CYLINDER HEAD ASSEMBLY

FIG.NO. 01

NO.OFF

REF

PART

DESCRIPTION

RTR 180

REMARKS

NO.

NO.

RR. DISC

1

N90105107D

CYLINDER HEAD ASSEMBLY KIT

1

**

2

-----

COVER CYLINDER HEAD

1

3

M1010380

CAP INSPECTION HOLE

2

4

M1010390

O-RING 29.5x3

2

5

M1010540

PLUG ROCKER ARM SHAFT

2

6

M1080520

GASKET - OIL DRAIN 13.8 x 4.8

2

7

M7010850

SHAFT VALVE ROCKER ARM

2

8

M1200600

HEX FLANGE BOLT M6x45

2

9

M1200010

HEX FLANGE BOLT M6x55

4

10

N2010960

GASKET CYLINDER HD COVER BOLT

4

11

M1200590

HEX FLANGE BOLT M6x35

4

12

M7010780

ARM VALVE ROCKER ASSY.

2

13

S1010250

NUT TAPPET ADJUSTING

2

14

S1010240

SCREW TAPPET ADJUSTING

2

15

M1200060

PUNCHED WASHER 8.5 x 18 x 2.3

2

16

M1010090

PIN CYLINDER HEAD COVER KNOCK

2

17

M7010270

VALVE INTAKE

1

18

M1200050

DOMED NUT WITH FLANGE M8

4

19

M1010360

GASKET CYLINDER HEAD NUT

2

20

M7011010

SPARK PLUG (UR5 DDC)

1

21

N90105007D

HEAD COMP. CYLINDER

1

22

M1080990

TENSIONER CAM CHAIN

1

23

S1010320

COTTER VALVE

4

24

N2011040

RETAINER VALVE SPRING

2

25

N3011280

SPRING VALVE INNER

2

26

M1010580

SPRING VALVE OUTER

2

** - REFER KIT & KIT CONTENTS

FIG.No.01

CYLINDER HEAD ASSEMBLY

CYLINDER HEAD ASSEMBLY

FIG.NO. 01

NO.OFF

REF

PART

DESCRIPTION

RTR 180

REMARKS

NO.

NO.

RR. DISC

27

M1010610

SEAT VALVE SPRING

2

28

M1010620

SEAL VALVE STEM OIL

2

29

M1200220

O RING 31.7x2.4

1

30

M7040730

PIPE COMPLETE INTAKE

1

31

0332228

CRR PAN HEAD SCREW

2

32

M1040140

CLAMP INTAKE PIPE

1

33

M1080510

BOLT CAM CHAIN TENSIONER

1

34

M7010800

CAMSHAFT ASSY.

1

35

M7011110

DAMPER CYLINDER HEAD 1

2

36

M7011120

DAMPER CYLINDER HEAD 2

1

37

M7011130

DAMPER CYLINDER HEAD 3

2

38

M1010490

PIN SPROCKET KNOCK

1

39

M1200780

STUD BOLT CYLINDER HEAD

4

40

M7010280

VALVE EXHAUST

1

41

M1010200

CAM CHAIN . CAMSHAFT DRIVE (LINK 94)

1

42

M1010210

SPROCKET CAMSHAFT 32T

1

43

M1080500

WASHER SPROCKET

1

44

420452700

HEX SCREW M6x12

2

45

M7010840

C - RING CAMSHAFT

1

46

M7010910

PLUG CYLINDER HEAD

1

47

M7322010

ENGINE VALVE KIT

1

**

** REF. KIT & KIT CONTENTS

FIG.No.01

CYLINDER HEAD ASSEMBLY

CYLINDER BLOCK & CRANK SHAFT ASSY.

FIG.NO. 02

NO.OFF

REF

PART

DESCRIPTION

RTR 180

REMARKS

NO.

NO.

RR. DISC

1

M1010250

GUIDE CAM CHAIN

1

2

S1200270

TUBULAR DOWEL

4

3

M7011320

GASKET CYLINDER HEAD

1

4

M7011310

CYLINDER COMPLETE (180cc)

1

5

M1200900

HEX FLANGE NUT M6

4

6

M1010660

GASKET CYLINDER (BASE)

1

7

M1010510

GASKET TENSIONER ADJUSTER

1

8

M7011370

ADJUSTER ASSY. TENSIONER

1

9

N2200500

HEX FLANGE BOLT M6x25

2

10

M1010440

CIRCLIP PISTON PIN

2

11

N9020150

RING SET PISTON - STD

1

**

11A

N9323030

RING SET PISTON - I O/S

1

"

11B

N9323040

RING SET PISTON - II O/S

1

"

12

N3080170

KEY 4x4x15 (RECTANGULAR)

1

13

M1200760

WOODRUFF KEY ( HALF ROUND TYPE)

1

14

N9020120

CRANKSHAFT ASSEMBLY

1

15

M7020370

PIN PISTON

1

16

N9020140

PISTON KIT DIA 62.5 - STD

1

**

17

N9323010

PISTON KIT 62.75 - I O/S

1

**

18

N9323020

PISTON KIT DIA 63 - II O/S

1

**

19

N9323000

CYLINDER BLOCK & PISTON KIT

1

20

R1321190

O' RING ADJUSTER TENSIONER

1

21

R1321210

O' RING CAP ADJUSTER

1

22

R1321200

CAP ADJUSTER TENSIONER

1

23

N9180030

ENGINE ASSEMBLY ES

1

** REF KIT & KIT CONTENTS

FIG.No.02

CYLINDER BLOCK & CRANK SHAFT ASSY.

CRANKCASE LH, RH & OIL PUMP ASSY.

FIG.NO. 03

NO.OFF

REF

PART

DESCRIPTION

RTR 180

REMARKS

NO.

NO.

RR. DISC

1

N9322780

CRANKCASE ASSY. RH

1

2

M1080360

UNION BREATHER

1

3

M1080650

CLAMP HOSE

1

4

M1040740

TUBE BREATHER

1

5

M1200510

HEX FLANGE BOLT M6x25

2

6

M1081090

UNION BOLT OIL PIPE

1

7

M1060060

STARTER MOTOR ASSY.

1

8

M1080380

UNION BOLT OIL PIPE

2

9

M1080370

GASKET OIL PIPE UNION

6

10

M1010260

PIPE COMP. HEAD & T/M OIL

1

11

0074010

DOWEL PIN

4

12

M1010400

BOLT CYLINDER STUD L142

4

13

M70300707D

CRANKCASE COMP. LH

1

14

N2081720

OILSEAL

1

15

M1200920

PUNCHED WASHER

1

16

M1200870

CIRCLIP 12x1

1

17

M1200430

HEX FLANGE BOLT M6x55

9

18

M1200440

HEX FLANGE BOLT M6x75

3

19

M1080430

PIN MAGNETO COVER

1

20

M1200450

HEX FLANGE BOLT M6x95

1

21

M1080420

GASKET TDC PLUG

1

22

M1200080

HEX SCREW M12x10

1

23

M1200780

STUD BOLT CYLINDER HEAD

2

24

M7200530

BALL BEARING 35x72x17

1

25

M1080580

PLUG OIL DRAIN

1

FIG.No.03

CRANKCASE LH, RH & OIL PUMP ASSY.

CRANKCASE LH, RH & OIL PUMP ASSY.

FIG.NO. 03

NO.OFF

REF

PART

DESCRIPTION

RTR 180

REMARKS

NO.

NO.

RR. DISC

26

S1011290

SEALING WASHER

1

27

M1200530

HEX FLANGE BOLT M6x20

3

28

M1080570

CAP OIL STRAINER

1

29

M1080610

O-RING 60.5x2.4

1

30

420515700

CRR PAN HD SCREW M4x10

2

31

M1080560

STRAINER COMP. ENGINE OIL

1

32

M1030120

PIN CRANKCASE

2

33

M1200070

HEX FLANGE BOLT M10x12

2

34

N2081600

GASKET OIL GALLERY PLUG

2

35

M1200140

BALL BEARING 28x68x18

1

36

N9080240

PUMP ASSEMBLY OIL

1

37

M1200730

CIRCLIP 6x0.8

1

38

0332228

CRR CSK HEAD SCREW M6x20

3

39

0064014

PIN CLUTCH SPG

1

40

M7081220

GEAR OIL PUMP DRIVEN

1

FIG.No.03

CRANKCASE LH, RH & OIL PUMP ASSY.

CLUTCH & COVER CLUTCH ASSY.

FIG.NO. 04

NO.OFF

REF

PART

DESCRIPTION

RTR 180

REMARKS

NO.

NO.

RR. DISC

1

M1200540

HEX FLANGE BOLT M6x65

2

2

M1200520

HEX FLANGE BOLT M6x16

1

3

M70809607D

CAP OIL FILTER PAINTED

1

4

M1080600

O RING 52.6x2.4

1

5

M1080620

SPRING OIL FILTER

1

6

M1080540

FILTER COMPLETE ENGINE OIL

1

7

M1080590

O RING 13x1.9

1

8

M70304207D

COVER CLUTCH

1

9

N2081150

GUAGE OIL LEVEL

1

10

M1080400

O RING 16.8x3.1

1

11

M7200510

BEARING BUSH

2

12

M7200490

OIL SEAL 12x18x4

1

13

M7070380

SPRING CLUTCH CABLE RETURN

1

14

M7200500

SPRING DOWEL

1

15

M7070350

ROD COMP. CLUTCH RELEASE

1

16

N2200550

OIL SEAL 12x2x17

1

17

0074010

DOWEL PIN

2

18

M1080330

GASKET CLUTCH COVER

1

19

M7200740

HEX FLANGE BOLT M6x30

10

20

M1080630

WASHER PRIMARY DRIVE GEAR

1

21

M1080010

GEAR OIL PUMP DRIVE

1

22

M1080080

GEAR PRIMARY DRIVE (21T)

1

23

0339060

BALL BEARING 12x28x8

1

24

M1200530

HEX SOCKET CAP SCREW M6x25

4

25

M7070130

PIN ASSY CLUTCH RELEASE

1

FIG.No.04

CLUTCH & COVER CLUTCH ASSEMBLY

CLUTCH & COVER CLUTCH ASSY.

FIG.NO. 04

NO.OFF

REF

PART

DESCRIPTION

RTR 180

REMARKS

NO.

NO.

RR. DISC

26

N2070360

PLATE CLUTCH RELEASE

1

27

M7070440

SPRING CLUTCH

4

28

M7070100

NUT CLUTCH SHAFT

1

29

M7070110

SPRING WASHER CLUTCH SHAFT

1

30

M7070060

HUB CLUTCH

1

31

M7321890

SET PLATE CLUTCH DRIVE (5 Nos)

1

32

M7321900

SET PLATE CLUTCH DRIVEN (4Nos)

1

33

N2070200

DISC CLUTCH PRESSURE

1

34

M7070240

WASHER CLUTCH HUB

1

35

M7080840

GEAR ASSY. PRIMARY DRIVEN

1

36

0339310

BUSH PRIMARY DRIVEN GEAR

2

37

M1200250

HEX NUT M16x1.5

1

38

M7070330

BRACKET CLUTCH CABLE

1

FIG.No.04

CLUTCH & COVER CLUTCH ASSEMBLY

MAGNETO & IGNITION COIL ASSEMBLY

FIG.NO. 05

NO.OFF

REF

PART

DESCRIPTION

RTR 180

REMARKS

NO.

NO.

RR. DISC

1

M1080320

GASKET MAGNETO COVER

1

2

N2081680

PLUG TDC

1

3

M1080420

GASKET TDC PLUG

1

4

M70301707D

COVER MAGNETO

1

5

M7200700

HEX FLANGE BOLT M6x40

9

6

N92210907D

COVER ENGINE SPROCKET

1

7

M1200670

CRR PAN HD SCREW SCREW M6x20

2

8

N2081690

O RING 22.7x3.1

1

9

M7080980

PLUG CRANKSHAFT HOLE

1

10

M1203670

CRR PAN HEAD SCREW M6x12

1

11

N9060180

COIL ASSEMBLY IGNITION

1

12

0098010

SEAL HIGH TENSION CORD

1

13

N9060280

CAP ASSEMBLY SPARK PLUG

1

14

S1060310

SEAL SPARK PLUG

1

15

M1070100

CLAMP MAGNETO LEAD - 2

1

16

0331708

CRR PAN HEAD SCREW M5x12

4

17

M1121040

CLAMP MAGNETO LEAD -1

1

18

N9322450

STATOR ASSEMBLY

1

19

M1200820

CRR PAN HEAD SCREW M6x25

2

20

M1200770

HEX FLANGE NUT M12x1.25

1

21

M1200790

HEX SOCKET HEAD CAP SCREW M6

3

22

N9060400

MAGNETO ASSEMBLY

1

FIG.No.05

MAGNETO & IGNITION COIL ASSEMBLY

MAGNETO & IGNITION COIL ASSEMBLY

FIG.NO. 05

NO.OFF

REF

PART

DESCRIPTION

RTR 180

REMARKS

NO.

NO.

RR. DISC

23

N9321920

ROTOR ASSEMBLY

1

24

N9060320

PULSAR COIL

1

25

M1080480

GEAR COMP. STARTER CLUTCH

1

26

R1060110

CLUTCH STARTER ONE WAY

1

27

M1080460

GEAR STARTER IDLE

1

28

M1080490

SPACER STARTER IDEL GEAR

1

29

M1200170

NEEDLE ROLLER BEARING

1

30

N9080440

STOPPER STARTER GEAR

1

FIG.No.05

MAGNETO & IGNITION COIL ASSEMBLY

MUFFLER ASSEMBLY

FIG.NO. 06

NO.OFF

REF

PART

DESCRIPTION

RTR 180

REMARKS

NO.

NO.

RR. DISC

1

N5200180

HEX SOC HD CAP SCREW M8x30

2

2

S1125310

CUSHION

1

3

M1200890

HEX FLANGE U NUT M12x1.25

1

4

N9053160

MUFFLER ASSY. (WITH GUARD)

1

5

N3200210

PUNCHED WASHER 8.2x25x2

2

6

N9053180

MUFFLER COMP. (WITHOUT GUARD)

1

7

N9051850

CUSHION GUARD EXHAUST

1

8

N9051520

DAMPER BRACKET EXHAUST

1

9

N9051860

CUP WASHER

3

10

0335518

PUNCHED WASHER 8.2x16x1.2

2

11

N9221180

GUARD EXHAUST REAR

1

12

N8200150

HEX BOLT M8x60

1

13

N8050690

INSULATOR GUARD EXHAUST

3

14

R1200220

SPL SCREW PAN HEAD SCREW M6x12

2

15

N9053170

GASKET EXHAUST PIPE

1

16

N9221200

GUARD EXHAUST FRONT

1

17

N9200100

HEX FLANGE BOLT M6x8

2

FIG.No.06

MUFFLER ASSEMBLY

CARBURETTOR ASSEMBLY

FIG.NO. 07

NO.OFF

REF

PART

DESCRIPTION

RTR 180

REMARKS

NO.

NO.

RR. DISC

1

N9041400

CARBURETTOR ASSY.

1

2

M1040530

SCREW DIAPHRAGM COVER

2

3

M1040190

COVER DIAPHRAGM

2

4

M7320220

SPRING DIAPHRAGM

1

5

M1040760

SCREW PLATE JET NEDDLE

2

6

M1040910

PLATE JET NEEDLE

1

7

M1040770

SPRING JET NEDDLE

1

8

M1040780

PACKING JET NEEDLE

1

9

M1040250

E- RING JET NEEDLE

1

10

N9322960

RING JET NEEDLE

1

11

N9322870

JET NEEDLE (NEEDLE)

1

12

M1040220

DIAPHRAGM

1

13

N9322880

PISTON VALVE

1

14

M1040800

RING PISTON VALVE

1

15

M1040500

E-RING THROTTLE SHAFT

1

16

M1040510

PACKING THROTTLE SHAFT

1

17

M1040520

O RING THROTTLE SHAFT

2

18

M1041070

AIR JET (PAJ 2) - 145

1

19

M1040430

O RING MCS

1

20

M1040420

WASHER MCS

1

21

M1040410

SPRING MCS

1

22

N9322940

MIXTURE CONTROL SCREW (MCS)

1

23

N9322890

NEEDLE JET (JET)

1

24

M1040810

O RING JET HOLDER

1

25

N9322900

JET HOLDER

1

FIG.No.07

CARBURETTOR ASSEMBLY

CARBURETTOR ASSEMBLY

FIG.NO. 07

NO.OFF

REF

PART

DESCRIPTION

RTR 180

REMARKS

NO.

NO.

RR. DISC

26

N9322910

MAIN JET

1

27

N9322920

PILOT JET (15)

1

28

M1040490

SPRING IDLING SCREW

1

29

M1040470

PACKING IDLING SCREW

1

30

M1040460

IDLING SCREW

1

31

N9322950

NEEDLE VALVE ASSEMBLY

1

32

M1040340

FLOAT ASSEMBLY

1

33

M1040280

SCREW VALVE SEAT

1

34

M1040290

PIN FLOAT

1

35

M1040820

SEAL BOWL

1

36

N9322930

FLOAT BODY ASSEMBLY

1

37

M1040440

SCREW DRAIN

1

38

M1040540

SCREW FLOAT CHAMBER

2

39

M7321340

HOSE DRAIN

1

40

M7321350

HOSE AIR VENT

1

41

M1040370

PLUNGER STARTER

1

42

M1040380

SPRING STARTER

1

43

M1040870

O RING STARTER

1

44

M1040390

GUIDE HOLDER ASSEMBLY

1

45

M1040570

CAP STARTER

1

46

-----

SPRING THROTTLE SHAFT

1

N.S

47

-----

BUSH THROTTLE SAHFT

1

"

48

-----

THROTTLE VALVE

1

"

49

-----

THROTTLE SHAFT

1

"

50

M1040900

SCREW THROTTLE VALVE

1

51

M1040940

CAP CARBURETTOR

1

FIG.No.07

CARBURETTOR ASSEMBLY

AIR CLEANER ASSEMBLY

FIG.NO. 08

NO.OFF

REF

PART

DESCRIPTION

RTR 180

REMARKS

NO.

NO.

RR. DISC

1

M7041070

AIR CLEANER ASSEMBLY

1

2

M1040630

CLAMP OUTLET PIPE

1

3

M1040170

TRAP COMP. FLAME

1

4

M1040700

FILTER COMP. AIR CLEANER

1

5

M1040670

GASKET INLET

1

6

M7041090

INLET COMP. AIR CLEANER

1

7

M1200660

CRR PAN HEAD SCREW M5x16

4

8

0332275

CRR PAN HEAD SCREW

2

9

M7040749

CASE AIR CLEANER

1

10

0335608

PUNCHED WASHER 6.5x16x1.2

2

11

M1040610

GASKET TRAP FLAME

1

12

M7040790

SAI FOAM

1

13

M7040780

RESONATOR

1

14

M7040820

HOSE CLIP DIA 18

1

15

M7041030

HOSE CLIP DRAIN PIPE

1

16

N3040360

DRAIN PIPE

1

17

K140820

HOSE CLIP

2

18

M7041000

BREATHER HOSE PCV

1

19

N9321790

FOAM KIT

1

**

** - REF. KIT & KIT CONTENTS

FIG.No.08

AIR CLEANER ASSEMBLY

KICK STARTER ASSEMBLY

FIG.NO. 09

NO.OFF

REF

PART

DESCRIPTION

RTR 180

REMARKS

NO.

NO.

RR. DISC

1

N2081720

OIL SEAL KICK STARTER SHAFT

1

2

0335014

SHIM 15x30x1

1

3

M7080570

GEAR KICK STARTER DRIVE

1

4

M1080890

RATCHET KICK STARTER

1

5

M1080930

SPRING KICK STARTER

1

6

M1201190

HEX SCREW M6x30

2

7

M1080900

GUIDE KICK STARTER

1

8

N2081650

STOPPER KICK STARTER

1

9

M7080740

SHAFT KICK STARTER

1

10

0335714

SHIM 16x30x0.5

1

11

M1080940

SPRING KICK SHAFT RETURN

1

12

N3080270

GUIDE KICK STARTER SPRING

1

13

M7081950

JOINT KICK STARTER

1

14

N2081450

PIN LEVER ASSY. KICK STARTER

1

15

N3200240

CIRCLIP - TYPE E

1

16

N2081440

BALL LEVER ASSY. K S LEVER

1

17

N2081430

SPRING LEVER ASSY. KICK STARTER

1

18

N2081760

RUBBER KICK STARTER LEVER

1

19

M7081500

LEVER ASSY. KICK STARTER

1

20

M7081490

LEVER KICK STARTER

1

FIG.No.09

KICK STARTER ASSEMBLY

TRANSMISSION ASSEMBLY

FIG.NO. 10

NO.OFF

REF

PART

DESCRIPTION

RTR 180

REMARKS

NO.

NO.

RR. DISC

1

M1200260

BALL BEARING 20x47x14

1

2

M7200250

OIL SEAL 20x40x6

1

3

M7081100

RETAINER DRIVE SHAFT

1

4

0332068

CRPH SCREW M6x12

2

5

N9112830

DRIVE CHAIN WITH O RING 130 LINKS

1

6

N9322720

LINK SET CHAIN

1

7

N9080250

SPROCKET ENGINE 14T

1

8

M7080870

LOCK PLATE ENGINE SPROCKET

1

9

M1200940

HEX SCREW M5x10

2

10

M7200260

NEEDLE ROLLER BEARING 15x23x12

1

11

0335014

SHIM 15x30x1.0

1

12

M7080400

GEAR COMP. KICK START. IDLE (26T)

1

13

M7080340

GEAR COMP. 1st DRIVEN

1

14

M7200420

SHIM

1

15

M7080310

GEAR 4th DRIVEN

1

16

0330174

CIRCLIP 20x1.2

1

17

M7080860

SHIM 15x30x1.0

1

18

M7080280

GEAR 3rd DRIVEN

1

19

M7080320

GEAR 5th DRIVEN

1

20

M7081300

SHAFT COMP. DRIVE

1

21

M7080890

GEAR 2nd DRIVEN (27T)

1

22

N5080060

BUSH Ist DRIVEN

1

23

M7200040

THRUST WASHER

1

24

M7080460

COUNTER SHAFT ASSY.

1

25

M7080439

SHAFT COMP. COUNTER

1

26

M7080309

GEAR 4TH DRIVE

1

FIG.No.10

TRANSMISSION ASSEMBLY