1977 Diagrams
1977 · Engine Parts List
Engine
MC/GS 250 · MC/GS 400 · MC/GS 440 · 5-Speed · 200 parts
250400440
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| Item No. | Part No. | Description | 250 | 400 | 440 |
|---|---|---|---|---|---|
| 1 | 3349 | Crankcase right hand | 1 | 1 | 1 |
| 2 | 3350 | Guide bush for pawl pin | 1 | 1 | 1 |
| 3 | 331 | Guide bush | 1 | 1 | 1 |
| 4 | 1895 | Pin 8x14 | 2 | 2 | 2 |
| 5 | 1787 | Stud M 8x28 Din 940 | 4 | 4 | 4 |
| 6 | 3352 | Crankcase left hand | 1 | 1 | 1 |
| 7 | 1831 | Tension pin 8x10 Din 7346 | 2 | 2 | 2 |
| 8 | 1888 | Pin 5x14 Din 7 | 1 | 1 | 1 |
| 9 | 3353 | Inside ring | 1 | 1 | 1 |
| 10 | 398 | Crankcase cover right hand | 1 | 1 | 1 |
| 11 | 3355 | Crankcase cover left hand | 1 | 1 | 1 |
| 12 | 400 | Oil drain plug complete | 1 | 1 | 1 |
| 13 | 3498 | Crankcase gasket | 1 | 1 | 1 |
| 14 | 3356 | Crankcase cover gasket left | 1 | 1 | 1 |
| 15 | 2969 | Crankcase cover gasket right | 1 | 1 | 1 |
| 16 | 3499 | Ventilation pipe | 1 | 1 | 1 |
| 17 | 1667 | Hexagon nut M 6 Din 934 | 1 | 1 | 1 |
| 18 | 407 | Sealing ring 6x10 | 7 | 7 | 7 |
| 19 | 408 | Screw plug M 20x1.5 Din 910 | 1 | 1 | 1 |
| 20 | 410 | Sealing ring A 14x18 Din 7603 | 1 | 1 | 1 |
| 21 | 409 | Sealing ring A 20x24 Din 7603 | 1 | 1 | 1 |
| 22 | 1533 | Cylinder head screw M 6x18 Din 84 | 1 | 1 | 1 |
| 23 | 1546 | Cylinder head screw M 6x85 Din 84 | 2 | 2 | 2 |
| 24 | 1539 | Cylinder head screw M 6x40 Din 84 | 7 | 7 | 7 |
| 25 | 1538 | Cylinder head screw M 6x35 Din 84 | 4 | 4 | 4 |
| 26 | 1537 | Cylinder head screw M 6x28 Din 84 | 3 | 3 | 3 |
| 27 | 1552 | Cylinder head screw M 8x16 Din 84 | 1 | 1 | 1 |
| 28 | 430 | Sealing ring A 8x14 Din 7603 | 1 | 1 | 1 |
| 29 | 2981 | Crankshaft complete 250 | 1 | - | - |
| 29 | 709 | Crankshaft complete 400/440 | - | 1 | 1 |
| 30 | 424 | Needle bearing KBK 18x22x24 | 1 | 1 | 1 |
| 31 | 425 | Ball bearing 6305 Din 625 | 1 | 1 | 1 |
| 32 | 693 | Ball bearing 3305 C3 Din 625 | 1 | 1 | 1 |
| 33 | 547 | Oil seal 32x52x7/9 | 1 | 1 | 1 |
| 34 | 3469 | Oil seal 25x52x8 | 1 | 1 | 1 |
| 35 | 713 | Spacer ring | 1 | 1 | 1 |
| 36 | 3470 | Duplex sprocket 250 | 1 | - | - |
| 36 | 714 | Triplex sprocket 400/440 | - | 1 | 1 |
| 37 | 504 | Lock washer | 1 | 1 | 1 |
| 38 | 505 | Sleeve pinion nut | 1 | 1 | 1 |
| 39 | 522 | Piston 66.95 (250) | 1 | - | - |
| 39 | 533 | Piston 76.95 (400) | - | 1 | - |
| 39 | 2110 | Piston 81.92 (440) | - | - | 1 |
| 40 | 523 | L-ring 250 | 1 | - | - |
| 40 | 534 | L-ring 400 | - | 1 | - |
| 40 | 2111 | L-ring 440 | - | - | 1 |
| 41 | 535 | Piston pin 250 | 1 | - | - |
| 41 | 537 | Piston pin 400/440 | - | 1 | 1 |
| 42 | 536 | Piston pin clip | 2 | 2 | 2 |
| 43 | 2500 | Cylinder cpl 250 with exhaust manifold | 1 | - | - |
| 43 | 715 | Cylinder cpl 400 with exhaust manifold | - | 1 | - |
| 43 | 2591 | Cylinder cpl 440 with exhaust manifold | - | - | 1 |
| 44 | 2502 | Cylinder head 250 | 1 | - | - |
| 44 | 719 | Cylinder head 400 | - | 1 | - |
| 44 | 2593 | Cylinder head 440 | - | - | 1 |
| 45 | 65 | Cylinder head gasket 250 | 1 | - | - |
| 45 | 720 | Cylinder head gasket 400 | - | 1 | - |
| 45 | 2582 | Cylinder head gasket 440 | - | - | 1 |
| 46 | 721 | Cylinder base gasket | 1 | 1 | 1 |
| 47 | 2967 | Cylinder head stud 250 | 5 | - | - |
| 47 | 2968 | Cylinder head stud 400/440 | - | 5 | 5 |
| 48 | 1705 | Spring washer B 8 Din 127 | 9 | 9 | 9 |
| 49 | 1670 | Hexagon nut M 8 Din 934 | 4 | 4 | 4 |
| 50 | 78 | Hexagon nut M 8 Din 6330 | 5 | 5 | 5 |
| 51 | 3386 | Clutch guide | 1 | 1 | 1 |
| 52 | 725 | Clutch push pin | 1 | 1 | 1 |
| 53 | 1869 | Ball 1/8" | 14 | 14 | 14 |
| 54 | 455 | Push pin nut | 1 | 1 | 1 |
| 55 | 443 | Duplex primary chain 3/8x7/32 (250) | 1 | - | - |
| 55 | 735 | Triplex primary chain 3/8x7/32 (400/440) | - | 1 | 1 |
| 56 | 444 | Thrust washer | 1 | 1 | 1 |
| 57 | 3389 | Bush | 1 | 1 | 1 |
| 58 | 2580 | Clutch body | 1 | 1 | 1 |
| 59 | 447 | Lock washer | 1 | 1 | 1 |
| 60 | 448 | Clutch nut | 1 | 1 | 1 |
| 61 | 449 | Cup spring | 20 | 20 | 20 |
| 62 | 3396 | Outer clutch disc | 6 | 6 | 6 |
| 63 | 3390 | Inner clutch disc | 6 | 6 | 6 |
| 64 | 3391 | Terminal disc | 1 | 1 | 1 |
| 65 | 461 | Lock ring | 2 | 2 | 2 |
| 66 | 462 | Clutch spindle | 1 | 1 | 1 |
| 67 | 464 | Sealing ring | 1 | 1 | 1 |
| 68 | 437 | Clutch lever | 1 | 1 | 1 |
| 69 | 1750 | Washer B 6.4 Din 9021 | 1 | 1 | 1 |
| 70 | 1667 | Hexagon nut M 6 Din 934 | 1 | 1 | 1 |
| 71 | 3398 | Clutch housing duplex T=41 (250) | 1 | - | - |
| 71 | 2577 | Clutch housing triplex T=39 (400/440) | - | 1 | 1 |
| 72 | 730 | Kickstarter pinion | 1 | 1 | 1 |
| 73 | 731 | Ratchet spring | 1 | 1 | 1 |
| 74 | 732 | Spring cup | 1 | 1 | 1 |
| 75 | 733 | Snap-spring | 1 | 1 | 1 |
| 76 | 729 | Kickstarter ratchet wheel | 1 | 1 | 1 |
| 77 | 1906 | Oval head rivet 4x10 Din 662 | 8 | 8 | 8 |
| 78 | 3433 | Mainshaft MG | 1 | 1 | 1 |
| 79 | 3434 | 3rd gear on mainshaft M T=24 (250) | 1 | - | - |
| 79 | 3443 | 3rd gear on mainshaft M T=23 (400/440) | - | 1 | 1 |
| 80 | 3435 | 4th gear on mainshaft MG T=26 | 1 | 1 | 1 |
| 81 | 3706 | Spacer ring | 1 | 1 | 1 |
| 82 | 492 | Retainer ring | 3 | 3 | 3 |
| 83 | 3436 | Sleeve pinion M T=28 (250) | 1 | - | - |
| 83 | 3444 | Sleeve pinion G T=29 (400/440) | - | 1 | 1 |
| 84 | 3454 | Sleeve pinion plug | 1 | 1 | 1 |
| 85 | 3437 | Layshaft M T=17 (250) | 1 | - | - |
| 85 | 3445 | Layshaft G T=16 (400/440) | - | 1 | 1 |
| 86 | 3456 | Washer 2nd gear | 1 | 1 | 1 |
| 87 | 512 | Shim 0.2/0.3mm | 1 | 1 | 1 |
| 88 | 3438 | 1st gear on layshaft M1 T=26 (250) | 1 | - | - |
| 88 | 3446 | 1st gear on layshaft G1 T=28 (400/440) | - | 1 | 1 |
| 89 | 905 | Needle bearing K 16x21x10 FV | 1 | 1 | 1 |
| 90 | 3439 | 2nd gear on layshaft M1 T=23 (250) | 1 | - | - |
| 90 | 3447 | 2nd gear on layshaft G1 T=24 (400/440) | - | 1 | 1 |
| 91 | 3757 | Needle bearing K 20x24x12 | 1 | 1 | 1 |
| 92 | 3461 | Lock ring | 1 | 1 | 1 |
| 93 | 499 | Ball bearing 6005 2RS Din 625 | 1 | 1 | 1 |
| 94 | 1852 | Lock ring 47x1.75 Din 472 | 1 | 1 | 1 |
| 95 | 3462 | Bearing bush | 1 | 1 | 1 |
| 96 | 3463 | Ball bearing 6005 2RS Din 625 | 1 | 1 | 1 |
| 97 | 1854 | Lock ring 55x2 Din 472 | 1 | 1 | 1 |
| 98 | 3464 | Spacer ring | 1 | 1 | 1 |
| 99 | 3465 | Sprocket T=13 | 1 | 1 | 1 |
| 100 | 1848 | Lock ring A 29x1.5K | 1 | 1 | 1 |
| 101 | 3466 | Needle gauge K 17x21x13 | 3 | 3 | 3 |
| 102 | 749 | Bush | 1 | 1 | 1 |
| 103 | 3440 | 2nd gear on mainshaft M T=21 (250) | 1 | - | - |
| 103 | 3448 | 2nd gear on mainshaft G T=20 (400/440) | - | 1 | 1 |
| 104 | 3441 | 1st gear on mainshaft M T=19 (250) | 1 | - | - |
| 104 | 3449 | 1st gear on mainshaft G T=17 (400/440) | - | 1 | 1 |
| 105 | 513 | Needle bearing HK 1612 | 1 | 1 | 1 |
| 106 | 514 | Needle bearing BK 1616 | 1 | 1 | 1 |
| 107 | 3442 | Twin block gear on layshaft M T=21/19 (250) | 1 | - | - |
| 107 | 3450 | Twin block gear on layshaft G T=21/18 (400/440) | - | 1 | 1 |
| 108 | 3467 | Washer 1st gear layshaft | 1 | 1 | 1 |
| 109 | 555 | Gear change lever | 1 | 1 | 1 |
| 110 | 556 | Rubber pad | 1 | 1 | 1 |
| 111 | 1570 | Hexagon screw M 6x25 Din 933 | 1 | 1 | 1 |
| 112 | 1712 | Spring B 6 Din 137 | 1 | 1 | 1 |
| 113 | 2503 | Gear change crank | 1 | 1 | 1 |
| 114 | 3399 | Pull rod | 1 | 1 | 1 |
| 115 | 3402 | Shifting segment | 1 | 1 | 1 |
| 116 | 511 | Plug | 1 | 1 | 1 |
| 117 | 3407 | Shifting plate | 1 | 1 | 1 |
| 118 | 3408 | Gear rack | 1 | 1 | 1 |
| 119 | 1824 | Tension pin | 2 | 2 | 2 |
| 120 | 572 | O-ring | 1 | 1 | 1 |
| 121 | 587 | Lock ring | 1 | 1 | 1 |
| 122 | 3410 | Hooked ratchet | 1 | 1 | 1 |
| 123 | 573 | Return spring | 1 | 1 | 1 |
| 124 | 576 | Hooked ratchet spring | 1 | 1 | 1 |
| 125 | 3411 | Guide rail | 2 | 2 | 2 |
| 126 | 3412 | Flat head screw M 6x16 Din 923 | 2 | 2 | 2 |
| 127 | 3493 | Flat head screw M 6x10 Din 923 | 2 | 2 | 2 |
| 128 | 1712 | Spring washer B 6 Din 137 | 4 | 4 | 4 |
| 129 | 1667 | Hexagon nut M 6 Din 934 | 4 | 4 | 4 |
| 130 | 3413 | Gear selection fork spindle | 1 | 1 | 1 |
| 131 | 3414 | Gear selection fork | 3 | 3 | 3 |
| 132 | 3415 | Pawl pin | 1 | 1 | 1 |
| 133 | 3422 | Compression spring | 1 | 1 | 1 |
| 134 | 410 | Sealing ring A 14x18 Din 7603 | 1 | 1 | 1 |
| 135 | 3416 | Locking screw | 1 | 1 | 1 |
| 136 | 3417 | Tension spring holding screw | 1 | 1 | 1 |
| 137 | 1667 | Nut M 6 Din 934 | 1 | 1 | 1 |
| 138 | 652 | Kickstarter lever upper | 1 | 1 | 1 |
| 139 | 2508 | Kickstarter lever lower | 1 | 1 | 1 |
| 140 | 1874 | Ball | 1 | 1 | 1 |
| 141 | 655 | Tension spring | 1 | 1 | 1 |
| 142 | 656 | Rubber pad | 1 | 1 | 1 |
| 143 | 1840 | Lock washer 9 Din 6799 | 1 | 1 | 1 |
| 144 | 1816 | Tension pin 3x10 Din 1481 | 1 | 1 | 1 |
| 145 | 3471 | Kickstarter shaft | 1 | 1 | 1 |
| 146 | 659 | O-ring | 2 | 2 | 2 |
| 147 | 1570 | Hexagon screw M 6x25 Din 933 | 1 | 1 | 1 |
| 148 | 1704 | Spring ring B 6 Din 127 | 1 | 1 | 1 |
| 149 | 666 | Kickstarter return spring | 1 | 1 | 1 |
| 150 | 588 | Magneto housing complete | 1 | 1 | 1 |
| 151 | 592 | Rotor bolt | 1 | 1 | 1 |
| 152 | 1714 | Spring washer B 8 Din 137 | 1 | 1 | 1 |
| 153 | 1527 | Cylinder head screw M 4x10 | 1 | 1 | 1 |
| 154 | 1730 | Washer 4.3 Din 125 | 1 | 1 | 1 |
| 155 | 1702 | Spring ring B 4 Din 127 | 1 | 1 | 1 |
| 156 | 611 | Magnet rotor | 1 | 1 | 1 |
| 157 | 1534 | Cylinder head screw AM 6x20 Din 84 | 3 | 3 | 3 |
| 158 | 1732 | Spring ring B 6 Din 127 | 3 | 3 | 3 |
| 159 | 1704 | Washer 6.4 Din 125 | 3 | 3 | 3 |
| 160 | 603 | Spark plug | 2 | 2 | 2 |
| 161 | 609 | Contact breaker | 1 | 1 | 1 |
| 162 | 613 | Carburetor complete 250 | 1 | - | - |
| 162 | 614 | Carburetor complete 400/440 | - | 1 | 1 |
| 163 | 681 | Spacer tube | 1 | 1 | 1 |
| 164 | 3143 | Rubber flange | 1 | 1 | 1 |
| 165 | 683 | Clamp | 3 | 3 | 3 |
| 166 | 343 | Rubber sleeve | 1 | 1 | 1 |
| 167 | 517 | Decompression valve cpl (400/440) | - | 1 | 1 |
| 168 | 410 | Sealing ring (decompression) | - | 1 | 1 |
| 169 | 577 | Cover plate | 1 | 1 | 1 |
| 170 | 579 | Locking plate | 1 | 1 | 1 |
| 171 | 1564 | Hexagon screw M 6x10 Din 933 | 1 | 1 | 1 |
| 172 | 467 | Exhaust flange | 1 | 1 | 1 |
| 173 | 298 | Exhaust flange gasket | 1 | 1 | 1 |
| 174 | 1635 | Socket screw M 6x25 Din 912 | 4 | 4 | 4 |
| 175 | 1704 | Spring ring B 6 Din 127 | 4 | 4 | 4 |
NOTES:
250 uses duplex primary chain and clutch housing (T=41)
400/440 use triplex primary chain and clutch housing (T=39)
5-speed gearbox — M-series gears for 250, G-series for 400/440
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