-060608-08C 94050-06000-00K 96400-082223 11351111-000 94101-0816020-00L 96000-080128-10C 96000-060708-08C 96000-120158-14C 94101-1221320-00L 96501-19300500000 11150156-001 11201158-003 91001-081878-00C 11101158-000 91001-081818-00C 96000-060508-00C Q'TY 1 1 2 2 1 1 1 4 1 2 1 2 2 3 1 1 1 1 1 2 1 2 1
19
D-13: CRANKSHAFTITEM 1 2 3 4 5 6 DESCRIPTION Ring Set, Piston Clip, Piston Pin Piston Key, Woodruff Asm., Crankshaft Pin, Piston P/N 13011158-000 13115119-000 13100158-000 90471-04014 13020202-000 13111158-000 Q'TY 1 2 1 1 1 1
20
D-14: AIR CLEANERITEM 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 DESCRIPTION Clamp, Hose Boot Clamp Inlet, Air Box Box, Air Cleaner Gasket, Cover Bolt Duct, Inlet Spring Screw Cover, Air Cleaner Filter, Air Cleaner Screw Element, Air Cleaner Seal Filter, Inlet, Separator Cover, Separator Bolt Rubber Clamp Hose, Drain Plug, Trap Clamp Hose Clamp P/N 17102119-000 17253201-000 94509-09000 17257119-000 17206119-000 17213119-000 93500-050108-00K 17255119-000 17258119-000 93903-2050208-00K 17207119-000 17205119-000 93903-1040128-00K 17234119-000 17212119-000 17235119-000 17232119-000 96000-060328-16C 81113153-000 94510-12000 94404-08012-000 17370119-000 94509-08500 11211119-000 94510-08000 Q'TY 1 1 1 1 1 1 2 1 1 7 1 1 2 1 1 1 1 1 1 2 1 1 1 1 1
21
D-15: EXHAUST PIPE/CARBURETORITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 DESCRIPTION Asm., Carburetor Throttle Valve, Diaphragm Screw, Idle Spring Bracket, Throttle Cable Valve, Float Valve, Needle Jet, Main Float Jet, Pilot Bolt Washer Bolt Gasket Shield, Silencer Gasket Gasket Pipe, Exhaust Nut P/N 16100203-000 16050202-000 16171201-000 16172201-000 16120119-000 16117201-000 16105182-000 16108211-000 16118182-000 16110182-000 96000-080168-0KL 94101-0822020-00C 96000-060108-00B 94102-0613010-000 18315156-000 94102-0817020-000 18291119-000 18301186-000 90301-08000-00C Q'TY 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 2 1 1 2
22
D-16: FRAME BODYITEM 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 DESCRIPTION Bolt Bracket, Engine Mount, RH Bolt Washer, Spring Bushing, Rubber Bracket, Engine, RH Nut Bracket, Footwell, RH Bolt Bolt Bolt Rubber, Seat Strap Cap, Valve, Grease Seat, Grease Contain Nut Cover, Swing Arm Seal Arm, Swing Valve, Grease Sleeve, Rubber Tube, Spacer Bolt Bracket, Engine Mount, LH Bracket, Engine Mount, RH Bracket, Footwell, LH Bolt Shield, Chassis Asm., Frame P/N 96000-100438-0KL 50351202-000 96000-100208-0KL 94111-1001502-00K 96400-102822 50372201-000 90350-10000-0UC 51105156-000 96000-080128-00K 96000-080408-00K 96000-081258-00K 77220131-000 89569131-000 51301131-000 52524131-000 90350-14000-0UC 52422131-000 52410182-A03 51300131-000 52423156-000 52420131-000 96000-142908-00C 50371201-000 50355202-000 51120156-000 92005-060168-00K 50106158-000 50100182-A01 Q'TY 2 1 6 6 2 1 2 1 8 3 1 2 21 2 2 1 2 1 2 1 1 1 1 1 1 5 1 1
23
D-17: BUMPER/RACKITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 DESCRIPTION Bracket, Front Rack Washer Bolt Bolt Cover, Headlight Bolt Bumper Nut Washer Bracket, RH Rubber Bracket, Rear Rack Bolt P/N 50495182-A00 94121-0816010-00K 96000-080168-0KL 93100-050168-00K 50460182-000 92003-060168-00K 50455182-A00 90350-05000-00K 94101-0514010-00K 81121182-A00 81113153-000 81111182-A00 96000-080208-0KL Q'TY 1 16 14 8 1 2 1 8 8 2 2 1 2
24
D-18: SWING ARM/FOOTRESTITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 DESCRIPTION Shield, Heat Bolt Washer Nut Arm, Suspension, Silver, RH Bolt Cap, Rubber Bushing Spacer Valve, Grease Nut Cap, Valve, Grease Arm, Suspension, Silver, LH Nut Washer Footwell, LH Bolt Footwell, RH P/N 50480156-000 93100-050168-00K 94101-0514010-00K 90350-05000-00K 53030202-00A 96000-100758-0KL 52426156-000 53135203-000 53140156-000 51300131-000 94050-10000-00C 51301131-000 53130202-00A 90350-06000-00K 94101-0613010-00K 64310156-001 92005-060168-00K 64300156-000 Q'TY 1 4 4 4 1 4 8 8 4 4 4 4 1 8 8 1 8 1
25
D-19: FENDERITEM 1 1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 15 16 17 17 18 19 20 21 22 23 24 DESCRIPTION Cover, Front Fender (red) Cover, Front Fender (green) Screw Bolt Mudflap, Front, RH U-Nut Cab, Front (red) Cab, Front (green) Bracket, Battery Nut, U-Plate Bolt Bolt Washer Bolt Mudflap, Rear, RH Rubber, Battery O-Ring Washer Cab, Rear (red) Cab, Rear (green) Bolt Washer Nut Mudflap, Rear, LH Decal, Isolation Mudflap, Front, LH Rubber P/N 61300182-485 61300182-617 93903-1040128-00K 92003-060168-00K 61105182-000 90345-04000-02T 61100182-485 61100182-617 31521201-000 90344-06000-00C 93100-050128-00K 93800-060168-00K 94150-0717050-00K 92005-060168-00K 61005182-000 31510201-000 93210-04635 94150-0717075-00K 61000182-485 61000182-617 93100-050168-00K 94101-0514010-00K 90350-05000-00K 61010182-000 80140131-000 61110182-000 81113153-000 Q'TY 1 1 2 2 1 2 1 1 1 4 8 4 2 4 1 2 2 2 1 1 32 40 40 1 1 1 1
26
D-20: SEATITEM 1 2 3 DESCRIPTION Seat Hook, Seat Nut P/N 77200182-000 77210131-000 94050-06000-00C Q'TY 1 1 2
27
D-21: FUEL TANKITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 DESCRIPTION Cap, Fuel Vent, Fuel Cap Diaphragm, Fuel Cap Cap Bolt Rubber, Fuel Tank Hose, Fuel Clamp Clamp Valve, Fuel Bolt Clamp Hose, Fuel Hose, Fuel Filter, Fuel Clip Tube, Oil Tank, Fuel P/N 17623156-000 17621156-000 17625131-000 83574131-000 92005-060168-00K 64319131-000 94401-05009-001 94510-12000 94510-08000 17950111-000 96000-060168-00K 94510-08000 94401-05009-050 94401-05009-150 17952111-000 94510-06000 94403-04008-300 17500156-000 Q'TY 1 1 1 2 2 2 1 1 1 1 1 5 1 1 1 1 1 1
28
D-22: SUSPENSIONITEM 1 2 3 4 5 6 7 8 DESCRIPTION Bolt Nut Spring, Suspension, Front Tube, Inner, Suspension, Front Shaft, Suspension, Rear Spring, Suspension, Rear Shock, Rear Pin, Cotter P/N 96000-100408-0KL 94050-10000-00C 51101156-00B 51102156-00B 52415156-000 52401156-001 52402156-000 94201-25190 Q'TY 5 4 2 2 1 1 1 1
29
D-23: FRONT WHEELITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 DESCRIPTION Seal, Oil Spacer Bearing, Ball Drum, Brake, Front Spacer Valve, Rim Nut Nut Cap, Hub Pin, Cotter Washer Washer Tire Rim, Front P/N 96500-233506A7271 44312156-000 96100-60030-ZZ000 45008156-000 44311156-000 42616131-000 90350-10000-0UC 90353-14000-00C 42730151-000 94201-32320 94121-1426016-000 94101-1443030-00C 42711209-000 42701182-000 Q'TY 2 2 4 2 2 2 8 2 2 2 2 2 2 2
30
D-24: REAR WHEELITEM 1 2 3 4 5 6 7 8 9 10 DESCRIPTION Hub, Wheel Rim, Rear Nut Tire Washer Washer Pin, Cotter Cap, Hub Nut Valve, Rim P/N 42010202-000 42801182-000 90350-10000-0UC 42811162-001 94101-1443030-00C 94121-1426016-000 94201-32320 42730151-000 90352-14000-00C 42616131-000 Q'TY 2 2 8 2 2 2 2 2 2 2
31
D-25: FRONT BRAKEITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 DESCRIPTION Asm.,Cable, Brake Pedal Bolt, Insert Nut Arm, Swing Bracket, Pedal Cable, Pedal, LH Cable, Pedal, RH Bolt Pin Cable, Front Brake Shoe, brake, Rear Shaft, Cam, Front Brake Washer Indicator, Brake Nut Arm, Front Brake, RH Bolt Seal, Oil Plate, Front Brake, Rh Arm, Front Brake, LH Plate, Front Brake, LH Strap P/N 45454203-000 45421133-000 90353-08000-00G 43452133-001 43453133-001 45457203-000 45455203-000 93902-060088-00B 94205-02052 45450204-000 43120111-00C 45141156-000 94101-1722010-00K 45142156-000 94001-06000-00C 45409159-000 92000-060308-00B 96500-4052060 45020156-001 45410159-000 45010156-000 89769111-000 Q'TY 1 3 3 1 1 1 1 2 1 2 2 2 2 2 2 1 2 2 1 1 1 1
32
D-26: REAR BRAKEITEM 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 DESCRIPTION Pads, Brake Bracket, Pads Asm., Caliper, Rear Washer Bolt, Banjo Hose, Brake Asm., Master Cylinder Bolt Spring Lever, Brake, Foot Pin Cotter Pin Washer Arm, Master Cylinder Bracket, Rear Cable Spring, Switch Bolt Switch, Brake Cable,Hand Brake, Rear Strap Asm., Housing, Rear Axle Seal, Oil Bearing, Ball Tube, Spacer Bolt Bolt Bolt Bolt Hub, Disc Disc,Brake Bolt Bolt Cover, Rear P/N 45120182-000 43510201-000 45000182-000 94101-1015012-U0B 45456111-000 45450182-000 43500182-000 96000-060128-10K 43421201-000 43456204-000 94302-07018 94203-12200 94121-1221005-000 43457201-000 50357202-000 43421202-000 92001-080148-0KL 34916201-000 43450182-000 89768151-000 42803206-A00 96500-426208A7271 96100-60070-ZZ000 42810156-001 96008-120328-0CL 96008-120288-0CL 96000-080388-0KL 92001-080208-0KL 43490182-000 45010182-000 45016131-00K 96000-080128-00K 40550156-A00 Q'TY 1 1 1 4 2 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 2 1 3 1 2 2 1 1 3 2 1
33
D-27: HANDLEBARITEM 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 DESCRIPTION Grip, Handlebar Asm., Lever, RH Seat, Lever, RH Bolt, Brake lever, RH Lever, Brake, RH Bracket, Brake Cable Nut Wire, Brake Switch Choke, Cable, Manual Cable, Throttle Clamp, Lower Nut Strap Sensor, Brake Lever, Brake, LH Asm., Lever LH Perch, lever, LH Bolt Bolt Screw Asm., Manual Choke Asm., Switch, LH Handlebar Clamp, Upper, LH Bolt Clamp, Upper, RH Mirror, LH Shield, Pod U-Nut Bracket, Pod Bolt Pod, Handlebar Screw Bolt Mirror, RH P/N 53167201-000 53172201-000 53176201-000 90115-090228-000 53175180-000 53177131-000 90350-06000-00K 53174201-000 53922182-000 53910182-000 53200204-000 90350-10000-00C 89768151-000 53173131-000 53178131-000 53171204-000 53170201-000 90116-090238-00K 93500-060088-00K 93100-030048-00B 35160151-000 35151204-000 53100182-A00 53210204-000 91000-080258-00K 53220204-000 88120201-001 64212182-000 90345-04000-02T 53310181-00A 93100-050168-00K 64211181-000 93903-1040128-00K 96000-060128-10K 88110204-000 Q'TY 2 1 1 1 1 1 2 1 1 1 2 2 1 1 1 1 1 1 1 2 1 1 1 1 4 1 1 1 2 1 3 1 2 2 1
34
D-28: REAR WHEEL AXLEITEM 1 2 3 4 5 6 7 DESCRIPTION Nut Washer Nut Sprocket, Drive, Final Hub, Sprocket Axle Washer, Sprocket P/N 94001-33000-00K 94121-3345012-000 94002-10000-00C 41201156-000 41210156-000 42000158-000 41202156-000 Q'TY 2 2 4 1 1 1 2
35
D-29: CHAINITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 DESCRIPTION Bolt Nut Adjuster, Chain Nut Fixed Bracket, Chain Tensioner Bolt E-Clip Roller, Chain Tensioner Spring Bolt Cover, Sprocket Asm., Drive Chain Bolt P/N 92000-080608-00B 94050-08000-00C 40543156-000 90350-08000-0UK 40539202-000 90108-080158-00K 94513-1020E 40545201-000 40541201-000 96000-080168-00K 40520182-000 40530159-000 96000-080148-00K Q'TY 1 1 1 1 1 1 1 1 1 4 1 1 1
36
D-30: STEERINGITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 DESCRIPTION Cap, Rubber Sleeve, Steering Shaft Clamp, steering Spacer Bracket, Wire Collector Washer, Lock Bolt Asm., Tie Rod Pin, Cotter Nut Cap, Dustproof Asm., Steering Knuckle, RH Bolt Asm., Steering Knuckle, LH Washer Washer Nut O-Ring Post, Streering Shaft, Steering P/N 19611202-000 51220156-000 53500156-000 51317156-000 51318156-000 51319156-000 92000-080608-00B 53410202-000 94201-25190 90352-10000-00C 52424156-000 51330202-000 96004-101058-00K 51325202-000 94121-1020010-000 94101-1022010-00U 90350-10000-0UC 93210-01525 51111156-000 51112205-A00 Q'TY 1 2 2 2 1 1 2 2 7 6 4 1 2 1 4 1 1 2 2 1
37
D-31: LIGHTSITEM 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 DESCRIPTION Asm., Low Beam Bulb Screw Nut Bracket, Headlight Washer, Spring Bolt Bulb, Parking Screw Asm., Hight Beam Lens, Signal Bulb, Signal Socket, Signal, LH Asm., Signal, Front, LH Nut Washer Reflector Bolt License Plate Nut Washer Nut Washer Socket, Taillight Bulb, Taillight Lens, Taillight Bolt Asm,. Taillight Gasket Strap Asm., Signal, Front, RH Socket, Right Signal P/N 33100203-000 34901201-000 93100-030068-00B 94001-06000-00K 33122201-000 94111-0610010-00K 92005-060128-00K 34909201-000 93903-1050128-00K 33100204-000 33402201-000 33905201-000 33451201-000 33450182-000 94050-05000-00C 94101-0519010-00K 33741131-000 93100-050168-00K 33708182-000 90350-05000-00K 94101-0514010-00K 94050-06000-00C 94101-0619010-00C 33711205-000 34906201-000 33702202-000 93500-035398-SUS 33700208-000 33716205-000 89768151-000 33400182-000 33401201-000 Q'TY 1 2 2 4 4 4 4 2 4 1 4 4 2 2 1 1 1 10 1 10 10 2 2 1 1 1 2 1 1 2 2 2
38
D-32: GENERATOR/STARTING MOTORITEM 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 DESCRIPTION Bolt Stator Bolt Fan Bolt Nut Washer Flywheel Asm., Generator Asm., One Way Clutch Bearing, Needle Gear, Starter Washer Nut, Lock Motor, Starter Bolt Nut O-Ring Shaft, Starter Motor Gear, Starter Asm., Gear Starter P/N 92000-050128-00C 31120201-000 96000-060208-08C 19510119-000 96000-060188-08C 94050-12000-00C 94101-1225023-000 31110207-000 31100204-000 28410201-000 96200-283217 28220119-000 94101-2231025-000 94071-22000-000 31200119-000 96000-060188-08C 94050-06000-00C 93210-02431 28424119-000 28423119-000 28422119-000 Q'TY 2 1 2 1 4 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1
39
D-33: ELECTRICAL PARTSITEM 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 40 DESCRIPTION Screw, Tapping Bracket, Cable Asm., Main Switch Switch, Main Bolt Lock, Steering Clip, Main Switch Bolt Relay, Signal Asm., Speedometer Nut Bolt Screw Bolt Bracket, Electrical Bolt Sensor Nut Switch, Shift Control Battery Nut Asm., Starter Relay Harness, Main Wire Fuse Wire, Ground Wire, Battery Pouch, Tool Asm., CDI Unit Pad, Rubber Rectifier/ Regulator Bolt Extended Wires Bush, Plug Cap Bolt Asm., Ignition Coil Sensor, Fuel Bolt Asm., Speedometer Sensor, Speedometer Magnet, Speedometer P/N 93906-1030088-00K 32107201-000 35100221-000 35102211-000 93100-050128-00K 35106206-000 35101131-000 93100-050168-00K 38302133-000 37200212-000 94050-06000-00C 93501-030108-00K 93100-040168-00K 92005-060168-00K 32104201-000 93501-030108-00K 34912203-000 94001-03000-00K 34913201-000 31500156-001 94050-06000-00K 38501119-000 32103201-000 32106201-000 32102159-000 32102182-000 89120119-000 30410159-000 30411156-000 31600204-000 96000-060128-10K 32101201-000 30701201-000 96000-050208-00C 30510119-000 37800201-000 96000-060128-10K 37205202-002 37202202-000 37203204-000 Q'TY 4 4 1 1 2 1 1 4 1 1 2 2 2 2 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
D-33: ELECTRICAL PARTSITEM 41 42 43 44 45 DESCRIPTION Bracket, Speedometer Nut Bolt Horn Washer P/N 37201159-000 90350-04000-00K 91000-050168-00K 38110119-000 94101-0412010-00K Q'TY 1 2 2 1 2
41
D-34: DECALSITEM 1 2 3 4 5 6 7 8 9 10 DESCRIPTION Decal, Tank, RH Decal , Waring, Reverse Decal, OVERLAND 180 Decal, Waring, Chain Decal, Waring Decal, General Waring Decal, Warning, Rack Decal, Tank, LH Decal, Fragile, Frame Decal, AEON, Logo P/N 87720209-000 87854202-000 87716208-000 87858156-001 87851159-000 87852159-000 87869131-000 87721209-000 87871204-000 87711162-000 Q'TY 1 1 2 1 1 1 2 1 1 1
42
PART NO. INDEXP/N11101158-000 11150156-001 11191122-000 11201158-003 11211119-000 11330156-002 11334119-000 11341156-001 11345179-000 11349156-000 11351111-000 11351119-000 11359119-000 11393156-000 11610113-000 12101158-000 12191158-000 12201158-000 12204119-000 12206119-000 12209119-000 12211158-000 12251158-000 12309158-000 12310158-000 12391119-000 13011158-000 13020202-000 13100158-000 13111158-000 13115119-000 14111119-000 14400122-000 14401119-000 14431119-000 14452158-000 14453158-000 14456119-000 14500119-000 14521119-000
DESCRIPTIONCrankcase, RH Spacer, Collar Gasket Crankcase, LH Hose Cover, Crankcase, RH Plug, Drain, Oil Cover, Clutch Duct, Inlet Cap Bracket, Carburator Tube Hook, Hose Gasket Gasket, Crankcase, RH Breather, Crankcase, Lower Cylinder Gasket, Cylinder Head, Cylinder Guide, Valve Intake Guide, Valve Exhaust Seal, Valve Bracket, Cam Shaft Gasket, Cylinder Head Cover, Cylinder Head Asm., Head Cover O-Ring, Head Cover Ring Set, Piston Asm., Crankshaft Piston Pin, Piston Clip, Piston Pin Clamp, Manifold, Intake Asm., Cam Shaft Chain, Cam Arm, Valve, Rocker Shaft, Intake, Rocker Arm Shaft, Exhaust, Rocker Arm Asm., Decomp. Release Guide, Cam Chain, LH Tensioner
Q.TY1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 1 1 1 1
PAGE19 19 19 19 21 12 12 14 14 14 19 14 14 12 17 11 11 9 9 9 9 9 9 8 8 8 20 20 20 20 20 9 9 10 9 9 9 9 10 10
ITEM21 18 5 19 24 7 11 4 11 13 11 14 1 5 6 1 2 13 15 16 17 24 10 3 2 4 1 5 3 6 2 3 23 7 30 32 29 31 8 4
P/N14523119-000 14535119-000 14550119-000 14711122-000 14721122-000 14751119-000 14761119-000 14771119-000 14775119-000 14781119-000 15100158-000 15141119-000 15150119-000 15421119-000 15426119-000 15651201-000 15711119-000 16050202-000 16100203-000 16105182-000 16108211-000 16110182-000 16117201-000 16118182-000 16120119-000 16171201-000 16172201-000 17100179-000 17102119-000 17112119-000 17113119-000 17205119-000 17206119-000 17207119-000 17212119-000 17213119-000 17232119-000 17234119-000 17235119-000 17237201-000
DESCRIPTIONGasket, Tensioner Pivot, Guide Guide, Cam Chain, RH Valve, Intake Valve, Exhaust Spring, Valve, Outer Spring, Valve, Inner Retainer, Valve, Spring Seat, Valve, Spring, Outer Clip, Retainer Asm., Pump, Oil Chain, Oil Pump Sprocket, Oil Pump Screen Spring, Screen Dipstick Cover, Oil Pump Throttle Valve, Diaphragm Asm., Carburetor Valve, Needle Jet, Main Jet, Pilot Valve, Float Float Bracket, Throttle Cable Screw, Idle Spring Asm., Manifold, Intake Clamp, Hose Insulator, Manifold Gasket, Manifold Filter, Air Cleaner Box, Air Cleaner Cover, Air Cleaner Seal Gasket, Cover Cover, Separator Element, Air Cleaner Filter, Inlet, Separator Bracket. Air Cleaner
Q.TY1 1 1 1 1 2 2 2 2 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
PAGE10 10 10 9 9 9 9 9 9 9 13 13 13 12 12 12 13 22 22 22 22 22 22 22 22 22 22 9 21 9 9 21 21 21 21 21 21 21 21 19
ITEM5 9 6 11 12 19 20 21 18 22 7 3 5 8 9 1 2 2 1 7 8 10 6 9 5 3 4 1 1 6 7 12 5 11 15 6 17 14 16 7
43
PART NO. INDEXP/N17253201-000 17255119-000 17257119-000 17258119-000 17370119-000 17500156-000 17621156-000 17623156-000 17625131-000 17950111-000 17952111-000 18291119-000 18301186-000 18315156-000 19215156-001 19220158-001 19230158-001 19235156-000 19510119-000 19529119-000 19610119-001 19611156-000 19611202-000 19615201-000 19621119-000 19623119-000 19625119-000 19628119-000 19629119-000 19633119-000 19635119-000 21301158-002 21311156-000 21312156-000 21313156-000 21314156-000 21315156-000 21316201-000 21317156-000 21318156-000
DESCRIPTIONBoot Duct, Inlet Inlet, Air Box Spring Plug, Trap Tank, Fuel Vent, Fuel Cap Cap, Fuel Diaphragm, Fuel Cap Valve, Fuel Filter, Fuel Gasket Pipe, Exhaust Shield, Silencer Radiator Hose, Inlet Hose, Outlet Washer ,Rubber Fan Cap Cover Set, Fly Wheel Cap Cap, Rubber Elbow, Outlet Asm., Shroud, Lower Asm., Shroud, Upper Gasket, Shroud, Lower Clamp Clamp Plug, Rubber Gasket, Shroud, Upper Cover, Transmission Pin, Shift Gear Fork, Shift Gear Bracket, Shift Fork, Shift Asm., Positioner Rod End Lever, Shift Bracket, Shift Lever
Q.TY1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
PAGE21 21 21 21 21 28 28 28 28 28 28 22 22 22 12 12 12 12 39 7 7 7 37 7 7 7 7 7 7 7 7 17 17 17 17 17 18 17 17 18
ITEM2 8 4 9 22 18 2 1 3 10 15 17 18 15 16 14 15 17 4 8 7 9 1 5 11 1 12 3 10 4 13 7 28 27 32 35 52 38 40 41
P/N21319201-000 21320201-000 21321156-000 21323156-000 21324156-000 21325156-000 21327158-000 21328158-000 21395156-000 22001156-000 22100119-000 22102156-000 22103160-000 22110156-000 22121158-000 22131158-000 22132156-000 22350119-000 22351119-000 22401119-000 22430201-000 22535156-000 22804119-000 23100122-000 23200119-000 23210119-000 23220119-000 23225119-000 23226119-000 23233158-000 23237119-000 23238119-000 23411119-000 23420156-000 23431156-002 23433156-000 23434201-000 23435201-000 23436201-000 23437156-000
DESCRIPTIONLever, Shift Spring, Shift Pin, Lever, Shift Gate, Shift Pin Spring Cover Knob, Transmission Lever Gasket, Transmission Cover Asm., Drive Clutch Clutch, Outer Sheave, moveable Asm., Drive Clutch Sheave Roller Plate, Sheave Bushing, Slider Plate, Drive, Inner Plate, Drive, Side Spring, Clutch Ratchet, Shift Weight, Clutch Bushing, Rubber Belt, Driven Asm., Sheave, Driven Sheave, Driven Sheave, Moveable Pin, Guide Roller, Guide Spring, Clutch Seal, Collor Seal, Collor Shaft, Drive Asm., Reverse Shaft Shaft Asm.,Idler Shaft Gear , Shift Washer, Spline Retainer Washer
Q.TY1 1 1 1 1 1 1 1 1 1 1 1 1 1 6 1 3 1 1 3 1 3 3 1 1 1 1 3 3 1 1 1 1 1 1 1 2 3 3 1
PAGE18 18 18 18 18 18 18 18 17 16 16 15 15 15 15 15 15 16 16 16 17 16 16 16 16 16 16 16 16 16 16 16 17 17 17 17 17 17 17 17
ITEM43 45 44 48 54 53 50 49 9 1 9 25 28 22 20 19 18 7 3 4 19 5 6 24 19 20 16 18 17 12 13 11 23 22 12 21 13 18 17 29
44
PART NO. INDEXP/N23438156-000 23801159-001 23811201-000 28211119-000 28220119-000 28223119-000 28230119-000 28231119-000 28241119-000 28242119-000 28250119-000 28251119-000 28252119-000 28281119-000 28282119-000 28300156-000 28410201-000 28422119-000 28423119-000 28424119-000 30410159-000 30411156-000 30510119-000 30701201-000 31100204-000 31110207-000 31120201-000 31200119-000 31500156-001 31510201-000 31521201-000 31600204-000 32101201-000 32102159-000 32102182-000 32103201-000 32104201-000 32106201-000 32107201-000 32961119-000
DESCRIPTIONRetainer Sprocket, Drive Bracket, Sprocket Bushing, Kick Start Gear, Starter Spring, Kick Start Gear Gear, Kick Start, Driven Asm., Idle Gear, Starter Idler Shaft, Starter Spring Asm., Shaft, Kick Start Asm., Shaft, Starter Arresting Recoil, Kick Start Pin Asm., Kick Start Asm., One Way Clutch Asm., Gear Starter Gear, Starter Shaft, Starter Motor Asm., CDI Unit Pad, Rubber Asm., Ignition Coil Bush, Plug Cap Asm., Generator Flywheel Stator Motor, Starter Battery Rubber, Battery Bracket, Battery Rectifier/ Regulator Extended Wires Wire, Ground Wire, Battery Harness, Main Wire Bracket, Electrical Fuse Bracket, Cable Clamp, Wire, Stator
Q.TY1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 4 1
PAGE17 17 17 15 39 15 15 15 15 15 15 15 15 15 15 14 39 39 39 39 40 40 40 40 39 39 39 39 40 26 26 40 40 40 40 40 40 40 40 12
ITEM30 3 2 17 12 13 14 16 10 12 9 1 4 8 11 8 10 21 20 19 28 29 35 33 9 8 2 15 20 14 7 30 32 25 26 23 15 24 2 22
P/N33100203-000 33100204-000 33122201-000 33400182-000 33401201-000 33402201-000 33450182-000 33451201-000 33700208-000 33702202-000 33708182-000 33711205-000 33716205-000 33741131-000 33905201-000 34901201-000 34906201-000 34909201-000 34912203-000 34913201-000 34916201-000 35100221-000 35101131-000 35102211-000 35106206-000 35151204-000 35160151-000 37200212-000 37201159-000 37202202-000 37203204-000 37205202-002 37800201-000 38110119-000 38302133-000 38501119-000 40520182-000 40530159-000 40539202-000 40541201-000
DESCRIPTIONAsm., Low Beam Asm., Hight Beam Bracket, Headlight Asm., Signal, Front, RH Socket, Right Signal Lens, Signal Asm., Signal, Front, LH Socket, Signal, LH Asm,. Taillight Lens, Taillight License Plate Socket, Taillight Gasket Reflector Bulb, Signal Bulb Bulb, Taillight Bulb, Parking Sensor Switch, Shift Control Switch, Brake Asm., Main Switch Clip, Main Switch Switch, Main Lock, Steering Asm., Switch, LH Asm., Manual Choke Asm., Speedometer Bracket, Speedometer Sensor, Speedometer Magnet, Speedometer Asm., Speedometer Sensor, Fuel Horn Relay, Signal Asm., Starter Relay Cover, Sprocket Asm., Drive Chain Fixed Bracket, Chain Tensioner Spring
Q.TY1 1 4 2 2 4 2 2 1 1 1 1 1 1 4 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
PAGE38 38 38 38 38 38 38 38 38 38 38 38 38 38 38 38 38 38 40 40 33 40 40 40 40 34 34 40 41 40 40 40 40 41 40 40 36 36 36 36
ITEM1 10 5 31 32 11 14 13 28 26 19 24 29 17 12 2 25 8 17 19 18 3 7 4 6 22 21 10 41 39 40 38 36 44 9 22 11 12 5 9
45
PART NO. INDEXP/N40543156-000 40545201-000 40550156-A00 41201156-000 41202156-000 41210156-000 42000158-000 42010202-000 42616131-000
DESCRIPTIONAdjuster, Chain Roller, Chain Tensioner Cover, Rear Sprocket, Drive, Final Washer, Sprocket Hub, Sprocket Axle Hub, Wheel Valve, Rim
Q.TY1 1 1 1 2 1 1 2 2 2
PAGE36 36 33 35 35 35 35 31 30 31 30 30 30 31 31 33 33 31 32 33 33 33 32 32 33 33 33 33 33 30 30 33 30 32 33 33 32 33 32 32
ITEM3 8 33 4 7 5 6 1 6 10 14 13 9 8 2 21 24 4 11 9 16 19 4 5 10 14 29 7 2 5 2 3 4 21 30 31 19 1 12 14
P/N45409159-000 45410159-000 45421133-000 45450182-000 45450204-000 45454203-000 45455203-000 45456111-000 45456156-604 45457203-000 50100182-A01 50106158-000 50351202-000 50355202-000 50357202-000 50371201-000 50372201-000 50455182-A00 50460182-000 50480156-000 50495182-A00 51101156-00B 51102156-00B 51105156-000 51111156-000 51112205-A00 51120156-000 51220156-000 51300131-000
DESCRIPTIONArm, Front Brake, RH Arm, Front Brake, LH Bolt, Insert Hose, Brake Cable, Front Brake Asm.,Cable, Brake Pedal Cable, Pedal, RH Bolt, Banjo Bolt, Banjo Cable, Pedal, LH Asm., Frame Shield, Chassis Bracket, Engine Mount, RH Bracket, Engine Mount, RH Bracket, Rear Cable Bracket, Engine Mount, LH Bracket, Engine, RH Bumper Cover, Headlight Shield, Heat Bracket, Front Rack Spring, Suspension, Front Tube, Inner, Suspension, Front Bracket, Footwell, RH Post, Streering Shaft, Steering Bracket, Footwell, LH Sleeve, Steering Shaft Valve, Grease
Q.TY1 1 3 1 2 1 1 2 4 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 2 1 1 2 2 4
PAGE32 32 32 33 32 32 32 33 12 32 23 23 23 23 33 23 23 24 24 25 24 29 29 23 37 37 23 37 23 25 23 25 37 37 37 37 37 29 29 23
ITEM16 20 2 6 10 1 7 5 13 6 28 27 2 24 15 23 6 7 5 1 1 3 4 8 19 20 25 2 19 10 14 12 4 5 6 14 12 6 7 18
42701182-000 42711209-000 42730151-000
Rim, Front Tire Cap, Hub
2 2 2 2
42801182-000 42803206-A00 42810156-001 42811162-001 43120111-00C 43421201-000 43421202-000 43450182-000 43452133-001 43453133-001 43456204-000 43457201-000 43490182-000 43500182-000 43510201-000 44311156-000 44312156-000 45000182-000 45008156-000 45010156-000 45010182-000 45016131-00K 45020156-001 45120182-000 45141156-000 45142156-000
Rim, Rear Asm., Housing, Rear Axle Tube, Spacer Tire Shoe, brake, Rear Spring Spring, Switch Cable,Hand Brake, Rear Arm, Swing Bracket, Pedal Lever, Brake, Foot Arm, Master Cylinder Hub, Disc Asm., Master Cylinder Bracket, Pads Spacer Spacer Asm., Caliper, Rear Drum, Brake, Front Plate, Front Brake, LH Disc,Brake Bolt Plate, Front Brake, Rh Pads, Brake Shaft, Cam, Front Brake Indicator, Brake
2 1 1 2 2 1 1 1 1 1 1 1 1 1 1 2 2 1 2 1 1 3 1 1 2 2
51301131-000
Cap, Valve, Grease
2 4
51317156-000 51318156-000 51319156-000 51325202-000 51330202-000 52401156-001 52402156-000 52410182-A03
Spacer Bracket, Wire Collector Washer, Lock Asm., Steering Knuckle, LH Asm., Steering Knuckle, RH Spring, Suspension, Rear Shock, Rear Arm, Swing
2 1 1 1 1 1 1 1
46
PART NO. INDEXP/N52415156-000 52420131-000 52422131-000 52423156-000 52424156-000 52426156-000 52524131-000 53030202-00A 53100182-A00 53130202-00A 53135203-000 53140156-000 53167201-000 53170201-000 53171204-000 53172201-000 53173131-000 53174201-000 53175180-000 53176201-000 53177131-000 53178131-000 53200204-000 53210204-000 53220204-000 53310181-00A 53410202-000 53500156-000 53910182-000 53922182-000 61000182-485 61000182-617 61005182-000 61010182-000 61100182-485 61100182-617 61105182-000 61110182-000 61300182-485 61300182-617
DESCRIPTIONShaft, Suspension, Rear Tube, Spacer Cover, Swing Arm Seal Sleeve, Rubber Cap, Dustproof Cap, Rubber Seat, Grease Contain Arm, Suspension, Silver, RH Handlebar Arm, Suspension, Silver, LH Bushing Spacer Grip, Handlebar Perch, lever, LH Asm., Lever LH Asm., Lever, RH Sensor, Brake Wire, Brake Switch Lever, Brake, RH Seat, Lever, RH Bracket, Brake Cable Lever, Brake, LH Clamp, Lower Clamp, Upper, LH Clamp, Upper, RH Bracket, Pod Asm., Tie Rod Clamp, steering Cable, Throttle Choke, Cable, Manual Cab, Rear (red) Cab, Rear (green) Mudflap, Rear, RH Mudflap, Rear, LH Cab, Front (red) Cab, Front (green) Mudflap, Front, RH Mudflap, Front, LH Cover, Front Fender (red) Cover, Front Fender (green)
Q.TY1 1 2 1 4 8 2 1 1 1 8 4 2 1 1 1 1 1 1 1 1 1 2 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1
PAGE29 23 23 23 37 25 23 25 34 25 25 25 34 34 34 34 34 34 34 34 34 34 34 34 34 34 37 37 34 34 26 26 26 26 26 26 26 26 26 26
ITEM5 21 17 20 11 7 15 5 23 13 8 9 1 17 16 2 14 8 5 3 6 15 11 24 26 30 8 3 10 9 17 17 13 21 6 6 4 23 1 1
P/N64211181-000 64212182-000 64300156-000 64310156-001 64319131-000 77200182-000 77210131-000 77220131-000 80140131-000 81111182-A00 81113153-000
DESCRIPTIONPod, Handlebar Shield, Pod Footwell, RH Footwell, LH Rubber, Fuel Tank Seat Hook, Seat Rubber, Seat Decal, Isolation Bracket, Rear Rack Rubber
Q.TY1 1 1 1 2 1 1 2 1 1 1 2 1
PAGE34 34 25 25 28 27 27 23 26 24 21 24 26 24 28 42 42 42 42 42 42 42 42 42 42 34 34 40 23 14 33 34 38 32 9 36 34 34 16 9
ITEM32 28 18 16 6 1 2 12 22 12 19 11 24 10 4 10 3 1 8 5 6 2 4 7 9 35 27 27 13 10 20 13 30 22 28 6 4 18 8 27
81121182-A00 83574131-000 87711162-000 87716208-000 87720209-000 87721209-000 87851159-000 87852159-000 87854202-000 87858156-001 87869131-000 87871204-000 88110204-000 88120201-001 89120119-000 89569131-000 89669-119-001 89768151-000
Bracket, RH Cap Decal, AEON, Logo Decal, OVERLAND 180 Decal, Tank, RH Decal, Tank, LH Decal, Waring Decal, General Waring Decal , Waring, Reverse Decal, Waring, Chain Decal, Warning, Rack Decal, Fragile, Frame Mirror, RH Mirror, LH Pouch, Tool Strap Clamp Strap
2 2 1 2 1 1 1 1 1 1 2 1 1 1 1 21 1 1 1 2
89769111-000 90012-06015 90108-080158-00K 90115-090228-000 90116-090238-00K 90202-28000-00C 90206-05000-00A
Strap Screw, Tappet Adj. Bolt Bolt, Brake lever, RH Bolt Nut Nut, Tappet Adj.
1 2 1 1 1 1 2
47
PART NO. INDEXP/N90301-08000-00C 90344-06000-00C 90345-04000-02T
DESCRIPTIONNut Nut, U-Plate U-Nut
Q.TY2 4 2 2
PAGE22 26 26 34 41 24 25 26 38 17 25 34 17 36 19 34 23 30 31 37 23 37 31 32 30 20 17 41 17 34 9 9 19 19 39 17 32 36 37 33
ITEM19 8 5 29 42 8 4 20 20 37 14 7 25 4 1 12 7 7 3 17 16 10 9 3 8 4 34 43 39 25 8 34 22 20 1 1 17 1 7 17
P/N92001-080208-0KL 92003-060168-00K
DESCRIPTIONBolt Bolt
Q.TY2 2 2
PAGE33 24 26 38 23 25 26 28 40 12 10 34 38 40 26 40 24 25 26 34 38 40 9 9 10 17 37 12 39 12 16 26 38 14 21 34 40 40 26 32
ITEM28 6 3 7 26 17 12 5 14 18 1 20 3 13 9 5 4 2 18 31 18 8 4 14 3 31 18 2 18 10 14 15 27 9 7 19 12 16 10 8
92005-060128-00K 92005-060168-00K
Bolt Bolt
4 5 8 4 2 2
90350-04000-00K 90350-05000-00K
Nut Nut
2 8 4 40 10
90350-06000-00K
Nut
2 8 2
92005-060258-00K 93000-060068-00K 93100-030048-00B 93100-030068-00B 93100-040168-00K 93100-050128-00K
Bolt Screw Screw Screw Screw Bolt
2 1 2 2 2 8 2
90350-08000-0UK
Nut
1 1
90350-10000-00C
Nut
1 2
90350-10000-0UC
Nut
2 8 8 1
93100-050168-00K
Bolt
8 4 32 3 10 4
90350-14000-0UC 90352-10000-00C 90352-14000-00C 90353-08000-00G 90353-14000-00C 90471-04014 91000-050098-00K 91000-050168-00K 91000-060258-00K 91000-080258-00K 91001-060728-00C 91001-080328-00C 91001-081818-00C 91001-081878-00C 92000-050128-00C 92000-060108-00C 92000-060308-00B 92000-080608-00B
Nut Nut Nut Nut Nut Key, Woodruff Bolt Bolt Bolt Bolt Stud Stud Stud Stud Bolt Bolt Bolt Bolt
1 6 2 3 2 1 1 2 2 4 2 2 2 2 2 2 2 1 2
93210-00227 93210-00915
O-Ring O-Ring
1 2 1
93210-01425 93210-01525 93210-01835 93210-02431 93210-03132 93210-03920 93210-04635 93500-035398-SUS 93500-040258-00K 93500-050108-00K 93500-060088-00K 93501-030108-00K
O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring Bolt Bolt Bolt Bolt Bolt
1 2 1 1 1 2 2 2 1 2 1 2 1
93800-060168-00K 93902-060088-00B
Bolt Bolt
4 2
92001-080148-0KL
Bolt
2
48
PART NO. INDEXP/N93902-060308-00B 93903-1040128-00K
DESCRIPTIONScrew Screw
Q.TY2 2 2 2
PAGE13 21 26 34 14 38 21 7 40 40 32 38 35 35 38 9 13 27 38 39 40 19 40 9 36 25 29 15 16 39 39 41 17 24 25 26 38 38 25 38
ITEM6 13 2 33 12 9 10 2 1 18 15 4 1 3 15 2 4 3 22 17 11 9 21 25 2 11 2 27 10 6 14 45 33 9 3 19 21 16 15 23
P/N94101-0816015-00C 94101-0816020-00L 94101-0818023-00U 94101-0822020-00C 94101-1015012-U0B 94101-1022010-00U 94101-1022020-00C 94101-1221320-00L
DESCRIPTIONWasher Washer Washer Washer Washer Washer Washer Washer
Q.TY3 2 4 2 4 1 1 8 1
PAGE17 19 9 22 33 37 19 12 19 15 15 39 15 30 31 32 39 22 22 38 14 23 24 37 33 30 31 35 26 26 18 29 37 30 31 33 32 12 14 17
ITEM26 12 26 12 4 16 2 12 16 15 26 7 7 12 5 13 13 14 16 6 7 4 2 15 13 11 6 2 11 16 46 8 9 10 7 12 9 4 2 8
93903-1040168-00K 93903-1050128-00K 93903-2050208-00K 93904-3050168-00K 93906-1030088-00K 94001-03000-00K 94001-06000-00C 94001-06000-00K 94001-33000-00K 94002-10000-00C 94050-05000-00C 94050-06000-00C
Screw Screw Screw Screw, Tappinmg Screw, Tapping Nut Nut Nut Nut Nut Nut Nut
1 4 7 4 4 1 2 4 2 4 1 2 1 2 2 1 2
94101-1225023-000
Washer
1 1 1
94101-1422012-00K 94101-1443030-00C
Washer Washer
1 2 2
94101-1722010-00K 94101-2231025-000 94102-0613010-000 94102-0817020-000 94111-0610010-00K 94111-0611020-00K 94111-1001502-00K 94121-0816010-00K 94121-1020010-000 94121-1221005-000 94121-1426016-000
Washer Washer Gasket Gasket Washer, Spring Washer, Spring Washer, Spring Washer Washer Washer Washer
2 1 2 2 4 1 6 16 4 1 2 2
94050-06000-00K
Nut
1 2
94050-08000-00C
Nut
4 1
94050-10000-00C
Nut
4 4
94050-12000-00C
Nut
1 1 1
94121-3345012-000 94150-0717050-00K 94150-0717075-00K 94201-25190
Washer Washer Washer Pin, Cotter
2 2 2 1 1 7
94071-22000-000 94101-0412010-00K 94101-0510010-00B 94101-0514010-00K
Nut, Lock Washer Washer Washer
1 2 1 8 4 40 10
94201-32320
Pin, Cotter
2 2
94203-12200 94205-02052 94301-08140
Cotter Pin Pin Pin, Dowel
1 1 2 2 2
94101-0519010-00K 94101-0613010-00K 94101-0619010-00C
Washer Washer Washer
1 8 2
49
PART NO. INDEXP/N94301-08140 94301-10140
DESCRIPTIONPin, Dowel Pin, Dowel
Q.TY2 4 2
PAGE19 9 11 33 28 28 28 28 21 17 21 21 28 21 28 28 21 28 16 15 16 36 40 22 13 15 17 18 33 34 40 40 18 28 39 39 39 10 14 18
ITEM4 9 3 11 7 13 14 17 21 5 23 3 16 25 9 12 20 8 2 21 22 7 34 13 1 5 36 47 8 34 31 37 51 11 5 16 3 2 6 42
P/N96000-060258-08C
DESCRIPTIONBolt
Q.TY3 4
PAGE7 8 21 12 14 19 19 19 12 9 12 14 12 23 33 19 36 36 22 24 24 33 23 23 23 29 23 25 19 19 23 37 33 33 30 17 33 17 17 17
ITEM6 1 18 3 3 23 8 14 19 33 21 5 20 9 32 13 13 10 11 3 13 27 10 11 3 1 1 6 6 15 22 13 26 25 3 10 23 14 16 20
96000-060328-16C 96000-060408-08C
Bolt Bolt
1 1 7
94302-07018 94401-05009-001 94401-05009-050 94401-05009-150 94403-04008-300 94404-08012-000 94408-05007-170 94509-08500 94509-09000 94510-06000 94510-08000
Pin Hose, Fuel Hose, Fuel Hose, Fuel Tube, Oil Hose, Drain Hose Clamp Clamp Clip Clamp
1 1 1 1 1 1 1 1 1 1 1 1 5
96000-060508-00C 96000-060608-08C 96000-060708-08C 96000-060958-08C 96000-061008-08C
Bolt Bolt Bolt Bolt Bolt
1 4 3 5 2 1 1
96000-061108-08C 96000-080128-00K
Bolt Bolt
2 8 2
96000-080128-10C 96000-080148-00K 96000-080168-00K 96000-080168-0KL
Bolt Bolt Bolt Bolt
2 1 4 2 14
94510-12000
Clamp
2 1
94511-0700E 94512-2800R 94512-280IR 94513-1020E 96000-050208-00C 96000-060108-00B 96000-060128-08C
Clip, Cir Clip, Cir Clip, Cir E-Clip Bolt Bolt Bolt
3 2 1 1 1 2 2 1
96000-080208-0KL 96000-080388-0KL 96000-080408-00K 96000-081258-00K 96000-100208-0KL 96000-100408-0KL 96000-100438-0KL 96000-100758-0KL 96000-101978-14C 96000-120158-14C 96000-142908-00C 96004-101058-00K 96008-120288-0CL 96008-120328-0CL 96100-60030-ZZ000 96100-60050-U0000 96100-60070-ZZ000 96100-62020-00000 96100-62030-00000 96100-62040-JR2C3
Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bolt Bearing, Ball Bearing, Ball Bearing, Ball Bearing, Ball Bearing, Ball Bearing, Ball
2 2 3 1 6 5 2 4 1 1 1 2 1 3 4 1 2 4 1 1
96000-060128-10C 96000-060128-10K
Bolt Bolt
2 2 1 2 1 1
96000-060168-00K
Bolt
1 1
96000-060188-08C
Bolt
4 2
96000-060208-08C 96000-060228-14C 96000-060258-00K
Bolt Bolt Bolt
2 2 1 1
50
PART NO. INDEXP/N96100-69020-U0000 96100-TMB30-10000 96200-202918 96200-283217 96220-30085 96400-082223
DESCRIPTIONBearing, Ball Bearing, Ball Bearing, Needle Bearing, Needle Rollor Bushing, Rubber
Q.TY1 1 1 1 1 2 2
PAGE16 17 16 39 15 17 19 19 23 15 15 15 15 17 30 17 16 32 33 12 19 9
ITEM21 24 23 11 3 4 10 3 5 2 6 24 23 15 1 11 15 18 22 6 17 5
P/N
DESCRIPTION
Q.TY
PAGE
ITEM
96400-102822
Bushing, Rubber
2 2
96401-121612 96401-141816 96401-172451 96401-242830 96500-203206T3034 96500-233506A7271 96500-304707A7271 96500-34410400000 96500-4052060 96500-426208A7271 96501-19300500000
Bushing Bushing Bushing Bushing Seal, Oil Seal, Oil Seal, Oil Seal, Oil Seal, Oil Seal, Oil Seal, Oil
1 1 1 1 1 2 1 2 2 2 1 1
98076119-00A
Plug, Spark
1
51