Cushman 1600XD 4X4 User manual

X
™
OWNER’S MANUAL
1600XD 4X4
25045G-GB (Rev.0)
RJL 100 May 2012

TABLE OF CONTENTS
[ENGINE]
3C100LWU-E010 CYLINDER BLOCK GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . .1
3C100LWU-E020 OIL PAN GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3C100LW-E030 CYLINDER HEAD COVER GROUP. . . . . . . . . . . . . . . . . . . . .4
3C100A-E040 GEAR CASE GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3C100LW-E040 GEAR CASE GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
3C100A-E050 MAIN BEARING CASE GROUP. . . . . . . . . . . . . . . . . . . . . . . .11
3C100A-E080 VALVE ROCKER ARM GROUP. . . . . . . . . . . . . . . . . . . . . . . .12
3C093LW-E090 CYLINDER HEAD COVER GROUP. . . . . . . . . . . . . . . . . . . . .13
3C100A-E100 CAMSHAFT GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3C100A-E110 PISTON & CRANKSHAFT GROUP. . . . . . . . . . . . . . . . . . . . . 15
3C100LWU-E110 PISTON & CRANKSHAFT GROUP. . . . . . . . . . . . . . . . . . . . . 17
3C100LWU-E120 FLYWHEEL GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
3C100LWU-E130 NOZZLE HOLDER GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3C100LWU-E140 FUEL CAMSHAFT GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3C100A-E150 SPEED CONTROL LEVER GROUP. . . . . . . . . . . . . . . . . . . . .22
3C100LW-C-E160 ENGINE STOP LEVER GROUP. . . . . . . . . . . . . . . . . . . . . . . .24
3C100A-E170 GOVERNOR GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
3C100LWU-E190 WATER HOSE GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3C100LWU-E200 ALTERNATOR GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3C100LWU-E220 MANIFOLD GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
[FRONT AXLE]
U1-T230A BEVEL PINION SHAFT GROUP. . . . . . . . . . . . . . . . . . . . . . . 31
U1-U0550A Front Axle Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
[TRANSMISSION]
U1-T100A TRANSMISSION CASE GROUP. . . . . . . . . . . . . . . . . . . . . . . 33
U1-U0100A TRANSMISSION GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
U1-T110A DRIVE SHAFT GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
U1-T120A SHIFT SHAFT GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
U1-T130A SPRIAL BEVEL GEAR GROUP. . . . . . . . . . . . . . . . . . . . . . . . 38
U1-T140A REAR WHEEL DRIVING SHAFT GROUP. . . . . . . . . . . . . . . . 39
U1-T150A FRONT WHEEL DRIVE SHAFT GROUP. . . . . . . . . . . . . . . . . 40
U1-T160A FRONT DRIVE FORK GROUP. . . . . . . . . . . . . . . . . . . . . . . . .41
U1-T170A SHIFT FORK GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
U1-T180A REAR AXLE CASE GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . .43
U1-T190A REAR DIFF SYSTEM GROUP. . . . . . . . . . . . . . . . . . . . . . . . . 44
U1-T200A REAR DIFF FORK GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . 46
U1-T210A FRONT AXLE CASE GROUP. . . . . . . . . . . . . . . . . . . . . . . . . .47
U1-T220A FRONT DIFF SYSTEM GROUP. . . . . . . . . . . . . . . . . . . . . . . .48
U1-U0230A Front Axle Drive Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
U1-U0235A Rear Differential Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
U1-U0240A Rear Axle Drive Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
- i -

- ii -
U1-U0245A Propeller Shaft Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
U1-U0300A Rear Differential Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
[CHASSIS]
U3-U0200A Structure Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
U1-U0210A Guard Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
U3-U0220A ROPS GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
U1-U0250A ENGINE MOUNTING GROUP. . . . . . . . . . . . . . . . . . . . . . . . . 59
U1-U0260A LEVER GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
U1-U0270A Accelerator Pedal Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
U1-U0284A CVT Group, DC(STD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
U3-U0287A CLUTCH COVER GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
U1-U0290A Wheel & Tire Group(WORK). . . . . . . . . . . . . . . . . . . . . . . . . . .69
U1-U0400A Front Break Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
U1-U0410A Rear Break Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
U1-U0420A BRAKE PEDAL GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
U1-U0430A PACKING BACKE GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . .75
U1-U0500A Front Suspension Group(STD). . . . . . . . . . . . . . . . . . . . . . . . . 76
U1-U0510A Rear Suspension Group(STD). . . . . . . . . . . . . . . . . . . . . . . . . 79
U1-U0522A Steering Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
U1-U0700A Fuel System Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
U1-U0710A Intake System Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
U3-U0720A Exhaust System Group(STD). . . . . . . . . . . . . . . . . . . . . . . . . . 88
U1-U0730A RADIATOR GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
U1-U0800A IP GROUP(KIOTI). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
U1-U0802A IP Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
U3-U0811A Seat Group(With SUS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
U3-U0858A Label Group(1600XD-EU). . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
U3-U0900A Molding Group(STD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
U1-U0922A Deck Group(STD-BLACK). . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
U3-U0990A MIRROR GROUP(STD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
U3-U1020A FRONT HITCH GROUP(EEC)- STD. . . . . . . . . . . . . . . . . . . . .104
U3-U1110A SWING DRAWBAR GROUP(EEC)- STD. . . . . . . . . . . . . . . . . 105
U1-U1670A PARKING LOCK BUZZER GROUP. . . . . . . . . . . . . . . . . . . . . 106
U1-U1680A NUMBER PLATE GROUP (STD). . . . . . . . . . . . . . . . . . . . . . . 107
U3-U1750A ALARM SYSTEM BACKUP, GROUP(STD). . . . . . . . . . . . . . . 108
U1-U3950A HAND THROTTLE GROUP-OPT. . . . . . . . . . . . . . . . . . . . . . . 109
U1-U5030A WINCH GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
U1-U5080A SUSP DUST SHIELD GROUP-OPT. . . . . . . . . . . . . . . . . . . . .111
[ELECTRICAL]
U1-U0600A ELECTRICAL SYSTEM 1 GROUP. . . . . . . . . . . . . . . . . . . . . .112
U1-U0610A ELECTRICAL SYSTEM 2 GROUP. . . . . . . . . . . . . . . . . . . . . .113
U1-U0620A ELECTRICAL SYSTEM 2 GROUP. . . . . . . . . . . . . . . . . . . . . .114
U1-U0630A Battery Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
- ii -

- iii -
U1-U0640A HEAD LIGHT GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
U1-U3933A WIPER GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
U1-U3936A WIPER GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
[OPTION]
U1-U0820A HEAD REST GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
U1-U0913A HOOD GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
U3-U0980A OPTIONAL LAMP GROUP(EU). . . . . . . . . . . . . . . . . . . . . . . . 123
U1-U1000A Gas Spring GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
U1-U3291A Wheel & Tire Group(OPT-Mud). . . . . . . . . . . . . . . . . . . . . . . . .127
U1-U3292A Wheel & Tire Group(OPT-Turf). . . . . . . . . . . . . . . . . . . . . . . . .128
U1-U3830A REAR SCREEN GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
U3-U3931A SAFTY GLASS GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
U3-U3932A WIND SHIELD GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
U1-U3940A HYDRAULIC SYSTEM GROUP (1)-OPT. . . . . . . . . . . . . . . . . 133
U1-U3941A HYDRAULIC SYSTEM GROUP (2)-OPT. . . . . . . . . . . . . . . . . 138
U1-U3960A SKID PLATE GROUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
U1-U3970A CANOPY GROUP-OPT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
U3-U5650A WORKING LAMP 2 GROUP(OPTION). . . . . . . . . . . . . . . . . . .141
U1-U5660A WORKING LAMP GROUP(OPTION). . . . . . . . . . . . . . . . . . . . 142
U1-U5920A DECK EXTENSION GROUP(OPTION). . . . . . . . . . . . . . . . . . 143
INDEX 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
INDEX 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
INDEX 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

3C100LWU-E010 CYLINDER BLOCK GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
1 E5763-A0012 1 CYLINDER BLOCK ASSY
1 E5763-A0013 1<---- CYLINDER BLOCK ASSY
2 06311-75015 3T1.6*18*18 PLUG
3 06311-75040 1 PLUG
4 15321-9626-3 6 PLUG
5 E5900-96021 9 PLUG
6 E5900-96031 1 PLUG
7 05012-00609 4 PIN, PARALLEL
8 05012-00814 2DIA10*20 PIN, PARALLEL
9 E5205-33961 2 TUBE PIN
10 15221-3365-1 1 PIN, TUBE
11 E5500-33702 1 O RING
12 E5205-73911 1 COVER
13 E5700-73922 1 GASKET
14 01023-50618 2 BOLT, WASHER
15 06312-10020 1PT1/4 PLUG
16 E5700-35012 1 OIL PUMP ASSY
17 E5700-35154 1 GASKET, OIL PUMP
18 E5205-91021 4 BOLT, WASHER
- 1 -

3C100LWU-E010 CYLINDER BLOCK GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
19 E5700-35662 1 GEAR, OIL PUMP DRIVE
20 05712-00408 15*5*12 KEY
21 E5753-35681 1 NUT, FLANGE
22 E5500-39013 1 OIL SWITCH
23 E5760-23471 1 METAL 1, CRANKSHAFT
- 2 -

3C100LWU-E020 OIL PAN GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
1 E5775-A0071 1 FAN OIL ASSY
1 E5775-A0072 1<---- ASSY FAN,OIL
2 15221-3375-2 1 PLUG, OIL DRAIN
2 E1100-33752 1<---- PLUG, OIL DRAIN
3 04717-01200 1 WASHER, SEAL
3 E6303-33661 1<---- GASKET
4 E5700-01624 1 GASKET, OIL PAN
5 E5700-91094 18 BOLT
6 E5775-32111 1 FILTER 1, OIL
7 04811-00140 1 O RING
8 01654-50820 1 BOLT, FLANGE WITH PIN
9 E5752-35692 1 GUIDE, OIL GAUGE
10 E5752-36422 1 GUIDE PIPE, OIL GAUGE
11 E7310-36431 1 PACKING
12 E5752-36412 1 OIL GAUGE
- 3 -

3C100LW-E030 CYLINDER HEAD COVER GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
1 E5763-A0302 1 CYLINDER HEAD TOTAL ASSY
1 E5763-A0303 1<---- TOTAL CYLINDER HEAD ASSY
1 E5763-A0304 1<---- TOTAL CYLINDER HEAD ASSY
2 E5205-03371 5 CAP
3 15321-9626-3 1 PLUG
4 E5900-96021 2 PLUG
5 E5205-13542 3 GUIDE, INTAKE VALVE
6 E5205-13562 3 GUIDE, VALVE
7 E5760-03141 3 HOT FLUG
8 E5770-03451 14 BOLT, CYLINDER HEAD
9 E5760-03313 1 GASKET, CYLINDER HEAD
9 E5760-03314 1<---- GASKET, HEAD
10 15221-0175-1 1 ENGINE HOOK
11 E5760-01751 1 ENGINE HOOK
12 01123-50816 1M8*P1.25 BOLT, WASHER
13 01513-50822 1M8*1.25 STUD
14 02156-50080 1M8XP1.25 NUT
14 02763-50080 1<---> M8XP1.25 FLANGE NUT
15 04512-50080 1M08 SPRING WASHER
- 4 -

3C100LW-E030 CYLINDER HEAD COVER GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
16 01513-50620 6 STUD
- 5 -

3C100A-E040 GEAR CASE GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
1 E5760-A0202 1 GEAR CASE TOTAL ASSY
1 E5760-A0204 1<---> GEARCASE ASSY
1 E5760-A0205 1<---> GEARCASE ASSY
2 E5760-04111 1 CASE, GEAR
2 E5760-04114 1<---> CASE, GEAR
3 E5900-96031 2 PLUG
4 04811-06130 3 O RING
5 E5760-04132 1 GASKET, GEAR CASE
6 E5752-91031 2 BOLT, WASHER
7 02761-50060 2M6XP1.0 FLANGE NUT
8 01023-50665 9MEX10*76 BOLT, WASHER
9 01023-50670 2MEX10*81 BOLT, WASHER
10 01023-50675 1MEX10*86 BOLT, WASHER
11 E5205-32291 1 TUBE, CONNECTING
12 09550-00008 1 SEAL, OIL
13 E5205-32091 1 FILTER
14 E5700-36071 1 RELIFE VALVE ASSY
15 E5700-36911 1 BODY, RELIEF VALVE
16 15241-3695-2 1 SPRING
- 6 -

3C100A-E040 GEAR CASE GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
17 E5700-36932 1 SEAT, VALVE
18 07715-03213 113/32"(10.31
88)
STEEL BALL
19 04810-00150 1 O RING
20 E5700-32313 1 SUPPORT, OIL FILTER
21 04811-05140 2 O RING
22 01513-50618 1M6*1.0 STUD
23 01023-50630 2 BOLT, WASHER
24 01513-50614 2 STUD
25 E5760-73032 1 WATER PUMP ASSY
25 E5760-73033 1<---> WATER PUMP ASSY
26 E5760-73042 1 BODY, WATER PUMP
26 E5760-73043 1<---> BODY, WATER PUMP
27 E5205-73551 1 BEARING
27 E5760-73551 1<---> BEARING
28 E5800-73052 1 MECHANICAL SEAL ASSY
29 E5760-73512 1 IMPELLER
30 E5205-73523 1 FLANGE
30 E5205-73524 1<---> FLANGE
31 E5700-73342 1 HOSE, COOLING WATER RETURN
- 7 -

3C100A-E040 GEAR CASE GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
32 E5760-73432 1 GASKET, WATER PUMP
33 01023-50625 4M6XP1.0 BOLT
34 E5205-72951 1 HOSE 3, COOLING WATER
35 E5752-18171 3 CLAMP, STAINLESS HOSE
36 E5760-72871 1 HOSE, COOLING WATER
36 E5760-72872 1<---- HOSE, REFRIGERANT
- 8 -

3C100LW-E040 GEAR CASE GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
1 E5760-A0205 1 GEARCASE ASSY
2 E5900-96031 2 PLUG
3 04811-06130 3 O RING
4 E5760-04133 1 GASKET, GEAR CASE
5 E5752-91031 2 BOLT, WASHER
6 02761-50060 2M6XP1.0 FLANGE NUT
7 01023-50665 9MEX10*76 BOLT, WASHER
8 01023-50670 2MEX10*81 BOLT, WASHER
9 01023-50675 1MEX10*86 BOLT, WASHER
10 E5205-32291 1 TUBE, CONNECTING
11 09550-00008 1 SEAL, OIL
12 E5205-32091 1 FILTER
13 E5700-36071 1 RELIFE VALVE ASSY
14 E5700-36911 1 BODY, RELIEF VALVE
15 15241-3695-2 1 SPRING
16 E5700-36932 1 SEAT, VALVE
17 07715-03213 113/32"(10.31
88)
STEEL BALL
18 04810-00150 1 O RING
19 01513-50614 2 STUD
- 9 -

3C100LW-E040 GEAR CASE GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
20 E5760-73032 1 WATER PUMP ASSY
20 E5760-73033 1<---> WATER PUMP ASSY
21 E5760-73042 1 BODY, WATER PUMP
21 E5760-73043 1<---> BODY, WATER PUMP
22 E5205-73551 1 BEARING
22 E5760-73551 1<---> BEARING
23 E5800-73052 1 MECHANICAL SEAL ASSY
24 E5760-73512 1 IMPELLER
25 E5205-73523 1 FLANGE
25 E5205-73524 1<---> FLANGE
26 E5700-73342 1 HOSE, COOLING WATER RETURN
27 E5760-73432 1 GASKET, WATER PUMP
28 01023-50625 4M6XP1.0 BOLT
29 E5205-72951 1 HOSE 3, COOLING WATER
30 E5752-18171 3 CLAMP, STAINLESS HOSE
31 E5760-72872 1 HOSE, REFRIGERANT
- 10 -

3C100A-E050 MAIN BEARING CASE GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
1 E5760-04043 1 BEARING CASE ASSY
2 E5761-04541 2 BOLT 1, BEARING CASE
3 E5760-23481 6 METAL 2, CRANKSHAFT
4 E5760-04361 1 GASKET, BEARING CASE
5 E5760-04811 1 COVER, BEARING CASE
6 E5760-04822 1 GASKET, COVER
7 01754-50825 8M8XP1.25 FLANGE BOLT
8 01754-50822 9 BOLT, FLANGE
9 E5760-04461 1 SEAL, OIL
10 E5760-04053 1 MAIN BEARING CASE ASSY, 1
11 E5761-04541 2 BOLT 1, BEARING CASE
12 E5760-23531 2 SIDE METAL, 1
13 E5760-04063 1 MAIN BEARING CASE ASSY, 2
14 E5761-04541 2 BOLT 1, BEARING CASE
15 E5760-23541 2 SIDE METAL, 2
16 E5205-04561 2 BOLT 2, BEARING CASE
17 04014-50080 2 WASHER, PLAIN
- 11 -

3C100A-E080 VALVE ROCKER ARM GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
1 E5760-13111 3 VALVE, INTAKE
2 E5760-13121 3 EXHAUST VALVE
3 E5205-13241 6 SPRING, VALVE
4 E5700-13332 6 RETAINER, VALVE SPRING
5 E5700-13363 12 COLLET, VALVE SPRING
5 E5763-13361 12 <---> COLLET, VALVE SPRING
6 E5205-13152 6 SEAL, VALVE STEM
7 E5753-14001 1 ROCKER ARM TOTAL ASSY
8 E5753-14051 1 ROCKER ARM SHAFT ASSY
9 E5753-14351 3 SUPPORT, ROCKER ARM
10 E5753-14431 2 WASHER, PLAIN
11 E5753-14311 2 SPRING, ROCKER ARM
12 04612-00130 2 SNAP RING
13 E5753-14111 6 ARM, ROCKER
14 E5700-14232 6 SCREW, ADJUSTING
15 E5205-14241 6 NUT, ADJUSTING
16 E5752-91501 3 BOLT, ROCKER ARM SUPPORT
- 12 -

3C093LW-E090 CYLINDER HEAD COVER GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
1 E5770-14501 1 CYLINDER HEAD COVER ASSY
2 E5760-14511 1 COVER, CYLINDER HEAD
3 E6510-05552 1 CONNECTOR, AIR BREATHER HOSE
4 E5500-33142 1 PLUG, OIL FILLER
5 04811-50300 1G30 O RING
6 E5752-14562 1 PLATE, OIL PROTECTING
7 E5752-14521 1 GASKET, CYLINDER HEAD COVER
8 E6510-05511 1 HOSE, AIR BREATHER
9 09318-88180 2 CLMAP, HOSE
10 E6510-33661 5 BOLT, CYLINDER HEAD COVER
11 E5500-33671 2 STUD, CYLINDER HEAD COVER
12 E5500-35681 2 NUT, FLANGE
- 13 -

3C100A-E100 CAMSHAFT GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
1 E5700-15552 6 TAPPET
2 E5760-15111 6 ROD, PUSH
3 E5760-16011 1 CAMSHAFT ASSY
4 E5205-16511 1 GEAR, CAMSHAFT
5 05712-00515 1 KEY
6 E5205-16272 1 STOP, CAM SHAFT
7 04612-00180 1 SNAP RING
8 01023-50614 2M6P1.0 BOLT, WASHER
9 E5205-24012 1 IDLE GEAR ASSY
10 E5205-24281 2 BUSH, IDLE GEAR
11 E5205-24361 1 COLLAR, 1
12 E5205-24371 1 COLLAR, 2
13 E5205-24321 1 RING, SNAP
14 E5700-24252 1 SHAFT, IDLE GEAR
15 01654-50618 3 BOLT, FLANGE WITH PIN
- 14 -

3C100A-E110 PISTON & CRANKSHAFT GROUP ENGINE
----> Old replace New <---- New replace Old
<-X-> Not interchangeable <---> Interchangeable
<-O-> Interchangeable with another part(s)
No. Part Number Desciption Q'TY Remark
A B C D E I.C
A : 1600XD-R
1 E5760-21011 3 PISTON PIN ASSY
2 E5760-21111 3 PISTON
3 E5760-21311 3 PIN, PISTON
4 E5760-21051 3 PISTON RING ASSY
5 E5760-21001 3 PISTON RING, 1
6 E5700-21105 3 RING 2, PISTON
7 E5760-21151 3 OIL RING ASSY
8 E5205-21331 6 RING, SNAP
9 E5760-22011 3 CONNECTOR ROD ASSY
9 E5760-22013 3<---> CONNECTOR ROD ASSY
10 E5205-21354 3 BUSH, PISTON PIN
11 E5760-22143 6<---> BOLT, CONNECTING ROD
12 E5760-22311 6 METAL, CRANK PIN
13 E5760-23011 1 CRANKSHAFT ASSY
13 E5760-23012 1<---> CRANKSHAFT ASSY
14 08121-06001 1#6001ZZ BALL BEARING
15 E5205-24112 1 GEAR, CRANKSHAFT
16 05712-00515 1 KEY
17 E5205-23311 1 SLINGER, OIL
- 15 -