YAMAHA K40J’03 PARTS CATALOGUE

K40J’03

(6H92)

1B6H9−200E1

FOREWORD

This Parts Catalogue is related to the parts for the model(s) in the below frame. When you are ordering replace­ment parts, please refer to this Parts Catalogue and quote both part numbers and part names correctly.

K40J’03(6H92)

1. Modifications or additions which have been made after issue of the Parts Catalogue will
be announced in the Yamaha Parts News.
It is advisable that you make necessary corrections to the Parts Catalogue according to
the Yamaha Parts News.

2. Abbreviations
The Following abbreviations are used in this Parts Catalogue.

“UR” Use specified parts number.

“UN” Use as many as needed.

“AP” Alternate Parts

“LM” Local Made

(Parts need to be ordered locally)

“O/S” Over Size

3. Parts, which are to be supplied in an assembly, are listed with a dot(.) in front of the part
name as shown below.

EXAMPLE

CARBURETOR ASSY

.JET, PILOT

.NOZZLE, MAIN

4. Number of component for assembly
The numeral appearing to the right of each component part indicates the quantity of
parts for each assembly unit.

EXAMPLE

PART NO. DESCRIPTION REMARKS

6E0−85500−70 C.D.I. MAGNETO ASSY 1

6E0−85550−70 .ROTOR ASSY 1

6E0−15723−00−94..PULLY, STARTER 1

E

EHT

EH

5. Quantity Column Information

NAME for Q’TY COLUMN

MH K40JMH

W K40JW

6. Applicable Starting Serial No. and Color Code

1) Engine Starting Serial No.

K40JMH S/L 6H9K : 1000001
K40JW S 6H9K : 1000001

2) Color Code

Color Code

004D DARK BLUISH GRAY METALLIC 2 DBNM2

7. Note that the illustrations for reference in finding parts numbers, not to be used for as­sembling. When assembling, please use the applicable service manual.

8. The asterisk (*) before a reference number indicates modification items after the first
edition.

Color Name Abbreviation

APPLICABLE MODEL

A2

CONTENTS

SHEET 1/2

TOP COWLING A4.....................................

CYLINDER. CRANKCASE A5............................

CRANKSHAFT. PISTON A7..............................

INTAKE B1............................................

CARBURETOR B3.....................................

FUEL 1 B5............................................

FUEL 2 B7............................................

STARTER C1..........................................

GENERATOR C3.......................................

ELECTRICAL 1 C4.....................................

ELECTRICAL 2 C5.....................................

STARTING MOTOR C7..................................

BOTTOM COWLING D1.................................

STEERING D3.........................................

CONTROL 1 D5........................................

CONTROL 2 D7........................................

BRACKET 1 E1........................................

BRACKET 2 E4........................................

UPPER CASING E6....................................

LOWER CASING. DRIVE 1 E7...........................

LOWER CASING. DRIVE 2 F4...........................

FUEL TANK F6........................................

STEERING GUIDE F7..................................

INDEX

NUMERICAL INDEX G1.................................

SHEET

REMOTE CONTROL BOX A4*............................

REMOTE CONTROL ASSY A5*...........................

SWITCH. PANEL B1*....................................

REPAIR KIT 1 B2*.......................................

REPAIR KIT 2 B4*.......................................

2/2

INDEX

NUMERICAL INDEX G1*.................................

A3

FIG. 1 TOP COWLING

REF.
NO.

10 92995−06600 .WASHER 4 4

11 6F5−42615−00 .SEAL 1 1

12 6F5−W0070−K0 .GRAPHIC SET 1 1

13 6F5−42678−K0 .GRAPHIC, REAR 1 1

14 69P−42677−H0 .GRAPHIC, FRONT 1 1

15 677−13437−08 .MARK, CAUTION 1 1

PART NO. DESCRIPTION REMARKS

1 6F5−42610−L0−4D TOP COWLING ASSY 1 1

2 6A0−15761−00 .SEAL, RUBBER 1 1 1

3 6E9−42651−01 .HOOK 1 1

4 90266−04M04 .RIVET 2 2

5 6F5−42652−01 .HOOK 1 1

6 90266−04M01 .RIVET 2 2

7 6F5−42613−01−4D .MOLDING, AIR DUCT 1 1

8 97095−06016 .BOLT 4 4

9 92995−06100 .WASHER, SPRING 4 4

MH

W

A4

FIG. 2 CYLINDER. CRANKCASE

REF.
NO.

10 93210−65M50 O−RING 1 1

11 93210−22M02 O−RING 1 1

12 93440−68M03 CIRCLIP 1 1

13 91690−30010 PIN, SPRING 1 1

14 676−45251−00 ANODE 1 1

15 97095−06016 BOLT 1 1

PART NO. DESCRIPTION REMARKS

1 6F5−W0090−63−1S CRANK CYLINDER ASSY 1 1

2 6F6−15100−00−1S CRANKCASE ASSY 1 1

3 624−14485−00 .PIPE, JOINT 1 1

4 650−11370−01 .CHECK VALVE ASSY 2 2

5 93608−12063 PIN, DOWEL 2 2

6 90119−10005 BOLT, WITH WASHER 10 10

7 6F5−15396−01−5B HOUSING, OIL SEAL 1 1

8 93101−30M33 OIL SEAL 2 2

9 93104−16M01 OIL SEAL 1 1

MH

W

A5

16 92995−06600 WASHER 1 1

17 676−11325−00 ANODE 1 1

18 90141−06M00 SCREW, COUNTERSUNK 1 1

19 6F5−11325−00 ANODE 1 1

20 97880−05030 SCREW, PAN HEAD 2 2

21 6F5−11119−00 HANGER, ENGINE 1 1

22 90101−08001 BOLT 1 1

23 6F5−11111−00−1S HEAD, CYLINDER 1 1 1

24 6F5−11181−A1 GASKET, CYLINDER HEAD 1 1 1

25 90119−08MA5 BOLT, WITH WASHER 11 11

26 6F5−11191−00−1S COVER, CYLINDER HEAD 1 1 1

27 6F5−11193−A1 GASKET, HEAD COVER 1 1 1

FIG. 2 CYLINDER. CRANKCASE

REF.
NO.

28 90119−06MA3 BOLT, WITH WASHER 5 5

29 6F5−12411−02 THERMOSTAT 1 1

30 676−12413−00−1S COVER, THERMOSTAT 1 1

31 676−12414−A1 GASKET, COVER 1 1

32 90119−06MA2 BOLT, WITH WASHER 4 4

33 6F5−41113−01−1S OUTER COVER, EXHAUST 1 1

34 650−24378−00 .PIPE, JOINT 4 1 1

35 6F5−41112−A0 GASKET, EXHAUST INNER COVER 1 1

36 6F5−41111−01−1S INNER COVER, EXHAUST 1 1

37 6F5−41114−A0 GASKET, EXHAUST OUTER COVER 1 1

38 90119−06MA3 BOLT, WITH WASHER 16 16

39 90445−09M37 HOSE (L240) 1 1

40 94702−00040 PLUG, SPARK (NGK B7HS) 2 2

PART NO. DESCRIPTION REMARKS

MH

W

A6

FIG. 3 CRANKSHAFT. PISTON

REF.
NO.

10 93440−68M03 .CIRCLIP 1 1

11 6F5−11651−00 .ROD, CONNECTING 2 2

12 6F5−11681−00 .PIN, CRANK 1 2 2

13 90202−27M23 .WASHER, PLATE 4 4

14 93310−727V7 .BEARING 2 2

15 6F6−11631−00−95 PISTON (STD) 2 2

PART NO. DESCRIPTION REMARKS

1 6F5−11400−10 CRANKSHAFT ASSY 1 1

2 6F5−11412−11 .CRANK 1 1 1

3 6F5−11422−11 .CRANK 2 1 1

4 6F5−11432−11 .CRANK 3 1 1

5 6F5−11442−11 .CRANK 4 1 1

6 93306−307U0 .BEARING 1 1

7 93332−000UE .BEARING 1 1

8 93306−306U2 .BEARING 1 1

9 6F5−11515−00 .SEAL, LABYRINTH 1 1 1

MH

W

A7

6F6−11635−00 PISTON (0.25MM O/S) 2 2 AP

6F6−11636−00 PISTON (0.50MM O/S) 2 2 AP

16 6F5−11610−00 PISTON RING SET (STD) 2 2

6F5−11610−10 PISTON RING SET (0.25MM O/S) 2 2 AP

6F5−11610−20 PISTON RING SET (0.50MM O/S) 2 2 AP

17 6F5−11633−00 PIN, PISTON 2 2

18 663−11634−00 CLIP, PISTON PIN 4 4

19 93603−21111 PIN, DOWEL 56 56

20 90201−20417 WASHER, PLATE 4 4

FIG. 4 INTAKE

REF.
NO.

10 90116−06M17 BOLT, STUD 4 4

11 97013−06065 BOLT 2 2

12 92903−06600 WASHER, PLATE 2 2

13 97013−06025 BOLT 7 7

14 92903−06600 WASHER, PLATE 7 7

15 90467−06016 CLIP 2 2

PART NO. DESCRIPTION REMARKS

1 6F5−13610−00 REED VALVE ASSY 2 2

2 6F5−W0004−00 .REED SET 1 1

3 6F6−13641−00−1S MANIFOLD 1 1 1

4 6F6−11370−01 .CHECK VALVE ASSY 1 1

5 650−11370−01 .CHECK VALVE ASSY 1 1

6 6F5−13646−A2 GASKET, MANIFOLD 2 1 1

7 97880−05014 SCREW, PAN HEAD 2 2

8 92990−05100 WASHER, SPRING 2 2

9 6F5−13621−A1 GASKET, VALVE SEAT 1 1

MH

W

B1

16 6F6−13643−01−1S COVER, MANIFOLD 1 1

17 97880−05014 SCREW, PAN HEAD 2 2

18 92990−05100 WASHER, SPRING 2 2

19 6F5−13621−A1 GASKET, VALVE SEAT 1 1

20 6F5−13645−A1 GASKET, MANIFOLD 1 1 1

21 624−14485−00 PIPE, JOINT 3 3

22 90467−06016 CLIP 1 1

23 6F5−14198−A1 GASKET 1 1

24 92995−06600 WASHER 4 4

25 95380−06600 NUT, HEXAGON 4 4

26 6F5−14417−00 COVER 1 1 1

27 6F5−14418−00 COVER 2 1 1

FIG. 4 INTAKE

REF.
NO.

28 90159−06M01 SCREW, WITH WASHER 3 3

29 97780−50716 SCREW, TAPPING 4 4

30 6F5−14476−00 SEAL 1 1

31 624−14485−00 PIPE, JOINT 1 1

32 90445−07240 HOSE (L330) 1 1

33 90467−06016 CLIP 1 1

34 6F5−14483−00 GASKET 1 1

35 6F5−41252−00 LEVER, CHOKE 1 1 1

36 682−41271−00 KNOB, CHOKE 1 1

37 689−41273−00 GROMMET 1 1

38 6F5−41256−00 ROD, CHOKE 1 1 1

39 661−41262−02 JOINT, CHOKE LEVER 2 2

40 91690−40032 PIN, SPRING 1 1

41 90445−07254 HOSE (L118) 1 1

42 90445−07240 HOSE (L330) 2 2

PART NO. DESCRIPTION REMARKS

MH

W

B2

43 90445−07M24 HOSE (L240) 1 1

44 90467−06016 CLIP 6 6

FIG. 5 CARBURETOR

REF.
NO.

10 647−14342−45 .JET, PILOT (# 90) 2 2

11 647−14342−30 .JET, PILOT (# 60) 2 2

12 6F5−14390−21 .NEEDLE VALVE ASSY 1 1

13 367−14195−00 .GASKET 2 2

14 98980−04006 .SCREW, BIND 2 2

15 6E5−14386−01 .PIN, FLOAT 1 1

PART NO. DESCRIPTION REMARKS

1 6F5−14301−42 CARBURETOR ASSY 1 1 1

2 6F5−14384−00 .GASKET, FLOAT CHAMBER 1 1

3 6F5−14381−00 .BODY, FLOAT CHAMBER 1 1

4 6F5−14341−00 .NOZZLE, MAIN 2 2

5 1J2−14398−00 .GASKET 2 2

6 677−14343−73 .JET, MAIN (#145) 2 2

7 6F6−14385−00 .FLOAT 1 1

8 6F5−14398−00 .GASKET 1 1

9 6F5−14383−00 .PLATE, COVER 1 1

MH

W

B3

16 6F5−14399−00 .GASKET 1 1

17 6F5−14182−41 .COVER, FLOAT CHAMBER 1 1

18 6F5−14390−12 .NEEDLE VALVE ASSY 1 1

19 367−14386−00 .PIN, FLOAT 1 1

20 6F5−14387−00 .ARM, FLOAT 1 1

21 6F5−14381−11 .BODY, FLOAT CHAMBER 1 1

22 6E5−14383−10 .SCREW, DRAIN 2 2

23 6E5−14398−00 .GASKET 2 2

24 626−14385−00 .FLOAT 1 1

25 6F5−14384−10 .GASKET, FLOAT CHAMBER 1 1

26 6F5−14397−00 .O−RING 1 1

27 6F5−14372−01 .SEAT, PACKING 2 2

FIG. 5 CARBURETOR

REF.
NO.

28 6A4−14355−00 .SEAT, BALL 1 1

29 6F5−14332−01 .SPRING 1 1

30 6F5−14369−00 .BALL 1 1

31 6F5−14370−02 .PLUNGER STARTER ASSY 1 1

32 6F5−14339−00 .SPRING 1 1

33 6A4−14394−00 .SCREW, DRAIN 1 1

34 652−14397−00 .O−RING 1 1

35 6F5−14371−00 .PLUNGER, STARTER 1 1

36 647−14344−35 .JET, STARTER (# 70) 1 1

37 6F5−14377−00 .STOPPER 1 1

38 97603−04114 .SCREW, PAN HEAD WITH WASHER 8 8

39 97603−06120 .SCREW, PAN HEAD WITH WASHER 2 2

40 6F5−14323−01 .SCREW, AIR ADJUSTING 2 2

41 6F5−14334−01 .SPRING, AIR ADJUSTING 2 2

42 6F5−41262−01 .JOINT, THROTTLE LEVER 2 2

PART NO. DESCRIPTION REMARKS

MH

W

B4

43 6F5−14379−00 .ROD, STARTER 1 1

44 650−14321−01 .SCREW, THROTTLE 1 1

45 647−14334−00 .SPRING 1 1

46 6F5−14346−00 .PLATE 1 1

47 654−14243−00 .WASHER 4 4

48 97603−06113 .SCREW, PAN HEAD WITH WASHER 4 4

49 97603−05117 .SCREW, PAN HEAD WITH WASHER 4 4

50 6F5−14340−00 .NOZZLE, ACCELERATING 1 1

51 6F5−14425−00 .DAMPER 1 1 1

52 90445−09M55 .HOSE (L20) 2 2

53 6F5−14397−00 .O−RING 1 1

54 6F5−13940−01 .CHECK VALVE ASSY 1 1

FIG. 6 FUEL 1

REF.
NO.

10 61N−24563−00 .ELEMENT, FILTER 1 1

11 61N−24521−00 .CUP, FILTER 1 1

12 93210−32738 .O−RING 1 1

13 6F5−24566−00 BRACKET, FILTER 1 1

14 95380−08600 NUT 2 2

15 97013−06014 BOLT 1 1

PART NO. DESCRIPTION REMARKS

1 680−24304−01 FUEL PIPE JOINT COMP. 1 1 1

2 97095−06025 BOLT 1 1

3 92995−06600 WASHER 1 1

4 6A4−24329−00 SEAL 1 1

5 90445−09226 HOSE (L390) 1 1

6 90445−10M43 HOSE (L400) 1 1

7 90467−08004 CLIP 2 2

8 90467−09M03 CLIP 2 2

9 61N−24560−00 FILTER ASSY 2 2

MH

W

B5

16 90445−09M54 HOSE (L225) 1 1

17 90445−10M50 HOSE (L170) 1 1

18 90467−08004 CLIP 2 2

19 90467−09M03 CLIP 2 2

20 6F5−24410−06 FUEL PUMP ASSY 1 1

21 677−24444−01 .SCREW 4 4

22 677−24413−01 .BODY 2 1 1

23 677−24471−01 .DIAPHRAGM 1 1

24 677−24435−02 .GASKET, BODY 2 1 1

25 682−24412−01 .BODY 1 1 1

26 677−24411−02 .DIAPHRAGM 1 1

27 677−24434−02 .GASKET, BODY 1 1

FIG. 6 FUEL 1

REF.
NO.

28 648−24434−01 .GASKET, BODY 1 1

29 648−24411−00 .DIAPHRAGM 1 1

30 648−24424−00 .SEAT, SPRING 1 1

31 648−24423−00 .SPRING, DIAPHRAGM 1 1

32 6A0−24421−01 .VALVE, CHECK 4 4

33 6A0−14325−00 .SCREW, PAN HEAD 2 2

34 6E7−14325−00 .SCREW, PAN HEAD 2 2

35 95380−03600 .NUT 4 4

36 663−24411−00 .DIAPHRAGM 1 1

37 648−24435−02 .GASKET, BODY 2 1 1

38 6A0−24413−00 .BODY 2 1 1

39 98503−05028 .SCREW, PAN HEAD 3 3

40 92990−05100 .WASHER, SPRING 3 3

41 6A0−24412−02 .BODY 1 1 1

42 650−24431−A0 GASKET, FUEL PUMP 1 1 1

PART NO. DESCRIPTION REMARKS

MH

W

B6

43 97095−06055 BOLT 2 2

44 92995−06600 WASHER 2 2

45 90445−09M53 HOSE (L160) 1 1

46 90445−10M50 HOSE (L170) 1 1

47 90467−08004 CLIP 2 2

48 90467−09M03 CLIP 2 2

49 676−W2810−01 TOOL KIT 1 1

50 626−28193−01−94 PLUG, WATER CHECK 1 1 AP D:15MM

FIG. 7 FUEL 2

REF.
NO.

PART NO. DESCRIPTION REMARKS

1 6Y3−24306−04 FUEL PIPE COMP. 1 1 AP

2 90445−11M06 .HOSE (L2050) 1

3 61J−24360−00 .PRIMER PUMP ASSY 1

4 90445−11M05 .HOSE (L850) 1

5 650−24351−01 .BAND 1 4

6 680−24305−01 .FUEL PIPE JOINT COMP. 2 1

7 93210−08287 ..O−RING 2

8 90445−11M81 .HOSE (L3000) 1

MH

W

B7

FIG. 8 STARTER

REF.
NO.

10 97013−08030 .BOLT 1 1

11 6F5−15726−01 .WASHER, FLAT 1 1

12 95303−08700 .NUT 1 1

13 * .WIRE (L:1900MM) 1 1

14 689−15755−01 .HANDLE, STARTER 1 1

15 6F5−15764−00 .COLLAR 1 1 1

PART NO. DESCRIPTION REMARKS

1 6F5−W1571−02 STARTER ASSY 1 1

2 6F5−15711−01 .CASE, STARTER 1 1

3 6F5−15714−03 .DRUM, SHEAVE 1 1

4 6F5−15741−01 .PAWL, DRIVE 1 1

5 6F5−15713−00 .SPRING, STARTER 1 1

6 6F5−15715−00 .SPRING, FRICTION 1 1

7 6F5−15734−01 .SPRING, RETURN 1 1

8 6F5−15716−01 .PLATE, DRIVE 1 1

9 6F5−15754−00 .BUSH 2 1 1

MH

W

C1

16 6F5−15752−00 .ROLLER, WIRE 1 1

17 6F5−15753−00 .BUSH 1 1

18 6F5−15791−00 .WASHER, LOCK 1 1

19 6F5−15768−00 .BOLT 1 1

20 6F5−15739−00 .WASHER, THRUST 1 1

21 6F5−15779−02 .COVER 1 1

22 6F5−15723−01 PULLEY, STARTER 1 1

23 90105−08M10 BOLT, FLANGE 3 3

24 90119−08M10 BOLT, WITH WASHER 3 3

25 90385−12M04 BUSH 6 6

*

CUT FROM 50M ROLLS, PART NO. 90890−44373,
CUTTING LENGTH 1.9M

FIG. 8 STARTER

REF.
NO.

26 90387−08M05 COLLAR 3 3

27 6A0−15758−01−94 GUIDE, ROPE 1 1

28 97095−06016 BOLT 2 2

29 92995−06600 WASHER 2 2

30 6A0−15762−00 SEAL, RUBBER 2 1 1

31 6A0−15789−00 DAMPER 1 1

32 6F5−15771−00−94 STAY 1 1 1

33 97013−08035 BOLT 2 2

34 92903−08600 WASHER, PLATE 2 2

35 6F5−15772−00−94 STAY 2 1 1

36 97013−08035 BOLT 2 2

37 92903−08600 WASHER, PLATE 2 2

38 6F5−15747−00 LINK 1 1

39 6F5−15746−00 ARM 1 1

40 6F5−15770−00 CABLE COMP., STARTER STOP 1 1

PART NO. DESCRIPTION REMARKS

MH

W

C2

41 6F5−15774−00 STAY 4 1 1

42 6F5−15773−00 STAY 3 1 1

43 656−15748−00 PLUNGER, STARTER STOP 1 1

44 90501−10227 SPRING, COMPRESSION 1 1

45 97095−06016 BOLT 1 1

46 92995−06600 WASHER 1 1

47 97095−06030 BOLT 1 1

48 92995−06600 WASHER 1 1

49 90387−06M29 COLLAR 1 1

50 661−41262−02 JOINT, CHOKE LEVER 2 2

51 6F6−14488−00 LABEL, CAUTION 1 1

FIG. 9 GENERATOR

REF.
NO.

10 93102−35M18 .OIL SEAL 1 1

11 6F5−85515−00 .LEAD WIRE ASSY 1 1

12 90280−05015 KEY, WOODRUFF 1 1

13 90170−20137 NUT 1 1

14 90201−21M18 WASHER, PLATE 1 1

PART NO. DESCRIPTION REMARKS

1 6F5−85550−A2 ROTOR ASSY 1

6F5−85550−F2 ROTOR ASSY 1

2 6F5−85560−A2 BASE ASSY 1 1

3 6F5−85520−00 .COIL, CHARGE 1 1

4 90159−05040 .SCREW, WITH WASHER 2 2

5 6F5−85533−00 .COIL, LIGHTING 1 1

6 90159−05040 .SCREW, WITH WASHER 2 2

7 6F5−85580−00 .COIL, PULSER 1 1

8 90159−04063 .SCREW, WITH WASHER 2 2

9 90159−04035 .SCREW, WITH WASHER 1 1

MH

W

C3

15 93210−75M51 O−RING 1 1

16 97095−06040 BOLT 3 3

17 92995−06600 WASHER 3 3