Parts

Parts listed here are for your assistance. Do not take part numbers as gospel. You must verify them for yourself. Yamaha changes part numbers; I make mistakes. Exercise diligence. Yamaha parts explosion diagrams and part numbers can be found online on many Yamaha parts suppliers’ websites. They can also be found at www.StarMotorcycles.com. Though websites are subject to change, the current, direct web-address for Yamaha parts listings can be found at www.StarMotorcycles.com/star/parts/.

Below are the part numbers you’ll need. Most are required; some are optional, depending on whether or not you’re disassembling the entire engine, and if you’re disassembling all the subassemblies. I tried to indicate, “Optional” when appropriate. Also see the Complete Engine Tear Down, Orientation article for more information on what parts of the engine you’ll be disassembling.

Gaskets and Oil Seal Part Numbers Listing

• Exhaust header gasket, Yamaha part#: 3EG-14613-00-00, ($3 to $6ea). or AutoZone part#: Fel-Pro 23588, (less than $1.50ea).
• Cam cover (deep one), Yamaha part#: 5PX-12286-00-00, GASKET, DECOMPRESSION
• Cam cover (chrome cover), Yamaha part#: 5PX-15462-00-00, GASKET, CRANKCASE COVER 3
• Clutch cover, Yamaha part#: 5PX-15451-00-00, GASKET, CRANKCASE COVER 1
• Oil tank/Cap, Yamaha part#: 4WM-17932-00-00, GASKET, 3. Optional. Needed only if you’re disassembling the transfer case. See the article, Disassembling The Transfer Case in this article series, for details of how this can be avoided.
• Transfer case- skinny case, Yamaha part#: 5PX-17929-00-00, GASKET 1. Optional. Needed only if you’re disassembling the transfer case.
• Transfer case- oil pump, Yamaha part#: 4WM-13116-00-00, GASKET, PUMP CASE. Optional. Needed only if you’re disassembling the transfer case.
• Transfer case- little washer gasket, Yamaha part#: 4WM-17931-00-00, GASKET 2
• Generator cover, Yamaha part#: 5PX-15461-02-00, GASKET.
• Generator-cover bolt washer, Yamaha part#: 90430-06014-00, GASKET. Optional but recommended. This is the little copper or aluminum washer for the lower, long bolt.
• Cylinder base (2)--should come with Big Bore Kit, if performing a big bore build.
• Head (2)--should come with Big Bore Kit, if performing a big bore build.
• If using stock cylinders:
  • Cylinder base (all years), Yamaha part#: 4WM-11351-00-00, GASKET, CYLINDER
  • Head gasket (’99 – ‘03), Yamaha part#: 4WM-11181-00-00, GASKET, CYLINDER HEAD 1
  • Head gasket (’04 – ‘05), Yamaha part#: 5PX-11181-00-00, GASKET, CYLINDER HEAD 1
  • Head gasket (’06 – ‘07), Yamaha part#: 5PX-11181-01-00, GASKET, CYLINDER HEAD 1
• Valve cover – Spacer, (black metal), as needed,
  • Yamaha part#: 4WM-11193-00-00, GASKET, HEAD COVER 1, for ’99 - ‘03 only
• Valve cover - Top, (black metal), as needed,
  • Yamaha part#: 4WM-11194-00-00, GASKET, HEAD COVER 2, for ’99 - ’03 only
  • Yamaha part#: 5VN-11193-00-00, GASKET, HEAD COVER 1, for 2004+ only
• Rocker Base (black metal), as needed,
  • Yamaha part#: 4WM-11182-00-00, GASKET, CYLINDER HEAD 2, for 1999-2003 only
  • Yamaha part#: 5VN-11182-00-00, GASKET, CYLINDER HEAD 2, for 2004+ only
• Transfer case, middle driven shaft, bearing oil seal, (if you're pulling bearings out), Yamaha part#: 93102-40330-00, OIL SEAL
• Transmission output shaft, bearing oil seal, (if you're pulling bearings out), Yamaha part#: 93103-38184-00, OIL SEAL
• Transmission axle-and-crankcase ball bearings: See the article, Working on the Disassembled Engine, in this series for part numbers and detailed information
• Rubber oil seals for Pushrod tubes, as needed,
  • Yamaha part#: 4WM-12152-00-00, SUPPORT, ROCKER AR for 1999-2003 only
  • Yamaha part#: 5PX-12215-00-00, CAP, TENSIONER CASE for 2004+ only
• Valve stem seals, (qty: 8), if you will be taking out the valves Yamaha part#: 4KM-12119-00-00

O-Rings Part Numbers Listing

Replace O-rings as needed, only.

• Tiny ones for lifter-block area, Yamaha part#: 93210-48364-00, O-RING
• Lifter-blocks (2 sizes), Yamaha part#: 93210-54175-00, and 93210-54452-00, O-RING
• Pushrod Tubes,
  • Yamaha part#: 93210-472A9-00, O-RING (upper), for 2004+ only
  • Yamaha part#: 93210-40745-00, O-RING (lower), for 2004+ only
  • Yamaha part#: 93210-472A9-00, O-RING (upper and lower), for 1999-2003 only
• Thin-thin one for primary-drive-shaft, Yamaha part#: 93210-30660-00, .O-RING
• Thin-thin one for middle-driven-shaft, Yamaha part#: 93210-30660-00, .O-RING
• Thick-huge one for primary-drive-shaft, Yamaha part#: 93210-750A1-00, O-RING
• Tiny ones for crankcase oil cross-over tube, Yamaha part#: 93210-10001-00, .O-RING
• Oil filter bracket (2), Yamaha part#: 93210-23326-00, O-RING
• Intake manifold (2), non-aluminum type,Yamaha part#: 93210-505A4-00, O-RING

Other Parts Listing

Warning: You must verify all these numbers with your supplier, as numbers changes periodically, and I may have misprinted something.

• Piston Rings (’99 – ’03 only), Yamaha part#: 34L-11610-00-00, PISTON RING SET (STD), if using stock bore pistons.
• Piston Rings (’04 – ’07 only), Yamaha part#: 5PX-11610-00-00, PISTON RING SET (STD), if using stock bore pistons.
• Piston Wrist-Pin Circlip, Yamaha part#: 93450-24028-00, CIRCLIP, Qty needed: 4
• Tab-lock washer for transmission primary-drive shaft, Yamaha part#: 90215-30233-00, WASHER, LOCK
• Tab-lock washer for middle-driven shaft, Yamaha part#: 90215-30233-00, WASHER, LOCK
• Copper washers for external oil lines on left side engine (qty: 2, & qty: 1), Yamaha part#: 90430-10188-00, 90430-08119-00, GASKET
• Copper washers for sight plugs 9 total, highly recommended, Yamaha part#: 90430-05126-00, 90430-08119-00, GASKET
• Oil Filter, see your owner’s manual for details.
• Spark plugs (qty: 4), see your owner’s manual for details.
• Oil driven gear, only needed for 1999 – 2001 engines. See Failed Parts to Watch For in this website for details. Yamaha part#: 5PX-13360-00-00