KM55RCEZ

Drawing A Crankcase, Cylinder
KM 55, KM 55 C, KM 55 R, KM 55 RC SCS 03-2007 3.23

1
Drawing A Crankcase, Cylinder
Reference Item number Qty Description
1 4140 021 0300 1 Crankcase

2 9639 003 1230 2 Oil seal12x22x7
3 9503 003 0242 2 Grooved ball bearing 6201
4 4140 036 0300 2 Washer
5 4140 030 0401 1 Crankshaft (25.2005)
6 4140 029 2300 1 Cylinder gasket
7 4140 021 2500 1 Engine pan
8 4140 020 1202 1 Cylinder with piston Ø 34 mm
☐ 10 - 14
9 ✻ 4140 020 1200 1 Cylinder with piston Ø 34 mm (23.2003)

☐ 10 - 14
10 4140 030 2000 1 Piston Ø 34 mm

☐ 11 - 13
11 4137 034 3000 2 Piston ring Ø 34x1.5 mm
12 9463 650 0807 2 Snap ring 8x0.7
13 4137 034 1500 1 Piston pin 8x5x22
14 9075 478 4268 4 Pan head self-tapping screw IS-D5x60
17 4140 190 2010 1 Driver (2,4-6)
☐ 18, 19
18 0000 998 0612 2 Torsion spring (2,4-6)
19 4133 195 7201 2 Pawl (2,4-6)
20 0000 400 7000 1 Spark plug NGK BPMR7A
20 1110 400 7005 1 Spark plug Bosch WSR 6 F
21 0783 830 2000 1 Tube of sealant Dirko HT red (B)
4140 007 1050 1 Set of gaskets
☐ 2, 6
(1) KM 55, (2) KM 55 C-E, (3) KM 55 R, (4) KM 55 RC-E, (5) KM 55 RC-E DZ,
(6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z
2
Drawing B Rewind starter

3
Drawing B Rewind starter
8 0000 190 3404 1 Starter grip ElastoStart Ø 3 mm (B)

☐ 9, 10
0000 930 2208 1 Starter rope Ø 3 mm x 30.5 m (A,B)
10 0000 195 7000 1 Cap (B)
4
Drawing C Rewind starter ErgoStart

5
Drawing C Rewind starter ErgoStart
1 4140 190 4010 1 Rewind starter (2,4-6)

☐ 2 - 12
2 4140 190 0601 1 Rewind spring (2,4-6)
3 4140 195 0410 1 Rope rotor (2,4-6)
4 4140 195 3400 1 Starter grip (2,4-6)
5 4137 195 8200 1 Starter rope Ø 2.7x910 mm (2,4-6)
6 4116 195 7200 1 Pawl (2,4-6)
7 0000 958 0923 1 Washer (2,4-6)
8 1118 195 3500 1 Spring (2,4-6)
9 4140 190 0710 1 Spring housing (2,4-6)
10 4140 195 2010 1 Carrier (2,4-6)
11 9307 021 0120 1 Washer 5.3 (2,4-6)
12 9022 399 0950 1 Spline screw IS-M5x10 (2,4-6)
14 4140 967 1520 1 Model plate KM 55 RC (4-6)
15 0000 951 1100 3 Screw IS-D5x20 (2,4-6)
16 4140 084 6801 1 Spacer (2,4-6)
17 0000 967 4208 1 Tag Easy2Start (5,6) USA, CDN
6
Drawing D Muffler

7
Drawing D Muffler
2 4140 140 0610 1 Muffler (6,8) USA, AUS, CDN

☐3
3 4140 140 6903 1 Stub with screen (6,8) USA, AUS, CDN
5 ✻ 4140 140 0605 1 Muffler (6,8) USA, AUS, CDN (23.2003)

☐6
6 ✻ 4140 140 6900 1 Stub with screen (6,8) USA, AUS, CDN (23.2003)
7 4140 149 0602 1 Exhaust gasket (1-4,6,8)

8 9075 478 4268 2 Pan head self-tapping screw IS-D5x60 (1-4,6,8)
9 0783 830 2000 1 Tube of sealant Dirko HT red (B) (1-4,6,8)
4140 007 1050 1 Set of gaskets (1-4,6,8)
☐7
8
Drawing E Muffler Cat.

9
Drawing E Muffler Cat.
10
Drawing F Ignition system, Clutch

11
Drawing F Ignition system, Clutch
1 4140 400 1200 1 Flywheel (25.2005)

2 4140 162 8900 1 Washer
3 4140 162 9101 1 Spacer sleeve
4 4140 160 2005 1 Clutch

☐ 2, 5, 6
5 4140 162 7900 2 Tension spring

6 1 Cup spring 31.7x20.4x0.4 (D)
7 4140 160 2903 1 Clutch drum
8 4140 400 1305 1 Ignition module
9 4140 431 2100 1 Connector tag
12
Drawing G Engine housing (Bike handle)

13
Drawing G Engine housing (Bike handle)
14
Drawing H Engine housing (Loop handle)

15
Drawing H Engine housing (Loop handle)
1 4140 020 3000 1 Engine housing (3-8)

2 4140 080 1600 1 Shroud (3-8)
☐3
4 9075 478 4159 4 Pan head self-tapping screw IS-D5x24 (3-8)
5 4140 180 1105 1 Throttle cable (3-8)
6 4140 440 1900 2 Lead (3-8)
7 4229 430 0201 1 Stop switch (3-8)
8 4140 180 1500 1 Throttle trigger (3-8)
9 4140 182 4500 1 Torsion spring (3-8)
10 4140 791 5400 1 Support (3-8)
11 4140 182 0800 1 Trigger interlock (3-8)
12 4140 182 4505 1 Torsion spring (3-8)
16
Drawing J Air filter, Fuel tank

17
1 4140 124 2800 1 Filter

2 4140 140 2850 1 Filter housing
☐ 1, 3, 4, 5, 7
3 4140 141 3700 1 Lever
4 4140 141 3801 1 Choke shutter
5 9417 003 7512 1 Push nut 4.0x9.6x1.8
6 9210 261 0700 2 Hexagon nut M5
7 4140 141 0502 1 Filter cover
8 4140 129 0900 1 Gasket
9 4140 120 0612 1 Carburetor C1QS97
10 ✻ 4140 120 0606 1 Carburetor C1QS71 (25.2004)

11 ✻ 4140 120 0603 1 Carburetor C1Q-S66 (36.2002)
12 4114 149 1205 1 Gasket

13 4140 121 1605 1 Spacer flange
14 4140 182 7601 1 Tensioner
15 9022 313 0680 1 Spline screw IS-M4x16
17 9007 319 1135 2 Hexagon head screw M5x65
18 4140 129 0906 1 Gasket
18

19
19 4232 350 0411 1 Fuel tank

☐ 20 - 28
20 1125 084 8900 1 Grommet
21 4140 358 7702 1 Hose
22 0000 350 3506 1 Pickup body
23 0000 351 3201 1 Sleeve
24 4140 353 2402 1 Support
25 9074 478 4135 1 Pan head self-tapping screw IS-P5x20
26 4128 350 0505 1 Filler cap
☐ 27, 28
27 0000 350 0900 1 Rope
28 0000 353 0800 1 Filler cap retainer
29 4140 352 8100 3 Insert
30 0000 967 3693 1 Warning pictogram Filler cap (5-8) USA, CDN
4140 007 1050 1 Set of gaskets
☐ 8, 12, 18
18
Drawing K Carburetor C1QS97

21
Drawing K Carburetor C1QS97
4140 120 0612 1 Carburetor C1QS97

☐ 1 - 34
1 4140 120 7101 1 Throttle shaft with lever
2 1123 122 3000 1 Spring
3 4128 121 8900 1 Pin
4 4137 121 8600 1 Washer
5 1120 122 9000 1 E-clip
6 4229 121 3303 1 Throttle shutter
7 1125 122 7403 1 Round head screw
8 1125 122 9001 1 E-clip
9 1129 121 4800 1 Pump diaphragm
10 1123 129 0905 1 Gasket
11 1123 121 0800 1 End cover
12 1120 122 7800 1 Oval head screw
13 4116 121 5100 1 Inlet needle
14 1120 122 3004 1 Spring
15 1125 121 5000 1 Inlet control lever
16 1120 121 9200 1 Spindle
17 1120 122 6600 1 Collar screw
18 4229 129 0901 1 Gasket
19 4229 121 4700 1 Metering diaphragm
20 4228 120 2200 1 Flange
21 4226 122 7100 4 Screw
22 4229 122 6701 1 High speed adjustment screw
23 4140 122 6800 1 Low speed adjustment screw
24 1123 121 7800 1 Strainer
25 4140 121 0800 1 End cover
26 4226 121 2700 1 Cap
27 4140 122 6200 1 Idle speed adjustment screw
28 1125 122 4200 1 Ball
29 4229 121 2701 1 Cap
30 4228 121 5602 1 Fixed jet 0.39
31 4180 121 5800 1 Pump piston
32 1132 122 3600 1 Sealing ring
33 4180 122 3002 1 Spring
34 1120 121 7801 1 Strainer
4140 007 1060 1 Set of carburetor parts
☐ 9, 10, 18 - 20
22
Drawing L Carburetor C1QS71

23
Drawing L Carburetor C1QS71
✻ 4140 120 0606 1 Carburetor C1QS71 (C) (25.2004)

☐ 1 - 34
1 ✻ 4137 120 7100 1 Throttle shaft with lever (25.2004)
2 ✻ 1123 122 3000 1 Spring (25.2004)
3 ✻ 4137 121 8900 1 Pin (25.2004)
4 ✻ 4137 121 8600 1 Washer (25.2004)
5 ✻ 1120 122 9000 1 E-clip (25.2004)
6 ✻ 4140 121 3302 1 Throttle shutter (25.2004)
7 ✻ 1125 122 7403 1 Round head screw (25.2004)
8 ✻ 1125 122 9001 1 E-clip (25.2004)
9 ✻ 1129 121 4800 1 Pump diaphragm (25.2004)
10 ✻ 1123 129 0905 1 Gasket (25.2004)
11 ✻ 1123 121 0800 1 End cover (25.2004)
12 ✻ 1120 122 7800 1 Oval head screw (25.2004)
13 ✻ 4116 121 5100 1 Inlet needle (25.2004)
14 ✻ 1120 122 3004 1 Spring (25.2004)
15 ✻ 1125 121 5000 1 Inlet control lever (25.2004)
16 ✻ 1120 121 9200 1 Spindle (25.2004)
17 ✻ 1120 122 6600 1 Collar screw (25.2004)
18 ✻ 4229 129 0901 1 Gasket (25.2004)
19 ✻ 4229 121 4700 1 Metering diaphragm (25.2004)
20 ✻ 4228 120 2200 1 Flange (25.2004)
21 ✻ 4226 122 7100 4 Screw (25.2004)
22 ✻ 4229 122 6701 1 High speed adjustment screw (25.2004)
23 ✻ 4229 122 6800 1 Low speed adjustment screw (25.2004)
24 ✻ 1123 121 7800 1 Strainer (25.2004)
25 ✻ 4140 121 0800 1 End cover (25.2004)
26 ✻ 4226 121 2700 1 Cap (25.2004)
27 ✻ 4229 122 6200 1 Idle speed adjustment screw (25.2004)
28 ✻ 1125 122 4200 1 Ball (25.2004)
29 ✻ 4229 121 2701 1 Cap (25.2004)
30 ✻ 4228 121 5602 1 Fixed jet 0.39 (25.2004)
31 ✻ 4229 121 5800 1 Pump piston (25.2004)
32 ✻ 4140 122 3600 1 Sealing ring (25.2004)
33 ✻ 4229 122 3001 1 Spring (25.2004)
34 ✻ 1120 121 7801 1 Strainer (25.2004)
✻ 4140 007 1060 1 Set of carburetor parts (25.2004)
☐ 9, 10, 18 - 20
24
Drawing M Carburetor C1QS66 (36.2002)

25
Drawing M Carburetor C1QS66 (36.2002)
✻ 4140 120 0603 1Carburetor C1Q-S66 (36.2002)

☐ 1 - 34
1 ✻ 4137 120 7100 1 Throttle shaft with lever (36.2002)
2 ✻ 1123 122 3000 1 Spring (36.2002)
3 ✻ 4137 121 8900 1 Pin (36.2002)
4 ✻ 4137 121 8600 1 Washer (36.2002)
5 ✻ 1120 122 9000 1 E-clip (36.2002)
6 ✻ 4140 121 3302 1 Throttle shutter (36.2002)
7 ✻ 1125 122 7403 1 Round head screw (36.2002)
8 ✻ 1125 122 9001 1 E-clip (36.2002)
9 ✻ 1129 121 4800 1 Pump diaphragm (36.2002)
10 ✻ 1123 129 0905 1 Gasket (36.2002)
11 ✻ 1123 121 0800 1 End cover (36.2002)
12 ✻ 1120 122 7800 1 Oval head screw (36.2002)
13 ✻ 4116 121 5100 1 Inlet needle (36.2002)
14 ✻ 1120 122 3004 1 Spring (36.2002)
15 ✻ 1125 121 5000 1 Inlet control lever (36.2002)
16 ✻ 1120 121 9200 1 Spindle (36.2002)
17 ✻ 1120 122 6600 1 Collar screw (36.2002)
18 ✻ 1129 129 0900 1 Gasket (36.2002)
19 ✻ 4129 121 4700 1 Metering diaphragm (36.2002)
✻ 4140 007 1060 1 Set of carburetor parts (36.2002)
☐ 20
20 ✻ 1 Flange (D) (36.2002)
21 ✻ 4226 122 7100 4 Screw (36.2002)
22 ✻ 4229 122 6700 1 High speed adjustment screw (36.2002)
23 ✻ 4229 122 6800 1 Low speed adjustment screw (36.2002)
24 ✻ 1123 121 7800 1 Strainer (36.2002)
25 ✻ 4140 121 0800 1 End cover (36.2002)
26 ✻ 4226 121 2700 1 Cap (36.2002)
27 ✻ 4229 122 6200 1 Idle speed adjustment screw (36.2002)
28 ✻ 1125 122 4200 1 Ball (36.2002)
29 ✻ 4229 121 2700 1 Cap (36.2002)
30 ✻ 4229 121 5603 1 Fixed jet 0.37 (36.2002)
31 ✻ 4229 121 5800 1 Pump piston (36.2002)
32 ✻ 4140 122 3600 1 Sealing ring (36.2002)
33 ✻ 4229 122 3001 1 Spring (36.2002)
34 ✻ 1120 121 7801 1 Strainer (36.2002)
✻ (2)
(1) KM 55, 1129
KM007 1062(3) KM
55 C-E, 1 55
SetR,of(4)
carburetor parts(5)
KM 55 RC-E, (36.2002)
KM 55 RC-E DZ,
☐ 9, 10, 18,
(6) KM 55 RC-E Z, (7) KM 55 R-DZ, (8) KM 55 R-Z19

26
Drawing N Bike handle

27
Drawing N Bike handle
28
Drawing O Drive tube assembly, Loop handle

29
Drawing O Drive tube assembly, Loop handle
1 4140 710 7128 1 Drive tube assembly Ø 25.4 mm / 1''

☐ 13
2 4140 711 3203 1 Drive shaft
3 4140 740 3501 1 Carrier
☐4-7
4 4140 160 5201 1 Bushing
5 1118 162 8935 2 Washer
6 4140 716 2200 2 Bow
7 9455 621 0850 1 Circlip 10x1
8 4140 160 0700 1 Coupling sleeve
☐ 9 - 12
9 9022 341 1350 1 Spline screw IS-M6x25
10 4140 790 7501 1 Tommy screw
11 9210 319 0900 2 Hexagon nut M6
12 ✻ 9291 021 0140 1 Washer 6.4
13 4137 711 2101 1 Plug

14 0000 711 2500 1 Sleeve (3-8)
18 4130 790 1316 1 Loop handle (3-8)
☐ 19 - 22
19 4123 791 7400 2 Clamp (3-8)
20 9022 341 1350 2 Spline screw IS-M6x25 (3-8)
21 9222 068 0900 2 Square nut M6 (3-8)
22 9291 021 0140 2 Washer 6.4 (3-8)
23 4130 791 4400 1 Barrier bar (3-8)
24 0781 120 1110 1 Gear lubricant 225 g (B) (3-8)
30
Drawing P Drive tube extension HT-KM

31
Drawing P Drive tube extension HT-KM
2 4140 710 7143 1 Drive tube assembly 1 m (B) (5-8) USA

☐ 3, 5 - 14
3 4140 791 7201 2 Sleeve (B) (3-8)
5 0000 967 3638 1 Instruction label (B) (5-8) USA
6 4230 791 2000 1 Handle hose 185 mm / 7 5/16'' (B) (3-8)

7 4140 710 3200 1 Drive shaft (B) (3-8)
☐ 3, 8, 9
8 4140 711 2500 1 Sleeve (B) (3-8)
9 4140 716 2200 1 Bow (B) (3-8)
10 4140 160 0700 1 Coupling sleeve (B) (3-8)
☐ 11 - 14
11 9022 341 1350 1 Spline screw IS-M6x25 (B) (3-8)
12 4140 790 7501 1 Tommy screw (B) (3-8)
13 9210 319 0900 2 Hexagon nut M6 (B) (3-8)
14 ✻ 9291 021 0140 1 Washer 6.4 (B) (3-8)
32
Drawing Q Carbon Drive tube extension HT-KM, HL-KM

33
Drawing Q Carbon Drive tube extension HT-KM, HL-KM
4180 710 7107 1 Drive tube assembly 1 m (B) (5-8) USA

☐ 2 - 11, 13
2 4180 710 7108 1 Drive tube assembly Ø 25.4 mm / 1'' (B) (5-8) USA
☐ 13
3 4180 711 7300 1 Flexible liner (B) (3-8)
4 4180 710 3200 1 Drive shaft (B) (3-8)

☐ 5, 6
5 4140 716 2200 2 Bow (B) (3-8)
6 4180 711 2501 1 Sleeve (B) (3-8)
7 4180 791 7204 1 Sleeve (B) (3-8)
8 4140 160 0700 1 Coupling sleeve (B) (3-8)

☐ 9 - 11
9 9022 341 1350 1 Spline screw IS-M6x25 (B) (3-8)
10 4140 790 7501 1 Tommy screw (B) (3-8)
11 9210 319 0900 2 Hexagon nut M6 (B) (3-8)
13 4180 967 4001 1 Instruction label (B) (5-8) USA
34
Drawing R Tools, Extras

35
Drawing R Tools, Extras
1 0812 370 1000 1 Screwdriver T27x120x70

2 4130 893 7800 1 Locking pin (B)
3 4128 890 3400 1 Combination wrench (B)
4 0000 890 2300 1 Screwdriver
4 0000 890 2305 1 Screwdriver available in Brazil only
5 0000 891 0801 1 Tool roll (B)

6 0000 884 0307 1 Safety glasses (B)
7 0000 886 1411 1 Safety glasses (B) available in Brazil only
8 4119 710 9001 1 Full harness (B)

☐ 9 - 19
9 4119 710 6306 1 Backplate with strap
10 1 Strap 38x780mm / 1.5x30.7'' (D)
0000 930 2242 1 Webbing 38 mm x 5 m / 1.5x197'' (A, B)
11 1 Strap 25 mm x 1.18 m / 1x46.5'' (D)
0000 930 2241 1 Webbing 25 mm x 10 m / 1'' x 33' (A, B)
12 4119 718 6300 2 Slide
13 4119 718 6305 2 Slide
14 4119 718 6310 1 Slide
15 9408 021 4530 12 Rivet shank 4x8x6
16 9409 021 4420 12 Rivet head 4x8
17 4119 718 7400 1 Guard plate
4119 710 6406 1 Buckle with strap
☐ 18
18 4119 710 6400 1 Buckle
19 4119 710 6906 1 Spring safety hook
20 4130 710 9000 1 Harness (B)
36

KM55RCEZ

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Drawing A Crankcase, Cylinder

KM 55, KM 55 C, KM 55 R, KM 55 RC SCS 03-2007 3.23

Reference Item number Qty Description

1 4140 021 0300 1 Crankcase

9 ✻ 4140 020 1200 1 Cylinder with piston Ø 34 mm (23.2003)

10 4140 030 2000 1 Piston Ø 34 mm

KM 55, KM 55 C, KM 55 R, KM 55 RC SCS 03-2007 3.23

Reference Item number Qty Description

8 0000 190 3404 1 Starter grip ElastoStart Ø 3 mm (B)

KM 55, KM 55 C, KM 55 R, KM 55 RC SCS 03-2007 3.23

Reference Item number Qty Description

1 4140 190 4010 1 Rewind starter (2,4-6)

KM 55, KM 55 C, KM 55 R, KM 55 RC SCS 03-2007 3.23

Reference Item number Qty Description

2 4140 140 0610 1 Muffler (6,8) USA, AUS, CDN

5 ✻ 4140 140 0605 1 Muffler (6,8) USA, AUS, CDN (23.2003)

7 4140 149 0602 1 Exhaust gasket (1-4,6,8)

KM 55, KM 55 C, KM 55 R, KM 55 RC SCS 03-2007 3.23

Reference Item number Qty Description

KM 55, KM 55 C, KM 55 R, KM 55 RC SCS 03-2007 3.23

Reference Item number Qty Description

1 4140 400 1200 1 Flywheel (25.2005)

4 4140 160 2005 1 Clutch

5 4140 162 7900 2 Tension spring

KM 55, KM 55 C, KM 55 R, KM 55 RC SCS 03-2007 3.23

Reference Item number Qty Description

KM 55, KM 55 C, KM 55 R, KM 55 RC SCS 03-2007 3.23

Reference Item number Qty Description

1 4140 020 3000 1 Engine housing (3-8)

KM 55, KM 55 C, KM 55 R, KM 55 RC SCS 03-2007 3.23

Reference Item number Qty Description

1 4140 124 2800 1 Filter

10 ✻ 4140 120 0606 1 Carburetor C1Q­S71 (25.2004)

12 4114 149 1205 1 Gasket

KM 55, KM 55 C, KM 55 R, KM 55 RC SCS 03-2007 3.23

Reference Item number Qty Description

19 4232 350 0411 1 Fuel tank

KM 55, KM 55 C, KM 55 R, KM 55 RC SCS 03-2007 3.23

Reference Item number Qty Description

4140 120 0612 1 Carburetor C1Q­S97

KM 55, KM 55 C, KM 55 R, KM 55 RC SCS 03-2007 3.23

Reference Item number Qty Description

✻ 4140 120 0606 1 Carburetor C1Q­S71 (C) (25.2004)

KM 55, KM 55 C, KM 55 R, KM 55 RC SCS 03-2007 3.23

Reference Item number Qty Description

✻ 4140 120 0603 1Carburetor C1Q-S66 (36.2002)

KM 55, KM 55 C, KM 55 R, KM 55 RC SCS 03-2007 3.23

KM 55, KM 55 C, KM 55 R, KM 55 RC SCS 03-2007 3.23

Reference Item number Qty Description

KM 55, KM 55 C, KM 55 R, KM 55 RC SCS 03-2007 3.23

Reference Item number Qty Description

1 4140 710 7128 1 Drive tube assembly Ø 25.4 mm / 1''

12 ✻ 9291 021 0140 1 Washer 6.4

13 4137 711 2101 1 Plug

KM 55, KM 55 C, KM 55 R, KM 55 RC SCS 03-2007 3.23

Reference Item number Qty Description

2 4140 710 7143 1 Drive tube assembly 1 m (B) (5-8) USA

3 4140 791 7201 2 Sleeve (B) (3-8)

5 0000 967 3638 1 Instruction label (B) (5-8) USA

10 ✻ 4140 120 0606 1 Carburetor C1QS71 (25.2004)

4140 120 0612 1 Carburetor C1QS97

✻ 4140 120 0606 1 Carburetor C1QS71 (C) (25.2004)