DIAMO Discovery XLT PARTS CATALOG - CHASSIS First Edition August 2008
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1 DIAMO Discovery XLT PARTS CATALOG - CHASSIS First Edition August 2008 Copyright LS MotorSports, LLC. Reproduction without written permission is completely forbidden.
2 The information and diagrams included in this catalog are the exclusive property of LS MotorSports, LLC and may not be reproduced in any media without the express written consent of LS MotorSports, LLC. For more information contact: LS MotorSports, LLC S Sam Houston Parkway W Houston, TX Information contained in this publication is subject to change without notice. For the most up to date information please contact DIAMO USA or an Authorized Dealer Copyright LS MotorSports, LLC. Reproduction without written permission is completely forbidden.
3 CONTENTS PAGE TITLE 4 Documents 5 Shifter 6 Frame 7 Frame Cont. 8 Front Cover 9 Side Cover 10 Final Drive and Drive Shaft 11 Final Drive and Drive Shaft Cont. 12 Front Differential 13 Front Differential Cont. 14 Rear A-Arm 15 Rear Shock and Sway Bar 16 Front Suspension 17 Fuel Tank 18 Steering 19 Seat 20 Front Wheel and Axle 21 Disc Brake Calipers 22 Rear Wheel and Axle 23 Footrest and Foot Controls 24 Instruments 25 Head Light 26 Tail Light 27 Electrical 1 28 Electrical 2 29 Guard 30 Front Guard 31 Cargo Box 32 Cargo Box Cont. 33 Master Cylinder 34 Emblem 1 35 Emblem 2 36 Air Filter 37 Exhaust 38 Radiator 39 Oil Cooler Hose 40 Evap Kit 41 Crankcase Air Duct
4 Fig. 00 Documents Ref Code Part Number Description Owners Manual Parts Catalog CD Service Manual CD
5 Fig. 01 Shifter Ref Code Part Number Description Shifter Assy Shift Knob Shift Boot Shifter Housing Assy Shift Rod Shift Rod Joint Shift Guide 8 GB/T Washer 9 GB/T Bolt M8X12 10 GB/T Bolt M8X Bolt, Shift Knob Clamp, Shift Boot Clamp, Drain Pipe Drain Pipe
6 Fig. 02 Frame Ref Code Part Number Description Frame, Main Damper, Engine Mount Rubber Support 2, Engine Mount Support 3,Engine Mount 5 GB/T Nut 6 GB/T Bolt M6X16 7 GB/T Bolt M8X16 8 GB/T Bolt M8X Damper 2, Engine Mount 10 GB/T Nut 11 GB/T Bolt 12 GB/T Nut 13 GB/T Bolt M6X Brace, Frame 15 GB/T Bolt M6X16 16 GB/T Bolt Support, LFT Seat Support, RGT Seat 19 GB/T Bolt M8X Plug 1, frame tube Plug 2, frame tube Mark Mark Mark Tool Kit
7 Fig. 02 Frame Cont. Ref Code Part Number Description Tire Gauge Heat Insulation Board 28 GB/T Bolt M6X Heat Insulation Board, Muffler Heat Insulation Board, Muffler 2 31 GB/T Bolt Bracket, Front Insert 33 GB/T Bolt Bracket, Front Guard 35 GB/T Bolt M12X35X GB/T Gasket Washer 6 38 GB/T Bolt M10X25X GB/T Nut M12X GB/T Nut M10X GB/T Nut M10X Cushion, Cargo Box 43 GB/T Washer
8 Fig. 03 Front Cover Ref Code Part Number Description Front Cover Body Latch Collar 4 GB/T Washer 6 5 GB/T Bolt M6X Washer 7 GB/T Bolt M Lock, Glove Box 9 GB/T Nut M6 10 GB/T Nut M Grill Clip Seat, Body Latch Screw 15 GB/T Screw M6X Hinge, Glove Box Screw Cover, Glove Box Pin GB/T Collar pin 3.2X Panel, Lower Dash 22 GB/T Nut M6 23 GB/T Bolt M6X Panel, Upper Dash 25 GB/T Bolt M6X1.25X35 26 GB/T Screw M6X20 27 GB/T Nut M6 28 GB/T Bolt M6X1.25X35 29 GB/T Washer Cushion Fender Flare, Left Front Decorative Cover, Right Decorative Cover, Left Fender Flare, Right Front Decorative Cover, Small Left Decorative Cover, Small Right Trim, Hood Speaker Grill Speaker Box 40 GB/T Bolt M6X20
9
10 Fig. 04 Side Cover Ref Code Part Number Description Side Panel, LFT 2 GB/T Bolt M10x16 3 GB/T Bolt M10x16 4 GB/T Bolt M10x Side Panel, RGT Rivnut 7 GB/T Bolt M10x Protection Cover, LFT Side Center Cover Right Seal Left Seal Cover, Air Intake Grill, Air Intake Tie Protection Cover, RGT Side 16 GB/T Bolt M10x Screw Nut clip 19 GB/T Bolt Support, LFT Side Panel 21 GB/T Bolt M10x Support, RGT Side Panel 23 GB/T Bolt M10x16
11 Fig. 05 Final Drive and Drive Shaft Ref Code Part Number Description RR Differental Assy Housing, RR Differental 3 GB Bearing, RR Pinion Gear 4 GB Bearing, RR Ring Gear RR Pinion Gear 6 GB/T Bearing, RR Pinion Shaft Coupling, RR Drive Shaft Seal, RR Pinion 9 GB/T Nut, Special O-Ring Washer 12 GB/ Nut M Housing, Pinion Bearing Shim, Pinion 15 GB/T Bolt M8x20 16 GB/T Washer Thrust Washer
12 Fig. 05 Final Drive and Drive Shaft Cont. Ref Code Part Number Description Fill Plug O-Ring, Fill Plug Vent Housing, Ring Gear Bearing 22 GB Stopper, Ring Gear 23 GB/T Washer GB/T Nut M Oil Seal, RR Axle 26 GB/T Bearing O-Ring Shim, Ring Gear 29 GB/T Bolt M8x25 30 GB/T Washer GB/T Bolt M10x22 32 GB/T Bolt M8x20, Drain Plug 33 GB/T Gasket, Drain Plug Spring Drive Shaft, RR Differential 36 GB/T Circlip Coupling 38 GB/T Circlip Nut FR Dust Boot, RR Drive Shaft RR Dust Boot, RR Drive Shaft Tube, Vent Clip 44 GB/T Washer Clamp Clamp Ring Gear Band, Dust Boot 49 GB/T Bolt M10x125
13 Fig. 06 Front Differential Ref Code Part Number Description FR Differential Assy Housing, FR Differntial Housing, FR Ring Gear Bearing FR Pinion Gear Yoke, FR Drive Shaft Pinion 6 GB/T Nut O-Ring Oil Seal, FR Pinion Oil Seal, FR LFT Axle A Thrust Washer - 0.1T B Thrust Washer - 0.2T C Thrust Washer - 0.5T 11 GB/T Bolt M8x Ring Gear 13 GB/T Bolt M8x25 14 GB/T Bolt M8x Drain Bolt M10x Snap Ring Column Pin 5X WD / 4WD Servo Motor Clutch, Differential Shaft O-Ring O-Ring 23 GB/T Bearing GB/T Bearing GB/T Bearing GB/T Bearing HK152112, Pinion 27 GB/T Bolt M14x Washer 14X2 29 GB/T Nut 30 GB/T Washer Shift Fork Universal Joint 33 GB/T Drain Bolt Yoke, FR Drive Shaft Tube, Breather Clip Band, Dust Boot Drive Shaft, FR Differential 39 GB/T Circlip Washer
14 Fig. 06 Front Differential Cont. Ref Code Part Number Description Spring FR Dust Boot, FR Drive Shaft RR Dust Boot, FR Drive Shaft 44 GB/T Bolt 45 GB/T Washer 46 GB/T Bolt
15 Fig. 07 Rear A-Arm Ref Code Part Number Description Rear Left Upper A-Arm Rear Right Lower A-Arm Rear Left Lower A-Arm Bushing 5 GB/T Bolt M10X1.25X70 6 GB/T Locknut M10x Rear Right Upper A-Arm Washer CV Guard, RGT CV Guard, LFT Rear Left Upper A-Arm Assy Rear Left Lower A-Arm Assy Rear Right Upper A-Arm Assy Rear Right Lower A-Arm Assy
16 Fig. 08 Rear Shock and Sway Bar Ref Code Part Number Description Rear Shock 2 GB/T Bolt 3 GB/T Bolt 4 GB/T Nut M12x Stabilizer Bar LFT Joint, Stabilizer Bar RGT Joint, Stabilizer Bar 8 GB/T Locknut M Bushing, Stabilizer Bar Bracket, Stabilizer Bar Bushing 11 GB/T Bolt M8x16 12 GB/T Washer
17 Fig. 09 Front Suspension Ref Code Part Number Description Upper Left A-Arm Upper Left Ball Joint 3 GB Circlip Upper Right A-Arm Upper Right Ball Joint 6 GB Circlip Lower Left A-Arm Lower Right A-Arm Bushing 10 GB/T Bolt 11 GB/T Locknut M10X Washer 13 GB/T Locknut M10x GB/T Cotter Pin Front Shock 16 GB/T Locknut M10x GB/T Bolt CV Guard 19 GB/T Nut 20 GB/T Bolt M6x Upper Right A-Arm Assy Upper Left A-Arm Assy Lower Right A-Arm Assy Lower Left A-Arm Assy
18 Fig. 10 Fuel Tank Ref Code Part Number Description Fuel Pump Bushing Hose Clip Fuel Line Clamp Vacuum Hose Clamp 8 GB/T Bolt M6x Vent Hose Hose Clip Insulator Insulator Damper, Fuel Tank Damper, Fuel Tank Stay 16 GB/T Bolt M8x Clip Fuel Tank Fuel Pickup O-ring Screw M5x Fuel Sensor Gasket, Fuel Sensor Screw M5X Cap, Fuel Tank Fuel Filter Stay, Fuel Tank Fuel Line Fuel Line Clip Heat Insulation Oil Tank Y-Pipe Heat Insulation Heat Insulation Cap, Oil Tank Oil Return Hose, Oil Tank Oil Inlet Hose, Oil Tank Clip Air Inlet Hose, Oil Tank Clip Vacuum Hose 2
19 Fig. 11 Steering Ref Code Part Number Description Steering Rack Steering Gear 3 GB/T Split Washer Bearing Cover, Adjust Spring Washer 8 GB/T Nut Cover, Steering Band, Steering Dust Boot Dust Boot 12 GB/T Bolt M10x Tie Rod End 14 GB/T Locknut, Tie Rod End Steering Shaft 16 GB/T Bolt M8x Steering Column 18 GB/T Bolt M8x16 19 GB/T Castle Nut M12 20 GB/T Cotter Pin Steering Wheel 22 GB/T Nut M12x GB/T Washer 12
20 Fig. 12 Seat Ref Code Part Number Description Seat Washer Base, Seat 4 GB/T Bolt M8x30 5 GB/T Locknut M8x GB/T Bolt M8X Latch, Seat 8 GB/T Bolt M6X38 9 GB/T Nut M Pin, Seat Damper, Seat Pad Bushing Grip 15 GB/T Bolt M6X Head Rest 17 GB/T Bolt M8X30 18 GB/T Nut M10X GB/T Bolt M10X25-Φ14X Bolt M10X1.25X Cover Latch, Seatbelt Seat Belt Assy 24 GB/T Nut M10X GB/T Special Bolt M10X1.25X22 26 GB/T BoltM10X1.25X25 27 GB/T Wassher Cushion
21 Fig. 13 Front Wheel and Axle Ref Code Part Number Description Front Wheel 12X Front tire 25x Valve cap Lugnut M10X Cap, Hub CV Half Shaft, LFT CV Half Shaft, RGT 8 GB/T Nut M22X Front Hub 10 GB/T Screw M6X Protecting Cover, Front Brake Steering Knuckle Assy, LFT FR Steering Knuckle Assy, RGT FR Dust Boot, Inner Dust Boot, Outer Front Steering Knuckle Outer Oil Seal, Front Steering Knuckle Inner Oil Seal, Front Steering Knuckle Shaft, Front CV Clip, Front CV Shaft Bearing, Front Steering Knuckle Circlip Clip, Front CV Shaft Spacer Clamp, Outer Dust Boot Clamp, Inner Dust Boot Front Wheel / Tire Assy
22 Fig. 14 Disc Brake Calipers Ref Code Part Number Description Disc, FR Brake 2 GB/T Bolt M10 3 GB/T Bolt Disc, RR Brake Bolt 6 GB/T Nut M6X Brake Pad Set, FR Brake Brake Pad Set, RR Brake Brake Caliper Assy, FR Brake Brake Caliper Assy, RR Brake
23 Fig. 15 Rear Wheel and Axle Ref Code Part Number Description Rear Wheel 12X Rear Tire 25X Valve Cap Rear Hub Wheel Stud Lugnut M10x CV Half Shaft, LFT RR CV Half Shaft, RGT RR Cap, Hub 10 GB/T Nut M22X Shaft, Rear CV Dust Boot, Outer Dust Boot, Inner 14 GB/T Nut Washer Cover 17 GB/T Six Point Bolt M10X1.25X Rear turning bracket shaft tube Rear turning bracket shaft liner 20 JB/T Grease Zerk Inner Oil Seal, Rear Knuckle Outer Oil Seal, Rear Knuckle Clamp Bearing, Rear Knuckle Seal Clamp, Dust Boot Outer Clamp, Dust Boot Inner Protecting Plate, Left Rear Knuckle Protecting Plate, Right Rear Knuckle Rear Wheel / Tire Assy
24 Fig. 16 Footrest & Foot Controls Ref Code Part Number Description Left Floorboard 2 GB/T Screw Center Floorboard Heat Insulation 5 GB/T Screw Nut,spring Right Floorboard Dust Cover, Pedal Assy 9 GB/T Screw Pedal Support 11 GB/T Bolt M8x Accelerator Pedal Washer E-Clip Spring Brake Pedal Washer E-Clip Spring Throttle Cable Tie 7(L=200) Tie 4(L=150) Tie 3(L=200) Dust Cover, Parking Brake Parking Brake Handle Assy Parking Brake Lever Handle, Parking Brake Bolt, Parking Brake Handle 29 GB/T Bolt M6x Cable Clip Nut,Choke Cable Tie 7(L=200) Cable Clip 35 GB/T Bolt M6x Choke Cable Screw
25 Fig. 17 Instruments Ref Code Part Number Description Instrument Assy 2 GB/T Nut M5
26 Fig. 18 Head Light Ref Code Part Number Description Head Light, RGT Head Light, LFT Wiring Harness, Head Light Adjusting Bolt, Head Light Adjusting Spring, Head Light Cushion, Head Light Adjusting Bolt Spring Nut Bolt Adjusting Nut, Head Light Bulb, Head Light 12V/35W/35W Buld, Parking Light 12V/5W Head Light Assy, LFT Head Light Assy, RGT
27 Fig. 19 Tail Light Ref Code Part Number Description Lens, Tail Light Bulb, Tail Light Housing, Tail Light Tail Light Assy 5 GB/T Bolt 3.9X16
28 Fig. 20 Electrical 1 Ref Code Part Number Description CDI Gear Position Sensor O Ring 4 GB/T Bolt Reverse Switch 6 GB/T Washer Coil 8 GB/T Bolt M6x20 9 GB/T Bolt M6x20 10 GB/T Washer Spark Plug Cap Temperature Sensor Cooling Fan Switch Speedometer Sensor 15 GB/T Bolt M6x Rectifier 17 GB/T Bolt M6x Battery Battery Box Cover, Battery Box Cushion, Battery Box Auxilary Relay Strap, Battery 24 GB/T Bolt 25 GB/T Bolt M6X20 26 GB/T Screw M6X16 27 GB/T Nut Spring, Brake Light Switch Tie Battery Cable, Pos Battery Cable, Neg 32 GB/T Bolt M6x20 33 GB/T Nut 34 GB/T Bolt M6x Starter Relay Fuse (30A) 37 GB/T Bolt M6x Ignition Switch Wire Harness, Main Fuse (5A) Breaker Brake Light Switch Fuse (10A) Fuse (15A)
29 Fig. 21 Electrical 2 Ref Code Part Number Description V Accessory Outlet Cover, 12V Accessory Outlet Nut, 12V Accessory Outlet Connector Tie Tie Clip Tie Clip Tie Tie Tie Tie Tie Tie Tie Clip Tie Tie Tie Tie Tie Branch Line 1, Main Cable Tie Tie Clip Grommet Tie N/A Tie Clip Tie Grommet Light switch WD / 4WD Switch 36 GB/T Bolt M6x12 37 GB/T Washer GB/T Nut
30 Fig. 22 Guard Ref Code Part Number Description Right Main Hoop Bolt 3 GB/T Nut Bolt Nut Washer Left Main Hoop Bolt 9 GB/T Nut Bolt Nut Washer Cross Bar Bolt Cross Bar Bolt Support Bolt Bolt Support 2 21 GB/T Bolt M10X1.25X Cross Support
31 Fig. 23 Front Guard Ref Code Part Number Description Front Bumper Plug, Front Bumper 3 GB/T Bolt M6x25 4 GB/T Bolt M6x Cover, Front Bumper 6 GB/T Bolt, Front Bumper Cover Guard, Front Washer 1 9 GB/T Bolt M6x Guard, Frame Washer 2 12 GB/T Bolt M6x16
32 Fig. 24 Cargo Box Ref Code Part Number Description Cargo Box Cushion Cushion Clevis Pin 12X62 5 GB/T Washer 6 GB/T Pin 2.5X Guard, Lever 8 GB/T Bolt Panel, Cargo Box LFT Fender Rivnut, Plastic 11 GB/T Bolt M6x Tiedown 1 13 GB/T Spring Washer 6 14 GB/T Cap Nut 15 GB/T Bolt M6X Panel, Cargo Box RGT Fender Bolt 18 GB/T Bolt M6X Tiedown 2 20 GB/T Bolt M6X16 21 GB/T Cap Nut 22 GB/T Bolt M6X Tailgate Assy Latch, Tailgate Backing Plate, Tailgate Latch 26 GB/T Bolt M6X20 27 GB/T Bolt M6X Inner Panel, Tailgate 29 GB/T Bolt M6X Hinge Cover 31 GB/T Bolt Cable, Tailgate 33 GB/T Bolt M6X BlotM6X Cushion Grommet Bushing 38 GB/T Bolt Holder Grommet
33 Fig. 24 Cargo Box Cont. Ref Code Part Number Description Spring Plate 1 43 GB/T Bolt 44 GB/T Nut 45 GB/T Nut Lever, Cargo Box Cap, Cargo Box Lever Bracket, Damper 49 GB/T Bolt M6X Damper 51 GB/T Nut M Mat, Cargo Box Plate Clamp 55 GB/T Bolt M6X12 56 GB/T Bolt M8X Bracket Fender Flare, RGT Fender Flare, LFT Cover, Tailgate
34 Fig. 25 Master Cylinder Ref Code Part Number Description Master Cylinder Assy 2 GB/T Bolt M6X Tie Tie Tie 6 6 GB/T Bolt M6X30 7 GB/T Bolt M6X Band 9 GB/T Bolt M6X Holder, Brake Line Brake System Assy
35 Fig. 26 Emblem 1 Ref Code Part Number Description EPA 3 Metal Sticker Sticker Sticker Warning Sticker Rivet Sticker Warning Sticker Sticker Sticker Rivet
36 Fig. 27 Emblem 2 Ref Code Part Number Description X4 Emblem Discovery XLT 500 Emblem Discovery XLT 700 Emblem Hood Emblem DIAMO Emblem
37 Fig. 28 Air Filter Ref Code Part Number Description Clamp, Carburetor Pipe Joint, Air Cleaner Clamp, Air Cleaner Foam filter core parts Air Filter Assy 7 GB/T Screw M Clamp Oil & Air Separator Clip Air Chamber Clamp Duct, Intake F Carburetor F Air Pipe Air Pipe Air Pipe Clip Y-Pipe Clip Air Pipe Comp, RGT Air Pipe Comp, LFT Air Inlet Pipe, Separator Air Outlet Pipe, Separator Overflow Pipe, Separator
38 Fig. 29 Exhaust Ref Code Part Number Description Connection Plate, Exhaust Exhaust Pipe Gasket, Muffler 4 GB/T Bolt M6X Gasket, Exhaust Pipe Clamp, Exhaust Pipe 7 GB/T Washer 8 GB/T Bolt M8X Muffler Damper, Exhaust 11 GB/T Washer 12 GB/T Bolt M8X Nut 14 GB/T Bolt M8X Bushing Oulet Pipe 17 GB/T Bolt M6X Spark Arrestor Muffler Assy Cushion Clamp,Muffler Damper, Muffler
39 Fig. 30 Radiator Ref Code Part Number Description Water Hose Water Pipe Water Hose Water Hose Water Pipe Water Hose Clamp Clamp 9 GB/T Bolt M6X Radiator and Cooling Fan Assy Cooling Fan Assy 12 GB/T Screw M GB/T Cushion Nut Clip Radiator Cap Upper Bracket, Radiator Lower Bracket, Radiator Radiator Assy Guard, Radiator Oil Cooler 21 GB/T Bolt M GB/T Cushion 23 GB/T Boit M GB/T Cushion Bushing Grommet Recovery Tank Guard, Oil Cooler Water Hose Clip Water Hose Clip
40 Fig. 31 Oil Cooler Hose Ref Code Part Number Description Oil Pipe Oil Pipe Clip, Oil Pipe 4 GB/T Bolt M6X Clamp Oil Pipe Oil Pipe Oil Hose Oil Hose Oil Hose Cushion Cushion 2
41 Fig. 32 Evap Kit Ref Code Part Number Description Air Valve Clamp Air Hose 1 4 GB/T Bolt M6X Clamp Air Hose Air Hose Clamp Evap Air Filter Y-Pipe
42 Fig. 33 Crankcase Air Ducts Ref Code Part Number Description Clamp Joint, Air Duct Air Duct 1 4 GB/T Bolt M GB/T Clip Clamp Joint, Air Duct Air Duct 2 9 GB/T Bolt M6X Plate, Air Duct Cap, Air Duct 1
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