background image

27

Exhaust

5

14

1

2

3

9

6

7

8

4

4

12

11

13

10

15

15

4

842-5001524

LOCK WA SHER, M6, ZINC

14

1

611-5001703

EXHA UST A SSEMBLY

13

3

849-5001701

HEA DER SHROUD WA SHER, FIBER

INCLUDED IN 611-5001703

12

3

814-5001700

HEA DER SHROUD BOLTS

INCLUDED IN 611-5001703

11

1

613-5001699

EXHA UST, HEA DER SHROUD

INCLUDED IN 611-5001703

10

4

836-5001605

NUT, HEX FLA NGE, M6-12PT

9

1

814-5000612

FLA NGE BOLT, M8X35

8

1

803-5000803

GROMMET, SILENCER

7

1

849-5001455

TOP-HA T WA SHER, SILENCER

6

1

841-5001451

FENDER WA SHER, M8

5

2

849-5001345

EXHA UST CRUSH WA SHER

4

2

814-5000095

FLA NGE BOLT, M6X20        

3

1

613-5001760

EXHA UST, SILENCER

INCLUDED IN 611-5001703

2

1

613-5001698

EXHA UST, HEA DER PIPE 

INCLUDED IN 611-5001703

1

2

613-5001702

SPRING, EXHA UST

INCLUDED IN 611-5001703

MX FX XC EX

NOTES

MODEL

EXHAUST  PART S LIST

DESCRIPTION

ITEM 

NO

QTY  

REQD

DEA LER PA RT 

NUMBER

Summary of Contents for 2001 MX400

Page 1: ...TE 25 ELECTRICAL 26 EXHAUST 27 RADIATOR 28 AIRBOX 29 AIR FILTERS 30 THROTTLE BODY 31 FUEL TANK 32 FUEL PUMP 33 FUEL INJECTORS 34 FUEL PRESSURE REGULATOR 35 CAM COVER SPARK PLUG 36 CYLINDER HEAD 37 VAL...

Page 2: ...ZINC 8 1 073 5000047 FRONT ROTOR 7 1 053 5000536 FRONT WHEEL RIM INCLUDED IN 051 5000020 6 1 053 5000028 FRONT RIM LOCK 5 1 053 5000029 FRONT RIM STRIP 4 1 053 5000030 FRONT INNER TUBE 3 1 053 5000031...

Page 3: ...7 REAR SPROCKET 52 T 11 1 183 5000117 REAR SPROCKET 50 T 10 1 183 5001847 MASTER LINK 9 1 183 5001601 DRIVE CHAIN 114 LINKS 8 4 817 5000138 FHCS M8X16 NYLKZINC 7 1 173 5000090 REAR ROTOR 6 1 153 50000...

Page 4: ...53 5000024 FRONT WHEEL SPACER DISC SIDE 6 4 881 5000355 SEALED BEARING 20X42X12 5 4 871 5000356 DOUBLE LIP SEAL 32X42X4 4 1 153 5001091 REAR WHEEL SPACER 3 1 153 5000071 REAR HUB 2 1 153 5000072 REAR...

Page 5: ...8 9 10 11 12 13 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 47 48 50 51 52 53 54 55 57 58 29 59 12 14 57 57 57 57 57 42 41 49 57 57 57 57 57 57 48 56 45 46 4...

Page 6: ...MPER ROD BUSHING 28 2 013 5000584 FORK DAMPER ROD SLEEVEO RING 27 2 013 5000583 FORK DAMPER ROD SLEEVE 26 2 013 5000582 DAMPING CARTRIDGETUBECAP 25 2 013 5000581 DAMPER ROD CIRCLIP 24 2 013 5000580 HY...

Page 7: ...00100 FHB M8X45 mm 7 2 814 5000101 FHB M12X35 mm NLK 6 2 012 5000534 UPPER HANDLEBAR CLAMP 5 2 012 5000533 LOWER HANDLEBAR CLAMP 4 1 012 5000373 LOWER TRIPLE CLAMP ASSY 3 1 012 5000001 UPPER TRIPLE CL...

Page 8: ...01270 BRAKE GUIDE CLAMP 5 1 073 5000038 BRAKE GUIDE MOUNT ASSY 4 2 814 5001013 FLNG HD BLT M6X16 NLK 3 1 073 5000824 FRONT BRAKE GUIDE MOUNT UPPER 2 2 073 5000535 FRONT BRAKE GUIDE 1 1 073 5000132 FRO...

Page 9: ...CABLEADJUSTER BOOT INCLUDED IN 212 5000889 16 1 213 5000128 CLUTCH LEVER BOOT INCLUDED IN 212 5000889 15 1 153 5000080 CLUTCH LEVER INCLUDED IN 212 5000889 14 1 212 5000889 CLUTCH LEVER ASSEMBLY 13 1...

Page 10: ...CIRCLIP INCLUDED IN 072 5000032 5000033 9 1 072 5000033 FT BRAKE MSTR CYL KIT INCLUDED IN 072 5000032 8 1 072 5000045 FT BRAKE LEVER ADJ BOLT KIT INCLUDED IN 072 5000032 7 1 072 5000041 FT BRAKE LEVE...

Page 11: ...073 5000268 NISSIN BRAKE GREASE 2 GRAM AS REQURIED 6 1 073 5000050 SLIDE PIN BOOT SMALL 5 2 814 5000863 FLANGE HEAD BOLT M8X40 mm 4 1 072 5000035 FRONT BRAKE CALIPER PAD KIT 3 1 072 5000036 FRONT BRA...

Page 12: ...19 5000399 BOLT BRAKE PEDAL 4 1 804 5000413 RR BRAKE COTTER PIN 3 1 173 5000109 BRAKE PEDAL YOKE PIN INCLUDED IN 173 5001226 2 1 173 5000112 SPRING BRAKE PEDAL 1 1 173 5001226 REAR BRAKE PEDAL MX FX X...

Page 13: ...EAR BRAKE LINE 9 1 171 5000102 RR BRAKE MSTR CYL ASSY 8 AR 073 5000268 NISSIN BRAKE GREASE 2 GRAM AS REQUIRED 7 1 172 5000085 RR BRAKE RESERVOIR ASSY 6 1 172 5000104 RR BRAKE RESERVOIR HOSE KIT 5 1 17...

Page 14: ...BRAKE GREASE 2 GRAM AS REQUIRED 6 1 073 5000050 SLIDE PIN BOOT SMALL 5 1 172 5000081 REAR BRAKE CALIPER ASSEMBLY 4 1 173 5000096 REAR BRAKE CALIPER BRACKET 3 1 172 5000098 REAR BRAKE PAD PIN KIT 2 1...

Page 15: ...X40 NYLK 14 1 814 5000728 FLNGE HEAD BOLT M8X55 13 1 814 5000111 FLNG HD BLT M8X50 NYLK 12 1 811 5001629 SHCS M8X65 ZINC 11 1 203 5001092 RT SWNGRM MOUNT PLUG 10 1 203 5001374 CHAIN ROLLER SPACER Befo...

Page 16: ...m efore VIN 224 Use 815 5000139 4 2 815 5000139 SHLDR SS M10X12 NLKZC 3 1 833 5001593 THREADED INSERT M8 INCLUDED IN 201 5000523 2 7 833 5000888 RIVNUT M6 INCLUDED IN 201 5000523 1 1 201 5000523 SUBFR...

Page 17: ...2 814 5000527 FLNG HD BLT M10X90 NLK 4 6 833 5000190 THREADED INSERT M8 INCLUDED IN 201 5000521 5000522 3 8 833 5000888 RIVNUT M6 INCLUDED IN 201 5000521 5000522 2 1 201 5000522 FRAME RAIL LEFT 1 1 20...

Page 18: ...ARE KIT MX FX XC EX ITEM NO QTY REQD DEALER PART NUMBER DESCRIPTION NOTES MODEL LEFT FOOTPEG PARTS LIST 2 8 7 6 3 5 4 8 2 812 5001264 BHCS M10X25 NYLKZNC 7 1 203 5000529 FOOTPEG BRACKET RIGHT 6 1 203...

Page 19: ...7 REAR BRAKE LINE GUIDE FRONT 21 1 173 5000088 REAR BRAKE LINE GUIDE REAR 20 1 253 5000231 REAR AXLE BLOCK 19 1 153 5000070 AXLE REAR WHEEL 18 1 252 5000743 SWINGARM WELDMENT 17 1 253 5000114 DRIVE CH...

Page 20: ...HOCK SPRING SEAT 7 1 103 5001295 SHOCK SPRING PRELOAD LOCK RING 6 1 103 5001330 RESERVOIR BODY OHLINS DECAL 5 1 103 5001331 RESERVOIR BODY WRNG DECAL 103 5000059RR SHOCK SPRING 95 N mm OPTIONAL 4 2 10...

Page 21: ...G HD BLT M6X16 NLK 4 2 814 5000093 FLNG HD BLT M6X25 NYLK 1 303 5001572 NUMBER PANEL RIGHT RED 3 1 303 5001573 NUMBER PANEL RIGHT BLACK 1 303 5001574 NUMBER PANEL LEFT RED 2 1 303 5001575 NUMBER PANEL...

Page 22: ...D RIGHT BLACK 1 303 5001570 RADIATOR SHROUD LEFT RED 4 1 303 5001571 RADIATOR SHROUD LEFT BLACK 3 6 849 5001531 TOP HAT WASHER PLASTIC 2 4 814 5001612 PHLPS HD SCRW M6X12 1 2 814 5000095 FHB M6X20 NYL...

Page 23: ...7 1 303 5001567 FRONT NUMBER PLATE BLACK 6 1 849 5001531 TOP HAT WASHER PLASTIC 5 2 814 5001184 FLNG HD BLT M6X12 NLK 4 4 849 5001514 TOP HAT WASHER 3 5 841 5000192 FLAT WASHER M6 2 1 839 5001512 FEN...

Page 24: ...AR FENDER RED 5 1 303 5001577 REAR FENDER BLACK 4 4 849 5001531 TOP HAT WASHER 3 4 839 5001348 GUIDE PLATE NUT 2 4 839 5001720 FENDER NUT M6 1 6 814 5001184 FLNG HD BLT M6X12 NLK MX FX XC EX NOTES MOD...

Page 25: ...T M6X16 15 1 814 5001184 FHB M6X12 14 2 814 5000350 FHB M6X30 13 2 814 5000095 FHB M6X20 12 2 812 5000141 BHCS M6X12 ZINC 11 5 805 5001240 FUSE HOLDER RIVET 10 1 473 5001558 ECM MOUNT PLATE 9 1 472 50...

Page 26: ...AIN POWER RELAY 10 2 817 5000596 FHCS M5X12 mm ZINC 9 2 836 5000570 NUT HEX FLANGE M5 8 1 463 5000855 POSITIVE BATTERY CABLE 7 1 463 5000854 NEGATIVE BATTERY CABLE 6 1 493 5000856 STARTER MOTOR CABLE...

Page 27: ...0 4 836 5001605 NUT HEX FLANGE M6 12PT 9 1 814 5000612 FLANGE BOLT M8X35 8 1 803 5000803 GROMMET SILENCER 7 1 849 5001455 TOP HAT WASHER SILENCER 6 1 841 5001451 FENDER WASHER M8 5 2 849 5001345 EXHAU...

Page 28: ...814 5001184 FLNG HD BLT M6X12 NLK 8 4 814 5000093 FLNG HD BLT M6X25 NYLK 7 4 803 5000178 GROMMET 3 8 ID 6 1 403 5001511 RADIATOR DRAIN PLUG 5 1 403 5001464 COOLANT HOSE RAD TO WATER PUMP 4 1 403 50014...

Page 29: ...6 805 5001238 RIVET AB4 6CLD INCLUDED IN 603 5001035 05 5 2 603 5001239 INTAKE END RETAINING RING INCLUDED IN 603 5001035 05 4 1 603 5001236 SEALING TAPE 3 1 603 5001035 03 AIRBOX 2 1 603 5000989 AIR...

Page 30: ...AIR FILTER 1 1 603 5000327 MAIN AIR FILTER HOLD DOWN MX FX XC EX ITEM NO QTY REQD DEALER PART NUMBER DESCRIPTION NOTES MODEL MAIN AIR FILTER PARTS LIST 2 1 3 3 1 841 5000192 FLAT WASHER M6 2 1 814 50...

Page 31: ...603 5001354 THROTTLE CABLE STOP 11 1 603 5001142 THROTTLE SPRING SLEEVE 10 1 603 5000827 SPRING IDLE ADJUST THUMBWHEEL 9 2 881 5001744 BEARING THROTTLE SHAFT 1 603 5001956 X THROTTLE CABLE PULLEY MX O...

Page 32: ...RING 008 16 1 849 5000799 TOP HAT WASHER FUEL TANK TAB 15 1 849 5000765 TOP HAT WASHER SEAT PAN 14 2 841 5000192 FLAT WASHER M6 13 2 817 5000137 FHCS M6X16 ZINC 12 1 814 5000862 FLNG HD BLT M6X40 mm...

Page 33: ...9 5001543 WASHER NYLON 8 2 834 5001641 NUT HEX 6 7 2 814 5000095 FLNG HD BLT M6X20 NYLK 6 2 353 5001541 ISOLATION STRIP FUEL PUMP 5 2 353 5001502 BANJO BOLT 4 2 353 5001501 BANJO FITTING 3 1 353 50012...

Page 34: ...1 FUEL HOSE 6 4 mm ID 110 mm TO FUEL PUMP 6 1 353 5000478 FUEL INJECTOR BASE RIGHT 5 1 353 5000812 FUEL INJECTOR BASE LEFT 4 2 836 5001458 NUT HEX FLANGE M3 3 2 353 5000171 FUEL INJECTOR CLIP 2 2 351...

Page 35: ...FUEL PRESSURE REGULATOR 8 1 851 5000836 INTERNAL RETAINING RING 36mm 7 1 353 5001544 FUEL REGULATOR HOUSING PLASTIC 6 2 803 5001578 GROMMET FUEL REGULATOR 5 2 849 5001579 TOP HAT WASHER FUEL REGULATO...

Page 36: ...483 5000852 COIL HOLD DOWN 12 1 807 6000393 02 X PLUG INCLUDED IN 552 6000496 11 4 811 5001941 SCKTHD HEX SCREW M5X0 8X20 10 2 811 5001942 SCKTHD HEX SCREW M5X0 8X35 9 1 513 5000914 CAM COVER RBR LEFT...

Page 37: ...1259 OIL TRANSFER TUBE 12 2 872 5000482 O RING 2 011 11 1 513 5001861 IDLER GEAR BRACKET 10 2 872 5000487 O RING 2 012 9 1 513 5000252 CAMSHAFT IDLER GEAR 31T 8 1 883 5001007 NEEDLE BEARING 12X16X10 7...

Page 38: ...38 Valve Train 10 13 12 11 24 4 20 3 1 5 6 7 9 30 25 18 28 19 14 26 21 15 27 23 17 22 2 14 29 8 16...

Page 39: ...1 Valve Shim 2 75 15 1 512 5001756 EXHAUST CAMSHAFT ASSY 503 5001192 Valve Shim 2 80 14 4 503 5000874 RETAINER BEARING 503 5001193 Valve Shim 2 85 13 4 503 5000463 VALVE STEM SEAL 503 5001194 Valve Sh...

Page 40: ...SHCS M5X0 8X50 mm 12 2 811 5001491 SHCS M6X1 0X16 mm 11 1 512 5001102 CAM CHAIN TENSIONER ASSEMBLY 10 1 852 5001028 EXTRNL RETANING RING M10 9 1 513 5000671 04 CAM CHAIN TENSIONER SHOE 8 2 811 500148...

Page 41: ...41 Crankcase 20 8 10 2 21 5 3 4 6 7 9 21 19 25 24 23 26 28 27 22 18 16 17 15 14 13 12 29 11 30 34 33 31 32...

Page 42: ...650 FT INNER ENGNE MOUNTING BUSHING 18 2 801 5001136 SPLIT DOWEL PIN 5X10 17 1 883 5001675 NEEDLE BEARING 15X21X16 16 1 871 5000469 OIL SEAL 20X30X7 HMS4 15 1 882 5001784 ROLLER BEARING 31 5X52X15 14...

Page 43: ...001608 FLTHD SCRW M6X1 0X12 7 1 881 5000816 BALL BEARING 17X40X12 SEALED 6 1 532 5001124 BALANCE SHAFT ASSY 5 1 883 5001793 BEARING NEEDLE 20X26X16 4 1 849 5001622 ONE WAY CLUTCH SPACER 3 1 533 500028...

Page 44: ...72 5000921 O RING 2 019 8 1 872 5000915 O RING 2 023 7 1 553 5001866 PISTON PIN ACCESS COVER 6 1 879 5000627 QUAD RING CYLINDER LINER 5 1 522 5001842 PISTON 95 mm 180 4 1 523 5001424 CYLINDER LINER 95...

Page 45: ...5000452 02 TDC WASHER 8X13X5 5 mm 13 1 811 5000428 TDC SCREW 12 1 801 5000629 06 IDLR GEAR SHAFT 10X45 11 1 593 5000390 SCAVENGE PUMP IDLER GEAR 10 1 882 5001152 ROLLER BEARING 10X14X12 9 1 844 50012...

Page 46: ...000517 BUSHING 7 1 819 5000978 THCS M5X0 8X10 ome VIN s may require 817 5000414 6 1 841 5001895 WASHER BRASS 5X9X 9 mm ome VIN s may require 872 5000304 5 1 872 5000828 O RING 2 016 4 1 553 5001434 TR...

Page 47: ...5 8 493 5001498 03 STARTER CLUTCH BUSHING 7 493 5001496 04 STARTER CLUTCH PRESSURE PLATE 6 493 5001497 02 STARTER CLUTCH METALLIC DISC 5 493 5001495 STARTER CLUTCH FRICTION DISC 4 493 5001465 04 START...

Page 48: ...TE CLUTCH 12 10 563 5001499 CLUTCH PLATE ALUM 1 0mm 11 1 563 5001069 WASHER SPLINED 10 1 562 5000948 CLUTCH PUSHROD 9 6 563 5001924 SPRING CLUTCH PK6 8 9 563 5000333 CLUTCH PLATE FRICTION 2 32mm 1 562...

Page 49: ...0880 WSHR 251X 560X 062 17 1 573 5000364 DETENT LEVER SPRING 16 1 573 5000358 DETENT LEVER BOLT 15 1 572 5000935 DETENT LEVER ASSEMBLY 14 1 841 5001548 WASHER TRA 411 13 1 572 5001131 SHIFT DRUM ASSEM...

Page 50: ...2 849 5000454 SPLINED WASHER 25 6 1 543 5000293 MAINSHAFT 5TH GEAR 5 1 543 5000292 MAINSHAFT SPLINED BUSHING 4 1 543 5000291 MAINSHAFT 4TH GEAR 3 1 543 5000290 MAINSHAFT 3RD GEAR 2 1 543 5000289 05 MA...

Page 51: ...ER 19 10 1 844 5000445 THRUST WASHER 25 2X30 9 1 844 5000441 THRST WASHER MAINSHAFT 8 1 543 5000301 COUNTERSHAFT 5TH GEAR 7 1 543 5000300 COUNTERSHAFT 4TH GEAR 6 1 543 5000299 COUNTRSHAFT 3RD GEAR 5 1...

Page 52: ...PLUNGER 16 1 573 5000351 SHIFT PAWL B 15 1 573 5000352 SHIFT PAWL A 14 2 573 5000353 SHIFT PAWL SPRING 13 1 573 5000660 SCREW SHIFT PIN 12 1 573 5000662 MAINSHAFT END CAP 11 1 872 5000968 O RING 2 025...

Page 53: ...LATE 5 1 839 5000991 RETANING NUT 1 183 5000278 COUNTERSHAFT SPROCKET 15T 1 183 5000276 COUNTERSHAFT SPROCKET 14T 4 1 183 5000118 COUNTERSHAFT SPROCKET 13T STOCK 3 1 849 5000990 SPLINED LOCK WASHER 2...

Page 54: ...RATOR ALIGNMENT COLLAR 1 463 6000322 X GENERATOR STATOR 9 1 463 5001510 X GENERATOR STATOR 8 1 861 5001258 ALUM CLAMP 7 1 812 5001473 BHCS M4X0 7X8 mm 6 1 462 5001857 FLYWHEEL 5 1 842 5001580 LOCK WAS...

Page 55: ...ET WATER 8 1 872 5000915 O RING 2 023 7 1 841 5001933 WSHR 320X 547X 040 in 6 1 403 5001442 WATER PUMP IMPELLER 5 1 403 5000180 WATER PUMP GASKET 4 1 403 5001860 WATER PUMP HOUSING 3 2 841 5001040 FLA...

Page 56: ...3 8 1 851 5000897 INTRNL RETAINING RING 35 7 1 849 5001705 WASHER ENGINE DRAIN 6 1 801 5001630 DOWEL PIN 3 X11 8 mm 5 1 593 5001279 ENGINE OIL DRAIN PLUG 4 1 593 5000309 ENGINE OIL PICKUP SCREEN 3 1 5...

Page 57: ...LIP 8 mm 8 1 844 5000448 THRUST WASHER 687X 511X 040 7 1 801 5001089 DOWEL PIN 125 X 635 6 2 801 5001036 SCAVENGE PUMP DRIVE PIN 5 1 593 5001159 GEROTOR ASSY THICK 4065 X 165 4 1 593 5001158 GEROTOR A...

Page 58: ...PRESSURE BLOW OFF PLUG 12 1 593 5001098 OIL CHECK PLUG 11 2 593 5001005 PRESSURE PUMP SPRING 10 1 593 5001003 PRESSURE CHECK BALL 9 1 593 5001001 3 8 GROUND RUBBER BALL 8 1 593 5000643 COVER OIL FILTE...

Page 59: ...PLY BRIDGE ASSY 9 1 871 5000689 OIL SEAL 8X14X4 8 1 849 5000965 SEALING WASHER 6mm 7 1 872 5000487 O RING 2 012 6 1 593 5001066 OIL RETURN PIPE 5 1 593 5001065 OIL RETURN FITTING 4 2 872 5001061 O RIN...

Page 60: ...11 8 8 1 801 5001183 DOWEL PIN 3 X 9 8 7 1 593 5000993 PRESSURE RELIEF SPRING 6 1 593 5000992 PRESSURE RELIEF BALL 5 1 593 5000669 TRANS OIL PUMP DRIVE GEAR 4 1 593 5001867 TRANSMISSION OIL PUMP COVE...

Page 61: ...DECAL KIT 01 MX 400 BLACK 5 1 314 5001708 PRE CUT BACKGROUND KIT 4 1 313 5001460 SWINGARM SET 3 1 313 5001500 WARNING SET 2 1 313 5000266 REAR FENDER WARNING 1 1 313 5001398 FORK GUARD C SET MX FX XC...

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