VK540ECZ (8HT1) RUSSIAN FEDERATION
1J8HT-370E1
()
VK540ECZ
PARTS CATALOGUE
©2009 by Yamaha Motor Co., Ltd.
1st edition, July 2009
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan.
FOREWORD
This Parts Catalogue is related to the parts for the model(s) on the cover page. When you are
ordering replacement parts, please refer to this Parts Catalogue and quote both part numbers
and part names correctly.
1. Modifications or additions which have been made after the issue of the Parts Catalogue
will be announced in the Parts News.
It is advisable that you make the necessary corrections to the Parts Catalogue according
to the 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” Locally Made (Parts need to be ordered locally)
“F#” Frame No. (Applicable machine No.)
“O/S” Over Size
3. The number of components for assembly
• Parts, which are to be supplied in an assembly, are listed with a dot (.) in front of the
part name as shown below.
• The numeral appearing to the right of each component part indicates the quantity of
parts for each assembly unit.
PART NO. DESCRIPTION Q’TY REMARKS
2F5–83310–60 FRONT FLASHER LIGHT ASSY 2
115–83311–60 .BULB (6V–18W) 1
6. The asterisk (*) before a reference number indicates modified items after the first edition.
4. Applicable colours of graphics are represented in the “REMARKS” as shown below.
PART NO. DESCRIPTION Q’TY REMARKS
2N4–24110–00–X5 FUEL TANK COMP. 2 MXR
3J1–24240–10 .GRAPHIC, FUEL TANK 1 FOR MXR
5. Note that the illustrations for reference in finding parts numbers are not to be used for
assembling. When assembling, please use the applicable service manual.
FOREWORD
7. Applicable Serial No.
Engine Serial No. Frame Serial No.
8. Applicable Colour Code (The (*) mark shows Model colour.)
Abbreviation Colour Name Colour Code
RW(*) RADICAL WHITE 00UJ
10. Applicable Starting Serial No.
Frame Serial No.
Serial No. Name Of Q’ty Column Model Code
JYE8HT004AA000053 8HT1 8HT1
9. Quantity Column Information
Column No. Name Of Q’ty Column Destination
1 8HT1 RUSSIAN FEDERATION
ENGINE
CYLINDER HEAD ................................................................. 1
CRANKSHAFT & PISTON .................................................... 2
AIR SHROUD & FAN ............................................................4
OIL PUMP ............................................................................. 6
PUMP DRIVE GEAR .............................................................7
INTAKE .................................................................................8
CARBURETOR .....................................................................10
EXHAUST .............................................................................12
CRANKCASE ........................................................................13
STARTER ..............................................................................14
DRIVE
PRIMARY SHEAVE ..............................................................15
SECONDARY SHEAVE ........................................................ 17
BODY
ENGINE BRACKET ............................................................... 18
OIL TANK .............................................................................. 19
FRAME ..................................................................................20
SKI ......................................................................................... 23
STEERING ............................................................................26
STEERING GATE ................................................................. 28
FUEL TANK ........................................................................... 29
SEAT .....................................................................................31
BRAKE ..................................................................................32
CONTROL CABLE ................................................................ 33
TRACK SUSPENSION 1 ....................................................... 34
TRACK SUSPENSION 2 ....................................................... 36
TRACK SUSPENSION 3 ....................................................... 40
TRACK DRIVE 1 ...................................................................41
TRACK DRIVE 2 ...................................................................42
TRACK DRIVE 3 ...................................................................45
SHROUD ...............................................................................47
EMBLEM ...............................................................................50
WINDSHIELD ........................................................................51
GUARD & LUGGAGE BOX ................................................... 52
BUMPER ...............................................................................53
INSTRUMENT PANEL .......................................................... 55
ELECTRICAL
GENERATOR ........................................................................57
CONTENTS
STARTING MOTOR ............................................................. 58
METER ................................................................................. 59
HEADLIGHT ......................................................................... 60
TAILLIGHT ............................................................................ 61
HANDLE SWITCH & LEVER ................................................ 62
ELECTRICAL 1 ..................................................................... 63
ELECTRICAL 2 ..................................................................... 65
ALTERNATE REBUILD KIT .................................................. 66
ALTERNATE CLUTCH TUNE UP KIT .................................. 67
INDEX
NUMERICAL INDEX ............................................................. 68
FIG. 1 CYLINDER HEAD
REF.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
PART NO. DESCRIPTION
8R6–11111–00
94702–00188
83R–11161–00
83R–11181–00
90116–08104
95707–08500
90179–08269
90201–08100
83R–11311–00
83R–11162–00
95612–08318
89N–11351–00
90116–08302
90179–08268
HEAD, CYLINDER 1 2
PLUG, SPARK (NGK BR9ES) 2
ABSORBER 1 12
GASKET, CYLINDER HEAD 1 2
BOLT, STUD 12
NUT, FLANGE 8
NUT 4
WASHER, PLATE 4
CYLINDER 1 2
ABSORBER 2 8
BOLT, STUD 4
GASKET, CYLINDER 1
BOLT, STUD 8
NUT 8
8HT1
REMARKS
1
FIG. 2 CRANKSHAFT & PISTON
REF.
NO.
1
PART NO. DESCRIPTION
8R6–11631–00–95
PISTON (STD) 2
8HT1
REMARKS
8R6–11635–00
8R6–11636–00
2
8R6–11601–00
8R6–11601–10
8R6–11601–20
3
8H8–11633–00
4
93450–21053
5
93310–320G0
6
8AT–11400–01
7
83R–11412–01
8
8H8–11422–01
9
8H8–11432–01
10
8AT–11442–00
11
90209–24073
12
8R6–11651–00
13
93310–524K4
14
8H8–11515–00
PISTON (0.25MM O/S) 2 AP
PISTON (0.50MM O/S) 2 AP
PISTON RING SET (STD) 2
PISTON RING SET (0.25MM O/S) 2 AP
PISTON RING SET (0.50MM O/S) 2 AP
PIN, PISTON 2
CIRCLIP 4
BEARING 2
CRANKSHAFT ASSY 1
.CRANK 1 1
.CRANK 2 1
.CRANK 3 1
.CRANK 4 1
.WASHER 2
.ROD, CONNECTING 2
.BEARING 2
.SEAL, LABYRINTH 1 1
15
91609–30010
16
93306–30627
17
93306–30628
18
90201–33299
19
93306–20617
20
93306–20620
21
93103–32095
22
8K2–13178–00
23
8A7–11685–00
.PIN, SPRING 1
.BEARING 1
.BEARING 1
.WASHER, PLATE 1
.BEARING 2
.BEARING 1
.OIL SEAL 1
.GEAR, PUMP DRIVE 1
.WASHER, CRANK PIN 2
2
FIG. 2 CRANKSHAFT & PISTON
REF.
NO.
24
25
26
27
28
29
PART NO. DESCRIPTION
90280–05014
93440–78069
93103–32156
90280–05014
90170–16425
92907–16100
.KEY, WOODRUFF 1
CIRCLIP 1
OIL SEAL 1
KEY, WOODRUFF 1
NUT 1
WASHER 1
8HT1
REMARKS
3
FIG. 3 AIR SHROUD & FAN
REF.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PART NO. DESCRIPTION
88F–12621–02
8Y0–12679–00
8Y0–12658–00
97027–08040
92907–08600
97027–08055
92907–08600
97027–08075
92907–08600
97027–08075
93306–20315
99009–40500
90201–17713
8H8–12611–01
90280–05014
CASE, FAN 1
DAMPER, SHROUD 6 1
DAMPER, AIR SHROUD 1 1
BOLT, HEXAGON 2
WASHER, PLATE 2
BOLT, HEXAGON 1
WASHER, PLATE 1
BOLT, HEXAGON 1
WASHER, PLATE 1
BOLT, HEXAGON 1
BEARING 2
CIRCLIP 1
WASHER, PLATE 1
FAN 1
KEY, WOODRUFF 1
8HT1
REMARKS
16
8H8–12619–01
17
90214–17017
90214–17018
18
92907–16100
19
90201–17713
20
90170–16425
21
8H8–12612–00
22
8H8–12618–01
23
8H8–12651–02
24
99246–00080
25
8H8–12658–00
26
8H8–12659–00
PULLEY 2 2
WASHER, CLAW (0.5T) 1 UR UN
WASHER, CLAW (1.0T) 1 UR UN
WASHER 1
WASHER, PLATE 1
NUT 1
BELT 1
PULLEY 1 1
AIR SHROUD, CYLINDER 1 1
EMBLEM, YAMAHA 1
DAMPER, AIR SHROUD 1 2
DAMPER, AIR SHROUD 2 1
4
FIG. 5 PUMP DRIVE GEAR
REF.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PART NO. DESCRIPTION
8AT–15416–00
93101–10001
821–13176–00
866–13175–00
821–13188–00
90206–11016
137–13148–00
99009–10400
93603–22028
8K4–15426–00
99530–08016
95027–06040
95027–06055
8H8–13179–00
93306–00002
COVER, OIL PUMP 1
OIL SEAL 1
METAL, WORM SHAFT OUTER 1
SHAFT, WORM 1
GEAR, DRIVE (32T) 1
WASHER, WAVE 1
PLATE, CAM THRUST 1
CIRCLIP 1
PIN, DOWEL 1
COVER, OIL PUMP 2 1
PIN, DOWEL 2
BOLT, FLANGE 1
BOLT, FLANGE 1
GEAR, IDLE (34T) 1
BEARING 1
8HT1
REMARKS
16
8G8–13342–00
17
90201–10119
18
8K4–13119–00
SHAFT, IDLE GEAR 1
WASHER, PLATE 2
SEAL, GREASE 1
7
FIG. 7 CARBURETOR
REF.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
PART NO. DESCRIPTION
84R–14101–02
82A–14134–00
620–14211–00
8M6–14126–00
8M6–14261–00
286–14198–00
214–14195–00
83R–14190–15
68V–14186–00
8M6–14185–00
83R–14941–4E
3G2–1414E–56
CARBURETOR ASSY 1 1
.SPRING, AIR ADJUSTING 1
.SCREW, PILOT ADJUSTING 1
.GASKET 1
.HOLDER 1
.GASKET 1
.WASHER, NEEDLE VALVE 1
.NEEDLE VALVE ASSY 1
.PIN, FLOAT 1
.FLOAT 1
.NOZZLE, MAIN 1
.JET, MAIN (#141.3) 1 STD
8HT1
REMARKS
3G2–14231–77
3G2–14231–27
3G2–14231–78
3G2–14231–28
3G2–14231–79
13
8U9–14174–00
14
127–14135–00
15
8G8–14171–00
16
193–14142–90
193–1414F–00
17
8V0–14118–00
18
89A–14125–00
19
2J2–14133–00
20
89A–14265–00
21
22F–14117–00
.JET, MAIN (#132.5) 1 AP
.JET, MAIN (#135) 1 AP
.JET, MAIN (#137.5) 1 AP
.JET, MAIN (#140) 1 AP
.JET, MAIN (#142.5) 1 AP
.CAP, PLUNGER 1
.COIL, SPRING 1
.PLUNGER, STARTER 1
.JET, PILOT (# 90) 1 STD
.JET, PILOT (# 100) 1 AP
.CAP 2
.SCREW 1
.SPRING, THROTTLE STOP 1
.COLLAR 1
.WASHER, PLUG SCREW 1
10
FIG. 7 CARBURETOR
REF.
NO.
22
23
24
25
26
27
28
29
PART NO. DESCRIPTION
1UF–14952–00
8X0–14358–00
8A7–14169–00
80L–14227–00
127–14124–20
802–14161–00
89A–24529–00
87S–8259A–01
.WASHER 1
.NUT 1
.CAP 1
.WASHER 1
.SCREW, CABLE ADJUSTING 1
.NUT, CABLE ADJUSTING 1
.SPRING 1
.SWITCH, CARBURETOR 1
8HT1
REMARKS
11
FIG. 11 PRIMARY SHEAVE
REF.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PART NO. DESCRIPTION
88R–17611–02
8V0–17639–00
89F–17621–00
90389–41031
90387–0501R
90105–05644
95607–05200
8BW–17640–11
8BW–17653–00
91609–50032
90387–0501R
90113–05053
90105–05644
95607–05200
88R–17631–01
SHEAVE, PRIMARY FIXED 1
STOPPER 2
SHEAVE, PRIMARY SLIDING 1
BUSH 1
COLLAR 3
BOLT, FLANGE 3
NUT, U FLANGE 3
SPIDER COMPLETE 1
SLIDER 6
PIN, SPRING 3
COLLAR 3
BOLT, SET 6
BOLT, FLANGE 3
NUT, U FLANGE 3
CAP 1
8HT1
REMARKS
16
90389–28032
17
97017–06030
18
92907–06600
19
90109–066F4
20
90202–08204
21
88R–17624–01
22
90386–08183
23
93450–13133
24
90202–08204
25
8AT–17605–00
26
90386–08182
27
90261–06019
BUSH 1
BOLT 4
WASHER, PLATE 4
BOLT 2
WASHER, PLATE 6
ROLLER, COMP 3
.BUSH 1
.CIRCLIP 1
WASHER, PLATE 6
WEIGHT COMP 3
.BUSH 1
RIVET, COUNTERSUNK (ST13.3MM) 3 STD
15
FIG. 11 PRIMARY SHEAVE
REF.
NO.
27
28
PART NO. DESCRIPTION
90261–06017
90501–481J1
RIVET, COUNTERSUNK (ST11.3MM) 3 AP
SPRING, COMPRESSION 1 STD (SL-BL-SL)
8HT1
REMARKS
90501–581J7
90501–556G6
29
87X–17641–00
30
8V0–17647–00
31
92907–16100
SPRING, COMPRESSION 1 AP (YELLOW)
SPRING, COMPRESSION 1 AP (BLUE)
V-BELT 1
BOLT (L=156.5MM) 1
WASHER 1
16
FIG. 12 SECONDARY SHEAVE
REF.
NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
PART NO. DESCRIPTION
88R–17660–03
8AT–17670–01
8X6–17688–00
90154–06062
90384–90081
90201–345G2
90214–29060
93440–34170
8AT–17684–01
90508–50746
88N–17680–02
88N–47631–00
93306–20582
99009–52500
97027–08020
SECONDARY FIXED SHEAVE COMP. 1
SECONDARY SLIDING SHEAVE 1
.SHOE, RAMP 3
.SCREW, BINDING 3
.BUSH, BIMETAL FORMED 1
WASHER, PLATE 2
WASHER, CLAW 1
CIRCLIP 1
SEAT, SECONDARY SPRING 1
SPRING, TORSION 1
SECONDARY SHAFT COMP. 1
HOUSING, BEARING 1
BEARING 1
CIRCLIP 1
BOLT, HEXAGON 4
8HT1
REMARKS
16
92907–08600
17
90201–252F1
90201–25527
90201–25526
18
90201–257J2
19
93410–25017
20
90201–104A7
21
95817–10020
22
90465–08316
WASHER, PLATE 4
WASHER, PLATE (T0.5) 1 UR UN
WASHER, PLATE (T1.0) 2 UR UN
WASHER, PLATE (T2.0) 2 UR UN
WASHER, PLATE 2
CIRCLIP 1
WASHER, PLATE 1
BOLT, FLANGE 1
CLAMP 1
17